Pressure intensifier for hydraulically setting a downhole tool

Abstract

A downhole tool and a method of moving the downhole tool between a radially retracted state and a fully radially expanded state. The downhole tool includes a mandrel, and a pressure intensifier positioned radially about the mandrel, the pressure intensifier including a first piston having a first pressure receiving end with a piston surface area (A1) and a first pressure output end with a piston surface area (A2), where A1 is greater than A2; a second piston having a second pressure receiving end with a piston surface area (A3), where A3 is greater than A2; a piston cylinder radially encompassing the first and second pistons; a fluid chamber defined between the first pressure output end of the first piston, the second pressure receiving end of the second piston, and the piston cylinder, the fluid chamber fluidly coupling the first pressure output end of the first piston to the second pressure receiving end of the second piston; and a pressure relief system, wherein the pressure relief system evacuates fluid from the fluid chamber when pressure in the fluid chamber rises above a pressure relief system threshold.