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 suitable for housing a power charge; an outer cylindrical piston enclosing the upper section of the inner mandrel; a slidable ring formed concentric, and between the inner mandrel and the outer cylindrical piston; and an actuation chamber located between the outer cylindrical piston, the ring, and the inner mandrel, and configured to receive a pressured gas from the internal chamber, through a slot that extends transversal to a 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 configured to house a power charge, and the lower section configured to connect to an adjuster sub for affixing the auxiliary tool; an outer cylindrical piston slidably located over the inner mandrel; a ring slidably located between the inner mandrel and the outer cylindrical piston; an actuation chamber located between the inner mandrel and the outer cylindrical 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 outer cylindrical piston to stroke downward to set the auxiliary tool in the well.

2. The setting tool of claim 1, wherein the ring, the inner mandrel, and the outer cylindrical 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 a shoulder of the outer cylindrical piston and the lower section of the inner mandrel so that when the outer cylindrical piston is fully stroked, the shoulder of the outer cylindrical piston squeezes the dampening element against the adjuster sub.

7. The setting tool of claim 1, wherein a length of the setting tool as measured from one end of the inner mandrel to another end of the inner mandrel, prior to activation of the power charge, is 20 inches or less.

8. The setting tool of claim 1, wherein the upper section of the inner mandrel has threads configured to engage corresponding treads of the adaptor sub.

9. 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 communicate the first port with a second port formed in the actuation chamber.

10. The setting tool of claim 1, wherein the outer cylindrical piston is simultaneously in direct contact with the adaptor sub and the ring.

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 ring and the outer cylindrical piston, the venting mechanism being configured to allow the pressured gas from the activation chamber outside the setting tool, wherein the venting mechanism is closed when the outer cylindrical piston is not actuated, and the venting mechanism is open when the outer cylindrical piston 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 suitable for housing a power charge; an outer cylindrical piston enclosing the upper section of the inner mandrel; a slidable ring formed concentric, and between the inner mandrel and the outer cylindrical piston; and an actuation chamber located between the outer cylindrical piston, the ring, and the inner mandrel, and configured to receive a pressured gas from the internal chamber, through a slot that extends transversal to a 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 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 the tread 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 outer cylindrical piston to stroke downward to set the auxiliary tool in the well.

19. The setting tool of claim 13, further comprising: a dampening element located around the lower section of the inner mandrel so that when the outer cylindrical piston is fully stroked, a shoulder of the outer cylindrical piston squeezes the dampening element against an adjuster sub attached to the inner mandrel.

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

21. 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, through a slot formed through threads of the inner mandrel, to a ring; actuating the ring with the pressured gas so that the ring is pushing an outer cylindrical piston along the inner mandrel; and setting an auxiliary tool attached to the setting tool when the outer cylindrical piston is fully stroked.

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, before being activated;

[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 detail of the disposable, ultra-short, setting tool after being activated;

[0018] FIG. 7 illustrates a venting mechanism of the disposable, ultra-short, setting tool; and

[0019] FIG. 8 is a flowchart of a method for using the disposable, ultra-short, setting tool.

DETAILED DESCRIPTION

[0020] 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.

[0021] 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.

[0022] According to an embodiment, a setting tool for setting an auxiliary tool (e.g., a plug) in a well includes 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 a sub for affixing an auxiliary tool, an outer cylindrical piston configured to slide along the inner mandrel, an annular activation chamber located between the outer cylindrical piston and the inner mandrel, and a gas flow slot formed through threads of the inner mandrel, to provide a fluid communication path between the inner mandrel internal chamber and the annular actuation chamber of the outer cylindrical piston. Activation of the power charge by the ignitor causes gas to pressurize the annular activation chamber and the outer cylindrical piston to stroke downward to set the auxiliary tool in the well. In one embodiment, there is no seal extending between the interior surface of the outer cylindrical piston and the outer surface of the inner mandrel. In this embodiment, the outer cylindrical piston does not even contact the inner mandrel.

[0023] The setting tool is shown in FIG. 2 in a preactivated state as the setting tool 200 is run into the casing 202 (note that for simplicity, FIG. 2 shows only the bottom part of the casing, and not the upper part). In this embodiment, the setting tool 200 contains no hydraulic fluid (e.g., no oil) and thus, it may be readily disposed of after use, without a redressing operation, which is dangerous to the operator, as discussed in Background section. Further, because the setting tool includes no oil, the disposal operation does not raise environmental issues. The term “disposable setting tool” is interpreted in this document to mean a setting tool that does not store oil (a hydraulic fluid) for acting on a piston. In the configuration shown in FIG. 2, the setting tool 200 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, the 51 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. The adaptor sub 210 is configured to connect with appropriate threads to a casing element.

[0024] The adaptor sub 210 includes a passage 214 therethrough for ignition of a power charge 216, which is located in this embodiment, partially 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 forms a power charge chamber 230, that is filled with the power charger 216, and the power charge chamber 230 terminates at a first blind end 232. The power charge 216 is partially located within the passage 214 of the adaptor sub 210, as also shown in FIG. 2. Opposite the 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. 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 an 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).

[0025] An outer cylindrical piston 250 is configured to enclose the upper section 222 of the inner mandrel 220 and also the lower part 210A of the adaptor sub 210, when the setting tool is not actuated. In one embodiment, the outer cylindrical piston 250 is placed coaxial with the power charge 216. In another embodiment, the outer cylindrical piston 250 is mostly located to enclose the adaptor sub 210, and partially the upper section 222 of the inner mandrel 220. The outer cylindrical piston 250 is formed a single piece, having an interior shoulder 256 that extends radially, toward the inner mandrel 222. However, the interior shoulder 256 stops short of reaching the inner mandrel 222, so that a small passage 257, as illustrated in FIG. 3, is formed between the interior shoulder 256 and the exterior surface of the inner mandrel 222. The purpose of the passage 257 is discussed later. Because of this configuration, the outer cylindrical piston 250 does not contact the inner mandrel 222 and thus, it does not need a seal with inner mandrel.

[0026] Further, FIG. 3 shows a ring 260 located around the upper section 222 of the inner mandrel 220. The ring 260 includes a first seal 262, that seals an interface between the exterior surface of the ring 260 and the interior surface of the outer cylindrical piston 250, and a second seal 264, that seals an interface between the interior surface of the ring 260 and the exterior surface of the upper section 222 of the inner mandrel 220. Note that there is only one seal between the ring 264 and the inner mandrel 220. Thus, there is only one seal between (1) the ring 264 and the outer cylindrical piston 250, and (2) the inner mandrel 220.

[0027] The ring 260, the outer cylindrical piston 250, the adaptor sub 210, and the upper section 222 of the inner mandrel 220 define an actuation chamber 320. The first seal 262 and the second seal 264 of the ring 260 ensure that a pressured gas that arrives in the actuation chamber 320 does not escape along the interface between the ring and the inner mandrel and the interface between the ring and the outer cylindrical piston. Further, the ring 260 is configured to slide along the inner mandrel, along the longitudinal axis X. Note that the ring 260 is not part of the outer cylindrical piston 250 and is not mechanically attached to the outer cylindrical piston 250, except for the fact they are simply in contact with each other.

[0028] In its run-in state, the upper section 222 of the inner mandrel 220, and the outer cylindrical piston 250 are nested with each other, thus reducing the overall setting tool length L. Nesting herein refers to the concentric arrangement of the outer cylindrical piston 250 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. For example, in this embodiment, the length L of the setting tool is about 20″ and a length I from the top part of the outer cylindrical piston 250 to the top part of the adaptor sub 210 is about 6″.

[0029] FIG. 3 also shows 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 transversely along axis X, along the upper section 222. 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 the longitudinal axis X, across the threads 302 of the upper section 222, i.e., the slots 402 are transversal to the threads 302. The upper end 222A of the upper section 222 is shown in FIG. 4 being open, i.e., it communicates with the passage 214 in FIG. 3. 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 a 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.

[0030] Returning to FIG. 3, 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 (1) the power charge chamber 230 and the passage 214, and (2) the actuation chamber 320, and the role of this passage is to direct the pressured gas formed as a result of igniting the power charge 216, from the power charge chamber 230 and the passage 214, to the actuation chamber 320, to actuate the outer cylindrical piston 250. Note that the actuation chamber 320 in this embodiment is shaped as an annulus.

[0031] In one or more embodiments, the power charge 216 may be comprised of a compact power charge that when used with the disclosed tool further nests the mandrel and barrel 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 20 inches. 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.

[0032] FIG. 5 shows the setting tool 200 in its fully stroked state following the activation of the power charge 216. Ignitor 212 ignites the power charge 216, which results in a pressurized gas being formed within the power charge chamber 230 and the passage 214. The pressurized gas exits the power charge chamber 230 of the upper section 222 of the inner mandrel 220, through the first port 310, then moves along the slot 402 (see FIG. 4), and then enters, at the second port 314 (see FIGS. 3 and 4 for details of the passage 315 followed by the pressured gas), into the actuation chamber 320, which is located outside the inner mandrel 220 and within the outer cylindrical piston 250, as illustrated in FIG. 5. In one application, the first port may include a rupture disk.

[0033] The pressured gas directly strikes the ring 260 when entering the actuation chamber 320, which in turn pushes the outer cylindrical piston 250, which results in the downward movement of the outer cylindrical piston 250. Thus, there is no need for any oil to activate the outer cylindrical piston 250. The path of the pressured gas, from the power charge chamber 230 to the actuation chamber 320, is illustrated by arrows in FIG. 6. Note that the ring 260 has acted directly on the interior shoulder 256 until the shoulder has hit a damping element 270, while the upper end 250A of the outer cylindrical piston 250 remains in contact with the adaptor sub 210, thus preserving the integrity of the actuation chamber 320.

[0034] In one embodiment, a seal 211 is provided between the adaptor sub 210 and the upper end 250A of the outer cylindrical piston 250 for preventing the pressured gas escaping from the actuation chamber 320, at the interface between the adaptor sub 210 and the outer cylindrical piston 250. Also note that the lower end 250B of the outer cylindrical piston 250 passes over the damping element 270 and moves over the adjuster sub 240. Thus, in this embodiment, upon activation of the setting tool 200, the outer cylindrical piston 250 imparts the compressive setting force F relative to the adjuster sub 240, which does not move because it is fixedly attached to the inner mandrel.

[0035] 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 600, which is located, as shown in FIG. 6, between the ring 260 and the shoulder 256 of the outer cylindrical piston 250. In one implementation, as illustrated in FIG. 7, the venting mechanism 500 includes a step down in the thickness of the outer cylindrical piston 250, from a first thickness T1 to a smaller thickness T2, so that a passage 510 (or annulus) is formed between the ring 260 and the inner surface of the outer cylindrical piston 250. A shoulder 502 defines the reduction in thickness of the outer cylindrical piston 250. When the most upper part of the ring 260, which fits tightly inside the actuation chamber 230, moves downward past the shoulder 502, the actuation chamber 230 automatically becomes fluidly connected, through the passage 510, to the one or more ports 239 formed in the lower section 224 of the inner mandrel 220, and to the auxiliary chamber 238, so that the pressured gas from the actuation chamber 230 is free to escape into the auxiliary chamber, as indicated by the arrows in FIG. 7. Note that the auxiliary chamber fluidly communicates with the bore of the casing after the setting tool is activated and the auxiliary tool is set.

[0036] The venting mechanism 500 may also be implemented as one or a combination of a slot, channel or a step down in the diameter of the outer cylindrical piston. Note that the location of the thinner thickness T2 of the outer cylindrical piston 250 is selected such that when the ring 260 fully strokes past the shoulder 502 of the outer cylindrical piston 250, the gas pressure may thus escape between the two sections and external to the setting tool. This self-venting is accomplished downhole as part of the activation sequence and thus removes the need to depressurize the setting tool at the surface.

[0037] 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.

[0038] 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. 6, for example, the damping element 270 is placed concentric to the lower section 224 of the inner mandrel 220, so that the outer cylindrical piston 250 is stopped by the damping element 270 when fully stroked by the pressurized gas. Alternatively, the damping element 270 may be attached to the outer cylindrical piston 250, for example, to the internal shoulder 256.

[0039] A method for setting the setting tool is now discussed with regard to FIG. 8. The method starts in step 800 by lowering the setting tool 200 into the casing 202. The setting tool 200 has the outer cylindrical piston 250 located mostly over the adaptor sub 210. 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 802. Pressured gas formed within the power charger chamber 230, as a consequence of the ignition step, is directed in step 804, along the passage 315, to the actuation chamber 320, formed between the inner mandrel 222 and the outer cylindrical piston 250, and actuates in step 806 the outer cylindrical piston 250 to fully stroke. Then, in step 808, the auxiliary tool (e.g., plug) attached to the setting tool 200 is set inside the casing.

[0040] 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.

[0041] 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.

[0042] 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.