Redefining Setting Tool Safety and Speed
AERO Set™ is a multi-use, gas-driven setting tool fully integrated with the AERO Perforating System. Designed specifically for high-tempo unconventional pump-down frac operations, AERO Set eliminates the complexity, maintenance burden, and surface hazards associated with legacy hydraulic setting tools.
With a compact, lightweight profile and a self-bleeding gas-driven mechanism, AERO Set delivers consistent, repeatable setting performance while dramatically reducing HSE exposure and stage-to-stage transition time.
Designed specifically for high-tempo unconventional pump-down frac operations, AERO Set eliminates the complexity, maintenance burden, and surface hazards associated with legacy hydraulic setting tools.
What is AERO Set?
AERO Set™ is an intelligent, field-optimized setting tool engineered as an integral component of the AERO Perforating System.
Unlike traditional hydraulic tools that rely on oil levels, complex redress procedures, and multi-person handling, AERO Set uses a gas-only setting mechanism that simplifies operations from redress to run-in-hole.
Factory-integrated by design, AERO Set pairs seamlessly with AERO system logic and firing heads — removing field integration risk and ensuring predictable, repeatable performance on every stage.
Why AERO Set is Different?
Designed to Replace Hydraulic Complexity
Legacy hydraulic setting tools introduce unnecessary hazards and variability. AERO Set replaces those risks with a clean, gas-driven, self-bleeding solution optimized for modern frac operations.
Built for Speed & Simplicity
•Single-person handling
•Minimal redress components
•No hydraulic oil
•No trapped pressure on retrieval
Key Features
Enhanced Safety
•Eliminates heavy lifting requirements
•Removes surface high-pressure hazards
•Self-bleeding design ensures the tool returns to surface unpressurized, eliminating trapped pressure risks
Operational Efficiency
•Consistent 10–12 second set time
•Gas-only system uses just six O-rings
•Fast, simple cleaning and redress
•Accelerates stage-to-stage transitions
Reliability by Design
•Formulated power charges optimized for time consistency
•Factory integration removes variability from field wiring and manual connections
•Power charge presence verified before run-in-hole
Reduced Field Risk
•Short, lightweight profile
•Easy single-operator handling
•Designed for high-tempo unconventional operations
How AERO Set Works
1. Gas-Driven Setting Event
A formulated power charge initiates a controlled gas-driven stroke.
2. High-Force Setting Performance
Despite its compact size, AERO Set reliably delivers up to 55,000 lbs of setting force at high temperature and pressure.
3. Self-Bleeding Safety Mechanism
As the piston strokes out after setting, internal gas vents through weep holes — ensuring the tool returns to surface with no trapped pressure.
AERO Ignite Compatibility
AERO Set is fully compatible with AERO Ignite, an integrated switch and igniter that uses AERO Perforating System firing logic.
Key safeguards include:
- Detection of power-charge presence before run-in-hole
- Floating igniter holder that prevents electrical contact if the power charge is missing
- Protection against misruns and dry fires
Anti-Preset Protection
An integrated anti-preset shear screw (~2,000 lbs) ensures the tool remains secure during run-in-hole operations.
Designed for Modern Frac Operations
AERO Set is purpose-built for:
•High-tempo unconventional pump-down frac operations
•Composite and dissolvable frac plug deployments
•Operators seeking to reduce HSE exposure without sacrificing performance
•Crews demanding faster stage execution with fewer redress steps
Its compact footprint, high-force capability, and integrated safety logic make AERO Set a natural extension of the AERO Perforating System.
Why Operators Choose AERO Set
Simple. Fast. Reliable.
•Gas-driven simplicity replaces hydraulic complexity
•Consistent, repeatable set times
•No trapped pressure on retrieval
•Integrated safety logic reduces misrun risk
•Reusable, field-efficient design
•Seamless AERO system integration
| Feature | Specification |
|---|---|
| Tool OD | 3.25” (82.55 mm) |
| Length | ~32.4” (~0.82 m) |
| Stroke Length | 7” (17.78 cm) |
| Maximum Setting Force | 55,000 lbs. |
| Pressure Rating | 20,000 psi |
| Temperature Rating | 350°F (176°C) with control |
| Configuration | Reusable |
| Casing Compatability | 4.5” and 5.5” |
| Power Charge | Formulated for consistency; detected by AERO Ignite |