Patent Application
20190128657
The embodiments described herein relate to an igniter and ignition device for a power charge for downhole setting tools and methods of using the same.
A downhole setting tool may use a power charge to set a device within a wellbore. The power charge is detonated to generate the force required to set the device. For example, the force from the detonated power charge may move a piston causing the setting of the device. The power charge of the downhole setting tool may be used to set various devices in a wellbore as would be appreciated by one of ordinary skill in the art. For example, a downhole setting tool with a power charge may be used to set bridge plugs, cement retainers, packers, and various other downhole devices.
An electrical signal is typically sent down a conduit to the setting tool to actuate a primary igniter in the firing head of the setting tool. The actuation of the primary igniter is used to detonate the power charge, which is typically located downhole from the primary igniter in a chamber connected to the firing head via a cartridge seat. The downhole setting tool may include a secondary igniter that is used to detonate the power charge upon the actuation of the primary igniter. The primary igniter often comprises black powder (e.g., gun powder, a mixture of sulfur, charcoal, and saltpeter) that is ignited from the electrical signal.
It has been recognized that it would be beneficial to increase the reliability with which the power charge of downhole setting tools detonates and sets the downhole device. For example, on Jan. 13, 2017, Applicant filed U.S. patent application Ser. No. 15/406,040 entitled “SETTING TOOL POWER CHARGE INITIATION” that is directed to devices and methods for initiating or setting off a power charge and on Jul. 12, 2017, Applicant filed U.S. patent application Ser. No. 15/648,009 entitled “RETAINING AND POSITIONING END CAP FOR DOWNHOLE SETTING TOOL POWER CHARGES,” both of which are incorporated by reference herein in its entirety.
The power charge 250 includes an outer housing 255 and is positioned within a chamber 245 of a housing 240 connected to the firing head 210. The downhole side of the housing 240 is connected to a sub 280 that is connected to the device (not shown) to be set within the wellbore. The sub 280 provides communication with a mechanism, such as a piston, configured to move and set the device upon the detonation of the power charge 250 as would be appreciated by one of ordinary skill in the art. The downhole end 252 of the power charge 250 is inserted into the cavity 245 of the housing 240 and the power charge 250 is pushed into the cavity 245 until the downhole end 252 is positioned within the sub 280. The housing 240 containing the power charge 250 is then connected to the firing head 210 and the adapter 230. The uphole end 251 of the power charge 250 includes an igniter 260 that helps to detonate the power charge 250 upon the ignition of the primary igniter 220 and the secondary igniter 235. However, the igniter 260 relies on the ignition of the primary igniter 220 and the secondary igniter 235. As used herein, the uphole end refers to the end of an object that is closer to the opening of a wellbore at the surface in comparison to the other end of the object, referred to herein as the downhole end.
Conventional downhole setting tools that include power charges are very reliable and are used to set a large number of devices in a wellbore. However, even if conventional setting tools are 99% reliable, the removal of one setting tool and device out of one hundred from the wellbore is a potentially costly and time consuming operation. On occasion, the primary igniter 220 and the secondary igniter 235 fail to ignite the igniter 260 positioned within the power charge 250, thus failing to set off the power charge 250. On occasion, the igniter 260 is ignited by the primary igniter 220 and/or the secondary igniter 235, but the igniter 260 fails to cause the detonation of the power charge 250, thus failing to set a desired tool. Other disadvantages may exist.
The present disclosure is directed to an igniter and ignition device for a power charge for downhole setting tools and methods of use that overcome some of the problems and disadvantages discussed above.
An embodiment of the disclosure is a downhole setting tool comprising a first housing, a second housing connected to the first housing, the second housing having a chamber, a power charge positioned within the chamber, an igniter connected to a portion of the power charge, and an ignition device connected to the igniter. The ignition device is configured to actuate upon receipt of an electrical signal.
The igniter may be connected to an uphole end of the power charge. The downhole setting tool may include an adapter positioned between the first housing and the second housing, the adapter being positioned adjacent to the uphole portion of the power charge. The igniter may be embedded into the power charge. The ignition device may be positioned within a recess in the igniter. The ignition device may be a thermal match or a heater cartridge. The ignition device may be an electric trigger that causes a chemical reaction in the power charge by the application of a voltage or a current. The igniter may comprise thermite, a metal and an oxidizer, such as, but not limited to, aluminum and iron oxide, aluminum and copper oxide, aluminum and titanium oxide, magnesium and titanium oxide, aluminum and silicon dioxide, magnesium and titanium oxide, aluminum and vanadium oxide, combinations thereof, or the like.
An embodiment of the disclosure is a method of using a downhole setting tool comprising attaching an igniter to an uphole end of a power charge configured to be selectively detonated to set a device within a wellbore. The method comprises attaching an ignition device to the igniter. The ignition device being configured to selectively ignite the igniter upon receipt of an electrical signal via an electrical conduit.
The method may comprise running the downhole setting tool into the wellbore. The method may include detonating the power charge to set the device in the wellbore. The igniter may be embedded into the power charge. The ignition device may be positioned within a cavity in the igniter.
An embodiment of the disclosure is a power charge for a downhole setting tool comprising a power charge configured to be detonated to set a tool within a wellbore, the power charge having an uphole end and a downhole end when installed within the downhole setting tool, the power charge including an outer housing. The power charge comprises an igniter connected to the uphole end of the power charge, the igniter configured to cause the detonation of the power charge upon ignition of the igniter and an ignition device connected to the igniter, the ignition device configured to selectively ignite the igniter upon receipt of an electrical signal.
The igniter may be embedded within the power charge and the ignition device may be positioned within a cavity in the igniter. The ignition device may be an electric trigger, a heater cartridge, an electric match, or a combination thereof. The igniter may comprise thermite, a metal and an oxidizer, such as, but not limited to, aluminum and iron oxide, aluminum and copper oxide, aluminum and titanium oxide, magnesium and titanium oxide, aluminum and silicon dioxide, magnesium and titanium oxide, aluminum and vanadium oxide, combinations thereof, or the like.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the intention is to cover all modifications, equivalents and alternatives falling within the scope of the invention as defined by the appended claims.
A power charge 150 is positioned within a chamber 145 within the second housing 140. The power charge 150 includes an uphole end 151, a downhole end 152 (shown in
The actuation of the ignition device 170 causes the ignition of the igniter 160 and, thus, the detonation of the power charge 150, as discussed herein. The actuation of the ignition device 170 may be accomplished by providing voltage or current to the igniter 160 to cause the ignition of the igniter 160. Alternatively, the actuation of the ignition device 170 may be rapidly applying heat to the igniter 160 to cause the ignition of the igniter 160.
The igniter 160 is configured to cause the detonation of the power charge 150 upon ignition of the igniter 160. The igniter 160 may be comprised of various materials as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. The igniter 160 may be embedded in the power charge 150, positioned in a cavity or recess in the power charge 150, positioned adjacent to the power charge 150, or attached to a portion of the power charge 150. The igniter 160 may comprise a react on-demand material. A chemical reaction in the react on-demand material may release high energy heat upon receipt of an electrical triggering signal from the electrical ignition device 170. Examples of react on-demand materials that may be actuated upon an application of an electric voltage or current are, but not limited to, a metal and an oxidizer, such as, aluminum and iron oxide, aluminum and copper oxide, aluminum and titanium oxide, magnesium and titanium oxide, aluminum and silicon dioxide, magnesium and titanium oxide, aluminum and vanadium oxide, combinations thereof, or the like. The igniter 160 may be configured so that the high energy heat from the chemical reaction is sufficient to cause the detonation of the power charge 150. The reaction time, heat released, and/or voltage or current needed to cause the actuation of the igniter 160 may be varied depending on the application as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure.
In one embodiment, the igniter 160 may be comprised of a pyrotechnic material, such as thermite. In one embodiment, a pellet of thermite may be embedded into the power charge 150. The igniter 160 may be positioned adjacent to and/or may be attached to the power charge 150. The igniter 160 may be positioned within a recess or cavity within the power charge 150. Various mechanisms may be used to attach the igniter 160 to the power charge 150 as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. For example, an adhesive material may attach or bond the igniter 160 to the power charge 150.
The igniter 160 may include a recess, opening, or cavity configured to receive the electric ignition device 170. Alternatively, the electric ignition device 170 may be positioned adjacent to and/or attached to the igniter 160. The electric ignition device 170 is configured to ignite or be actuated upon receipt of a signal. For example, an electrical signal may be transmitted to the electric ignition device 170 via lines or wires 171. Upon receipt of a signal along line 171, the electric ignition device 170 may ignite cause the ignition of the igniter 160, which in turn causes the detonation of the power charge 150. The detonation of the power charge 150 may be used to set a downhole tool as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. Receipt of a signal causes the electric ignition device 170 to be actuated, which in turn causes the ignition of igniter 160. For example, the electric ignition device 170 may rapidly heat upon receipt of a signal, which in turn causes the ignition of the igniter 160. The electric ignition device may be, but is not limited to, a thermal match, a heater cartridge, an electrical trigger, or a combination thereof.
An ignition device 170 may positioned within the igniter 160. As discussed above, the ignition device 170 may be, but is not limited to, a thermal match, a heater cartridge, an electrical trigger, or a combination thereof that may be actuated upon receipt of a signal transmitted to the ignition device 170 via a communication line or wire 171. The power charge 150 is shown without an ignition device adapter 172 (shown in
The method 300 may include running the setting tool into a wellbore, at step 330. The setting tool may be run to a desired location within a wellbore at which it is desired to set a device within the wellbore. The method may also include detonating the power charge to set the device in the wellbore, as step 340, with an electrical signal communicated to the electrical ignition device via an electrical line or wire. The use of an electrical signal to an electrical ignition device connect to an igniter attached to or embedded within the power charge may provide for selective and reliable detonation of a power charge within a downhole setting tool.
Although this disclosure has been described in terms of certain preferred embodiments, other embodiments that are apparent to those of ordinary skill in the art, including embodiments that do not provide all of the features and advantages set forth herein, are also within the scope of this disclosure. Accordingly, the scope of the present disclosure is defined only by reference to the appended claims and equivalents thereof.
