Downhole setting tool

Abstract

A downhole setting tool includes an upper cylinder, and a piston positioned in the upper cylinder. A charge chamber is defined on one side of the piston within the upper cylinder, and a first hydraulic chamber is defined on an opposite side of the piston and within the upper cylinder. The tool also includes a mandrel coupled to the upper cylinder. A flow port is defined in the mandrel, the flow port being in fluid communication with the first hydraulic chamber. The tool further includes a lower cylinder coupled to the mandrel, the mandrel and the lower cylinder defining a second hydraulic chamber within the lower cylinder, and the flow port being in fluid communication with the second hydraulic chamber. The lower cylinder is configured to move with respect to the mandrel when the setting tool is actuated.

What is claimed is: 
     
         1 . A downhole setting tool, comprising:
 an upper cylinder;   a piston positioned in the upper cylinder, wherein a charge chamber is defined on one side of the piston within the upper cylinder, and a first hydraulic chamber is defined on an opposite side of the piston and within the upper cylinder;   a mandrel coupled to the upper cylinder, wherein a flow port is defined in the mandrel, the flow port being in fluid communication with the first hydraulic chamber; and   a lower cylinder coupled to the mandrel, the mandrel and the lower cylinder defining a second hydraulic chamber within the lower cylinder, and the flow port being in fluid communication with the second hydraulic chamber, wherein the lower cylinder is configured to move with respect to the mandrel when the downhole setting tool is actuated.   
     
     
         2 . The downhole setting tool of  claim 1 , wherein the charge chamber is configured to contain an explosive charge, wherein, detonating the explosive charge forces the piston toward mandrel so as to move the lower cylinder. 
     
     
         3 . The downhole setting tool of  claim 2 , wherein the first and second hydraulic chambers are configured to contain a hydraulic fluid therein, such that, when the piston is forced toward the mandrel, at least some of the hydraulic fluid is forced from the first hydraulic chamber to the second hydraulic chamber. 
     
     
         4 . The downhole setting tool of  claim 3 , wherein the lower cylinder is configured to slide with respect to the mandrel, such that forcing the hydraulic fluid from the first hydraulic chamber to the second hydraulic chamber causes the lower cylinder to slide so as to increase a volume of the second hydraulic chamber. 
     
     
         5 . The downhole setting tool of  claim 1 , wherein the lower cylinder comprises a shoulder, and wherein the mandrel extends through and seals with the shoulder. 
     
     
         6 . The downhole setting tool of  claim 5 , wherein the second hydraulic chamber is at least partially defined between an end face of a head of the mandrel and the shoulder. 
     
     
         7 . The downhole setting tool of  claim 5 , further comprising a mandrel adapter that is connected to the mandrel, wherein the mandrel adapter is configured to engage the shoulder of the lower cylinder at a bottom of a stroke of the lower cylinder. 
     
     
         8 . The downhole setting tool of  claim 1 , wherein the mandrel comprises a head that is connected to the upper cylinder, and an extension that extends from the head and through at least a portion of the lower cylinder, and wherein the flow port extends axially into but not through the mandrel, and extends at least partially radially outward in the head into fluid communication with the second hydraulic chamber. 
     
     
         9 . The downhole setting tool of  claim 1 , wherein the mandrel is configured to apply an uphole-directed force on a mandrel of a subjacent tool, and wherein the lower cylinder is configured to apply a downhole-directed force on a setting assembly of the subjacent tool. 
     
     
         10 . The downhole setting tool of  claim 1 , further comprising one or more shear members connecting the lower cylinder to the mandrel, wherein the one or more shear members are configured to shear to allow the lower cylinder to slide relative to the mandrel upon actuation. 
     
     
         11 . The downhole setting tool of  claim 1 , wherein the upper cylinder comprises:
 a sub in which the charge chamber is defined, the sub defining an upper connection for the tool that is configured to be connected to a tool string; and   a sleeve in which the first hydraulic chamber is defined, the sleeve being connected to the mandrel, such that the mandrel is configured not to move with respect to the sleeve during actuation of the tool.   
     
     
         12 . The downhole setting tool of  claim 11 , wherein the mandrel comprises:
 a head connected to the sleeve, wherein the lower cylinder is received around and sealed with the head, wherein the second hydraulic chamber is at least partially defined between an end face of the head and a shoulder of the lower cylinder; and   an extension extending from the head and through the shoulder, the extension being sealed with the shoulder of the lower cylinder and configured to couple to a mandrel of a subjacent tool.   
     
     
         13 . A method for setting a downhole tool, comprising:
 coupling a mandrel of the downhole tool to a setting tool, wherein the setting tool comprises:
 an upper cylinder; 
 a piston positioned in the upper cylinder, wherein a charge chamber is defined on one side of the piston within the upper cylinder, and a first hydraulic chamber defined on an opposite side of the piston and within the upper cylinder, the first hydraulic chamber having hydraulic fluid therein; 
 a mandrel attached to the upper cylinder, wherein the mandrel of the setting tool is coupled the mandrel of the downhole tool, and wherein the mandrel and is in fluid communication with the first hydraulic chamber; 
 a lower cylinder coupled to the mandrel, the mandrel and the lower cylinder defining a second hydraulic chamber within the lower cylinder that is in fluid communication with the first hydraulic chamber; 
   deploying the tool and the setting tool into a wellbore; and   detonating a charge in the charge chamber of the setting tool, wherein detonating the charge causes a force to be applied to the piston, wherein applying the force to the piston causes the piston to force at least some of the hydraulic fluid to flow from the first hydraulic chamber to the second hydraulic chamber, and wherein causing at least some of the hydraulic fluid to flow from the first hydraulic chamber to the second hydraulic chamber causes the lower cylinder to move with respect to the mandrel and to apply a setting force to the downhole tool.   
     
     
         14 . The method of  claim 13 , wherein the setting tool further comprises a flow port extending at least partially through the mandrel and between the first and second hydraulic chambers, and wherein detonating the charge presses the at least some of the hydraulic fluid from the first hydraulic chamber, through the flow port, and into the second hydraulic chamber, expanding the second hydraulic chamber. 
     
     
         15 . The method of  claim 14 , wherein the flow port comprises at least one radial opening communicating with the second hydraulic chamber, and wherein detonating the charge causes the at least some of the hydraulic fluid to flow through the at least one radial opening, and from the at least one radial opening into the second hydraulic chamber. 
     
     
         16 . The method of  claim 13 , wherein detonating causes the lower cylinder to move axially past a lower end of the mandrel so as to press downwards on the downhole tool while the mandrel pulls upwards on the downhole tool. 
     
     
         17 . The method of  claim 13 , wherein the lower cylinder is positioned at least partially around the mandrel, and wherein detonating the charge causes the lower cylinder to slide along an outer diameter surface of the mandrel. 
     
     
         18 . The method of  claim 17 , wherein the mandrel is coupled to and connects together the upper cylinder and the lower cylinder. 
     
     
         19 . The method of  claim 18 , wherein the mandrel is connected to the lower cylinder via one or more restraining members, and wherein detonating the charge causes the one or more restraining members to yield, thereby permitting the lower cylinder to slide relative to the mandrel. 
     
     
         20 . A downhole setting tool, comprising:
 an upper cylinder comprising a sub configured to contain an explosive charge, the upper cylinder at least partially defining a first hydraulic chamber therein;   a piston positioned in the first hydraulic chamber and movable with respect to the upper cylinder in response to detonating the charge;   a mandrel comprising:
 a head coupled to the upper cylinder and defining a flow port therein, wherein the piston moving in response to the charge detonating is configured to cause hydraulic fluid to flow from the first hydraulic chamber and through the flow port; and 
 an extension extending from the head and configured to couple to a subjacent tool so as to apply an axially-directed force thereto; 
   a lower cylinder received at least partially around the mandrel and comprising a shoulder that is sealed with the extension of the mandrel, wherein the shoulder and the head of the mandrel define a second hydraulic chamber axially therebetween, the first and second hydraulic chambers being in fluid communication with one another via the flow port; and   one or more retaining members connecting the lower cylinder to the head of the mandrel, wherein the one or more retaining members are configured to release and allow the lower cylinder to move relative to the mandrel and relative to the upper cylinder.