Patent Grant
12209481
See Application Data Sheet.
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The present invention relates to isolating zones in a wellbore. More particularly, the present invention relates a frac plug device that has a multiple stage full expansion configuration to seal at wide setting positions in the wellbore. The frac plug sets a seal for isolating zones in large wellbores. Even more particularly, the present invention relates to a frac plug with a segmented cone and a segment cap member to increase expansion diameter of the slip device at the wide setting position in the wellbore. 2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98.
Within a wellbore, the hydrocarbons are located at particular depths within a rock formation. These depths can be organized into production zones so that the delivery of production fluids can be targeted to the location of the hydrocarbons. The production fluids facilitate the recovery of the hydrocarbons from the wellbore. Other depth levels do not contain hydrocarbons, which can be called “non-productive zones”. There is no need to waste production fluids on non-productive zones without hydrocarbons. Thus, the productive zones are isolated from the non-productive zones for the recovery of hydrocarbons from the wellbore.
There are known downhole tools to separate a production zone from a non-productive zone so that the production fluids can be delivered to the production zone and not the non-productive zone. Examples of downhole tools to isolate zones include a plug, a packer or other tool with an isolation valve.
In the conventional process, the frac plug or frac plug device is run-in to a downhole location. When located in the correct place, the setting tool that traveled with the frac plug device will set the packer, i.e. expand the frac plug against the walls of the borehole. Then, the settling tool is removed. The frac plug still must be activated in order seal the zone. The frac plug is sealed to the borehole, but fluid still flows through the packer. Conventionally, a frac ball is dropped into the borehole. The frac ball travels to the downhole location to sit on a ball seat, which triggers expansion of the frac plug to the borehole walls and can even be incorporated as part of the seal across the frac plug. Fracking can commence with the seal across the packer. The frac fluids are only delivered to the isolated zone, and production fluids are only harvested from the isolated zone.
There are also simplified, compact, and condensed frac plug systems comprised of different material compositions. Fewer components and selection of material composition allow for frac plugs to the removed more easily after use. As the material selection of components is controlled, the use of drilling out removal or the use of dissolving metallic or non-metallic compositions can be selected. As the number of components is reduced, the amount of milling out or the amount of dissolving chemicals can be reduced. Some of these simplified and condensed frac plug systems are wedge type or ramp type frac plug systems comprised of a wedge or ramp, a sealing ring, and a slip device.
The limitation of these simplified quick setting frac plugs is the amount of radial expansion. The wedge or cone expands the slip device to the widest diameter of the cone. This amount of radial expansion must happen over the length of the cone. The length and widest diameter of the cone define how much radial expansion and how fast and how far the cone must move in order to reach the widest diameter.
The length and widest diameter of the cone are already limited to the size of the borehole. That is, the widest diameter must be small enough to travel through the borehole in the run-in configuration. The widest diameter cannot be larger than the borehole to be traveled. Also, the length of the cone is limited by the angle of the cone surface from the initial diameter to the widest diameter. If the angle is too steep, then there is no sufficient force to deploy the slip device. If the angle is too shallow, then the slip device will deploy too easily and prematurely. The slip device must also be dimensioned to travel through the borehole. Even in the run-in configuration, the length and widest diameter of the slip device are restricted to initial physical dimensions.
The radial expansion of the slip device is limited to respective dimensions of the cone and the slip device. For large wellbores or boreholes and casings with large diameters, the frac plug may not be able to radially expand sufficiently to seal against these larger diameters.
Various patents and publications have addressed expansion at the setting position with additional components beyond the wedge or cone and slip device. U.S. patent Ser. No. 10/794,132, issued on 6 Oct. 2020 to Mhaskar et al. discloses an expansion ring with an initial run-in configuration beyond the thickness of the slip segments and the cone. However, the expansion ring is expanded to match the slip segments in the extended configuration for sealing at the setting position. U.S. patent Ser. No. 11/255,151, issued on 22 Feb. 2022 to Nichols et al., adds another version of an expansion ring with a different relationship to the wedge and slip device. The final extended diameter still remains based on the wedge diameter and the slip thickness. US Patent Publication No. 2017/0130553, published on 11 May 2017 for Harris et al, discloses collet fingers to press the wedge, which expands the slip device. U.S. Pat. No. 3,493,046, issued on 3 Feb. 1970 to Johnson et al, describes adding another set of cones and slip devices.
A prior art frac plug device with multiple cones is another prior art solution to expansion at the setting position. U.S. patent Ser. No. 10/364,639, issued on 30 Jul. 2019 to Svartvatn et al, U.S. patent Ser. No. 11/261,683, issued on 1 Mar. 2022 to Kellner et al, and CN109973043 5 Jul. 2019 Guo Daiin, et al, all disclose a frac plug system with more than one cone. The two cones are cooperative and placed in opposite directions so as to expand the slip device from both sides of the slip device. The diameter expansion is still limited to the diameter of the cone and the thickness of the slip segments of the slip device. The prior art frac plugs lack the structures and function to expand beyond the thickness of the slip segments and thickness of the cone as the final expansion diameter for sealing a wide borehole.
It is an object of the present invention to provide a frac plug device with a final expansion diameter to span large wellbores and casings.
It is another object of the present invention to provide a simplified frac plug device with a final expansion diameter to span large wellbores and casings with the fewest components.
It is an object of the present invention to provide a frac plug device with high expansion at the setting position in the borehole.
It is another object of the present invention to provide a frac plug device with a multiple stage expansion to reach a full expansion configuration at the setting position in the borehole.
It is still another object of the present invention to provide a frac plug device with a segmented cone and a segmented cap member to determine the full expansion configuration.
It is yet another object of the present invention to provide a frac plug device with slip segments stabilized in the full expansion configuration.
It is another object of the present invention to provide a frac plug device with slip segments locked around the cone in the full expansion configuration when set by the segmented cone and the segmented cap member.
It is an object of the present invention to provide a method for sealing a borehole at a wide setting position with a wedge type or ramp type frac plug.
These and other objectives and advantages of the present invention will become apparent from a reading of the attached specification, drawings and claims.
Embodiments of the present invention include a frac plug device comprising a core cone, a segmented cone, a slip device, a segmented cap member, and a core cap member. The frac plug device has a run-in configuration for deployment through the borehole to a setting position. The thickness, taper angles and dimensions of the core cone, segmented cone, slip device, segmented cap member, and core cap member in the run-in configuration fit through the narrowest portions of the borehole to reach the setting position. The frac plug device has an initial expansion configuration and a final expansion configuration for sealing at the setting position in a larger diameter portion of the borehole. The frac plug device has a final expansion configuration for maximum radial expansion to stably seal in these larger portions of the borehole. The frac plug device is a wedge type or ramp type frac plug with a simplified setting action. The radial expansion of the frac plug device is no longer limited to respective dimensions of the cone and the slip device.
Embodiments of the core cone include a first core cone end, a second core cone end, and an inner core cone channel extending from the first core cone end to the second core cone end. A mandrel can extend through the inner core cone channel for the setting action of the frac plug device. The core cone has a tapered outer core cone surface decreasing in outer core cone diameter toward the second core cone end.
Embodiments of the segmented cone include a first segmented cone end and a second segmented cone end. The segmented cone is comprised of a plurality of cone segments. Each cone segment has an inner cone segment surface and a tapered outer cone segment surface that determines an outer segment diameter. The tapered outer segment surface tapers toward the second segmented cone end. The inner cone segment surface is in sliding engagement with the tapered outer core cone surface of the core cone.
Embodiments of the slip device include a first slip end and a second slip end. The slip device is comprised of a plurality of slip segments. Each slip segment has an inner slip segment surface and an outer slip segment surface. There can also be an engagement means for the borehole on the outer slip segment surface. The inner slip segment surface is in sliding engagement with a respective tapered outer segmented cone surface of a cone segment. Each slip segment is expanded with a respective cone segment. The radial expansion of the outer slip diameter is determined by the slip device and the outer segment diameter of the cone segments as set by the outer core diameter of the core cone.
Embodiments of the segmented cap member have a first segmented cap end and a second segmented cap end. The segmented cap member is comprised of a plurality of cap segments. Each cap segment has an inner tapered cap segment surface and an outer tapered cap segment surface. The inner slip segment surface is in sliding and locked engagement with a respective outer tapered cap segment surface of each cap segment. Each slip segment is expanded with a respective cap segment and a respective cone segment. The radial expansion of the outer slip diameter is supported by the cap segments, which hold the position of the slip segments around the segmented cone and the core cone.
Embodiments of the core cap member have a first core cap end and a second core cap end. There is an inner core cap channel extending from the first core cap end to the second core cap end. The mandrel can extend through the core cone and the inner core cap channel for the setting action of the frac plug device. The inner tapered cap segment surface of each cap segment is in sliding and locked engagement with the tapered outer core cap surface. The core cap member holds the cap segments around the core cap member.
In the full expansion configuration, the second core cone end, the second segmented cone end, the first segmented cap end, and the first core cap end are within the slip device. The outer slip diameter of the slip device in the full expansion configuration is comprised of the slip device and the outer segment diameter of the segmented cone as set by the outer core cone diameter of the core cone. The maximum radial expansion in the full expansion configuration is stable and locked by the segmented cap member and core cap member.
Embodiments of the frac plug device also include a segmented cone support ring and a segmented cap member support ring. There can also be at least one slip support ring. The support rings control the amount of force needed to expand the corresponding pluralities of slip segments, cone segments, and cap segments. Premature expansion is prevented so that the frac plug device can be expanded only at the desired setting position in the borehole.
Some embodiments of the slip segment of the slip device include the inner slip segment surface having a first tapered inner slip portion and a second tapered inner slip portion. The first tapered inner slip portion is in sliding engagement with a respective tapered outer segmented cone surface of a corresponding cone segment. The second tapered inner slip portion is in sliding and locked engagement with a respective outer tapered cap segment surface of a corresponding cap segment.
In the sliding and locked engagement between the slip segments and the cap segments. The outer tapered cap segment surface has an outer tapered cap groove, and the inner slip segment surface has an inner slip ridge. In the sliding and locked engagement between the cap segments and the core cap member, the inner tapered cap segment surface has an inner tapered cap ridge, and the tapered outer core cap surface has an outer cap groove. The cap segments cannot radially shift around the core cap member and are held in place around the core cap member. The slip segments are locked to the cap segments so that the slip segments also remain in the final expansion configuration.
The present invention includes the method for sealing a borehole with the frac plug device. The method includes the step of deploying the frac plug device in a borehole to a downhole location with the frac plug device in the run-in configuration. The method also includes moving the segmented cone toward the segmented cap member within the slip device and placing the frac plug device in the initial expansion configuration. Then, the method includes the step of placing the frac plug device in the full expansion configuration. Embodiments of the method include the step of placing the frac plug device in the full expansion configuration further comprising the step of locking the slip device around the core cone in the full expansion configuration.
The high expansion of the slip device at the setting positions in larger diameter portions of the borehole allows the frac plug device to seal in the desired locations, even if the borehole is wider. The segmented cap member and core cap member lock the slip segments around the core cone so that the risk of misalignment and collapse is reduced.
A frac plug has a radial expansion limited by the dimensions of the component parts, which are further limited by being able to pass through the narrowest portion of the borehole during deployment to the setting position. Adding more components, like expansion rings and another cone, can be implemented in a complex frac plug with double sided slips and collet fingered rings. For wedge type or ramp type frac plugs, those added complexities are not compatible with the simplified setting action. The frac plug device 10 of the present invention can comply with the dimension limitations set by passing through the narrowest portion of the borehole and incorporate additional components compatible with the simplified setting action of a wedge type or ramp type frac plug. The radial expansion of the frac plug device 10 of the present invention is no longer limited to respective dimensions of the cone and the slip device. For a setting position in the wide and large diameter portion of boreholes and casings, the wedge type frac plug device 10 of the present invention has a full expansion configuration to seal against these larger diameters.
Embodiments of the segmented cone 30 and a cone segment 40 from
Embodiments of the slip device 50 are shown in
The inner slip segment surface 62 is in sliding engagement with a respective tapered outer segmented cone surface 44 of each cone segment 40. Each slip segment 60 is expanded with a respective cone segment 40, as shown in
Embodiments of the segmented cap member 70 from
The inner slip segment surface 62 is in sliding and locked engagement with a respective outer tapered cap segment surface 84 of each cap segment 80. Each slip segment 60 can also be expanded with a respective cap segment 80, as shown in
Embodiments of the core cap member 90 from
The inner tapered cap segment surface 82 of each cap segment is in sliding and locked engagement with the tapered outer core cap surface 98 of the core cap member 90. While the cap segments 80 hold the position of the slip segments 60 around the segmented cone 30 and the core cone 20, the core cap member 90 holds the cap segments 80 around the core cap member 90. The slip segments 60 are also stacked around the cap segments 80 around the core cap member 90. The risk of toppling or misaligning to collapse the slip segments 60 back to the core cap member 90 is also avoided by the cap segments 80.
In the full expansion configuration with the core cone 20 and the core cap member 90, the second core cone end 24, the second segmented cone end 34, the first segmented cap end 72, and the first core cap end 92 are within the slip device 50. The outer slip diameter 58 of the slip device in the full expansion configuration is comprised of the slip device 50 and the outer segment diameter 46 of the segmented cone 30 as set by the outer core cone diameter 29 of the core cone 20. The outer slip diameter 58 is no longer limited by the thickness, taper angle, and dimension by the frac plug device 10 needing to pass through the narrowest portions of the borehole to reach the setting position. Even though each slip segment 60 remains limited in thickness, taper angle, and dimension, the outer slip diameter 58 of the slip device 50 in the present invention is no longer limited. The frac plug device 10 of the present invention now passes through the narrowest portions of the borehole to reach the setting position and achieves high expansion for the setting position in larger diameters of the borehole. Additionally, the maximum radial expansion in the full expansion configuration is stable and locked by the segmented cap member 70 and core cap member 90.
As radial expansion of each slip segment 60 to the outer slip diameter 58 is maximized by the cone segments 40 on the core cone 20, the stacking on the cap segments 80 on the core cap member 90 also can expand to the final expansion configuration, as shown in
Embodiments of the frac plug device 10 also include a segmented cone support ring 36 removably engaged with the plurality of cone segments 40 at the first segmented cone end 32 and a segmented cap member support ring 76 removably engaged with the plurality of cap segments 80 at the second segmented cap end 74.
The present invention includes the run-in configuration with the core cone 20 and the core cap member 90 having the second core cone end 24 at the first segmented cone end 32, the second segmented cone end 34 at the first slip end 52, the second slip end 54 at the first segmented cap end 72, and the second segmented cap end 74 at the first core cap end 92. The outer slip diameter 58 in the run-in configuration is thickness, taper angle, and dimension of the slip device 50.
In embodiments with the support rings 36, 56, 76, the segmented cone support ring 36, the segmented cone support ring 76, and the slip support rings 56 are respectively engaged in the run-in configuration to prevent accidental or premature expansion of any of the segmented cone 30, the slip device 50, and the segmented cap member 70.
Embodiments of the present invention further include the initial expansion configuration with the core cone 20 and the core cap member 90 having the second core cone end 24 at the first segmented cone end 32, the second segmented cone end 34 and the first segmented cap end 72 within the slip device 50, and the second segmented cap end 74 at the first core cap end 92. The outer slip diameter 58 in the initial expansion configuration is comprised of thickness, taper angle, and dimension of the slip device 50 and the outer segment diameter 46 of the segmented cone 30. There is no relationship to the core cone 20 to set the outer slip diameter 58 in the initial expansion configuration. The second segmented cone end 34 can be in contact with the first segmented cap end 72 within the slip device 50 in the initial expansion configuration.
In embodiments with the support rings 36, 56, 76, the segmented cone support ring 36, the segmented cone support ring 76, and the slip support rings 56 are still respectively engaged in the initial expansion configuration to prevent accidental or premature expansion of any of the segmented cone 30 and the segmented cap member 70. The slip support rings 56 are removed from the slip segments 60 in the initial expansion configuration. The slip device 50 can expand, and the outer slip diameter 58 may be sufficient to attach to the borehole with a compatible borehole diameter. Alternatively, the initial expansion configuration is an intermediate configuration during the transition from the run-in configuration to the full expansion configuration.
The present invention includes the method for sealing a borehole with the frac plug device 10. The method includes the step of deploying the frac plug device 10 in a borehole to a downhole location with the frac plug device 10 in the run-in configuration of the core cone 20 and the core cap member 90. When ready to seal by expansion of the slip device 50, the method includes moving the segmented cone 30 toward the segmented cap member 70 within the slip device 50 and placing the core cone 20 and the core cap member 90 in the initial expansion configuration. The outer slip diameter 58 is comprised of the slip device 50 and the outer segment diameter 46 of the segmented cone 30 in the initial expansion configuration.
The method includes the step of moving the core cone 20 toward the core cap member 90 within the slip device 50. The intermediate step in the initial expansion configuration is temporary. The maximum radial expansion of the slip device 50 has not yet been reached. The method then includes the step of placing the core cone 20 and the core cap member 90 in the full expansion configuration with the outer slip diameter 58 being comprised of the slip device 50 and the outer segment diameter 46 as set by the outer core cone diameter 29.
Embodiments of the method of the present invention include the frac plug device 10 being comprised of the segmented cone support ring 36 removably engaged with the plurality of cone segments 40, the segmented cap member support ring 76 removably engaged with the plurality of cap segments 80, and at least one slip support ring 56 removably engaged with the plurality of slip segments 60. The step of deploying in the run-in configuration includes the segmented cone support ring 36 being engaged with the plurality of cone segments 40, the segmented cap member support ring 76 being engaged with the plurality of cap segments 80, and at least one slip support ring 56 being engaged with the plurality of slip segments 60. The step of placing the core cone and the core cap member in the initial expansion configuration further includes the segmented cone support ring 36 beings engaged with the plurality of cone segments 40, the segmented cap member support ring 76 being engaged with the plurality of cap segments 80, and the slip support ring 56 being removed from the plurality of slip segments 60. The slip device 50 is allowed to radial expand in the initial expansion configuration to an intermediate amount of expansion. Choosing the strength of the slip support rings 56 can control premature or accidental expansion.
The step of placing the core cone 20 and the core cap member 90 in the final expansion configuration further includes the segmented cone support ring 36 being removed from the plurality of cone segments 40 and the segmented cap member support ring 76 being removed from the plurality of cap segments 80. The slip support rings 56 have already been removed from the plurality of slip segments 60 so the slip device 50 can move the maximum radial expansion with the outer slip diameter 58 as a combination of the thickness, taper angle, and dimension of the slip segments 60, the thickness, taper angle, and dimension of the cone segments 40, and the thickness, taper angle, and dimension of the core cone 20, in particular the outer core cone diameter 29.
Embodiments of the method include the step of placing the core cone 20 and the core cap member 90 in the full expansion configuration further comprising the step of locking the slip device 50 around the core cone 20 in the full expansion configuration. The locking prevents misalignment and collapse of the slip segments 60 to the core cone 20 or core cap member 90. The step of locking the slip device 50 around the core cone 20 comprises the steps of sliding the inner slip segment surface 62 along a respective outer tapered cap segment surface 84 of each cap segment 80 and sliding the inner tapered cap segment surface 82 along a respective tapered outer core cap surface 98 of the core cap member 90.
The present invention provides a frac plug device able to span large wellbores and casings so as to seal the borehole at setting positions in these larger diameter portions of the borehole. The final expansion configuration is no longer limited by the thickness, taper angle, and dimensions for passing through the narrowest portion of the borehole during deployment to the setting position. The frac plug device of the present remains a wedge type or ramp type frac plug with fewer components and simplified setting action. The segmented cone and the segmented cap member are compatible with the core cone and the core cap member in a simplified setting action. The outer slip diameter in the final expansion configuration is the maximum radial expansion to span larger diameters in the borehole. The thickness, taper angle, and dimensions of the slip device and now the outer segment diameter and the outer core cone diameter determine the maximum radial expansion. A high expansion of the slip device at the setting positions in larger diameter portions of the borehole allows the frac plug device to seal in the desired locations, even if the borehole is wider. The frac plug device further remains useful for setting positions in regular portions of the borehole. The multiple stage expansion from run-in configuration to initial expansion configuration and to final expansion configuration allows the intermediate stage of the initial expansion configuration to be used to seal at a setting position in a regular portion of the borehole. The present invention further locks the slip segments around the core cone so that the risk of misalignment and collapse is reduced. The cone segments still expand the slips along slidable tapered surface interaction. The cap segments and core cap member both slide and lock the radial positions of the slip segments around the core cone and core cap member without interfering with the simplified setting action of the core cone and segmented cone. The frac plug device of the present invention has high expansion at setting positions in large diameter portions of the borehole and can stably seal at these setting positions as a simplified wedge type or ramp type frac plug.
The foregoing disclosure and description of the invention is illustrative and explanatory thereof. Various changes in the details of the illustrated structures, construction and method can be made without departing from the true spirit of the invention.
| Number | Name | Date | Kind |
|---|---|---|---|
| 3493046 | Johnson et al. | Feb 1970 | A |
| 5566762 | Braddick | Oct 1996 | A |
| 5678635 | Dunlap | Oct 1997 | A |
| 6241017 | Doane et al. | Jun 2001 | B1 |
| 9650858 | Williamson | May 2017 | B2 |
| 10364639 | Svartvatn et al. | Jul 2019 | B2 |
| 10794132 | Mhaskar et al. | Oct 2020 | B2 |
| 11255151 | Nichols et al. | Feb 2022 | B2 |
| 11261683 | Kellner et al. | Mar 2022 | B2 |
| 11555364 | Mitchell | Jan 2023 | B2 |
| 11732546 | Qiu | Aug 2023 | B1 |
| 20170130553 | Harris et al. | May 2017 | A1 |
| 20180016864 | Parekh et al. | Jan 2018 | A1 |
| Number | Date | Country |
|---|---|---|
| 109973043 | Jul 2019 | CN |
