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 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.

Provided are devices for generating a desired gas or mixture of gases by thermally decomposing a gas-generating composition (e.g. an oxalate salt) using the thermal energy generated by reaction of a heat-generating composition (e.g. a thermite mixture), and methods of making and using such devices. The devices of some embodiments include phase-changing separators, i.e. separators that at least partially melt, vaporize, or sublimate as a result of the thermal energy generated by the heat-generating composition.

Provided are devices for generating a desired gas or mixture of gases by thermally decomposing a gas-generating composition (e.g. an oxalate salt) using the thermal energy generated by reaction of a heat-generating composition (e.g. a thermite mixture), and methods of making and using such devices. The devices of some embodiments include phase-changing separators, i.e. separators that at least partially melt, vaporize, or sublimate as a result of the thermal energy generated by the heat-generating composition.

What is presented is a combustible pellet for creating heated gas. The combustible pellet is insertable into a cutting apparatus or a high power igniter or both. The combustible pellet is compacted to be resistant to mechanical damage and is resistant to unintentional ignition. The combustible pellet is ignitable without a loose powdered form of combustible material when the combustible pellet is in the cutting apparatus or the high power igniter.

What is presented is a combustible pellet for creating heated gas. The combustible pellet is insertable into a cutting apparatus or a high power igniter or both. The combustible pellet is compacted to be resistant to mechanical damage and is resistant to unintentional ignition. The combustible pellet is ignitable without a loose powdered form of combustible material when the combustible pellet is in the cutting apparatus or the high power igniter.

What is presented is a high power igniter that releasably secures to a cutting apparatus that is used for radially projecting a flow of heated gas to cut from an internal surface through an external surface of a conduit used for oil, gas, mining, and underwater pressure sealed tool applications. The high power igniter comprises an igniter housing adapted to be positioned in the conduit. The igniter housing comprises a containment sub and a nozzle sub that releasably secure to each other. The nozzle sub for directing the flow of the heated gas toward the cutting apparatus and releasably securing to the cutting apparatus. A high wattage heater in the igniter housing comprises a metal magnalium thermite pellet insertable into the igniter housing for creating the flow of heated gas when the high power igniter is in use and a pellet igniting device.

What is presented is a high power igniter that releasably secures to a cutting apparatus that is used for radially projecting a flow of heated gas to cut from an internal surface through an external surface of a conduit used for oil, gas, mining, and underwater pressure sealed tool applications. The high power igniter comprises an igniter housing adapted to be positioned in the conduit. The igniter housing comprises a containment sub and a nozzle sub that releasably secure to each other. The nozzle sub for directing the flow of the heated gas toward the cutting apparatus and releasably securing to the cutting apparatus. A high wattage heater in the igniter housing comprises a metal magnalium thermite pellet insertable into the igniter housing for creating the flow of heated gas when the high power igniter is in use and a pellet igniting device.

What is presented is a high power igniter comprising an igniter housing adapted to be positioned in a conduit. The igniter housing comprises a containment sub and a nozzle sub that releasably secure to each other. A high wattage heater located in the igniter housing comprises a combustible pellet insertable into the igniter housing for creating a flow of heated gas when the combustible pellet is ignited with a pellet igniting device while the high power igniter is in use. The high power igniter is free from a loose powdered form of combustible material when the combustible pellet is in the igniter housing. The nozzle sub directs the flow of heated gas in the system.

What is presented is a high power igniter comprising an igniter housing adapted to be positioned in a conduit. The igniter housing comprises a containment sub and a nozzle sub that releasably secure to each other. A high wattage heater located in the igniter housing comprises a combustible pellet insertable into the igniter housing for creating a flow of heated gas when the combustible pellet is ignited with a pellet igniting device while the high power igniter is in use. The high power igniter is free from a loose powdered form of combustible material when the combustible pellet is in the igniter housing. The nozzle sub directs the flow of heated gas in the system.