In the oil and gas field, packers are used to isolate one wellbore region from another for a variety of different reasons, but often for pressure-containment purposes. Packers are generally deployed or “run” into the wellbore in a run-in configuration, and then actuated to a set configuration when they reach a desired depth in the well. Oftentimes, packers need to be able to pass through restrictions in a well, and thereafter increase in radial dimension to seal against a surrounding tubular that is larger in diameter than the restriction. Accordingly, packers may increase in radial dimension when actuated from the run-in configuration to the set configuration. Such radial size increase may be caused by swelling, inflating, or mechanically compressing a sealing element such that it expands outward.
Embodiments of the disclosure provide a downhole tool including a housing defining a charge chamber and a hydraulic chamber, the hydraulic chamber containing a hydraulic fluid, and a piston disposed in the hydraulic chamber. The piston prevents the hydraulic fluid from communicating with the charge chamber, and is in communication with the hydraulic fluid and the charge chamber. The tool also includes one or more charges disposed in the charge chamber. The one or more charges are configured to ignite and thereby expand a gas in the charge chamber. The tool further includes a fluid-metering device coupled to the housing. The fluid-metering device is configured to control a rate at which the hydraulic fluid is pressed out of the hydraulic chamber.
Embodiments of the disclosure also provide a method including charging an inflation tool using one or more charges and a hydraulic fluid, connecting the inflation tool to an inflatable device, deploying the inflation tool and the inflatable device into a wellbore, and activating the inflation tool by igniting the one or more charges. Activating the inflation tool forces at least some of the hydraulic fluid into the inflatable device, and at least some of the hydraulic fluid that is forced into the inflatable device presses an inflatable element radially outward into engagement with a surrounding tubular.
Embodiments of the disclosure also provide a downhole tool including a housing defining a charge chamber and a hydraulic chamber, a piston disposed in the hydraulic chamber. The piston prevents a hydraulic fluid in the hydraulic chamber from communicating with the charge chamber, and the piston is in communication with the hydraulic fluid and the charge chamber. The tool further includes one or more charges disposed in the charge chamber, and an inflatable element coupled to the housing. The piston is configured to move from a first position that is proximal to the charge chamber, to a second position in the hydraulic chamber by pressure generated by igniting the one or more charges. The piston moving from the first position to the second position displaces the hydraulic fluid and causes the inflatable element to inflate.
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:
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.”
The inflation tool 100 may include a cylindrical housing 102. The housing 102 may be a single, unitary structure, or may be made from two or more components that are connected together. For example, in this embodiment, the housing 102 includes an upper sub 104, a first outer housing 106, a connector sub 108, a second outer housing 110, and a lower sub 112. As shown, the upper sub 104 may be threaded into the first outer housing 106, the first outer housing 106 may be threaded onto the connector sub 108, the connector sub 108 may be threaded into the second outer housing 110, and the second outer housing 110 may be threaded onto the lower sub 112. It will be appreciated that any of these components may be combined with the other, e.g., formed from a single piece, and/or any of these components may be made from two or more pieces that are connected together.
The housing 102 may have an upper end 114 and a lower end 116. For example, the upper sub 104 may include the upper end 114 and the lower sub 112 may include the lower end 116. The upper and lower ends 114, 116 may be threaded, e.g., externally (male), for connection with adjacent tubulars or other devices. For example, the upper end 114 may be connected to an ignition assembly, which may include a check valve and an electrical igniter. The lower end 116 may be connected to a subjacent tool, such as a packer, as will be described in greater detail below.
The housing 102 may define a charge chamber 120 and a hydraulic chamber 122 therein. For example, the charge chamber 120 may be located within the first outer housing 106, e.g., generally proximal to the upper end 114 of the housing 102. The hydraulic chamber 122 may be located within the second outer housing 110, e.g., generally proximal to the lower end 116. The connector sub 108 may separate the hydraulic chamber 122 from the charge chamber 120, and a bore 123 extending through the connector sub 108 may permit communication therebetween. In some embodiments, the bore 123 may be smaller in radial dimension than the hydraulic chamber 122 and the charge chamber 120.
A piston 130 may be positioned in the hydraulic chamber 122 and may be movable therein. For example, the hydraulic chamber 122 may be loaded with a hydraulic fluid 124, which may, in a run-in configuration, substantially fill the hydraulic chamber 122 between the piston 130 and the lower sub 112.
The piston 130 may be configured to move in the hydraulic chamber 122 under force applied by expanding gasses in the charge chamber 120. In particular, the charge chamber 120 may include one or more charges (two shown: 132, 134). The charges 132, 134 may be positioned end-to-end, or “in series” such that the charge 134 ignites after the charge 132. The igniter (connected to the upper end 114) may initiate such ignition in a conventional manner. The number of charges 132, 134 may be selected to produce a predetermined force and a predetermined amount of time that force is to be applied on the piston 130 and eventually to the subjacent tool, as will be described in greater detail below. Accordingly, additional charges 132, 134 may be associated with the application of a higher pressure, over a longer period of time, or both. Moreover, the charges 132, 134 may be of a standard size, such that they are readily commercially available.
The lower sub 112 may include a fluid-metering device 140.
Referring again to
While it is intact, the rupture disk 300 may prevent communication between the interior and exterior of the upper sub 104 via the port 304 and pocket 302. Once the rupture disk 300 is ruptured, however, the fluid communication may be established between the interior and exterior of the upper sub 104, which may allow for gas at relatively high pressure (e.g., after the pressure charge(s) 132, 134 have ignited) to be released from within the charge chamber 120.
In this example, the inflatable device 400 generally includes a connection/actuation assembly 402, an inflatable assembly 404, and a lower ring assembly 406. In an embodiment, the connection/actuation assembly 402 includes a housing 408, which may be received onto the lower sub 112 of the tool 100. An inner mandrel 410 may extend at least partially through the housing 408, but may be separated axially apart from the lower end 116 of the tool 100, such that fluid is able to move through the bore 202 in the lower sub 112 and around the outside of the end of the inner mandrel 410. In some embodiments, the inner mandrel 410 may be provided by two (or more) mandrel portions 410A, 410B that are connected together, but in other embodiments, the mandrel 410 may be a single piece.
A collet 412 may also be disposed in the housing 408 and may be received into a recess 413 formed in the housing 408 so as to secure the lower end 116 in position, at least axially, relative to the housing 408. A release piston 414 may be positioned radially between the housing 408 and the inner mandrel 410, and at least partially between the collet 412 and the inner mandrel 410. The release piston 414 may be held in position by a shear screw 415 (or any other member configured to shear or otherwise release under a predetermined force) that is connected to the housing 408. Accordingly, the piston 414 may be prevented from moving relative to the housing 408 and may prevent the collet 412 from deflecting radially inwards toward the inner mandrel 410, which in turn prevents the device 400 from decoupling from the tool 400.
At least a portion of the inner mandrel 410 defines a bore 420 therein. For example, the bore 420 may extend through the mandrel portion 410A and into, but not through, the mandrel portion 410B. The bore 420 is thus in communication with the bore 202 through the lower sub 112 and thus in communication with the hydraulic chamber 122 (
A poppet valve element 430 may be positioned radially between the housing 408 and the inner mandrel 410, e.g., the mandrel portion 410B. The poppet valve element 430 may be in communication with the ports 422. Further, a biasing member 432 (e.g., spring) may engage and bias the poppet valve element 430 into a reduced-diameter section 434 of the housing 408. In the reduced-diameter section 434, the poppet valve element 430 seals the annulus between the housing 408 and the inner mandrel 410. When pressure applied via the ports 422 onto the poppet valve element 430 generates a force that exceeds the biasing force of the biasing member 432, the poppet valve element 430 may slide out of the reduced-diameter section 434 into an enlarge diameter section 436 of the housing 408. The poppet valve element 430 may be configured not to seal with the housing 408 and/or mandrel 410 in the enlarged-diameter section 436. As such, fluid received through the ports 422 may be able to flow around the poppet valve element 430, when the poppet valve element 430 is moved out of the reduced-diameter section 434.
The inflatable assembly 404 may include an inflatable element 440, which may be a rubber element or another type of flexible member that is received around and connected to the mandrel 410. An interior of the inflatable element 440, between the inflatable element 440 and the mandrel 410 may be in communication with the enlarged-diameter section 436 of the housing 408. Accordingly, fluid received around the poppet valve element 430 and into the enlarged-diameter section 436 may then proceed into the area between the inflatable element 440 and the mandrel 410, which may deform the inflatable element 440 radially outward, e.g., into engagement with a surrounding tubular 450.
The lower ring assembly 406 may also be connected to the mandrel 410 and the inflatable element 440. The lower ring assembly 406 may be configured to retain pressure within the inflatable element 440 and locate the inflatable element 440 in position on the mandrel 410, at least initially.
The method 500 includes charging the inflation tool 100, as at 502. Charging the inflation tool 100 may include selecting a number of charges (e.g., the two charges 132, 134 of
Before, during, or after charging the inflation tool 100, the method 500 may include connecting the inflation tool 100 to an inflatable device 400, as at 504, e.g., directly or via one or more intermediary components. For example, a releasable, collet-based connection may be employed to connect the tool 100 and the device 400; however, shearable members such as shear threads, screws, etc., or other types of releasable connections could also be used to connect the tool 100 and device 400 together in a manner that is releasable in the wellbore.
Once connected together, the tool 100 and the device 400 may be run into a well, e.g., as part of a string of tubulars, as at 506. When the inflatable device 400 reaches a desired position in the well, the inflation tool 100 may be actuated to inflate the inflatable device 400, as at 508. For example, the inflation tool 100 may be actuated by electric signal to an ignition assembly that is also connected to (e.g., an upper end 114 of) the inflation tool 100. This may result in the charges 132, 134 igniting, e.g., sequentially with the charge 132 closest to the upper end 112 igniting first, and then the next closest charge 134, etc. As the charges 132, 134 ignite, heat is generated, which rapidly expands the gas in the charge chamber 120. This expanding gas builds up pressure against the piston 130. In response, the piston 130 advances into the hydraulic chamber 122, which expels the hydraulic fluid therein through the bore 220. However, the fluid-metering device 140 ensures that this expulsion is relatively slow and controlled, despite the relatively rapid expansion of the gas and associated pressure build-up behind the piston 130.
Proceeding from
Referring again to
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.
This application claims priority to U.S. Provisional Patent Application Ser. No. 63/080,157, which was filed on Sep. 18, 2020, and is incorporated herein by reference in its entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/US2021/050035 | 9/13/2021 | WO |
Number | Date | Country | |
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63080157 | Sep 2020 | US |