Downhole tool system with multiple safety barriers

Abstract

The present invention discloses a downhole tool system with multiple safety barriers. The system comprises a first housing, a mandrel, a shuttle disposed over the mandrel adjacent to the first housing, a slip module disposed over the mandrel adjacent to the shuttle, a drag block assembly disposed over the mandrel adjacent to the slip module, and a firing head assembly disposed adjacent to the drag block assembly. The system comprises a bismuth lock ring to immobilize the drag block assembly and the components of the system until a specific temperature is reached, ensuring safe operation. The system further comprises a pressure inlet port to control firing of the system. The system is configured to perform operational sequences involving precise movements facilitated by the shuttle, slip module, and drag block assembly to open the pressure inlet port and arm the firing head assembly. The operational sequences act as another safety barrier.

Description

DOWNHOLE TOOL SYSTEM WITH MULTIPLE SAFETY BARRIERS TECHNICAL FIELD

[0001] The present disclosure relates generally to a downhole tool system, and more particularly, to a downhole tool system with multiple safety barriers.BACKGROUND

[0002] The completion of oil or gas wells often involves perforating the well casing to create passages or holes, allowing fluid communication between the wellbore and the hydrocarbon-producing formation. The perforations in oil or gas wells are typically created using a downhole system having a perforating gun equipped with shaped charges. This gun is inserted into the wellbore using various means such as electric wireline, slickline, tubing, or coiled tubing. The gun is lowered to reach a desired depth, usually adjacent to a hydrocarbon-producing formation. Subsequently, a surface signal activates a firing head associated with the perforating gun.

[0003] The firing head triggers the detonation of the percussion, electric or electronic detonators. The resulting projectiles or jets penetrate the casing, enabling formation fluids to flow from the formation through the perforations and into the production string for extraction to the surface. In the conventional downhole system, the entire tool is exposed to a high-pressure environment and the operation of the system could not be halted during overpressure events. Further, a tensile element shears and activates the firing head on receiving a signal from the downhole system. The tensile element acts as a barrier to prevent unintentional detonation of explosives.

[0004] However, conventional downhole systems provide only one barrier and fail to offer adequate measures to prevent inadvertent activation of explosive elements. The lack of enhanced safety protocols and preventative measures within downhole operations increases the risk of unintended detonation, which could lead to serious consequences such as injury, equipment damage, or environmental hazards. One scenario involves a downhole tool, such as a perforating gun, prematurely discharging at the surface of a wellbore while personnel are in the process of rigging the tool for deployment into the wellbore. Such incidents pose significant risks to the safety of personnel and the integrity of equipment.

[0005] Therefore, there is a need for a downhole tool system that facilitates the safe and consistent initiation of detonators within a firing head assembly in a wellbore tool. Further,there is a need for a firing head assembly equipped with safety features that prevent the firing head assembly from firing unless specific deliberate actions are taken by the operator, indicating a clear intent to initiate the firing sequence.SUMMARY OF THE INVENTION

[0006] The present invention discloses a downhole tool system. The present invention discloses a downhole tool system. The system comprises a first housing, a mandrel coupled to the first housing, a shuttle disposed around the mandrel and adjacent to the first housing, a slip module disposed around the mandrel and adjacent to the shuttle, a drag block assembly disposed around the mandrel and adjacent to the slip module, a third lock ring disposed at a first end portion of the drag block assembly engaging with slip module and a firing assembly disposed adjacent to the drag block assembly. The system further comprises a piston extending from the first housing to the firing assembly within the mandrel.

[0007] The shuttle comprises one or more pressure equalizer ports defined at a first end portion and the mandrel comprises one or more pressure inlet ports at a portion the shuttle is positioned on the mandrel. The pressure inlet port is in fluid communication with the first housing. The shuttle is locked to the mandrel via a first lock ring. The shuttle further comprises a second lock ring and a second tapered end portion. In one embodiment, the third lock ring is a J-lock pin. In one embodiment, the second lock ring is configured to lock the shuttle to a recess at the mandrel.

[0008] The system further comprises a fourth lock ring disposed at a second end portion of the drag block assembly. The fourth lock ring is configured to melt on exposure to a predefined temperature. The fourth lock ring comprises a bismuth lock ring.

[0009] The firing assembly comprises a second housing coupled to the first mandrel. The second housing comprises a first end portion having a tapered configuration. The firing head assembly further comprises a sealing module comprising a slick rod disposed in the second housing and a pull rod extends within the slick rod. The sealing module is restrained from axial movement within the second housing. The piston extends within the second housing and is coupled to the slick rod.

[0010] The firing head assembly further comprises a firing pin disposed below the sealing module. The firing pin is shiftable from a first position to a second position to strike a percussion initiator to create an explosion event. The firing head assembly further comprises a tensile element arranged between the firing pin and the initiator. The tensile element is configured to shear in response to a threshold pressure applied to the tensile element torelease the firing pin from the first position to move to the second position. The downhole system further comprises a top sub coupled to the first housing.

[0011] The downhole tool system further comprises a first tubular member extending from the second end portion of the second housing. The firing pin is disposed at the first tubular member. The downhole tool system further comprises a second tubular member connected to the first tubular member. The initiator is disposed at the second tubular member. The downhole tool system further comprises a drop bar connected to the firing pin. The drop bar extends from the first tubular member to the second tubular member.

[0012] The downhole tool system further comprises a ball retainer having ball bearings to hold the pull rod in position and prevent movement of the pull rod. The downhole tool system further comprises a pin member disposed adjacent to the pull rod configured to lock components of the firing head assembly. The pin member is configured to shear on operation of the piston.

[0013] In one embodiment, a method of operation of the downhole tool system is disclosed. Upon melting of the fourth lock ring, the tool system is enabled to perform a first upward movement. The drag block assembly remains stationary due to friction with a tubing and enables the tapered configuration of the second housing to contact the drag block assembly to create a movement to switch a position of the third lock ring. At another step, the tool system is configured to perform a second downward movement after the first upward movement. The second downward movement enables the slip module to engage the second tapered end portion of the shuttle and expands the slip module to engage the tubing, thereby locking the shuttle, slip module and the drag block assembly to the tubing and only allows movement of the mandrel. After the second downward movement, the tool system is enabled to move downwards, which moves the mandrel and the first housing, while the shuttle, slip module and the drag block assembly remain stationary, to lock the first lock ring of the shuttle with the mandrel and expose the pressure equalizer port and the pressure inlet port to a wellbore pressure. After locking the shuttle, the tool system is adjusted to a desired position in the tubing to initiate firing and the piston moves the slick rod and pull rod. The opening of the pressure inlet port exposes the tensile element to an external pressure condition existing external to the second housing and if the external pressure applied to the tensile element is greater than a pressure rating of the tensile element, the tensile element shears thereby shifting the firing pin to the second position to strike the initiator and create an explosion event.

[0014] Other objects, features and advantages of the present innovation will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples, while indicating specific embodiments of theinnovation, are given by way of illustration only, since various changes and modifications within the spirit and scope of the innovation will become apparent to those skilled in the art from this detailed description.BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1 exemplarily illustrates a downhole tool system, according to an embodiment of the present invention.

[0016] FIG. 2 exemplarily illustrates a see-through view of a downhole tool system, according to an embodiment of the present invention.

[0017] FIG. 3 exemplarily illustrates a top sub, a first housing connected to the top sub and a mandrel connected to the first housing, according to an embodiment of the present invention.

[0018] FIG. 4 exemplarily illustrates a see-through view of the top sub, the first housing connected to the top sub and the mandrel connected to the first housing, according to an embodiment of the present invention.

[0019] FIG. 5 exemplarily illustrates a shuttle disposed over the mandrel, according to an embodiment of the present invention.

[0020] FIG. 6 exemplarily illustrates a see-through view of the shuttle disposed over the mandrel, according to an embodiment of the present invention.

[0021] FIG. 7 exemplarily illustrates a drag block assembly and a slip module, according to an embodiment of the present invention.

[0022] FIG. 8 exemplarily illustrates a see-through view of the drag block assembly and the slip module, according to an embodiment of the present invention.

[0023] FIG. 9 exemplarily illustrates a side view of a firing head assembly of the downhole tool system of FIG. 1.

[0024] FIG. 10 exemplarily illustrates a see-through view of the firing head assembly of the downhole tool system of FIG. 1.

[0025] FIG. 11 exemplarily illustrates a side view of an arrangement of a slick rod and a slickrod nut of the firing head assembly, according to an embodiment of the present invention.

[0026] FIG. 12 exemplarily illustrates a side view of an arrangement of a pull rod and ball bearings of the firing head assembly, according to an embodiment of the present invention.

[0027] FIG. 13 exemplarily illustrates a side view of an arrangement of a firing pin, a drop bar and an initiator of the firing head assembly, according to an embodiment of the present invention.

[0028] FIG. 14 exemplarily illustrates a run-in-hole configuration of the downhole tool system, according to an embodiment of the present invention.

[0029] FIG. 15 exemplarily illustrates the downhole tool system after melting of the bismuth lock ring, according to an embodiment of the present invention.

[0030] FIG. 16 exemplarily illustrates the downhole tool system being pick-up to enable the drag block assembly to engage with the tapered configuration of the second housing, according to an embodiment of the present invention.

[0031] FIG. 17 exemplarily illustrates the downhole tool system being moved downwards to enable the drag block assembly, slip module and shuttle to anchor to tubing, according to an embodiment of the present invention.

[0032] FIG. 18 exemplarily illustrates a piston being lift to open the pressure inlet port, according to an embodiment of the present invention.

[0033] FIG. 19 exemplarily illustrates the downhole tool system being moved downwards to arm the firing head assembly to shear the pin member, according to an embodiment of the present invention.

[0034] FIG. 20 exemplarily illustrates the downhole tool system being pick-up to shooting depth, according to an embodiment of the present invention.

[0035] FIG. 21 exemplarily illustrates the downhole tool system increasing pressure at the firing head assembly to shear tensile element and firing the initiator, according to an embodiment of the present invention.

[0036] FIG. 22 exemplarily illustrates the downhole tool system being moved downwards to switch the J-pin to lock, according to an embodiment of the present invention.

[0037] FIG. 23 exemplarily illustrates the downhole tool system being pick-up to Pull Out Of Hole (POOH), according to an embodiment of the present invention.

[0038] FIG. 24 exemplarily illustrates a flowchart of a method of operation of the downhole tool system of FIG. 1.DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

[0039] Example, embodiments of the disclosure now will be described more fully hereinafter with reference to the accompanying drawings, in which example embodiments are shown. The concepts discussed herein may, however, be embodied in many different forms and should not be construed as limited to the example embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope to those of ordinary skill in the art. Like numbers refer to like elements but not necessarily the same or identical elements throughout.

[0040] Referring to FIG. 1 and FIG. 2, a downhole tool system 100 comprises a top sub 110, a first housing 102 connected to the top sub 110, a mandrel 104 extending from the first housing 102, and a shuttle 106 disposed around the mandrel 104 and adjacent to the first housing 102. The shuttle 106 comprises a first end portion and a second tapered end portion 126 opposite to the first end portion.

[0041] The system 100 further comprises a slip module 112 disposed around the mandrel 104 and adjacent to the shuttle 106. The system 100 further comprises a drag block assembly 114 disposed around the mandrel 104 and adjacent to the slip module 112. The system 100 further comprises a firing head assembly 130 disposed adjacent to the drag block assembly 114 and a piston 120 extends from the first housing 102 to the firing head assembly 130 within the mandrel 104.

[0042] Referring to FIG. 2, the shuttle 106 comprises one or more pressure equalizer ports 124 defined at the first end portion and the mandrel 104 comprises one or more pressure inlet ports 122 at a portion the shuttle 106 is positioned on the mandrel 104. The shuttle 106 is positioned to keep the pressure inlet port 122 closed. The pressure inlet port 122 is configured to open on meeting certain conditions during operation of the system 100.

[0043] The pressure inlet port 122 is in fluid communication with the first housing 102 via the mandrel 104. The pressure equalizer port 124 is configured to equalize the pressure in thesystem 100. The pressure equalizer port 124 is configured to release pressure from the system 100.

[0044] The system 100 further comprises a fourth lock ring 118 to lock the drag block assembly 114. Further, the firing head assembly 130 comprises a second housing 132. The piston 120 from the first housing 102 to the firing head assembly 130 within the mandrel 104. The piston 120 further extends within the second housing 132.

[0045] Referring to FIG. 3 and FIG. 4, the shuttle is locked to the mandrel via a first lock ring 108 (shown in FIG. 6). In some embodiments, the first lock ring 108 may be, but not limited to, a rod, a cone carrier pin. The 'first lock ring 108' is more shaped as a 'rod' rather than a ring. However, it does provide the 'lock function'. The term, 'lock ring' herein, defined same as second lock ring 162, third lock ring 116 and fourth lock ring 118. (which are actual lock rings). The shuttle 106 comprises a second lock ring 162 (shown in FIG. 6) configured to lock with a recess 164 defined at the mandrel 104 during operation of the tool system 100. Referring to FIG. 5 and FIG. 6, the shuttle 106 is composed of a cone sub 166 and a cone 168. The shuttle 106 is locked with the mandrel 104 via a first lock ring 108. The shuttle 106 is configured to move over the mandrel 104 to create movement of other components of the system 100.

[0046] Referring to FIG. 7 and FIG. 8, the drag block assembly 114 is locked in place via the fourth lock ring 118. In one embodiment, the fourth lock ring 118 is a bismuth lock ring. In one embodiment, the fourth lock ring 118 is made of a low temperature metal. In one embodiment, the fourth lock ring 118 is configured to melt at 73°C to 80°C. In another embodiment, the fourth lock ring 118 could be mixed with any other alloy to enable the fourth lock ring 118 to melt at certain high temperature. The fourth lock ring 118 is configured to prevent the movement of all components of the system 100. To operate the system 100, the fourth lock ring 118 needs to be fully melted. If the system 100 has not reached a temperature to melt the bismuth lock ring, any components of the system 100 cannot operate. The fourth metal ring 118 defines a first safety barrier. The drag block assembly 114 comprises a bowspring centralizer 174.

[0047] The slip module 112 extends from the drag block assembly 114. The system 100 further comprises a track pin 176, a top bowspring 178, a swivel pin 180 and a bottom bowspring 182 to control the slip module 112 and the drag block assembly 114. Referring to FIG. 6 and FIG. 8, the piston 120 is composed of a top pull rod 170 and a bottom pull rod 172.

[0048] Referring to FIG. 9 and FIG. 10, the firing head assembly 130 comprises a second housing 132, a sealing module, a firing pin 140, a tensile element 142 and a percussion initiator 144. The second housing 132 is coupled to the mandrel 104. The second housing 132comprises a first end portion and a second end portion.

[0049] Referring to FIG. 10 to FIG. 12, the sealing module comprises a pull rod 138 and a slick rod 136. The slick rod 136 is disposed at the first end portion of the second housing 132. The pull rod 138 is disposed below the slick rod 136. The sealing module is connected to the piston 120 via a slick rod adapter 134. Further, one or more O-rings 160 are provided at the slick rod 136. The sealing assembly and the O-rings 160 prevent entry of pressure into the firing head assembly 130. The piston 120 enables the slick rod 136 and the pull rod 138 to move or perform stroking operation. The piston 120 enables the slick rod 136 and the pull rod 138 to move on receiving the signal to initiate the firing.

[0050] The firing head assembly 130 comprises a pin member 156 disposed proximal to the pull rod 138. The pin member 156 is configured to lock the components of the firing head assembly 130. The pin member 156 is configured to shear on operation of the piston 120 and enables the operation of the components of the firing head assembly 130.

[0051] Referring to FIG. 11 and FIG.12, a slick rod nut 158 is provided to lock the slick rod 136. Further, the pull rod 138 is disposed below the slick rod 136. The pull rod 138 extends within the slick rod 136 through the slick rod nut 158. Further, the firing head assembly 130 comprises one or more ball bearings 154 and a ball retainer 152 to lock the pull rod 138. The slick rod 136 and the pull rod 138 are positioned above a first tubular member 146. The ball bearing 154 also locks the pull rod 138. On shearing of the pin member 156, the pull rod 138 is enabled to operate.

[0052] Referring to FIG. 10 to FIG. 13, the firing pin 140 is disposed below the sealing module. Specifically, the firing pin 140 is disposed below the pull rod 138. The firing pin 140 is configured to shift from a first position to a second position to strike the initiator 144. The firing head assembly 130 comprises a first tubular member 146 extending from the second end portion of the second housing 132. The firing pin 140 is disposed at the first tubular member 146. The firing pin 140 disposed at the first tubular member 146 extends from the second end portion of the second housing 132 and is received within the first tubular member 146. The firing head assembly 130 further comprises a second tubular member 148 connected to the first tubular member 146. The initiator 144 is disposed at the second tubular member 148. The tensile element 142 is arranged between the firing pin 140 and the initiator 144. Further, a drop bar 150 is connected to the firing pin 140. The drop bar 150 is disposed to extend from the first tubular member 146 to the second tubular member 148.

[0053] The tensile element 142 is exposed to pressure on movement of the pull rod 138 and the slick rod 136. The tensile element 142 is configured to shear in response to a thresholdpressure applied to the tensile element 142 to release the firing pin 140 from the first position to move to the second position. Further, if the tensile element 142 is exposed to an external pressure exceeding its rated pressure, the tensile element 142 will shear, thereby causing the firing pin 140 to transition from the initial first position to the subsequent second position. The pressure inlet port 122 exposes the sealing module to the wellbore pressure.

[0054] Referring to FIG. 14, in a run-in-hole configuration of the downhole tool system 100, the pressure inlet port 122 is closed by the shuttle 106 and the fourth lock ring 118 locks operation and movement of the components of the system 100. To operate the system 100, the downhole hole system 100 is made to pass through a predefined firing location in the tubing and enabled to perform a sequence of movements to reach the firing location and initiate the firing of the firing head assembly 130. Referring to FIG. 15, the system 100 on reaching a desired location at the tubing, the system 100 is exposed to a predefined temperature to melt the bismuth lock ring. Further, on melting of the bismuth lock ring, when the system 100 is moved downwards, the drag block assembly 114 drags upwards and when the system 100 is moved upwards, the drag block assembly 114 drags downwards.

[0055] Referring to FIG. 16, upon melting of the fourth lock ring 118, the system 100 is enabled to perform a sequence of movement. Initially, the system 100 is enabled to perform a first upward movement. During the first upward movement, the drag block assembly 114 remains stationary due to friction with the tubing and enables a tapered configuration 128 of the second housing 132 to contact the drag block assembly 114 to create a movement to switch a position of the third lock ring 116. In one embodiment, the third lock ring 116 is a J-lock pin.

[0056] The mandrel 104 also includes a J -si ot area for receiving and guiding a J-pin rotatably disposed in the drag block assembly 114, which is disposed around the mandrel 104. The J-slot area is designed such that the J-pin is permitted to redundantly move around the mandrel 104. In one embodiment, at least 50% of the cylindrical surface area of the mandrel 104 is comprised of the debossed areas and / or the holes. In one embodiment, the first upward movement enables the J-lock pin to switch position from the J-slot area.

[0057] Referring to FIG. 17, the tool system 100 is configured to perform a second downward movement after the first upward movement. The second downward movement enables the slip module 112 to engage the second tapered end portion 126 of the shuttle 106. On engaging the shuttle 106, the slip module 112 expands and engages the tubing, thereby locking the shuttle 106, slip module 112 and the drag block assembly 114 to the tubing and only allows movement of the mandrel 104. At this stage, the shuttle 106 is locked with the mandrel 104 and also engaged with the tubing.

[0058] Referring to FIG. 18 and FIG. 19, after the second downward movement, the tool system 100 is enabled to move downwards, which moves the mandrel 104 and the first housing 102, while the shuttle 106, slip module 112 and the drag block assembly 114 remain stationary, to lock the first lock ring 108 of the shuttle 106 with the mandrel 104 and expose the pressure equalizer port 124 and the pressure inlet port 122 to a wellbore pressure. The movement of the mandrel 104 independently with respect to the shuttle 106 engaging the tubing, exposes and opens the pressure inlet port 122. The pressure inlet port 122 is opened to hydrostatic.

[0059] Referring to FIG. 19, the piston 120 is enabled to move upwards to move the slick rod 136 and the pull rod 138 to shear the pin member 156. Referring to FIG. 20, the tool system 100 is adjusted to a desired position or adjusted to reach the shooting depth in the tubing to initiate firing.

[0060] Referring to FIG. 21, the opening of the pressure inlet port 122 exposes the tensile element 142 to an external pressure condition existing external to the second housing 132. If the rated pressure of the tensile element 142 is lower than the pressure of the external pressure, the tensile element 142 shears thereby shifting the firing pin 140 to the second position to strike the initiator 144. The system 100 enables to apply pressure exceeding a pressure rating of the tensile element 142, which has been planned before run-in-hole. As a result, the tensile element 142 undergoes shear failure and imparts an impact on the initiator 144 to initiate firing.

[0061] Referring to FIG. 22, the downhole tool system 100 is moved downwards to switch the J-pin to lock in the J-slot. Referring to FIG. 23, after the downhole operation is finished and a waiting period has elapsed, during which pressurization and successful detonation of downhole explosives are verified, the pressure is gradually released. Subsequently, the process of "pulling out of the hole" (POOH) is initiated, following the specific procedure outlined by the customer. Finally, upon completion of the operation, the downhole tool system 100 is disengaged.

[0062] FIG. 24 exemplarily illustrates a flowchart 2400 of a method of operation of the downhole tool system 100 of FIG. 1. At step 2402, the downhole tool system 100 is lowered into a wellbore. In one embodiment, the wellbore is formed by a drilling process in which dirt, rock and other subterranean materials are removed to create the wellbore. In some embodiments, a portion of the wellbore is cased with a casing (not illustrated). In other embodiments, the wellbore is maintained in an open-hole configuration without casing. The embodiments described herein are applicable to either cased or open-hole configurations ofwellbore, or a combination of cased and open-hole configurations in a particular wellbore.

[0063] After drilling of wellbore is complete and the associated drill bit and drill string are “tripped” from wellbore, a tubing or a conveyance, which may be a drill string, drill pipe, coiled tubing, production tubing, wireline, downhole tractor or another type of tubing deployable in a wellbore, is lowered into wellbore.

[0064] In certain configurations, the tubing serves as a conduit for lowering downhole tool system 100. The tubing facilitates the movement of the tool system 100 to a desired downhole location within the formation. The tubing provides a pathway for fluid communication between the surface of the well and the downhole location. This allows fluids to flow into an annulus surrounding the system 100. Subsequently, the tool system 100 could be activated or manipulated as needed to perform specific operations within the wellbore.

[0065] The target temperature is acquired from historical well data or parameters. Further, the temperature on the bismuth lock ring is set to ensure the tool system 100 reaches the minimum temperature required to reach the target depth before any tool initiation begins is crucial. The bismuth lock ring acts as a preventive measure, holding back the initiation of motion sequence until the downhole temperature is achieved.

[0066] At step 2404, upon reaching the target temperature, a specific sequence is activated to initiate the arming process. With the temperature set as per requirement, the motion sequence is initiated as follows. The system 100 is moved down, during which the drag block assembly 114 is locked in an initial position. Then, the system 100 is moved upwards, during which the drag block assembly 114 is released. Then, the system 100 is moved downwards, to anchor the drag block assembly 114 to the tubing, and the pressure inlet port 122 is opened. Then, the system 100 is moved upwards and releases the drag block assembly 114.

[0067] Then, the system 100 is moved downwards to lock the drag block assembly 114 in its initial position again. This sequence can be repeated until the final motion sequence is activated by jarring while moving down and anchored to the tubing. Upon completion of this sequence, the firing head assembly 130 is armed.

[0068] At step 2406, depth adjustment or additional correlation could be performed in relation to the existing motion sequence. Before applying pressure to fire the explosives, it's crucial to ensure that the system 100 is free. Once ready, pressure exceeding the tensile element 142 rating is applied, as planned beforehand. After a waiting period of 15 minutes post-pressure-up and confirmation of successful detonation of explosives downhole, the pressure is bled off, and the process of pulling out of the hole (POOH) begins, following thecustomer's specified procedure.

[0069] The system 100 is utilized for initiating primary explosive events, which in turn activate various explosive events commonly employed in oil industry operations such as tube puncture, tubing cutter, and event perforation. These operations are frequently utilized in plug and abandon (P&A) procedures within the oil industry. The system 100 controls the opening of the pressure inlet port 122 to control the firing of the firing head assembly 130. The multiple safety barriers of system 100 prevent the firing head assembly 130 from firing unless specific deliberate actions are taken by the operator, indicating a clear intent to initiate the firing sequence. The bismuth lock ring and movement sequences provide multiple safety barriers to the system 100.

[0070] The system 100 provides robust safety barriers for the deployment and recovery of explosive devices. Traditionally, this task has relied on electronic triggers, which introduce additional complexity and time consumption to the process. However, the present invention provides a purely mechanical approach, eliminating the need for electronic detonations and firing mechanisms. This not only enhances safety but also streamlines operations, reducing the risk of shock damage to electronic boards. With extensive practice and a focus on mechanical reliability, system 100 surpasses industry standards, and ensures safe and efficient deployment and recovery of explosive devices.

[0071] Although the features, functions, components, and parts have been described herein in accordance with the teachings of the present disclosure, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all embodiments of the teachings of the disclosure that fairly fall within the scope of permissible equivalents.

[0072] Many modifications and other implementations of the disclosure set forth herein will be apparent having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the disclosure is not to be limited to the specific implementations disclosed and that modifications and other implementations are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

CLAIMS1. A downhole tool system, comprising:a first housing;a mandrel coupled to the first housing;a shuttle disposed around the mandrel and adjacent to the first housing, wherein the shuttle comprises one or more pressure equalizer ports defined at a first end portion, wherein the mandrel comprises one or more pressure inlet ports at a portion the shuttle is positioned on the mandrel, wherein the pressure inlet port is in fluid communication with the first housing, wherein the shuttle is locked to the mandrel via a first lock ring, wherein the shuttle further comprises a second lock ring and a second tapered end portion;a slip module disposed around the mandrel and adjacent to the shuttle;a drag block assembly disposed around the mandrel and adjacent to the slip module;a third lock ring disposed at a first end portion of the drag block assembly engaging with slip module, wherein the third lock ring is a J-lock pin;a fourth lock ring disposed at a second end portion of the drag block assembly, wherein the fourth lock ring is configured to melt on exposure to a predefined temperature, anda firing assembly disposed adjacent to the drag block assembly, anda piston extends from the first housing to the firing assembly within the mandrel, wherein the firing assembly comprises:a second housing coupled to the first mandrel, wherein the second housing comprises a first end portion having a tapered configuration,a sealing module comprising a slick rod disposed in the second housing and a pull rod extends within the slick rod, wherein the sealing module is restrained from axial movement within the second housing, wherein the piston extends within the second housing and coupled to the slick rod,a firing pin disposed below the sealing module, wherein the firing pin is shiftable from a first position to a second position to strike a percussion initiator to create an explosion event, anda tensile element arranged between the firing pin and the initiator, the tensile element is configured to shear in response to a threshold pressure applied to the tensile element to release the firing pin from the first position to move to the second position.

2. The downhole tool system of claim 1 , wherein, upon melting of the fourth lock ring, the tool system is enabled to perform a first upward movement, the drag block assembly remains stationary due to friction with a tubing and enables the tapered configuration of the second housing to contact the drag block assembly to create a movement to switch a position of the third lock ring,wherein the tool system is configured to perform a second downward movement after the first upward movement, wherein the second downward movement enables the slip module to engage the second tapered end portion of the shuttle and expands the slip module to engage the tubing, thereby locking the shuttle, slip module and the drag block assembly to the tubing and only allows movement of the mandrel,wherein, after the second downward movement, the tool system is enabled to move downwards, which moves the mandrel and the first housing, while the shuttle, slip module and the drag block assembly remains stationary, to lock the first lock ring of the shuttle with the mandrel and expose the pressure equalizer port and the pressure inlet port to a wellbore pressure,wherein, after locking the shuttle, the tool system is adjusted to a desired position in tubing to initiate firing and the piston moves the slick rod and pull rod, andwherein the opening of the pressure inlet port exposes the tensile element to an external pressure condition existing external to the second housing and if the external pressure applied to the tensile element is greater than a pressure rating of the tensile element, the tensile element shears thereby shifting the firing pin to the second position to strike the initiator.

3. The downhole tool system of claim 1, further comprises a top sub coupled to the first housing.

4. The downhole tool system of claim 1, wherein the second lock ring is configured to lock the shuttle to a recess at the mandrel.

5. The downhole tool system of claim 1 , further comprises a first tubular member extending from the second end portion of the second housing, wherein the firing pin is disposed at the first tubular member.

6. The downhole tool system of claim 5, further comprises a second tubular member connected to the first tubular member, wherein the initiator is disposed at the second tubular member.

7. The downhole tool system of claim 6, further comprises a drop bar connected to the firing pin, wherein the drop bar extends from the first tubular member to the second tubular member.

8. The downhole tool system of claim 1 , further comprises a ball retainer having ball bearings to hold the pull rod in position and prevent movement of the pull rod.

9. The downhole tool system of claim 1 , further comprises a pin member disposed adjacent to the pull rod configured to lock components of the firing head assembly, wherein the pin member is configured to shear on operation of the piston.

10. The downhole tool system of claim 1, wherein the fourth lock ring comprises a bismuth lock ring.

11. A method for activating a downhole tool system, comprising:lowering a downhole tool system into a tubing;positioning the downhole tool system at a desired location within the tubing, wherein the downhole tool system comprisesa first housing;a mandrel coupled to the first housing;a shuttle disposed around the mandrel and adjacent to the first housing, wherein the shuttle comprises one or more pressure equalizer ports defined at a first end portion, wherein the mandrel comprises one or more pressure inlet ports at a portion the shuttle is positioned on the mandrel, wherein the pressure inlet port is in fluid communication with the first housing, wherein the shuttle is locked to the mandrel via a first lock ring, wherein the shuttle further comprises a second lock ring and a second tapered end portion;a slip module disposed around the mandrel and adjacent to the shuttle;a drag block assembly disposed around the mandrel and adjacent to the slip module;a third lock ring disposed at a first end portion of the drag block assembly engaging with slip module, wherein the third lock ring is a J-lock pin;a fourth lock ring disposed at a second end portion of the drag block assembly, wherein the fourth lock ring is configured to melt on exposure to a predefined temperature, anda firing assembly disposed adjacent to the drag block assembly, anda piston extends from the first housing to the firing assembly within the mandrel, wherein the firing assembly comprises:a second housing coupled to the first mandrel, wherein the second housing comprises a first end portion having a tapered configuration,a sealing module comprising a slick rod disposed in the second housing and a pull rod extends within the slick rod, wherein the sealing module is restrained from axial movement within the second housing, wherein the piston extends within the second housing and coupled to the slick rod,a firing pin disposed below the sealing module, wherein the firing pin is shiftable from a first position to a second position to strike a percussion initiator to create an explosion event, anda tensile element arranged between the firing pin and the initiator, the tensile element is configured to shear in response to a threshold pressure applied to the tensile element to release the firing pin from the first position to move to the second position,upon melting of the fourth lock ring, enabling the tool system to perform a first upward movement, during which the drag block assembly remains stationary due to friction with a tubing and enables the tapered configuration of the second housing to contact the drag block assembly to create a movement to switch a position of the third lock ring;enabling the tool system to perform a second downward movement after the first upward movement, wherein the second downward movement enables the slip module to engage the second tapered end portion of the shuttle and expands the slip module to engage the tubing, thereby locking the shuttle, slip module and the drag block assembly to the tubing and only allows movement of the mandrel;enabling the tool system to move downwards, after the second downward movement, which moves the mandrel and the first housing, while the shuttle, slip module and the drag block assembly remain stationary, to lock the first lock ring of the shuttle with the mandrel and expose the pressure equalizer port and the pressure inlet port to a wellbore pressure;locking the shuttle and adjusting the tool system to a desired position in tubing to initiate firing and the piston moves the slick rod and pull rod, andopening the pressure inlet port and exposing the tensile element to an external pressure condition existing external to the second housing, wherein if the external pressure applied to the tensile element is greater than a pressure rating of the tensile element, the tensile element shears thereby shifting the firing pin to the second position to strike the initiator and create the explosion event.

12. The method of claim 11 , further comprises a top sub coupled to the first housing.

13. The method of claim 11 , wherein the second lock ring is configured to lock the shuttle to a recess at the mandrel.

14. The method of claim 11, further comprises a first tubular member extending from thesecond end portion of the second housing, wherein the firing pin is disposed at the first tubular member.

15. The method of claim 14, further comprises a second tubular member connected to the first tubular member, wherein the initiator is disposed at the second tubular member.

16. The method of claim 15, further comprises a drop bar connected to the firing pin, wherein the drop bar extends from the first tubular member to the second tubular member.

17. The method of claim 11 , further comprises a ball retainer having ball bearings to hold the pull rod in position and prevent movement of the pull rod.

18. The method of claim 11 , further comprises a pin member disposed adjacent to the pull rod configured to lock components of the firing head assembly, wherein the pin member is configured to shear on operation of the piston.

19. The method of claim 11 , wherein the fourth lock ring comprises a bismuth lock ring.

20. The method of claim 11, wherein the fourth lock ring and movement sequences acts defines a multiple safety barrier.

Images