Setting tool for downhole applications
First Claim
1. A well tool comprising:
- a chamber comprising side walls and an activator disposed at a first end of the chamber, wherein the chamber is configured to contain a non-explosive gas and plasma-generating fuel;
a liner configured to protect the side walls from the plasma of the non-explosive gas and plasma-generating fuel;
a tool body comprising a cavity configured to receive pressure from the chamber, wherein the tool body comprises a first inside diameter and a second inside diameter longitudinally disposed with respect to the first inside diameter, wherein one or more o-rings disposed upon the piston form a gas-tight seal between the piston and the first inside diameter, and wherein the second inside diameter is greater than the first inside diameter;
a bleed sub, positioned between the chamber and the tool body, configured to control pressure from the chamber as it is applied to the cavity;
a piston disposed within the cavity and oriented to stroke in a first direction in response to a pressure increase in the cavity; and
a shaft mechanically connected to the piston and stroking in the first direction with the piston in response to the pressure increase in the cavity,wherein the well tool is configured so that pressurizing the chamber by activation of the non-explosive gas and plasma-generating fuel causes the piston and shaft to stroke.
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Accused Products
Abstract
A setting tool for deploying a downhole tool within a wellbore is described herein. The setting tool uses an in situ non-explosive gas-generating power source to generate high-pressure gas, which drives a mechanical linkage to actuate the deployment of the downhole tool. According to certain embodiments the non-explosive gas-generating setting tool contains no hydraulic stages and may contain only a single piston. The setting tool may be fitted to provide different stroke lengths and can provide usable power over a greater percentage of its stroke length, compared to setting tools using explosive/pyrotechnic power sources. Methods of using a non-explosive gas-generating setting tool to deploy a downhole tool within a wellbore are also disclosed.
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Citations
26 Claims
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1. A well tool comprising:
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a chamber comprising side walls and an activator disposed at a first end of the chamber, wherein the chamber is configured to contain a non-explosive gas and plasma-generating fuel; a liner configured to protect the side walls from the plasma of the non-explosive gas and plasma-generating fuel; a tool body comprising a cavity configured to receive pressure from the chamber, wherein the tool body comprises a first inside diameter and a second inside diameter longitudinally disposed with respect to the first inside diameter, wherein one or more o-rings disposed upon the piston form a gas-tight seal between the piston and the first inside diameter, and wherein the second inside diameter is greater than the first inside diameter; a bleed sub, positioned between the chamber and the tool body, configured to control pressure from the chamber as it is applied to the cavity; a piston disposed within the cavity and oriented to stroke in a first direction in response to a pressure increase in the cavity; and a shaft mechanically connected to the piston and stroking in the first direction with the piston in response to the pressure increase in the cavity, wherein the well tool is configured so that pressurizing the chamber by activation of the non-explosive gas and plasma-generating fuel causes the piston and shaft to stroke. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
wherein pressure is produced by the thermite reaction, the gas, or the combinations thereof.
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9. The well tool of claim 1, further comprising a compressible member configured in relationship with the shaft such that the compressible member is compressed by the piston when the piston is stroked in the first direction, thereby decelerating the piston and shaft.
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10. The well tool of claim 1, wherein the piston strokes in the first direction from the first inside diameter to the second inside diameter, and wherein the one or more o-rings do not form a gas-tight seal between the piston and the second inside diameter.
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11. The well tool of claim 1, further comprising a shaft sub, wherein the shaft slides through the shaft sub in the first direction when stroked, and wherein one or more o-rings disposed within the shaft sub form a gas-tight seal between the shaft sub and the shaft.
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12. The well tool of claim 11, wherein the shaft comprises a fluted section, and wherein the intersection between the fluted section and the shaft sub prevents the one or more o-rings from forming a gas-tight seal between the shaft sub and the shaft.
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13. The well tool of claim 1, further comprising a second bleed sub disposed between the chamber and the piston, wherein the second bleed sub comprises a carbon-containing disk member configured to protect components of the second bleed sub from gases generated within the chamber.
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14. A self-bleeding well tool comprising:
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a tubular tool body comprising a first inside diameter and a second inside diameter, wherein the second inside diameter is greater than the first inside diameter; and a shaft mechanically linked to a piston and configured to stroke with the piston from a first position to a second position within the tubular tool body in a first direction, wherein the piston comprises one or more first o-rings about a circumference of the piston; and a shaft sub, wherein the one or more first o-rings form a gas-tight seal with the first inside diameter when the piston is positioned at the first position within the first inside diameter and the one or more first o-rings do not form the gas-tight seal with the second inside diameter when the piston is positioned at the second position within the second inside diameter, wherein the shaft slides through the shaft sub when stroking from the first position towards the second position, and wherein one or more second o-rings disposed within the shaft sub form a gas-tight seal between the shaft sub and the shaft, and wherein the shaft comprises a fluted section, and wherein an intersection between the fluted section and the shaft sub prevents the one or more second o-rings from forming the gas-tight seal between the shaft sub and the shaft while stroking from the first position to the second position.
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15. A modular well tool kit, comprising:
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a chamber comprising side walls and an activator disposed at a first end of the chamber, wherein the chamber contains a non-explosive gas and plasma-generating fuel; and a first tool body comprising a cavity configured to receive pressure from the chamber and to contain a piston mechanically connected to one shaft of at least two interchangeable shafts, wherein the at least two interchangeable shafts comprise different lengths, and wherein each shaft of the at least two interchangeable shafts is configured to mechanically connect to the piston and to stroke within the first tool body when the first tool body is operably connected with the chamber, and wherein the at least two interchangeable shafts comprise a fluted section, and the fluted section and the shaft sub prevents one or more o-rings from forming a gas-tight seal around the shaft. - View Dependent Claims (16)
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17. A method of deploying a downhole tool within a wellbore, the method comprising:
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activating a non-explosive gas and plasma-generating fuel contained within a chamber of a setting tool operatively connected to the downhole tool; directing the non-explosive gas within the chamber to impinge directly on a piston; actuating the piston mechanically linked to a shaft to stroke within a tubular tool body; and mechanically actuating a setting mechanism of the downhole tool with the piston, wherein plasma is blocked from impinging on the piston by a filtering plug. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24)
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25. A well tool comprising:
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a chamber comprising side walls and an activator disposed at a first end of the chamber, wherein the chamber is configured to contain a non-explosive gas and plasma-generating fuel; a liner configured to protect the side walls from the plasma of the non-explosive gas and plasma-generating fuel; a tool body comprising a cavity configured to receive pressure from the chamber; a bleed sub, positioned between the chamber and the tool body, configured to control pressure from the chamber as it is applied to the cavity; a piston disposed within the cavity and oriented to stroke in a first direction in response to a pressure increase in the cavity; a shaft sub, wherein the shaft slides through the shaft sub in the first direction when stroked, and wherein one or more o-rings disposed within the shaft sub form a gas-tight seal between the shaft sub and the shaft; and a shaft mechanically connected to the piston and stroking in the first direction with the piston in response to the pressure increase in the cavity, wherein the shaft comprises a fluted section, and wherein the intersection between the fluted section and the shaft sub prevents the one or more o-rings from forming a gas-tight seal between the shaft sub and the shaft, wherein the well tool is configured so that pressurizing the chamber by activation of the non-explosive gas and plasma-generating fuel causes the piston and shaft to stroke.
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26. A well tool comprising:
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a chamber comprising side walls and an activator disposed at a first end of the chamber, wherein the chamber is configured to contain a non-explosive gas and plasma-generating fuel; a liner configured to protect the side walls from the plasma of the non-explosive gas and plasma-generating fuel; a tool body comprising a cavity configured to receive pressure from the chamber; a first bleed sub, positioned between the chamber and the tool body, configured to control pressure from the chamber as it is applied to the cavity; a piston disposed within the cavity and oriented to stroke in a first direction in response to a pressure increase in the cavity; a second bleed sub, disposed between the chamber and the piston, wherein the second bleed sub comprises a carbon-containing disk member configured to protect components of the second bleed sub from gases generated within the chamber; and a shaft mechanically connected to the piston and stroking in the first direction with the piston in response to the pressure increase in the cavity, wherein the well tool is configured so that pressurizing the chamber by activation of the non-explosive gas and plasma-generating fuel causes the piston and shaft to stroke.
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Specification