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  Deformable release device for use with downhole toolsRelated Patent Categories: Wells, Packers Or Plugs, With Expanding Anchor, With Detachable Setting MeansDeformable release device for use with downhole tools description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070151722, Deformable release device for use with downhole tools. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS REFERENCE TO RELATED APPLICATION [0001] This application is a Non-provisional application claiming benefit of U.S. Provisional Application Ser. No. 60/755,358, entitled, "Deformable Release Device for Use with Downhole Tools," by Douglas J. Lehr, Gabriel A. Slup, and James Van Lue, filed Dec. 30, 2005, hereby incorporated by reference in its entirety herein. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates generally to a release device that may be used with downhole setting tools. Specifically, the release device of the present disclosure deforms to provide a releasable detachment mechanism for a setting tool used to set a downhole tool, such as a Python Frac Plug from BJ Services Company of Houston, Tex. A deformable release device may provide a releasable detachment to any customary setting tool used to set a downhole packer-type device, for example. As would be appreciated by one of ordinary skill in the art having the benefit of this disclosure, customary setting tools include electric line, hydraulic, hydrostatic, and mechanical setting tools or other setting tool designs that use a combination of these methods for actuating a packer-type device in a subterranean well. [0004] 2. Description of the Related Art [0005] Many types, sizes, brands and models of packer devices are used to isolate a portion of a well bore. Each type of packer is run into the wellbore and then set. Typically a setting tool is used to run and set the packer. A number of different setting tools used to run and set a packer are available, but typically the lower end of the setting tool has different dimensions than the packer. Thus, regardless of the type of packer and setting tool used, an "adapter kit" is used to adapt the setting tool to the packer. The adapter kit also enables the detachment of the setting tool from the packer once the packer is set in the wellbore. Hence adapter kits are intermediate devices, inserted between the setting tool and the packer, which adapt the connection between the setting tool and the packer and allow for the detachment of the two after the packer is set. [0006] Many different methods can be used to convey the setting tool, adapter kit, and packer device into a wellbore, to set the packer, and to detach the setting tool and adapter kit from the packer. One method may use jointed pipe, whereas other methods may use coiled tubing, wireline, or slick line, for example. The method selected to run and set the packer depends on a number of variables, such as time constraints, costs, deviation of the wellbore, or which part of the servicing cycle the well is in. Due to the number of methods to run and set a packer, many different adapter kits are utilized in the oil and gas industry, such as mechanical, hydraulic, or wireline adapter kits. [0007] One such adapter kit, a wireline adapter kit ("WLAK"), is used to temporarily adapt or connect a wireline setting tool to a wireline packer device and also to enable the disengagement of the setting tool from the packer. An adapter kit used with a mechanical setting tool might utilize a simple coarse screw thread, such as an acme thread running around the perimeter of the lower end of the adapter kit, to connect the setting tool to the packer. The packer has mating threads to engage the threads of the adapter kit. The relatively simple coarse screw thread also allows the setting tool to be rotationally disengaged from the packer device once the packer device has been set. However, in some situations, such as in horizontal wells, it can be relatively difficult to rotate the setting tool and adapter kit. [0008] Another means for disengaging the adapter kit from the packer device is a design that includes a portion of the connection adapted to release when subjected to a predetermined mechanical load. Designs that release under a predetermined mechanical load may be designed to release either automatically or manually. An automatic release occurs during the setting sequence, once the packer/adapter kit connection is subjected to a load above a predetermined limit. A manual release requires the application of the predetermined load to the adapter kit after the setting sequence. Examples of a manual release are rotational releases, as described above, or merely pulling tension into the adapter kit. [0009] One type of adapter kit that automatically releases under a mechanical load is a wireline adapter kit. The release of a wireline setting tool adapter kit may be accomplished by mechanically failing a component of the adapter kit such as a "release stud," shear screw(s), a shear ring, or shear pin(s) with a known amount of force. Such components fail with the application of a predetermined amount of a tensile or axial force. The Baker Model B WLAK is an example of an adapter kit that uses a device, specifically a release stud, that automatically fails with a known axial force, which in one size is approximately 33,000 lbs, when applied to the adapter kit. [0010] One potential problem with using release devices that fail under a designated mechanical force, such as a release stud or shear pin, is that debris from the release device remains in the well bore after the device has released. This debris can accumulate on top of packing elements. Additionally, the debris may accumulate on or in a moving part of a downhole tool possibly causing the downhole tool to malfunction. A malfunction of the downhole tool increases the normal operating costs of the well. Further, the downhole tool or packer may need to be removed from the wellbore to clear the debris, to correct a malfunction, or to replace the downhole tool or packer itself due to a malfunction. [0011] Another disadvantage of using shear pins, or other mechanically failing devices, is that a hole for the insertion of a shear screw or shear pin is typically drilled in a component, such as the packer. The drilling of a hole into the packer may weaken the overall strength of the packer, especially if the hole is drilled into a brittle material such as cast iron, possibly leading to premature failure of the component. [0012] Other adapter kits and mechanical release devices are generally rather complex in design. This complexity increases the manufacturing and assembly costs for the system. Generally, mechanical release devices that release by failing a mechanical component, such as shear screws, leave remnants of those components in the wellbore, as discussed above. A build up of these remnants in the wellbore may require the milling out or drilling out of the wellbore, which adds to the cost of production and leads to delays in production from the well. [0013] In light of the foregoing, it would be desirable to provide a release device for an adapter kit that does not leave remnants or debris in the wellbore. Additionally, it would be desirable to provide a release device for an adapter kit that reduces the need to drill holes into the packer assembly and the adapter kit. It would also be desirable to provide a release device that simplifies the manufacturing of the adapter kit as well as the assembly of the adapter kit and packing assembly, thus reducing costs. It would further be desirable to provide a release device that decreases well servicing time, such as drilling out downhole debris. [0014] The present invention is directed to overcoming, or at least reducing the effects of, one or more of the issues set forth above. SUMMARY OF THE INVENTION [0015] The present application discloses a deformable release device for use in releasing a downhole tool after setting a wellbore plug. The deformable release device is designed to minimize the likelihood of breaking or shearing release components, thus minimizing debris in the wellbore. The deformable release device may deform to release a downhole tool connection. In one embodiment, the deformable release device may be a circular plate having a central circular opening. The deformable release device may be metallic, but may be comprised of any material that sufficiently deforms under a designated axial load as would be recognized by one of ordinary skill in the art having the benefit of this disclosure. Likewise, the geometrical shape of the deformable release device may be one of a various shapes as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. [0016] The deformable release device may be connected to the lower end of the mandrel of a packer assembly. An opening of the deformable releasing device may enclose a central portion of a plunger that may be connected to a release stinger. The release stinger may be connected to a setting tool. The plunger may be substantially circular in cross-section and include an upper portion and a lower portion. The outer diameter of the upper portion of the plunger may be smaller than the diameter of the central opening of the deformable release device. The outer diameter of the lower portion of the may be larger than the diameter of the central opening of the deformable release device. The deformable release device may be adapted to pass the lower portion of the plunger with the application of a known axial force. [0017] In one embodiment, a deformable release device having an opening may be located substantially at the bottom of a downhole tool mandrel, and may be located between a release stinger and a plunger. When a requisite upward axial force is applied to the release stinger, the plunger may be pulled through the deformable release device deforming the opening of the deformable release device. By modifying the material, thickness, and other dimensions of the deformable release device and the plunger, the force required for the plunger to pull through the deformable release device can be predetermined. The force required to deform the deformable release device is resisted by the downhole tool, and is thereby converted into the setting force. [0018] In one embodiment, the deformable release device may enable the automatic disengagement of the setting tool from the plug. Specifically, once the requisite axial upward force is applied to the release stinger, the plunger is pulled through the deformable release device. Alternatively, the deformable release device may be used in a manual detachment of the setting tool, such as in a mechanical adapter kit to set a cast iron bridge plug run into the wellbore with a mechanical setting tool on jointed pipe. The deformable release device could also be used in a wireline adapter kit for setting permanent packers using a wireline pressure setting assembly such as a Baker Model E-4. However, the deformable release device of the present disclosure may be used with various adapter kits, setting tools, and downhole assemblies as would be recognized by one of ordinary skill in the art having the benefit of this disclosure. [0019] In one embodiment, the deformable release device is used with a wireline adapter kit that includes an adapter sleeve and a release stinger used to connect a setting tool to a downhole tool. The adapter sleeve may be threaded onto the wireline pressure setting assembly and extend down to the plug assembly. One end of the release stinger may be threaded onto the downhole end of the wireline pressure setting assembly. A torsional spring may prevent the release stinger from unintentionally unthreading from the wireline pressure setting assembly. A plunger may be threaded onto the downhole end of the release stringer. A coiled spring may retain the plunger against the release stinger. During the process of setting the plug, the release stinger and the plunger pull up on the deformable release device connected to the bottom of mandrel of the downhole tool. Pins may secure the deformable release device to the mandrel. Once the upward force reaches the deformation strength of the deformable release device, the plunger is pulled through the deformable release device, thus deforming the opening of the deformable release device and releasing the adapter kit and setting tool from the downhole tool. [0020] In one embodiment of the present disclosure the upper end of the plunger is adapted to connect to a release stinger. The upper end of the plunger may be adapted to fit through an opening of the deformable release device. The lower end of the plunger may be larger than the diameter of the deformable release device opening. Additionally, the plunger may include a protrusion positioned lower than the deformable release device that has a larger outer diameter than the diameter of the opening. Alternatively, the cross-section of the plunger and the deformable release device opening may be non-circular as would be recognized by one of ordinary skill in the art having the benefit of this disclosure. [0021] In one embodiment, a bumper may be connectable to the bottom of the plunger. As would be appreciated by one of ordinary skill in the art having the benefit of this disclosure, after the plunger is pulled through the deformable release device there may be a tendency for the wireline adapter kit to bounce up and down due to the large force exerted on the assembly, which was previously countered by the deformable release device. Thus, the bumper may be comprised of any material, such as nylon, that would minimize damage of downhole components due to the impact of the bumper as the wireline adapter kit bounces up and down in the wellbore as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. Continue reading about Deformable release device for use with downhole tools... Full patent description for Deformable release device for use with downhole tools Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Deformable release device for use with downhole tools patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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