Setting tools and assemblies for setting a downhole isolation device such as a frac plug

A method of setting a frac plug in a well, comprising:

• providing a pre-assembled unit as defined as follows at a controlled shop environment, wherein:
• the pre-assembled unit is a frac plug setting assembly, comprising:
• a setting tool, comprising:
• a mandrel having an upper end and a lower end, the mandrel comprising a chamber for housing expandable gas and a gas port in fluid communication with the chamber, the lower end of the mandrel being couplable to an upper end of a frac plug mandrel, wherein the upper end of the mandrel is configured for coupling to a firing head that enables igniting a power charge to generate pressurized gas within the chamber;
• a barrel piston having a central bore configured for housing the mandrel, a lower end of the barrel piston being couplable to a setting sleeve for setting the frac plug;
• and
• an expansion region defined between the mandrel and the barrel piston and being in fluid communication with the gas port so as to receive the pressurized gas, the expansion region being further defined by seals provided in between the mandrel and the barrel piston, thereby enabling the pressurized gas to exert force on the mandrel and the barrel piston to cause a stroke of the barrel piston over the mandrel as the expansion region expands axially;
• an adapter kit, comprising:
• the setting sleeve having an upper part coupled to the lower end of the barrel piston and a lower part;
• and
• a shear cap having an upper portion secured to the lower end of the mandrel, and a lower portion housed within part of the setting sleeve;
• a frac plug, comprising:
• a plug mandrel removably mounted to the lower portion of the shear cap;
• and
• a load member arranged in spaced relation with respect to the lower part of the setting sleeve, such that when the barrel strokes over the mandrel the setting sleeve engages the load member while the shear cap disengages from the plug mandrel in order to set the frac plug;
• wherein the frac plug is pre-assembled with the setting tool and the adapter kit to provide the pre-assembled unit;
• shipping the pre-assembled unit to a well site that includes the well extending into a reservoir;
• deploying the pre-assembled unit down the well;
• operating the pre-assembled unit such that the barrel strokes over the mandrel and causes the setting sleeve to engage the load member of the frac plug while the shear cap disengages from the plug mandrel, thereby setting the frac plug within the well;
• removing the setting tool and the adapter kit as a connected unit from the well;
• and
• disposing of the connected unit.

A method of setting a downhole isolation device in a well, comprising:

• providing a pre-assembled unit at a first location, wherein the pre-assembled unit comprises:
• a setting tool, comprising:
• a mandrel having an upper end and a lower end, the mandrel comprising a chamber for housing expandable gas and a gas port in fluid communication with the chamber, the lower end of the mandrel being couplable to an upper end of a downhole isolation device mandrel, wherein the upper end of the mandrel is configured for coupling to a firing head that enables igniting a power charge to generate pressurized gas within the chamber;
• and
• a barrel piston having a central bore configured for housing the mandrel, a lower end of the barrel piston being couplable to a setting sleeve for setting the downhole isolation device;
• wherein the mandrel and the barrel piston are configured to enable the pressurized gas to exert force on the mandrel and the barrel piston to cause a stroke of the barrel piston over the mandrel;
• an adapter kit, comprising:
• the setting sleeve having an upper part coupled to the lower end of the barrel piston and a lower part;
• and
• a shear cap having an upper portion secured to the lower end of the mandrel, and a lower portion;
• a downhole isolation device, comprising:
• the downhole isolation device mandrel removably mounted to the lower portion of the shear cap;
• and
• a load member arranged in spaced relation with respect to the lower part of the setting sleeve, such that when the barrel strokes over the mandrel the setting sleeve engages the load member while the shear cap disengages from the plug mandrel in order to set the frac plug;
• wherein the downhole isolation device is pre-assembled with the setting tool and the adapter kit to provide the pre-assembled unit;
• shipping the pre-assembled unit to a well site that includes the well extending into a reservoir;
• deploying the pre-assembled unit down the well;
• operating the pre-assembled unit such that the barrel strokes over the mandrel and causes the setting sleeve to engage the load member of the downhole isolation device while the shear cap disengages from the downhole isolation device mandrel, thereby setting the downhole isolation device within the well;
• and
• removing the setting tool and the adapter kit as a connected unit from the well.