ULTRA-SHORT DISPOSABLE SETTING TOOL

Abstract

A setting tool for setting an auxiliary tool in a well, the setting tool including an inner mandrel having an upper section and a lower section, the upper section having an internal chamber configured to house a power charge; a barrel piston enclosing the upper section of the inner mandrel, the barrel piston having (1) an outer section fixedly attached with a tread to the upper section, and (2) an inner section slidably inserted between the outer section and the upper section; and an actuation chamber located between the upper section of the inner mandrel and the outer section of the barrel piston and configured to receive a pressured gas from the internal chamber, through a slot that extends transversal to the thread of the upper section of the inner mandrel.

Claims

1. A setting tool for setting an auxiliary tool in a well, the setting tool comprising: an adaptor sub for affixing an ignitor; an inner mandrel having an upper section and a lower section, the upper section having an internal chamber suitable for housing a power charge, and the lower section configured to connect to an adapter sub for affixing the auxiliary tool; a barrel piston having slidably engaged inner and outer sections; an actuation chamber located between the upper section of the inner mandrel and the outer section of the barrel piston; and a first port located on the upper section of the inner mandrel, wherein the first port is part of a fluid communication passage between the internal chamber and the actuation chamber, wherein activation of the power charge by the ignitor causes gas to pressurize the actuation chamber and the inner section of the barrel piston to stroke downward to set the auxiliary tool in the well.

2. The setting tool of claim 1, wherein the upper section of the inner mandrel, the inner section of the barrel piston, and the outer section of the barrel piston are concentrically positioned, in this order, prior to activation.

3. The setting tool of claim 1, wherein the setting tool contains no hydraulic fluid.

4. The setting tool of claim 1, wherein the adaptor sub further comprises a manual back-off for gas bleeding.

5. The setting tool of claim 1, wherein the setting tool is self-venting.

6. The setting tool of claim 1, further comprising: a dampening element located between an end of the inner section of the barrel piston and the lower section of the inner mandrel so that when the inner section is fully stroked, the end of the inner section squeezes the dampening element against the adapter sub.

7. The setting tool of claim 1, wherein a length of the setting tool as measured from an upper end of the inner mandrel to a lower end of the inner mandrel, prior to activation of the power charge, is 22.5 inches or less.

8. The setting tool of claim 1, wherein the upper section of the inner mandrel has threads configured to engage (1) corresponding treads of the adaptor sub and (2) corresponding threads of the outer section of the barrel piston.

9. The setting tool of claim 8, wherein the outer section of the barrel piston is fixedly attached to the inner mandrel and the inner section of the barrel piston moves in an annulus formed by the inner mandrel and the outer section.

10. The setting tool of claim 8, wherein one or more slots are formed perpendicular to the threads of the upper section of the inner mandrel, and the one or more slots fluidly communicates the first port with a second port formed in the actuation chamber.

11. The setting tool of claim 1, wherein the first port is formed in a lip of the upper section of the inner mandrel.

12. The setting tool of claim 1, further comprising: a venting mechanism located between the inner section and the outer section of the barrel piston, the venting mechanism being configured to allow the pressured gas from the activation chamber to escape outside the setting tool, wherein the venting mechanism is closed when the inner section is not actuated, and the venting mechanism is open when the inner section is fully stroked.

13. A setting tool for setting an auxiliary tool in a well, the setting tool comprising: an inner mandrel having an upper section and a lower section, the upper section having an internal chamber configured to house a power charge; a barrel piston enclosing the upper section of the inner mandrel, the barrel piston having (1) an outer section fixedly attached with a tread to the upper section, and (2) an inner section slidably inserted between the outer section and the upper section; and an actuation chamber located between the upper section of the inner mandrel and the outer section of the barrel piston and configured to receive a pressured gas from the internal chamber, through a slot that extends transversal to the thread of the upper section of the inner mandrel.

14. The setting tool of claim 13, further comprising: a first port located on the upper section of the inner mandrel, wherein the first port (310) is fluidly connected to a first end of the slot.

15. The setting tool of claim 14, wherein the first port is formed in a lip of the upper section of the inner mandrel.

16. The setting tool of claim 14, further comprising: a second port located on the upper section of the inner mandrel, wherein the second port is fluidly connected to a second end of the slot.

17. The setting tool of claim 13, further comprising: an adaptor sub attached to an upper end of the inner mandrel; and an adjuster sub attached to a lower end of the inner mandrel.

18. The setting tool of claim 17, further comprising: an ignitor located in the adaptor sub; and the power charge located in the internal chamber, wherein activation of the power charge by the ignitor causes gas to pressurize the actuation chamber and the inner section of the barrel piston to stroke downward to set the auxiliary tool in the well.

19. The setting tool of claim 13, wherein the upper section of the inner mandrel, the inner section of the barrel piston, and the outer section of the barrel piston are concentrically positioned, in this order, prior to activation, and the setting tool contains no hydraulic fluid.

20. The setting tool of claim 13, further comprising: a dampening element located between an end of the inner section of the barrel piston and the lower section of the inner mandrel so that when the inner section is fully stroked, the end of the inner section squeezes the dampening element against an adapter sub attached to the lower section.

21. The setting tool of claim 13, further comprising: a venting mechanism located between the inner section and the outer section of the barrel piston, the venting mechanism being configured to allow the pressured gas from the activation chamber to escape the setting tool, wherein the venting mechanism is closed when the inner section is not actuated, and the venting mechanism is open when the inner section is fully stroked.

22. A method for using a setting tool in a casing, the method comprising: lowering the setting tool into the casing; igniting a power charge located inside an inner mandrel of the setting tool; directing a pressured gas generated by the ignited power charge between an inner section and an outer section of a barrel piston; actuating the inner section with the pressured gas so that the inner section moves relative to the outer section; and setting an auxiliary tool attached to the setting tool when the inner section is fully stroked, wherein an actuation chamber located between the inner mandrel and the outer section of the barrel piston is configured to receive the pressured gas from an internal chamber of the inner mandrel, through a slot that extends transversal to a thread of the upper section of the inner mandrel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate one or more embodiments and, together with the description, explain these embodiments. In the drawings:

[0012] FIG. 1 illustrates a traditional setting tool that needs to be retrieved to the surface for removing pressurized gas from inside;

[0013] FIG. 2 illustrates a disposable, ultra-short, setting tool, before being activated;

[0014] FIG. 3 illustrates a detail of the disposable, ultra-short, setting tool;

[0015] FIG. 4 illustrates an end of an inner mandrel of the disposable, ultra-short, setting tool;

[0016] FIG. 5 illustrates the disposable, ultra-short, setting tool after being activated;

[0017] FIG. 6 illustrates a venting mechanism of the disposable, ultra-short, setting tool; and

[0018] FIG. 7 is a flowchart of a method for using the disposable, ultra-short, setting tool.

DETAILED DESCRIPTION

[0019] The following description of the embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. The following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims. The following embodiments are discussed, for simplicity, with regard to a setting tool. However, the embodiments discussed herein are also applicable to any tool in which a high-pressure is generated and then that high-pressure needs to be transferred to a piston without the presence of an oil.

[0020] Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.

[0021] According to an embodiment, a setting tool for setting an auxiliary tool in a well includes an adaptor sub for affixing an ignitor, an inner mandrel having an upper and a lower section, the upper section having an internal chamber suitable for housing a power charge, and the lower section configured to connect to a sub for affixing an auxiliary tool, a barrel piston having slidably engaged inner and outer sections, an annular gas chamber located between the barrel piston inner and outer sections, and a gas flow port located on the upper section of the inner mandrel, where the gas flow port provides a fluid communication path between the inner mandrel internal chamber and the annular gas chamber of the barrel piston. Activation of the power charge by the ignitor causes a gas to pressurize the annular gas chamber of the barrel piston and the inner section of the barrel piston to stroke downward to set the auxiliary tool in the well.

[0022] An example embodiment is shown in FIG. 2 in a preactivated state as the setting tool is run into the casing. In preferred embodiments, the setting tool 200 contains no hydraulic fluid and thus may be readily disposed of after use. Therefore, the term “disposable setting tool” is interpreted in this document to mean a setting tool that does not store oil for acting on a piston. In the configuration shown in FIG. 2, the setting tool may be provided with an adaptor sub 210 configured to accept an S1® Ignitor 212 manufactured by the present applicant GEODynamics and described in U.S. Pat. No. 10,036,236, which is incorporated herein. Other types of ignitors 212 and firing devices may be readily accepted in the adaptor sub 210 as shown. Alternatively, the setting tool 200 is provided alone and is configured to accept common industry firing heads, devices, or subs. In this exemplary embodiment, an S1 ignitor 212 is installed into the provided adaptor sub 210 located at the uphole end of the setting tool. Note that “upper” or “uphole” end are terms used herein to mean to the left as shown in a figure and this end corresponds to a higher level in a vertical well, or towards the heel when discussing a lateral portion of a well. Conversely, “lower” or “downhole” end refer to a lower position to the right of a figure or further down a well towards the end or toe of the well.

[0023] The adaptor sub 212 includes a passage 214 therethrough for ignition of a power charge 216, which is located in this embodiment within the inner mandrel 220 of the setting tool 200. The inner mandrel 220 has two sections, an upper section 222 and a lower section 224. The upper section 222 contains the power charge chamber 230, which terminates at a first blind end 232. Opposite that first blind end 232 is a wall 234 separating a second blind end 236, which defines an auxiliary chamber 238. The second blind end 236 marks the beginning of the lower section 224 of the inner mandrel 220. In one embodiment, the auxiliary chamber 238 is not present and thus, there is no second blind end 236. If the auxiliary chamber 238 is present, as in FIG. 2, it may have one or more ports 239 that fluidly communicate an exterior of the lower section 224 to the auxiliary chamber 238. The lower section 224 is configured with threads 225 to accept the adjuster sub 240 for connection to a downhole auxiliary tool, such as a frac or bridge plug or other device to be set within the casing (not shown).

[0024] An outer barrel piston 250 is configured to enclose the upper section 222 of the inner mandrel 220. The outer barrel piston 250 has two slidably connected sections, an inner section 252 and an outer section 254. As illustrated in FIG. 2, The inner section 252 is directly facing the inner mandrel 220 and the outer section 254 is directly facing the inner section 252, so that the inner section 252 is sandwiched between the inner mandrel 220 and the outer section 254. Thus in its run-in state, the upper portion 222 of the inner mandrel 220, and the inner section 252 and the outer section 254 of the barrel piston 250 are tightly nested together, thus reducing the overall tool length L. The term “nesting” herein refers to the concentric arrangement of the outer barrel piston and the upper section of the setting tool in their pre-activated state. The more concentrically arranged these sections initially results in a shorter setting tool, thus reducing the overall tool string length, which aids in the ability to run the string (having the setting tool) into the casing and maneuver the string through bends and other deviations in the wellbore trajectory. In the presently disclosed embodiments, three (222, 252, and 254) of the four main sections (222, 224, 252, and 254) of the setting tool 200 are initially nested (i.e., coaxial with each other), with only a portion of the lower section 224 extending outside the nest in its pre-activated, run-in state.

[0025] FIG. 3 shows in more detail how the upper section 222 of the inner mandrel 220 is attached with threads 302 to the adaptor sub 210, which has its own threads 211. The threads 302 extend along the upper section 222 so that the outer section 254 of the barrel piston 250 also attaches with corresponding threads 255 to the upper section 222. In this embodiment, the outer section 254 has a shoulder 256 that radially extends toward the upper section 222 and directly contacts it with the threads 255. A seal 304 may be located between the outer section 254 and the adaptor sub 210, and a seal 306 may be located between the inner section 252 and the outer section 254, as shown in FIGS. 2 and 3.

[0026] FIG. 3 further shows that a first port 310 is formed at the lip 312 of the upper section 222. The first port 310 and the lip 312 of the upper section 222 are shown in more detail in FIG. 4. Note that this figure shows one or more gas passage slots 402 that extend along a longitudinal axis X of the threads 302 of the upper section 222, i.e., the slot 402 extends transversally to the threads 302. Further, this figure shows that the slot 402 cuts into the threads 302 so that a pressurized gas, which is discussed later, can move unimpeded along the slot 402, from the first port 310 to a second port 314. FIG. 4 shows four such slots 402 and four corresponding first ports 310. However, one skilled in the art will know that any number of ports and corresponding slots may be used. Slot 402 extends from first port 310, through all the threads 302, to the second port 314. The second port 314 is bordered by a raised zone 316 of the upper section 222, which is also illustrated in FIG. 3.

[0027] Returning to FIG. 3, an actuation chamber 320 is formed by the upper section 222, the inner section 252, and the outer section 254. The second port 314 is positioned to also define the actuation chamber 320. This means that a passage 315, including the first port 310, the slot 402, and the second port 314, is formed between the power charge chamber 230 and the actuation chamber 320, and the role of this passage is discussed later. Note that the actuation chamber 320 is shaped as an annulus between the upper section 222 of the inner mandrel 220 and the outer section 254 of barrel piston 250.

[0028] In one or more embodiments, the power charge 216 may be comprised of a compact power charge that when used within the upper section of the inner mandrel further promotes the nesting of the inner mandrel and barrel piston's sections, which results in a setting tool of significantly reduced length. In this embodiment, the length L, as measured from the upper most end of the inner mandrel 220 to the lowermost end that accepts the adjuster sub 240, measures approximately 22.31 inches for a 7-inch stroke S (shown in FIG. 5). Other reductions in length are readily contemplated by those skilled in the art having the benefit of the present disclosure and may include tools of 20 inches or less. Depending upon the setting force required for the given tool to be set, a shorter stroke may be required and or less force and thus the power charge requirements may be reduced, thus shortening the tool's length depending upon specific applications.

[0029] Returning to FIG. 2, a seal 308 is shown being located between the upper section 222 of the inner mandrel 220 and the inner section 252 of the barrel piston 250. This seal ensures that a pressurized gas that is transferred from the power charge chamber 230 into the actuation chamber 320 is not escaping along an interface between the upper section 222 of the inner mandrel 220 and the inner section 252 of the barrel piston 250. Note that in this embodiment, the seal 308 is the only seal between the barrel piston and the inner mandrel, i.e., there is no second seal present between the barrel piston and the inner mandrel.

[0030] FIG. 5 shows the setting tool 200 in its fully stroked state following activation. Ignitor 212 ignited the power charge 216, which resulted in a pressurized gas being formed within the power charge chamber 230. The pressurized gas exits the power charge chamber 230 of the upper section 222 of the inner mandrel 220, though the first port 310, then moves along the slot 402, and then enters, through the second port 314 (see FIGS. 3 and 4 for details of the passage 315 followed by the pressurized gas), into the actuation chamber 320, which is located outside the mandrel 220 and in between the upper section 222 of the inner mandrel 220 and the outer section 254 of the barrel piston 250, as illustrated in FIG. 5. In one application, the first port may include a rupture disk.

[0031] The pressured gas directly strokes the inner section 252 of the barrel piston 250 when entering the actuation chamber 320, which results in the downward movement of the inner section 252. Thus, there is no need for any oil to activate the inner section 252. The path of the pressured gas from the power charge chamber to the actuation chamber is illustrated by arrows in FIG. 5. Note that because the outer section 254 of the barrel piston is attached by threads to the upper section 222 of the inner mandrel, the outer section 254 is fixed while the inner section 252 is movable. Thus, in this embodiment, upon activation of the setting tool, the outer section 254 remains stationary within the casing while the inner section 252 imparts the compressive setting force F to the auxiliary tool while the adjuster sub 240 holds the auxiliary tool. Other arrangements are readily contemplated whereby the nested design of the setting tool may include a stationary mandrel with a barrel piston that strokes, for example.

[0032] As mentioned above, the setting tool 200 has the ability to self-vent the pressurized gases while still downhole, following activation. This is achieved by the venting mechanism 500, which is located, as shown in FIG. 5, between the inner section 252 and the outer section 254. In one implementation, as illustrated in FIG. 6, the venting mechanism 500 includes a step down in the thickness of the outer section 254, from a first thickness T1 to a smaller thickness T2, so that a passage 510 (or annulus) is formed between the inner section 252 and the outer section 254. A shoulder 502 defines the reduction in thickness of the outer section 254 of the barrel piston 250. When the upper part 253 of the inner section 252, which fits tightly inside the actuation chamber 230, moves downward past the shoulder 502, the actuation chamber 320 is fluidly connected, through the passage 510, with an exterior (ambient) of the setting tool, i.e., with the bore 602 of the casing 604, so that the pressured gas from the actuation chamber 320 is free to escape into the bore, as indicated by the arrows in FIG. 6. The venting mechanism may also be implemented as one or a combination of a slot, a channel or the step down in the diameter of the cylindrical body of the barrel piston. Note that the starting point of the thinner thickness T2 of the outer section 254 is selected such that when the inner section 252 fully strokes, past the shoulder 502 of the venting mechanism 500, the gas pressure automatically escapes along the passage 510, outside of the setting tool. This self-venting is accomplished while the setting tool is downhole as part of the activation sequence and thus removes the need to depressurize the setting tool at the surface. FIG. 6 further shows the seal 306 between the inner section 252 and the outer section 254 and the seal 308 between the inner section 252 and the inner mandrel 220. Note that the seal 306 prevents the pressured gas to exit the activation chamber 320 as long as the seal is located in an upward direction relative to the venting mechanism 500, but allows the gas escape after moving past the shoulder 502 in this embodiment.

[0033] Returning to FIG. 5, the adaptor sub 212 may include a gas passage 520, which is closed by a cap 522, that allows a secondary manual bleed or vent capability. As discussed above, the setting tool will self-vent (“self-bleed”) gas pressure downhole as part of the activation sequence. However, in certain scenarios, a setting tool may jam or otherwise not fully complete its activation as defined by full extension of its normal stroke. An incomplete stroke thus does not allow a piston or mandrel to fully extend past the point at which the bleed port of valve opens, thus leaving the setting tool in a pressurized state. In that event, the setting tool must be withdrawn from the well and depressurized for safety. The present adaptor sub gas passage 520 allow that venting to be safely and readily conducted at the surface in the event of a faulty or incomplete activation.

[0034] In any of the above embodiments, the lower section 224 of the inner mandrel 220 may include a damping element 270, for example, elastomeric grommet, bushing, sleeve, O-ring or a combination of these or other elastomeric elements, that is configured to dampen the shock that occurs during the setting tool activation process. As shown in FIG. 5, for example, the damping element 270 is placed concentric to the lower section 224 of the inner mandrel 220, so that the inner section 252 of the barrel piston 250 is stopped by the damping element 270 when fully stroke by the pressurized gas. Alternatively, the damping element 270 may be attached to the inner section 252.

[0035] A method for setting the setting tool 200 is now discussed with regard to FIG. 7. The method starts in step 700 by lowering the setting tool 200 into the casing 604. The setting tool 200 has the inner section 252 tucked into the outer section 254 of the outer barrel piston 250. After the setting tool 200 arrives at its final position inside the well, the power charge 216 stored in the power charge chamber 230 is ignited in step 702. Pressured gas formed within the power charger chamber 230, as a consequence of the ignition step, is directed in step 704, along the passage 315, to the actuation chamber 320, formed between the upper section 222 and the outer section 254, and actuates in step 706 the inner section 252 to fully stroke. Then, in step 708, the auxiliary tool (e.g., plug) attached to the setting tool 200 is set inside the casing.

[0036] The disclosed embodiments provide methods and an ultra-short setting tool for well operations in which the setting tool is disposable, i.e., does not use oil for activating an auxiliary tool. It should be understood that this description is not intended to limit the invention. On the contrary, the exemplary embodiments are intended to cover alternatives, modifications and equivalents, which are included in the spirit and scope of the invention as defined by the appended claims. Further, in the detailed description of the exemplary embodiments, numerous specific details are set forth in order to provide a comprehensive understanding of the claimed invention. However, one skilled in the art would understand that various embodiments may be practiced without such specific details.

[0037] Although the features and elements of the present exemplary embodiments are described in the embodiments in particular combinations, each feature or element can be used alone without the other features and elements of the embodiments or in various combinations with or without other features and elements disclosed herein.

[0038] This written description uses examples of the subject matter disclosed to enable any person skilled in the art to practice the same, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims.