Not applicable.
This disclosure relates generally to techniques for plugging tubulars and, more particularly to improved plug devices to restrict fluid flow within selected sections in a tubular.
In the oilfield industry, the completion of subsurface wells to produce hydrocarbons entails the insertion of casing tubulars into a wellbore traversing the subsurface formations. Specialized tools are then inserted into the casing to perforate the walls of the tubular at desired subsurface locations in order to allow the hydrocarbons in the surrounding formation to flow into the casing for collection at the surface. Once the casing is perforated, a well stimulation technique known as hydraulic fracturing is applied to create cracks in the rock formations surrounding the wellbore to create fissures or fractures through which natural gas, petroleum, and other fluids can flow more freely. In this process, a fluid is injected into the casing at high-pressure to penetrate the formation via the perforations in the casing.
Some reservoirs, such as unconventional shale reservoirs, require that the wellbore be drilled horizontally and completed using multi-stage hydraulic fracturing. The hydraulic fracturing of a particular stage along the casing requires the casing to be perforated and the remainder of the horizontal well to be plugged or sealed. In this way, the hydraulic fracture will be created at the location of the perforations. In such operations, a “plug” is set in the casing prior to perforating to seal off the casing section to receive the high-pressure fluid.
A number of techniques have been developed to plug or seal casing tubulars. Conventional plug devices are deployed in the casing using a setting tool to install the plug. Such plug devices are typically annular in shape and have a hole or opening in the center to allow for fluid passage. A common technique for closing off the hole in the plug device entails the use of a ball. Once the plug is set, the plug setting tool is removed from the well and a spherical ball is inserted into the casing at the surface. The start of the hydraulic fracturing operation begins with pumping liquid into the casing at a relatively low rate. This flow pushes the ball down the casing until it reaches the plug. A ball with a larger diameter than the plug hole is used to ensure that the ball does not pass through the plug. The ball lodges against the opening in the plug and the combination of the ball and plug block flow of the fluid from going further. Continued pumping of the fluid from the surface results in increased pressure within the casing. As the pumping rate is increased, the pressure rises more rapidly until the reservoir fractures. Once the fracture is initiated, pumping continues until the desired volume of fluid has been pumped through the casing perforations and into the surrounding rock formation. Subsequent stages along the casing are created in the same way, until all the stages have been fractured.
Once all the stages have been fractured, the series of plugs are removed so that the well can be produced via the perforations from all the stages. This can be done in several ways. In one method, the balls are produced back to the surface by the fluid entering the perforated casing from the formation. This requires that the balls increase in size from one plug to the next in the uphole direction. In another method, the balls may be constructed of a material that dissolves over time. Once the balls are retrieved or dissolve, if the flow along the casing is excessively impeded by the plugs, the plugs may need to be removed. This typically requires that the plugs be drilled out or that the plugs themselves be dissolvable. A shortcoming of plugs that are drilled out is that they leave debris in the well. This debris can create problems with subsequent operations in the well, or at the surface, should it be produced. The volume of debris is determined by the volume of the plug. Conventional plugs tend to be long and thick structures, producing a significant volume of debris when they are drilled out.
Thus, a need remains for improved techniques for plugging tubulars and isolating sections within tubulars to restrict the passage and flow of fluids therethrough.
According to an aspect of the invention, a plug apparatus includes a plurality of segments configured to interact with one another to form a ring having a central opening; wherein the plurality of segments are configured for disposal within a tubular; and wherein the plurality of segments are each configured to move in a radial direction from the center of the ring when a force is applied to at least one of the plurality of segments.
According to another aspect of the invention, a plug system includes a plurality of segments configured to interact with one another to form a ring having a central opening; wherein the plurality of segments are configured for disposal within a tubular; wherein the plurality of segments are each configured to move in a radial direction from the center of the ring when a force is applied to at least one of the plurality of segments; and an element configured for disposal within the tubular to engage with and obstruct the central opening of the ring.
According to another aspect of the invention, a method for plugging a tubular includes disposing a plurality of segments within a tubular, wherein the segments are configured to interact with one another to form a ring having a central opening; moving each segment of the plurality of segments in a radial direction from the center of the ring to contact an inner surface of the tubular; and disposing an element within the tubular to engage with and obstruct the central opening of the ring.
The following figures form part of the present specification and are included to further demonstrate certain aspects of the present claimed subject matter, and should not be used to limit or define the present claimed subject matter. The present claimed subject matter may be better understood by reference to one or more of these drawings in combination with the description of embodiments presented herein. Consequently, a more complete understanding of the present embodiments and further features and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like reference numerals may identify like elements, wherein:
Certain terms are used throughout the following description and claims to refer to particular components and configurations. As one skilled in the art will appreciate, the same component may be referred to by different names. This document does not intend to distinguish between components that differ in name but not function. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . .” As used herein, the term “tubular” encompasses any type of tube structure (e.g., conduits, casing, pipes, risers, hoses, etc.) and thus is not to be limited to any specific structure.
The foregoing description of the figures is provided for the convenience of the reader. It should be understood, however, that the embodiments are not limited to the precise arrangements and configurations shown in the figures. Also, the figures are not necessarily drawn to scale, and certain features may be shown exaggerated in scale or in generalized or schematic form, in the interest of clarity and conciseness.
While various embodiments are described herein, it should be appreciated that the present invention encompasses many inventive concepts that may be embodied in a wide variety of contexts. The following detailed description of exemplary embodiments, read in conjunction with the accompanying drawings, is merely illustrative and is not to be taken as limiting the scope of the invention, as it would be impossible or impractical to include all of the possible embodiments and contexts of the invention in this disclosure. Upon reading this disclosure, many alternative embodiments of the present invention will be apparent to persons of ordinary skill in the art. The scope of the invention is defined by the appended claims and equivalents thereof.
Illustrative embodiments of the invention are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. In the development of any such actual embodiment, numerous implementation-specific decisions may need to be made to achieve the design-specific goals, which may vary from one implementation to another. It will be appreciated that such a development effort, while possibly complex and time-consuming, would nevertheless be a routine undertaking for persons of ordinary skill in the art having the benefit of this disclosure.
In some embodiments, one or more of the segments 12 may be implemented with at least one protrusion 18 extending out from the segment surface forming the outer diameter of the ring. The protrusion(s) 18 may comprise a raised portion extending out from the segment 12 outer surface. Although
The segments 12 alternate between male and female segments.
As depicted in
Segment 12 embodiments may be implemented with one or multiple ridges 30 formed on the outer surface of the segment. The ridges 30 may be implemented as a series of peaks and valleys formed on the segment 12 via conventional manufacturing processes. For applications where additional hardness is desired, the ridges 30 may be carburized via conventional techniques as known in the art. Some embodiments may be configured with a combination of ridges 30 and protrusions 18 implemented on the outer surface of the segment 12 (not shown). Yet other plug 10 embodiments may be configured with some segments 12 on the ring implemented with protrusions 18 and other segments on the ring implemented with ridges 30 (not shown). Some plug 10 embodiments may be formed with the ridge 30 protrusions having sharp edges, forming a series of teeth-like extensions that allow the segments 12 to more securely anchor against the inner surface of a tubular when the plug assembly is expanded (
Turning to
As depicted in
The setting tool 34 is configured with a telescoping mechanism comprising an inner sleeve 46 coaxially disposed within the housing 36. The inner sleeve 46 is of a smaller diameter than the first sleeve 42, allowing the inner sleeve to reside and slide within the first sleeve. The inner sleeve 46 terminates at the lower end of the setting tool 34 with a plurality of inner sleeve legs 48 extending out from the open end in the housing 36. The inner sleeve legs 48 are narrow and extend parallel to one another along the longitudinal axis of the tool 34. The legs 48 extend out circumferentially, in a cage-like pattern with open gaps between adjacent legs. The end of each inner sleeve leg 48 is affixed to the gauge ring 40. Each inner sleeve leg 48 also holds an individual plug 10 segment 12 between the housing 36 open end and the gauge ring 40.
The gauge ring 40 is a donut-shaped member with a central opening 52. As depicted in
Once the setting tool 34 (fitted with the plug 10) is deployed within the tubular 16 to the desired location, an activation mechanism 60 (
Since the gauge ring 40 is also pinned to the inner sleeve legs 48, once the legs disengage from the lower segments 12 the legs pass through the central plug 10 opening as the setting tool 34 is retrieved from the tubular 16, until the gauge ring abuts the anchored plug and the gauge ring shear pin(s) 56 breaks. When this happens the gauge ring 40 becomes a loose body in the tubular 16.
Embodiments of the plug 10 can be made for applications in tubulars 16 of different inner diameters. Similarly, embodiments of the setting tool 34 can also be implemented with appropriately sized housing 36 diameters to accommodate different diameter tubulars 16. It will be appreciated by those skilled in the art that conventional shear pin 50, 56 devices and activation mechanisms 60 (e.g., hydraulic, pneumatic, electric servo, etc.) may be used to implement the setting tool 34. It will also be appreciated by those skilled in the art that conventional downhole tool electronics and hardware may be used to implement setting tool 34 embodiments of this disclosure. Actuation of the activation mechanism 60 may be achieved via electric signal communication (e.g. along a wireline 38 or cabled tubing). In some embodiments, electronics in the insertion tool 34 may include a processor programmed with instructions to automatically actuate the activation mechanism 60 to set the plug 10 when the tool reaches a specified depth or position within the tubular 16.
In completion operations, after the plug 10 is set at the desired location within the tubular 16 and the setting tool 34 is tripped out of the tubular, a plugging element is inserted into the tubular from the surface. A ball or dart are often used to plug or restrict fluid flow along the wellbore.
As previously discussed, embodiments of the plug 10 may be made of metal. In addition to metallic embodiments, some plug 10 embodiments may also be produced with segments 12 formed using composite materials or materials that dissolve when exposed to certain fluids as known in the art. It is well known that magnesium-based components may be used in oilfield applications where the components are exposed to high pressure and high temperature to perform their functions for a projected period of time before they start disintegrating in the wellbore. Conventional balls 66 and darts 70 used in oilfield operations may be used to implement embodiments of this disclosure. Some embodiments may also be implemented using conventional balls 66 and darts 70 formed from dissolvable materials. For example, dissolvable frac balls available from DISSOLVALLOY™ (www.dissolvalloy.com) can be used to implement the disclosed embodiments. Similarly, embodiments of the gauge ring 40 may also be formed from dissolvable materials. Dissolvable plug 10, gauge ring 40, ball 66, and dart 70 embodiments disappear over time, so they do not become an obstruction or create debris, eliminating the need to retrieve or drill out these components from the tubular 16. Other plug 10 embodiments may be formed with a combination of metallic and non-metallic segments 12 as suitable for the particular application. It will be appreciated by those skilled in the art that embodiments of this disclosure may be implemented using conventional materials and combinations of materials as desired for the particular application.
In accordance with some embodiments,
It will be appreciated that plug 10 embodiments can be implemented in different sizes and diameters depending on the desired application. An advantage of the disclosed plug 10 embodiments for use in oilfield applications is the short axial length of the device (e.g., embodiments can be less than 6 inches in height). Once set in a tubular, the internal plug 10 diameter is large. For example, in 5½ inch casing tubing having an internal diameter of 4.892 inches, the internal diameter of a plug 10 embodiment can be 3.5 inches or larger.
In light of the principles and example embodiments described and depicted herein, it will be recognized that the example embodiments can be modified in arrangement and detail without departing from such principles. Also, the foregoing discussion has focused on particular embodiments, but other configurations are also contemplated. Even though expressions such as “in one embodiment,” “in another embodiment,” or the like are used herein, these phrases are meant to generally reference embodiment possibilities, and are not intended to limit the invention to particular embodiment configurations. As used herein, these terms may reference the same or different embodiments that are combinable into other embodiments. As a rule, any embodiment referenced herein is freely combinable with any one or more of the other embodiments referenced herein, and any number of features of different embodiments are combinable with one another, unless indicated otherwise.
In view of the wide variety of useful permutations that may be readily derived from the example embodiments described herein, this detailed description is intended to be illustrative only, and should not be taken as limiting the scope of the invention. What is claimed as the invention, therefore, are all implementations that come within the scope of the following claims, and all equivalents to such implementations.
This application claims priority to U.S. Provisional Patent Application No. 62/627,049, filed on Feb. 6, 2018, titled “Apparatus and Methods for Plugging a Tubular.” The entire disclosure of Application No. 62/627,049 is hereby incorporated herein by reference.
Number | Date | Country | |
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62627049 | Feb 2018 | US |