Patent Publication Number: US-11377936-B2

Title: Cartridge system and method for setting a tool

Description:
BACKGROUND 
     1. Field of Invention 
     This disclosure relates in general to oil and gas tools, and in particular, to systems and methods for fracturing operations including setting tools. 
     2. Description of the Prior Art 
     In oil and gas production, hydraulic fracturing may be utilized to recover hydrocarbons from an underground formation. Hydraulic fracturing operations may include a cased wellbore that is plugged and perforated, for example using a setting tool to plug the wellbore and one or more perforating guns to explosively form holes through the casing and into the formation. Often, the perforating guns are arranged in series and may be connected by one or more subs to transmit instructions and/or explosive energy for ignition. Additionally, a setting tool may form a portion of the gun string in order to block subsequent flow into the wellbore when fracturing fluid is introduced after perforating. Presently, various ignitors are coupled through the various intermediate subs, which may be positioned at interfaces subject to fluid ingress, misalignment, and the like. 
     SUMMARY 
     Applicant recognized the limitations with existing systems herein and conceived and developed embodiments of systems and methods, according to the present disclosure, for improved setting tools. 
     In an embodiment, an assembly for perforating a downhole formation includes a perforating gun, coupled to a downhole conveyance system, the perforating gun including an explosive charge and an uphole contact. The assembly also includes a tandem, coupled to the perforating gun proximate the uphole contact, the tandem including a cartridge assembly communicatively coupled to the downhole contact and a primary igniter communicatively coupled to the cartridge assembly. The assembly further includes an intermediate sub, coupled to the tandem opposite the perforating gun, the intermediate sub receiving at least a portion of the primary igniter, the intermediate sub having a fuse and secondary igniter. The assembly also includes a setting tool coupled to the intermediate sub, the setting tool receiving a setting signal via the secondary igniter. 
     In an embodiment, a tandem sub for transmitting a setting signal includes a body, the body having coupling components at a first end and a second end. The sub also includes a channel, extending through at least a portion of the body. The sub further includes a cartridge assembly, positioned within the channel, the cartridge assembly having circuitry for transmitting electrical signals from the first end to the second end. The sub also includes a primary igniter, the primary igniter electrically coupled to the cartridge assembly via a downhole contact formed completely within the body. 
     In an embodiment, a method for forming a perforating gun string includes providing a perforating gun. The method also includes coupling a tandem sub to the perforating gun at a first end, the tandem sub having a cartridge assembly forming an uphole contact with the perforating gun. The method further includes coupling a setting tool to a second send of the tandem sub, opposite the perforating gun, a power charge of the setting tool being explosively coupled to the cartridge assembly. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present technology will be better understood on reading the following detailed description of non-limiting embodiments thereof, and on examining the accompanying drawings, in which: 
         FIG. 1  is a cross-sectional side view of an embodiment of an wellbore system, in accordance with embodiments of the present disclosure; 
         FIG. 2  is a schematic cross-sectional view of a prior art gun string; 
         FIG. 3  is a schematic cross-sectional view of an embodiment of a gun string portion, in accordance with embodiments of the present disclosure; and 
         FIG. 4  is a flow chart of an embodiment of a method for assembling a gun string portion, in accordance with embodiments of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The foregoing aspects, features and advantages of the present technology will be further appreciated when considered with reference to the following description of preferred embodiments and accompanying drawings, wherein like reference numerals represent like elements. In describing the preferred embodiments of the technology illustrated in the appended drawings, specific terminology will be used for the sake of clarity. The present technology, however, is not intended to be limited to the specific terms used, and it is to be understood that each specific term includes equivalents that operate in a similar manner to accomplish a similar purpose. 
     When introducing elements of various embodiments of the present invention, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Any examples of operating parameters and/or environmental conditions are not exclusive of other parameters/conditions of the disclosed embodiments. Additionally, it should be understood that references to “one embodiment”, “an embodiment”, “certain embodiments,” or “other embodiments” of the present invention are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, reference to terms such as “above,” “below,” “upper”, “lower”, “side”, “front,” “back,” or other terms regarding orientation are made with reference to the illustrated embodiments and are not intended to be limiting or exclude other orientations. 
     Embodiments of the present disclosure are directed toward systems and methods that may improve the reliability of transmitting signals to setting tools used in perforating gun strings. Various embodiments include a sub or tandem that receives a cartridge assembly for transmitting instructions and/or operational energy to set setting tool. By way of example, the cartridge assembly may include a contact that is closely positioned and/or in contact with a primary igniter. Upon activation, the contact may transmit a voltage to the primary igniter, which ignites the primary igniter and transmits energy to a fuse extending through an intermediate sub. The fuse may provide energy to a secondary igniter, which is utilized to ignite a power charge, which may set the setting tool. Embodiments of the present disclosure may provide a tandem or sub assembly that houses both the cartridge assembly and the primary igniter, among other components. By arranging the cartridge assembly in a common housing with the primary igniter, the likelihood of misalignment or damage during gun string makeup is reduced. For example, often gun strings are formed at a well site, where various components may be exposed to dirt or debris. This dirt or debris may block the contact between the cartridge assembly and the primary igniter, thereby preventing transmission of energy and setting of the tool, which may lead to undesirable additional runs to correct the error. Closely positioning the contact and the primary igniter in a common housing enables a controlled assembly in an environment with a reduced risk of contamination and also reduces assembly on site, thereby simplifying operations. 
       FIG. 1  is a schematic cross-sectional view of an embodiment of a wellbore system  100  including a downhole tool  102  arranged within a wellbore  104  formed in a formation  106 . The downhole tool  102  is lowered from a surface location  108  via a conveyance system, such as the illustrated wireline  110 . In various embodiments, the electric wireline may transmit electric signals and/or energy from the surface location  108  into the wellbore, for example to provide operational power for the tool  102  and/or to transmit data, such as data obtained from sensors arranged on the tool  102 . In various embodiments, the tool  102  may be utilized to perform downhole operations, such as plug and perf fracturing operations, by way of example. It should be appreciated that embodiments exist where the downhole tool  102  is deployed with any other type of conveyance means, including coiled tubing, pipes, cable, and slickline. That is, embodiments of the present disclosure may be utilized in other scenarios. 
     The wellbore system  100  includes a wellhead assembly  112 , shown at an opening of the wellbore  104 , to provide pressure control of the wellbore  104  and allow for passage of equipment into the wellbore  104 , such as the cable  110  and the tool  102 . In this example, the cable  110  is a wireline being spooled from a service truck  114 . The wellhead assembly  112  may include a blowout preventer (BOP)  116  (e.g., pressure control device). 
     In various embodiments, the downhole tool  102  is a perforating system that includes a series of perforating guns  118  coupled together in series. In this embodiment, the perforating guns may include intermediate subs  120  and also a setting tool  122  at and end of the string. In operation, an electrical signal may be transmitted down the wireline  110  to begin fracturing operations, which may include igniting one or more of the guns  118  and also initiating the setting tool  122 . The setting tool  122  may include one or more expandable components that block flow to areas downhole of the setting tool  122 , thereby enabling fracturing operations to commence after perforating. 
     Certain fracturing operations may be referred to as plug and perf, where a setting tool is coupled to the gun string to facilitate plugging the well before, during, and/or after perforating operations. The setting tool may be activated using a firing head that contains an igniter. With the introduction of addressable switches, a switch cartridge is incorporated into the gun strings to activate the setting tool. This adds length to the string, additional components, and additional opportunity for error. Switch cartridges may include an electric pin that makes contact with the igniter, and when voltage is applied the igniter is ignited and a flame output initiates the power charge, which sets the plug. Embodiments of the present disclosure may overcome problems with existing methods by incorporating the igniter into the switch cartridge. The electric pin is replaced with the igniter and becomes part of the cartridge, which is inserted prior to running. Accordingly, embodiments may increase the reliability of the tool by eliminating steps of separate igniter assembly, which may lead to missed runs when assembly is performed incorrectly. 
       FIG. 2  is a cross-sectional view of a prior art gun string portion  200 , which may be part of a longer string that includes multiple different perforating guns  118  coupled together. In the illustrated embodiment, the perforating gun  118  may be activated by an addressable switch. In this configuration, a cartridge assembly  202  is positioned within a tandem  204  that is coupled between a body  206  of the perforating gun  118  and a body  208  of the setting tool  122 . Furthermore, an intermediate sub  210  is also arranged between the tandem  204  and the body  208 . As will be appreciated, in various configurations one or more of the subs may be replaced or extended. 
     In operation, the cartridge assembly  202  may include circuitry to transmit a signal, received from an uphole or surface source, toward the setting tool  122  to enable activation of the setting tool. The illustrated cartridge assembly  202  includes an uphole contact  212  and a downhole contact  214  to transmit information and/or energy between components. For example, the uphole contact  212  may receive an electrical signal that is transmitted along the circuity  216  (e.g., conductors, processors, timers, etc.) of the cartridge assembly  202  toward the downhole contact  214 . The downhole contact  214  may include a pin  218  that extends outwardly from the cartridge assembly  202 . In operation, the pin  218  may contact and engage a primary igniter  220  positioned within the intermediate sub  210  or the setting tool body  208 , in certain configurations. 
     A voltage may be supplied that ignites the primary igniter  220 , which may be a volume sensitive igniter, that is transmitted along the intermediate sub  210  via a fuse or delay  222 . The fuse or delay  222  may ignite a secondary igniter  224 , which actives the power charge  226  of the setting tool  122 . In this manner, the command may be transmitted along the gun string to the setting tool  122 . The present configuration has various drawbacks that are addressed and overcome by embodiments of the present disclosure. For example, misalignment or damage of the pin  218  with respect to the primary igniter  220  may cause a misfire event, which would lead to a second tool run in order to set the setting tool  122 . These errors increase time and cost at the well site. Because the pin  218  is typically a component extending from the cartridge assembly  202 , it is subject to mechanical damage (e.g., bending) as well as exposed to the environment and may be coated or otherwise interact with dust or debris. While operators may attempt to correct these issues at the site, it may be difficult with a crowded well site that is exposed to environmental conditions. Accordingly, embodiments of the present disclosure are directed to a cartridge assembly that may include the primary igniter  220  as an integrated component. 
       FIG. 3  is a cross-sectional view of an embodiment of a gun string portion  300  utilizing embodiments of the present disclosure. The illustrated configuration includes the tandem  204  arranged between the gun  118  and the setting tool  122 , and further includes the intermediate sub  210  between the tandem  204  and the setting tool  122 . A cartridge assembly  302  extends through a channel  304  in the tandem  204 . As noted above, the uphole contact  212  receives a signal, such as an electrical impulse, from an uphole component, which may be the gun  118 , a controller, or the like, and transmits the signal to the downhole contact  214 , which in this embodiment is shown within the tandem  204 , rather than spanning across an interface between the tandem  204  and the intermediate sub  210 . In this configuration, the primary igniter  220  is formed within the tandem  204 , and as a result, problems associated with misalignment or errors between the downhole contact  214  and the primary igniter  220  may be reduced or eliminated. 
     When compared to the configuration of  FIG. 2 , the primary igniter  220  is moved out of the intermediate sub  210  and/or the setting tool  122 . As a result, the connection between the downhole contact  214  and the primary igniter  220  may be formed in a controlled environment, such as an off-site production facility, which may reduce the likelihood of the above-described damage or contamination of the pin. In this configuration, the primary igniter  220  may still be volume sensitive, and as a result, is arranged to extend into a cavity  306  of the intermediate sub  210 , which positions the primary igniter  220  proximate the fuse  222 . Upon receipt of the signal, the command may be transmitted to the primary downhole contact  214 , for example as a voltage, that sets off the primary igniter  220 , is transferred along the fuse  222 , sets off the secondary igniter  224 , and then activates the power charge  226 . In this manner, the setting tool  122  may be set. 
     In the illustrated embodiment, the primary igniter  220  is arranged at a downhole end  308  and extends beyond a tandem downhole face  310 . Accordingly, when the intermediate sub  210  is coupled to the downhole end  308 , for example via threads, the primary igniter  220  is positioned within the cavity  306 . As will be appreciated, various components, such as a primary igniter length, cavity depth, and the like may be particularly selected to facilitate alignment and coupling between the primary igniter  220  and the fuse  222 . 
     Embodiments of the present disclosure may enable the use of fewer parts and simplified assembly at the well site. For example, operators may prepare the gun string and then install the cartridge assembly  302 , with the primary igniter  220 , into the channel  304  for use. Because sensitive components, such as the downhole contact  214 , are not exposed during this operation, the likelihood of damage or error may be decreased. Furthermore, using the cartridge assembly  302  may enable use with existing systems, for example, by substituting an older cartridge that does not include the primary igniter  220 . As noted above, the illustrated cartridge assembly  302  eliminates operator assembly of the igniter because the igniter is preassembled in a controller environment and prepared for operation. 
       FIG. 4  is a flow chart of an embodiment of a method  400  for preparing a setting tool. It should be appreciated that this method, or any method described herein, may be performed in a different order or in parallel. Moreover, there may be more or fewer steps. In this example, a perforating gun is provided  402 . The perforating gun may include a coupling at a lower end, which enables attachment of a tandem to the perforating gun  404 . In various embodiments, the tandem includes a channel for receiving a cartridge assembly  406 . The cartridge assembly, as described above, may include a primary igniter, as opposed to other cartridge assemblies that include a contact pin and are utilized to activate primary igniters that are assembled and mounted separately. The tandem is then coupled to a setting tool  408 . In certain embodiments, the setting tool may include a fuse or secondary igniter. However, in other embodiments, an intermediate sub may be positioned between the tandem and the setting tool. In this manner, a setting tool is positioned for installation in a wellbore, where the setting tool may be activated by use of the cartridge assembly. 
     Although the technology herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present technology. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present technology as defined by the appended claims.