Field of the Invention
The present invention pertains to a valve assembly that can be used in wellbore operations (such as, for example, in oil, gas, water or disposal wells). More particularly, the present invention pertains to a downhole valve assembly that can be used in wellbore operations, such as well intervention and/or hydraulic fracturing operations. More particularly still, the present invention pertains to a downhole flapper valve assembly having a dissolvable or frangible flapper.
Brief Description of the Prior Art
Frequently, it is desirable to install at least one bridge plug, or other anchoring and sealing device, within a wellbore. Such assemblies can be installed for various reasons: to isolate one portion of a wellbore from another, to prevent fluid flow from one portion of a wellbore to another, and/or provide a fluid pressure sealing barrier at a desired location within said wellbore. Such downhole bridge plugs or other anchoring/sealing devices are frequently installed within the central bore of a casing or tubing string, and both grip/anchor and provide a fluid pressure seal against the inner wall of such pipe. In certain applications, such plugs can also be installed within a section of drilled “open hole” (that is, a section of a wellbore that is not cased with pipe).
Conventional bridge plugs typically comprise an anchoring system designed to grip the inner surface of a surrounding wellbore, as well as a sealing system or packing element to form a fluid pressure seal against said inner surface. Some predetermined amount of force is generally required to energize/expand said packing element and actuate said anchoring system. In certain plug assemblies, such force or load can be supplied by pipe weight situated above the bridge plug, or by tensile loading applied from a wellbore surface; such plugs generally must be continually attached to a pipe string during the setting process in order to receive the force required to actuate said anchor system and energize/expand said sealing mechanism. In other cases, such plug assemblies can be conveyed into a wellbore on spooled wireline to a desired location, and actuated using a specially designed plug setting tool.
Conventional bridge plugs are frequently used in connection with hydraulic fracturing (commonly referred to as “fracking”) operations, which generally entails pumping fluid into a wellbore at elevated pressures in order to fracture subterranean rock formations surrounding said wellbore. In many well fracturing operations, a bridge plug or “frac plug” is conveyed to a desired location within a wellbore. Once positioned at a desired location within a wellbore, the frac plug is actuated to secure or anchor said plug in position and prevent axial movement within said wellbore. Thereafter, a setting tool or other device used to set said plug in place can then be removed, leaving the plug securely anchored within the well bore.
Although designs can vary, many frac plugs have a central axial through bore as well as sealing seat on one end. A ball, dart or other object is typically launched or released into the wellbore from the surface or other point above said plug; eventually, said ball/dart/object will reach the plug and land on said seat. Once said ball/dart/object is securely received on said seat, said central through bore is blocked and fluid is prevented from flowing around said ball through said central through bore. With the central through bore of said plug blocked, hydraulic fracturing can be undertaken in up-hole section(s) of the well bore—that is, the portion of the well between the surface and said plug. Additionally, during downhole well intervention operations (that is, operations other than hydraulic fracturing), plugs and valves are periodically used inside a well bore to control, stop or regulate certain well performance variables such as flowrate and pressure.
Conventional bridge plugs typically suffer from a number of significant limitations. Many conventional mechanical bridge plugs are “permanent”, in the sense that they generally cannot be opened or removed from a wellbore after being set without performing complicated and/or expensive downhole milling operations. Although not as “permanent” in design, ball and seat valves can nonetheless be problematic, particularly during cementing and stimulation operations. Cement and stimulation proppant material (such as, for example, “frac sand” used in hydraulic fracturing operations) can negatively affect the sealing function and operation of said valves.
Thus, there is a need for an effective and versatile down-hole bridge plug that can be set at a desired location within a wellbore. The bridge plug should permit isolation of desired portion(s) of a wellbore, while permitting removal and/or opening of said plug when desired.
In a preferred embodiment, present invention comprises a valve assembly. Uses for said valve assembly can include, but are not limited to, a frac plug, fluid flow valve, check valve or well intervention device. The plug of the present invention can be used in bored holes, flow lines, sewer lines, open or closed well bores, agricultural applications, and medical procedures.
In a preferred embodiment, the present invention comprises a selectively closable flapper and a seat against which said flapper, when in a closed configuration, can form a fluid pressure seal. In addition, the present invention further comprises means (such as gripping slip members) to securely grip against a surrounding surface, and create a fluid pressure seal between said valve assembly and said inner surface of a surrounding wellbore or other structure. The sealing member(s) may be elastomeric or any other material that can create a seal between the invention and the inner walls of a surrounding wellbore or hole.
Actuation of said slip member(s) and seal(s) is typically accomplished using a conventional setting tool employing hydraulics, explosives, electronics, fluid pressure and/or the application of mechanical force. In a preferred embodiment, the present invention can also comprise at least one friction reducing element disposed on its outer surface to assist in running in a wellbore (including, without limitation, restrictions therein). Such friction reducing elements can be rolling devices such as ball transfer units or stationary sliding pads beneficially disposed on the exterior of the device.
The present invention can also be used as a check valve by setting a flapper to spring closed if fluid flow is in the opposite direction than desired. When acting as a check valve, the springs or other actuation methods on the present invention will make the device return to original (typically open) state once fluid pressure or flow has dissipated sufficiently to meet a predetermined level. The present invention can be used inside a well bore as a fluid flow control valve by controlling the flapper motion with a spring or other actuator. Depending on system needs, an actuator on the flapper can be sized to open and close in response to particular predetermined flow rates.
The present process that is used in the oilfield when setting a frac plug downhole is to deliver the plug to the desired position in the well, set the plug's slip and seals and then pull the setting tool and entire tool string out of the hole. The well head is opened and a ball is inserted into the well. The well head is closed again and the ball is pumped down into the well until it arrives at the seat. This process requires a large amount of fluid to pump the ball down but also a large amount of rig time which is extremely costly. The present invention does not require any additional pumping of fluid to seat a ball, thereby reducing the expense of fluid and this also reduces expensive rig time compared to such conventional methods.
Another benefit of the present invention is to reduce the amount of water pumped into downhole formations, which can adversely affect productivity of certain reservoirs. The present invention also allows a user, if desired, to perform other operations such as perforating an interval without the need to fully retrieve a toolstring or pipe completely out the well. The present invention facilitates increased efficiency of time, resources and money spent to perform current tasks common to industries such as the oilfield in particular in well hydraulic fracturing operations.
The present invention can also be used as a check valve by setting a flapper to spring closed if fluid flow is in an opposite direction than desired. When acting as a check valve, springs or other actuation methods on the present invention will make the device return to original (typically open) state once fluid pressure or flow has dissipated sufficiently to meet a predetermined level. The present invention can be used inside a well bore as a fluid flow control valve by controlling the flapper motion with a spring or other actuator. Depending on system needs, an actuator on the flapper can be sized to open and close in response to particular predetermined flow rates.
After a fracturing procedure is completed, the valve assembly becomes an obstruction that does not allow a well to flow past said valve assembly. However, fluid or pressure differential from below the invention can open the flapper, therefore allowing fluid or pressure movement. In one embodiment, the flapper of the current invention includes a spring that biases said flapper after pumping from the surface stops to allow for the well to begin flowing. With this embodiment, a standard oilfield fishing tool can be used to stab back into the body opening to retrieve the device from the well without milling or drilling. In another embodiment, the flapper of the said invention can be in a normally opened or closed position. Applied or natural fluid pressure, or pressure differential, can open the flapper from the normally closed position or close the flapper from a normally opened position.
The foregoing summary, as well as any detailed description of the preferred embodiments, is better understood when read in conjunction with the drawings and figures contained herein. For the purpose of illustrating the invention, the drawings and figures show certain preferred embodiments. It is understood, however, that the invention is not limited to the specific methods and devices disclosed in such drawings or figures.
Referring to the drawings,
Downhole valve assembly 100 of the present invention can be installed to selectively isolate one portion of a wellbore from another, to prevent fluid flow from one portion of a wellbore to another and/or to provide a fluid pressure sealing barrier at a desired location within a wellbore. Valve assembly 100 of the present invention can be beneficially set within the internal bore of a string of casing (such as casing string 10 depicted in
Valve assembly 100 of the present invention generally comprises a fluid pressure sealing flapper assembly having flapper 110, a mating flapper seat 111, upper gripping slip members 120, lower gripping slip members 130, sealing member 140 and body section 150. Although other relative positioning of said components can be used without departing from the scope of the present invention, said upper gripping slip members 120 and lower gripping slip members 130 are typically disposed on either side of said seal member 140.
In operation, valve assembly 100 of the present invention can be attached to a setting tool (such as setting tool 20) and conveyed into a well to a desired depth via continuous wire (such as, for example, electric line, slick line or braided line), continuous or coiled tubing, or jointed pipe. Once said valve assembly 100 is positioned at a desired location within a wellbore—that is, at the depth at which setting of valve assembly 100 is desired—said setting tool 20 can be actuated. Such actuation of setting tool 20 causes said upper gripping slip members 120 and lower gripping slip members 130 to expand radially outward to engage against a surrounding surface (such as inner surface 11 of casing string 10), and anchor said valve assembly 100 in place against axial movement within casing string 10. Such actuation of setting tool 20 also causes seal member 140 of said valve assembly 10 to expand radially outward until it contacts and forms a fluid pressure seal against a surrounding surface (such as inner surface 11 of casing string 10).
In a preferred embodiment, setting tool 20 can comprise a conventional wireline packer setting tool such as, for example, a Baker E4 Model 10 Setting Tool, which is well known to those having skill in the art. Notwithstanding the foregoing, it is to be observed that any number of other conventional setting tools can be used without departing from the scope of the present invention. As depicted in
Still referring to
In operation, setting tool 20 can be actuated, causing upper gripping slip members 120 and lower gripping slip members 130 to expand radially outward to engage against a surrounding surface (such as inner surface 11 of casing string 10 depicted in
Following such actuation and setting of valve assembly 100, setting tool 20 can be released from valve assembly 100 (such as by shearing of pins, for example) and pulled away from said valve assembly 100. As central mandrel 21 of setting tool 20 is extracted from the central bore of flapper seat body member 112, flapper 110 is no longer blocked and is allowed to pivot about hinge pin 113. Said flapper 110 can close until it contacts in mating relationship with flapper seat 111.
As depicted in
Referring to
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As depicted in
Flapper 110 can be constructed of a dissolvable material. If such dissolvable material is used, after a predetermined or preselected length of time, the flapper will dissolve, thereby substantially eliminating any flow obstruction blocking central flow bore 117 of flapper seat body member 112. Although other dissolvable materials having desired characteristics can be used without departing from the scope of the present invention, said flapper 110 can be constructed of magnesium alloy (such as, for example, the compound marketed under the mark “SoluMag”™) having a high but well-controlled corrosion rate, thereby effectively causing flapper 110 to dissolve in a known time.
Alternatively, said flapper 110 may also be constructed of a frangible material that can easily be broken into smaller pieces using a conventional device (such as, for example, an oilfield jar tool) to apply a predetermined contact force to said flapper. After contact with said breaking device, the pieces of flapper 110 are sufficiently small that they can fall to the bottom of the well, or can be circulated back to the surface for removal from a well. Flapper 110 can also be constructed of an easily drillable or millable material; for applications that do not require such removal of said flapper, a stronger, more durable material may be used.
In order to withstand greater loading and/or differential pressure across flapper 110, said flapper 110 can optionally include an increased or thicker body section 172 as depicted in
Further, in order to withstand greater loading and/or differential pressure across flapper 110, seat 111 and tool body 112 can be modified to add support as depicted in
The embodiments depicted in
During operation, valve assembly 100 of the present invention can be conveyed into a wellbore (via wireline or pipe) to a desired depth. Once at said depth, said valve assembly can be set to grip or anchor to, and form a fluid pressure seal against, the internal surface of a surrounding wellbore. When conveyed on wireline, said valve assembly can be set using a conventional wireline setting tool; when conveyed on pipe, said valve assembly can be set with a conventional hydraulic setting tool. The setting tool can then be at least partially removed from said valve assembly, permitting a flapper (such as flapper 110) to alternate from an open position to a closed position, and contact/close against a seat to form a fluid pressure seal preventing fluid from flowing around said flapper and through a central flow bore of said valve assembly.
Hydraulic fracturing or other operations can be performed within said wellbore. When desired, a frangible flapper can be selectively shattered into many small pieces by the application of contact force, such as via a conventional oilfield jar device. Such smaller shattered pieces can fall to the bottom of the wellbore, or can be circulated out of the wellbore. Alternatively, a dissolvable flapper can be permitted to dissolve within fluid(s) contained in said wellbore, thereby eliminating said fluid pressure seal between said flapper and seat.
Number | Date | Country | |
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62290512 | Feb 2016 | US |