The subject matter of the present disclosure generally relates to pressure isolation plugs for oil and gas wells and more particularly to pressure isolation plugs that can be advantageously deployed in wellbores having horizontal sections.
The wellbore 10 is shown in a stage of completion after perforating guns have formed perforations 13, 15 near production zones 12, 14 of the formation. At the stage shown, a pressure isolation plug 100 on the end of a wireline 40 has been deployed downhole to a desired depth for isolating pressures in the wellbore 10. The plug 100, which is shown in partial cross-section in
After being deployed in the casing 20, a setting tool sets the tool by applying axial forces to the upper slip 130A while maintaining the mandrel 110 and the lower slip 130B in a fixed position. The force drives the slips 130A-B up cones 140A-B so that the slips 130A-B engage the inner walls of the casing 20. In addition, the force compresses the packing element 120 and forces it to seal against the inner wall of the casing 20. In this manner, the compressed packing element 120 seals fluid communication in the annular gap between the plug 100 and the interior wall of the casing 20, thereby facilitating pressure isolation.
Once set in the desired position within the wellbore 10, the plug 100 can function as a bridge plug and a frac plug. For example, the plug 100 has a lower ball 180 and a lower ball seat 118 that allow the plug 100 to function as a bridge plug. In the absence of upward flow, the lower ball 180 is retained within the plug 100 by retainer pin 119. When there is upward flow, however, the lower ball 180 engages the lower ball seat 118, thereby restricting flow through the plug 100 and isolating pressure from below. During completion or production operations, for example, the plug 100 acting as a bridge plug can sustain pressure from below the plug 100 and prevent the upward flow of production fluid in the wellbore 10.
To function as a frac plug, for example, the plug 100 has an upper ball 160 and an upper ball seat 116 in the plug. In the absence of downward flow, the upper ball 160 is retained within the plug by retainer pin 117. When there is downward flow of fluid, however, the upper ball 160 engages the upper ball seat 116, thereby restricting flow of fluid through the plug and isolating pressure from above. In a fracing operation, for example, operators can pump frac fluid from the surface into the wellbore 10. Acting as a frac plug, the plug 100 can sustain the hyrdualic pressure above the plug 100 so that the frac fluid will interact with the upper zone 12 adjacent to upper perforations 13 and will not pass below the plug 100.
Although
Accordingly, a need exists for a pressure isolation plug that can be advantageously used in wellbores having not only vertical sections but also horizontal sections and that can allow perforating guns and other equipment to be moved downhole without the need of tractors or coil tubing. The subject matter of the present disclosure is directed to overcoming, or at least reducing the effects of, one or more of the problems set forth above.
A wellbore pressure isolation plug is deployed in a wellbore and has a sealing element that can be activated to seal against an interior surface of a surrounding tubular. Once set, a ball valve in the plug restricts upward fluid communication through the plug, and another ball valve in the plug can restrict downward fluid communication through the plug. To facilitate deployment of the plug in a horizontal section of the wellbore, the plug has a plurality of rollers positioned on a distal body portion. In addition, the plug has a ring disposed about its body between the distal body portion and an adjacent body portion. This ring has an outside diameter at least greater than that of the adjacent body portion. The increase diameter ring enhances a pressure differential across the plug that facilitates pumping of the plug in the wellbore, and especially within a horizontal section of the wellbore.
Referring to
When used in a wellbore, the plug 200 is essentially actuated in the same way discussed previously to form a pressure isolation seal between the packing element 220 and the inner wall of surrounding casing or the like. For example, the plug 200 can be deployed in the wellbore using any suitable conveyance means, such as wireline, threaded tubing, or continuous coil tubing. In addition, an appropriate setting tool known in the art can be used to set the plug 200 once deployed to a desired position. In
When used in the wellbore, it may be the case that the plug 200 is run through a vertical section as illustrated in
To facilitate deployment of the plug 200 in a horizontal section, the plug 200 has a distal portion 214 as shown in
The number of rollers 290 used on the plug 200 depends in part on the overall outside diameter D1. For example,
To further facilitate deployment of the plug 200 in a horizontal section, the plug 200 has a ring 280 positioned between the smaller diameter D2 of the distal portion 214 and the larger diameter D1 of the adjacent portion 216 of the mandrel 210. In one embodiment, the ring 280 can be integrally formed with the mandrel 210 and composed of the same material. In the present embodiment, the ring 280 is a separate component preferably composed of Teflon.
As shown in more detail in
Selection of the various outside cross-sectional diameters to use for the plug's components depends on a number of factors, such as the inside diameter of the casing, the drift diameter of the casing, the pressure levels, etc. As shown in
Furthermore, the outside diameter D3 of the ring 280 (and hence the size of the exposed portion 283) to use for a given implementation of the plug 200 can depend on a number of implementation-specific details, such as the diameter of the wellbore casing 20, overall diameter D1 of the plug's mandrel 210, fluid pressures, grade of the horizontal section of the wellbore, etc. As shown, the diameter D3 of the ring 280 can be at least greater than the lager outside diameter D1 of the mandrel 210 and at least less than the inside diameter of the surrounding casing 20. In one example, the ring's diameter D3 can be anywhere between 80-100% of the drift diameter of the casing in which it is intended to be used and is preferably about 95% of the intended casing's drift diameter.
In one illustrative example, the plug 200 may have an outside diameter D1 of about 3.665-inches and may be intended for use in casing 20 having an inside diameter of about 3.920-inches. The distal portion 214 may have a diameter D2 of about 3.25-inches. The ring 280 for such a configuration may have an outside diameter D3 of about 3.724-inches, and the rollers 290 may have an outside diameter D4 of about 3.795-inches. In another illustrative example, the same plug 200 having outside diameter D1 of about 3.665-inches may likewise be intended for use in casing 20 having a larger inside diameter of about 4.090-inches. In this example, the ring 280 for such a configuration may have an outside diameter D3 of about 3.766-inches and the rollers 290 may have an outside diameter D4 of about 3.965-inches.
Once deployed and set in a wellbore, the plug 200 is capable of functioning as a bridge plug and/or a frac plug. For example, a lower ball 260 and a lower ball seat 216 allow the plug 200 to function as a bridge plug. When upward flow of fluid (e.g., production fluid) causes the lower ball 260 to engage the lower ball seat 216, the plug 200 restricts upward flow of fluid through the plug's bore 212 and isolates pressure from below the plug 200. In the absence of any upward flow, the lower ball 260 is retained within the plug 200 by retainer pin 262.
An upper ball 270 and an upper ball seat 217 also allow the plug 200 to function as a frac plug. This upper ball 270 can be dropped to the plug 200 so it can seat on the upper ball seat 217 at the end of the mandrel 210. The upper ball 270 can be urged upwards and away from the ball seat 217 by upward flow of the production fluid. In fact, the ball 270 can be carried far enough upward so that it no longer affects the upward flow of the production fluid. When there is downward fluid flow during a frac operation, the ball 270 engages the ball seat 217 and isolates the wellbore below the plug 200 from the fracing fluid above the plug 200.
During use, the plug 200 is attached to an adapter kit that is attached to a setting tool with perforating guns above, and the entire assembly is deployed into the wellbore via a wireline 40 or other suitable conveyance member. If needed during deployment and as shown in
After being set, the upward flow of production fluid can be stopped as the lower ball 260 seats in the ball seat 216. The perforating guns can then be raised to a desired depth, and the guns can be fired to perforate the casing 20. If the guns do not fire, the wireline 40 with the unfired guns can be pulled from the wellbore, and new guns can be installed on the wireline 40. The new guns can then be pump to the desired depth because the ball 260 and seat 216 in the plug 200 allow fluid to be pumped through it.
Once the casing is perforated, the plug 200 allows fracing equipment to be pumped downhole while the plug 200 is set. To then commence frac operations, operators can drop the upper ball 270 from the surface to seal on the upper seat 217 of the plug 200, allowing the operators to commence with the frac operations. Downward flow of fracing fluid ensures that the upper ball 270 seats on the upper ball seat 217, thereby allowing the frac fluid to be directed into the formation through corresponding perforations.
After a predetermined amount of time and after the frac operations are complete, the production fluid can be allowed to again resume flowing upward through the plug 200, towards the surface. For example, the lower ball 260 can be configured to disintegrate into the surrounding wellbore fluid after a period of time, or the plug 200 can be milled out of the casing 20 using techniques known in the art. The above operations can be repeated for each zone that is to be fractured with a frac operation. Of course, the plug 200 of
Other embodiments of plugs may have different configurations of check or ball valves than plug 200 in
In
In general, the balls used in the ball valves of the disclosed plugs can be composed of any of a variety of materials. In one embodiment, one or more of the balls can be constructed of material designed to disintegrate after a period of time when exposed to certain wellbore conditions as disclosed in U.S. Pat. Pub. No. 2006/0131031, which is incorporated herein by reference in its entirety. For example, the disintegratable material can be a water soluble, synthetic polymer composition including a polyvinyl, alcohol plasticizer, and mineral filler. Furthermore, other portions of the disclosed plugs, such as portion of the sealing system 215, can also be made of a disintegratable material and constructed to lose structural integrity after a predetermined amount of time.
The foregoing description of preferred and other embodiments is not intended to limit or restrict the scope or applicability of the inventive concepts conceived of by the Applicants. For example, the ring 280 may be disposed in any of a variety of locations along the length of the disclosed plug and not necessarily only in the location shown in the Figures. Moreover, the rollers 290 also may be positioned in any of a variety of locations along the length of the disclosed plug as well. In exchange for disclosing the inventive concepts contained herein, the Applicants desire all patent rights afforded by the appended claims. Therefore, it is intended that the appended claims include all modifications and alterations to the full extent that they come within the scope of the following claims or the equivalents thereof.
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