FIELD
Illustrative embodiments of the disclosure generally relate to downhole bridge plugs for plugging a subterranean well. More particularly, illustrative embodiments of the present disclosure relate to downhole bridge plugs having a pair of slip assemblies characterized by enhanced grip strength, slip assemblies characterized by enhanced grip strength and methods of fabricating slip assemblies with enhanced grip strength.
BACKGROUND
The background description provided herein is solely for the purpose of generally presenting the context of the illustrative embodiments of the disclosure. Aspects of the background description are neither expressly nor impliedly admitted as prior art against the claimed subject matter.
In the production of fluids such as hydrocarbons from a subterranean well, it may be desirable to selectively seal or plug the well at various locations. For example, in hydrocarbon (oil and/or gas) production wells, it may be necessary or desirable to seal off a lower hydrocarbon-producing formation during the extraction of hydrocarbons from an upper hydrocarbon-producing formation. In other applications, it may be necessary or desirable to isolate the bottom of the well from the wellhead. Downhole bridge plugs are extensively used in such applications to establish a removable seal in the well.
A conventional downhole bridge plug may include a central mandrel on which is provided at least one expandable sealing element. An annular cone and a ridged slip assembly may be provided on the mandrel on each side of the sealing element or elements. The bridge plug may be set in place between adjacent hydrocarbon-producing fractions in the well casing by initially running the bridge plug to the desired location in the casing on a tubing string or using an alternative method and then sliding the slip assemblies onto the respective cones using a hydraulic or other setting tool, causing the slip assemblies to expand against the interior of the casing as they travel on the cones. Simultaneously, the cones move inwardly toward each other and against the sealing element, causing the cones and the sealing element to expand outwardly against the well casing. Therefore, the slip assemblies, the cones and the sealing elements together form a fluid-tight seal to prevent movement of fluids from one fraction to another within the well. When it is desired to re-establish fluid communication between the fractions in the well, the downhole bridge plug may be removed from the well casing. A backup ring on the mandrel between each cone and the sealing element or elements may reinforce the sealing element or elements after expansion against the casing.
One type of downhole bridge plug, commonly known as a drillable bridge plug, can be removed from the well casing by drilling or milling the bridge plug rather than by retrieving the plug from the casing. In this process, a milling cutter or drill bit is extended through the casing and rotated to grind the plug into fragments until the plug no longer seals the well casing. Drillable bridge plugs may be constructed of a drillable metal, engineering-grade plastic or composite material that can be drilled or ground into fragments by the milling cutter or drill bit.
One drawback of conventional downhole bridge plugs is that the slip assemblies may inadequately reinforce the cones against the sealing element or elements in the casing after the plug expansion process. This may allow the cones and the sealing element or elements to slip on the mandrel during application of pressure to the plug. A common drawback of conventional drillable bridge plugs is that during milling or drilling and grinding of the plug, the mandrel has a tendency to rotate or spin with the cutter or drill bit while the sealing elements, cones and/or other outer sealing components of the plug remain stationary against the interior surface of the well casing. This effect may reduce drilling efficiency and prolong the time which is necessary to remove the plug from the well bore.
Accordingly, downhole bridge plugs having a pair of slip assemblies characterized by enhanced grip strength, slip assemblies characterized by enhanced grip strength and methods of fabricating slip assemblies with enhanced grip strength may be desirable for some applications.
SUMMARY
The disclosure is generally directed to downhole bridge plugs. An illustrative embodiment of the downhole bridge plugs includes a mandrel, at least one sealing element provided on the mandrel and at least one backup ring provided on the mandrel on at least one side of the at least one sealing element. The at least one backup ring includes a first backup ring portion having a first backup ring portion body with a first outer ring section, a first inner ring section and a first spiraled ring groove separating the first outer ring section from the first inner ring section. The first inner ring section and the first outer ring section may be expandable partially circumferentially outwardly responsive to outward pressure applied to the first inner ring section. A second backup ring portion may be disposed adjacent to the first backup ring portion. The second backup ring portion may have a second backup ring portion body with a second outer ring section, a second inner ring section and a second spiraled ring groove separating the second outer ring section from the second inner ring section. The second inner ring section and the second outer ring section may be expandable partially circumferentially outwardly responsive to outward pressure applied to the second inner ring section. A pair of pressure-applying elements may be provided on the mandrel on respective sides of the at least one sealing element and the at least one backup ring, respectively. Each of the pair of pressure-applying elements may include a cone and a slip assembly engaging the cone. The slip assembly may have a reinforcing ring which may include a ring wall, a plurality of ring ridges protruding from the ring wall and a plurality of ring grooves between the plurality of ring ridges. A mandrel cap may engage one of the pair of pressure-applying elements.
Illustrative embodiments of the disclosure are further generally directed to backup rings for a downhole bridge plug. An illustrative embodiment of the backup rings includes a first backup ring portion having a first backup ring portion body with a first outer ring section, a first inner ring section and a first spiraled ring groove separating the first outer ring section from the first inner ring section. The first inner ring section and the first outer ring section may be expandable partially circumferentially outwardly responsive to outward pressure applied to the first inner ring section. A second backup ring portion may be disposed adjacent to the first backup ring portion. The second backup ring portion may have a second backup ring portion body with a second outer ring section, a second inner ring section and a second spiraled ring groove separating the second outer ring section from the second inner ring section. The second inner ring section and the second outer ring section may be expandable partially circumferentially outwardly responsive to outward pressure applied to the second inner ring section.
The disclosure is further generally directed to methods of fabricating a reinforcing ring of a pressure-applying element for a downhole bridge plug. An illustrative embodiment of the methods includes placing a plurality of reinforcing ring sections in a mold, closing the mold, injecting a liquid molding material into the mold inside and around the reinforcing ring sections, forming a ring insert by curing the liquid molding material and removing the reinforcing ring from the mold.
BRIEF DESCRIPTION OF THE DRAWINGS
The disclosure will now be made, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a side perspective view of an illustrative embodiment of the downhole bridge plugs;
FIG. 2 is a longitudinal sectional view of an illustrative embodiment of the downhole bridge plugs, with the plug shown in a pre-expanded, well casing-disengaging configuration;
FIG. 3A is a side view of a typical mandrel of an illustrative embodiment of the downhole bridge plugs;
FIG. 3B is a side view of a typical mandrel cap or bottom sub of an illustrative embodiment of the downhole bridge plugs;
FIG. 3C is a front view of the mandrel, taken along viewing lines 3C-3C in FIG. 3A;
FIG. 3D is a rear view of the mandrel, taken along section lines 3D-3D in FIG. 3B;
FIG. 4A is a longitudinal sectional view of a typical cone element for a slip assembly of an illustrative embodiment of the downhole bridge plugs;
FIG. 4B is an end view, taken along viewing lines 4B-4B in FIG. 4A, of the cone element for the slip assembly;
FIG. 5 is a side view of a typical sealing element of the downhole bridge plugs;
FIG. 6 is an end view of the sealing element;
FIG. 7 is a side view of a typical reinforcing ring of each slip assembly;
FIG. 8 is a side view of the reinforcing ring with interior components of the reinforcing ring illustrated in phantom;
FIG. 9 is a cross-sectional view of the reinforcing ring;
FIG. 10 is a cross-sectional view of the reinforcing ring of the slip assembly with a typical ring insert seated in and threadably attached to the reinforcing ring;
FIG. 11 is a perspective view of the reinforcing ring and ring insert;
FIG. 12 is a perspective view of a typical molded ring insert of a multi-sectioned reinforcing ring;
FIG. 13 is a perspective view of the multi-sectioned reinforcing ring with a molded ring insert and multiple ring sections on the ring insert in typical fabrication of the molded ring insert;
FIG. 14 is an outer perspective view of a typical ring section of the multi-sectioned reinforcing ring;
FIG. 15 is an inner perspective view of the ring section;
FIG. 16 is a side perspective view of the ring section;
FIG. 17 is a longitudinal sectional view of the molded ring insert;
FIG. 18A is an exploded side view of the multi-sectioned reinforcing ring with the molded ring insert and ring sections on the ring insert;
FIG. 18B is a sectional view of the multi-sectioned reinforcing ring;
FIG. 19A is a longitudinal sectional view of the downhole bridge plug disposed in a well casing, with the lower cone, sealing element and upper cone disengaging the well casing in the pre-expanded configuration of the downhole bridge plug;
FIG. 19B is a longitudinal sectional view of the downhole bridge plug with a setting shaft deployed in place and coupled to the mandrel cap preparatory to deployment of the downhole bridge plug in the expanded configuration against the well casing;
FIG. 19C is a longitudinal sectional view of the downhole bridge plug deployed in the expanded configuration and the lower cone, sealing element and upper cone engaging the well casing;
FIG. 20 is a flow diagram of an illustrative embodiment of the reinforcing ring fabrication methods;
FIG. 21 is a side view of a typical outer backup ring portion of a backup ring suitable for implementation of the downhole bridge plug;
FIG. 22 is an outer surface view of the outer backup ring portion;
FIG. 23 is a side view of a typical inner backup ring portion of the backup ring;
FIG. 24 is an outer surface view of the outer backup ring portion;
FIG. 25 is an exploded side view of the backup ring, more particularly illustrating typical pinning of the outer backup ring portion to the inner backup ring portion in assembly of the backup ring;
FIG. 26 is an inner surface view of the backup ring;
FIG. 27 is a perspective view of an alternative illustrative embodiment of the downhole bridge plugs;
FIG. 28 is a longitudinal sectional view of the downhole bridge plug illustrated in FIG. 27;
FIG. 28A is a sectional view illustrating typical interlocking of a pair of downhole bridge plugs to prevent rotation of the downhole bridge plugs during drilling and removal of the plugs from a wellbore;
FIG. 29 is an exploded sectional view illustrating mating of a typical sealing element and backup ring suitable for implementation o the downhole bridge plug illustrated in FIG. 27; and
FIG. 30 is a longitudinal sectional view of the downhole bridge plug illustrated in FIG. 27, deployed in the expanded configuration and the lower cone, sealing element and upper cone engaging the well casing.
DETAILED DESCRIPTION
The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to practice the disclosure and are not intended to limit the scope of the claims. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. As used herein, relative terms such as “upper” and “lower” are intended to be used in an illustrative and not a limiting sense. In some applications, therefore, those elements which are identified as “upper” may be located beneath those elements which are identified as “lower” in the following detailed description. As used herein, the terms “upper” and “proximal” are intended to denote the end of a component which is closer to the well surface and the terms “lower” and “distal” are intended to denote the end of a component which is farther from the well surface.
Referring initially to FIGS. 1-11, 19A-19C and 21-26 of the drawings, an illustrative embodiment of the downhole bridge plug is generally indicated by reference numeral 1. As illustrated in FIG. 2, the downhole bridge plug 1 may include a mandrel 2 which may include any suitable type of rigid drillable material including but not limited to metal, composite material and/or engineering-grade plastic. The mandrel 2 may have a mandrel base 3 which may be generally cylindrical in shape. A mandrel shaft 4, which may be generally elongated and cylindrical with a longitudinal mandrel shaft bore 9, may extend from the mandrel base 3. As illustrated in FIGS. 3A and 3C, a mandrel shaft groove 10 may extend into the exterior surface of the mandrel shaft 4, in parallel relationship to the longitudinal axis of the mandrel shaft 4, for purposes which will be hereinafter described. In some embodiments, the mandrel shaft groove 10 may be elongated and generally U-shaped in cross-section. The mandrel shaft groove 10 may extend along at least a portion of the length of the mandrel shaft 4. In typical application of the downhole bridge plug 1, which will be hereinafter described, a running-in tool 100 (FIGS. 19A-19C) may operably engage the mandrel 2 for purposes which will be hereinafter described. As illustrated in FIG. 2, in some embodiments, a pair of spaced-apart cone pin openings 5 may extend into the mandrel shaft 4 for purposes which will be hereinafter described.
As further illustrated in FIG. 2, a mandrel cap 12 may engage the mandrel shaft 4 of the mandrel 2. The mandrel cap 12 may include a mandrel cap base 13 which may be generally cylindrical. A mandrel cap wall 14 may extend from the mandrel cap base 13. A mandrel cap bore 15 may extend through the mandrel cap base 13. The mandrel cap wall 14 may form a mandrel cap interior 16 which communicates with the mandrel cap bore 15 of the mandrel cap base 13. In the assembled downhole bridge plug 1, the mandrel cap interior 16 may accommodate the mandrel shaft 4 of the mandrel 2. Accordingly, the mandrel cap 12 may be positional with respect to the mandrel 2 between a pre-expanded configuration illustrated in FIGS. 2 and 19A and an expanded configuration illustrated in FIG. 19C for purposes which will be hereinafter described.
As illustrated in FIGS. 19A and 19B, in some embodiments, at least one mandrel cap coupling pin 11 may normally couple the mandrel cap 12 to the mandrel shaft 4 of the mandrel 2. The mandrel cap coupling pin 11 may normally secure the mandrel cap 12 in the pre-expanded configuration with respect to the mandrel 2. Accordingly, the intact mandrel cap coupling pin 11 may normally extend through a mandrel cap pin opening 26 in the mandrel cap wall 14 of the mandrel cap 12 and through a registering mandrel pin opening 6 in the mandrel shaft 4 of the mandrel 2. Responsive to actuation of the running-in tool 100, as will be hereinafter described, the mandrel coupling pin 11 may be sheared as the mandrel shaft 4 is displaced in the mandrel cap interior 16 of the mandrel cap 12 from the pre-expanded configuration of FIG. 19A to the expanded configuration of FIG. 19C, for purposes which will be hereinafter described.
As illustrated in FIG. 2, in some embodiments, an anti-rotation pin slot 8 may be provided in the distal or extending end of the mandrel shaft 4 of the mandrel 2. An anti-rotation pin opening 17 may be provided in the mandrel cap wall 14 at the distal or extending end of the mandrel cap interior 16. An anti-rotation pin 21 may extend through the anti-rotation pin opening 17. The purpose of the anti-rotation pin slot 8, the anti-rotation pin opening 17 and the anti-rotation pin 21 will be hereinafter described.
The mandrel cap 12 may be configured for coupling to a lower tubing string 94 (FIGS. 19A-19C) according to any suitable technique which is known by those skilled in the art. As illustrated in FIGS. 1 and 2, in some embodiments, a mandrel cap lock 18a may extend from the mandrel cap 12. The mandrel cap lock 18a may include a curved or semicircular major cam lock flange 19 having a curved major flange surface 20 which slopes away from the end of the mandrel cap base 13. A major flange tab 22 (FIG. 1) may extend from the major flange surface 20 at the extending or distal end of the major cam lock flange 19. A curved or semicircular minor cam lock flange 23 may extend from the mandrel base 3 in generally adjacent and diametrically-opposed relationship to the major cam lock flange 19. The minor cam lock flange 23 may have a generally curved minor flange surface 24. A minor flange tab 25 may extend from the minor flange surface 24 at the extending or distal end of the minor cam lock flange 23. As further illustrated in FIGS. 1 and 2, the major cam lock flange 19 may protrude beyond the minor cam lock flange 23.
A tubing string lock 95 (FIGS. 19A-9C) which is companion or complementary in design to the mandrel cap lock 18a may be provided on the lower tubing string 94. Accordingly, the mandrel cap 12 may be selectively coupled to the lower tubing string 94 by interlocking engagement of the mandrel cap lock 18a with the companion or complementary tubing string lock 95 on the lower tubing string 94. Alternative techniques known by those skilled in the art, including but not limited to threads, couplings and/or pins, may be used in addition to or instead of the mandrel cap lock 18a and the tubing string lock 95 to facilitate coupling of the mandrel cap 12 with the lower tubing string 94.
The mandrel 2 may be configured for coupling to the running-in tool 100 according to any suitable technique which is known by those skilled in the art. As illustrated in FIG. 2, in some embodiments, a tool lock 18b may extend from the mandrel base 3. The tool lock 18b may have a design which is the same as or similar to that of the mandrel cap lock 18a, with like numerals designating like components. A running-in tool lock 101 (FIGS. 19A-19C) which is companion or complementary in design to the tool lock 18b may be provided on the running-in tool 100. Accordingly, as illustrated in FIGS. 19A-19C, in typical application of the downhole bridge plug 1, which will be hereinafter described, the running-in tool 100 may be selectively coupled to the mandrel 2 by interlocking engagement of the running in tool lock 101 on the running-in tool 100 with the companion or complementary tool lock 18b on the mandrel base 3. The running-in tool 100 may be coupled to an upper tubing string (not illustrated) to facilitate placement and deployment of the assembly 1 in a well casing 80 in use of the assembly 1, as will be hereinafter described. Alternative techniques known by those skilled in the art, including but not limited to threads, couplings and/or pins, may be used in addition to or instead of the tool lock 18b and the running-in tool lock 101 to facilitate coupling of the mandrel 2 with the running-in tool 100.
A distal or lower pressure-applying element, such as an annular lower slip assembly 28a having a reinforcing ring 29, may be provided on the mandrel shaft 4 of the mandrel 2 adjacent to the mandrel cap 12. A proximal or upper pressure-applying element, such as an annular upper slip assembly 28b, also having a reinforcing ring 29, may be provided on the mandrel shaft 4 of the mandrel 2 generally adjacent to the mandrel base 3. An annular proximal or lower cone 72a may be provided on the mandrel shaft 4 in engagement with the lower slip assembly 28a. An annular distal or upper cone 72b may be provided on the mandrel shaft 4 in engagement with the upper slip assembly 28b. A lower backup ring 160a may be provided on the mandrel shaft 4 in engagement with the lower cone 72a. An upper backup ring 160b may be provided on the mandrel shaft 4 in engagement with the upper cone 72b. In some embodiments, each of the lower backup ring 160a and the upper backup ring 160b may have a structure which is the same as or similar to that described in U.S. patent application Ser. No. 14/794,890, filed Jul. 9, 2015, now U.S. Pat. No. 9,784,066, issued Oct. 10, 2017, and entitled DOWNHOLE BRIDGE PLUG OR PACKER ASSEMBLIES, which patent application is incorporated by reference herein in its entirety.
Referring next to FIGS. 21-26 of the drawings, a typical design for each of the lower backup ring 160a and the upper backup ring 160b (FIG. 2) is indicated by reference numeral 160 in FIG. 25. Each of the upper backup ring 160a and the lower backup ring 160b may include an outer backup ring portion 136 (FIGS. 21 and 22) and an inner backup ring portion 176 (FIGS. 23 and 24). The outer backup ring portion 136 may include an annular outer backup ring portion body 137 which may include rubber or other elastomeric material and through which extends a ring opening 141. In some embodiments, the outer backup ring portion body 137 may have a continuous unitary or one-piece construction and may include PEEK (polyether ether ketone), for example and without limitation. The outer backup ring portion body 137 may have an annular exterior engaging ring surface 138 and an annular ring opening edge 142 which encircles and faces the ring opening 141. As illustrated in FIG. 21, a beveled outer ring surface 139 and a beveled inner ring surface 140 may extend or taper inwardly toward each other from the exterior engaging ring surface 138 to the ring opening edge 142. In the assembled downhole bridge plug 1, the outer ring surface 139 of the upper backup ring 160a faces outwardly and is engaged by the corresponding upper cone 72b, whereas the outer ring surface 139 of the lower backup ring 160b faces outwardly and is engaged by the lower cone 72a. The inner ring surface 140 of the outer backup ring portion 136 of the upper backup ring 160a and the inner ring surface 140 of the outer backup ring portion 136 of the lower backup ring 160b face inwardly and engage the corresponding inner backup ring portion 176, as illustrated in FIG. 25.
As illustrated in FIG. 22, a single spiraled, multi-segmented ring groove 190 is provided in the outer backup ring portion body 137 of the outer backup ring portion 136 of each backup ring 160. As illustrated in FIG. 22, the ring groove 190 may divide the outer backup ring portion body 137 into an inner ring section 137a and an outer ring section 137b. Accordingly, responsive to outward pressure applied to the inner ring section 137a, the inner ring section 137a and the outer ring section 137b may be partially circumferentially expandable outwardly for purposes which will be hereinafter described. As used herein, “partially circumferentially outwardly” means that the inner ring section 137a and the outer ring section 137b may be expandable outwardly along a portion of the are or curvature of the outer backup ring portion body 137, such as 180 degrees, for example and without limitation. The depth of the spiraled ring groove 190 may extend from the engaging ring surface 138 through part of the thickness of the outer backup ring portion body 137 to the inner ring surface 140. As illustrated in FIG. 21, the spiraled ring groove 190 may include an elongated main groove segment 191 which may be generally straight or axial in side view of the outer backup ring body 136 and extends along a portion of the circumference of the engaging ring surface 138; a generally curved inner surface groove segment 192 (FIG. 22) the length of which extends from the main groove segment 191 along a portion of the inner ring surface 140 to the ring opening edge 142; and a generally curved or straight outer surface groove segment 193 (FIG. 22) the length of which extends from the main groove segment 191 along a portion of the outer ring surface 139 to the ring opening edge 142. The main groove segment 191 may have an outer main groove segment end 191a (FIG. 21) at the outer ring surface 139 and an inner main groove segment end 191b (FIG. 22) at the inner ring surface 140. In some embodiments, from the outer main groove segment end 191a to the inner main groove segment end 191b, the main groove segment 191 may traverse about 180 degrees of the circumference of the engaging ring surface 138.
The inner surface groove segment 192 (FIG. 22) of the spiraled ring groove 190 may extend lengthwise from the engaging ring surface 138 to the ring opening edge 142. As particularly illustrated in FIG. 22, the inner surface groove segment 192 may be generally tangential with respect to both the engaging ring surface 138 and with respect to the ring opening edge 142. At the engaging ring surface 138, the inner surface groove segment 192 may communicate with the inner main groove segment end 191b of the main groove segment 191.
As further illustrated in FIG. 22, the outer surface groove segment 193 of the spiraled ring groove 190 may extend lengthwise from the engaging ring surface 138 to the ring opening edge 142. At the engaging ring surface 138, the outer surface groove segment 193 may communicate with the outer main groove segment end 191a (FIG. 21) of the main groove segment 191. Therefore, the main groove segment 191, the inner surface groove segment 192 and the outer surface groove segment 193 of the spiraled ring groove 190 may be contiguous with each other. As illustrated in FIG. 22, the spiraled ring groove 190 divides a portion of the outer backup ring portion body 137 into the inner ring section 137a and the circumferentially expandable outer ring section 137b. Accordingly, application of outwardly-directed pressure to the inner ring section 137a of the outer backup ring portion body 137 facilitates uniform outward circumferential expansion of the expandable outer ring section 137b from the inner ring section 137a, for purposes which will be hereinafter described.
At least one retainer pin opening 144 may extend into the outer ring surface 139 of the outer backup ring portion body 137. As illustrated in FIG. 25, a shear-able ring retainer pin 145 may be seated in the retainer pin opening 144 and in a corresponding registering pin opening 75 (FIG. 4B) in the corresponding adjacent lower cone 72a or upper cone 72b. The ring retainer pin 145 may normally retain the upper backup ring 160a and the lower backup ring 160b in the pre-expanded configuration during installation of the downhole bridge plug 1 in the well casing 52 and prior to expansion of the downhole bridge plug 1.
As illustrated in FIG. 25, at least one outer coupling retainer pin opening 147 may extend through the outer backup ring body portion 137 from the outer ring surface 139 to the inner ring surface 140 of the outer backup ring portion 136. As illustrated in FIG. 22, the outer coupling retainer pin opening 147 may be disposed about 120 degrees relative to the retainer pin opening 144. As further illustrated in FIG. 25, a coupling retainer pin 184 may be inserted in and may extend through the outer coupling retainer pin opening 147. The coupling retainer pin 184 may couple the outer backup ring portion 136 to the inner backup ring portion 176 of each backup ring 160, typically as will be hereinafter described. The coupling retainer pin 184 may prevent premature expansion of the corresponding upper backup ring 160a and lower backup ring 160b as well as maintain proper orientation of the outer backup ring portion 136 and the inner backup ring portion 176 relative to each other in the upper backup ring 160a and the lower backup ring 160b.
In some embodiments, at least one fluid emission channel (not illustrated) may extend into the engaging ring surface 138 of the outer backup ring portion body 137. The fluid emission channel may traverse the width of the outer backup ring portion body 137 from the outer ring surface 139 to the inner ring surface 140. The fluid emission channel may facilitate emission of fluids from the outer backup ring portion body 137 upon expansion of the downhole bridge plug 1.
As illustrated in FIGS. 23 and 24, the inner backup ring portion 176 of each backup ring 160 may include an annular inner backup ring portion body 177 which may include rubber and/or other elastomeric material. In some embodiments, the inner backup ring portion body 177 may have a continuous unitary or one-piece construction and may include PEEK (polyether ether ketone), for example and without limitation. A ring opening 181 that registers with the ring opening 141 (FIGS. 21 and 22) of the outer backup ring portion 136 extends through the inner backup ring portion body 177. The inner backup ring portion body 177 may have an annular exterior engaging ring surface 178 and an annular interior ring opening edge 182 which faces the ring opening 181. A beveled inner backup ring surface 180 (FIG. 23) may extend or taper from the exterior engaging ring surface 178 to the ring opening edge 182 in the ring opening 181. A beveled annular outer ring surface 179m179 may extend or taper from the engaging ring surface 178. An annular ring lip 174 may protrude from the outer ring surface 179. A beveled annular ring opening surface 186 may extend from the ring opening edge 182 through the ring lip 174 and faces the ring opening 181. In the assembled downhole bridge plug 1, the outer ring surface 179 of the inner backup ring portion 176 faces outwardly and is engaged by the inner ring surface 140 of the outer backup ring portion 136, as illustrated in FIG. 25, whereas the inner backup ring surface 180 of the inner backup ring portion 176 faces inwardly and engages the sealing element 64 (FIG. 2).
A single spiraled ring groove 170 extends along the inner backup ring portion body 177 of the inner backup ring portion 176. As illustrated in FIG. 24, the spiraled ring groove 170 may divide the backup ring body 177 into an inner ring section 177a and an outer ring section 177b. Accordingly, responsive to outward pressure applied to the inner ring section 177a, the inner ring section 177a and the outer ring section 177b may be partially circumferentially expandable outwardly for purposes which will be hereinafter described. As used herein, “partially circumferentially outwardly” means that the inner ring section 177a and the outer ring section 177b may be expandable outwardly along a portion of the arc or curvature of the backup ring body 177, such as 180 degrees, for example and without limitation. The spiraled ring groove 170 may include a main groove segment 171 which extends along the engaging ring surface 178, an inner surface groove segment 172 which extends from the main groove segment 171 along the inner backup ring surface 180, an interior groove segment 175 (FIG. 24) which extends from the inner surface groove segment 172 along the ring opening surface 186 and an outer surface groove segment 173 which extends along the outer ring surface 179 from the interior groove segment 175 back to the main groove segment 171. As illustrated in FIG. 23, the main groove segment 171 of the spiraled ring groove 170 may be generally straight or axial in side view of the inner backup ring portion 176 and extends along a portion of the circumference of the engaging ring surface 178.
The inner surface groove segment 172 of the spiraled ring groove 170 may be generally curved and extends lengthwise from the main groove segment 171 along a portion of the inner backup ring surface 180 to the ring opening surface 186. As particularly illustrated in FIG. 24, the inner surface groove segment 172 may be generally tangential with respect to both the engaging ring surface 178 and the ring opening edge 182.
The outer surface groove segment 173 of the spiraled ring groove 170 may be generally curved and extends lengthwise from the inner surface groove segment 172 along a portion of the outer ring surface 179 and may terminate at the ring lip 174.
The interior groove segment 175 of the spiraled ring groove 170 may extend lengthwise from the outer surface groove segment 173 along the ring opening surface 186 from the inner surface groove segment 172 in the inner backup ring surface 180 to the outer surface groove segment 173 at the ring lip 174. In some embodiments, the main groove segment 171, the inner surface groove segment 172, the outer surface groove segment 173 and the interior groove segment 175 of the spiraled ring groove 170 may be contiguous with each other and may traverse about 180 degrees of the circumference of the inner backup ring portion body 177. Accordingly, as illustrated in FIG. 24, the spiraled ring groove 170 divides a portion of the inner backup ring portion body 177 into the inner ring section 177a and the expandable outer ring section 177b. Therefore, application of outwardly-directed pressure to the backup ring body 177 facilitates uniform outward circumferential expansion of the expandable outer ring section 177b from the inner ring section 177a against the well casing 152 (FIG. 16) to seal adjacent fractions from each other, as was heretofore described.
As illustrated in FIGS. 23 and 24, at least one inner coupling retainer pin opening 183 may extend into the beveled outer ring surface 179 of the inner backup ring portion body 177. As illustrated in FIG. 24, the inner coupling retainer pin opening 183 may be disposed generally at or near the junction where the inner surface groove segment 172 of the spiraled ring groove 170 meets the engaging ring surface 178 of the inner backup ring portion body 177.
As illustrated in FIG. 25, each backup ring 160 may be assembled by initially orienting the outer backup ring portion 136 and the inner backup ring portion 176 such that the beveled outer ring surface 179 on the inner backup ring portion 176 faces the complementary inner ring surface 140 on the outer backup ring portion 136. The outer backup ring portion 136 and/or the inner backup ring portion 176 is rotated until the outer coupling retainer pin opening 147 in the outer backup ring portion 136 aligns or registers with the companion inner coupling retainer pin opening 183 in the inner backup ring portion 176. The ring lip 174 on the outer backup ring portion 176 is inserted through the ring opening 141 of the outer backup ring portion 136 as the beveled outer ring surface 179 on the inner backup ring portion 176 engages the companion beveled inner ring surface 140 on the outer backup ring portion 136. Accordingly, as illustrated in FIG. 26, the spiraled ring groove 170 in the inner backup ring portion 176 traverses approximately a first half of the backup ring 160, whereas the spiraled ring groove 190 in the outer backup ring portion 136 traverses approximately a second half of the backup ring 160. Therefore, in the assembled lower backup ring 160a and upper backup ring 160b, the outer backup ring portion 136 may be oriented about 180 degrees relative to the inner backup ring portion 176 such that the spiral ring groove 190 of the outer backup ring portion 136 does not overlap the spiral ring groove 170 of the inner backup ring portion 176, as further illustrated in FIG. 26. The coupling retainer pin 184 maintains the outer backup ring portion 136 in position relative to the inner backup ring portion 176.
As illustrated in FIG. 2, an annular sealing element 64, which will be hereinafter described, may be provided on the mandrel shaft 4 between the lower backup ring 160a and the upper backup ring 160b. In some embodiments, the sealing element 64 may include rubber and/or other elastomeric material. As illustrated in FIGS. 5 and 6, in some embodiments, the sealing element 64 may include a generally cylindrical sealing element wall 65 which defines a longitudinal sealing element bore 66. A sealing element interior surface 67 of the sealing element wall 65 may face the sealing element bore 66. A longitudinal sealing element ridge 68 may protrude from the sealing element interior surface 67 into the sealing element bore 66. The longitudinal sealing element ridge 68 may traverse at least a portion of the length of the sealing element 64. The longitudinal sealing element ridge 68 may have a cross-sectional size and shape which are generally complementary to the cross-sectional size and shape of the mandrel shaft groove 10 (FIG. 3) in the mandrel shaft 4 of the mandrel 2. Accordingly, as illustrated in FIG. 2, when the sealing element 64 is placed on the mandrel shaft 4, the sealing element ridge 68 inserts into the companion mandrel shaft groove 10 (FIGS. 3A and 3C) to prevent rotation of the sealing element 64 relative to the mandrel 2 for purposes which will be hereinafter described. As illustrated in FIG. 5, in some embodiments, a circumferential sealing element notch 69 may extend into the sealing element interior surface 67. The sealing element ridge 68 may include a pin, bump, key or any other type of protuberance which extends from, engages or extends into the sealing element interior surface 67 and inserts into the mandrel shaft groove 10.
A typical design for each of the lower cone 72a and the upper cone 72b is indicated by reference numeral 72a, b in FIGS. 4A and 4B. The lower cone 72a and the upper cone 72b may have the same or similar design. The cones 72a, 72b may include a generally conical cone wall 73. The cone wall 73 may define a longitudinal cone bore 78. The cone wall 73 may have a tapered inner cone wall surface 74, a straight outer cone wall surface 76, and a straight cone wall surface 79 and a tapered cone wall surface 82 which extend from the inner cone wall surface 74 to the outer cone wall surface 76. An annular straight interior cone wall surface 81 may extend from the inner cone wall surface 74 to the outer cone wall surface 76 in facing relation to the cone bore 78. A longitudinal cone pin opening 77a may extend into the interior cone wall surface 81 of the cone wall 73 in facing and communicating relationship to the cone bore 78. The cone pin opening 77a may traverse at least a portion of the length of the cone 72a, 72b. As illustrated in FIG. 4A, in some embodiments, at least one radial cone pin opening 83 may extend through the cone wall 73 for purposes which will be hereinafter described.
As illustrated in FIG. 2, when each of the lower cone 72a and the upper cone 72b is placed on the mandrel shaft 4, a cone pin 77 may insert into and may be glued and/or otherwise secured in the cone pin opening 77a in the corresponding lower cone 72a or upper cone 72b, and the cone pin 77 may insert into the companion mandrel shaft groove 10 (FIGS. 3A and 3C) in the exterior surface of the mandrel shaft 4 of the mandrel 2 to prevent rotation of the lower cone 72a and the upper cone 72b relative to the mandrel 2, for purposes which will be hereinafter described. As further illustrated in FIG. 2, the inner cone wall surface 74 of the lower cone 72a may engage the outer backup ring portion 136 of the adjacent lower backup ring 160a. Likewise, the inner cone wall surface 74 of the upper cone 72b may engage the outer backup ring portion 136 of the adjacent upper backup ring 160b. As illustrated in FIGS. 4A and 4B, in some embodiments, multiple pin openings 75 may extend into the inner cone wall surface 74 of each of the lower cone 72a and the upper cone 72b. Registering pin openings (not illustrated) may extend into the facing outer surface in the outer backup ring portion 136 of the lower backup ring 160a and upper backup ring 160b, respectively. A ring retainer pin 145 (FIG. 2) may insert into the pin opening 75 (FIGS. 4A and 4B) in the corresponding lower cone 72a and the upper cone 72b and the interfacing retainer pin opening 144 (FIGS. 21 and 25) in the outer ring surface 139 of the outer backup ring portion 136 of the corresponding lower backup ring 160a and upper backup ring 160b to secure the lower backup ring 160a to the lower cone 72a and the upper backup ring 160b to the upper cone 72b. As illustrated in FIGS. 2 and 19A, in some embodiments, a cone pin 90 may be extended through the cone pin opening 83 (FIG. 4A) in the cone wall 73 of each of the lower cone 72a and the upper cone 72b and into the corresponding registering cone pin opening 5 (FIG. 3) in the mandrel shaft 4 of the mandrel 2 to secure the lower cone 72a and the upper cone 72b on the mandrel shaft 4. The cone pin 77 may include a pin, bump, key or any other type of protuberance which extends from, engages or extends into the corresponding lower cone 72a or upper cone 72b and inserts into the mandrel shaft groove 10.
As illustrated in FIGS. 7-9, the reinforcing ring 29 of each of the lower slip assembly 28a and the upper slip assembly 28b may include an annular reinforcing ring wall 30 which may be generally cylindrical and forms a reinforcing ring bore 35 (FIG. 9). In some embodiments, the reinforcing ring wall 30 may be a continuous, one-piece construction, as illustrated in FIGS. 7 and 8. In other embodiments, the reinforcing ring wall 30 may be divided into multiple adjacent ring sections 48, connected by at least one frangible connection 62, as illustrated in FIG. 11i and will be hereinafter further described. As illustrated in FIG. 10, the reinforcing ring wall 30 may have an inner reinforcing ring wall end 30a and an outer reinforcing ring wall end 30b. Multiple adjacent, spaced-apart, concentric ring ridges 31 may protrude from an exterior surface of the reinforcing ring wall 30. Concentric ring grooves 36 may be defined between the adjacent ring ridges 31. An annular ring shoulder 32 may be provided in an interior surface of the reinforcing ring wall 30 at the inner reinforcing ring wall end 30a. An annular ring flange 33 may protrude from the interior surface of the reinforcing ring wall 30 at the outer reinforcing ring wall end 30b. Ring threads 34 (FIG. 9) may protrude from the interior surface of the reinforcing ring wall 30 adjacent to the ring flange 33.
As illustrated in FIG. 10, a ring insert 38 may be inserted in the ring bore 35 of the reinforcing ring 29. In some embodiments, the ring insert 38 may include a ring insert wall 39 having an inner ring insert wall end 39a and an outer ring insert wall end 39b. The ring insert wall 39 may have a straight insert wall portion 44 which extends from the outer ring insert wall end 39b and a tapered wall portion 45 which extends from the straight wall portion 44 to the inner ring insert wall end 39a. The ring insert wall 39 may form a ring insert interior 43. An annular ring insert flange 42 may protrude outwardly from the inner ring insert wall end 39a of the ring insert wall 39. The ring insert flange 42 may engage the inner reinforcing ring wall end 30a of the reinforcing ring wall 30 in meshing relation to the ring shoulder 32 of the reinforcing ring 29. An annular flange receiving groove 40 may be provided in the outer reinforcing ring wall end 39b of the ring insert wall 39. The flange receiving groove 40 may receive the companion ring flange 33 on the reinforcing ring 29. The reinforcing ring 29 may threadably engage the ring insert 38 at the ring threads 34 (FIG. 9). A lip receiving groove 41 may be provided in the outer surface of the ring insert wall 39 adjacent to the flange receiving groove 40. Ring insert threads 70 may be provided in the lip receiving groove 41 and along the exterior length of the ring insert wall 39. As illustrated in FIG. 10, the ring insert threads 70 may mesh with companion ring threads 34 provided in the interior surface of the ring wall 30 of each reinforcing ring 29 to secure the reinforcing ring 29 on the ring insert 38. In some embodiments, the ring insert threads 70 may be provided along substantially the entire exterior length of the ring insert wall 39 and the ring threads 34 may be provided along substantially the entire length of the ring wall 30 of the reinforcing ring 29. In some embodiments, a bonding resin (not illustrated) may be applied to the ring threads 34 and the ring insert threads 70 and cured to achieve a strong bond between the reinforcing ring 29 on the ring insert 38. In some embodiments, the ring insert 38 may include a composite material and/or other non-metallic drillable material which is consistent with the functional requirements of the slip assemblies 28a, 28b.
The reinforcing ring 29 may be fabricated using a conventional injection-molding process, which will be hereinafter described. The reinforcing ring 29 may include any suitable type of rigid drillable material including but not limited to metal, composite material and/or engineering-grade plastic. For example and without limitation, in some embodiments, the reinforcing ring 29 may include cast iron. After it is cured, the sectioned reinforcing ring 29 may be removed from the mold (not illustrated). As illustrated in FIGS. 11 and 13, the sectioned reinforcing ring 29 may include multiple, adjacent ring sections 48, each of which corresponds to a radial portion of the reinforcing ring 29. Each ring section 48 may include multiple ring ridges 31 and intervening ring grooves 36 between the ring ridges 31.
In typical application, the downhole bridge plug 1 may be used as a permanent packer, a retrievable packer or a drillable plug, for example and without limitation. The upper slip assembly 28b may be placed on the mandrel shaft 4 of the mandrel 2, typically by extending the mandrel shaft 4 through the ring insert interior 43 (FIG. 10) of the ring insert 38, until the outer ring wall end 30b on the ring wall 30 of the reinforcing ring 29 engages the mandrel base 3 of the mandrel 2. The upper cone 72b may then be placed on the mandrel shaft 4. The cone pin 77 (FIG. 2) may be inserted in the cone pin opening 77a (FIG. 4A) in the upper cone 72b and in the mandrel shaft groove 10 (FIGS. 3A and 3C) to prevent rotation of the upper cone 72b on the mandrel 2. The outer backup ring portion 136 of the upper backup ring 160b may then be placed on the mandrel shaft 4, and the ring retainer pins 145 may be inserted in the respective pin openings 75 (FIG. 4B) in the inner cone wall surface 74 of the upper cone 72b and the respective registering retainer pin openings 144 (FIG. 21) in the outer ring surface 139 of the outer backup ring portion 136. The inner backup ring portion 176 of the upper backup ring 160b may be placed on the mandrel shaft 4 against the outer backup ring portion 136.
Next, the sealing element 64 may be placed on the mandrel 2 by inserting the mandrel shaft 4 of the mandrel 2 through the sealing element bore 66 (FIG. 6) until the sealing element 64 engages the inner backup ring portion 176 of the upper backup ring 160b. As illustrated in FIG. 2, the sealing element ridge 68 provided on the sealing element 64 may simultaneously be inserted into and slid along the mandrel shaft groove 10 (FIGS. 3A and 3C) provided in the mandrel shaft 4 of the mandrel 2. The inner backup ring portion 176 of the lower backup ring 160a may next be placed on and slid along the mandrel shaft 4 against the sealing element 64, and the outer backup ring portion 136 of the lower backup ring 160a may be placed on and slid along the mandrel shaft 4 against the inner backup ring portion 176.
The lower cone 72a may be placed on the mandrel shaft 4 of the mandrel 2. The lower cone 72a may be slid along the mandrel shaft 4 until the inner cone wall surface 74 of the cone wall 73 engages the outer backup ring portion 136 of the lower backup ring 160a. The ring retainer pins 145 may be inserted in the respective pin openings 75 (FIG. 4B) in the inner cone wall surface 74 of the lower cone 72a and the respective registering retainer pin openings 144 (FIG. 25) in the outer backup ring portion 136. The cone pin 90 may be extended through the cone pin opening 83 (FIG. 4A) in the cone wall 73 of each of the lower cone 72a and the upper cone 72b and into the corresponding registering cone pin opening 5 (FIG. 2) in the mandrel shaft 4 of the mandrel 2.
The lower slip assembly 28a may be placed on the mandrel shaft 4, typically by extending the mandrel shaft 4 through the ring insert interior 43 (FIG. 10) of the ring insert 38, and sliding the lower slip assembly 28a along the mandrel shaft 4 until the ring insert 38 receives and engages the tapered cone wall surface 82 of the cone wall 73 of the lower cone 72a. The mandrel cap 12 may then be pinned to the mandrel shaft 4 of the mandrel 2 by inserting the mandrel coupling pin or pins 11 (FIGS. 19A-19C) through the respective mandrel cap pin opening or openings 26 in the mandrel cap wall 14 of the mandrel cap 12 and the registering mandrel pin opening or openings 6 in the mandrel shaft 4 of the mandrel 2.
The running-in tool 100 (FIGS. 19A-19C) may be coupled to the mandrel base 3 of the mandrel 2 typically by interlocking the running-in tool lock 101 on the running-in tool 100 with the companion tool lock 18b on the mandrel base 3. In like manner, the lower tubing string 94 may be coupled to the mandrel cap 12 typically by interlocking the tubing string lock 95 on the lower tubing string 94 with the companion mandrel cap lock 18a on the mandrel cap 12. An upper tubing string (not illustrated) may be coupled to the running-in tool 100 typically by threading, pinning and/or other suitable technique known by those skilled in the art.
As illustrated in FIGS. 19A-19C, in typical application, the downhole bridge plug 1 may be placed in a well casing 80 which extends into a subterranean fluid-producing well (not illustrated) such as an oil and/or gas well, for example and without limitation, between two adjacent production fractions in the well to seal the fractions from each other and prevent flow of fluid between the fractions. Accordingly, the upper tubing string may be inserted in the well casing 80 with the running-in tool 100 and the mandrel 2 coupled thereto, the mandrel cap 12 coupled to the mandrel shaft 4 of the mandrel 2 typically via the mandrel coupling pin or pins 11 and the lower tubing string 94 coupled to the mandrel cap 12. In some applications, the well casing 80 may be oriented in a vertical position in the well in which case the lower slip assembly 28a, the lower cone 72a and the lower backup ring 160a may be oriented beneath the sealing element 64 and the upper slip assembly 28b, the upper cone 72b and the upper backup ring 160b may be oriented above the sealing element 64. In other applications, the well casing 80 may be oriented in a horizontal or diagonal position.
Deployment of the downhole bridge plug 1 from the pre-expanded to the expanded configuration may be as follows. As illustrated in FIG. 19B, a setting shaft 104 may be inserted through the mandrel shaft bore 9 of the mandrel shaft 4 and through the mandrel cap interior 16 and into the mandrel cap bore 15 of the mandrel cap 12. One or more shaft pins 106 may be extended through one or more shaft pin openings 27 in the mandrel cap bore 13 of the mandrel cap 12 and into one or more respective registering shaft pin openings (not numbered) in the setting shaft 104. A hydraulic setting tool (not illustrated), which may be conventional, may next be operated to pull the setting shaft 104, which in turn pulls the mandrel cap 12 along the mandrel shaft 4 such that the mandrel cap 12 impinges against the lower slip assembly 28a as the mandrel coupling pin or pins 11 is/are sheared. This action pushes the lower slip assembly 28a onto the lower cone 72a, as indicated by the arrow 91 in FIG. 19A. Simultaneously, the running-in tool 100 may push the upper slip assembly 28b onto the upper cone 72b, as indicated by the arrow 92 in FIG. 19A. Therefore, the lower cone 72a pushes or expands the lower slip assembly 28a outwardly until the ring ridges 31 on the reinforcing ring 29 of the lower slip assembly 28a and the lower backup ring 160a engage the interior surface of the well casing 80. In like manner, the upper cone 72b pushes or expands the upper slip assembly 28b outwardly until the ring ridges 31 on the reinforcing ring 29 of the upper slip assembly 28b and the upper backup ring 160b engage the interior surface of the well casing 80. The sealing element 64 is compressed between the lower backup ring 160a and the upper backup ring 160b and expands circumferentially outwardly to engage the interior surface of the well casing 80. In some applications, the frangible connection 62 (FIG. 11) between adjacent ring sections 48 of each reinforcing ring 29 may break as the ring sections 48 are wedged away from each other on the respective lower cone 72a and upper cone 72b. As each cone pin 90 is sheared, as illustrated in FIG. 19C, the lower cone 72a and the upper cone 72b travel along the mandrel 2 against the lower backup ring 160a and the upper backup ring 160b, respectively. This action compresses the sealing element 64, the lower backup ring 160a and the upper backup ring 160b between the lower slip assembly 28a and the upper slip assembly 28b. Consequently, the sealing element 64 circumferentially expands outwardly and engages the interior surface of the well casing 80, forming a fluid-tight seal between the downhole bridge plug 1 and the well casing 80. The lower slip assembly 28a, the lower backup ring 160a, the upper backup ring 160b and the upper slip assembly 28b may expand outwardly and engage the interior surface of the well casing 80, reinforcing and preventing movement of the sealing element 64 as pressure is subsequently placed on the downhole bridge plug 1 during well operations. The lower cone 72a applies outward pressure against the beveled outer backup ring surface 139 (FIG. 25) on the outer backup ring portion 136 of the lower backup ring 160a, and the upper cone 72b likewise applies outward pressure against the beveled outer backup ring surface 139 on the outer backup ring portion 136 of the upper backup ring 160b. Consequently, the inner ring section 137a (FIG. 22) and the outer ring section 137b of the outer backup ring portion 136 expand partially circumferentially outwardly to engage the interior surface of the well casing 80, as illustrated in FIG. 19C. In like manner, the sealing element 64 applies outward pressure against the beveled inner backup ring surface 180 (FIG. 25) on the inner backup ring portion 176 of each of the lower backup ring 160a and the upper backup ring 160b. Consequently, the inner ring section 177a (FIG. 24) and the outer ring section 177b of the inner backup ring portion 176 expand partially circumferentially outwardly to engage the interior surface of the well casing 80. The reinforcing ring 29 of each of the lower slip assembly 28a and the upper slip assembly 28b engages the well casing 80 with a grip strength greater than that which can be attained using conventional slip assembly designs. As further illustrated in FIG. 19C, a ball 120 may be dropped down the tubing string and onto a ball seat (not numbered) in the mandrel base 3 of the mandrel 2 to seal the portion of the well casing 80 below or distal to the downhole bridge plug 1. Fracking and/or other operations may then be carried out on the reservoir sections which are above or proximal to the downhole bridge plug 1.
In some applications, when removal of the downhole bridge plug 1 from the well casing 80 is desired, a drill bit or milling cutter (not illustrated) may be inserted through the well casing 80 and operated to grind the downhole bridge plug 1 into fragments according to the knowledge of those skilled in the art. It will be appreciated by those skilled in the art that during drilling or cutting of the downhole bridge plug 1, the mandrel 2 is locked in place with the sealing element 64 and each of the lower backup ring 160s, the upper backup ring 160b, the lower cone 72a and the upper cone 72b, since the sealing element ridge 68 (FIG. 6) on the sealing element 64 and the cone pin 77 (FIG. 2) in the cone pin opening 77a of each of the lower cone 72a and the upper cone 72b protrude into the mandrel shaft groove 10 (FIG. 3A) in the mandrel shaft 4 of the mandrel 2. As illustrated in FIG. 19C, in the expanded configuration of the downhole bridge plug 1, the anti-rotation pin slot 8 in the distal or extending end of the mandrel shaft 4 receives the anti-rotation pin 21 in the anti-rotation pin opening 17 of the mandrel cap wall 14. This expedient prevents rotation of the mandrel 2 and the mandrel cap 12 relative to each other during cutting of the downhole bridge plug 1. Therefore, because the mandrel 2 does not spin with the milling cutter or drill bit, speed and efficiency in cutting and removal of the downhole bridge plug 1 from the well casing 80 is enhanced. In some applications, the downhole bridge plug 1 may be used with a permanent packer or a retrievable packer.
It will be appreciated by those skilled in the art that the typically one-piece solid construction between the mandrel base 3 and the mandrel shaft 4 of the mandrel 2 enhances the structural strength and integrity of the downhole bridge plug 1. Thus, the mandrel base 3 applies the typically downward pressure against the upper slip assembly 28b as the setting shaft 104 applies the mandrel cap 12 with the typically upward pressure against the lower slip assembly 28a with sufficient force to ensure maximum longitudinal compression, radial expansion and exertion of the sealing element 64 against the interior surface of the well casing 80. Therefore, an optimum fluid-tight seal against the well casing 80 is ensured throughout deployment of the downhole bridge plug 1.
Referring next to FIGS. 11-18B of the drawings, in some embodiments, the reinforcing ring 29 of each of the lower slip assembly 28a and the upper slip assembly 28b may be multi-sectional and may be fabricated using an injection molding process. As illustrated in FIG. 12, multiple wall slots 55 may be provided in the tapered wall portion 45 of the ring insert wall 39. The wall slots 55 may partially divide the mold body wall 52 into multiple adjacent mold sections 56. A pair of spaced-apart insert partitions 58 may extend along opposite edges of each ring section 56. Insert cavities 116 (FIG. 17) may be formed by and between the adjacent insert partitions 58. Multiple, adjacent insert ring ridges 60 may extend between the insert partitions 58 in the insert cavity 116 of each insert section 56. Insert ring grooves 61 may extend between the adjacent insert ring ridges 60.
As illustrated in FIGS. 11 and 14-16, the sectioned reinforcing ring 29 may include multiple, adjacent ring sections 48, each of which corresponds to a radial portion of the reinforcing ring 29. Each ring section 48 may include a ring wall 30 having multiple ring ridges 31 and intervening ring grooves 36 between the ring ridges 31.
The sectioned reinforcing ring 29 may be fabricated by initially fabricating the ring sections 48 typically by injection molding. The ring sections 48 may then be placed in an injection mold (not illustrated) for fabrication of the ring insert 38. In some embodiments, the ring sections 48 may be attached to the injection mold by extending 6 fasteners (not illustrated) through respective fastener openings 37 (FIG. 14) in the respective ring sections 48 and threading the fasteners into respective fastener openings (not illustrated) in the mold.
A liquid molding material (not illustrated) which will form the ring insert 38 may next be injected into the mold. The liquid molding material may include any suitable type of rigid drillable material including but not limited to metal, composite material and/or engineering-grade plastic. The liquid molding material flows within and around the ring sections 48. As illustrated in FIGS. 13 and 17, the liquid molding material cures and forms the ring insert 38. After the sectioned reinforcing ring 29 is removed from the mold, the wall slots 55 may be cut into the tapered wall portion 45 in the ring insert wall 39 of the ring insert 38. The sectioned reinforcing rings 29 of the lower slip assembly 28a and the upper slip assembly 28b may then be assembled in the downhole bridge plug 1, typically as was heretofore described.
Application of the downhole bridge plug 1 having the lower slip assembly 28a and the upper slip assembly 28b may be as was heretofore described with respect to the downhole bridge plug 1 in FIGS. 19A-19C. The ring sections 48 may enhance outward radial expansion of each reinforcing ring 29 against the interior surface of the well casing 80 upon actuation of the running-in tool 100 and the mandrel cap 12 and radial expansion of the sealing element 64 against the well casing 80.
Referring next to FIG. 20 of the drawings, a flow diagram 2100 of an illustrative embodiment of the reinforcing ring fabrication methods is illustrated. Multiple reinforcing ring sections of a reinforcing ring may initially be fabricated using conventional injection molding and/or other techniques. At block 2102, the multiple reinforcing ring sections of the reinforcing ring may be placed in a mold. At block 2104, the mold may be closed. At block 2106, a liquid molding material may be injected into the mold inside and around the ring sections. The liquid molding material may include metal, composite material and/or engineering-grade plastic, for example and without limitation. At block 2108, a ring insert may be formed by curing the liquid molding material. At block 2110, the reinforcing ring may be removed from the mold.
Referring next to FIGS. 27-30 of the drawings, an alternative illustrative embodiment of the downhole bridge plugs is generally indicated by reference numeral 1a, where like reference numerals designate like elements to those of the downhole bridge plug 1 that was heretofore described with respect to FIGS. 1-26. The downhole bridge plug 1a may include an upper sealing element 264 which is provided on the mandrel shaft 204 of the mandrel 202. The upper sealing element 264 may directly engage the upper cone 72b. Accordingly, the upper backup ring (not illustrated) may be omitted from between the upper sealing element 264 and the upper cone 72b. A lower sealing element 296 may be provided on the mandrel shaft 204 in engagement with the upper sealing element 264. The upper backup ring 160a may be interposed between the lower cone 72a and the lower sealing element 296.
As illustrated in FIG. 29, the upper sealing element 264 may include an upper sealing element wall 265 which may be generally elongated and cylindrical. The upper sealing element wall 265 may have a proximal wall bevel 265a and a distal wall bevel 265b. The upper sealing element wall 265 may form an upper sealing element bore 266 which traverses the length of the upper sealing element 264. The upper sealing element bore 266 may be suitably sized to accommodate the mandrel shaft 4 of the mandrel 2. The upper sealing element bore 266 may have a sealing element bore surface 267. A longitudinal sealing element ridge 268 may protrude from the sealing element bore surface 267. The sealing element ridge 268 may traverse at least a portion of the length of the upper sealing element 264. In assembly of the downhole bridge plug 1a, the sealing element ridge 268 may insert into the companion mandrel shaft groove 10 (FIG. (FIG. 3C) in the mandrel shaft 4 of the mandrel 2, as was heretofore described with respect to the downhole bridge plug 1.
As further illustrated in FIG. 29, the lower sealing element 296 of the downhole bridge plug 1 may include a lower sealing element wall 297 which may be generally cylindrical or annular. A lower sealing element seat 299 and a beveled sealing element wall bevel 297a may be provided in opposite ends of the lower sealing element wall 297. The lower sealing element seat 299 may be suitably sized and configured to receive and accommodate the distal wall bevel 265b of the upper sealing element 264 in engaging relationship thereto in assembly of the downhole bridge plug 1. The sealing element wall bevel 297a may be suitably sized and angled to engage the inner backup ring portion 176 of the lower backup ring 160a in the assembled downhole bridge plug 1.
The lower sealing element wall 297 of the lower sealing element 296 may form a lower sealing element bore 298 which traverses the length of the lower sealing element 296. The lower sealing element bore 298 may be suitably sized to accommodate the mandrel shaft 4 of the mandrel 2. The lower sealing element bore 298 may have a sealing element bore surface 297T. A longitudinal sealing element ridge 297c may protrude from the sealing element bore surface 297b. The sealing element ridge 297c may traverse at least a portion of the length of the lower sealing element 296. In assembly of the downhole bridge plug 1a, the sealing element ridge 297c may insert into the companion mandrel shaft groove 10 (FIG. (FIG. 3C) in the mandrel shaft 4 of the mandrel 2, as was heretofore described with respect to the downhole bridge plug 1.
As illustrated in FIGS. 28 and 30, in some embodiments, a threaded shear insert 262 may be seated in the mandrel cap bore 15 adjacent to the mandrel cap interior 16 of the mandrel cap 12. The threaded shear insert 262 may be secured in the mandrel cap interior 16 via pins, threads, welding and/or other attachment technique known by those skilled in the art. For example and without limitation, in some embodiments, at least one radial insert retainer pin opening 270 may extend through the mandrel cap base 13 of the mandrel cap 12. An insert retainer pin 271 may extend through the insert retainer pin opening 270. The insert retainer pin 271 may be seated in a corresponding pin cavity (not numbered) provided in the threaded shear insert 262. The threaded shear insert 262 may have interior shear insert threads 263. In setting of the downhole bridge plug 1, a setting shaft (not illustrated) may be inserted through the mandrel shaft bore 9 of the mandrel shaft 4 and the mandrel cap interior 16 of the mandrel cap 12, as was heretofore described with respect to the setting shaft 104 in FIG. 19B. The setting shaft 104 may be threadably engaged with the shear insert threads 263 in the threaded shear insert 262 to deploy the downhole bridge plug 1a from the pre-expanded configuration to the expanded configuration, as was heretofore described with respect to FIGS. 19A-19C. The setting shaft 104 may be subsequently removed from the mandrel shaft bore 9 and mandrel cap interior 16 by reverse or downward movement of the setting shaft 104, thus typically facilitating shearing of the insert retainer pin or pins 271 and detachment of the threaded shear insert 262 from the mandrel cap bore 15 of the mandrel cap 12.
In typical application of the downhole bridge plug 1a, the upper slip assembly 28b and the upper cone 72b may be sequentially placed on the mandrel shaft 4 of the mandrel 2. Next, the upper sealing element 264 may be placed on the mandrel 2 by inserting the mandrel shaft 4 of the mandrel 2 through the sealing element bore 266 (FIG. 6) until the proximal wall bevel 265a on the upper sealing element 264 engages the inner backup ring portion 176 of the upper backup ring 160b. As illustrated in FIG. 28, the sealing element ridge 268 provided on the upper scaling element 264 may simultaneously be inserted into and slid along the mandrel shaft groove 10 (FIGS. 3A and 3C) provided in the mandrel shaft 4 of the mandrel 2.
The lower sealing element 296 may next be placed on the mandrel 2 by inserting the mandrel shaft 4 of the mandrel 2 through the lower sealing element bore 298 (FIG. 29) until the lower sealing element seat 299 in the lower sealing element 296 receives and engages the complementary-shaped distal wall bevel 265b on the upper sealing element 264. As illustrated in FIG. 28, the sealing element ridge 297c provided on the lower sealing element 296 may simultaneously be inserted into and slid along the mandrel shaft groove 10 (FIGS. 3A and 3C) provided in the mandrel shaft 4 of the mandrel 2.
The inner backup ring portion 176 of the lower backup ring 160a may next be placed on and slid along the mandrel shaft 4 against the sealing element wall bevel 297a on the lower sealing element 296, and the outer backup ring portion 136 of the lower backup ring 160a may be placed on and slid along the mandrel shaft 4 against the inner backup ring portion 176.
The lower cone 72a may be placed on the mandrel shaft 4 of the mandrel 2. The lower cone 72a may be slid along the mandrel shaft 4 until the inner cone wall surface 74 of the cone wall 73 engages the outer backup ring portion 136 of the lower backup ring 160a. In some embodiments, ring retainer pins 145 may be inserted in the respective pin openings 75 (FIG. 4B) in the inner cone wall surface 74 of the lower cone 72a and the respective registering retainer pin openings 144 (FIG. 25) in the outer backup ring portion 136. A cone pin 90 may be extended through the cone pin opening 83 (FIG. 4A) in the cone wall 73 of each of the lower cone 72a and the upper cone 72b and into the corresponding registering cone pin opening 5 (FIG. 2) in the mandrel shaft 4 of the mandrel 2.
The lower slip assembly 28a may be placed on the mandrel shaft 4, typically by extending the mandrel shaft 4 through the ring insert interior 43 (FIG. 10) of the ring insert 38, and sliding the lower slip assembly 28a along the mandrel shaft 4 until the ring insert 38 receives and engages the tapered cone wall surface 82 of the cone wall 73 of the lower cone 72a. The mandrel cap 12 may then be pinned to the mandrel shaft 4 of the mandrel 2 by inserting the mandrel coupling pin or pins 11 (FIGS. 19A-19C) through the respective mandrel cap pin opening or openings 26 in the mandrel cap wall 14 of the mandrel cap 12 and the registering mandrel pin opening or openings 6 in the mandrel shaft 4 of the mandrel 2.
Application of the downhole bridge plug 1a may be as was heretofore described with respect to the downhole bridge plug 1 in FIGS. 19A-19C. Upon deployment of the downhole bridge plug 1a from the pre-expanded configuration (FIG. 28) to the expanded configuration (FIG. 30), the lower slip assembly 28a traverses the lower cone 72a and engages the lower backup ring 160a, which in turn engages the lower sealing element 296. The lower slip assembly 28a and the lower backup ring 160a expand outwardly to engage the well casing 80, as was heretofore described. Simultaneously, the upper slip assembly 28b traverses the upper cone 72b and engages the upper sealing element 264, and the upper slip assembly 28b expands outwardly to engage the well casing 80. The upper sealing element 264 and the lower sealing element 296 are compressed between the upper cone 72b and the lower backup ring 160a, expanding outwardly to engage the well casing 80. In some applications, after use, a drill bit or milling cutter (not illustrated) may be inserted through the well casing 80 and operated to grind the downhole bridge plug 1a into fragments to remove the downhole bridge plug 1a from the well casing 80, as was heretofore described.
As illustrated in FIG. 28, an annular lower cone receptacle 274 may be provided in the end surface of the mandrel cap wall 14 of the mandrel cap 12 which faces the lower slip assembly 28a. An upper cone receptacle 276 may in like manner be provided in the end surface of the mandrel base 3 of the mandrel 2 which faces the upper slip assembly 28b. The lower cone receptacle 274 and the upper cone receptacle 276 may be configured to receive and accommodate the lower cone 72a and the upper cone 72b, respectively, in the expanded configuration of the downhole bridge plug 1a.
As illustrated in FIG. 28A, during their removal from the well casing 80, the downhole bridge plugs 1a may sequentially drop in the well casing 80 as each downhole bridge plug 1a is drilled or cut and consequently disengages the interior surface of the well casing 80. Accordingly, the partially removed downhole bridge plug 1a which is being cut may drop in the well casing 80 such that the mandrel cap lock 18a on the mandrel cap 12 of the partially-cut downhole bridge plug 1a engages and interlocks with the companion tool lock 18b on the mandrel 2 of the next succeeding, typically lower downhole bridge plug 1a. Thus, the downhole bridge plugs 1a will not rotate relative to each other as cutting continues to remove the downhole bridge plugs 1a from the well casing 80. This feature may also characterize the downhole bridge plugs 1 which were heretofore described with respect to FIGS. 1-26 in their removal from the well casing 80.
While the preferred embodiments of the disclosure have been described above, it will be recognized and understood that various modifications can be made in the disclosure and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the disclosure.
Patent Grant
10309189
