Packer/Plug Slip and Cage With Travel Stop

Abstract

A first slip key is integral with an inner surface of a cage. A first travel stop is integral with the slip key. A first cone has a truncated head, a first shallow axial slot in the truncated head, and a first deep axial slot in the truncated head. The first deep axial slot is axially spaced from the first shallow axial slot. The first cone is insertable into the first end of the cage when the first deep axial slot is aligned with the first travel stop. The travel stop prevents the first cone from being extracted from the cage once the first cone is inserted into the first end of the cage and rotated relative to the cage about the longitudinal axis until the first travel stop is aligned with the first shallow axial slot.

Description

BACKGROUND

With current two ramp cone and/or slip designs there is a possibility of over travel of the cones on release. Such over travel may cause serious retrieval issues for intervention packers and/or plugs. Reducing the possibility of over travel is a challenge.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing a slip cage system with integral travel stops.

FIG. 2 is an exploded perspective view showing a slip cage system with integral travel stops.

FIG. 3A is a perspective view showing a cage.

FIG. 3B is a plan view showing one end of a cage.

FIG. 3C is a plan view showing a slip key.

FIG. 4A is a perspective view showing a slip.

FIG. 4B is a plan view showing a slip.

FIG. 5A is a perspective view showing a cone.

FIG. 5B is a perspective view showing a cone.

FIG. 5C is a plan view showing a cone.

FIG. 6 is a plan view showing a cone.

FIG. 7A is a cross-sectional perspective view showing the cage and slip being assembled.

FIG. 7B is a cross-sectional plan view showing the cage, slip and cone after assembly.

FIG. 8A is a perspective view showing a deep axial slot engaging a travel stop with the slips removed from the assembly.

FIG. 8B is a perspective view showing a travel stop engaging a shoulder with the slips removed from the assembly.

FIG. 9 is a perspective view showing a slip key engaging a shallow axial slot with the slips removed from the assembly.

FIG. 10 is a cross-sectional view showing slips engaging a cone with the cage removed from the assembly.

FIG. 11 is a cross-sectional view showing a slip cage system with one cone removed after the operations described in connection with FIG. 9 have been performed.

FIG. 12 is a cross-sectional view showing a slip cage system with force applied pushing the cones.

FIG. 13 is a cross-sectional view showing a slip cage system with force applied pulling the cones.

FIG. 14A is a cross-sectional plan view showing a bottom head surface engaging a first surface wall.

FIG. 14B is a perspective view showing a travel stop engaging a deep slot and a slip key engaging a shallow slot with the slips removed from the assembly.

FIG. 15 is a flow chart showing assembly of the slip cage system.

DETAILED DESCRIPTION

The following detailed description illustrates embodiments of the present disclosure. These embodiments are described in sufficient detail to enable a person of ordinary skill in the art to practice these embodiments without undue experimentation. It should be understood, however, that the embodiments and examples described herein are given by way of illustration only, and not by way of limitation. Various substitutions, modifications, additions, and rearrangements may be made that remain potential applications of the disclosed techniques. Therefore, the description that follows is not to be taken as limiting on the scope of the appended claims. In particular, an element associated with a particular embodiment should not be limited to association with that particular embodiment but should be assumed to be capable of association with any embodiment discussed herein.

Further, it will be understood that the equipment and techniques described herein are applicable in land-based systems, sea-based systems, multi-lateral wells, all types of production systems, all types of rigs, measurement while drilling (“MWD”)/logging while drilling (“LWD”) environments, wired drillpipe environments, coiled tubing (wired and unwired) environments, wireline environments, and similar environments.

The disclosed tool configurations and operations are best understood in the context of the larger systems in which they operate.

A slip cage system incorporates an integral travel stop at each end of the cage to prevent the cones from over traveling when they are released. Incorporating a stop shoulder at both ends of the cage, an axial and/or rotational bayonet type action is also incorporated to facilitate assembly and disassembly. The slips, cone and cage are built as a sub assembly with shear screws or pins, locking the parts together axially in the desired configuration for running in hole. Rotational location is provided by integrals keys. The sub assembly is then installed onto the packer and/or plug as a complete item during assembly.

FIG. 1 is a perspective view showing a slip cage system with integral travel stops. A slip cage system 105 has a cage 110. The cage 110 has a longitudinal axis 115. The cage 110 has an axial axis 120 substantially perpendicular (i.e., within 1, 5, or 10 degrees) to the longitudinal axis 115. The slip cage system 105 is coupled to a packer (not shown) and/or a plug (not shown).

The cage 110 is a hollow cylinder having a body 125, an outer surface 130 and an inner surface 135. The cage 110 has cage openings 140A-L (cage openings 140A-F are shown in FIG. 1, cage opening 140A and 140C are shown in view A of FIG. 1, cage openings 140G-L are not shown) in two axially-distributed rows in the body 125 of the cage 110. The cage 110 has at least two cage openings 140A and 140B longitudinally in line with each other. The plurality of cage openings 140 may be positioned axially and azimuthally along the body 125 of the cage 110. Although FIG. 1 illustrates six cage openings 140, it will be understood that the cage 110 may have more or fewer cage openings 140.

As illustrated in view A of FIG. 1, which shows a more detailed view of the portion of FIG. 1 bounded by dashed box A, the cage 110 may have a slip key 145 and a travel stop 150, which is described in more detail in connection with view B of FIG. 3A. The slip key 145 and the travel stop 150 are integral with each other.

The slip cage system 105 has slips 155A-F (slips 155A-B are shown in FIG. 1 and the others, which are arranged symmetrically around the circumference of the cage 110, are not shown to allow features of the slip cage system 105 to be illustrated). Only two slips 155A and 155B are shown. It will be understood the total number of slips 155 is variable according to system requirements. The slips 155 are coupled to the inner surface 135 of the cage 110. Slip 155A, which is representative of all of the slips 155, is positioned longitudinally along the inner surface 135 of the cage 110 and aligned with two cage openings 140A and 140B that are longitudinally parallel along the body 125 of the cage 110. The slips 155 fits into the cage openings 140.

The slip cage system 105 includes cone 160A and cone 160B (described in more detail in connection with FIG. 5). Cone 160A and cone 160B are couplable to the cage 110 and to the slips 155.

FIG. 2 is an exploded perspective view showing a slip cage system with integral travel stops. The slip cage system 105 includes the cage 110, the slips 155A-F and the cones 160A and 160B. The cage 110 includes the body 125, the outer surface 130 and the inner surface 135. The cage 110 has shear bolt holes 205A-L (shear bolt holes 205A-H and shear bolt holes 205K-L are shown in FIG. 2; shear bolt holes 2051-J are not shown). The shear bolt holes 205 (referring to shear bolt holes 205A-L) are positioned axially around the body 125 of the cage 110. The cage 110 has the first passage 210 (indicated by the arrow) and the second passage 215, opposite the first passage 210 (indicated by the arrow).

Each cone 160A, 160B has a respective cone body 220A, 220B. The cone body 220A, 220B has shear bolt holes 225A-F for cone 160A and shear bolt holes 225G-L for cone 160B positioned radially around the respective cone body 220A, 220B. Shear bolt holes 225A, 225E-F, 225G and 225K-L are shown in FIG. 2, and shear bolt holes 225B-D, and 225H-I are not shown. In application, the cone 160A is inserted into the first passage 210. The cone 160B is inserted into the second passage 215, or vice versa. When the cone 160A is inserted into the first passage 210 the shear bolt holes 225A-F align with cage shear bolt holes 205A-F. Shear bolts are inserted (not shown) into the aligned shear bolt holes (225A-F and 205A-F) securing the cage 110 and the cone 160A when deployed. This same method is performed for cone 160B and second passage 215.

FIG. 3A is perspective view showing a cage. The cage 110 has a plurality of slip keys 145 (referring to slip keys 145A-L, where slip keys 145A, 145C, 145G, 145J, 145K, and 145L are visible in FIG. 3A, slips keys 145A-F are visible in FIG. 3B, and slip keys 145H and 145I are not visible but are indicated in FIG. 3A) positioned substantially parallel (i.e., within 1, 5, or 10 degrees) to the longitudinal axis 115 and integral with the inner surface 135 of the cage 110 between consecutive cage openings 140A-L (e.g., slip key 145B is between cage opening 140B and 140D). The cage 110 has at least two slip keys 145 (such as slip keys 145A and 145G, slip keys 145B and 145H, slip keys 145C and 145I, slip keys 145D and 145J, slip keys 145E and 145K, slip keys 145F and 145L) positioned in line along the inner surface 135 and substantially parallel (i.e., within 1, 5, or 10 degrees) to the longitudinal axis 115. The slip keys 145A-F may be uniformly spaced around the circumference of the cage 110. The slip keys 145G-L may be uniformly spaced around the circumference of the cage 110. The slip keys 145A-F have the opposite orientation of the slip keys 145G-L. That is, the travel stop 150 on slip keys 145A-F is closer to the second passage 215 than the first passage 210 and the travel stop 150 on slip keys 145G-L is closest to the first passage 210 than the second passage 215.

FIG. 3B is a plan view showing the end of the cage 110 having the second passage 215. As illustrated, the outer surface 130 has a radius RO and the inner surface 135 has a radius RI, where the value of RO is greater than the value of RI (RO>RI). Although FIGS. 3A and 3B show or suggest twelve slip keys 145, it will be understood that the cage 110 may have more or fewer slip keys 145.

FIG. 3C is a plan view showing a slip key. The slip key 145G (which is representative of all slip keys 145A-L) has an axial height H measured from the inner surface 135 of the cage 110. The slip key 145G has a width W (illustrated in FIG. 3B) and a length L. The slip key 145G has the travel stop 150 (indicated by the cross-hatching)(the travel stops 150 on all of the slip keys 145A-L are the same and the following discussion applies to all such travel stops).

The travel stop 150 includes a first ramp 305 and a first surface 310 adjacent the first ramp 305. The first ramp 305 integrates with the first surface 310 at an angle M, where M is between 75 degrees and 10 degrees. The first surface 310 has a length L1. The first surface 310 has an axial height H1 measured from the inner surface 135 of the cage 110. In one or more embodiments, H1 is greater than H (H1>H). The first surface 310 is integral with and adjacent to a first surface wall 315. The first surface wall 315 is substantially (i.e., within 1, 5 or 10 degrees) perpendicular to the axial axis 120.

The travel stop 150 has a second surface 320 adjacent the first surface wall 315. The second surface 315 has a length L2. The second surface 315 has an axial height H2 measured from the inner surface 135 of the cage 110. H2 may be substantially equal (i.e., within 0.01 inches, 0.05 inches and 0.1 inch) to H. L2 may be less than L1 (L2<L1). The travel stop 150 has a second surface wall 325 integral with and adjacent to the second surface 320. The second surface wall 325 is substantially (i.e., within 1, 5, or 10 degrees) perpendicular to the axial axis 120.

The travel stop 150 has a third surface 330 adjacent to the second surface wall 325. The third surface 330 has a length L3. The third surface 320 has an axial height H3 measured from the inner surface 135 of the cage 110. H3 is less than H (H3<H). L3 is greater than L2 (L3>L2). In one embodiment, L3 is less than L1 (L3<L1). In one embodiment, L3 is greater than L1 L3>L1). In one embodiment, L3 is equal to L1 (L3=L1). The travel stop 150 may have a last ramp 335 adjacent the third surface 330. The last ramp 335 integrates with a last surface 340 at an angle N, where N is between 10 degrees and 75 degrees.

For example:

L=2.56 inch

L1=0.32 inch

L2=0.12 inch

L3=0.14 inch

H=0.23 inch

H1=0.31 inch

H2=0.23 inch

H3=0.18 inch

M=30 degrees

N=30 degrees

FIG. 4A is a perspective view showing a slip. FIG. 4B is a plan view showing a slip. The slip cage system 105 includes the slip 155 (referring to slips 155A-E). The slip 155 has a first raised end 405 and a second raised end 410 opposite the first raised end 405. The slip 155 has a middle recessed member 415. The middle recessed member 415 is positioned between the first raised end 405 and second raised end 410. The middle recessed member 415 is integral with the first raised end 405 and the second raised end 410. The slips 155 mate with the cage openings 140 as shown in FIG. 1. The middle recessed member 415 rests against the inner surface 135 of the cage 110.

The first raised end 405 has a first hook 420 and the second raised end 410 has a second hook 425. The first raised end 405 has a first hook wall 430 adjacent the first hook 420. The second raised end 410 has a second hook wall 435 adjacent the second hook 425.

FIGS. 5A and 5B are perspective views showing a cone. FIG. 5C is a plan view showing a cone. The cone 160 (representative of cones 160A and 160B) has a truncated head 505. The truncated head 505 may be inserted into the first passage 210, as shown in FIG. 1 and FIG. 2. The truncated head 505 may be inserted into the second passage 215, as shown in FIG. 1 and FIG. 2.

The truncated head 505 has a top head surface 510 facing in the direction of extension of the longitudinal axis 115 and a bottom head surface 515 facing in the direction of extension of the longitudinal axis 115. The edge of the bottom head surface 515 closest to the longitudinal axis 115 has a radius RH. RH is less than RI (i.e., the radius of the cage inner surface 135) (RH<RI).

The truncated head 505 has an outer surface 520 facing in the direction of extension of the axial axis 120 and located between the top head surface 510 and the bottom head surface 515. A truncated head ramp 525 is integral with and connects the outer surface 520 and the top head surface 510. The truncated head ramp 525 integrates with the outer surface at an angle P, where P is between 10 degrees and 75 degrees.

The truncated head 505 has deep axial slots 530A-F (deep axial slots 530A-B are shown in FIGS. 5A-C, deep axial slot 530C is shown in FIGS. 5A and 5B, and deep axial slots 530D-F are not shown in FIGS. 5A-C but are indicated in FIG. 5A) positioned axially around the outer surface 520. Although FIGS. 5A, 5B and 5C show six deep axial slots 530A-F, it will be understood that the truncated head 505 may have more or fewer deep axial slots.

The truncated head 505 has shallow axial slots 535A-F (shallow axial slots 535A-B are shown in FIGS. 5A-C, shallow axial slot 535C is shown in FIGS. 5A and 5B, and shallow axial slots 535D-F are not shown in FIGS. 5A-C but are indicated in FIG. 5A) positioned axially around the outer surface 520 alternating with the deep axial slots 530A-F. Although FIGS. 5A, 5B and 5C depict six shallow axial slots 535A-F, it will be understood that the truncated head 505 may have more or fewer shallow axial slots 535.

The cone 160 has a cone neck 540 integral with the bottom head surface 515 and having a cylindrical surface parallel to the longitudinal axis 115. The cone neck 540 has a radius RN that is less than RI (the inner radius of the inner surface 135 of the cage 110)−H1 (the height of the first surface 310 of the slip key 145), i.e. RN<RI−H1. The cone neck 540 has a height HN substantially equal to L1 (the length of the first surface 310 of the travel stop 150), which allow the first surface 310 of the travel stop 150 to fit against the cone neck 540.

The cone 160 has a shoulder 545 integral with the cone neck 540. The cone 160 has an angle Q between the shoulder 545 and neck 540, where Q is between 10 degrees and 75 degrees. The angle Q between the shoulder 540 and the cone neck 535 is substantially (i.e., within 1, 5, or 10 degrees) the same as the angle M between the first ramp 305 and the first surface 310 of the travel stop 150.

The shoulder 545 has deep slots 550A-F (deep slots 550A-C are shown in FIGS. 5A-C and deep slots 550D-F are not shown in FIGS. 5A-C but are located symmetrically around the shoulder 545) positioned longitudinally in line with respective shallow axial slots 535A-F (that is, deep slots 550A is longitudinally in line with shallow axial slot 535A, deep slots 550B is longitudinally in line with shallow axial slot 535B, deep slots 550C is longitudinally in line with shallow axial slot 535C, and so on). Although FIGS. 5A, 5B and 5C depict six deep slots 550A-F, it will be understood that the shoulder 545 may have more or fewer deep slots 550. Typically, the number of deep slots is the same as the number of shallow axial slots.

The cone body 220 is integral with the shoulder 545. The cone body 220 has a cylindrical surface 555 parallel to the longitudinal axis 115. The cone body 220 has a radius BR that is less than RI and greater than RN, i.e., RN<BR<RI.

The cone 160 includes a bottom end 560 that extends outside of the cage 110 when the truncated head 505 is inserted into the cage 110. The bottom end 560 has a cylindrical surface 565 parallel to the longitudinal axis 115. The bottom end 560 has a radius BER that is equal to or less than BR, i.e. BER≤BR.

FIG. 6 is a plan view showing the cone of FIG. 5C along sight line 6. View C of FIG. 6, which is an expanded view of one of the deep axial slots 530A (but is representative of all deep axial slots 530A-F), one of the shallow axial slots 535A (but is representative of all shallow axial slots 535A-F), and one of the deep slots 550A (but is representative of all of the deep slots 550A-F). The deep axial slot 530A has a cavity depth CDASD (cone deep axial slot depth) and a cavity width CDASW (cone deep axial slot width). CDASW is greater than the width W of the slip key 135. CDASW is greater than the width W of the slip key 135. The shallow axial slot 535A has a cavity depth CSASD (cone shallow axial slot depth) and a cavity width CSASW (cone shallow axial slot width). The dimensions are selected such that:

CDASD−(H2−H3)−tolerance<CSASD<CDASD−(H2−H3)  (1)

CSASW>W  (2)

In one embodiment, tolerance is 0.1 inch.

The deep slot 550A may have a cavity depth CDSD (cone deep slot depth) that is substantially (i.e., within 0.01 inches, 0.05 inches, or 0.1 inch) equal to H1 and a cavity width CDSW (cone deep slot width) that is greater than W:

CDSD=H1  (3)

CDSW>W  (4)

For example:

CDASD=0.150 inch

CDASW=0.300 inch

CSASD=0.180 inch

CSASW=0.290 inch

CDSD=0.160 inch

CDSW=0.375 inch

FIG. 7A is a cross-sectional perspective view showing the cage and slip being assembled. Slip 155A is coupled to the inner surface 135 of the cage 110, as indicated by arrow 705. Note, for simplicity of presentation, only one slip 155A is shown. Assembly of slips 155B-F into the cage 110 is similar. The first raised end 405 of the slip 155A aligns with the first cage opening 140A. The second raised end 410 of the slip 155 aligns with the second cage opening 140B. The middle recessed member 415 couples against the inner surface 135.

FIG. 7B is a cross-sectional plan view showing the cage, slip and cone after assembly. The cone 160A is inserted into the first passage 215, as illustrated by arrow 710. Insertion of the cone 160A into the first passage 215 causes the first raised end 405 of the slip 155A to rise into the first cage opening 140A, the second raised end 410 of the slip 155 to rise into the second cage opening 140B, and the middle recessed member 415 to couple against the inner surface 135 of the cage 110, as illustrated by arrow 715.

FIG. 8A is a perspective view showing a deep axial slot engaging a travel stop with the slips removed from the assembly. FIG. 8B is a perspective view showing a travel stop engaging a shoulder with the slips removed from the assembly.

As illustrated in FIG. 8A, once the cone 160A is inserted into the cage 110, the deep axial slot 530A engages with the first surface 310 of the travel stop 150. As illustrated in FIG. 8B, the cone 160A is further inserted causing the first surface 310 of the travel stop 150 to engage with the neck 540 of the cone 160A. The cone 160A is further inserted until the first ramp 305 engages the shoulder 545, at which point the cone 160A cannot be inserted any further into the cage 110.

FIG. 9 is a perspective view showing a slip key engaging a shallow axial slot with the slips removed from the assembly. After the cone 160A is inserted into the cage 110 and the first ramp 305 engages the shoulder 545, the cone 160A is rotated about the longitudinal axis 115 until the shallow axial slot 535 aligns with the third surface 330 of the travel stop 150. At this point, shear bolts are inserted into the shear bolt holes 205A-L in the cage 110 and 225A-L in the cones 160A and 160B, securing the cones 160A and 160B to the cage 110. At this point, the cone 160A can no longer rotate with respect to the cage 110. The interaction between the cone 160A and the slip key 145 up to this point is governed by the relationships set out in equations (1) and (2).

FIG. 10 is a cross-sectional view showing slips engaging a cone with the cage removed from the assembly. The first hook 420 of the first raised end 405 of the slip 155A couples to the neck 540 and shoulder 545 of the cone 160A. The second hook 425 of the second raised end 410 of the slip 155A couples to the neck 540 and shoulder 545 of the cone 160B (not shown, but has the same interaction as cone 160A). The relationship between the cones 160A, 160B and the slips A-F initially prevents the cones 160A and/or 160B from exiting the cage 110 but allows the cones 160A, 160B to rotate with respect to the cage 110.

FIG. 11 is cross-sectional view showing a slip cage system with one cone removed after the operations described in connection with FIG. 9 have been performed. As illustrated by arrows 1105 and 1110, the slip 155A rests against the cone 160A and shear bolts 1110 have been inserted. The slip 155A, the shear bolts 1110, and the shallow axial slot 535 prevent the cone 160A from being pulled from or rotated with respect to the cage 110.

FIG. 12 is a cross-sectional view showing a slip cage system with force applied pushing the cones. The slip cage system 105 can be inserted into a borehole 1205. When the slip cage system 105 is in the location where it is desired to deploy the slips 155A-F (slips 155A-C are shown, slips 155D-F are not shown), force is applied from the surface pushing the cones 160A, 160B into the cage 110, shearing the shear bolts 1110, moving the slip keys 145A-L (slip keys 145A, 145D, 145G and 145J are shown and slip keys 145B-C, 145E-F, 145H-I, and 145K-L are not shown) of the cage 110 into the deep slots 550 of the cones 160A, 160B, and deploying the slips 155 through the cage openings 140.

FIG. 13 is a cross-sectional view showing a slip cage system with force applied pulling the cones. Subsequently, when it is desired to un-deploy the slips 155A-F (slips 155A-C are shown, slips 155D-F are not shown), force is applied from the surface pulling the cones 160A, 160B from the cage 110, causing the first surface wall 315 of the slip keys 145A-L (slip keys 145A-D and slip keys 145G-J are shown; slip keys 145E-F and slip keys 145K-L are not shown) to engage with the bottom head surface 515 of the cones 160A, 160B.

FIG. 14A is a cross-sectional plan view showing a bottom head surface engaging a first surface wall. The cone 160A and/or 160B over travels when HV equals zero (i.e., the middle recessed member 415 rests against the inner surface wall 135) or when the slips 155A-F are stuck against the borehole wall. At this point, the cones 160A-B may over travel in the direction of the longitudinal axis 115. As illustrated in FIG. 12A, at the onset of potential over travel of cone 160A, the bottom head surface 515 engages with the first surface wall 315 preventing the cone 160A from over traveling and exiting the cage 110.

FIG. 14B is a perspective view showing a travel stop engaging a deep slot and a slip key engaging a shallow slot with the slips removed from the assembly. The deep slot 550 will engage the first ramp 305 preventing the cone 160A from traveling further into the cage 110. The cone 160A is thereby secured from over traveling in any direction along the longitudinal axis 115. Note, this method of preventing over travel is applicable with cone 160B and slips 155B-F. Prevention of the cone 160A or 160B is governed by the relationship of the equations (1)-(4).

FIG. 15 is a flow chart showing assembly of the slip cage system. A technique for preventing a cone from traveling may include coupling a slip (such as slip 155) to a cage (such as cage 110), the cage (such as cage 110) having: a longitudinal axis (such as longitudinal axis 115); an axial axis (such as axial axis 120) perpendicular to the longitudinal axis (such as longitudinal axis 115); an inner surface (such as inner surface 135); a slip key (such as slip key 145) integral to the inner surface (such as inner surface 135); and a travel stop (such as travel stop 150) integral to the slip key (such as slip key 145) (block 1505). Align a deep axial slot (such as deep axial slot 530) of a cone (such as cone 160) with the slip key (such as slip key 145) of the cage (such as cage 110) (block 1510). Insert the cone (such as cone 160) with the slip key (such as slip key 145) of the cage (such as cage 110) (block 1515). Rotate the cone (such as cone 160) relative to the cage (such as cage 110) until a shallow axial slot (such as shallow axial slot 535) in the cone (such as cone 160) and a deep slot (such as deep slot 550) in the cone (such as cone 160) are longitudinally aligned with the slip key (such as slip key 145) (block 1520). Affix the cone (such as cone 160) to the cage (such as cage 110) with a shear bolt) (block 1525). Insert the cage (such as cage 110), the cone (such as cone 160), and the slip (such as slip 155) into a borehole (such as borehole 1205) (block 1530). Apply force to push the cone (such as cone 160) into the cage (such as cage 110) causing the shear bolt to shear, the slip key (such as slip key 145) to move into the deep slot (such as deep slot 550) in the cone (such as cone 160), the slip (such as slip 155) to deploy against the borehole (such as borehole 1205) (block 1535). Apply force to pull the cone (such as cone 160) out of the cage (such as cage 110) causing the slip key (such as slip key 145) to move out of the deep slot (such as deep slot 550) but to be prevented from further travel by not being able to pass through the shallow axial slot (such as shallow axial slot 535) (block 1540).

In one aspect, an apparatus includes a cage having a longitudinal axis and an axial axis perpendicular to the longitudinal axis. The cage includes a first passage at a first end of the cage. The cage includes a second passage at a second end of the cage opposite the first end of the cage. The cage includes an outer surface having a radius RO, a cage inner surface having a radius RI, RO>RI. The cage includes a first cage opening in the cage outer surface and a second cage opening in the cage outer surface longitudinally in line with the first cage opening. The apparatus includes a first slip key substantially parallel to the longitudinal axis and integral with an inner surface of the cage and having an axial height H measured from the cage inner surface and a width W. The first slip key includes a first travel stop integral with the slip key. The apparatus includes a first cone having a truncated head, a first shallow axial slot in the truncated head, and a first deep axial slot in the truncated head. The first deep axial slot is axially spaced from the first shallow axial slot. The first cone is insertable into the first end of the cage when the first deep axial slot is aligned with the first travel stop. The travel stop prevents the first cone from being extracted from the cage once the first cone is inserted into the first end of the cage and rotated relative to the cage about the longitudinal axis until the first travel stop is aligned with the first shallow axial slot.

Implementations may include one or more of the following. The cage may include a first slip insertable into the cage. The slip may have a first raised end, a second raised end opposite the first raised end, and a middle recessed member between the first raised end and the second raised end. The first slip may be deployable through the first cage opening and the second cage opening when the travel stop is aligned with the shallow axial slot and force is applied pressing the first cone into the cage. A second slip key may be positioned in line with the first slip key along the inner surface of the cage and substantially parallel to the longitudinal axis. The second slip key may have a second travel stop, wherein the first travel stop may be integral to the first slip key on a portion of the first slip key that is closer to the first end of the cage. The second travel stop may be integral to the second slip key on a portion of the second slip key that is closer to the second end of the cage. A second cone may be insertable into the second end of the cage. The travel stop may include a first ramp and a first surface adjacent the first ramp. The first surface may have an axial height H1 measured from the cage inner surface>H, and a length L1 substantially parallel to the longitudinal axis. A second surface may be adjacent the first surface. The second surface may have an axial height H2 measured from the cage inner surface substantially equal to H; and may have a length L2<L1. A third surface may be adjacent the second surface. The third surface may have an axial height H3 measured from the cage inner surface<H; and a length L3, wherein L3>L2, and L3<L1. A last ramp may be adjacent the third surface. The truncated head may have a top head surface, a bottom head surface opposite the top head surface. The bottom head surface may have a radius RH; wherein RH<RI, and an outer surface between the top head surface and the bottom head surface. The deep axial slot may include a cavity depth CDASD, and a cavity width CDASW that is greater than W. The shallow axial slot may have a cavity depth CSASD, where CDASD−(H2−H3)−0.1<CSASD<CDASD−(H2−H3), and a cavity width CSASW greater than W. The first cone further may include a cone neck integral with the bottom head surface and having a cylindrical surface parallel to the longitudinal axis. The cone neck may have a radius<(RI−H1); and a height substantially equal to L1. A shoulder may be integral with the cone neck and substantially parallel to the first ramp. The shoulder may have a deep slot longitudinally in line with the shallow axial slot. The deep slot may have a cavity depth CDSD substantially equal to H; and a cavity width CDSW greater than to W. The first cone may have a bottom end that extends outside of the cage when the truncated head is inserted into the cage.

In one aspect, a system includes a packer. The packer is coupled to a cage. The cage has a longitudinal axis, and an axial axis perpendicular to the longitudinal axis. The cage includes a first passage at a first end of the cage. The cage includes a second passage at a second end of the cage opposite the first end of the cage. The cage includes an outer surface having a radius RO, a cage inner surface having a radius RI, RO>RI. The cage includes a first cage opening in the cage outer surface, a second cage opening in the cage outer surface longitudinally in line with the first cage opening. The apparatus includes a first slip key substantially parallel to the longitudinal axis and integral with an inner surface of the cage and having an axial height H measured from the cage inner surface and a width W. The first slip key includes a first travel stop integral with the slip key. The system includes a first cone having a truncated head, a first shallow axial slot in the truncated head, and a first deep axial slot in the truncated head. The first deep axial slot is axially spaced from the first shallow axial slot. The first cone is insertable into the first end of the cage when the first deep axial slot is aligned with the first travel stop. The travel stop prevents the first cone from being extracted from the cage once the first cone is inserted into the first end of the cage and rotated relative to the cage about the longitudinal axis until the first travel stop is aligned with the first shallow axial slot.

Implementations may include one or more of the following. The cage may include a first slip insertable into the cage. The slip may have a first raised end, a second raised end opposite the first raised end, and a middle recessed member between the first raised end and the second raised end. The first slip maybe deployable through the first cage opening and the second cage opening when the travel stop is aligned with the shallow axial slot and force is applied pressing the first cone into the cage. A second slip key may be positioned in line with the first slip key along the inner surface of the cage and substantially parallel to the longitudinal axis. The second slip key may have a second travel stop, wherein the first travel stop may be integral to the first slip key on a portion of the first slip key that is closer to the first end of the cage. The second travel stop may be integral to the second slip key on a portion of the second slip key that is closer to the second end of the cage. A second cone may be insertable into the second end of the cage. The travel stop may include a first ramp and a first surface adjacent the first ramp. The first surface may have an axial height H1 measured from the cage inner surface>H, and a length L1 substantially parallel to the longitudinal axis. A second surface may be adjacent the first surface. The second surface may have an axial height H2 measured from the cage inner surface substantially equal to H; and may have a length L2<L1. A third surface may be adjacent the second surface. The third surface may have an axial height H3 measured from the cage inner surface<H; and a length L3, wherein L3>L2, and L3<L1. A last ramp may be adjacent the third surface. The truncated head may have a top head surface, a bottom head surface opposite the top head surface. The bottom head surface may have a radius RH, wherein RH<RI, and an outer surface between the top head surface and the bottom head surface. The deep axial slot may include a cavity depth CDASD, and a cavity width CDASW that is greater than W. The shallow axial slot may have a cavity depth CSASD, where CDASD−(H2−H3)−0.1<CSASD<CDASD−(H2−H3), and a cavity width CSASW greater than W. The first cone further may include a cone neck integral with the bottom head surface and having a cylindrical surface parallel to the longitudinal axis. The cone neck may have a radius<(RI−H1) and a height substantially equal to L1. A shoulder may be integral with the cone neck and substantially parallel to the first ramp. The shoulder may have a deep slot longitudinally in line with the shallow axial slot. The deep slot may have a cavity depth CDSD substantially equal to H and a cavity width CDSW greater than to W. The first cone may have a bottom end that extends outside of the cage when the truncated head is inserted into the cage.

In one aspect, a method includes coupling a slip to a cage. The cage has a longitudinal axis and an axial axis perpendicular to the longitudinal axis. The cage has an inner surface, a slip key integral to the inner surface, and a travel stop integral to the slip key. A deep axial slot of a cone is aligned with the slip key of the cage. The cone is inserted into the cage. The cone is rotated relative to the cage until a shallow axial slot in the cone and a deep slot in the cone are longitudinally aligned with the slip key. The cone is affixed to the cage with a shear bolt. The cage, the cone, and the slip are inserted into a borehole. Force is applied to push the cone into the cage causing the shear bolt to shear, the slip key to move into the deep slot in the cone, and the slip to deploy against the borehole. Force is applied to pull the cone out of the cage causing the slip key to move out of the deep slot but to be prevented from further travel by not being able to pass through the shallow axial slot.

Implementations may include one or more of the following. The slip may include a first raised end, a second raised end opposite the first raised end, and a middle recessed member between the first raised end and the second raised end. A second cone may be inserted into the cage. The second cone may be rotated relative to the cage until a shallow axial slot in the second cone and a deep slot in the cone are longitudinally aligned with the slip key. The second cone may be affixed to the cage with a shear bolt.

The word “coupled” herein means a direct connection or an indirect connection.

The text above describes one or more specific embodiments of a broader invention. The invention also is carried out in a variety of alternate embodiments and thus is not limited to those described here. The foregoing description of an embodiment of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto.

Claims

1. An apparatus comprising:

a cage having: a longitudinal axis, an axial axis perpendicular to the longitudinal axis, a first passage at a first end of the cage, a second passage at a second end of the cage opposite the first end of the cage, a cage outer surface having a radius RO, a cage inner surface having a radius RI, RO>RI, a first cage opening in the cage outer surface, a second cage opening in the cage outer surface longitudinally in line with the first cage opening, a first slip key substantially parallel to the longitudinal axis and integral with an inner surface of the cage and having an axial height H measured from the cage inner surface and a width W; a first travel stop integral with the slip key;

a first cone having: a truncated head, a first shallow axial slot in the truncated head, and a first deep axial slot in the truncated head, the first deep axial slot being axially spaced from the first shallow axial slot, the first cone being insertable into the first end of the cage when the first deep axial slot is aligned with the first travel stop;

wherein the travel stop prevents the first cone from being extracted from the cage once the first cone is inserted into the first end of the cage and rotated relative to the cage about the longitudinal axis until the first travel stop is aligned with the first shallow axial slot.

2. The apparatus of claim 1 further comprising:

a first slip insertable into the cage, the slip having: a first raised end; a second raised end opposite the first raised end; and a middle recessed member between the first raised end and the second raised end;

wherein the first slip is deployable through the first cage opening and the second cage opening when the travel stop is aligned with the shallow axial slot and force is applied pressing the first cone into the cage.

3. The apparatus of claim 1 further comprising:

a second slip key positioned in line with the first slip key along the inner surface of the cage and substantially parallel to the longitudinal axis;

the second slip key having a second travel stop;

wherein the first travel stop is integral to the first slip key on a portion of the first slip key that is closer to the first end of the cage; and

wherein the second travel stop is integral to the second slip key on a portion of the second slip key that is closer to the second end of the cage.

4. The apparatus of claim 1, further comprising:

a second cone insertable into the second end of the cage.

5. The apparatus of claim 1 wherein the travel stop comprises:

a first ramp;

a first surface adjacent the first ramp, the first surface having: an axial height H1 measured from the cage inner surface>H; and a length L1 substantially parallel to the longitudinal axis;

a second surface adjacent the first surface, the second surface having: an axial height H2 measured from the cage inner surface substantially equal to H; and a length L2<L1;

a third surface adjacent the second surface, the third surface having: an axial height H3 measured from the cage inner surface<H; and a length L3, wherein L3>L2, and L3<L1; and

a last ramp adjacent the third surface.

6. The apparatus of claim 5 wherein:

the truncated head further comprises: a top head surface, a bottom head surface opposite the top head surface, the bottom head surface having a radius RH; wherein RH<RI, and an outer surface between the top head surface and the bottom head surface;

the deep axial slot has: a cavity depth CDASD, and a cavity width CDASW that is greater than W;

the shallow axial slot has: a cavity depth CSASD, where CDASD−(H2−H3)−0.1<CSASD<CDASD−(H2−H3), and a cavity width CSASW greater than W; and

the first cone further comprises: a cone neck integral with the bottom head surface and having a cylindrical surface parallel to the longitudinal axis, the cone neck having: a radius<(RI−H1); and a height substantially equal to L1; a shoulder integral with the cone neck and substantially parallel to the first ramp, the shoulder having: a deep slot longitudinally in line with the shallow axial slot, the deep slot having: a cavity depth CDSD substantially equal to H; and a cavity width CDSW greater than to W; and a bottom end that extends outside of the cage when the truncated head is inserted into the cage.

7. A system comprising:

a packer;

a cage coupled to the packer, the cage having: a longitudinal axis, an axial axis perpendicular to the longitudinal axis, a first passage at a first end of the cage, a second passage at a second end of the cage opposite the first end of the cage, a cage outer surface having a radius RO, a cage inner surface having a radius RI, RO>RI, a first cage opening in the cage outer surface, a second cage opening in the cage outer surface longitudinally in line with the first cage opening, a first slip key substantially parallel to the longitudinal axis and integral with an inner surface of the cage and having an axial height H measured from the cage inner surface and a width W; a first travel stop integral with the slip key; and

a first cone having: a truncated head, a first shallow axial slot in the truncated head, and a first deep axial slot in the truncated head, the first deep axial slot being axially spaced from the first shallow axial slot, the first cone being insertable into the first end of the cage when the first deep axial slot is aligned with the first travel stop;

wherein the travel stop prevents the first cone from being extracted from the cage once the first cone is inserted into the first end of the cage and rotated relative to the cage about the longitudinal axis until the first travel stop is aligned with the first shallow axial slot.

8. The system of claim 7 further comprising:

a first slip insertable into the cage, the slip having: a first raised end; a second raised end opposite the first raised end; and a middle recessed member between the first raised end and the second raised end;

wherein the first slip is deployable through the first cage opening and the second cage opening when the travel stop is aligned with the shallow axial slot and force is applied pressing the first cone into the cage.

9. The system of claim 7 further comprising:

a second slip key positioned in line with the first slip key along the inner surface of the cage and substantially parallel to the longitudinal axis; and

the second slip key having a second travel stop;

wherein the first travel stop is integral to the first slip key on a portion of the first slip key that is closer to the first end of the cage; and

wherein the second travel stop is integral to the second slip key on a portion of the second slip key that is closer to the second end of the cage.

10. The system of claim 7, further comprising:

a second cone insertable into the second end of the cage.

11. The system of claim 7 wherein the travel stop comprises:

a first ramp;

a first surface adjacent the first ramp, the first surface having: an axial height H1 measured from the cage inner surface>H; and a length L1 substantially parallel to the longitudinal axis;

a second surface adjacent the first surface, the second surface having: an axial height H2 measured from the cage inner surface substantially equal to H; and a length L2<L1;

a third surface adjacent the second surface, the third surface having: an axial height H3 measured from the cage inner surface<H; and a length L3, wherein L3>L2, and L3<L1; and

a last ramp adjacent the third surface.

12. The system of claim 11 wherein:

the truncated head further comprises: a top head surface, a bottom head surface opposite the top head surface, the bottom head surface having a radius RH; wherein RH<RI, and an outer surface between the top head surface and the bottom head surface;

the deep axial slot has: a cavity depth CDASD, and a cavity width CDASW that is greater than W;

the shallow axial slot has: a cavity depth CSASD, where CDASD−(H2−H3)−0.1<CSASD<CDASD−(H2−H3), and a cavity width CSASW greater than W; and

the first cone further comprises: a cone neck integral with the bottom head surface and having a cylindrical surface parallel to the longitudinal axis, the cone neck having: a radius<(RI−H1); and a height substantially equal to L1; a shoulder integral with the cone neck and substantially parallel to the first ramp, the shoulder having: a deep slot longitudinally in line with the shallow axial slot, the deep slot having: a cavity depth CDSD substantially equal to H; and a cavity width CDSW greater than to W; a bottom end that extends outside of the cage when the truncated head is inserted into the cage.

13. A method comprising:

coupling a slip to a cage, the cage having: a longitudinal axis; an axial axis perpendicular to the longitudinal axis; an inner surface; a slip key integral to the inner surface; and a travel stop integral to the slip key;

aligning a deep axial slot of a cone with the slip key of the cage;

inserting the cone into the cage;

rotating the cone relative to the cage until a shallow axial slot in the cone and a deep slot in the cone are longitudinally aligned with the slip key;

affixing the cone to the cage with a shear bolt;

inserting the cage, the cone, and the slip into a borehole;

applying force to push the cone into the cage causing: the shear bolt to shear, the slip key to move into the deep slot in the cone, the slip to deploy against the borehole; and

applying force to pull the cone out of the cage causing the slip key to move out of the deep slot but to be prevented from further travel by not being able to pass through the shallow axial slot.

14. The method of claim 13 wherein the slip comprises:

a first raised end;

a second raised end opposite the first raised end; and

a middle recessed member between the first raised end and the second raised end.

15. The method of claim 13 further comprising:

inserting a second cone into the cage;

rotating the second cone relative to the cage until a shallow axial slot in the second cone and a deep slot in the cone are longitudinally aligned with the slip key; and

affixing the second cone to the cage with a shear bolt.