Electrically powererd setting tool and perforating gun

Abstract

An electric setting tool powered through a cable or wire line for setting bridge plugs or other settable downhole tools and which may be used in conjunction with a select fire perforating gun. The electric setting tool is adapted to receive DC power and set a tool in the range of 20 to 60 seconds while operating at under 2.0 amps. The composite tool may be comprised of multiple perf guns subs, the electric setting tool, and bridge plug or other settable tool.

1 . A downhole electric setting tool for setting a settable tool in an oil and gas well having a casing, the electric setting tool comprising:
 a drive module having a drive module housing for housing an electronic control assembly capable of receiving, processing and outputting electric signals;   a motor module having a motor module housing and having a d.c. motor assembly for receiving output from the electronic control assembly and providing rotary motion responsive thereto;   a gear module having a gear module housing for housing a gear assembly, the gear assembly for receiving rotary motion from the motor module and providing a geared reduction for and output of the rotary motion;   a motion converter module having a motion converter module housing for housing a drive train that converts rotary motion output from the gear module to linear motion of a polished rod;   a seal module having a seal module housing for housing a dynamic seal assembly, the dynamic seal assembly for engaging the polished rod and the seal module housing to prevent pressurized fluids from entering the housing; and   an anti-rotation module including an anti-rotation module housing and an anti-rotation assembly, the anti-rotation assembly for receiving the polished rod and engaging the housing so as to prevent rotational motion of the polished rod or the housing;
 wherein the housings are removably coupled end to end in a fluid sealing manner to form an electric setting tool housing assembly having a fluid sealed first end and a second end. 
   
     
     
         2 . The electric setting tool of  claim 1 , further comprising a first adapter or a second adapter, wherein the first adapter is configured to engage the second end of the housing to a first settable downhole tool and wherein the second adapter is configured to engage the second end of the housing to a second settable downhole tool, the second settable downhole tool different structurally from the first downhole tool. 
     
     
         3 . The electric setting tool of  claim 1 , wherein the gear assembly provides a gear reduction in range of 30:1 to 350:1. 
     
     
         4 . The electric setting tool of  claim 1 , wherein the gear assembly comprises a planetary gear assembly. 
     
     
         5 . The electric setting tool of  claim 4 , wherein the planetary gear assembly comprises a first sun gear, a first carrier/planet gear assembly, and a ring gear. 
     
     
         6 . The electric setting tool of  claim 1 , wherein the gear assembly comprises a toothed part of an interior surface of the gear module housing. 
     
     
         7 . The electric setting tool of  claim 5 , wherein the planetary gear assembly has a longitudinal axis defined by the axis about which the first sun gear rotates and wherein the electric setting tool housing assembly has a longitudinal axis and wherein the longitudinal axis of the electric setting tool housing assembly and the first sun gear are coaxial. 
     
     
         8 . The electric setting tool of  claim 1 , wherein the d.c. motor assembly comprises a frameless, brushless d.c. motor. 
     
     
         9 . The electric setting tool of  claim 1 , wherein the d.c. motor assembly comprises a rotor assembly having a stepped bore. 
     
     
         10 . The electric setting tool of  claim 1 , wherein the d.c. motor includes a rotor assembly having a sleeve on an exterior surface thereof. 
     
     
         11 . The electric setting tool of  claim 1 , wherein the d.c. motor assembly is operable above at least about 300 volts. 
     
     
         12 . The electric setting tool of  claim 1 , further including a resolver for engaging the d.c. motor assembly to the electronic control assembly. 
     
     
         13 . The electric setting tool of  claim 1 , wherein the anti-rotation assembly includes a keyed shaft, and at least one key for engaging the walls of the housing to prevent rotation between the anti-rotation module housing and the keyed shaft while allowing the keyed shaft to move longitudinally within the anti-rotation module housing. 
     
     
         14 . The electric setting tool of  claim 1 , wherein the roller screw assembly further includes a roller screw nut, a threaded roller screw shaft and a thrust bearing unit. 
     
     
         15 . The electric setting tool of  claim 14 , wherein the thrust bearing unit engages the roller screw shaft to inner walls of the roller screw module housing. 
     
     
         16 . The electric setting tool of  claim 15 , wherein the roller screw shaft receives rotary output from the gear assembly and threadably engages the roller screw nut, and wherein the roller screw nut moves longitudinally as a result thereof and wherein the roller screw nut threadably engages the polished rod to move the polished rod longitudinally. 
     
     
         17 . The electric setting tool of  claim 1 , further including a sensor assembly for sensing environmental conditions in the casing. 
     
     
         18 . The electric setting tool of  claim 17 , wherein the sensor assembly can record time, and downhole temperature and pressure conditions. 
     
     
         19 . The electric setting tool of  claim 17 , wherein the sensor assembly can transmit, real time, time, temperature, and pressure conditions to the surface. 
     
     
         20 . The electric setting tool of  claim 1 , wherein the d.c. motor assembly, the gear assembly and the roller screw assembly are adapted to provide a stroke output of about 3 to 18 inches on the polished rod with a tensile force of at least about 15,000 pounds over a period of time less than about 120 seconds. 
     
     
         21 . The electric setting tool of  claim 20 , configured such that the d.c. motor receives a current of about 1.9 amps or less. 
     
     
         22 . The electric setting tool of  claim 21 , configured such that the d.c. motor provides power of less than about 750 watts. 
     
     
         23 . The electric setting tool of  claim 1 , wherein the electronic control assembly includes a current limiter that prevents the d.c. motor of the d.c. motor assembly from drawing more than about 1.9 amps. 
     
     
         24 . The electric setting tool of  claim 1 , further including a sensor for detecting the position of the polished rod. 
     
     
         25 . The electric setting tool of  claim 24 , wherein the sensor detects the rotations of the d.c. motor. 
     
     
         26 . The electric setting tool of  claim 1 , wherein the electronic control assembly is adapted to monitor the stroke length and to stop the motor when the full stroke length has been achieved. 
     
     
         27 . The electric setting tool of  claim 21 , wherein the motion converter module comprises a roller screw module having a roller screw module housing for housing a roller screw assembly, the roller screw assembly for receiving rotary motion output from the gear module and changing it to linear motion output to the polished rod. 
     
     
         28 . The electric setting tool of  claim 1 , wherein the motion converter is either roller screw assembly, a ball screw, a lead screw, 
     
     
         29 . The electric setting tool of  claim 1 , wherein anti-rotation module includes a grooved shaft, a sleeve and a key, the key slidably engaging the grooved shaft and removably engaging, through a fastener, the sleeve, the sleeve for locating the key in the groove fixed with respect to the anti-rotation module housing and sleeve. 
     
     
         30 . The electric setting tool of  claim 1 , wherein motion converter includes a thrust bearing having keeper in the thickness range of about 5 to 12 mm. 
     
     
         31 . The electric setting tool of  claim 30 , wherein the keeper includes multiple separate sections. 
     
     
         32 . The electric setting tool of  claim 21 , further including a pin and hole arrangement to transmit motion from one element to another. 
     
     
         33 . A downhole electric setting tool for setting a settable tool in an oil and gas well having a casing, the electric setting tool comprising:
 an electronic control assembly capable of receiving, processing, and outputting electric signals;   a drive train assembly including a drive train housing comprising a d.c. motor assembly, a gear assembly and a linear actuator, the drive train for generating and converting rotary motion output to linear motion of a polished rod; and   a dynamic seal assembly, the dynamic seal assembly for engaging the polished rod to prevent pressurized fluids from entering the drive train assembly housing.   
     
     
         34 . The tool of  claim 33 , further including an anti-rotation assembly, the anti-rotation assembly for receiving the polished rod and engaging the drive train housing so as to prevent rotational motion of the polished rod or the drive train housing. 
     
     
         35 . The electric setting tool of  claim 33 , further including an adapter to engage the drive train housing and the polished rod to the settable tool so as to hold the settable tool while retracting the polished rod. 
     
     
         36 . The electric setting tool of  claim 33 , wherein the gear assembly provides a gear reduction in range of 30:1 to 350:1. 
     
     
         37 . The electric setting tool of  claim 33 , wherein the gear assembly comprises a planetary gear assembly. 
     
     
         38 . The electric setting tool of  claim 37 , wherein the planetary gear assembly comprises a first sun gear, a first carrier/planet gear assembly, and a ring gear. 
     
     
         39 . The electric setting tool of  claim 38 , wherein the ring gear comprises part of an interior surface of a gear module housing. 
     
     
         40 . The electric setting tool of  claim 38 , wherein the planetary gear assembly has a longitudinal axis defined by the axis about which the sun gear rotates and wherein the drive train housing has a longitudinal axis and wherein the longitudinal axis of the drive train housing assembly and the sun gear are coaxial. 
     
     
         41 . The electric setting tool of  claim 33 , wherein the d.c. motor assembly comprises a frameless, brushless d.c. motor. 
     
     
         42 . The electric setting tool of  claim 33 , wherein the electronic setting tool and the d.c. motor assembly are adapted to draw less than about 1.9 amps. 
     
     
         43 . The electric setting tool of  claim 33 , further including a resolver for engaging the d.c. motor assembly to the electronic control assembly. 
     
     
         44 . The electric setting tool of  claim 34 , wherein the anti-rotation assembly includes a housing and a keyed shaft, and at least one key for engaging the inner walls of the housing to prevent rotation between the anti-rotation module housing and a keyed shaft while allowing the keyed shaft to move longitudinally within the anti-rotation module housing. 
     
     
         45 . The electric setting tool of  claim 33 , wherein the roller screw assembly further includes a roller screw nut, a roller screw shaft and a thrust bearing unit. 
     
     
         46 . The electric setting tool of  claim 45 , wherein the thrust bearing unit engages the roller screw shaft to inner walls of the housing. 
     
     
         47 . The electric setting tool of  claim 46 , wherein the roller screw shaft receives rotary output from the gear assembly and threadably engages the roller screw nut, and wherein the roller screw nut moves longitudinally as a result thereof and wherein the roller screw nut engages the polished rod to move the polished rod longitudinally. 
     
     
         48 . The electric setting tool of  claim 33 , further including a sensor assembly for sensing environmental conditions in the casing. 
     
     
         49 . The electric setting tool of  claim 48 , wherein the sensor assembly can record time, and downhole temperature and pressure conditions. 
     
     
         50 . The electric setting tool of  claim 48 , wherein the sensor assembly can transmit, real time, tool conditions to the surface. 
     
     
         51 . The electric setting tool of  claim 33 , wherein the d.c. motor assembly, the gear assembly and the roller screw assembly are adapted to provide a stroke output of about 3 to 18 inches on the polished rod with a tensile force of at least about 15,000 pounds over a period of time less than about 120 seconds. 
     
     
         52 . The electric setting tool of  claim 51 , wherein the d.c. motor receives less than 1.9 amps and develops less than about 750 watts of power. 
     
     
         53 . The electric setting tool of  claim 52 , wherein the d.c. motor uses an input power of less than about 700 watts. 
     
     
         54 . The electric setting tool of  claim 33 , wherein the electronic control assembly includes a current limiter that prevents the d.c. motor of the d.c. motor assembly from drawing more than 1.9 amps. 
     
     
         55 . The electric setting tool of  claim 33 , further including a sensor for detecting the position of the polished rod. 
     
     
         56 . The electric setting tool of  claim 55 , wherein the sensor detects the rotations of the d.c. motor. 
     
     
         57 . The electric setting tool of  claim 33 , wherein the electronic control assembly is adapted to monitor the stroke length and to stop the motor when the full stroke length has been achieved. 
     
     
         58 . The electric setting tool of  claim 54 , wherein the motion converter module comprises a roller screw module having a roller screw module housing for housing a roller screw assembly, the roller screw assembly for receiving rotary motion output from the gear module and changing it to linear motion output to the polished rod. 
     
     
         59 . The electric setting tool of  claim 33 , wherein the d.c. motor assembly includes a d.c. motor having a rotor with a sleeve on an external surface thereof. 
     
     
         60 . The electric setting tool of  claim 33 , wherein the d.c. motor having a rotor with a multistep bore. 
     
     
         61 . The electric setting tool of  claim 33 , wherein the d.c. motor wherein the linear actuator includes a keeper assembly adjacent a thrust bearing. 
     
     
         62 . The electric setting tool of  claim 33 , wherein the d.c. motor wherein the drive train includes a pin and hole assembly for transmitting motion.