1. Field of Invention
The present invention is directed to plug member seats for use in oil and gas wells and, in particular, to plug member seats having a seat sleeve that allows a plug element landing on the seat of the seat sleeve to block an area of fluid flow thorough the seat sleeve that is greater than the plug element landed on the seat sleeve.
2. Description of Art
Ball seats are generally known in the art. For example, typical ball seats have a bore or passageway that is restricted by a seat. The ball or drop plug is disposed on the seat, preventing or restricting fluid from flowing through the bore of the ball seat and, thus, isolating the tubing or conduit section in which the ball seat is disposed. As the fluid pressure above the ball or drop plug builds up, the conduit can be pressurized for tubing testing, actuating a tool connected to the ball seat such as setting a packer, or stimulating a wellbore. Ball seats are also used in cased hole completions, liner hangers, flow diverters, frac systems, and flow control equipment and systems.
Although the terms “ball seat” and “ball” may be used herein, it is to be understood that a drop plug or other shaped plugging device or element may be used with the “ball seats” disclosed and discussed herein. For simplicity it is to be understood that the term “ball” includes and encompasses all shapes and sizes of plugs, balls, or drop plugs unless the specific shape or design of the “ball” is expressly discussed.
Broadly, ball seats having a housing and a seat sleeve are disclosed. The seat sleeve comprises a seat sleeve bore that is fluid communication with the seat that receives the plug element or ball. The seat sleeve also includes one or more ports in fluid communication with one or more seat bypass channels disposed in the housing for fluid flow around the seat. Thus, when the seat sleeve is in the run-in position and a plug element has not been landed on the seat, fluid flows through the seat into the seat sleeve bore, and through each of the seat bypass channels, though the seat sleeve ports, and into the seat sleeve bore. The area open for fluid to flow through the seat sleeve in this position is referred to herein as the “initial fluid flow area.” The term “area” as used herein means the combined geometric area(s) of the cross-section(s) of the opening(s) allowing fluid to flow through the seat sleeve.
After a plug element is landed on the seat, fluid flow through the seat is restricted, however, until sufficient pressure builds above the seat sleeve, the seat sleeve remains in the run-in position and fluid flow continues to flow through the seat bypass channels, through the seat sleeve ports, and into the seat sleeve bore. The area open for fluid flow through the seat sleeve in this position is referred to herein as the “seat bypass channel fluid flow area.”
After the pressure above the seat sleeve increases sufficient to move the seat sleeve downward toward the set position of the seat sleeve, fluid flow through each of the seat sleeve ports begins to be restricted. As a result, the pressure above the seat increases so that a downhole operation can be performed, e.g., actuation of a downhole tool or allowing stimulation fluids to be injected into a wellbore. In one particular embodiment, the pressure above the seat can continue to increase causing the seat sleeve to continue to move downward until each of the seat sleeve ports becomes completely blocked. However, it is to be understood that each of the seat sleeve ports is not required to become completely blocked. The area open for fluid flow through the seat sleeve in the positions in which the seat bypass channel(s) is/are partial blocked or completely blocked is referred to herein as “operational fluid flow area” because at this point, the downhole operation can be performed. Because the initial fluid flow area is larger than the cross-sectional area of the opening through the seat on which the plug element lands, a plug element having a can be used to partially or completely block a fluid flow area that is larger than the fluid flow area through the seat. In other words, the apparatus allows a plug element such as a ball to close off fluid flow paths that have a combined fluid flow area that is greater than the size of the plug element, e.g., the diameter of the ball.
While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
Referring now to
Disposed within bore 46 and secured to inner wall surface 44, such as by threads 47, is housing 50. Housing 50 comprises upper end 51, lower end 52, outer wall surface 53, and inner wall surface 54 defining housing bore 56. As shown in the embodiment of
Stop or detent 66 is disposed on inner wall surface 54 toward lower end 52 of housing 50. Detent 66 restricts downward movement of seat sleeve 70. Detent 66 can be disposed at lower end 52 through any method or device known in the art. For example detent 66 can be secured to inner wall surface 54 by threads 57.
Disposed in housing bore 56 is seat sleeve 70. Seat sleeve 70 comprises upper end 71, lower end 72, outer wall surface 73, inner wall surface 74 defining seat sleeve bore 76, seat 75 and seat opening 69. Outer wall surface 73 of seat sleeve 70 is in sliding engagement with inner wall surface 54 of housing 50. Disposed between outer wall surface 73 and inner wall surface 74 and in fluid communication with seat sleeve bore 76 are ports 78. Although seat sleeve 70 is shown as having a plurality of seat sleeve ports 78, it is to be understood that seat sleeve 70 can have as few as one seat sleeve port 78.
In the specific embodiment shown in
As discussed in greater detail below, seat sleeve 70 comprises first or run-in position (
In the particular embodiment shown in
In the embodiment of
To reduce the likelihood of leak paths forming between tubular member 40 and housing 50 and between housing 50 and seat sleeve 70, seals 86 are disposed in grooves or recesses as illustrated in
In operation, housing 50 comprising seat sleeve 70 is disposed within bore 46 of tubular member 40. Tubular member 40 is included as part of a tubing or work string or conduit that is then disposed within a wellbore. Upon locating apparatus 30 at the desired location within the wellbore, plug element 90, shown as a ball, is dropped down the tubing string or conduit and landed on seat 75 (
After landing plug element 90 on seat 75, fluid pressure above seat sleeve 70 increases forcing plug element 90 into seat 75. Upon reaching a predetermined pressure, shear screw 84 breaks or shears and seat sleeve 70 begins moving from the first or run-in position (
In another specific embodiment, the downhole operation is not performed until all of seat sleeve ports 78 are completely blocked such as shown in
After performance of a downhole operation by restricting fluid flow through apparatus 30, restriction of fluid flow through apparatus 30 may no longer necessary. Accordingly, plug element 90 can be removed through methods and using devices known to persons of ordinary skill in the art, e.g., milling, dissolving, or fragmenting plug element 90. Alternatively, plug element 90 may be a lightweight “float” plug element such that, when pressure is reduced, plug element 90 is permitted to float up to the top of the well. In addition, housing 50 and seat sleeve 70 can be milled out of tubular member 40 so that fluid can flow through tubular member bore 46 unrestricted by housing 50 and seat sleeve 70.
Referring now to
It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. For example, the seat bypass fluid flow channels can have any shape desired or necessary to provide the secondary flow path. Although shown in the Figures as partial circles, the seat bypass fluid flow channels can have a full circle shape, square-shape, or polygonal-shape. In addition, the number of seat bypass fluid flow channels can be as low as one. Further, one or more of the seat bypass fluid flow channels can include a permeable matrix disposed within the channel. Similarly, the seat sleeve ports can have any shape desired or necessary to provide the secondary flow path and are not required to be elongated oval-shape as shown in the Figures. Nor are the seat sleeve ports required to be aligned with one or more of the seat bypass fluid flow channels. Moreover, the shape and size of the gallery can be modified and is not required to be in fluid communication with every seat bypass fluid flow channel.
Further, the size and shape of the plug element can be any size or shape desired or necessary to engage the seat of the seat sleeve to restrict fluid flow through the seat. Additionally, although the apparatuses described in greater detail with respect to the Figures are ball seats having a ball as their respective plug elements, it is to be understood that the apparatuses disclosed herein may be any type of seat known to persons of ordinary skill in the art that include a plug element. For example, the apparatus may be a drop plug seat, wherein the drop plug temporarily restricts the flow of fluid through the wellbore. Therefore, the term “plug” as used herein encompasses a ball as shown in the Figures, as well as any other type of device that is used to restrict the flow of fluid through a ball seat. Further, in all of the embodiments discussed with respect to the Figures, upward, toward the surface of the well (not shown), is toward the top of the Figures, and downward or downhole (the direction going away from the surface of the well) is toward the bottom of Figures. However, it is to be understood that the apparatuses may have their positions rotated. Accordingly, the apparatuses disclosed herein can be used in any number of orientations easily determinable and adaptable to persons of ordinary skill in the art. Accordingly, the invention is therefore to be limited only by the scope of the appended claims.
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