The present invention relates to downhole tools for use in well bores, as well as methods for using such downhole tools. In particular, the present invention relates to downhole tools and methods for plugging a well bore with a tool having a large flow-through inside diameter that allows fluids to flow freely after the isolation process.
A variety of downhole tools are used in the drilling, completion, and stimulation of hydrocarbon-producing wells. For example, it is often desirable to seal portions of a wellbore, such as during fracturing operations when various fluids and slurries are pumped from the surface into a casing string that lines the wellbore, and forced into a surrounding subterranean formation through the casing string. During the fracking process, it becomes necessary to seal the wellbore to provide zonal isolation at the location of the desired subterranean formation. Isolation tools, such as frac plugs, bridge plugs, and packers, are well known in the art for achieving zonal isolation.
These downhole tools typically can be lowered into a well bore in an unset position until the tool reaches a desired setting depth. Upon reaching the desired setting depth, the downhole tool is set. Once set, the downhole tool acts as a plug preventing fluid from traveling from above the downhole tool to below the downhole tool. After the desired operation is complete, the seal formed by the wellbore isolation tool must be broken in order to allow production operations to commence. This is generally accomplished by removing the tool, typically by a complex retrieval operation that involves milling or drilling out a portion of the tool, and subsequently mechanically retrieving its remaining portions. This milling and/or retrieving process can be a costly and time-consuming process. Prior downhole tools were typically made of very hard metals, such as steel, that are very difficult to drill through, adding significant cost and difficulty to the removal process.
Recent developments have been made to improve the removal of downhole tools. For example, U.S. Pat. No. 6,220,349 describes downhole plugs constructed of non-metallic, composite parts that are easier to drill through. As another example, U.S. Patent Publ. No. 2011/0048743 describes downhole plugs constructed of parts designed to dissolve when exposed to certain downhole conditions. Although the foregoing developments represent considerable advancements in the removal of downhole tools, there still remains a need in the industry to reduce or eliminate this time consuming removal step altogether.
The present invention discloses a downhole tool, such as a bridge plug or a frac plug, that eliminates the need for drill-out in order to re-enter the wellbore, thereby reducing the transition time to production.
In one claimed embodiment of the present invention, a downhole tool configured on a wireline adapter kit in the run-in position is disclosed, the downhole tool comprising a large open bore when the downhole tool is set and the wireline adapter kit is removed, wherein the large open bore allows production to commence without removal of the downhole tool. The large bore diameter may be greater than 2 inches for a 4.5 inch casing, or greater than 2.5 inches for a 5.5 inch casing.
In a second claimed embodiment of the present invention, a downhole tool configured on a wireline adapter kit in the run-in position is disclosed, the downhole tool comprising upper slips and lower slips configured to grippingly engage the well casing when the downhole tool is in the set position, a means for sealing the annulus between the downhole tool and the well casing when the downhole tool is in the set position, and a large open bore when the downhole tool is set and the wireline adapter kit is removed, wherein the large open bore allows production to commence without removal of the downhole tool. The large bore diameter may be greater than 2 inches for a 4.5 inch casing, or greater than 2.5 inches for a 5.5 inch casing. The wireline adapter kit comprises a setting sleeve, a tension mandrel (constructed of a high strength alloy steel), and a mule shoe. Both the setting sleeve and the upper portion of the tension mandrel are threadingly engaged to a setting tool. The mule shoe is engaged to the lower portion of the tension mandrel using shear screws. In a preferred aspect of the present invention, the downhole tool is bottom set.
In a third claimed embodiment of the present invention, a downhole tool configured on a wireline adapter kit in the run-in position is disclosed, the downhole tool comprising upper slips and lower slips configured to grippingly engage the wellbore or well casing when the downhole tool is in the set position, an upper cone slidingly engaged with the upper slips, a lower cone slidingly engaged with the lower slips, an extrusion limiter arranged adjacent to the lower cone, and a packer cup element arranged adjacent to the extrusion limiter and slidingly engaged with the upper cone. The wireline adapter kit comprises a setting sleeve arranged adjacent to the upper slips, a tension mandrel, and a mule shoe. Both the setting sleeve and the upper portion of the tension mandrel are threadingly engaged to the setting tool. The mule shoe is engaged to the lower portion of the tension mandrel and is arranged adjacent to the lower slips. The downhole tool is set by the setting tool creating a push on the setting sleeve while creating a pull on the tension mandrel, with the push on the setting sleeve setting the upper slips and the pull on the tension mandrel setting the lower slips. The pull on the tension mandrel also forces the packer cup element into sealing engagement between the upper cone and the wellbore. The downhole tool further comprises a large open bore when the downhole tool is set and the wireline adapter kit is removed, wherein the large open bore allows production to commence without removal of the downhole tool. The large bore diameter may be greater than 2 inches for a 4.5 inch casing, or greater than 2.5 inches for a 5.5 inch casing. A dissolvable ball may be seated within the downhole tool to seal the large open bore in order to conduct wellbore services. It is a preferred aspect of the present invention that one or more of the upper slips, upper cone, extrusion limiter, lower cone, and lower slips are at least partially constructed of composite materials. Alternatively, one or more of the upper slips, upper cone, extrusion limiter, lower cone, and lower slips are at least partially constructed of dissolvable materials.
The novel features of the present invention will be best understood by reference to the following detailed description when read in conjunction with the accompanying drawings:
Referring generally to
Plug 100 is assembled directly on a wireline adapter kit (WLAK), and thus eliminates the need for a separate mandrel. When plug 100 is set, the WLAK shears off the plug and is removed from the wellbore leaving chamfered shoulder 216 on upper cone 108 for frac ball 218 to seat upon, as depicted in
Referring to
Upper slips 106 is arranged adjacent to setting sleeve 102, and is slidingly engaged with upper cone 108. Packer cup 110 having elastomer lip 111 is arranged adjacent to upper cone 108, and as discussed below with reference to
Referring now to
Referring now to
Ball 218 is then disposed in the upper opening portion 212 and is adapted for engagement with shoulder 216 in the presence of downward pressure, as is shown in
Once ball 218 has dissolved or otherwise cleared from central bore 210, plug 100 does not need to be removed from the wellbore in order to commence production operations. According to certain embodiments of the present invention, central bore 210 of plug 100 has a set inside diameter preferably greater than 2.0″, more preferably greater than 2.5″, and most preferably greater than 3.0″ or more, in order to allow fluids to flow freely through the tool after the fracking (or other workover) process is completed. As such, one important aspect of the present invention is that operators can re-enter the wellbore, if needed, and without removing plug 100, with 2⅞″ tubing or production tubing.
The foregoing disclosure describes a plug 100 capable of expediting well completion and stimulation services by eliminating any need for drilling out or retrieval to commence production operations. In a first preferred embodiment, plug 100 is constructed of primarily composite materials. For example, any one or more of upper slips 106, upper cone 108, extrusion limiter 112, lower cone 114, and lower slips 116 may be constructed of a filament wound fiberglass/resin, or a molded thermoset plastic, as is well known in the art. Packer cup 110 is preferably made from a nitrile elastomeric material, suitable for forming a tight seal against well casing 200 when plug 100 is set. In second preferred embodiment, plug 100 may be constructed of primarily dissolvable materials. For example, any one or more of upper slips 106, upper cone 108, extrusion limiter 112, lower cone 114, and lower slips 116 may be constructed of a magnesium alloy, with packer cup 110 made from a degradable elastomeric material. In a third preferred embodiment, plug 100 may be constructed as a hybrid of the above two embodiments.
In one illustrative embodiment of the present invention, for a casing size of 5.5″ (17 lb/ft), plug 100 has an un-set outside diameter of 4.37″ and uncompressed total length of 15.36″, with a corresponding set inside diameter of 2.50″ and set length of 9.85″. This provides an installed flow area for central bore 210 of 4.9 in2.
In another illustrative embodiment of the present invention, for a casing size of 5.5″ (20 lb/ft), plug 100 has an un-set outside diameter of 4.50″ and uncompressed total length of 15.36″, with a corresponding set inside diameter of 3.90″ and set length of 9.85″. This provides an installed flow area for central bore 210 of 11.9 in2.
In yet another illustrative embodiment of the present invention, for a casing size of 5.5″ (23 lb/ft), plug 100 has an un-set outside diameter of 4.38″ and uncompressed total length of 15.36″, with a corresponding set inside diameter of 3.77″ and set length of 9.85″. This provides an installed flow area for central bore 210 of 11.2 in2.
In still yet another illustrative embodiment of the present invention, for a casing size of 4.5″ (15.1 lb/ft), plug 100 has an un-set outside diameter of 3.50″ and uncompressed total length of 15.36″, with a corresponding set inside diameter of 2.90″ and set length of 9.85″. This provides an installed flow area for central bore 210 of 6.6 in2.
In still another illustrative embodiment of the present invention, for a casing size of 4.5″ (13.5 lb/ft), plug 100 has an un-set outside diameter of 3.63″ and uncompressed total length of 15.36″, with a corresponding set inside diameter of 3.02″ and set length of 9.85″. This provides an installed flow area for central bore 210 of 7.2 in2.
In a further illustrative embodiment of the present invention, for a casing size of 4.5″ (11.6 lb/ft), plug 100 has an un-set outside diameter of 3.75″ and uncompressed total length of 15.36″, with a corresponding set inside diameter of 3.15″ and set length of 9.85″. This provides an installed flow area for central bore 210 of 7.8 in2.
Another preferred embodiment of the present invention is a method for completing a well and a method for reducing time for well completion, comprising installing plug 100 as described hereinabove, performing fracking operations, dissolving or otherwise removing ball 218, and commencing production operations without removing or retrieving plug 100.
Therefore, the present invention is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present invention.
This application is a Continuation of U.S. application Ser. No. 16/660,604, filed Oct. 22, 2019, entitled “Cup Plug Having a Large Flow-Through Inside Diameter,” which is a Continuation of U.S. application Ser. No. 15/466,523, filed Mar. 22, 2017, entitled “Cup Plug Having a Large Flow-Through Inside Diameter,” which is hereby incorporated by reference in its entirety.
Number | Date | Country | |
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Parent | 16660604 | Oct 2019 | US |
Child | 17809252 | US | |
Parent | 15466523 | Mar 2017 | US |
Child | 16660604 | US |