Note: Descriptions are shown in the official language in which they were submitted.
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Impact Resistant Material in Setting Tool
RELATED APPLICATIONS
111 This application claims priority to U.S. Provisional Application No.
62/634,734, filed
February 23, 2018.
BACKGROUND OF THE INVENTION
[2] Generally, when completing a subterranean well for the production of
fluids, minerals, or
gases from underground reservoirs, several types of tubulars are placed
downhole as part of the
drilling, exploration, and completions process. These tubulars can include
casing, tubing, pipes,
liners, and devices conveyed downhole by tubulars of various types. Each well
is unique, so
combinations of different tubulars may be lowered into a well for a multitude
of purposes.
131 A subsurface or subterranean well transits one or more formations.
The formation is a body
of rock or strata that contains one or more compositions. The formation is
treated as a continuous
body. Within the formation hydrocarbon deposits may exist. Typically a
wellbore will be drilled
from a surface location, placing a hole into a formation of interest.
Completion equipment will be
put into place, including casing, tubing, and other downhole equipment as
needed. Perforating the
casing and the formation with a perforating gun is a well-known method in the
art for accessing
hydrocarbon deposits within a formation from a wellbore.
[4] Explosively perforating the formation using a shaped charge is a
widely known method for
completing an oil well. A shaped charge is a term of art for a device that
when detonated generates
a focused output, high energy output, and/or high velocity jet. This is
achieved in part by the
geometry of the explosive in conjunction with an adjacent liner. Generally, a
shaped charge
includes a metal case that contains an explosive material with a concave
shape, which has a thin
metal liner on the inner surface. Many materials are used for the liner; some
of the more common
metals include brass, copper, tungsten, and lead. When the explosive
detonates, the liner metal is
compressed into a super-heated, super pressurized jet that can penetrate
metal, concrete, and rock.
Perforating charges are typically used in groups. These groups of perforating
charges are typically
held together in an assembly called a perforating gun. Perforating guns come
in many styles, such
as strip guns, capsule guns, port plug guns, and expendable hollow carrier
guns.
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[5] Perforating charges are typically detonated by detonating cord in
proximity to a priming
hole at the apex of each charge case. Typically, the detonating cord
terminates proximate to the
ends of the perforating gun. In this arrangement, an initiator at one end of
the perforating gun can
detonate all of the perforating charges in the gun and continue a ballistic
transfer to the opposite
end of the gun. In this fashion, numerous perforating guns can be connected
end to end with a
single initiator detonating all of them.
[6] The detonating cord is typically detonated by an initiator triggered
by a firing head. The
firing head can be actuated in many ways, including but not limited to
electronically, hydraulically,
and mechanically.
171 Expendable hollow carrier perforating guns are typically
manufactured from standard sizes
of steel pipe with a box end having internal/female threads at each end. Pin
ended adapters, or
subs, having male/external threads are threaded one or both ends of the gun.
These subs can
connect perforating guns together, connect perforating guns to other tools
such as setting tools and
collar locators, and connect firing heads to perforating guns. Subs often
house electronic,
mechanical, or ballistic components used to activate or otherwise control
perforating guns and
.. other components.
[8] Perforating guns typically have a cylindrical gun body and a charge
tube, or loading tube
that holds the perforating charges. The gun body typically is composed of
metal and is cylindrical
in shape. Charge tubes can be formed as tubes, strips, or chains. The charge
tubes will contain
cutouts called charge holes to house the shaped charges.
[9] It is generally preferable to reduce the total length of any tools to
be introduced into a
wellbore. Among other potential benefits, reduced tool length reduces the
length of the lubricator
necessary to introduce the tools into a wellbore under pressure. Additionally,
reduced tool length
is also desirable to accommodate turns in a highly deviated or horizontal
well. It is also generally
preferable to reduce the tool assembly that must be performed at the well site
because the well site
is often a harsh environment with numerous distractions and demands on the
workers on site.
[10] Electric initiators are commonly used in the oil and gas industry for
initiating different
energetic devices down hole. Most commonly, 50-ohm resistor initiators are
used. Other initiators
and electronic switch configurations, such as the Hunting ControlFire
technology and DynaSelect
technology, are also common.
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1111 In setting tools a metering fluid, typically an oil, is used to dampen
any violent shock forces
due to the actuation of the setting tool.
[12] Bridge plugs are often introduced or carried into a subterranean oil or
gas well on a conduit,
such as wire line, electric line, continuous coiled tubing, threaded work
string, or the like, for
engagement at a pre-selected position within the well along another conduit
having an inner
smooth inner wall, such as casing. The bridge plug is typically expanded and
set into position
within the casing. The bridge plug effectively seals off one section of casing
from another. Several
different completions operations may commence after the bridge plug is set,
including perforating
and fracturing. Sometimes a series of plugs are set in an operation called
"plug and perf' where
several sections of casing are perforated sequentially. When the bridge plug
is no longer needed
.. the bridge plug is reamed, often though drilling, reestablishing fluid
communication with the
previously sealed off portion of casing.
[13] Setting a bridge plug typically requires setting a "slip" mechanism
that engages and locks
the bridge plug with the casing, and energizing the packing element in the
case of a bridge plug.
This requires large forces, often in excess of 20,000 lbs. The activation or
manipulation of some
setting tools involves the activation of an energetic material such as an
explosive pyrotechnic or
black powder charge to provide the energy needed to deform a bridge plug. The
energetic material
may use a relatively slow burning chemical reaction to generate high pressure
gases. One such
setting tool is the Model E-4 Wireline Pressure Setting Tool of Baker
International Corporation,
sometimes referred to as the Baker Setting Tool.
[14] After the bridge plug is set, the explosive setting tool remains
pressurized and must be
raised to the surface and depressurized. This typically entails bleeding
pressure off the setting tool
by piercing a rupture disk or releasing a valve.
SUMMARY OF EXAMPLE EMBODIMENTS
[15] An example embodiment may include a setting tool comprising a first
cylindrical body
with an inner bore, a second cylindrical body with an inner bore, being
coaxial with and coupled
to the first cylindrical body, a third cylindrical body slideably with a first
end engaged to the inner
bore of the first cylindrical body and having an inner cavity with an axial
opening at the first end
adapted to accept a power charge and a having a distal end with a shoulder
slideably engaged with
the second cylindrical body inner bore, a fourth cylindrical body with a first
end coupled to the
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distal end of the third cylindrical body and having a distal end with a
transverse slot, a fifth
cylindrical body fixed to the distal end of the second cylindrical body and
having an inner bore
wherein the fourth cylindrical body is slideably engaged therewith and further
having a radial face
within the second cylindrical body, a disc shaped impact dampening material
with a hollow center
having the fourth cylindrical body is located therethrough and coupled to the
radial face of the fifth
cylindrical body, and a sixth cylindrical body coupled to the fifth
cylindrical body and having a
transverse slot; wherein the shoulder of the third cylindrical body engages
the disc shaped impact
dampening material when the third cylindrical body travels a predetermined
distance within the
second cylindrical body.
[16] A variation of the example embodiment may include the inner cavity of the
third cylindrical
body forming a power charge chamber. The fourth cylindrical body may be a
piston. A chamber
may be formed by the first piston and the cylindrical body.
[17] An example embodiment may include a setting tool apparatus comprising a
cylindrical
body having a center axis, a first end, a second end, an inner surface, and an
outer surface, a first
piston located within the cylindrical body and axially aligned with the
cylindrical body, having a
first end and a second end, the first end coupled to a second cylindrical body
with a raised radial
shoulder, a cylindrical mandrel extending from the second end of the first
piston and being axially
aligned with the cylindrical body, a cylinder head coupled to the second end
of the cylindrical
body and axially aligned with the cylindrical body and having an inner radial
face with the
cylindrical mandrel located therethrough, an impact dampening material in
contact with the inner
radial face, wherein the impact dampening material absorbs the energy of the
piston moving
downhole within the cylindrical body without a dampening fluid.
[18] A variation of the example embodiment may include a power charge located
proximate to
the first cylindrical body, wherein gases generated by the power charge can
enter second
cylindrical body. It may include a firing head coupled to the power charge.
[19] An example embodiment may include a method for setting a plug in a
borehole comprising
activating a firing head, starting a gas pressure generating chemical
reaction, pressurizing a
chamber located with a cylinder with the generated gas pressure, moving a
piston disposed within
the cylinder in a downhole axial direction with the generated gas, setting an
expandable packer
using the downhole motion of the piston, and impacting the first piston
against an impact
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dampening material, wherein the impact stops the movement of the piston
without the use of a
hydraulic fluid.
[20] A variation of the example embodiment may include placing a setting tool
in a borehole at
a predetermined location for installing a bridge plug. It may include shearing
a shear stud coupled
between a setting tool and a setting plug. It may include removing the setting
tool from the borehole
after setting a bridge plug. The expandable packer may be a bridge plug.
BRIEF DESCRIPTION OF THE DRAWINGS
[21] For a thorough understanding of the present invention, reference is made
to the following
detailed description of the preferred embodiments, taken in conjunction with
the accompanying
drawings in which reference numbers designate like or similar elements
throughout the several
figures of the drawing. Briefly:
FIG. 1 shows an example embodiment of a side view of a setting tool prior to
setting an
expandable packer.
FIG. 2 shows an example embodiment of a side view of a setting tool prior to
setting an
expandable packer.
FIG. 3 shows an example embodiment of an exploded view of a setting tool.
FIG. 4 shows an example embodiment of a side view of a setting tool after
setting an
expandable packer.
FIG. 5 shows an example embodiment of a side view of a setting tool after
setting an
expandable packer.
DETAILED DESCRIPTION OF EXAMPLES OF THE INVENTION
[22] In the following description, certain terms have been used for brevity,
clarity, and
examples. No unnecessary limitations are to be implied therefrom and such
terms are used for
descriptive purposes only and are intended to be broadly construed. The
different apparatus,
systems and method steps described herein may be used alone or in combination
with other
apparatus, systems and method steps. It is to be expected that various
equivalents, alternatives,
and modifications are possible within the scope of the appended claims.
[23] An example embodiment may include replacing the oil in a setting tool
with an impact
resistant material. This may remove the auxiliary chamber in some setting
tools for oil to flow into
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which may reduce the overall length of the setting tool. The impact resistant
material may provide
a more reliable dampening system. The impact resistant material may improve
the life of setting
tools and the entire tools string by dampening shock typically seen from
actuation of the setting
tool, which travels throughout the tool string. Using an impact resistant
material may provide for
easier assembly in the field. The impact resistant material is molded into a
preferred geometry that
allows the user to install the material into a setting tool during assembly.
Actuating the setting tool
causes the material to compress at a constant rate to a predetermined volume.
Upon reaching this
predetermined volume the material acts as an impact dampener and absorbs and
or dissipates
energy seen as the setting tool's actuation exerts shock loading.
[24] An example embodiment is shown in FIG. 1 from a side view cross-section
of a setting
tool prior to setting. A setting tool 10 may include a top cylinder 11 coupled
to a lower cylinder
12. An upper cylinder 35 is slideably engaged with the top cylinder 11. The
upper cylinder 35
includes an inner bore referred to as the power charge chamber 15. The upper
cylinder 35 is
coupled to a piston 14. Piston 14 slideably engaged with the inner bore 36 of
the mandrel 16.
Mandrel 16 is slideably engaged with the transfer sleeve 18. Transfer sleeve
18 is coupled via
crosslink bolt 19 engaged with slot 45 to the distal end of piston 14.
Crosslink bolt 19 in slideably
engaged with the slot 31 of the mandrel 16. The cylinder head 13 is coupled to
the lower portion
of the lower cylinder 12. The upper portion of the lower cylinder 12 is
coupled to the lower portion
of the top cylinder 11. Cylinder head 13 includes a disk shaped impact
resistance material 17
located on the inner face 38 of the cylinder head 13. The lower cylinder 12
combined with the
piston 14, the shoulder face 33 of piston coupling 39, and the impact
dampening material 17 form
a chamber 32.
[25] Nylon plug 21 seals off chamber 40 from the outside of the setting tool
10. 0-rings 27 seal
the upper cylinder 35 to the inner bore of top cylinder 11. Set screw 23
secures the top cylinder 11
to the lower cylinder 12. 0-rings 29 seal the piston coupling 39 to the inner
surface of lower
cylinder 12. Set screw 41 secures the piston coupling 39 to the piston 14. 0-
rings 28 seal the
cylinder head 13 to the inner surface of lower cylinder 12. 0-rings 26 seal
the cylinder head 13 to
the piston 14. Set screw 24 secures the cylinder head 13 to the mandrel 16.
[26] The impact resistant material 17 may be a viton based elastomer or a
polyurethane energy
absorbing material. An example impact resistant material 17 may include "D30",
which is a
polyurethane energy-absorbing material containing several additives and
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polyborodimethylsiloxane, a dilatant non-Newtonian fluid.
Polyborodimethylsiloxane is a
substance called a dilatant that in its raw state flows freely but on shock
locks together to absorb
and disperse energy as heat before returning to its semi fluid state. The
commercial material known
as "D30" is in essence a closed cell polyurethane foam composite with
polyborodimethylsiloxane
(PBDMS) as the dilatant dispersed through the foam matrix which makes the
product rate sensitive
thus dissipating more energy than plain polyurethane at specific energy
levels. An example of the
optimal proportions for a shock absorbing foam composite formula may include,
by volume, 15-
35% of PBDMS and 40-70% fluid (the gas resulting from the foaming process,
generally carbon
dioxide) with the remainder being polyurethane.
[27] An example embodiment is shown in FIG. 2 from a top view cross-section of
a setting tool
prior to setting. The setting tool 10 may include a top cylinder 11 coupled to
a lower cylinder 12.
An upper cylinder 35 is slideably engaged with the top cylinder 11. The upper
cylinder 35 includes
an inner bore referred to as the power charge chamber 15. The upper cylinder
35 is coupled to a
piston 14. Piston 14 slideably engaged with the inner bore 36 of the mandrel
16. Mandrel 16 is
slideably engaged with the transfer sleeve 18. Transfer sleeve 18 is coupled
via crosslink bolt 19
engaged with slot 45 to the distal end of piston 14. Crosslink bolt 19 in
slideably engaged with the
slot 31 of the mandrel 16. The cylinder head 13 is coupled to the lower
portion of the lower cylinder
12. The upper portion of the lower cylinder 12 is coupled to the lower portion
of the top cylinder
11. Cylinder head 13 includes a disk shaped impact resistance material 17
located on the inner face
38 of the cylinder head 13. The lower cylinder 12 combined with the piston 14,
the shoulder face
33 of piston coupling 39, and the impact dampening material 17 form a chamber
32.
[28] Nylon plug 21 seals off chamber 40 from the outside of the setting tool
10.0-rings 27 seal
the upper cylinder 35 to the inner bore of top cylinder 11. Set screw 23
secures the top cylinder 11
to the lower cylinder 12. 0-rings 29 seal the piston coupling 39 to the inner
surface of lower
cylinder 12. Set screw 41 secures the piston coupling 39 to the piston 14. 0-
rings 28 seal the
cylinder head 13 to the inner surface of lower cylinder 12.0-rings 26 seal the
cylinder head 13 to
the piston 14. Set screw 24 secures the cylinder head 13 to the mandrel 16.
Set screw 25 secures
the retention ring 20 to the transfer sleeve 18.
[29] An example embodiment is shown in FIG. 3 using an assembly view cross-
section of a
setting tool. The setting tool 10 may include a top cylinder 11 coupled to a
lower cylinder 12. An
upper cylinder 35 is slideably engaged with the top cylinder 11. The upper
cylinder 35 includes an
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inner bore referred to as the power charge chamber 15. The upper cylinder 35
is coupled to a piston
14. Piston 14 slideably engaged with the inner bore 36 of the mandrel 16.
Mandrel 16 is slideably
engaged with the transfer sleeve 18. Transfer sleeve 18 is coupled via
crosslink bolt 19 engaged
with slot 45 to the distal end of piston 14. Crosslink bolt 19 in slideably
engaged with the slot 31
of the mandrel 16. The cylinder head 13 is coupled to the lower portion of the
lower cylinder 12.
The upper portion of the lower cylinder 12 is coupled to the lower portion of
the top cylinder 11.
Cylinder head 13 includes a disk shaped impact resistance material 17 located
on the inner face 38
of the cylinder head 13. The lower cylinder 12 combined with the piston 14,
the shoulder face 33
of piston coupling 39, and the impact dampening material 17 form a chamber 32.
Transfer sleeve
18 is coupled via crosslink bolt 19 engaged with slot 45 to the distal end of
piston 14.
[30] Nylon plug 21 seals off chamber 40 from the outside of the setting tool
10. 0-rings 27 seal
the upper cylinder 35 to the inner bore of top cylinder 11. Set screw 23
secures the top cylinder 11
to the lower cylinder 12. 0-rings 29 seal the piston coupling 39 to the inner
surface of lower
cylinder 12. Set screw 41 secures the piston coupling 39 to the piston 14. 0-
rings 28 seal the
cylinder head 13 to the inner surface of lower cylinder 12. 0-rings 26 seal
the cylinder head 13 to
the piston 14. Set screw 24 secures the cylinder head 13 to the mandrel 16.
Set screw 25 secures
the retention ring 20 to the transfer sleeve 18.
[31] An example embodiment is shown in FIG. 4 from a side view cross-section
of a setting
tool after the setting tool has been activated. The setting tool 10 may
include a top cylinder 11
coupled to a lower cylinder 12. An upper cylinder 35 is slideably engaged with
the top cylinder
11. The upper cylinder 35 includes an inner bore referred to as the power
charge chamber 15. The
upper cylinder 35 is coupled to a piston 14. Piston 14 slideably engaged with
the inner bore 36 of
the mandrel 16. Mandrel 16 is slideably engaged with the transfer sleeve 18.
Transfer sleeve 18 is
coupled via crosslink bolt 19 engaged with slot 45 to the distal end of piston
14. Crosslink bolt 19
in slideably engaged with the slot 31 of the mandrel 16. The cylinder head 13
is coupled to the
lower portion of the lower cylinder 12. The upper portion of the lower
cylinder 12 is coupled to
the lower portion of the top cylinder 11. Cylinder head 13 includes a disk
shaped impact resistance
material 17 located on the inner face 38 of the cylinder head 13. The lower
cylinder 12 combined
with the piston 14, the shoulder face 33 of piston coupling 39, and the impact
dampening material
17 form a chamber 32.
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.. [32] Nylon plug 21 seals off chamber 40 from the outside of the setting
tool 10. 0-rings 27 seal
the upper cylinder 35 to the inner bore of top cylinder 11. Set screw 23
secures the top cylinder 11
to the lower cylinder 12. 0-rings 29 seal the piston coupling 39 to the inner
surface of lower
cylinder 12. Set screw 41 secures the piston coupling 39 to the piston 14. 0-
rings 28 seal the
cylinder head 13 to the inner surface of lower cylinder 12. 0-rings 26 seal
the cylinder head 13 to
the piston 14. Set screw 24 secures the cylinder head 13 to the mandrel 16.
Set screw 25 secures
the retention ring 20 to the transfer sleeve 18.
[33] Still referring to FIG. 4 the shoulder face 33 is in contact with the
impact resistance material
17 located on the inner face 38 of the cylinder head 13. The chamber 32 is
substantially collapsed
from its original size. The transfer sleeve 18 has been fully extended along
the length of the
mandrel 16. This results in a push-pull effect where a packer or other
expandable attached to the
mandrel is pulled against the force exerted from the sliding transfer sleeve
18. Such combination
of forces allows for compressing rubber and or metal sealing surfaces
together, forcing radial
expansion against a wellbore, thus sealing the wellbore. Once an expandable is
set, the setting tool
can be removed from the expandable by a pulling force from the surface which
causes a shear pin
or other intentionally breakable component to intentionally fail, thus leaving
the expandable in
place as the setting tool is pulled uphole.
[34] An example embodiment is shown in FIG. 5 with a top view cross-section of
a setting tool
after the setting tool has been activated. The setting tool 10 may include a
top cylinder 11 coupled
to a lower cylinder 12. An upper cylinder 35 is slideably engaged with the top
cylinder 11. The
upper cylinder 35 includes an inner bore referred to as the power charge
chamber 15. The upper
cylinder 35 is coupled to a piston 14. Piston 14 slideably engaged with the
inner bore 36 of the
mandrel 16. Mandrel 16 is slideably engaged with the transfer sleeve 18.
Transfer sleeve 18 is
coupled via crosslink bolt 19 engaged with slot 45 to the distal end of piston
14. Crosslink bolt 19
in slideably engaged with the slot 31 of the mandrel 16. The cylinder head 13
is coupled to the
lower portion of the lower cylinder 12. The upper portion of the lower
cylinder 12 is coupled to
the lower portion of the top cylinder 11. Cylinder head 13 includes a disk
shaped impact resistance
material 17 located on the inner face 38 of the cylinder head 13. The lower
cylinder 12 combined
with the piston 14, the shoulder face 33 of piston coupling 39, and the impact
dampening material
17 form a chamber 32.
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.. [35] Although the invention has been described in terms of embodiments
which are set forth in
detail, it should be understood that this is by illustration only and that the
invention is not
necessarily limited thereto. For example, terms such as upper and lower or top
and bottom can be
substituted with uphole and downhole, respectfully. Top and bottom could be
left and right,
respectively. Uphole and downhole could be shown in figures as left and right,
respectively, or top
and bottom, respectively. Generally downhole tools initially enter the
borehole in a vertical
orientation, but since some boreholes end up horizontal, the orientation of
the tool may change. In
that case downhole, lower, or bottom is generally a component in the tool
string that enters the
borehole before a component referred to as uphole, upper, or top, relatively
speaking. The first
housing and second housing may be top housing and bottom housing,
respectfully. In a gun string
.. such as described herein, the first gun may be the uphole gun or the
downhole gun, same for the
second gun, and the uphole or downhole references can be swapped as they are
merely used to
describe the location relationship of the various components. Terms like
wellbore, borehole, well,
bore, oil well, and other alternatives may be used synonymously. Terms like
tool string, tool,
perforating gun string, gun string, or downhole tools, and other alternatives
may be used
synonymously. The alternative embodiments and operating techniques will become
apparent to
those of ordinary skill in the art in view of the present disclosure.
Accordingly, modifications of
the invention are contemplated which may be made without departing from the
spirit of the claimed
invention.
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