Patent Application
20170022781
There are various methods by which openings are created in a production liner for injecting fluid into a formation. In a “plug and perf” frac job, the production liner is made up from standard lengths of casing. Initially, the liner does not have any openings through its sidewalls. The liner is installed in the wellbore, either in an open bore using packers or by cementing the liner in place, and the liner walls are then perforated. The perforations are typically created by perforation guns that discharge shaped charges through the liner and, if present, adjacent cement.
The production liner is typically perforated first in a zone near the bottom of the well. Fluids then are pumped into the well to fracture the formation in the vicinity of the perforations. After the initial zone is fractured, a plug is installed in the liner at a position above the fractured zone to isolate the lower portion of the liner. The liner is then perforated above the plug in a second zone, and the second zone is fractured. This process is repeated until all zones in the well are fractured.
The plug and perf method is widely practiced, but it has a number of drawbacks, including that it can be extremely time consuming. The perforation guns and plugs are generally run into the well and operated individually. After the frac job is complete, the plugs are removed (e.g., drilled out) to allow production of hydrocarbons through the liner.
Embodiments of the disclosure may provide a downhole tool that includes an expandable sleeve defining a bore therethrough, and a first body positioned at least partially within the bore of the expandable sleeve. The first body is slidable relative to the expandable sleeve, and sliding the first body along the bore of the expandable sleeve causes the expandable sleeve to radially expand so as to actuate the downhole tool from a run-in configuration to a set configuration. The downhole tool also includes an isolation device received at least partially in the expandable sleeve in the set configuration. A pressure on the isolation device is at least partially transmitted to the expandable sleeve as a radially-outward force.
Embodiments of the disclosure may also provide a downhole tool that includes an expandable sleeve having a lower axial portion and an upper axial portion. A thickness of the lower axial portion of the expandable sleeve increases proceeding in a first axial direction, and a thickness of the upper axial portion of the expandable sleeve decreases proceeding in the first axial direction. The downhole tool also includes a first swage positioned in the upper or lower axial portion of the expandable sleeve, such that moving the first swage in an axial direction in the expandable sleeve causes the expandable sleeve to at least partially expand.
Embodiments of the disclosure may further provide a method that includes running a downhole tool into a wellbore. The downhole tool includes an expandable sleeve defining a bore therethrough, and a first body positioned at least partially within the bore of the expandable sleeve. The first body is slidable relative to the expandable sleeve, and sliding the first body along the bore of the expandable sleeve causes the expandable sleeve to radially expand so as to actuate the downhole tool from a run-in configuration to a set configuration. The method also includes expanding the expandable sleeve using the first body, and deploying an isolation device into the wellbore. The isolation device engages the downhole tool and applies a radial-outward force on the expandable sleeve. The method also includes performing a fracturing operation uphole of the downhole tool, after deploying the isolation device.
The foregoing summary is intended merely to introduce some aspects of the following disclosure and is thus not intended to be exhaustive, identify key features, or in any way limit the disclosure or the appended claims.
The present disclosure may best be understood by referring to the following description and accompanying drawings that are used to illustrate embodiments of the invention. In the drawings:
The following disclosure describes several embodiments for implementing different features, structures, or functions of the invention. Embodiments of components, arrangements, and configurations are described below to simplify the present disclosure; however, these embodiments are provided merely as examples and are not intended to limit the scope of the invention. Additionally, the present disclosure may repeat reference characters (e.g., numerals) and/or letters in the various embodiments and across the Figures provided herein. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed in the Figures. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact. Finally, the embodiments presented below may be combined in any combination of ways, e.g., any element from one exemplary embodiment may be used in any other exemplary embodiment, without departing from the scope of the disclosure.
Additionally, certain terms are used throughout the following description and claims to refer to particular components. As one skilled in the art will appreciate, various entities may refer to the same component by different names, and as such, the naming convention for the elements described herein is not intended to limit the scope of the invention, unless otherwise specifically defined herein. Further, the naming convention used herein is not intended to distinguish between components that differ in name but not function. Additionally, in the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.” All numerical values in this disclosure may be exact or approximate values unless otherwise specifically stated. Accordingly, various embodiments of the disclosure may deviate from the numbers, values, and ranges disclosed herein without departing from the intended scope. In addition, unless otherwise provided herein, “or” statements are intended to be non-exclusive; for example, the statement “A or B” should be considered to mean “A, B, or both A and B.”
The setting sleeve 110 may be substantially cylindrical and may have a bore 112 formed axially-therethrough. An outer surface 114 of the setting sleeve 110 may include a tapered portion 116 proximate to (e.g., extending from) a lower axial end 118 of the setting sleeve 110. More particularly, a thickness of the tapered portion 116 may decrease proceeding toward the lower axial end 118.
The inner body 120 may be positioned within the bore 112 of the setting sleeve 110 and may be movable with respect thereto. The inner body 120 may include an outer shoulder 122 that contacts an inner surface 115 of the setting sleeve 110, so as to guide the movement of the inner body 120. The inner body 120 may also define an axial bore 124 formed at least partially therethrough, proximate to a lower axial end 126 of the inner body 120. An inner surface 128 of the inner body 120 that defines the bore 124 may be threaded.
The first body 130 may be coupled to the inner body 120 proximate to the lower axial end 126 of the inner body 120. The first body 130 may have a bore formed axially-therethrough, in which the inner body 120 of the setting tool may be at least partially received. An inner surface of the first body 130 that defines the bore may include a protrusion (e.g., an annular protrusion) 132 that extends radially-inward therefrom. The protrusion 132 may be integral with the first body 130, or the protrusion 132 may be part of a separate component that is coupled to, or positioned within a recess in, the first body 130. The inner body 120 may abut against the protrusion 132.
The first body 130 may be at least partially tapered. For example, the first body 130 may expand in radial dimension (e.g., in a direction perpendicular to an axial direction parallel to a central longitudinal axis through the tool 100) from the upper axial end to an axially intermediate point, and then reduce to a lower axial end. In other embodiments, the first body 130 may have a section that increases in radial dimension, but may omit the section of decreasing radial dimension. Consistent with such tapered geometry, the first body 130 may be formed as a truncated cone, a truncated sphere, another shape, or a combination thereof.
A locking mechanism 150 may be coupled to the inner body 120 and/or the first body 130. The locking mechanism may be, for example, a bolt or screw, and may include a shank 152 and a head 154. The shank 152 may be received through the bore of the first body 130 and at least partially into the bore 124 of the inner body 120, e.g., threaded thereto, such that the protrusion 132 of the first body 130 is positioned between the lower axial end 126 of the inner body 120 and the head 154 of the locking mechanism 150. In other embodiments, the shank 152 may be otherwise attached to the inner body 120, e.g., the shank 152 may be pinned, adhered, soldered, welded, brazed, etc., to the inner body 120.
The expandable sleeve 160 may be positioned at least partially axially between the tapered portion 116 of the setting sleeve 110 and the first body 130. The expandable sleeve 160 may be positioned radially-outward from the tapered portion 116 of the setting sleeve 110, the inner body 120, the first body 130, or a combination thereof. An outer surface 162 of the expandable sleeve 160 may be configured to set in a surrounding tubular member (e.g., a liner, a casing, a wall of a wellbore, etc.).
In some embodiments, to set the expandable sleeve 160, the outer surface 162 may form a high-friction interface with the surrounding tubular, e.g., with sufficient friction to avoid axial displacement of the expandable sleeve 160 with respect to the surrounding tubular, once set therein. In an embodiment, the outer surface 162 may be applied with, impregnated with, or otherwise include grit. For example, such grit may be provided by a carbide material. Illustrative materials on the outer surface 162 of the expandable sleeve 160 may be found in U.S. Pat. No. 8,579,024, which is incorporated by reference herein in its entirety to the extent not inconsistent with the present disclosure. In other embodiments, the outer surface 162 may include teeth or wickers designed to bite into (e.g., partially embed in) the surrounding tubular when set.
The expandable sleeve 160 may include a first, upper axial portion 164 and a second, lower axial portion 166. One or both of the first and second axial portions 164, 166 may be tapered, such that the thickness thereof varies along the axial length thereof. For example, the inner diameter of the expandable sleeve 160 may decrease in the first axial portion 164, as proceeding toward a lower axial end 168 of the expandable sleeve 160, while the outer diameter may remain generally constant. Similarly, the inner diameter of the expandable sleeve 160 in the second axial portion 166 may increase as proceeding toward the lower axial end 168, while the outer diameter remains generally constant. Accordingly, in some embodiments, an inner surface 170 of the expandable sleeve 160 may be oriented at an angle with respect to a central longitudinal axis through the downhole tool 100. For example, the inner surface 170 may be oriented at a first angle in the first axial portion 164 and a second angle in the second axial portion 166. Both angles may be acute, for example, from about 5° to about 20°, about 10° to about 30°, or about 15° to about 40°.
The first body 130 may be positioned at least partially, radially between the expandable sleeve 160 (on one side) and the inner body 120 and/or the locking mechanism 150 (on the other side). For example, an outer surface 134 of the first body 130 may be configured to slide against the inner surface 170 of the expandable sleeve 160. In addition, the first body 130 may be positioned proximate to the lower axial end 168 of the expandable sleeve 160, e.g., at least partially within the expandable sleeve 160, when the downhole tool 100 is in the first, run-in configuration. The first body 130 may be configured to remain in the expandable sleeve 160 after the setting tool is removed, as will be described in greater detail below.
The method 200 includes running a downhole tool (e.g., the downhole tool 100) into a wellbore in a first, run-in configuration, as at 202, and as shown in and described above with respect to
The force required to pull the inner body 120, the first body 130, and the locking mechanism 150 in the uphole direction (or to maintain the position thereof while the setting sleeve 110 pushes the expandable sleeve 160 downwards) may increase as the first body 130 moves in the uphole direction due to the decreasing diameter of the inner surface 170 of the lower axial portion 166 of the expandable sleeve 160 (proceeding in the uphole direction). When the force reaches or exceeds a predetermined amount, a portion of the downhole tool 100, e.g., the protrusion 132, may shear, thereby releasing the inner body 120 from the first body 130.
In another embodiment, rather than the protrusion 132 shearing, the threaded engagement between the inner body 120 and the locking mechanism 150 may shear, allowing the inner body 120 to be pulled back to the surface, while the first body 130 remains positioned within the expandable sleeve 160. In this embodiment, the locking mechanism 150 may fall into the sump of the wellbore. In yet another embodiment, the inner body 120 may be coupled (e.g., threaded) to the inner surface of the first body 130, and the locking mechanism 150 may be omitted. In this embodiment, the threaded engagement between the inner body 120 and the first body 130 may shear, allowing the inner body 120 to be pulled back to the surface, while the first body 130 remains positioned within the expandable sleeve 160. In other embodiments, the inner body 120 and/or the locking mechanism 150 may yield, allowing the inner body 120 to be retrieved from the wellbore.
The method 200 may also include perforating a surrounding tubular with a perforating gun, as at 206. The surrounding tubular may be the tubular that the expandable sleeve 160 engages and bites into. In at least one embodiment, the surrounding tubular may be perforated after the expandable sleeve 160 expands and contacts the surrounding tubular.
The method 200 may also include introducing an isolation device 180, such as a ball into the wellbore, where the isolation device 180 is received in the expandable sleeve 160, as at 208. The isolation device 180 may have any suitable shape (spherical or not) employed to be caught by a seat so as to obstruct fluid communication in a wellbore.
The method 200 may also include increasing a pressure of a fluid in the wellbore, as at 210. The isolation provided by the expandable sleeve 160 and the isolation device 180 may allow the pressure uphole of the expandable sleeve 160 and isolation device 180 to be increased (e.g., using a pump at the surface), while the wellbore below the expandable sleeve 160 and the isolation device 180 may be isolated from such pressure increase. The increased pressure may cause the subterranean formation around the wellbore, above the expandable sleeve 160 and isolation device 180, to fracture. This may take place after perforation occurs.
In at least one embodiment, the first body 130, the expandable sleeve 160, and/or the isolation device 180 may be made of a material that dissolves after a predetermined amount of time in contact with a liquid in the wellbore. The predetermined amount of time may be from about 6 hours to about 12 hours, from about 12 hours to about 24 hours, from about 1 day to about 2 days, from about 2 days to about 1 week, or more. In one specific embodiment, the isolation device 180 may be made of a material the dissolves after the predetermined amount of time, and the first body 130 and the expandable sleeve 160 may be made of a metal, such as aluminum, that does not dissolve after the predetermined amount of time. In some embodiments, the expandable sleeve 160 may be made at least partially from a metal (e.g., aluminum), while the first body 130 and/or the isolation device 180 may be made from a dissolvable material (e.g., magnesium), such that the sleeve 160 may remain substantially intact after the dissolvable material is dissolved. Further, in some embodiments, all or a portion of a surface of any dissolvable component may include grooves, or other structures configured to increase a surface area of the surface, so as to increase the rate of dissolution.
For example, the first body 740 may be positioned near an upper axial end 767 of the expandable sleeve 160 and adjacent to the setting sleeve 710 when the downhole tool 700 is in the first, run-in position. The setting sleeve 710 may thus be configured to engage and bear upon the first body 740, e.g., in a downhole direction, toward the expandable sleeve 760.
Optionally, an outer surface 714 of the setting sleeve 710 may include the tapered portion 716 proximate to the lower axial end 718 thereof. More particularly, a thickness of the tapered portion 716 may decrease proceeding toward the lower axial end 718. An inner surface 742 of the first body 740 may also be tapered, such that engagement between the setting sleeve 710 and the first body 740 is effected through the tapered interface therebetween. As a further option, the outer surface 714 of the setting sleeve 710 may also include a shoulder 719 that extends radially-outward from the tapered portion 716, and the inner surface 742 of the first body 740 may include a shoulder to engage the shoulder 719. In other embodiments, however, the interface between the first body 740 and the setting sleeve 710 may be generally perpendicular to the central longitudinal axis of the tool 700 (e.g., straight radial), and such tapered surfaces may be substituted with flat surfaces.
The first body 740 may be received at least partially within the upper axial end 767 the expandable sleeve 760. As such, the first body 740 may be positioned at least partially, radially between the inner body 720 and the expandable sleeve 760. Further, at least a portion of the first body 740 may be tapered (e.g., curved or conical, as described above) such that the diameter of an outer surface 744 of the first body 740 decreases proceeding toward the lower axial end of the first body 740.
The second body 730 may be positioned at least partially within a lower axial end 768 of the expandable sleeve 760, opposite to the first body 740. The second body 730 may have a bore formed axially-therethrough, in which the inner body 720 may be at least partially received. An inner surface of the second body 730 that defines the bore may include a protrusion (e.g., an annular protrusion) 732 that extends radially-inward therefrom. The protrusion 732 may be integral with the second body 730 or part of a separate component that is coupled to, or positioned within a recess in, the second body 730. The second body 730 may be tapered such that a diameter of an outer surface 734 of the second body 730 increases proceeding toward a lower axial end of the second body 730.
The tool 700 may also include a locking mechanism 750, which may be or include a screw or both, and may thus include a head 754 and a shank 752. In some embodiments, the shank 752 may be threaded. Further, the shank 752 may be sized to engage threads within a bore formed in the lower axial end 726 of the inner body 720, or otherwise form an engagement with the inner body 720.
The protrusion 732 of the second body 730 may be positioned axially-between the lower axial end 726 of the inner body 720 and the head 754 of the locking mechanism 750. When the inner body 720 is engaged with the locking mechanism 750, the second body 730 may be secured in place between the inner body 720 and the head 754 of the locking mechanism 750.
The expandable sleeve 760 may be positioned at least partially, axially-between the second body 730 and the first body 740. Further, the expandable sleeve 760 may be positioned radially-outward from the inner body 720, the second body 730, the first body 740, or a combination thereof. The upper axial portion 764 of the expandable sleeve 760 may be tapered such that a thickness of the upper axial portion 764 of the expandable sleeve 760 decreases proceeding toward the upper axial end 767 of the expandable sleeve 760. A lower axial portion 766 may be reverse tapered in comparison to the upper axial portion 764, such that the radial thickness of the expandable sleeve 760 decreases as proceeding toward the lower axial end 768 thereof.
In some embodiments, one or more of the first body 730, the second body 740, the expandable sleeve 760, and/or the isolation device 780 or 782 may be dissolvable after a predetermined amount of time within the wellbore. For example, such component(s) may be made at least partially from magnesium. In some embodiments, the expandable sleeve 760 may be made from a material that does not dissolve in a certain fluid, while the first body 730, the second body 740, the isolation devices 780 or 782, or any combination thereof, is made from a material that dissolves in the fluid, such that the expandable sleeve 760 may remain intact after the dissolvable material is dissolved. Further, in some embodiments, all or a portion of a surface of any dissolvable component may include grooves, or other structures configured to increase a surface area of the surface, so as to increase the rate of dissolution.
The method 800 may also include moving a first portion of a setting tool and an expandable sleeve axially with respect to a second portion of the setting tool and a swage, as at 804. For example, the inner body 720 may be pulled uphole, while the setting sleeve 710 may be pushed downhole. In turn, the inner body 720 may pull the second body 730, and thus the expandable sleeve 760 uphole, while the setting sleeve 710 may prevent movement of the first body 740, or may even push the first body 740 downhole. This may cause the expandable sleeve 760 to move over the first body 740, which may result in at least a portion of the expandable sleeve 760 being expanded radially-outward by the first body 740 as the first body 740 slides across the tapered inner surface 770. Accordingly, the expandable sleeve 760 may be actuated into a set position, e.g., in which the expandable sleeve 760 engages a surrounding tubular.
In some embodiments, to set the expandable sleeve 760, the outer surface 762 may form a high-friction interface with the surrounding tubular, e.g., with sufficient friction to avoid axial displacement of the expandable sleeve 760 with respect to the surrounding tubular, once set therein. In an embodiment, the outer surface 762 may be applied with, impregnated with, or otherwise include grit. For example, such grit may be provided by a carbide material or another type of material. Illustrative materials on the outer surface 762 of the expandable sleeve 760 may be found in U.S. Pat. No. 8,579,024, which is incorporated by reference above. In other embodiments, the outer surface 762 may include teeth or wickers designed to bite into (e.g., partially embed in) the surrounding tubular when set.
The force required to pull the inner body 720, the second body 730, the locking mechanism 750, and the expandable sleeve 760 in the uphole direction may increase as the expandable sleeve 760 moves in the uphole direction with respect to the first body 740 due to the decreasing diameter of the inner surface 770 of the upper axial portion 764 of the expandable sleeve 760 (proceeding in the downhole direction). When the force reaches or exceeds a predetermined amount, a portion of the downhole tool 700, e.g., the protrusion 732, may shear. The setting tool may then be removed, while the first body 740 remains in the expandable sleeve 760, continuing to provide a radially-outward force thereon which causes the expandable sleeve 760 to remain in an expanded, set configuration.
Referring back to
The method 800 may also include introducing the isolation device 780 into a wellbore, as at 808. As shown in
Referring back to
In at least one embodiment, the first body 740, the expandable sleeve 760, and/or the isolation device 780, 782 may be made of a material that dissolves after a predetermined amount of time in contact with a liquid in the wellbore. The predetermined amount of time may be from about 6 hours to about 12 hours, from about 12 hours to about 24 hours, from about 1 day to about 2 days, from about 2 days to about 1 week, or more. In some embodiments, the expandable sleeve 760 may be made at least partially from a metal (e.g., aluminum), while the first body 740 and/or the isolation device 780 or 782 may be made from a dissolvable material (e.g., magnesium), such that the sleeve 760 may remain substantially intact after the dissolvable material is dissolved. Further, in some embodiments, all or a portion of a surface of any dissolvable component may include grooves, or other structures configured to increase a surface area of the surface, so as to increase the rate of dissolution.
For example, the first body 1330 may be positioned proximate to a lower axial end 1326 of the inner body 1320 and a lower axial end 1368 of the expandable sleeve 1360. The first body 1330 may have a bore formed axially-therethrough, and the inner body 1320 may be received at least partially therein. An outer surface 1334 of the first body 1330 may be tapered such that a cross-sectional width of the outer surface 1334 of the first body 1330 decreases proceeding toward the upper axial end of the first body 1330. As such, the outer surface 1334 of the first body 1330 may be oriented at an acute angle with respect to the central longitudinal axis through the downhole tool 1300.
The second body 1340 may be positioned proximate to the upper axial end 1367 of the expandable sleeve 1360, opposite to the first body 1330. Further, the second body 1340 may be positioned adjacent to a lower axial end 1318 of the setting sleeve 1310. Optionally, the setting sleeve 1310 and the second body 1340 may form a tapered engagement therebetween. For example, the second body 1340 may include an inner surface 1342 that is tapered at substantially the same angle as a tapered portion 1316 of the setting sleeve 1310. As an additional option, an upper axial end of the second body 1340 may abut (e.g., directly or indirectly) a shoulder 1319 of the setting sleeve 1310.
Further, the second body 1340 may have a bore formed axially-therethrough, through which the inner body 1320 may pass. At least a portion of an outer surface 1344 of the second body 1340 may be tapered (conical or spherical) such that the cross-sectional width (e.g., diameter) of the outer surface 1344 of the second body 1340 decreases proceeding toward the lower axial end of the second body 1340.
A shear ring 1336 may be positioned within a recess in the first body 1330. The shear ring 1336 may include the protrusion 1338 that is positioned axially-between the lower axial end 1326 of the inner body 1320 and a head 1354 of a locking mechanism 1350. The locking mechanism 1350 may also include a shank 1352 that may be attached to the lower axial end 1326 of the inner body 1320.
The expandable sleeve 1360 may thus be positioned at least partially axially-between the first and second bodies 1330, 1340 when the downhole tool 1300 is in the first, run-in position. Further, the expandable sleeve 1360 may be positioned radially-outward from the inner body 1320, the first and second bodies 1330, 1340, or a combination thereof.
The upper axial portion 1364 of the sleeve 1360 may be tapered. As such, a thickness of the upper axial portion 1364 of the sleeve 1360 may decrease proceeding toward the upper axial end 1367 of the sleeve 1360. The inner surface 1370 of the upper axial portion 1364 of the expandable sleeve 1360 may be oriented at an acute angle with respect to the central longitudinal axis through the downhole tool 1300.
The lower axial portion 1366 of the sleeve 1360 may also be tapered. As such, a thickness of the lower axial portion 1366 of the sleeve 1360 may decrease proceeding toward the lower axial end 1368 of the sleeve 1360. The inner surface 1370 of the lower axial portion 1366 of the sleeve 1360 may be oriented at an acute angle with respect to the central longitudinal axis through the downhole tool 1300. In an embodiment, the upper and lower axial portions 1364, 1366 may be oriented at substantially the same angles (but mirror images of one another).
The method 1400 may also include moving a first portion of a setting tool and a first swage axially with respect to a second portion of the setting tool and a second swage, as at 1404. This may actuate the sleeve 1360 radially-outward into a “set” position. For example, the first and second bodies 1330, 1340 may provide such first and second swages. Further, such moving may be effected by pulling the inner body 1320, the first body 1330, the locking mechanism 1350 and the expandable sleeve 1360 in an uphole direction, or by pushing the setting sleeve 1310, the second body 1340, and the expandable sleeve 1360 in a downhole direction, or both.
During such movement, the first and second bodies 1330 move with respect to the expandable sleeve 1360. The movement of the first body 1330 with respect to the expandable sleeve 1360 causes the lower axial portion 1366 of the expandable sleeve 1360 to expand radially-outward, while the movement of the second body 1340 with respect to the expandable sleeve 1360 causes the upper axial portion 1364 of the expandable sleeve 1360 to expand radially-outward.
In some embodiments, to set the expandable sleeve 1360, the outer surface 1362 may form a high-friction interface with the surrounding tubular, e.g., with sufficient friction to avoid axial displacement of the expandable sleeve 1360 with respect to the surrounding tubular, once set therein. In an embodiment, the outer surface 1362 may be applied with, impregnated with, or otherwise include grit. For example, such grit may be provided by a carbide material. Illustrative materials on the outer surface 1362 of the expandable sleeve 1360 may be found in U.S. Pat. No. 8,579,024, which is incorporated by reference above. In other embodiments, the outer surface 1362 may include teeth or wickers designed to bite into (e.g., partially embed in) the surrounding tubular when set.
The force required to move the first and second bodies 1330, 1340 with respect to the expandable sleeve 1360 may increase as the movement continues, due to the tapered inner surface 1370. When the force reaches or exceeds a predetermined amount, a portion of the downhole tool 1300, e.g., the shear ring 1336, may shear, releasing the inner body 1320 from the first body 1330. The first and second bodies 1330, 1340 may thus remain in the expandable sleeve 1360 after the setting tool is removed, such that the first and second bodies 1330, 1340 continue to provide a radially outward force on the expandable sleeve 1360, keeping the expandable sleeve 1360 in engagement with the surrounding tubular.
In another embodiment, the isolation device 1380 may be larger, and may be received by the expandable sleeve 1360, proximate to the first body 1330. The larger isolation device 1380 may also be sized to further radially expand the expandable sleeve 1360 by transmitting at least a portion of a force incident on the isolation device 1380 due to pressure in the wellbore to a radial outward force on the expandable sleeve 1360. As shown, the protrusion 1338 of the shear ring 1336 may shear, allowing the inner body 1320 and the locking mechanism 1350 to be pulled back to the surface, while the first and second bodies 1330, 1340 remain positioned within the sleeve 1360. In another embodiment, rather than the protrusion 1338 shearing, the threaded engagement between the inner body 1320 and the locking mechanism 1350 may shear, allowing the inner body 1320 to be pulled back to the surface, while the first and second bodies 1330, 1340 remain positioned within the sleeve 1360. In this embodiment, the locking mechanism 1350 may fall into the sump of the wellbore.
Referring back to
The method 1400 may also include introducing the isolation device 1380 into a wellbore, as at 1408. As shown in
Referring back to
In at least one embodiment, the first and second bodies 1330, 1340, the sleeve 1360, and/or the isolation device 1380 may be made of a material that dissolves after a predetermined amount of time in contact with a liquid in the wellbore. The predetermined amount of time may be from about 6 hours to about 12 hours, from about 12 hours to about 24 hours, from about 1 day to about 2 days, from about 2 days to about 1 week, or more. In some embodiments, the sleeve 1360 may be made from a material (e.g., aluminum) that does not dissolve in the liquid in the wellbore, while the first body 1130, the second body 1340, and/or the isolation device 1380 is made from a material (e.g., magnesium) that dissolves in the liquid, such that the sleeve 1360 may remain intact after the dissolvable material is dissolved.
In any of the foregoing embodiments, the isolation device received on either the expandable sleeve or the first or second body may be configured to come off of its seat, thereby allowing for flowback, uphole, through the downhole tool. This may facilitate introduction of fluids configured to dissolve the dissolvable components of the downhole tool in the wellbore. Further, the expandable sleeve and/or the first or second body may be ported, to allow for such fluid to pass, at a predetermined (low) flow rate past the isolation device, so as to facilitate dissolving the dissolvable component(s) of the tool. In addition, various process or techniques may be employed to increase the rate at which the dissolvable component(s) dissolve. For example, if the expandable sleeve is dissolvable, notches or cuts may be made in the inner surface thereof, which increase the surface area in contact with the wellbore fluids and thus increase the rate at which the sleeve dissolves. Further, in at least some embodiments, a sealing element (e.g., an elastomeric member) may be positioned around the expandable sleeve, e.g., on the outer surface thereof, to form a seal with the surrounding tubular, when the expandable sleeve is expanded. In some embodiments, all or a portion of a surface of any dissolvable component may include grooves, or other structures configured to increase a surface area of the surface, so as to increase the rate of dissolution.
Internally, the sleeve 1900 may include a profiled, e.g., tapered, interior surface or shoulder 1908 defined in the body 1902. In some embodiments, the shoulder 1908 may not be tapered but may extend straight in a radial direction or may be radiused.
In one embodiment, the body 1902 may be made from a dissolvable material, such as a dissolvable alloy or a dissolvable composite. The dissolvable material may be configured to dissolve over a predetermined amount of time or upon contact with a specific type of fluid. In other embodiments, the body 1902 may be made from a material, such as aluminum, that may not be configured to dissolve in the fluid. Further, in some embodiments, all or a portion of a surface of any dissolvable component may include grooves, or other structures configured to increase a surface area of the surface, so as to increase the rate of dissolution. As will be described herein, the sleeve 1900 is configured to be expanded from a first outer diameter to a second larger outer diameter upon application of a radial force.
As shown in
Although the illustrated embodiment depicts an embodiment in which the sleeve 1900 includes both the seal member 1904 and the engaging member 1906 on the body 1902, in another embodiment, the seal member 1904 and/or the engaging member 1906 may be optional and potentially omitted. In other words, the body 1902 of the sleeve 1900 may create a seal with the surrounding tubular upon expansion of the sleeve 1900 when the seal member 1904 is not used. Additionally, the body 1902 of the sleeve 1900 may grip the surrounding tubular upon expansion of the sleeve 1900 when the engaging member 1906 is not used.
The setting tool 2000 may also include a setting sleeve 2006 positioned around the body 2002. The setting sleeve 2006 may be positioned axially adjacent to the expandable sleeve 1900, opposite to the ramped surface 2004 and may abut the first end 1910 of the sleeve 1900. For example, in the run-in position, the sleeve 1900 may be disposed between the setting sleeve 2006 and the ramped surface 2004, which may prevent the sleeve 1900 from moving axially. In some embodiments, an amount of space may be provided between the expandable sleeve 1900 and either or both of the ramped surface 2004 and/or the setting sleeve 2006. Further, it will be appreciated that the illustrated setting tool is but one example among many, and other setting tools, such as one or more embodiments of the setting tools described above or others (e.g., rotary expanders) may be employed without departing from the scope of the present disclosure.
During activation of the setting tool 2000, the inner body 2002 may be pulled axially with respect to the sleeve 1900, e.g., in the direction indicated by arrow 2102. The body 2002 may be prevented from moving by an opposite force applied by the setting sleeve 2006. In other embodiments, the body 2002 may be stationary and the setting sleeve 2006 may push the sleeve 1900 axially with respect to the body 2005. In still other embodiments, both the setting sleeve 2006 and the body 2002 may be moved axially during setting.
Such relative movement causes the sleeve 1900 to move up the ramped surface 2004, beginning with the second end 1912 and at least partially, e.g., entirely, across the body 1902 to the first end 1910. As a result, the sleeve 1900 is radially expanded from a first outer diameter to a second, larger outer diameter. The ramped surface 2004 may thus be considered a swage. The second outer diameter may be at least as large as the inner diameter of the tubular 2100, and thus the sleeve 1900 may be pressed into engagement with an inner surface 2104 of the tubular 2100. Since the body 1902 (and the shoulder 1908) may be expanded when the sleeve 1900 is expanded, the shoulder 1908 may also increase in diameter correspondingly (potentially, but not necessarily to the same degree or proportionally).
When the sleeve 1900 engages the tubular 2100, the seal member 1904 may form a seal with the tubular 2100, and the engaging members 1906 may bite into or otherwise form a high-friction interface with the inner surface 2104 of the tubular 2100. After the sleeve 1900 is engaged with the tubular 2100, the setting tool 2000, which may have been moved axially through the sleeve 1900, may be removed from the tubular 2100.
The isolation device 2200 may be a ball, dart, or any other type of obstructing member that may be deployed into the wellbore. In an embodiment, the isolation device 2200 may be made from a dissolvable material, which may be configured to dissolve in the presence of a particular fluid (e.g., an acid) for a certain amount of time.
In operation, after the sleeve 1900 is placed within the tubular 2100, the tubular 2100 may be perforated using a perforating gun (not shown). Next, the isolation device 2200 is dropped or pumped into the wellbore and subsequently is received in the sleeve 1900. The isolation device 2200 is configured to cooperate with the sleeve 1900, e.g., the shoulder 1908, to close off the bore 2201 of the sleeve 1900. This may isolate regions of the wellbore uphole of the tool 1901 from those downhole of the tool 1900. Thus, frac fluid injected into the wellbore during a fracking operation may be directed through the perforations, rather than through the bore 2201 of the sleeve 1900.
Furthermore, during the fracking operation, the frac fluid may apply a pressure, which in turn applies a force, generally in the axial direction indicated by arrow 2202, on the isolation device 2200. As a result, the isolation device 2200 may apply a force, as indicated by arrow 2204, on the sleeve 1900. Since the isolation device 2200 bears against the shoulder 1908, which may be formed as a tapered or wedge-shaped structure (in cross-section), this axial force may be partially transferred to radially-outward force, as indicated by arrow 2206. Thus, increased pressure in the wellbore uphole of tool 1901 may serve to enhance the seal by the sealing member 1904 and/or the grip of the engaging members 1906 with the surrounding tubular 2100.
After the first fracking operation is complete, another sleeve may be run into the tubular 2100 at a location above the sleeve 1900, and the process may be repeated until several (e.g., all) of the zones in the wellbore are fractured. Each sleeve may be configured to receive the same size isolation device. As mentioned above, the isolation device 2200 may be made from a dissolvable material. Accordingly, after the fracking operation is complete, the isolation device 2200 may be removed by introducing the solvent thereto (or by waiting for a certain amount of time if the solvent is already present). Similarly, the sleeve 1900 itself may be dissolvable, and thus the sleeve 1900 may be removed by introducing a solvent thereto. In other embodiments, the sleeve 1900 may be removed by deploying a gripping member and attaching the gripping member to the sleeve and pulling the sleeve from the tubular. In another embodiment, the sleeve 1900 may be removed using a mill or drill bit.
For example, the seal member 2310 may be positioned proximal to a first end 2315A of the first sleeve 2306, and the engaging members 2312 may be positioned proximal to a second end 2315B of the first sleeve 2306, e.g., opposite to the first end 2315A. In other embodiments, this relative positioning of the engaging members 2312 and the seal member 2310 may be swapped, and/or either or both of the engaging members 2312 and/or the seal member 2310 may be omitted.
Additionally, a first shoulder 2314 may be formed on an inner surface of the first sleeve 2306, e.g., proximate to the first end 2315A and facing in an uphole direction. In some embodiments, the shoulder 2314 may be tapered or wedge shaped. In other embodiments, the shoulder 2314 may be curved or flat. The first sleeve 2306 may also include a second shoulder 2323, which may be spaced axially apart from the first shoulder 2314 and may, in some embodiments, be relatively flat, extending inward in the radial direction.
The setting tool 2304 includes an inner body 2316 having ramped surfaces 2318A, 2318B, which may be adjacent to one another, extend outward from the inner body 2316, and face generally in opposite axial direction, e.g., on either axial side of a protrusion extending outwards from the inner body 2316. In some embodiments, the first sleeve 2306 and the second sleeve 2308 may be positioned around the inner body 2316, e.g., engaging the ramped surfaces 2318A and 2318B, respectively. The setting tool 2304 further includes a setting sleeve 2320 that is positioned adjacent to the first sleeve 2306 and is configured to entrain the first sleeve 2306 between the ramped surface 2318A and the setting sleeve 2320 prior to activation.
The second sleeve 2308 may be connected to the inner body 2316 via a connection member 2322, such as a shear pin, shear screw, adhesive, or other shearable structure or device. In some embodiments, the second sleeve 2308 may include a tapered first shoulder 2324 that may engage or face the ramped surface 2318B, and may be configured to slide axially and radially on the ramped surface 2318B. Further, the second sleeve 2308 may include a second shoulder 2326 which may be positioned on a radial outside of the second sleeve 2308 and may be configured to engage the second shoulder 2323 of the first sleeve 2306.
At this point, the first sleeve 2306 is radially expanded from the first outer diameter to the second larger outer diameter and into engagement with an inner surface 2404 of the tubular 2400. Thus, the first sleeve 2306 resists movement relative to the tubular 2400 because it is gripping the tubular 2400. With the second shoulders 2323, 2326 engaging one another, and the first sleeve 2306 gripping the surrounding tubular, further movement of the setting tool 2304 is resisted by the connection between the second sleeve 2308 and the inner body 2316. As such, the connection member 2322 yields under the force applied by the setting tool 2304, thus allowing the setting tool 2304 to be disconnected from the expandable sleeve 2302, while the first and second sleeves 2306, 2308 may remain in engagement with one another.
When the first sleeve 2306 of the sleeve 2302 engages the tubular 2400, the seal member 2310 forms a seal with the tubular 2400 and the engaging members 2312 may bite into the inner surface 2404 of the tubular 2400. After the sleeve 2302 is engaged with the tubular 2400, the setting tool 2304 may be removed from the tubular 2400.
During the fracking operation, the frac fluid may apply a pressure on the isolation device 2500, which may in turn generate a force in the direction indicated by arrow 2504 thereon. As a result, the isolation device 2500 may apply a force, as indicated by arrow 2506, on the sleeve 2302. With the first shoulders 2314, 2324 being wedge shaped, at least some of this axial force 256 may be transferred to a radial force, as indicated by arrow 2510, on the sleeve 2302. This may serve to further expand the sleeve 2302 and thereby enhance the seal by the sealing member 210 and/or the grip of the engaging members 2312.
After the first fracking operation is complete, another sleeve may be run into the tubular 2400 at a location above the first sleeve 2306, and the process is repeated until all the zones in the wellbore are fractured. Each sleeve may be configured to receive the same size isolation device. After the fracking operation is complete, the sleeve may be removed by dissolving the sleeve if the sleeve is made from a dissolvable material. In an alternative embodiment, the sleeve may be removed by deploying a gripping member and attaching the gripping member to the sleeve and pulling the sleeve from the tubular. In another embodiment, the sleeve may be removed using a drill bit.
The body 2702 of the slip member 2700 may be made from a dissolvable material, e.g., a dissolvable matrix, such as a dissolvable alloy or a dissolvable composite. The dissolvable material may be configured to dissolve over a predetermined amount of time or upon contact with a specific type of fluid. In one embodiment, the dissolvable material may be hardened by mixing cast iron with the dissolvable material. In another embodiment, the dissolvable material matrix may include dissolvable material and ceramic powder (similar to frac sand). During the forming process of the body 2702, the dissolvable material matrix may be ground to a shape. The ceramic powder (or another material harder than 40 Rockwell Hardness—C Scale) is mixed into the dissolvable material matrix, and as a result, the final product will be able to bite into the surrounding tubular since the final product will be harder than the surrounding tubular. In another embodiment, the dissolvable material matrix may include dissolvable material and carbide. In another embodiment, the dissolvable material matrix is a powder metal mixture. For instance, the dissolvable material matrix may include a percentage of hardenable material, such cast iron, steel powder or steel flakes, and a percentage dissolvable material. The hardenable material may be hardened using induction heat treating or other common heat treat methods prior to or after being mixed within the dissolvable material matrix. The percentage of hardenable material may be from 15 percent, or about 20 percent, or about 25 to about 35 percent, about 40 percent or about 50 percent, and the remainder of the power metal mixture being dissolvable material. The powder may include a portion of ceramic powder or sand. In a further embodiment, the body 2702 may be made from dissolvable material matrix which has an outer surface that may be coated with a grip material, such as tungsten carbide coating or carbide powder.
Referring to
The body 2804 may also define a bore 2808 therein, extending at least partially from top 2805 to bottom 2802. The bore 2808 in the body 2804 may be used to allow the fluid to come in contact more rapidly with a larger surface area of the dissolvable body 2804. The bore 2808 may also be promote the insert 2800 breaking apart at a predetermined time, e.g., when being milled out.
The insert 2800 may be made from a metal (e.g., a carbide, steel, hardened steel, etc.) and/or may be provide as a dissolvable material matrix, such as a dissolvable alloy or a dissolvable composite. The dissolvable material matrix may be configured to dissolve over a predetermined amount of time or upon contact with a specific type of fluid. The insert 2800 may be configured to dissolve at the same time as the body 2804 of the slip member 2700 or at a different time. In one embodiment, the dissolvable material matrix of the body 2804 is a powder metal mixture. For instance, the dissolvable material matrix may include a percentage of hardenable material, such cast iron, and a percentage dissolvable material. In another embodiment, the dissolvable material matrix of the body 460 may include dissolvable material and ceramic powder (similar to frac sand). In another embodiment, the dissolvable material matrix of the body 460 may include dissolvable material and carbide
In view of the foregoing, it will be appreciated that embodiments consistent with the tool of any of
As used herein, the terms “inner” and “outer”; “up” and “down”; “upper” and “lower”; “upward” and “downward”; “above” and “below”; “inward” and “outward”; “uphole” and “downhole”; and other like terms as used herein refer to relative positions to one another and are not intended to denote a particular direction or spatial orientation. The terms “couple,” “coupled,” “connect,” “connection,” “connected,” “in connection with,” and “connecting” refer to “in direct connection with” or “in connection with via one or more intermediate elements or members.”
The foregoing has outlined features of several embodiments so that those skilled in the art may better understand the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.
This application claims priority to U.S. Provisional Patent Application No. 62/196,712, which was filed on Jul. 24, 2015. This application also claims priority to U.S. Provisional Patent Application No. 62/319,564, which was filed on Apr. 7, 2016. The entirety of both of these priority provisional applications is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 62196712 | Jul 2015 | US | |
| 62319564 | Apr 2016 | US |
