BACKGROUND This disclosure relates generally to methods and apparatus to install a plug on a reusable auto-reset setting tool. This disclosure relates more particularly to methods and apparatus for providing a setting tool able to actuate subsequent plugs on subsequent downhole deployment runs, without the need to use tooling or recharges between each subsequent run. The auto-reset setting tool may include components able to automatically recover their run-in-hole position after the downhole actuation to set a plug for example.
This application claims the benefit of provisional patent application 63/334,092, filed 2022 Apr. 23 by the present inventors, which is incorporated by reference in its entirely.
FIG. 1 refers to one environment example in which the methods and apparatus for providing a plug inside a tubing string containing well fluid, described herein, may be implemented and used.
FIG. 1 illustrates a typical cross section of an underground section dedicated to a cased-hole operation. The type of operation is often designated as Multi-Stage-Stimulation or Multi-Stage Frac, as similar operations are repeatedly performed inside a tubing string in order to stimulate the wellbore area.
The wellbore may have a cased section, represented with tubing string 1. The tubing string typically contains several sections from the surface 3 until the well end. The tubing string represented schematically includes a vertical and horizontal section. The entire tubing string contains a well fluid 2, which can be pumped from surface, such as water, gel, brine, acid, and also coming from downhole formation such as produced fluids or condensates, like water and hydrocarbons in liquid or gas form.
The tubing string 1 can be partially or fully cemented, referred to as cemented stimulation, or partially or fully free within the borehole, referred to as open-hole stimulation. Typically, a stimulation will include temporary or permanent section isolation between the formation and the internal volume of the tubing string.
The bottom section of FIG. 1 illustrates several stimulation stages starting from well-end. In this particular well embodiment, at least stages 4a, 4b, 4c have been stimulated and isolated from each other. The stimulation is represented with fluid penetration inside the formation through fracturing channels 7, which are initiated from a fluid entry point inside the tubing string. This fluid entry point can typically come from perforations or sliding sleeves openings.
Each isolation of a stage includes a set plug 6 with its untethered object 5, represented as a spherical ball as one example.
The stimulation and isolation are typically sequential from the well end, from downhole to uphole. At the end of stage 4c, after its stimulation 7, another isolation and stimulation, represented as subsequent stage 4d, may be performed in the tubing string 1.
In this representation, a toolstring 10 is conveyed via a cable or wireline 9, which is controlled by a surface unit 8. Other conveyance methods may include tubing conveyed toolstring or coiled tubing. Along with a cable, a combination of gravity, tractoring and pump-down may be used to bring the toolstring 10 to the desired position inside the tubing string 1. The toolstring 10 may convey an unset plug 23, dedicated to isolating stage 4c from stage 4d.
Additional pumping rate and pressure may create a fluid stimulation 7 inside the formation located on or near stage 4d. When the stimulation is completed, another plug may be set and the overall sequence of stages 4a to 4d may start again. Typically, the number of stages within a wellbore may typically be between ten and hundred stages within one wellbore, depending on the technique used, the length of the wellbore and spacing of each stage.
By convention, the downhole direction 13 is directed from top to bottom. If observing a tubing string 1, the downhole direction 13 would be the direction from surface towards the well end. The uphole direction 14 is directed from bottom to top, opposite to the downhole direction. If observing a tubing string 1, the uphole direction 14 would be the direction from the well end towards surface. Therefore, downhole pumping would correspond to pumping well fluid 2 towards the downhole direction 13. Uphole pumping or flowing, typically referred as flowback, would correspond to pumping or flowing well fluid 2 towards the uphole direction 14.
BRIEF DESCRIPTION OF THE DRAWINGS For a more detailed description of the embodiments of the disclosure, reference will now be made to the accompanying drawings.
FIG. 1 is a wellbore cross-section view of typical Multi-Stage-Stimulation operation ongoing, with three stages completed and a toolstring conveyance to install the third isolation device for the fourth stage.
FIG. 2 is a cross-section view of a toolstring including an auto-reset setting tool and a push-and-click plug setting mechanism on the setting adapter.
FIG. 3 is an isometric cross-section view of the end of the toolstring depicted in FIG. 2 with details on the auto-reset setting tool and the push-and-click plug setting mechanism on the setting adapter.
FIG. 4 is an isometric cross-section view of a plug assembly with focus on the shear ring and the end nut.
FIG. 5 is an isometric cross-section exploded view of a plug assembly with a separated view for the shear ring and the end nut.
FIG. 6 is a cross-section view of the push-and-click plug setting mechanism on the setting adapter with plug in unset position, ready to be installed on the push-and-click mechanism.
FIG. 7 is a cross-section view of the push-and-click plug setting mechanism on the setting adapter with the plug in an unset position being started to be inserted on the push-and-click mechanism.
FIG. 8 is a cross-section view of the push-and-click plug setting mechanism on the setting adapter with the plug in an unset position being continued to be inserted on the push-and-click mechanism.
FIG. 9 is a cross-section view of the push-and-click mechanism seen in a plane perpendicular to the toolstring axis and passing through the radial spring of the mechanism, the mechanism being under load of the plug insertion, as on FIG. 8.
FIG. 10 is a cross-section view of the push-and-click plug setting mechanism on the setting adapter with the plug in an unset position being inserted to the end position, on the push-and-click mechanism.
FIG. 11 is a cross-section view of the push-and-click plug setting mechanism on the setting adapter with the plug in an unset position, with the plug fully inserted and the mechanism locking the plug in place.
FIG. 12 is a cross-section view of the push-and-click mechanism seen in a plane perpendicular to the toolstring axis and passing through the radial spring of the mechanism, the mechanism being re-expanded and locking the plug in position, as on FIG. 11.
FIG. 13 is a workflow sequence related to the push-and-click mechanism.
FIG. 14 is a cross-section view of a toolstring end with the auto-rest setting tool in a run-in-hole position, with an unset plug attached to the auto-rest setting tool, within a tubing string.
FIG. 15 is a cross-section view of a toolstring end with the auto-rest setting tool starting to be activated and setting the plug inside a tubing string.
FIG. 16 is a cross-section view of a toolstring end with the auto-rest setting tool finishing to actuate and shift and setting the plug inside a tubing string by shearing the shear-ring.
FIG. 17 is a cross-section view of a toolstring end with the auto-rest setting tool reaching the course end for the piston.
FIG. 18 is a cross-section view of a toolstring end with the auto-rest setting tool being released from the set plug within the tubing string.
FIG. 19 is a cross-section view of a toolstring end with the auto-rest setting tool being freed from the set plug, and engaging the auto-reset mechanism to recover its unactuated position.
FIG. 20 is a cross-section view of a toolstring end with the auto-rest setting tool having recovered its unactuated position, for a subsequent plug installation.
FIG. 21 is a workflow sequence related to the auto-reset setting tool deployment method.
FIG. 22 is a workflow sequence related to the auto-reset setting tool working method.
DETAILED DESCRIPTION It is to be understood that the following disclosure describes several exemplary embodiments for implementing different features, structures, or functions of the invention. Exemplary embodiments of components, arrangements, and configurations are described below to simplify the disclosure; however, these exemplary embodiments are provided merely as examples and are not intended to limit the scope of the invention.
A reference to U.S. application Ser. No. 17/275,509 filed Mar. 11, 2021, titled “Methods and Apparatus for providing a plug with a two-step expansion” can provide a detailed description of the FIG. 1. A reference to U.S. application Ser. No. 17/892,015 filed Aug. 19, 2022, titled “Methods and Apparatus for providing a plug activated by cup and untethered object” can provide a detailed description of the plug 23, as an example, as depicted in FIGS. 4-12.
FIG. 2 represents a cut view of the toolstring 10 depicted in FIG. 1. The toolstring 10 may include a generic section 20. The generic section 20 may include perforating or gun section, a sensor section, a communication section and a power distribution section. The sensor section may include for example CCL, Gamma Ray, Pressure and Temperature sensors. The power may be typically distributed from the cable 9 as depicted in FIG. 1. Power distribution may also occur through a turbine using flowrate pumped at surface as a power mean. Other power distribution may also include batteries comprised within the toolstring 10. At the downhole end of the tool string 10, a setting tool 21 may be present. Typically, associated with the setting tool 21, a setting adapter 22 may be positioned downhole from the setting tool 22, in order to adapt to the shape and features of the plug 23. A first goal of the setting tool 21 and setting adapter 22 may be to hold the plug 23 in an unset position during the conveyance sequence, i. e. run-in-hole with the toolstring 10 up to the wished position to set the plug 23 inside the wellbore 1. A second goal of the setting tool 21 and setting adapter 22 may be to actuate or set the plug 23 at the wished position inside the wellbore 1, and release the set plug 23 from the toolstring 10. Note that the limit of the setting tool 21 and setting adapter 22 may not be clearly defined as the setting tool 21 itself may already include some parts which allows to fit a specific plug 23.
FIG. 3 represents a detailed isometric cross-section view of the setting tool 21 and setting adapter 22. The setting tool 21 will further be detailed in FIGS. 14-20, while it will be considered as an auto-reset setting tool, with the features described thereafter.
The setting tool 21 may include a setting tool body 120. The setting tool body 120 may have the shape of an external sleeve, and may be positioned in the continuity of the generic section 20, as shown in FIG. 2. The setting tool body 120 may be connected to the guns or perforating section of the generic section 20, through threaded connection. The setting tool body 120 may include a rod 121, as an integral part. In FIG. 3 and further figures, the rod 121 and setting tool body 120 are displayed attached together with a fixed connection 122. Depending on the manufacturing process, the fixed connection 122 could be welded, threaded, pined or press-fit. The rod 121 could be considered part of the setting adapter 22, as its length, diameter and shape may be dependent on the plug 23, which will be conveyed and set with the setting tool 21 together with the setting adapter 22.
The setting tool 21 may include a piston 140. The piston 140 may shift longitudinally relative to the setting tool body 120 and the rod 121. The longitudinal direction of the piston 140 shifting may follow the center axis of the setting tool 21, the center axis being symbolized by a line 12, as center axis for the toolstring 10, including the generic section 20, the setting tool 21, the setting adapter 22, and the plug 23. The piston 140 may be constrained, from the uphole direction, by the fluid contained in a fluid pressure chamber 133, and, from the downhole direction, by the fluid contained in a relief pressure chamber 135. Depending on the pressure of the fluid contained in the fluid pressure chamber 133, and the surface in contact with the fluid inside the fluid pressure chamber 133, versus the surface exposed downhole of the piston 140 to the well fluid 2, the piston 140 may be set to move longitudinally away or towards the setting tool body 120. A physical stop 137 may be present between the setting tool body 120 and the piston 140. The physical stop 137 may have the shape of a shoulder or protrusion, as represented in FIG. 3.
As the piston 140 may shift longitudinally, seals 134, such as O-rings, may provide a dynamic fluid barrier between the fluid contained inside the fluid pressure chamber 133 and the relief pressure chamber 135. Other seals 138, such as O-rings or gaskets, may provide a dynamic fluid barrier between the fluid contained inside the fluid pressure chamber 133 and the well fluid 2. Other seals 141, such as O-rings or gaskets, may provide a dynamic fluid barrier between the fluid contained inside the relief pressure chamber 135 and well fluid 2. Note that the fluid contained inside the fluid pressure chamber 133 may be a water based or oil based mixture, typically controlled at surface. Other embodiment could include an intake of well fluid 2 to be used as the fluid contained inside the fluid pressure chamber 133. The relief pressure chamber 135 may typically include a gas or emulsion, such as air or inert gas, to keep a low pressure such as atmospheric pressure. Other fluid and gas combinations as filler inside the chambers 133 and 135 may be possible, as long as the piston may move and provide force to set a plug 23, not shown in the FIG. 3, though displayed in FIGS. 14-22.
A compression spring 136 may be present inside the relief pressure chamber 135. The compression spring 136 would provide a force on the piston 140 relative to the rod 121 and setting tool body 120. The compression spring 136 would provide a counter force to bring the piston 140 at the physical stop 137 on the setting tool body 120, in case no significant fluid pressure is available inside the fluid pressure chamber 133.
Towards the extremity of the rod 121, the apparatus for a plug push-and-click mechanism 24 to attach the plug 23 may be present. The plug push-and-click mechanism 24 may be used as the tool-free and screw-free installation of a plug onto a setting tool. As depicted in FIG. 3, the plug push-and-click mechanism 24 may include multiple retractable conical sections 200. Typically the plug push-and-click mechanism 24 may include between two and sixteen retractable conical sections 200, which may be positioned radially towards the outer surface of the rod 121. Each retractable conical section 200 may include a flared external surface 203, which may have a conical external shape, though other shapes may be possible such as flared facets or polygons. Each retractable conical section 200 may be associated with a compression spring 201, and with a stopping device 202. The compression spring 201 may be positioned underneath each retractable conical section 200. Each retractable conical section 200 may slide radially between two positions, an extended position and a retracted position. Each compression spring 201 may push radially outwards each retractable conical section 200 so that each retractable conical section 200 may stay in its extended position by default, when no other item blocks its radial expansion. The end of the extended position of each retractable conical section 200 may be limited by the position of the stopping device 202. Uphole of the retractable conical sections 200, a recess section 205 may be present within the rod 121. The recess section 205 may include an outer diameter which is smaller than the retractable conical sections 200 in their expanded position, and which is equivalent in outer circumference with the circumference of the multiple retractable conical sections 200 in their retracted position.
FIG. 4 depicts an isometric cross-section view of a plug 23. The features of the plug 23 may be taken as reference from application Ser. No. 17/892,015, published under US2022-0389789, filed on 19 Aug. 2022 as Continuation Application of application Ser. No. 17/275,509, filed on 11 Mar. 2021, with inventor named Gregoire Jacob. The push-and-click mechanism 24 may be compatible with other plugs which include similar features as the ones described in FIG. 4. The plug 23 may include a back-pushing ring 160, a shear ring 167 and an end nut 166. The plug 23 may include dissolvable material which may dissolve within well fluid 2 contained inside the tubing string 1 or wellbore.
FIG. 5 represents an exploded view of the key features of the plug 23, as depicted in FIG. 4. Visible are the shear ring 167 and the end nut 166, displayed aligned the toolstring axis 12. The end nut may be screwed inside an inner surface of the back-pushing ring 160 and secure longitudinally and radially the shear-ring 167. Therefore, the shear ring 167 may be secured within the plug 23 inside the back-pushing ring 160.
The shear-ring 167 may include multiple protrusions 210. As depicted, the shear ring 167 may include four protrusions 210, typically the same number as the number of retractable conical sections 200. As further described in FIGS. 6-12, the protrusion 210 will serve as shear section for the shear ring 167, at the end of the actuation of the plug 23. The thickness of the protrusion 210 of the shear-ring 167 may be smaller than the longitudinal width of the recess section 205, as described in FIG. 3.
FIG. 6 depicts a cross-section of the end section of the setting tool 21 and setting adapter 22, ready to adapt with the plug 23. The setting tool 21 and setting adapter 22 are in the status as depicted and described in FIG. 3. The plug 23 is in the same status as depicted and described in FIG. 4. Additional items on the plug may include a hemispherical cup 111, a locking ring 110, a sealing ring 170, a gripping ring 161 and anchoring devices 74.
FIG. 7 depicts a cross-section of the similar entity as in FIG. 6, with the setting tool 21 and setting adapter 22, and the plug 23 which has been longitudinally slid onto the exposed surface of the rod 121 and piston 140. Arrows 300 symbolize the sliding movement of the plug 23 along the setting tool 21 and setting adapter 22. Typically, the sliding movement is part of mounting the plug 23 on the toolstring 10. At the stage, the shear ring 166 has not come in contact yet with the multiple retractable conical sections 200. In particular, the internal diameter of the multiple protrusions 210 of the shear-ring 166 has not come in contact with the flared surface 203 of the multiple retractable conical sections 200.
FIG. 8 is a sequential view of the FIG. 7, and represents a cross-sectional view of the setting tool 21, setting adapter 22 with the plug 23. The process of longitudinal sliding represented with arrows 300 in FIG. 7 is continued in FIG. 8 and symbolized with arrows 301. At the stage of FIG. 8, the internal diameter of the shear ring 166 has come in circumference contact with the multiple retractable conical sections 200. In particular, the internal diameter of the multiple protrusions 210 of the shear-ring 166 is contacting the flared surface 203 of the multiple retractable conical sections 200, causing a radial retraction movement of the multiple retractable conical sections 200, symbolized with arrows 302. Therefore, a longitudinal movement 301, associated with longitudinal force, would cause the compression of the multiple springs 201, together with the radial retraction 302, of the multiple retractable conical sections 200. As further longitudinal movement 301 is provided, a further compression of the multiple springs 201 may occur, as a continuous contact between the internal diameter of the multiple protrusions 210 of the shear-ring 166 with the flared surface 203 of the of the multiple retractable conical sections 200. The continuous contact may be represented as contact area 304. The total compression force of the multiple springs 201 may be selected between 0.05 lbf and 50 lbf [2 N to 200 N] to provide a plug installation without damaging other components of the plug 23 or the setting adapter 22. On the other side, the compression springs, when back in extended position, may need to provide sufficient support of the multiple retractable conical sections 200 in order to hold the plug 23 in a conveyance situation, within a tubing string 1 or borehole, which may include shocks and fluid flow reaction.
A call-out 303 is depicted to position a cross-section view represented in FIG. 9.
FIG. 9 represents a cross-section view as called-out with arrows 303 in FIG. 8. The cross-section view of FIG. 9 passes through the multiple compression springs 201. As seen in FIG. 8, the multiple retractable conical sections 200 may be retracted as symbolized with arrows 302. Each retractable conical sections 200 may retract towards a different direction, though which is radial compared to the center of the toolstring 10. As depicted, four retractable conical sections 200 are represented, as well as four protrusions 210 for the shear ring 167. The protrusions 210 may be in contact with the corresponding external surface of each retractable conical section 200, at the contact area 304. Also visible are the cross-sections of the rod 121 and of the back-pushing ring 160.
FIG. 10 represents a cross-sectional view of the setting tool 21, setting adapter 22 with the plug 23, as sequential view compared to FIG. 8. In FIG. 10, the plug 23 may have moved longitudinally further, symbolized with arrow 311, to a stopping surface on the setting adapter 22. Examples of stopping surfaces are represented as surface 320 between the hemispherical cup 111 of the plug 23 with piston 140, as surface 321 between the locking ring 110 of the plug 23 with the piston 140, as surface 322 between the back-pushing ring 160 of the plug 23 with the rod 121. In the position depicted in FIG. 10, the inner section of the shear-ring 167 may not be any more in contact with the flared outer surface 203 of each retractable conical section 200. The protrusions 210 of the shear-ring 167 may fit longitudinally within the recess section 205. Each compression spring 201 may act on the each retractable conical section 200 to bring the retractable conical sections 200 to their expanded position, which will be depicted in FIG. 11.
FIG. 11 represents a cross-sectional view of the setting tool 21, setting adapter 22 with the plug 23, as sequential view compared to FIG. 10. The plug 23 can be considered secured on the setting adapter 22, and the plug push-and-click mechanism 24 may now be in an expanded stage, with each of the retractable conical section 200 back at an expanded position. The expansion movement of each of the retractable conical section 200 may occur through the expansion of the compression springs 201, symbolized with arrow movement 330. In the expanded position, each of the retractable conical section 200 may provide a locking surface for each of the multiple protrusions 210 of the shear-ring 167, positioned within the recess section 205 of the rod 121. With the shear-ring being secured with the end nut 166, the whole plug 23 may be secured together the setting adapter 22 and the setting tool 21. Further operation of conveyance within the tubing string 1 may be possible up to the setting of the plug 23 within the tubing string 1, after the actuation of the setting tool 21, as further depicted in FIG. 15-24.
A call-out 331 is depicted to position a cross-section view represented in FIG. 12.
FIG. 12 represents a cross-section view as called-out with arrows 331 in FIG. 11. The cross-section view of FIG. 12 passes through the multiple compression springs 201. As seen in FIG. 11, the multiple retractable conical sections 200 may be back in the expanded position, as symbolized with arrows 330. Each of the multiple retractable conical sections 200 may be pointing radially sufficiently in order to lock longitudinally each of the multiple protrusions 201 of the shear-ring 167. Also visible are the cross-sections of the rod 121 and of the back-pushing ring 160.
FIG. 13 represents a workflow sequence 340 related to the push-and-click mechanism 24. Step 341 comprises the insertion of a plug 23 at surface on a push-and-click mechanism 24 of a setting adapter 22 of a setting tool 21. Step 342 comprises the contact of a retractable section 200 of the push-and-click mechanism 24 with a shearing device 167 within the plug 23. Step 343 comprises the longitudinal sliding of the shearing device 167 together with the plug 23, in order to radially compress the retractable section 200 of the push-and-click mechanism 24, up to reaching a recess section 205 positioned uphole of the retractable section 200 of the push-and-click mechanism 24. Step 344 comprises the locking of the shearing device 167 within the recess section 205, after the re-expansion of the retractable sections 200 of the push-and-click mechanism 24. Step 345 comprises the deployment of the plug 23 inside a tubing string 1, on the setting tool 21 and the setting adapter 22. Step 346 comprises the actuation of the plug 23 by expanding a gripping portion 161 of the plug 23. Step 357 comprises the shearing of the shearing device 167, typically by actuation of the setting tool 21. Step 348 comprises the release of the plug from the push-and-click mechanism 24 of the setting adapter 22. Step 349 comprises the retrieval of the setting tool 21 and the setting adapter 22 back to surface, whereby the retractable sections 200 of push-and-click mechanism 24 remains in its expanded position, and shearing pieces are left inside the well. Step 350 comprises the re-use of the retrieved push-and-click mechanism 24 for a subsequent plug 23, without the need to redress, modify or replace a part of the push-and-click mechanism 24.
FIGS. 14-22 detail the method and apparatus for a reusable auto-reset setting tool, avoiding the need to redress at surface, after the use of the setting tool downhole.
Preliminary description of items has been done for FIG. 3, and the description of FIG. 14 continues the description of items done in FIG. 3. In particular, reference of descriptions done in FIG. 3 can be taken for: the setting tool body 120, the rod 121, the fixed connection 122, the piston 140, the tool center axis 12, the fluid pressure chamber 133, the relief pressure chamber 135, the physical stop 137, the seals 134, 138 and 141, the compression spring 136. Reference of descriptions done in FIG. 4 and FIG. 6 for the plug 23, can be taken for the plug items like: the hemispherical cup 111, the locking ring 110, the sealing ring 170, the gripping ring 161, the anchoring devices 74, the back-pushing ring 160, the shear ring 167, the end nut 166. Reference of descriptions done in FIG. 3 for the push-and-click mechanism 24, can be taken for items like the retractable conical sections 200, the compression springs 201, the stopping devices 202.
FIG. 14 represents a cross-sectional view of toolstring end with a setting tool, a setting adapter and a plug. The setting tool corresponds to a possible depiction of the reusable auto-reset setting tool. The end of the toolstring is represented within a tubing string 6, which contains well fluid 2. The tubing string 6 may be a casing, a tubing, a liner, inside which the toolstring 10 may be conveyed. The tubing string 6 may be cemented, anchored or floating within an open-hole wellbore, typically anchored with the use of packers. The reusable auto-reset setting tool may include a fluid reservoir 123. The fluid reservoir 123 may be filled with specific fluid such as hydraulic oil, or may be filled with the well fluid 2, available around the setting tool and toolstring 10 at time of fluid fill-up or suction. In case the fluid reservoir 123 is filled with well fluid 2, a fluid entry port 124 may be available on the wall of the setting tool body 120, in order to communicate fluid between the well fluid 2 present in the wellbore 1, and the fluid reservoir 123. The fluid entry port 124 may include a filter as well as a one-way check valve, in order to filter the well fluid 2 before penetrating inside the setting tool body 120, as well as retain the well fluid 2 inside the fluid reservoir 123. A fluid pump 152 may be present within the fluid reservoir 123, in order to pump and pressurize the fluid present inside the fluid reservoir 123. The output of the fluid pump 152 may be the fluid pressure chamber 133, possibly passing through a channel 132. Sealing 153, such as O-ring or gaskets, may be present to provide a fluid pressure tightness between the fluid reservoir 123 and the fluid pressure chamber 135. A motor 151 may be associated with the pump 152 in order to provide the power necessary to engage the fluid pump 152. The motor 151 may be itself power through wiring connecting to the conveyance cable 9, or could be self-powered with energy source present within the toolstring 10, such as batteries or a turbine using the fluid flow available around the toolstring 10 during conveyance sequence. Fluid flow to power a turbine may be available as the toolstring 10 is conveyed using its gravity weight in vertical sections, or using pumping resources available at surface, such as frac pumps, which may be available during the conveyance of the toolstring 10 within vertical or horizontal wellbore sections.
FIG. 14 represents a toolstring end with the reusable auto-reset setting tool, the setting adapter and a plug, all in run-in-hole configuration, or unactuated stage.
FIG. 15 represents a cross-sectional view of the same toolstring end as of FIG. 14, which may be a subsequent step of FIG. 14. The reusable auto-reset setting tool may have been actuated. With the actuation of the fluid pump 152, a fluid pressure P may have increased inside the fluid pressure chamber 133, and may have acted on the surface S of the piston 140 exposed to the fluid pressure chamber. A resultant force, such as F=P*S, may have contributed to the longitudinal shifting of the piston 140, relative to the setting tool body 120. The resultant force is symbolized as arrows 240 in FIG. 15. The resultant force 240 may be larger than the sums of forces resulting from the pressure inside the relief pressure chamber 135, the compression of the compression spring 136, and the setting of the plug as displayed in FIG. 15. As an example, the setting of the displayed plug may include the longitudinal and radial expansion of the gripping ring 161 and of the sealing ring 170 over the locking ring 110. The radial expansion of the gripping ring, and typically of the plug, may occur when the anchoring devices 74 contact the inner surface of the tubing string 6, and start solicitating longitudinally the shear ring 167. A force equilibrium is typically established to set the plug, whereby the necessary plug setting force is beneath the shear rating of the shear ring 167. Typical plug setting force may be in the range of 2,000 lbf to 70,000 lbf [8,900 N to 311,000 N].
FIG. 16 represents a cross-sectional view of the same toolstring end as of FIGS. 14-15, which may be a subsequent step of FIG. 15. The resultant force 240 may have exceeded the shear rating of the shear ring 167, consequently provoking its shear with one or multiple shear segments, displayed with item(s) 168. The piston 140 may continue to move longitudinally away relative to the setting tool body 120, as long as the piston 140 has not reach its end course, and as long as the fluid pump 152 is still active, still providing sufficient fluid pressure inside the fluid pressure chamber 133. The force which brings this continuing movement to the piston 140 is symbolized with arrows 241. Typically, the force 241 would be smaller than the peak force 240 necessary to set the plug and shear the shear ring 167.
FIG. 17 represents a cross-sectional view of the same toolstring end as of FIGS. 14-16, which may be a subsequent step of FIG. 16. In FIG. 17, the course of the piston may have come to an end, which may be materialized by a retainer 139. The retainer 139 may have the shape of a pin, a screw or protrusion, in order to provide a physical stop to the longitudinal movement between the piston 140 and the setting tool body 120. The total course of the piston may be between a range of 1 inch and 10 inches [25 mm to 250 mm]. The compression rate of the compression spring 136 inside the relief pressure chamber 135 may have reached its peak. The fluid pressure pump 152 may be stopped after reaching the course end of the piston 140. The stopping of the pressure pump 152 may occur after a certain time predetermined to set the plug and linked with the motor 152. For example, the wires powering the motor 152 may include a timer switch which switches off the powering of the motor 152 after a predetermined time relative to the time of power on, as shown between FIGS. 14 and 15 in order to start the plug set. A time example for the predetermined timer may be between 2 seconds and 120 seconds. Another example to stop the powering of the motor 152 may be a feed-back loop whereby the retainer 139 includes a switch. The switch of the retainer 139 may be activated when the course of the piston 140 has reached its end, therefore sending back a wired or wireless signal to the powering of the motor 152 with the goal to switch off the motor 152.
FIG. 18 represents a cross-sectional view of the same toolstring end as of FIGS. 14-17, which may be a subsequent step of FIG. 17. In FIG. 18 as in FIG. 17, the piston 140 may have come to a stop. The toolstring 10 has been pulled uphole, typically through wireline 9 pull up. A flowback pumping of well fluid 2 may also contribute to the retrieval of the toolstring 10. As depicted in FIG. 18, the movement of the toolstring 10 may be symbolized with arrows 245, and may separate from the plug now set within the tubing string 6. All major parts of the plug, such as the gripping ring 161 with the anchoring services 74 may stay anchored and set at a fixed position within the tubing string 6. An untethered object, such as a ball, not shown, may be released from the toolstring 10, considered as ball-in-place, or launched from surface after the full retrieval at surface of the toolstring 10.
FIG. 19 represents a cross-sectional view of the same toolstring end as of FIGS. 14-18, which may be a subsequent step of FIG. 18. In FIG. 19, the toolstring 10 is released from the set plug and the toolstring 10 may be under retrieval back to surface. At this point within the tubing string, or at any time between the plug set time, as depicted in FIG. 17, or when the toolstring 10 is back at surface, the auto-reset mechanism of the setting tool may operate. The principle of the auto-reset mechanism may be to move back the piston 140 longitudinally to the unactuated position, as depicted in FIG. 14. The unactuated position of the piston 140 corresponds to the position allowing to carry or run-in-hole an unset plug, as depicted in FIG. 14. In order to bring back the piston 140 to its unactuated position, several action possibilities may occur, as further described.
One possibility to bring back the piston 140 to its unactuated position may be to reduce the fluid pressure inside the pressure chamber 133 to a sufficient level. The sufficient pressure level inside the pressure chamber 133 may need to be below the sum of the pressures or forces acting on the opposite surface of the piston 140, which includes the resultant force acting on surfaces exposed to the pressure of the well fluid 2, or hydrostatic pressure, the resultant force acting on the surface exposed to the pressure included inside the relief pressure chamber 135, and the expansion force of the compression spring 136. For example, at the end of the plug set actuation, with the piston 140 reaching the retainer 139, a wired or wireless signal may be sent to the motor 151 in order to stop rotating or start rotating in the opposite direction, which may cause the pump 152 to depressurize the fluid pressure contained inside the fluid pressure chamber 133.
Another possibility may be having a relief valve included inside the pump 152, allowing to release the fluid pressure contained inside the fluid pressure chamber 133, by opening a valve an re-equilibrating the fluid pressure with the hydrostatic pressure contained in the fluid reservoir 123, potentially in communication with well fluid 2 through the fluid entry port 124. With all fluids in equilibrium, the compression spring 136 may provide the additional necessary force to push back the piston 140.
Another possibility may be having a relief valve included inside the piston 140 and forced opened when the piston 140 reaches a position similar to the retainer 139. As depicted in FIG. 19, a fluid intake 146 may link the fluid pressure of the fluid pressure chamber 133 with a fluid outtake 148 towards the well fluid 2. In-between the intake 146 and outtake 148, a fluid opening switch 147 may be activated only when the piston 140 reaches its end course relative to the setting tool body 120. The fluid opening switch 147 may include an internal back-up spring allowing to close back and therefore reclose the flow path between the fluid pressure chamber 133 and the well fluid 2, after the piston 140 has recovered its unactuated position.
FIG. 20 represents a cross-sectional view of the same toolstring end as of FIGS. 14-19, which may be a subsequent step of FIG. 19. In FIG. 20, the piston 140 may have received its unactuated position, bringing the auto-reset mechanism of the setting tool back to its unactuated or run-in-hole position. If or when back to surface, a subsequent plug may be installed on the unactuated auto-reset setting tool, without the need to redress, refill, recharge, unmount or change any item of the setting tool.
FIG. 21 represents a workflow sequence 360 related to the auto-reset setting tool operation depicted in FIGS. 14-20. Step 361 comprises the installation of a plug at surface on an auto-reset setting tool, as depicted in FIG. 14. Step 362, comprises the deployment of the plug on the auto-reset setting tool into a tubing string. Step 363 comprises the actuation of the auto-reset setting tool by shifting the piston 140 from an unset position to a set position within the setting tool, as depicted in FIG. 15. Step 364 comprises the actuation of the plug by expanding the gripping ring 161, using the shifting force of the piston 140 of the setting tool, as depicted in FIG. 15. Step 365 comprises the contact of at least one anchoring device 74 of the gripping ring 161 with the inner surface of the tubing string 6, as depicted in FIG. 15 and FIG. 16. Step 366 comprises the release of the plug from the setting tool, as depicted in FIG. 18. Step 367 comprises the retrieval of the auto-reset setting tool back to surface, whereby the piston 140 recovers its unset position, as depicted in FIGS. 19-20. Step 368 comprises the performance of a downhole operation, such as a fracturing operation. Step 369 comprises the re-usage of the retrieved auto-reset setting tool to install a subsequent plug without the need to redress, modify or replace a part of the auto-reset setting tool.
FIG. 22 represents another workflow sequence 370 related to the auto-reset setting tool operation depicted in FIGS. 14-20. Step 371 comprises the deployment of an auto-reset setting tool inside a wellbore or a tubing string. Step 372 comprises the actuation of the auto-reset setting tool by increasing the fluid pressure inside the fluid pressure chamber 133, consequently shifting the piston 140, wherein the piston 140 is hydraulically connected by fluid pressure with the pressure chamber 133. Step 373 comprises shifting the piston 140 from an unset position to a set position within the auto-reset setting tool. Step 374 comprises the usage of the shifting of the piston 140 to set a device downhole, such as a plug, and to compress the compression spring 136. Step 375 comprises the release of the fluid pressure inside the fluid pressure chamber 133. Step 376 comprises the usage of the compression spring 136 to force the piston 140 back to its unset position. Step 377 comprises the retrieval of the auto-reset setting tool back to surface to perform a subsequent deployment without the need to redress, modify or preplace a part of the auto-reset setting tool.
