The present disclosure generally relates to tools used for isolation in well bores. More particularly, the present disclosure relates to downhole plug assemblies with collet adapters and methods thereof.
Technological innovations in the oil and gas industry are primarily focused on the Exploration and Production (E & P) business. Due to low permeability in the shale rocks and tight sands deep under the ground, it is extremely difficult to drill and stimulate production of crude oil otherwise popularly known as “black gold”. Hence the unconventional directional drilling associated with the Plug and Perf operations and the hydraulic fracturing process has been getting popularity from the wildcat wells to promising drill pads. Composite materials have replaced metals in various engineering applications owing to their numerous advantages, like high strength/weight ratio and other better physical properties. Due to these advantages, there has been an increasing demand for use of these materials in manufacturing frac plugs. Due to its lesser weight, the plug can be deployed with a faster speed, in addition, the milling time could be lesser compared to the metal based frac plugs.
Hydraulic fracturing has been of late getting lots of interests in the gas exploration and production process. It is a gas well stimulation and extraction technique designed for areas underlain by large shale formations found a mile or more below the ground surface.
Frac/Bridge plugs are deployed deep under the ground after the casing has already cemented in place. They are set at appropriate chosen locations using Baker #10 or Baker #20 setting tool, depending on the casing size and plug size. In the conventional prior art setting process, generally the plugs are set either by shearing the thread or by shearing the pins. Threads are either sheared externally or internally with respect to the mandrel. An axial force is applied to a composite mandrel in direction parallel to the axis of its bore, during which the elastomer seals the casing followed by slips biting the casing.
Conventional methods of installing the plugs onto the setting tool typically involve fastening the setting sleeve and the adapter to the plug by screws on the rig floor. Given the number of plugs (about 50 to 200 plugs per perf & frac operation in each well) used in the hydraulic fracturing process, this installing process itself becomes time consuming.
In the light of aforementioned discussion, there is a need for downhole plug assemblies which require lesser time for installation and are easier to install as well. The present invention discloses downhole plug assemblies with collet mechanisms that are easier and faster to install onto the setting tool and methods thereof. A collet adapter attached to the setting tool simply snaps onto a release sleeve of the downhole plug assembly during the installation on the rig floor without any need for fastening the plug with the setting tool by means of screws thus saving time. Further, after the downhole setting of the plugs, shearable screws coupling the release sleeve with the mandrel of the plug shear off during the release process without leaving any debris within the bore of the plug. Another advantage of the present invention is that the fiber composite mandrel does not experience substantial internal stress or does not need to have a high tensile strength, like that of the other plugs that undergo conventional shearing methods. Thus, the fiber composite mandrel need not be manufactured exclusively by filament winding process but can be made by a simple economical process.
The following presents a simplified summary of the disclosure in order to provide a basic understanding to the reader. This summary is not an extensive overview of the disclosure and it does not identify key/critical elements of the invention or delineate the scope of the invention. Its sole purpose is to present some concepts disclosed herein in a simplified form as a prelude to the more detailed description that is presented later.
Exemplary embodiments of the present disclosure are directed towards downhole plug assemblies. The downhole plug assembly comprises of a plug, an annular release sleeve and a collet adapter. The plug comprises of a substantially cylindrical central mandrel and a substantially cylindrical hollow outer subassembly disposed circumferentially around the central mandrel. The mandrel has a proximal portion configured to be oriented up hole, a distal portion configured to be oriented downhole and a substantially longitudinal bore. The proximal portion has a plurality of apertures disposed circumferentially, the apertures extending perpendicular to the longitudinal axis of the bore and being engaged with shearable fastening members. The outer subassembly comprises of an annular top element that is disposed circumferentially around the proximal portion, one or more of anchoring system disposed circumferentially around the mandrel for securely engaging the plug with a casing in a well bore, an expandable sealing system disposed circumferentially around the mandrel for sealing the gap between an outer surface of the plug and the casing and an annular nose element disposed circumferentially around the distal portion.
The release sleeve has a first end that is configured to be oriented up hole and a second end configured to be oriented downhole. The release sleeve has a constant outer diameter and a progressively tapering inner diameter with the inner diameter at the second end being lesser than the inner diameter at the first end. The release sleeve has an external and an internal surface with the external surface having a lesser length than the internal surface. The second end has a slanting face sloping towards the first end. The release sleeve has one or more receiving members that are configured for receiving and engaging a plurality of shearable fastening members. The release sleeve is releasably engaged and secured within the bore at the proximal portion by a plurality of the shearable fastening members. The release sleeve engaged with the plug forms a plug subassembly.
The collet adapter has an upper end that is configured to be oriented up hole and a lower end that is configured to be oriented downhole. The collet adapter is configured to be an adapter between a setting tool and the plug subassembly. The upper end is configured to be engaged with the setting tool. The lower end has a plurality of fingers separated by slots with each finger ending in a head at the tip. The collet adapter is slidable through the progressively tapering inner diameter of the release sleeve to compress and then snap into an engaging position where a lower surface of each head engages the face. The collet fingers are radially expandable to securely engage the sloping face upon application of a predetermined load greater than a predetermined setting load thus transferring the load to the release sleeve and then to the shearable fastening members causing the fastening members to shear and the release sleeve to release from the mandrel.
Other exemplary embodiments of the present subject matter are directed towards methods for installing, setting and releasing a plug for isolation in a well bore. The method begins with the step of providing a plug subassembly comprising a plug and an annular release sleeve. The plug and release sleeve have a conformation as described in the previous paragraphs. This is followed by providing a collet adapter with a conformation as described in the previous paragraphs. The next step is to install the plug subassembly onto the setting tool by sliding the collet adapter through the progressively tapering inner diameter of the release sleeve thus compressing and snapping the collet adapter into an engaging position wherein a lower surface of each head engages the slanting face of the release sleeve. This is followed by deploying the downhole plug subassembly engaged with the setting tool downhole to a predetermined location. Then a setting sleeve that is engaged with a setting tool at a first end and the top element at the second end is actuated with a predetermined setting load. This pushes the top element and sets the plug, wherein the anchoring system engages the plug with the casing and the sealing system seals the gap between the outer surface of the plug and the casing. Finally a predetermined load greater than the setting load is applied thus pulling the collet adapter. The collet fingers radially expand to securely engage the sloping face thereby transferring the load to the release sleeve and then to the shearable fastening members causing the fastening members to shear and the release sleeve thereof to release from the mandrel.
It is an object of the present invention to disclose downhole plug assemblies that are easier and faster to install onto the setting tool. For installing this plug assembly there is no need for threading or securing with set screws or for any special tool. A simple push with bare hands is enough to snap the collet adapter in place for installation. Thus the set up time on the rig floor is highly reduced.
It is another object of the present invention to disclose downhole plug assemblies that do not leave any debris within the bore of the plugs during the release process. The sheared debris will be pulled up to the ground along with the setting tool. A clean borehole is left behind for the free flow of material or for the frac ball to seat.
It is another object of the present invention to disclose downhole plug assemblies with fiber composite plugs that need not have a high tensile strength since the plug material itself does not undergo shearing during the release process.
It is another object of the present invention to disclose robust collet adapters that can be reused multiple times as it is never loaded beyond its strength.
Furthermore, the objects and advantages of this invention will become apparent from the following description and the accompanying annexed drawings.
Other objects and advantages of the present invention will become apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments, in conjunction with the accompanying drawings, wherein like reference numerals have been used to designate like elements, and wherein:
It is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The present disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
The use of “including”, “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. Further, the use of terms “first”, “second”, and “third”, and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.
According to different non limiting exemplary embodiments of the present disclosure, downhole plug assemblies for oil and gas wellbores are disclosed.
In accordance with different non limiting exemplary embodiments of the present subject matter, methods for installing, setting and releasing plugs for isolation in oil and gas well bores are disclosed.
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The downhole plug assembly 100 comprises of a plug 102, an annular release sleeve 108 and a collet adapter 112. The plug 102 comprises of a substantially cylindrical central mandrel 104 and a substantially cylindrical hollow outer subassembly 106 disposed circumferentially around the central mandrel 104. The mandrel 104 has a proximal portion 962 configured to be oriented up hole, a distal portion 964 configured to be oriented downhole and a substantially longitudinal bore 116. The proximal portion 962 has a plurality of apertures 128 disposed circumferentially, the apertures 128 extending perpendicular to the longitudinal axis of the bore 116 and being engaged with shearable fastening members. The outer subassembly 106 comprises of an annular top element 118 that is disposed circumferentially around the proximal portion 962, one or more of anchoring system disposed circumferentially around the mandrel 104 for securely engaging the plug 102 with a casing in a well bore, an expandable sealing system disposed circumferentially around the mandrel 104 for sealing the gap between an outer surface 107 of the plug 102 and the casing and an annular nose element 124 disposed circumferentially around the distal portion 964. The plug is preferably made of fiber composite material though metal plugs or plugs made partly of metal and partly of composite material can also be used in the assembly without limiting the scope of the present disclosure.
The release sleeve 108 has a first end 144 that is configured to be oriented up hole and a second end 146 that is configured to be oriented downhole. The release sleeve 108 has a constant outer diameter and a progressively tapering inner diameter with the inner diameter at the second end 146 being lesser than the inner diameter at the first end 144. The release sleeve 108 has an external 140 and an internal surface 142 with the external surface 140 having a lesser length than the internal surface 142. The second end 146 has a slanting face 132 sloping towards the first end 144. The release sleeve 108 has one or more receiving members that are configured for receiving and engaging a plurality of shearable fastening members. The receiving member can be a blind hole, a through hole or a circumferential groove without limiting the scope of the present disclosure. The release sleeve 108 is releasably engaged and secured within the bore 116 at the proximal portion 962 by a plurality of the shearable fastening members. The release sleeve engaged with the plug forms a plug subassembly.
The collet adapter 112 has an upper end 156 that is configured to be oriented up hole and a lower end 158 that is configured to be oriented downhole. The collet adapter 112 is configured to be an adapter between a setting tool and the plug subassembly. The upper end 156 is configured to be engaged with the setting tool. The lower end 158 has a plurality of fingers 138 separated by slots 160 with each finger 138 ending in a head 136 at the tip. The collet adapter 112 is slidable through the progressively tapering inner diameter of the release sleeve 108 to compress and then snap into an engaging position where a lower surface 134 of each head 136 engages part of the face 132. The collet fingers 138 are radially expandable to securely engage the sloping face 132 upon application of a predetermined load greater than a predetermined setting load thus transferring the load to the release sleeve 108 and then to the shearable fastening members causing the fastening members to shear and the release sleeve 108 to release from the mandrel 104. In some embodiments, the collet adapters are made of alloy steel though collet adapters made of any other suitable material with sufficient strength can also be used without limiting the scope of the present disclosure.
In some embodiments, the shearable fastening members that engage the mandrel and the release sleeve are shearable screws, though any other shearable fastening members such as pins can be used without limiting the scope of the present disclosure. In some embodiments, the shearable fastening members are made of brass though fastening members made of steel alloy, fiberglass or any other suitable material that can shear upon application of predetermined load can also be used without limiting the scope of the present disclosure. The choice of the material depends on strength requirements also. In some embodiments, the number of shearable fastening members used to engage the mandrel with the release sleeve is eight but the number can vary depending on the shear force used to set the plug. In other words, the shear load can be varied as per requirement by altering the number of screws used to hold the release sleeve within the mandrel.
In some embodiments, the plug further comprises of anti-preset means to prevent the plug from setting prior to the application of a predetermined setting load. The anti-preset means are one or more of shearable fastening members such as screws that shear off upon application of a predetermined setting load.
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In some other embodiments, the shearable screw is threaded only at a top portion of the stem which is engaged with the aperture and the lower portion of the stem is unthreaded. In such cases, the inner surface of the aperture in the mandrel is accordingly configured to threadably engage the screw.
In some embodiments, the shearable fastening member is a pin fastener that engages the aperture of the mandrel and the receiving member of the release sleeve by adhesive means or tight fit.
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Other exemplary embodiments of the present subject matter are directed towards methods for installing, setting and releasing a plug for isolation in a well bore. The method begins with the step of providing a plug subassembly comprising a plug and an annular release sleeve. The plug and release sleeve have conformations as described in the previous paragraphs. This is followed by providing a collet adapter with conformations as described in the previous paragraphs. The next step is to install the plug subassembly onto the setting tool by sliding the collet adapter engaged with the setting tool through the progressively tapering inner diameter of the release sleeve thus compressing and snapping the collet adapter into an engaging position wherein a lower surface of each head engages the slanting face of the release sleeve. This is followed by deploying the downhole plug assembly engaged with the setting tool downhole to a predetermined location. Then a setting sleeve that is engaged with a setting tool at a top end and the top element at the bottom end is actuated with a predetermined setting load. This pushes the top element and sets the plug, wherein the anchoring system engages the plug with the casing and the sealing system seals the gap between the outer surface of the plug and the casing. Finally a predetermined load greater than the setting load is applied thus pulling the collet adapter. The collet fingers radially expand to securely engage the sloping face thereby transferring the load to the release sleeve and then to the shearable fastening members causing the fastening members to shear and the release sleeve thereof to release from the mandrel.
Although the present disclosure has been described in terms of certain preferred embodiments and illustrations thereof, other embodiments and modifications to preferred embodiments may be possible that are within the principles and spirit of the invention. The above descriptions and figures are therefore to be regarded as illustrative and not restrictive.
Thus the scope of the present disclosure is defined by the appended claims and includes both combinations and sub combinations of the various features described herein above as well as variations and modifications thereof, which would occur to persons skilled in the art upon reading the foregoing description.