Actuating tool for actuating an auxiliary tool downhole in a wellbore

An actuating tool actuable by degradation of at least a portion of a seal assembly to set an auxiliary tool downhole in an oil and gas wellbore. A system and method for actuating the auxiliary tool downhole in the oil and gas wellbore using the actuating tool by degrading at least a portion of the seal assembly of the actuating tool.

BACKGROUND

The present disclosure relates generally to oil and gas operations and, more particularly, to an actuating tool for actuating an auxiliary tool downhole in a wellbore.

DETAILED DESCRIPTION

FIG. 1is a diagrammatic illustration of a system, according to one or more embodiments. Referring toFIG. 1, in an embodiment, the system is generally referred to by the reference numeral100and includes a conveyance truck105and a downhole tool110. The conveyance truck105is operable to deploy and retrieve the downhole tool110via a conveyance string115. The conveyance string115may be or include any type of conveyance string capable of being connected to the downhole tool110and conveyed together therewith into an oil and gas wellbore120that penetrates one or more subterranean formations. The wellbore120may be used in oil and gas exploration and production operations. The conveyance string115may include, but is not limited to, casing, drill pipe, coiled tubing, production tubing, other types of pipe or tubing strings, and/or other types of conveyance strings, such as wireline, slickline, or the like. In one or more embodiments, the conveyance string115is wireline and the conveyance truck105is a wireline truck. In one or more other embodiments, the conveyance string115is coiled tubing and the conveyance truck105is a coiled tubing truck.

As shown inFIG. 1, the system100further includes a lubricator125, a fracturing (or “frac”) tree130, and a wellhead135. The wellhead135is located at the top or head of the wellbore120. A pumpdown truck140may be connected to, and adapted to be in fluid communication with, the wellhead135. The pumpdown truck140is operable to supply pumpdown fluid to the wellhead135, which pumpdown fluid urges the downhole tool110downhole along the wellbore120(e.g., along a horizontal section of the wellbore120). In addition to, or instead of, being connected to, and adapted to be in fluid communication with, the wellhead135, the pumpdown truck140may be connected to, and adapted to be in fluid communication with, the frac tree130and/or the lubricator125. In those embodiments in which the pumpdown truck140is connected to, and in fluid communication with, the lubricator125, the pumpdown truck140may be further utilized to equalize pressure between the wellhead135and the lubricator125to thereby facilitate the opening of a valve (e.g., a swab valve, an upper master valve, the like, or a combination thereof) isolating the lubricator125from the wellhead135so that the downhole tool110may be deployed from the lubricator125, through the wellhead135, and into the wellbore120, as will be described in further detail below. In addition to, or instead of, the pumpdown truck140, a bypass line and/or a different pump may be utilized to equalize pressure between the wellhead135and the lubricator125to thereby facilitate the opening of the valve isolating the lubricator125from the wellhead135. The pumpdown truck140is needed in those instances where the conveyance string115is insufficiently rigid to move the downhole tool110downhole along the wellbore120(e.g., when the conveyance string115is wireline). Alternatively, the pumpdown truck140may be omitted from the system100in those instances where the conveyance string115is sufficiently rigid to move the downhole tool110downhole along the wellbore120.

The frac tree130is connected to, and adapted to be in fluid communication with, the wellhead135, opposite the wellbore120. For example, the frac tree130may be, include, or be part of the wellhead135. One or more frac pumps145are connected to, and adapted to be in fluid communication with, the frac tree130. The frac pump(s)145are operable to supply fracturing fluid to the wellbore120during a hydraulic fracturing operation, as will be described in further detail below. During such a hydraulic fracturing operation, the fracturing fluid is utilized to hydraulically fracture a target zone of a subterranean formation adjacent a perforated zone of the wellbore120. The lubricator125is connected to, and adapted to be in fluid communication with, the frac tree130, opposite the wellhead135. The lubricator125facilitates deployment of the downhole tool110through the wellhead135and into the wellbore120to a location proximate the target zone of the subterranean formation.

The downhole tool110includes an actuating tool150. In one or more embodiments, the actuating tool150is, includes, or is part of a setting tool. The downhole tool110is deployable from the lubricator125, through the wellhead135, and into the wellbore120to a location proximate the target zone of the subterranean formation, as will be described in further detail below. In one or more embodiments, as inFIG. 1, the downhole tool110further includes an auxiliary tool. In one or more embodiments, the auxiliary tool is or includes one or more perforating guns155and a plug160. In such instances, the downhole tool110is deployable from the lubricator125, through the wellhead135, and into the wellbore120to the location proximate the target zone of the subterranean formation to perform a plug-and-perforate operation, as will be described in further detail below. Although described herein as including the perforating gun(s)155, the actuating tool150, and the plug160for use during a plug-and-perforate operation, the downhole tool110may instead be another type of downhole tool of which the actuating tool150is a part for use in connection with another application, which application may include, but is not limited to, exploration, drilling, completions, production, measurement, logging, the like, or a combination thereof. More particularly, although described herein as including the perforating gun(s)155and the plug160, the perforating gun(s)155, the plug160, or both may be omitted from the auxiliary tool and replaced with one or more other downhole tools such as, for example, one or more flow control tools.

The perforating gun(s)155are connected to the conveyance string115at an end of the conveyance string115opposite the conveyance truck105. Moreover, the actuating tool150is connected to the perforating gun(s)155, opposite the conveyance string115, and the plug160is connected to the actuating tool150, opposite the perforating gun(s)155. The plug160is actuable (e.g., radially expandable) by the actuating tool150as part of the plug-and-perforate operation at a location proximate the target zone of the subterranean formation, as will be described in further detail below. Finally, the perforating gun(s)155are operable as part of the plug-and-perforate operation to perforate the wellbore120(e.g., a casing string cemented into the wellbore120) proximate the target zone of the subterranean formation, as will be described in further detail below.

FIG. 2is a perspective view of the actuating tool150and the plug160, according to one or more embodiments. Referring toFIG. 2, in an embodiment, the plug160includes a packer element165and a plurality of slip elements170. The packer element165is actuable by the actuating tool150as part of the plug-and-perforate operation to seal against a wall of the wellbore120(e.g., a casing string cemented in the wellbore120, an open hole section of the wellbore, the like, or a combination thereof). Likewise, the slip elements170are actuable by the actuating tool150as part of the plug-and-perforate operation to anchor the plug160to the wall of the wellbore120. The plug160further includes a central passage175extending therethrough, which central passage175is closable as part of the fracturing operation by seating an obturator in the plug160, as will be described in further detail below. As shown inFIG. 2, the actuating tool150includes a main housing180, a housing retainer185(which may also be referred to as a “sub” or an “end cap”), and an auxiliary sleeve190. In one or more embodiments, the auxiliary sleeve190is, includes, or is part of a setting sleeve. The auxiliary sleeve190is connected between the housing retainer185to the plug160. Radial openings192are formed through the auxiliary sleeve190adjacent the plug160to permit the insertion of fasteners194such as, for example, shear pins, therethrough, which fasteners194connect the plug160to the actuating tool150. The main housing180is connected to the housing retainer185, opposite the auxiliary sleeve190. Finally, in one or more embodiments, a conductor sub (not shown) is connected to the main housing180, opposite the housing retainer185.

FIG. 3Ais a cross-sectional view of the actuating tool150taken along the line3A-3A inFIG. 2, according to one or more embodiments. Referring toFIG. 3A, with continuing reference toFIG. 2, in an embodiment, the actuating tool150further includes a piston200and a plug adapter205. The piston200includes a piston head210aand a piston rod210b. The piston head210ais connected to the piston rod210band extends within the main housing180. In one or more embodiments, the piston head210aand210bare integrally formed as a unitary component. The main housing180defines an internal passage215sealed on opposing ends by the conductor sub (not shown) and the housing retainer185, respectively, to form a chamber220(e.g., an atmospheric chamber). In one or more embodiments, the main housing180and the housing retainer185are integrally formed as a unitary component. The piston head210asealingly engages the main housing180, thereby dividing the chamber220into opposing sub-chambers225aand225b. The auxiliary sleeve190defines an internal passage230sealed on one end by the housing retainer185. Radial openings232a-c(the radial opening232cis shown inFIG. 2) are formed through the auxiliary sleeve190into the internal passage230. The radial openings232a-care operable to communicate wellbore pressure from the wellbore120to the internal passage230, as will be described in further detail below. In addition to, or instead of, being communicated from the wellbore120to the internal passage230via the radial openings232a-c, the wellbore pressure may be otherwise communicated from the wellbore120to the internal passage230; in one or more such embodiments, the radial openings232a-care omitted.

The piston rod210bextends from the piston head210ain the main housing180and into the internal passage230of the auxiliary sleeve190. The plug adapter205is connected to the piston rod210b, opposite the piston head210a, and extends within the internal passage230of the auxiliary sleeve190. The plug160(not visible inFIG. 3A) is connected to the plug adapter205, opposite the piston rod210b, using the fasteners194so that the packer element165and the slip elements170extend outside the auxiliary sleeve190, as shown inFIG. 2. In addition to, or instead of, the fasteners194, the plug160may be connected to the plug adapter205using detents, protrusions, slots, ridges, grooves, ridges, the like, or a combination thereof. A seal assembly235engages the housing retainer185to prevent, or at least reduce, fluid communication between the internal passage230of the auxiliary sleeve190and the sub-chamber225b, as will be described in further detail below. A conductive fitting240extends through the piston head210aand between the sub-chambers225aand225b. An electrical conductor245a(e.g., a wire) connects the conductive fitting240extending through the piston head210ato the seal assembly235, as will be described in further detail below. An electrical conductor245b(e.g., a wire) connects the conductive fitting240extending through the piston head210ato the conductor sub (not shown).

FIG. 3Bis an enlarged view illustrating a portion of the actuating tool150shown inFIG. 3A, according to one or more embodiments. Referring toFIG. 3B, with continuing reference toFIG. 3A, in an embodiment, the piston head210adefines opposing end portions255aand255band an outer surface260. In one or more embodiments, the piston head210ais generally cylindrical. External annular grooves265aand265bare formed into the outer surface260of the piston head210a, which external annular grooves265aand265bare each adapted to accommodate a sealing element enabling the piston head210ato sealingly engage the main housing180, thereby dividing the chamber220into the sub-chambers225aand225b. An opening270is formed through the piston head210abetween the sub-chambers225aand225b. The conductive fitting240extends within the opening270and sealingly engages the piston head210a. A blind hole275is formed into the end portion255bof the piston head210a, which blind hole275only extends partially through the piston head210a. An internal threaded connection280is formed in the piston head210aat the blind hole275.

The piston rod210bdefines opposing end portions285aand285band an outer surface290. In one or more embodiments, the piston rod210bis generally cylindrical. An external threaded connection295is formed in the outer surface290of the piston rod210bat the end portion285a. The external threaded295connection of the piston rod210bthreadably engages the internal threaded connection280of the piston head210ato thereby connect the piston head210ato the piston rod210bat the end portion285aof the piston rod210b.

The main housing180includes an internal threaded connection300at an end portion thereof opposite the conductor sub (not shown). The housing retainer185defines opposing end portions305aand305band an outer surface310. An external threaded connection315is formed in the outer surface310of the housing retainer185at the end portion305a. The external threaded connection315of the housing retainer185engages the internal threaded connection300of the main housing180to connect the housing retainer185to the main housing180. External annular grooves320aand320bare formed into the outer surface310of the housing retainer185, which external annular grooves320aand320bare each adapted to accommodate a sealing element enabling the housing retainer185to sealingly engage the main housing180. Likewise, an external threaded connection325is formed in the housing retainer185at the end portion305b.

The housing retainer185includes a collar330extending outwardly from the outer surface310between the external annular grooves320aand320band the external threaded connection315. In one or more embodiments, the external threaded connection315of the housing retainer185is threaded into the internal threaded connection300of the main housing180until the collar330of the housing retainer185engages the end portion of the main housing180opposite the conductor sub (not shown). Spanner slots335aand335bare formed radially into the collar330(the spanner slot335ais also shown inFIG. 2), which spanner slots335aand335bare adapted to be engaged by a spanner wrench to facilitate assembly of the of the actuating tool150. The auxiliary sleeve190includes an internal threaded connection340at an end portion thereof opposite the plug160(shown inFIGS. 2 and 3A). The internal threaded connection340of the auxiliary sleeve190threadably engages the external threaded connection325of the housing retainer185to thereby connect the auxiliary sleeve190to the housing retainer185. In one or more embodiments, the internal threaded connection340of the auxiliary sleeve190is threaded onto the external threaded connection325of the housing retainer185until the end portion of the auxiliary sleeve190opposite the plug160engages the collar330of the housing retainer185.

An internal passage345is formed into the housing retainer185at the end portion305b, which internal passage345only extends partially through the housing retainer185. The internal passage345is in fluid communication with the internal passage230of the auxiliary sleeve190. A projection350extends from the end portion305aof the housing retainer185, which projection350forms part of the housing retainer185. The projection350has a diameter smaller than that of the housing retainer185at the end portion305a. An external shoulder355is formed at the end portion305aof the housing retainer185between the projection350and the external threaded connection315. An internal passage360extends through the housing retainer185, including the projection350, from the sub-chamber225binto the internal passage345. The internal passage345has a diameter larger than that of the internal passage360. The internal passage345defines an internal shoulder365in the housing retainer185, adjacent the internal passage360. The internal passage360accommodates the piston rod210bextending from the piston head210a. Internal annular grooves370aand370bare formed into housing retainer185at the internal passage360, which internal annular grooves370aand370bare each adapted to accommodate a sealing element enabling the housing retainer185to sealingly and slidably engage the piston rod210b. An opening375is formed through the housing retainer185, including at least a portion of the projection350(as more clearly shown inFIG. 3C), from the sub-chamber225binto the internal passage345. The seal assembly235extends within the opening375and sealingly engages the housing retainer185.

FIG. 3Cis a cross-sectional view of the actuating tool150taken along the line3C-3C ofFIG. 3B, according to one or more embodiments. Referring toFIG. 3C, with continuing reference toFIG. 3B, in an embodiment, radial openings380a-care formed through the projection350of the housing retainer185and into the internal passage360. The radial openings380a-care distributed (e.g., evenly) about a longitudinal center axis385of the housing retainer185. Likewise, blind holes390a-care formed radially into the piston rod210b, each of which blind holes390a-conly extends partially through the piston rod210b. The blind holes390a-care distributed (e.g., evenly) about a longitudinal center axis395of the piston rod210b. An internal threaded connection400is formed in the piston rod210bat each of the blind holes390a-c. The longitudinal center axes385and395are coaxial. The blind holes390a-ccorrespond to, and are aligned with, the radial openings380a-c. A shear pin405extends within both the radial opening380aand the blind hole390a. The shear pin405threadably engages the internal threaded connection400formed in the piston rod210bat the blind holes390a. As a result, the shear pin405restricts relative movement between the piston rod210band the housing retainer185until a threshold force is applied to the piston rod210b, as will be described in further detail below. Although shown with only the shear pin405extending within both the radial opening380aand the blind hole390a, in addition, or instead, additional shear pin(s) identical to the shear pin405may also extend within the radial opening380band the blind hole390b, the radial opening380cand the blind hole390c, or both.

FIG. 3Dis an enlarged view illustrating a sub-portion of the portion of the actuating tool150shown inFIG. 3B, according to one or more embodiments. Referring toFIG. 3D, in an embodiment, the opening270formed through the piston head210abetween the sub-chambers225aand225bincludes opposing end portions410aand410b. The end portions410aand410bof the opening270extend adjacent the sub-chambers225aand225b, respectively. The end portion410bof the opening270has a diameter larger than that of the end portion410a. The end portion410bof the opening270defines an internal shoulder415in the piston head210a, adjacent the end portion410a. An internal threaded connection416is formed in the piston head210aat the end portion410bof the opening270, adjacent the sub-chamber225b. The conductive fitting240extending within the opening270and sealingly engaging the piston head210aincludes a housing420and an electrical conductor425.

The housing420includes opposing end portions430aand430b. The end portion430aof the conductor housing420has a diameter smaller than that of the end portion430b. An external shoulder435is formed in the conductor housing420between the end portions430aand430b. The external shoulder435of the conductor housing420engages the internal shoulder415in the piston head210a. External annular grooves440aand440bare formed into the conductor housing420at the end portion430b, which external annular grooves440aand440bare each adapted to accommodate a sealing element enabling the conductor housing420of the conductive fitting240to sealingly engage the piston head210a. An external threaded connection445is formed in the conductor housing420at the end portion430b, adjacent the sub-chamber225b. The external threaded connection445formed in the conductor housing420threadably engages the internal threaded connection416formed in the piston head210ato thereby connect the conductor housing420to the piston head210a. An opening450is formed through the conductor housing420between the sub-chambers225aand225b, which opening450includes opposing end portions455aand455b. The end portions455aand455bof the opening450extend adjacent the sub-chambers225aand225b, respectively. The end portion455bof the opening450has a diameter larger than that of the end portion455a. The end portion455bof the opening450defines an internal shoulder460in the piston head210a, adjacent the end portion455a. An internal threaded connection465is formed in the conductor housing420at the end portion455bof the opening450.

The electrical conductor425defines opposing end portions470aand470b. A blind hole475is formed in the end portion470aof the electrical conductor425, which blind hole475only extends partially through the electrical conductor425. An external threaded connection480is formed in the electrical conductor425proximate the end portion470a. The external threaded connection480of the electrical conductor425threadably engages the internal threaded connection465of conductor housing420to thereby connect the electrical conductor425to the conductor housing420. The electrical conductor245b(e.g., the wire) connects the conductor sub (not shown) to the end portion470aof the electrical conductor425at the blind hole475. Likewise, a blind hole485is formed in the end portion470bof the electrical conductor425, which blind hole485only extends partially through the electrical conductor425. External annular grooves490aand490bare formed in the electrical conductor425at the end portion470b, which external annular grooves490aand490bare each adapted to accommodate a sealing element enabling the electrical conductor425to sealingly engage the conductor housing420. The electrical conductor245a(e.g., the wire) connects the seal assembly235to the end portion470bof the electrical conductor425at the blind hole485.

The opening375formed through the housing retainer185, including the at least a portion of the projection350(as more clearly shown inFIG. 3C), from the sub-chamber225binto the internal passage345, includes opposing end portions495aand495band an intermediate portion495c. The end portions495aand495bof the opening375extend adjacent the sub-chamber225band the internal passage345, respectively. The end portion495aof the opening375has a diameter larger than that of the intermediate portion495c. The end portion495aof the opening375defines an internal shoulder500in the housing retainer185, adjacent the intermediate portion495c. An internal frusto-conical surface505is formed in the housing retainer185at the intermediate portion495cof the opening375, adjacent the internal shoulder500. An internal threaded connection510is formed in the housing retainer185at the end portion495aof the opening375, adjacent the sub-chamber225b. The intermediate portion495cof the opening375has a diameter larger than that of the end portion495b. The intermediate diameter portion495cdefines an internal shoulder512in the housing retainer185, adjacent the end portion495b. The seal assembly235includes a seal plug515, a heating element520, a load ring525, and a seal retainer530. The seal plug515defines opposing end portions535aand535b. The end portion535bof the seal plug515engages the internal shoulder512of the housing retainer185and has a diameter smaller than that of the end portion535a. An external frusto-conical surface540is formed in the seal plug515between the end portions535aand535b, which external frusto-conical surface540engages the internal frusto-conical surface505formed in the housing retainer185. The end portion535bof the seal plug515extends within the end portion495bof the opening375. External annular grooves545aand545bare formed in the end portion535bof the seal plug515, which external annular grooves545aand545bare each adapted to accommodate a sealing element to enable the seal plug515to sealingly engage the housing retainer185at the end portion495bof the opening375. A blind hole550is formed in the end portion535aof the seal plug515, which blind hole550only extends partially through the seal plug515. The blind hole550accommodates the heating element520. In one or more embodiments, the seal plug515and the heating element520are integrally formed as a unitary component.

The load ring525defines opposing end portions555aand555b. An internal passage560extends through the load ring525from the end portion555ato the end portion555b. The internal passage560accommodates the heating element520. The end portion555bof the load ring525engages the end portion535aof the seal plug515. The seal retainer530defines opposing end portions565aand565b. The end portion565bof the seal retainer530engages the end portion555aof the load ring525. An external threaded connection570is formed in the seal retainer530. The external threaded connection570of the seal retainer530threadably engages the internal threaded connection510of the housing retainer185. An internal passage575extends through the seal retainer530. A tool receptacle580is formed in the seal retainer530at the internal passage575. Moreover, the internal passage575of the seal retainer530accommodates the heating element520. The tool receptacle580is adapted to receive a tool, which tool is utilized to threadably tighten the external threaded connection570of the seal retainer530into the internal threaded connection510of the housing retainer185. When so threadably tightened, the seal retainer530squeezes the load ring525against the seal plug515to hold the end portion535bof the seal plug515, including the external annular grooves545aand545beach accommodating a sealing element, within the end portion495bof the opening375. As a result, the seal plug515sealingly engages the housing retainer185at the end portion495bof the opening375, thereby preventing, or at least reducing, fluid communication between the internal passage345of the housing retainer185and the sub-chamber225b. The electrical conductor245a(e.g., the wire) connects the heating element520of the seal assembly235to the end portion470bof the electrical conductor425at the blind hole485.

FIGS. 4A-4Care flow diagrams of a method for utilizing the system100to hydraulically fracturing a zone of the wellbore120, according to one or more embodiments. Referring toFIG. 4A, in an embodiment, the method is generally referred to by the reference numeral585and includes, at a step590, performing a plug-and-perforate operation and, at a step595, performing a fracturing operation. Turning toFIG. 4B, the step590of performing the plug-and-perforate operation includes, at a sub-step590a, placing the downhole tool110in the lubricator125, as shown inFIG. 5. More particularly,FIG. 5is a diagrammatic illustration of the system100ofFIG. 1in an operational state or configuration caused by execution of the sub-step590a, that is, after the downhole tool110has been placed in the lubricator125. Turning back toFIG. 4B, the step590of the method585further includes, at a sub-step590b, deploying the downhole tool110from the lubricator125, through the wellhead135, and into the wellbore120to a depth proximate a target zone of the subterranean formation, as shown inFIG. 6. More particularly,FIG. 6is a diagrammatic illustration of the system ofFIG. 1in an operational state or configuration caused by execution of the sub-step590b, that is, after the downhole tool110has been deployed from the lubricator125, through the wellhead135, and into the wellbore120to the depth. Turning back toFIG. 4B, the step590further includes, at a sub-step590c, setting the plug160at the depth using the actuating tool150. The step590further includes, at a sub-step590d, detonating the perforating gun(s)155to perforate the wellbore120along an interval proximate the target zone. Finally, the step590includes, at a sub-step590e, retrieving the detonated perforating gun(s)155and the actuating tool150from the wellbore120into the lubricator125, as shown inFIG. 7. More particularly,FIG. 7is a diagrammatic illustration of the system ofFIG. 1in an operational state or configuration caused by execution of the sub-step590e, that is, after the detonated perforating gun(s)155and the actuating tool150have been retrieved from the wellbore120into the lubricator125. The step590eof retrieving the detonated perforating gun(s)155and the actuating tool150from the wellbore120includes detaching the plug adapter205from the plug160by shearing or otherwise disengaging the fasteners194and/or disengaging the detents, protrusions, slots, ridges, grooves, ridges, the like, or a combination thereof, used to detachably connect the plug160to the plug adapter205.

Turning toFIG. 4C, the step595of performing the fracturing operation includes, at a sub-step595a, dropping an obturator through the wellhead135and into the wellbore120. The step595further includes, at a sub-step595b, seating the obturator in the plug160, which is set at the depth, to close the central passage175of the plug160. Finally, the step595includes, at a sub-step595c, communicating hydraulic fracturing fluid to the target zone via the perforations along the interval. More particularly, the sub-step595cincludes pumping the fracturing fluid to the frac tree130using the frac pump(s)145so that the fracturing fluid flows through the frac tree130, through the wellhead135, into the wellbore120, through the perforations along the interval, and into the target zone of the subterranean formation.

FIG. 8is a flow diagram of the sub-step590cof the step590of the method585, according to one or more embodiments. Referring toFIG. 8, in an embodiment, the sub-step590cof setting the plug160at the depth using the actuating tool150includes, at a sub-step590ca, degrading (e.g., melting) at least a portion of the seal assembly235using the heating element520. The sub-step590caof degrading (e.g., melting) the at least a portion of the seal assembly235using the heating element520includes degrading the seal plug515, the load ring525, the sealing elements accommodated within the external annular grooves545aand545bof the seal plug515, or a combination thereof, using the heating element520. In one or more embodiments, the heating element520is a heating coil. For example, the heating element520may be or include a resistance wire such as, for example, nichrome wire. In one or more embodiments, the heating element520is an inductive heating element. The heating element520may be activated by communicating electricity to the heating element520via the electrical conductor245a, the electrical conductor425of the conductive fitting240(shown inFIGS. 3B and 3D), the electrical conductor245b, and the conductor sub (not shown). In addition, or instead, the heating element520may be activated by battery power. In addition, or instead, the heating element520may be activated by power that is initiated via a remote signal from the surface and/or another location in or near the downhole tool110(e.g., via a transmitter/receiver pair in the downhole tool110and the heating element520, respectively). For example, the downhole tool110may include an addressable switch associated with the heating element520and operable as a 2-way communication device to arm and activate the heating element520.

The sub-step590cfurther includes, at a sub-step590cb, communicating wellbore pressure through the opening375in the housing retainer185and into the sub-chamber225b, as shown inFIGS. 9A and 9B. More particularly,FIG. 9Ais a cross-sectional view of the actuating tool150similar to the view shown inFIG. 3A, except that the seal assembly235has been degraded to allow wellbore pressure to be communicated from the internal passage345of the housing retainer185, which internal passage345communicates with the wellbore120via the internal passage230and the radial openings232a-cof the auxiliary sleeve190, to the sub-chamber225bvia the opening375, according to one or more embodiments. Furthermore,FIG. 9Bis an enlarged view of a portion of the actuating tool150shown inFIG. 9A(similar to the view shown inFIG. 3B), according to one or more embodiments.

The sub-step590cfurther includes, at a sub-step590cc, moving the piston head210awithin the chamber220using the wellbore pressure in the sub-chamber225b, as shown inFIGS. 9A and 9B. Prior to degradation of the seal assembly235at the sub-step590ca, the chamber220, including the sub-chambers225aand225b, contains atmospheric pressure (or some other pressure lower than wellbore pressure at the depth adjacent the target zone of the subterranean formation). As a result, when the seal assembly235is degraded at the sub-step590ca, causing the wellbore pressure to be communicated to the sub-chamber225bat the sub-step590cb, the wellbore pressure in the sub-chamber225bexceeds the pressure (e.g., atmospheric pressure) in the sub-chamber225a. Due to the pressure in the sub-chamber225bexceeding the pressure in the sub-chamber225a, a force is exerted on the piston head210ain a direction600away from the housing retainer185and towards the conductor sub (not shown). When the force exerted on the piston head210aexceeds the threshold force required to shear the shear pin405(and/or the additional shear pin(s)), the shear pin405(and/or the additional shear pin(s)) is sheared and the piston head210amoves in the direction600, as shown inFIGS. 9A and 9B.

Finally, the sub-step590cincludes, at a sub-step590cd, radially expanding the plug160into engagement with a wall of the wellbore120using the movement of the piston head210a. Moving the piston head210awithin the chamber220using the wellbore pressure at the sub-step590ccalso causes the piston rod210band the plug adapter205to move in the direction600. The sealing elements accommodated within the internal annular grooves370aand370bof the housing retainer185sealingly and slidably engage the piston rod210bas the piston rod210bmoves in the direction600. The plug adapter205is connected to the plug160and, as a result, the movement of the plug adapter205actuates the plug160, causing the packer element165(shown inFIG. 2) to radially expand into sealing engagement with the wall of the wellbore120, and causing the slip elements170(shown inFIG. 2) to radially expand into anchoring engagement with the wall of the wellbore120(e.g., a casing string cemented in the wellbore120, an open hole section of the wellbore, the like, or a combination thereof).

Although described herein as including the seal plug515, the load ring525, the seal retainer530, and the heating element520, in addition, or instead, the seal assembly235may be or include another type of seal assembly such as, for example, a chemically-degradable seal assembly, a mechanically-actuable and/or mechanically-degradable seal assembly, a hydraulically-actuable and/or hydraulically-degradable seal assembly, the like, or a combination thereof. In such embodiments, the step590caof degrading the at least a portion of the seal assembly235using the heating element520is correspondingly altered or replaced with a step of chemically degrading at least a portion of the chemically-degradable seal assembly using a wellbore fluid (or another fluid), a step of mechanically actuating and/or mechanically degrading the mechanically-actuable and/or mechanically-degradable seal assembly, a step of hydraulically actuating and/or hydraulically degrading the hydraulically-actuable and/or hydraulically-degradable seal assembly, the like, or a combination thereof.

In one or more embodiments, the use of the actuating tool150and/or the execution of the method585eliminates the need for explosive or other energetic devices to actuate the plug160, permitting a slower, smoother, and steadier actuation of the plug160due to the constant wellbore pressure applied to the piston head210a. Further, the use of the actuating tool150and/or the execution of the method585eliminates, or at least decreases, the amount of shock usually associated with the actuation of plugs by detonation of energetic devices, thereby more reliably setting the plug160in the wellbore120. Further still, the use of the actuating tool150and/or the execution of the method585decreases the costs usually associated with the actuation of plugs by detonation of energetic devices by, for example, eliminating consumables and improving reusability.

In one or more embodiments, the actuating tool150is manufactured in accordance with the foregoing description, and/or one or more ofFIGS. 1-9B.

In one or more embodiments, the actuating tool150is produced in accordance with one or more methods, the one or more methods being described above and/or illustrated inFIGS. 1-9B.

In one or more embodiments, the actuating tool150is redressed. In one or more embodiments, the actuating tool150is redressed after use and/or the execution of the method585. In one or more embodiments, after the actuating tool150has been redressed, the redressed actuating tool150is operated in accordance with the foregoing description, and/or the method585is executed using the redressed actuating tool150. In one or more embodiments, redressing the actuating tool150after each use, and/or after each execution of the method585, allows the actuating tool150to be used repeatedly. In one or more embodiments, to redress the actuating tool150, a redress kit is provided, and component(s) of the redress kit is/are installed in the actuating tool150in accordance with the foregoing description and/orFIGS. 1-9B; in several embodiments, the redress kit includes a seal assembly that is identical to the seal assembly235; in several embodiments, the redress kit includes a seal plug that is identical to the seal plug515, and/or a heating element that is identical to the heating element520; in several embodiments, the redress kit includes a seal plug that is identical to the seal plug515, a heating element that is identical to the heating element520, a load ring that is identical to the load ring525, a seal retainer that is identical to the seal retainer530, or any combination thereof.

In several embodiments, the actuating tool150or a portion thereof is provided as a kit, which may be assembled. In several embodiments, a portion of the actuating tool150is provided as a kit, and the portion is assembled using the components of kit and/or is installed in the remainder of the actuating tool150.

A downhole tool has been disclosed, which downhole tool is adapted to be positioned into a wellbore. The downhole tool generally includes: an actuating tool, including: a main housing; a housing retainer connected to the main housing so that, in combination, the main housing and the housing retainer at least partially define a chamber; a piston extending through the housing retainer and dividing the chamber into first and second sub-chambers; an auxiliary sleeve connected to the housing retainer, opposite the main housing; and a seal assembly; and an auxiliary tool connected to the auxiliary sleeve, opposite the housing retainer; wherein the actuating tool is actuable to: a first configuration, in which: the seal assembly is sealingly disengaged from the housing retainer to permit fluid communication, via a first opening in the housing retainer, between the first sub-chamber and the wellbore; the fluid communication between the first sub-chamber and the wellbore moves the piston to a first axial position relative to the housing retainer; and the movement of the piston to the first axial position actuates the auxiliary tool to a first state. In one or more embodiments, the fluid communication between the first sub-chamber and the wellbore is further permitted via a second opening in the auxiliary sleeve. In one or more embodiments, the actuating tool is further actuable: from a second configuration, in which: the seal assembly sealingly engages the housing retainer to fluidically isolate the first sub-chamber from the wellbore; the piston is situated in a second axial position relative to the housing retainer; and the auxiliary tool is in a second state; to the first configuration. In one or more embodiments, the seal assembly includes: a heating element; and the heating element is adapted to degrade at least a portion of the seal assembly to sealingly disengage the seal assembly from the housing retainer, thereby actuating the actuating tool from the second configuration to the first configuration. In one or more embodiments, the piston includes: a piston head dividing the chamber into the first and second sub-chambers; and a piston rod connected to the piston head and extending through the housing retainer. In one or more embodiments, the actuating tool further includes: a conductive fitting extending through the piston head and between the first and second sub-chambers; and a first electrical conductor connecting the conductive fitting to the seal assembly; and the first electrical conductor is adapted to communicate electricity from the conductive fitting to the seal assembly to sealingly disengage the seal assembly from the housing retainer, thereby actuating the actuating tool from the second configuration to the first configuration. In one or more embodiments, the actuating tool further includes: a conductor sub connected to the main housing, opposite the housing retainer, so that, in combination, the main housing, the housing retainer, and the conductor sub define the chamber; and a second electrical conductor connecting the conductor sub to the conductive fitting; and the second electrical conductor is adapted to communicate electricity from the conductor sub to the conductive fitting. In one or more embodiments, the auxiliary tool includes a plug, which plug includes: a packer element; and a plurality of slip elements.

A first method has also been disclosed. The first method generally includes: positioning a downhole tool into a wellbore, the downhole tool including: an actuating tool, including: a main housing; a housing retainer connected to the main housing so that, in combination, the main housing and the housing retainer at least partially define a chamber; a piston extending through the housing retainer and dividing the chamber into first and second sub-chambers; an auxiliary sleeve connected to the housing retainer, opposite the main housing; and a seal assembly; and an auxiliary tool connected to the auxiliary sleeve, opposite the housing retainer; and actuating the actuating tool: to a first configuration, in which: the seal assembly is sealingly disengaged from the housing retainer to permit fluid communication, via a first opening in the housing retainer, between the first sub-chamber and the wellbore; the fluid communication between the first sub-chamber and the wellbore moves the piston to a first axial position relative to the housing retainer; and the movement of the piston to the first axial position actuates the auxiliary tool to a first state. In one or more embodiments, the fluid communication between the first sub-chamber and the wellbore is further permitted via a second opening in the auxiliary sleeve. In one or more embodiments, the method further includes: actuating the actuating tool: from a second configuration, in which: the seal assembly sealingly engages the housing retainer to fluidically isolate the first sub-chamber from the wellbore; the piston is situated in a second axial position relative to the housing retainer; and the auxiliary tool is in a second state; to the first configuration. In one or more embodiments, the seal assembly includes: a heating element; and actuating the actuating tool from the second configuration to the first configuration includes degrading, using the heating element, at least a portion of the seal assembly to sealingly disengage the seal assembly from the housing retainer. In one or more embodiments, the piston includes: a piston head dividing the chamber into the first and second sub-chambers; and a piston rod connected to the piston head and extending through the housing retainer. In one or more embodiments, the actuating tool further includes: a conductive fitting extending through the piston head and between the first and second sub-chambers; and a first electrical conductor connecting the conductive fitting to the seal assembly; and actuating the actuating tool from the second configuration to the first configuration includes communicating electricity, via the first electrical conductor, from the conductive fitting to the seal assembly to sealingly disengage the seal assembly from the housing retainer. In one or more embodiments, the actuating tool further includes: a conductor sub connected to the main housing, opposite the housing retainer, so that, in combination, the main housing, the housing retainer, and the conductor sub define the chamber; and a second electrical conductor connecting the conductor sub to the conductive fitting; and actuating the actuating tool from the second configuration to the first configuration further includes communicating electricity, via the second electrical conductor, from the conductor sub to the conductive fitting. In one or more embodiments, the auxiliary tool includes a plug, which plug includes: a packer element; and a plurality of slip elements.

An actuating tool has also been disclosed, which actuating tool is adapted to be positioned into a wellbore. The actuating tool generally includes: a main housing at least partially defining a chamber; a piston dividing the chamber into first and second sub-chambers; and a seal assembly; wherein the actuating tool is actuable to: a first configuration, in which: the seal assembly is sealingly disengaged to permit fluid communication, via a first opening, between the first sub-chamber and the wellbore; and the fluid communication between the first sub-chamber and the wellbore moves the piston to a first axial position relative to the main housing. In one or more embodiments, the actuating tool further includes: a housing retainer connected to the main housing so that, in combination, the main housing and the housing retainer at least partially define the chamber; wherein the first opening is formed in the housing retainer. In one or more embodiments, the actuating tool further includes: an auxiliary sleeve connected to the housing retainer, opposite the main housing; and the fluid communication between the first sub-chamber and the wellbore is further permitted via a second opening in the auxiliary sleeve. In one or more embodiments, the actuating tool is further actuable: from a second configuration, in which: the seal assembly is sealingly engaged to fluidically isolate the first sub-chamber from the wellbore; and the piston is situated in a second axial position relative to the main housing; to the first configuration. In one or more embodiments, the seal assembly includes: a heating element; and the heating element is adapted to degrade at least a portion of the seal assembly to sealingly disengage the seal assembly, thereby actuating the actuating tool from the second configuration to the first configuration. In one or more embodiments, the piston includes: a piston head dividing the chamber into the first and second sub-chambers; and a piston rod connected to the piston head. In one or more embodiments, the actuating tool further includes: a conductive fitting extending through the piston head and between the first and second sub-chambers; and a first electrical conductor connecting the conductive fitting to the seal assembly; and the first electrical conductor is adapted to communicate electricity from the conductive fitting to the seal assembly to sealingly disengage the seal assembly, thereby actuating the actuating tool from the second configuration to the first configuration. In one or more embodiments, the actuating tool further includes: a conductor sub connected to the main housing so that, in combination, the main housing and the conductor sub at least partially define the chamber; and a second electrical conductor connecting the conductor sub to the conductive fitting; and the second electrical conductor is adapted to communicate electricity from the conductor sub to the conductive fitting.

A second method has also been disclosed. The second method generally includes: positioning an actuating tool into a wellbore, the actuating tool including: a main housing at least partially defining a chamber; a piston dividing the chamber into first and second sub-chambers; and a seal assembly; and actuating the actuating tool: to a first configuration, in which: the seal assembly is sealingly disengaged to permit fluid communication, via a first opening, between the first sub-chamber and the wellbore; and the fluid communication between the first sub-chamber and the wellbore moves the piston to a first axial position relative to the main housing. In one or more embodiments, the actuating tool further includes: a housing retainer connected to the main housing so that, in combination, the main housing and the housing retainer at least partially define the chamber; and the first opening is formed in the housing retainer. In one or more embodiments, the actuating tool further includes: an auxiliary sleeve connected to the housing retainer, opposite the main housing; and the fluid communication between the first sub-chamber and the wellbore is further permitted via a second opening in the auxiliary sleeve. In one or more embodiments, the method further includes: actuating the actuating tool: from a second configuration, in which: the seal assembly is sealingly engaged to fluidically isolate the first sub-chamber from the wellbore; and the piston is situated in a second axial position relative to the main housing; to the first configuration. In one or more embodiments, the seal assembly includes: a heating element; and actuating the actuating tool from the second configuration to the first configuration includes degrading, using the heating element, at least a portion of the seal assembly to sealingly disengage the seal assembly. In one or more embodiments, the piston includes: a piston head dividing the chamber into the first and second sub-chambers; and a piston rod connected to the piston head. In one or more embodiments, the actuating tool further includes: a conductive fitting extending through the piston head and between the first and second sub-chambers; and a first electrical conductor connecting the conductive fitting to the seal assembly; and actuating the actuating tool from the second configuration to the first configuration includes communicating electricity, via the first electrical conductor, from the conductive fitting to the seal assembly to sealingly disengage the seal assembly. In one or more embodiments, the actuating tool further includes: a conductor sub connected to the main housing so that, in combination, the main housing and the conductor sub at least partially define the chamber; and a second electrical conductor connecting the conductor sub to the conductive fitting; and actuating the actuating tool from the second configuration to the first configuration further includes communicating electricity, via the second electrical conductor, from the conductor sub to the conductive fitting.

It is understood that variations may be made in the foregoing without departing from the scope of the present disclosure.

In several embodiments, the elements and teachings of the various embodiments may be combined in whole or in part in some or all of the embodiments. In addition, one or more of the elements and teachings of the various embodiments may be omitted, at least in part, and/or combined, at least in part, with one or more of the other elements and teachings of the various embodiments.

Although several embodiments have been described in detail above, the embodiments described are illustrative only and are not limiting, and those skilled in the art will readily appreciate that many other modifications, changes and/or substitutions are possible in the embodiments without materially departing from the novel teachings and advantages of the present disclosure. Accordingly, all such modifications, changes, and/or substitutions are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, any means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Moreover, it is the express intention of the applicant not to invoke 35 U.S.C. § 112(f) for any limitations of any of the claims herein, except for those in which the claim expressly uses the word “means” together with an associated function.