A compact setting tool that sets a packer or bridge plug in a wellbore and then self bleeds the pressure prior to pulling the string out of the wellbore.

A gas operated setting tool comprising a piston rod and an outer tool assembly having a hollow interior within which the piston rod is disposed coaxially. The outer tool assembly comprises a top cap connected to the cylinder's upper end and a bottom connector connected to the cylinder's lower end. The piston rod comprises an upper section to which a firing head attaches and a lower section to which a setting adapter attaches. The piston section's exterior surface fits within and is sealed against the cylinder's interior surface. The piston rod has a hollow power charge chamber and port holes that open into the bottom connector's upper surface. A shear ring engages a counterpart surface feature to prevents axial movement of the outer tool assembly relative to the piston rod until the power charge has fired and sheared the shear ring.

A setting tool for deploying a downhole tool within a wellbore is described herein. The setting tool uses an in situ non-explosive gas-generating power source to generate high-pressure gas, which drives a mechanical linkage to actuate the deployment of the downhole tool. According to certain embodiments the non-explosive gas-generating setting tool contains no hydraulic stages and may contain only a single piston. The setting tool may be fitted to provide different stroke lengths and can provide usable power over a greater percentage of its stroke length, compared to setting tools using explosive/pyrotechnic power sources. Methods of using a non-explosive gas-generating setting tool to deploy a downhole tool within a wellbore are also disclosed.

A tool string includes a perforating gun including a signal conductor, a sub that includes a sub housing including a first bulkhead receptacle extending into the sub housing from a first end, a second bulkhead receptacle extending into the sub housing from a second end, and a switch receptacle positioned between the first bulkhead receptacle and the second bulkhead receptacle, a first bulkhead connector, and a second bulkhead connector, and a switch positionable in the switch receptacle, wherein the switch is configured to establish an electrical connection with the signal conductor of the perforating gun in response to coupling of the sub with the perforating gun, and wherein the switch receptacle is isolated from fluid pressure external of the switch receptacle when the first bulkhead connector is positioned in the first bulkhead receptacle and the second bulkhead connector is positioned in the second bulkhead receptacle.

A completion system for perforating a tubular string positioned in a wellbore includes a tool string positionable in the wellbore, wherein the tool string includes a first perforating gun and a plurality of digital switches, a control system connectable to the tool string, wherein the control system is configured to generate a plurality of unique identifiers for each switch of the plurality of switches, assign each of the plurality of unique identifiers to one of the plurality of switches, and transmit a signal to a first switch of the plurality of switches including a first unique identifier of the plurality of unique identifiers to actuate the first perforating gun and perforate the tubular string, wherein the first unique identifier is assigned to the first switch.

A power charge (12) for a setting tool is composed of a propellant (16) and an igniter (32) embedded in the propellant (16). The propellant (16) is a homogeneous mixture of combustible components, an oxidizer and an epoxy binder, which together provide a continuous mass of solid form. The propellant (16) has an exterior (14) which, together with an outward face (36) of the igniter (32), is exposed and provides the outer surface of the power charge (12). A protuberant rib (28) extends along the length of the exterior (14) in a spiral-shaped pattern and provides a stand-off spacer between the power charge (12) and the setting tool. The igniter (32) has a main body portion (52) and an annular-shaped protrusion (48) which extends laterally outward from the main body portion (52) and into the propellant (16) to retain the igniter (32) within the propellant (16). The entire power charge (12) is formed of combustible materials.

A setting tool for setting frac plugs and the like can include a mandrel having a chamber for housing expandable gas and a gas port in fluid communication with the chamber; a firing head secured to the mandrel for igniting a power charge to generate pressurized gas within the chamber; a barrel piston housing the mandrel and connected to a sleeve for setting the frac plug; and an expansion region defined between the mandrel and the barrel piston and receiving the pressurized gas which exerts force to cause a stroke of the barrel piston over the mandrel as the expansion region expands axially. The setting tool can include various features, such as certain gas bleed systems, an enhanced shear screw assembly, a bleed port and plug assembly, a scribe line, a particular gas port configuration, a liquid escape conduit, no-shoulder barrel configuration, and/or a low-force design for frac plugs.

A single use setting tool for actuating a tool in a wellbore includes an inner piston extending through a central bore of an outer sleeve. The inner piston has a seal adapter portion and a piston cavity housing an initiator holder for receiving a push-in detonator. A gas diverter channel is open to and extends from the piston cavity through an annular wall of the piston, to transfer gas pressure to a gas expansion chamber for stroking the outer sleeve. A method of actuating a wellbore tool with a single use setting tool includes inserting an initiator into the initiator holder, attaching a tandem seal adapter to the seal adapter portion of the inner piston, and relaying an electrical signal to a line-in portion of the initiator, to initiate the initiator. The single use setting tool may be used in a wellbore tool string.

A downhole tool includes a setting tool having an outer surface, an inner surface defining a passage and a terminal end. An actuator mechanism is arranged in the passage. A setting member is arranged at the terminal end in the passage. The setting member includes a side portion that is angled radially inwardly from a first end portion to a second end portion. A collet member extends over the setting member, and a seal member is operatively connected to the collet member at the second end portion of the setting member.

A downhole tool has a setting cone including a body having an outer surface having a first end, a second end. At least a portion of the body includes a taper at the second end. A passage extends through the body. The passage includes a first portion having a first diameter and a second portion having a second diameter that is less than the first diameter. An anchor is arranged at the second end of the setting cone. The anchor includes a central passage that aligns with the passage through the setting cone. A mandrel extends through the passage of the setting cone and the central passage of the anchor. The mandrel includes a first end portion, a second end portion and an intermediate section. A conduit extends from the first end portion toward the second end portion. A portion of the conduit defines an actuation chamber.