DOWNHOLE SETTING TOOL

Abstract

A downhole setting tool includes an upper cylinder, and a piston positioned in the upper cylinder. A charge chamber is defined on one side of the piston within the upper cylinder, and a first hydraulic chamber is defined on an opposite side of the piston and within the upper cylinder. The tool also includes a mandrel coupled to the upper cylinder. A flow port is defined in the mandrel, the flow port being in fluid communication with the first hydraulic chamber. The tool further includes a lower cylinder coupled to the mandrel, the mandrel and the lower cylinder defining a second hydraulic chamber within the lower cylinder, and the flow port being in fluid communication with the second hydraulic chamber. The lower cylinder is configured to move with respect to the mandrel when the setting tool is actuated.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application having Ser. No. 62/960,323, which was filed on Jan. 13, 2020 and is incorporated herein by reference in its entirety.

BACKGROUND

In the oil and gas field, a variety of downhole tools may be employed to perform various functions in the well. For example, a packer may be deployed into the well and set therein to isolate one section from another. A setting tool is typically employed to set the packer. The setting tool may include a central mandrel that pulls up on a corresponding mandrel of the packer (or other type of tool such as a plug), and a setting sleeve that pushes down on a collar or another member of a setting assembly of the packer. The setting tool is actuated, e.g., by detonating a charge therein, to push downward on the sleeve holding the mandrel stationary. This results in the setting assembly being axially compressed and radially expanded, and thereby setting into the wellbore.

However, the setting tools are prone to failure, as they typically rely on several relatively movable pistons, rods, sleeves, etc. for movement of the setting sleeve and/or mandrel.

SUMMARY

Embodiments of the disclosure may provide a downhole setting tool. The tool includes an upper cylinder, and a piston positioned in the upper cylinder. A charge chamber is defined on one side of the piston within the upper cylinder, and a first hydraulic chamber is defined on an opposite side of the piston and within the upper cylinder. The tool also includes a mandrel coupled to the upper cylinder. A flow port is defined in the mandrel, the flow port being in fluid communication with the first hydraulic chamber. The tool further includes a lower cylinder coupled to the head of the mandrel, the mandrel and the lower cylinder defining a second hydraulic chamber within the lower cylinder, and the flow port being in fluid communication with the second hydraulic chamber. The lower cylinder is configured to move with respect to the mandrel when the setting tool is actuated.

Embodiments of the disclosure may also provide a method for setting a downhole tool. The method includes coupling a mandrel of the downhole tool to a setting tool. The setting tool includes an upper cylinder, and a piston positioned in the upper cylinder. A charge chamber is defined on one side of the piston within the upper cylinder, and a first hydraulic chamber is defined on an opposite side of the piston and within the upper cylinder, the first hydraulic chamber having hydraulic fluid therein. The setting tool also includes a mandrel attached to the upper cylinder. The mandrel of the setting tool is coupled the mandrel of the downhole tool. The setting tool further includes a lower cylinder coupled to the mandrel, the mandrel and the lower cylinder defining a second hydraulic chamber within the lower cylinder, the second hydraulic chamber being in fluid communication with the first hydraulic chamber. The method further includes deploying the tool and the setting tool into a wellbore, and detonating a charge in the charge chamber of the setting tool. Detonating the charge causes a force to be applied to the piston. Applying the force to the piston causes the piston to force at least some of the hydraulic fluid to flow from the first hydraulic chamber to the second hydraulic chamber. Causing at least some of the hydraulic fluid to flow from the first hydraulic chamber to the second hydraulic chamber causes the lower cylinder to move with respect to the mandrel and to apply a setting force to the downhole tool.

Embodiments of the disclosure also provide a downhole setting tool including an upper cylinder comprising a sub configured to contain a charge, the upper cylinder at least partially defining a first hydraulic chamber therein, a piston positioned in the first chamber and movable with respect to the upper cylinder in response to detonating the charge, and a mandrel including a head coupled to the upper cylinder and defining a flow port therein. The piston moving in response to the charge detonating is configured to cause hydraulic fluid to flow from the first hydraulic chamber and through the flow port. The mandrel also includes an extension extending from the head and configured to couple to a subjacent tool so as to apply an axially-directed force thereto. The setting tool also includes a lower cylinder received at least partially around the mandrel and comprising a shoulder that is sealed with the extension of the mandrel. The shoulder and the head of the mandrel define a second hydraulic chamber axially therebetween, the first and second hydraulic chambers being in fluid communication with one another via the flow port. The setting tool further includes one or more retaining members connecting the lower cylinder to the head of the mandrel. The one or more retaining members are configured to release and allow the lower cylinder to move relative to the mandrel and relative to the upper cylinder.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure may best be understood by referring to the following description and accompanying drawings that are used to illustrate some embodiments. In the drawings:

FIG. 1 illustrates a side, cross-sectional view of a downhole setting tool in a run-in configuration, according to an embodiment.

FIG. 2 illustrates a side, cross-sectional view of the downhole tool in an actuated configuration, according to an embodiment.

FIG. 3 illustrates a flowchart of a method for setting a downhole tool (e.g., a packer, plug, etc.) in a wellbore, according to an embodiment.

DETAILED DESCRIPTION

The following disclosure describes several embodiments for implementing different features, structures, or functions of the invention. Embodiments of components, arrangements, and configurations are described below to simplify the present disclosure; however, these embodiments are provided merely as examples and are not intended to limit the scope of the invention. Additionally, the present disclosure may repeat reference characters (e.g., numerals) and/or letters in the various embodiments and across the Figures provided herein. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed in the Figures. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact. Finally, the embodiments presented below may be combined in any combination of ways, e.g., any element from one exemplary embodiment may be used in any other exemplary embodiment, without departing from the scope of the disclosure.

Additionally, certain terms are used throughout the following description and claims to refer to particular components. As one skilled in the art will appreciate, various entities may refer to the same component by different names, and as such, the naming convention for the elements described herein is not intended to limit the scope of the invention, unless otherwise specifically defined herein. Further, the naming convention used herein is not intended to distinguish between components that differ in name but not function. Additionally, in the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.” All numerical values in this disclosure may be exact or approximate values unless otherwise specifically stated. Accordingly, various embodiments of the disclosure may deviate from the numbers, values, and ranges disclosed herein without departing from the intended scope. In addition, unless otherwise provided herein, “or” statements are intended to be non-exclusive; for example, the statement “A or B” should be considered to mean “A, B, or both A and B.”

FIG. 1 illustrates a side, cross-sectional view of a downhole setting tool 100, according to an embodiment. The tool 100 may be configured to connect to a subjacent tool, such as a packer, plug, etc., that is to be set into a wellbore. In one specific embodiment, the downhole setting tool 100 may be configured to push downward on an upper cone of a downhole tool, while pulling upward on a lower cone of the downhole tool. In such an embodiment, the downhole tool may be provided as any of the downhole tools discussed in U.S. Pat. No. 10,408,012, which is incorporated herein by reference in its entirety, to the extent not inconsistent with the present disclosure. In other embodiments, the downhole setting tool 100 may be configured to pull upward on a mandrel and press downward on a setting assembly (e.g., slips, seals, cones, etc.) that is slidably positioned around the mandrel, as commonly employed in packers, plugs, etc.

In an embodiment, the tool 100 may include an upper cylinder 102 and a lower cylinder 104. Although referred to as “cylinders,” it will be appreciated that this term, as used herein, includes geometries for the cylinders 102, 104 that may not be precisely cylindrical. For example, the cylinders 102, 104 may include shoulders, varying diameters, or other features as described herein or otherwise called for to support the functionality of the tool 100, while still being referred to as “cylinders”.

In at least one embodiment, the upper cylinder 102 may be formed from a plurality of members, e.g., a sleeve 106 and a sub 108 that are threaded, fastened, or otherwise connected together, end-to-end. The sleeve 106 may be generally hollow, and may at least partially define a first hydraulic chamber 110 therein. The first hydraulic chamber 110 may contain a generally incompressible hydraulic fluid, e.g., oil, therein.

The sub 108 may provide an upper connection 109 for the tool 100 to connect to a tool string (e.g., wireline, slickline, coiled tubing, etc.), and a bore therethrough, which may define a charge chamber 112. The charge chamber 112 may be configured to contain a powder charge, or any other type of explosive power source. In some embodiments, the sub 108 may also include a disc bleeder valve 116, which may be configured to vent gas in the charge chamber 112, e.g., to avoid damage to the tool 100 upon detonation of the powder charge.

The charge chamber 112 and the first hydraulic chamber 110 may be prevented from fluid communication therebetween by a piston 114. The piston 114 may be received within the upper cylinder 102, specifically within the sleeve 106, and may be sealed therewith. In the run-in configuration, as shown in FIG. 1, the piston 114 may also abut an end of the sub 108, and may be held in place by the hydraulic fluid filling the first hydraulic chamber 110, and/or may be pinned or otherwise temporarily restrained in position. The piston 114 may be configured to slide within the sleeve 106, e.g., in response to detonation of the powder charge in the charge chamber 112.

A mandrel 120 may be received through the lower cylinder 104 and into the upper cylinder 102. For example, the mandrel 120 may be threaded into or otherwise fastened to the upper cylinder 102, such that the mandrel 120 may generally not move with respect thereto during actuation. One or more restraining members 121 may be coupled to the lower cylindrical member 104 and to either or both of the upper cylinder 102 or (as shown) the mandrel 120. The restraining members 121 may temporarily fasten the lower cylinder 104 to the mandrel 120. Accordingly, the lower cylinder 104 may be configured to slide with respect to the mandrel 120 during actuation, but may be prevented from doing so prior to actuation by the restraining members 121. The one or more restraining members 121 may be shear pins, shear screws, clips, detents, or any other member configured to release upon exertion of a predetermined amount of force.

In an embodiment, the mandrel 120 may include a head 122 and an extension 124, with the head 122 defining a larger diameter than the extension 124, as shown. The head 122 and the extension 124 may be integrally-formed or may be formed from two separate pieces that are connected together. Further, the head 122 may be sealed with the lower cylinder 104 by one or more seals 123 so as to prevent fluid from communicating from the first hydraulic chamber 110 around mandrel 120. The extension 124 may extend through a shoulder 126 formed in the lower cylinder 104, and may seal therewith. Moreover, the shoulder 126 may be configured to slide along the extension 124.

Further, the head 122 may define an end face 128, which may be axially-oriented, where the extension 124 meets the head 122. A second hydraulic chamber 130 may be defined axially between the shoulder 126 and the end face 128. The head 122 may include a flow port 132 therein, which may communicate between the first and second hydraulic chambers 110, 130. For example, as shown, the flow port 132 may include an axial bore 134 in the head 122 extending from the first hydraulic chamber 110, but not entirely through the head 122. The flow port 132 may also include one or more radial openings 136, which extend at least partially radially from the axial bore 134 and to an outer diameter of the head 122, e.g., between the head 122 and the inner diameter of the lower cylinder 104, below (to the right of, as illustrated) the seals 123, and thus may fluidly communicate with the second hydraulic chamber 130 via the unsealed interface between the head 122 and the lower cylinder 104.

In some embodiments, the tool 100 may include a mandrel adapter 140. The mandrel adapter 140 may be configured to engage the mandrel of the subjacent tool and, upon actuation of the setting tool 100, to pull upward on the mandrel of the subjacent tool, as discussed above. Further, a lower end 142 of the lower cylinder 104 may be configured, upon actuation of the tool 100, to slide over and past the mandrel adapter 140 and into engagement with the setting assembly of the subjacent tool, so as to push downwardly thereon, as discussed above. The mandrel adapter 140 may also provide a lower stop for the movement of the lower cylinder 104, as will be described in greater detail below, thereby preventing the lower cylinder 104 from sliding away from the around the mandrel 120.

FIG. 2 illustrates a side, cross-sectional view of the tool 100 in an actuated position, that is, after actuation of the tool 100, according to an embodiment. Actuation of the tool 100 may generally occur by detonating the powder charge contained in the charge chamber 112. Detonation may expand the gas in the charge chamber 112 or otherwise apply a force on the piston 114 directed in a downhole direction (to the right in FIG. 2). This force causes the piston 114 to move from the position shown in FIG. 1 to that shown in FIG. 2.

The piston 114 moving causes the hydraulic fluid in the first hydraulic chamber 110 to flow through the flow port 132 and (e.g., directly) into the second hydraulic chamber 130. However, the flow port 132, e.g., the radial openings 136, may be relatively small in cross-section, as shown, and the hydraulic fluid may be viscous. Accordingly, the flow port 132 may serve to slow the movement of the piston 114, acting as a dashpot to limit shock loading of the subjacent tool.

As the fluid is forced from the first hydraulic chamber 110 into the second hydraulic chamber 130, the restraining members 121 holding the lower cylinder 104 in place release (e.g., yield), allowing the lower cylinder 104 to slide relative to the mandrel 120. This allows the volume of the second hydraulic chamber 130 to increase, as the pressure of the hydraulic fluid filling the second chamber 130 under force applied by the piston 114, drives the lower cylinder 104 away from the upper cylinder 102.

As the lower cylinder 104 is driven downhole, the mandrel 120 is prevented from moving with respect to the upper cylinder 102 and thus the tool string via the connection with the upper cylinder 102. As noted above, the mandrel 120 is connected to a subjacent mandrel, e.g., via the mandrel adapter 140. The subjacent mandrel may thus likewise be prevented from movement with respect to the upper cylinder 102.

The lower cylinder 104, however, is driven downhole, extending the lower end 142 thereof past the mandrel adapter 140, e.g., into engagement with the subjacent tool (or any other structure employed to set the subjacent tool), and applying a downhole-directed force thereto. In some embodiments, the shoulder 126 may engage the adapter 140 at a bottom of a downstroke of the lower cylinder 104, such that the adapter 140 prevents the lower cylinder 104 from sliding off of the mandrel 120. The combination of the pushing and pulling may cause the subjacent tool to radially expand, and thereby set into position, e.g., sealing with a surrounding tubular (e.g., casing, liner, wellbore wall, etc.).

FIG. 3 illustrates a flowchart of a method 300 for setting a downhole tool (e.g., packer, plug, etc.), according to an embodiment. For the sake of convenience, the downhole tool will be described as a packer, but it will be appreciated that this is merely an example. The method 300 may proceed by operation of the downhole setting tool 100 discussed above, and thus is described herein with reference thereto. However, it will be appreciated that other embodiments may employ other structures. Further, although one illustrated sequence of steps is described below for the method 300, it will be appreciated that the order may be changed, or the steps may be combined or separated into two or more steps, without departing from the scope of the present disclosure.

The method 300 may begin by connecting a mandrel 120 of the downhole setting tool 100 to a packer, as at 302. In some embodiments, the mandrel 120 may be connected to a mandrel of the packer, but in other embodiments, the mandrel 120 may be connected to a cone or another setting tool. The method 300 may also include connecting an upper cylinder 102 of the downhole setting tool 100 to a tool string, as at 304. The method 300 may then include running the tool string, including the setting tool 100 and the packer, into a wellbore, as at 306.

When the packer arrives at a desired position, the downhole setting tool 100 may be actuated, as at 308. Actuating the downhole setting tool 100 may be achieved by detonating a powder charge contained in a charge chamber 112 of the downhole setting tool 100. Further, detonating the powder charge may drive a piston 114 in the upper cylinder 102 in a downhole direction. Driving the piston 114 in the downhole direction may force a hydraulic fluid contained in a first hydraulic chamber 110 through a flow port 132 defined in the mandrel 120 and into a second hydraulic chamber 130. The second hydraulic chamber 130 is defined between the mandrel 120 and a lower cylinder 104. Forcing fluid into the second hydraulic chamber 130 may cause one or more restraining members 121 holding the lower cylinder 104 in place relative to the upper cylinder 102 to release, and may then cause the lower cylinder 104 to move downward with respect to the mandrel 120.

The lower cylinder 104 may move downward into engagement with the packer or another setting tool, so as to set the packer. The mandrel 120 may be prevented from moving with respect to the tool string via connection to the upper cylinder 102. Thus, the downward movement of lower cylinder 104 may push downward on the packer, while the mandrel 120 pulls upward on the mandrel or cone of the packer. As a result, a setting force (e.g., a downward force, an upward force, or a combination thereof) is applied by the setting tool 100 onto the packer, thereby radially expanding the packer, so as to set the packer in the wellbore.

The foregoing has outlined features of several embodiments so that those skilled in the art may better understand the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.

Claims

1. A downhole setting tool, comprising:

an upper cylinder;

a piston positioned in the upper cylinder, wherein a charge chamber is defined on one side of the piston within the upper cylinder, and a first hydraulic chamber is defined on an opposite side of the piston and within the upper cylinder;

a mandrel coupled to the upper cylinder, wherein a flow port is defined in the mandrel, the flow port being in fluid communication with the first hydraulic chamber; and

a lower cylinder coupled to the mandrel, the mandrel and the lower cylinder defining a second hydraulic chamber within the lower cylinder, and the flow port being in fluid communication with the second hydraulic chamber, wherein the lower cylinder is configured to move with respect to the mandrel when the downhole setting tool is actuated.

2. The downhole setting tool of claim 1, wherein the charge chamber is configured to contain an explosive charge, wherein, detonating the explosive charge forces the piston toward mandrel so as to move the lower cylinder.

3. The downhole setting tool of claim 2, wherein the first and second hydraulic chambers are configured to contain a hydraulic fluid therein, such that, when the piston is forced toward the mandrel, at least some of the hydraulic fluid is forced from the first hydraulic chamber to the second hydraulic chamber.

4. The downhole setting tool of claim 3, wherein the lower cylinder is configured to slide with respect to the mandrel, such that forcing the hydraulic fluid from the first hydraulic chamber to the second hydraulic chamber causes the lower cylinder to slide so as to increase a volume of the second hydraulic chamber.

5. The downhole setting tool of claim 1, wherein the lower cylinder comprises a shoulder, and wherein the mandrel extends through and seals with the shoulder.

6. The downhole setting tool of claim 5, wherein the second hydraulic chamber is at least partially defined between an end face of a head of the mandrel and the shoulder.

7. The downhole setting tool of claim 5, further comprising a mandrel adapter that is connected to the mandrel, wherein the mandrel adapter is configured to engage the shoulder of the lower cylinder at a bottom of a stroke of the lower cylinder.

8. The downhole setting tool of claim 1, wherein the mandrel comprises a head that is connected to the upper cylinder, and an extension that extends from the head and through at least a portion of the lower cylinder, and wherein the flow port extends axially into but not through the mandrel, and extends at least partially radially outward in the head into fluid communication with the second hydraulic chamber.

9. The downhole setting tool of claim 1, wherein the mandrel is configured to apply an uphole-directed force on a mandrel of a subjacent tool, and wherein the lower cylinder is configured to apply a downhole-directed force on a setting assembly of the subjacent tool.

10. The downhole setting tool of claim 1, further comprising one or more shear members connecting the lower cylinder to the mandrel, wherein the one or more shear members are configured to shear to allow the lower cylinder to slide relative to the mandrel upon actuation.

11. The downhole setting tool of claim 1, wherein the upper cylinder comprises:

a sub in which the charge chamber is defined, the sub defining an upper connection for the tool that is configured to be connected to a tool string; and

a sleeve in which the first hydraulic chamber is defined, the sleeve being connected to the mandrel, such that the mandrel is configured not to move with respect to the sleeve during actuation of the tool.

12. The downhole setting tool of claim 11, wherein the mandrel comprises:

a head connected to the sleeve, wherein the lower cylinder is received around and sealed with the head, wherein the second hydraulic chamber is at least partially defined between an end face of the head and a shoulder of the lower cylinder; and

an extension extending from the head and through the shoulder, the extension being sealed with the shoulder of the lower cylinder and configured to couple to a mandrel of a subjacent tool.

13. A method for setting a downhole tool, comprising:

coupling a mandrel of the downhole tool to a setting tool, wherein the setting tool comprises: an upper cylinder; a piston positioned in the upper cylinder, wherein a charge chamber is defined on one side of the piston within the upper cylinder, and a first hydraulic chamber defined on an opposite side of the piston and within the upper cylinder, the first hydraulic chamber having hydraulic fluid therein; a mandrel attached to the upper cylinder, wherein the mandrel of the setting tool is coupled the mandrel of the downhole tool, and wherein the mandrel and is in fluid communication with the first hydraulic chamber; a lower cylinder coupled to the mandrel, the mandrel and the lower cylinder defining a second hydraulic chamber within the lower cylinder that is in fluid communication with the first hydraulic chamber;

deploying the tool and the setting tool into a wellbore; and

detonating a charge in the charge chamber of the setting tool, wherein detonating the charge causes a force to be applied to the piston, wherein applying the force to the piston causes the piston to force at least some of the hydraulic fluid to flow from the first hydraulic chamber to the second hydraulic chamber, and wherein causing at least some of the hydraulic fluid to flow from the first hydraulic chamber to the second hydraulic chamber causes the lower cylinder to move with respect to the mandrel and to apply a setting force to the downhole tool.

14. The method of claim 13, wherein the setting tool further comprises a flow port extending at least partially through the mandrel and between the first and second hydraulic chambers, and wherein detonating the charge presses the at least some of the hydraulic fluid from the first hydraulic chamber, through the flow port, and into the second hydraulic chamber, expanding the second hydraulic chamber.

15. The method of claim 14, wherein the flow port comprises at least one radial opening communicating with the second hydraulic chamber, and wherein detonating the charge causes the at least some of the hydraulic fluid to flow through the at least one radial opening, and from the at least one radial opening into the second hydraulic chamber.

16. The method of claim 13, wherein detonating causes the lower cylinder to move axially past a lower end of the mandrel so as to press downwards on the downhole tool while the mandrel pulls upwards on the downhole tool.

17. The method of claim 13, wherein the lower cylinder is positioned at least partially around the mandrel, and wherein detonating the charge causes the lower cylinder to slide along an outer diameter surface of the mandrel.

18. The method of claim 17, wherein the mandrel is coupled to and connects together the upper cylinder and the lower cylinder.

19. The method of claim 18, wherein the mandrel is connected to the lower cylinder via one or more restraining members, and wherein detonating the charge causes the one or more restraining members to yield, thereby permitting the lower cylinder to slide relative to the mandrel.

20. A downhole setting tool, comprising:

an upper cylinder comprising a sub configured to contain an explosive charge, the upper cylinder at least partially defining a first hydraulic chamber therein;

a piston positioned in the first hydraulic chamber and movable with respect to the upper cylinder in response to detonating the charge;

a mandrel comprising: a head coupled to the upper cylinder and defining a flow port therein, wherein the piston moving in response to the charge detonating is configured to cause hydraulic fluid to flow from the first hydraulic chamber and through the flow port; and an extension extending from the head and configured to couple to a subjacent tool so as to apply an axially-directed force thereto;

a lower cylinder received at least partially around the mandrel and comprising a shoulder that is sealed with the extension of the mandrel, wherein the shoulder and the head of the mandrel define a second hydraulic chamber axially therebetween, the first and second hydraulic chambers being in fluid communication with one another via the flow port; and

one or more retaining members connecting the lower cylinder to the head of the mandrel, wherein the one or more retaining members are configured to release and allow the lower cylinder to move relative to the mandrel and relative to the upper cylinder.