Flapper on Frac Plug That Allows Pumping Down a New Plug
A zonal isolation device conveyed into the wellbore with a propped flapper valve. The zonal isolation device comprises a deformable sealing element and a support ring movably disposed within the inner bore of the sealing element. A flapper valve coupled to the support ring is configured to engage a sealing surface of support ring. The flapper valve blocks fluid flow through the zonal isolation device in a fully closed position, allows unrestricted fluid flow through the zonal isolation device in a fully open position, and allows restricted fluid flow through the zonal isolation device when held by a propping component in an intermediate or partially open position. The zonal isolation device is anchored to the wellbore by an anchoring assembly engaged with a wedge coupled to the downhole end of the sealing element.
This application is a Divisional of and claims priority to U.S. patent application Ser. No. 14/800,358 filed Feb. 25, 2020 and published as U.S. Patent Application Publication No. 2021/0054714 A1, which claims priority to U.S. Provisional Patent Application No. 62/890,991, filed on Aug. 23, 2019, both entitled “Flapper on Frac Plug That Allows Pumping Down a New Plug,” both of which are hereby incorporated by reference in their entirety.
BACKGROUNDWellbores are drilled into the earth for a variety of purposes including accessing hydrocarbon bearing formations. A variety of downhole tools may be used within a wellbore in connection with accessing and extracting such hydrocarbons. Throughout the process, it may become necessary to isolate sections of the wellbore in order to create pressure zones. Zonal isolation devices, such as frac plugs, bridge plugs, packers, and other suitable tools, may be used to isolate wellbore sections.
Frac plugs and other zonal isolation devices are commonly run into the wellbore on a conveyance such as a wireline, work string or production tubing. Such tools typically have either an internal or external setting tool, which is used to set the downhole tool within the wellbore and hold the tool in place. Upon reaching a desired location within the wellbore, the downhole tool is actuated by hydraulic, mechanical, electrical, or electromechanical means to seal off the flow of liquid around the downhole tool. After a treatment operation, zonal isolation devices may be removed from the wellbore by various methods, including dissolution and/or drilling. Certain zonal isolation devices may have numerous constituent parts, complicating removal. Some zonal isolation devices may include a ratchet or similar mechanism to retain the device in a set configuration. Ratchets may allow shifting or “free play” within each ratchet increment.
These drawings illustrate certain aspects of some of the embodiments of the present disclosure, and should not be used to limit or define the claims.
While embodiments of this disclosure have been depicted, such embodiments do not imply a limitation on the disclosure, and no such limitation should be inferred. The subject matter disclosed is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those skilled in the pertinent art and having the benefit of this disclosure. The depicted and described embodiments of this disclosure are examples only, and not exhaustive of the scope of the disclosure.
DESCRIPTION OF CERTAIN EMBODIMENTSIllustrative embodiments of the present disclosure are described in detail herein. In the interest of clarity, not all features of an actual implementation may be described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions may be made to achieve the specific implementation goals, which may vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of the present disclosure.
As used herein, the terms “casing,” “casing string,” “casing joint,” and similar terms refer to a substantially tubular protective lining for a wellbore. Casing can be made of any material, and can include tubulars known to those skilled in the art as casing, liner, and tubing. In certain embodiments, casing may be constructed out of steel. Casing can be expanded downhole, interconnected downhole and/or formed downhole in some cases.
As used herein, the term “downhole surface” and similar terms refer to any surface in the wellbore or subterranean formation. For example, downhole surfaces may include, but are not limited to a wellbore wall, an inner tubing string wall such as a casing wall, a wall of an open-hole wellbore, and the like.
As used herein, the term “degradable” and all of its grammatical variants (e.g., “degrade,” “degradation,” “degrading,” “dissolve,” dissolving,” and the like), refers to the dissolution or chemical conversion of solid materials such that reduced-mass solid end products are formed by at least one of solubilization, hydrolytic degradation, biologically formed entities (e.g., bacteria or enzymes), chemical reactions (including electrochemical and galvanic reactions), thermal reactions, reactions induced by radiation, or combinations thereof. In complete degradation, no solid end products result. In some instances, the degradation of the material may be sufficient for the mechanical properties of the material to be reduced to a point that the material no longer maintains its integrity and, in essence, falls apart or sloughs off into its surroundings. The conditions for degradation are generally wellbore conditions where an external stimulus may be used to initiate or effect the rate of degradation, where the external stimulus is naturally occurring in the wellbore (e.g., pressure, temperature) or introduced into the wellbore (e.g., fluids, chemicals). For example, the pH of the fluid that interacts with the material may be changed by introduction of an acid or a base. The term “wellbore environment” includes both naturally occurring wellbore environments and materials or fluids introduced into the wellbore.
Directional terms, such as “up”, “below”, “downhole”, etc. are used in the present disclosure. In general, use of the terms “up”, “above”, “upper”, “uphole”, “top”, or other like terms refer to a direction toward the surface of the earth along a wellbore; likewise, “down”, “lower”, “below”, “downhole”, or other like terms refer to a direction away from the surface of the earth along the wellbore, regardless of the wellbore orientation. For example, in a horizontal wellbore, two locations may be at the same level (i.e., depth within a subterranean formation), the location closer to the well surface (by comparing the lengths along the wellbore from the wellbore surface to the locations) is referred to as “above” the other location.
As used herein, the term “coupled” and its grammatical variants refer to two or more components, pieces, or portions that may be used operatively together, that are joined together, that are linked together. For example, coupled components may include, but are not limited to components that are detachably coupled, shearably coupled, coupled by compression fit, coupled by interference fit, joined, linked, connected, coupled by a bonding agent. or the like.
The present disclosure relates to downhole tools used in the oil and gas industry. Particularly, the present disclosure relates to an apparatus for isolating zones in a wellbore and methods of use.
More specifically, the present disclosure relates to a zonal isolation device, comprising: a tubular body having a fluid communication pathway formed along a longitudinal axis comprising: a sealing element comprising a deformable material and an inner bore forming at least a portion of the fluid communication pathway; an expansion ring disposed within the bore of the sealing element; a wedge engaged with a downhole end of the sealing element; and an anchoring assembly engaged with the wedge. In certain embodiments, the tubular body further comprises an end element adjacent the anchoring assembly.
In some embodiments, the present disclosure relates to a method comprising: inserting into a wellbore a zonal isolation device disposed on a setting tool adapter kit comprising a mandrel, wherein the zonal isolation device comprises: a sealing element comprising a deformable material and an inner bore; an expansion ring movably disposed within the inner bore of the sealing element; a wedge engaged with a downhole end of the sealing element; an anchoring assembly engaged with the wedge; and an end element adjacent the anchoring assembly and detachably coupled to the mandrel; and actuating to pull upwardly on the mandrel, wherein the upward movement of the mandrel longitudinally compresses the zonal isolation device, causing the expansion ring to axially move relative to the sealing element and radially expand the sealing element into a sealing engagement with a downhole surface.
In some embodiments, the present disclosure relates to a zonal isolation system, comprising: a setting tool adapter kit comprising a mandrel; a sealing element disposed on the mandrel for sealing engagement with a downhole surface; an expansion ring movably disposed on the mandrel and engaged with the sealing element; a wedge disposed on the mandrel; and an anchoring assembly disposed around the mandrel for locking engagement with a downhole surface.
Among the many potential advantages of the apparatus and methods of the present disclosure, only some of which are alluded to herein, the zonal isolation device of the present disclosure may be provided with fewer component parts. Further, a zonal isolation device according to certain embodiments of the present disclosure may include a large inner diameter than other devices, which may prove advantageous for increasing flow rates during production operations. Further, a zonal isolation device according to certain embodiments of the present disclosure may be provided with more controlled dissolution characteristics due to, for example, fewer components parts. In some embodiments, the zonal isolation device of the present disclosure may retain a set configuration without a ratchet or similar mechanism, which may result in a lower cost tool with better dissolution characteristics and/or may eliminate the shifting that may occur in devices with a ratchet. In some embodiments, the zonal isolation device of the present disclosure may provide a more stable set frac plug, as the sealing element may provide additional stability.
The zonal isolation device is generally depicted and described herein as a hydraulic fracturing plug or “frac” plug. It will be appreciated by those skilled in the art, however, that the principles of this disclosure may equally apply to any of the other aforementioned types of casing or borehole isolation devices, without departing from the scope of the disclosure. Indeed, the zonal isolation device may be any of a frac plug, a wellbore packer, a deployable baffle, a bridge plug, or any combination thereof in keeping with the principles of the present disclosure.
Embodiments of the present disclosure and their advantages are best understood by references to
Representatively illustrated in
The zonal isolation device 200 of
In some embodiments, the anchoring assembly 215 and sealing element 100 are sufficient to hold the zonal isolation device 200 in a set configuration, when in locking engagement and sealing engagement with a downhole surface, respectively. In certain embodiments, the zonal isolation device 200 may retain a set configuration without a ratchet or similar component.
The sealing element 100 may comprise an inner bore 105 that forms at least a part of the fluid communication pathway 206. In certain embodiments, a wedge 180 may be adjacent to the downhole end 101 of the sealing element 100. The wedge 180 and the sealing element 100 may be coupled or uncoupled. In some embodiments, wedge 180 and sealing element 100 may engage each other with interlocking tapered surfaces at an interface 102. In certain embodiments, wedge 180 and sealing element 100 may be coupled together by a compression fit or an interference fit. For example, wedge 180 and sealing element 100 may be longitudinally compressed together after the zonal isolation device 200 is set.
The sealing element 100 may be elastically or plastically deformable, and may be composed of any suitable elastically or plastically deformable material including, but not limited to, elastomers (including but not limited to rubber), polymers (including but limited to plastics), or metal. One of ordinary skill in the art will understand that the material selected and the deformable nature (elastic or plastic) is an understood design choice generally dictated by the application of the system and method described herein. Furthermore, one of ordinary skill in the art will understand that the material may be further selected to ease the removal of zonal isolation device 200 by, for example, choosing a material that easily broken up if drilled out or a material that is dissolvable.
With reference to
In some embodiments, the expansion ring 190 may also act be configured to receive a sealing device (e.g., a frac ball, frac dart, or the like). As shown in
The wedge 180 may have a frustoconical shape and be disposed between the sealing element 100 and the anchoring assembly 215. In certain embodiments, the anchoring assembly 215 is engaged with the wedge 180. In some embodiments, the wedge may be engaged with a downhole end 101 of the sealing element 100. In some embodiments, the wedge 180 may comprise a single frustoconical surface 182 (e.g., as depicted in
In certain embodiments, the anchoring assembly 215 allows the zonal isolation device to hold its position within the wellbore. As depicted in
The plurality of slip segments 216 may be fully interconnected (e.g., as depicted in
The slip segments 216 may comprise slip inserts 218 embedded therein. Slip inserts 218 may be wear buttons, wickers, wedges, or any other element for reducing wear of the slip segments 216. Slip inserts 218 may protrude from the slip segments 216 to penetrate or bite a downhole surface. Although each slip segment 216 is shown having four slip inserts 218 respectfully, it will be appreciated that any number of slip inserts, including one or a plurality (three, four, five, ten, twenty, and the like) of slip inserts may be embedded in each slip, without departing from the scope of the present disclosure. The slip segments 216 may have the same or a different number of slip inserts 218, without departing from the scope of the present disclosure. The slip inserts 218 in
In some embodiments, the slip inserts 218 may include hardened metals, ceramics, and any combination thereof. The material forming the slip inserts 218 may be an oxide or a non-oxide material. In certain embodiments, the thickness of a material may be increased in order to achieve the desired compressive strength. For example, in some embodiments the material forming the slip insert 218 may include, but is not limited to, iron (e.g., cast iron), steel, titanium, zircon, a carbide (e.g., tungsten carbide, a tungsten carbide alloy (e.g., alloyed with cobalt), silicon carbide, titanium carbide, boron carbide, tantalum carbide), a boride (e.g., osmium diboride, rhenium boride, tungsten boride, zirconium boride, iron tetraboride), a nitride (e.g., silicon nitride, titanium nitride, boron nitride, cubic boron nitride, boron carbon nitride, beta carbon nitride), diamond, synthetic diamond, silica (e.g., amorphous silica), an oxide (e.g., aluminum oxide, fused aluminum oxide, zirconium oxide, beryllium oxide, alumina-chrome oxide), corundite, topaz, synthetic topaz, garnet, synthetic garnet, lonsdaleite, and any combination thereof.
An end element 170 may be positioned at or secured at the downhole end of the zonal isolation device 200. As will be appreciated, the end element 170 of the wellbore isolation device 200 could be a mule shoe, or any other type of section that serves to terminate the structure of the wellbore isolation device 200, or otherwise serves as a connector for connecting the wellbore isolation device 200 to other tools, such as a valve, tubing, or other downhole equipment. The end element 170 may comprise end element inserts 171 embedded therein. End element inserts 171 may be wear buttons, wickers, wedges, or any other element for reducing wear of the end element 170. End element inserts 171 may be any shape or material discussed above with respect to slip inserts 218. In certain embodiments, the end element 170 may be adjacent, engaged with, and/or coupled to the anchoring assembly 215. For example, as shown in
With reference to
As depicted in
In some embodiments, one or more components of the setting tool adapter kit 160 or a setting tool coupled to the setting tool adapter kit 160 may be actuated to force the end element 170 upward by drawing the mandrel 161 upward. Drawing the end element 170 upward may force the anchoring assembly 215 upward such that the slip segments 216 engage with the wedge 180. For example, drawing the end element 170 upward may force the slip segments 216 up a surface of the wedge 180, causing the slip segments 216 to radially expand into locking engagement with a downhole surface.
In some embodiments, one or more portions of the setting tool adapter kit 160 may hold the expansion ring 190 stationary relative to the sealing element 100 and/or other elements of the zonal isolation device 200. In certain embodiments, the setting sleeve 167 may restrict upward movement of the expansion ring 190 during upward movement of the mandrel 161. For example, the setting tool 160 may comprise one or more retention elements shaped to restrict the upward movement of the expansion ring 190 during upward movement of the mandrel 161 and other components of the zonal isolation device 200. In certain embodiments, the retention element may include a ridge, flange, tab, pin, sleeve, or other element suitable to restrict upward movement of the expansion ring 190 during upward movement of the mandrel 161. Actuating the setting tool 160 may cause the sealing element 100 to move upward relative to the expansion ring 190, forcing the expansion ring 190 towards the downhole end 101 of the sealing element 100. Shifting of the expansion ring 190 towards the downhole end 101 of the sealing element 100 may radially expand the sealing element 100 into sealing engagement with a downhole surface. For example, a tapered surface of the expansion ring 190 may engage with a tapered surface of the inner bore 105 of the sealing element 100.
In certain embodiments, the zonal isolation device 200 may be made up in the form depicted in
In certain embodiments, the mandrel 161 may be shearably coupled to one or more components of the zonal isolation device 200 by one or more shear devices, including, but not limited to shear threads, shear pins, a shear ring, shear screws, shearable ridges, and the like, or any other shearable device. In embodiments where the mandrel 161 is shearably coupled to one or more components of the zonal isolation device 200, the mandrel 161 may overcome a shear force provided by the shear device. For example, during or after setting, enough upward force may be applied to the mandrel 161 to shear one or more shear devices and decouple the mandrel from one or more components of the zonal isolation device 200. In some embodiments, the mandrel 161 may be shearably coupled to the end element 170 by a shear device. In some embodiments, the shear force necessary to overcome one or more shear devices of the zonal isolation device 200 is from about 10,000 lbf to 50,000 lbf.
As discussed above, the end element 170 may be coupled or uncoupled to the anchoring assembly 215. As depicted in
In some embodiments, the zonal isolation device 200 may be run into a wellbore 120 via conveyance 140 in a sealed configuration. For example, as depicted in
As shown in
For example, in certain embodiments, one or more components of the zonal isolation device 200 may include a pump-down ring. A pump-down ring may, in certain embodiments, be a portion of a component of the zonal isolation device 200 or the setting tool adapter kit 160 with an increased outer diameter relative to at least one other portion of the component. For example, as depicted in
With reference to
One or more scarf cuts 233 may extend between the first end 234 and second end 235 at an angle 236 relative to one of the first end 234 and the second end 235 or any other suitable plane extending normal to a longitudinal axis of the expandable collar 220. In the illustrated embodiment in
The one or more scarf cuts 233 may permit diametrical expansion of the expandable collar 220 to an expanded state and into locking engagement with a downhole surface. In certain embodiments, due to the construction of the expandable collar 220, a large flow area can be provided through an inner diameter 237 of the body 230. During expansion of the expandable collar 220, the expandable collar 220 may radially expand into locking engagement with a downhole surface (e.g., with a casing). In the expanded state, a gap 238 may be formed between opposing angled surfaces 239a,b of the scarf cut 233. The angle 236 of the scarf cut 233 may be calculated such that when the expandable collar 220 moves to the expanded state, the opposing angled surfaces 239a,b of the scarf cut 233 axially overlap to at least a small degree such that no axial gaps are created in the body 230. Accordingly, the one or more scarf cuts 233 may enable the expandable collar 220 to separate at the opposing angled surfaces 239a,b and thereby enable a degree of freedom that permits expansion and contraction of the expandable collar 220 during operation. In certain embodiments, the first end 234 is movable relative to the second end 235 as the expandable collar 220 expands. In certain embodiments, the first end portion 234 rotates or otherwise moves circumferentially relative to the second end 235 during expansion. In certain embodiments, the first end 234 converges and/or diverges circumferentially relative to the second end 235 during expansion.
One or more components of the zonal isolation device 200 such as the wedge 180, expansion ring 190, anchoring assembly 215, end element 170, and/or lower mandrel 163 may comprise a variety of materials including, but not limited to, a metal, a polymer, a composite material, and any combination thereof. Suitable metals that may be used include, but are not limited to, steel, brass, aluminum, magnesium, iron, cast iron, tungsten, tin, and any alloys thereof. Suitable composite materials that may be used include, but are not limited to, materials including fibers (chopped, woven, etc.) dispersed in a phenolic resin, such as fiberglass and carbon fiber materials.
In some embodiments, one or more components of the zonal isolation device 200 such as the sealing element 100, wedge 180, expansion ring 190, anchoring assembly 215, end element 170, or lower mandrel 163 may be made of a degradable or dissolvable material. The degradable materials described herein may allow for time between setting a downhole tool (e.g., a zonal isolation device) and when a particular downhole operation is undertaken, such as a hydraulic fracturing treatment operation. In certain embodiments, degradable metal materials may allow for acid treatments and acidified stimulation of a wellbore. In some embodiments, the degradable metal materials may require a large flow area or flow capacity to enable production operations without unreasonably impeding or obstructing fluid flow while the zonal isolation device 200 degrades. As a result, production operations may be efficiently undertaken while the zonal isolation device 200 degrades and without creating significant pressure restrictions.
Degradable materials suitable for certain embodiments of the present disclosure include, but are not limited to borate glass, an aliphatic polyester, polyglycolic acid (PGA), polylactic acid (PLA), polyvinyl alcohol (PVA), a degradable rubber, a degradable polymer, a galvanically-corrodible metal, a dissolvable metal, a dehydrated salt, and any combination thereof. The degradable materials may be configured to degrade by a number of mechanisms including, but not limited to, swelling, dissolving, undergoing a chemical change, electrochemical reactions, undergoing thermal degradation, or any combination of the foregoing.
Degradation by swelling may involve the absorption by the degradable material of aqueous fluids or hydrocarbon fluids present within the wellbore environment such that the mechanical properties of the degradable material degrade or fail. Hydrocarbon fluids that may swell and degrade the degradable material include, but are not limited to, crude oil, a fractional distillate of crude oil, a saturated hydrocarbon, an unsaturated hydrocarbon, a branched hydrocarbon, a cyclic hydrocarbon, and any combination thereof. Exemplary aqueous fluids that may swell to degrade the degradable material include, but are not limited to, fresh water, saltwater (e.g., water containing one or more salts dissolved therein), brine (e.g., saturated salt water), seawater, acid, bases, or combinations thereof. In degradation by swelling, the degradable material may continue to absorb the aqueous and/or hydrocarbon fluid until its mechanical properties are no longer capable of maintaining the integrity of the degradable material and it at least partially falls apart. In some embodiments, the degradable material may be designed to only partially degrade by swelling in order to ensure that the mechanical properties of a component of the zonal isolation device 200 formed from the degradable material is sufficiently capable of lasting for the duration of the specific operation in which it is utilized.
Degradation by dissolving may involve a degradable material that is soluble or otherwise susceptible to an aqueous fluid or a hydrocarbon fluid, such that the aqueous or hydrocarbon fluid is not necessarily incorporated into the degradable material (as is the case with degradation by swelling), but becomes soluble upon contact with the aqueous or hydrocarbon fluid. Degradation by undergoing a chemical change may involve breaking the bonds of the backbone of the degradable material (e.g., a polymer backbone) or causing the bonds of the degradable material to crosslink, such that the degradable material becomes brittle and breaks into small pieces upon contact with even small forces expected in the wellbore environment. Thermal degradation of the degradable material may involve a chemical decomposition due to heat, such as the heat present in a wellbore environment. Thermal degradation of some degradable materials mentioned or contemplated herein may occur at wellbore environment temperatures that exceed about 93° C. (or about 200° F.).
With respect to degradable polymers used as a degradable material, a polymer may be considered “degradable” if the degradation is due to, in situ, a chemical and/or radical process such as hydrolysis, oxidation, or UV radiation. Degradable polymers, which may be either natural or synthetic polymers, include, but are not limited to, polyacrylics, polyamides, and polyolefins such as polyethylene, polypropylene, polyisobutylene, and polystyrene. Suitable examples of degradable polymers that may be used in accordance with the embodiments include polysaccharides such as dextran or cellulose, chitins, chitosans, proteins, aliphatic polyesters, poly(lactides), poly(glycolides), poly(ε-caprolactones), poly(hydroxybutyrates), poly(anhydrides), aliphatic or aromatic polycarbonates, poly(orthoesters), poly(amino acids), poly(ethylene oxides), polyphosphazenes, poly(phenyllactides), polyepichlorohydrins, copolymers of ethylene oxide/polyepichlorohydrin, terpolymers of epichlorohydrin/ethylene oxide/allyl glycidyl ether, and any combination thereof. In certain embodiments, the degradable material is polyglycolic acid or polylactic acid. In some embodiments, the degradable material is a polyanhydride. Polyanhydride hydrolysis may proceeds, in situ, via free carboxylic acid chain-ends to yield carboxylic acids as final degradation products. The erosion time may be varied over a broad range of changes in the polymer backbone. Examples of polyanhydrides suitable for certain embodiments of the present disclosure include, but are not limited to poly(adipic anhydride), poly(suberic anhydride), poly(sebacic anhydride), and poly(dodecanedioic anhydride). Other examples suitable for certain embodiments of the present disclosure include, but are not limited to poly(maleic anhydride) and poly(benzoic anhydride).
Degradable rubbers suitable for certain embodiments of the present disclosure include, but are not limited to degradable natural rubbers (i.e., cis-1,4-polyisoprene) and degradable synthetic rubbers, which may include, but are not limited to, ethylene propylene diene M-class rubber, isoprene rubber, isobutylene rubber, polyisobutene rubber, styrene-butadiene rubber, silicone rubber, ethylene propylene rubber, butyl rubber, norbornene rubber, polynorbornene rubber, a block polymer of styrene, a block polymer of styrene and butadiene, a block polymer of styrene and isoprene, and any combination thereof. Other degradable polymers suitable for certain embodiments of the present disclosure include those that have a melting point that is such that it will dissolve at the temperature of the subterranean formation in which it is placed.
In some embodiments, the degradable material may have a thermoplastic polymer embedded therein. The thermoplastic polymer may modify the strength, resiliency, or modulus of a portion of the zonal isolation device 200 and may also control the degradation rate. Thermoplastic polymers suitable for certain embodiments of the present disclosure include, but are not limited to an acrylate (e.g., polymethylmethacrylate, polyoxymethylene, a polyamide, a polyolefin, an aliphatic polyamide, polybutylene terephthalate, polyethylene terephthalate, polycarbonate, polyester, polyethylene, polyetheretherketone, polypropylene, polystyrene, polyvinylidene chloride, styrene-acrylonitrile), polyurethane prepolymer, polystyrene, poly(o-methylstyrene), poly(m-methylstyrene), poly(p-methylstyrene), poly(2,4-dimethylstyrene), poly(2,5-dimethylstyrene), poly(p-tert-butylstyrene), poly(p-chlorostyrene), poly(α-methylstyrene), co- and ter-polymers of polystyrene, acrylic resin, cellulosic resin, polyvinyl toluene, and any combination thereof. Each of the foregoing may further comprise acrylonitrile, vinyl toluene, or methyl methacrylate. The amount of thermoplastic polymer that may be embedded in a degradable material may be any amount that confers a desirable elasticity without affecting the desired amount of degradation. In some embodiments, the thermoplastic polymer may be included in an amount in the range of a lower limit of about 1%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, and 45% to an upper limit of about 91%, 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, and 45% by weight of the degradable material, encompassing any value or subset therebetween.
In certain embodiments, galvanically-corrodible metals may be used as a degradable material and may be configured to degrade via an electrochemical process in which the galvanically-corrodible metal corrodes in the presence of an electrolyte (e.g., brine or other salt-containing fluids present within the wellbore). Galvanically-corrodible metals suitable for certain embodiments of the present disclosure include, but are not limited to tin, aluminum, zinc, and magnesium. Galvanically-corrodible metals may include a nano-structured matrix. One example of a nano-structured matrix micro-galvanic material is a magnesium alloy with iron-coated inclusions. Galvanically-corrodible metals suitable for certain embodiments of the present disclosure include micro-galvanic metals or materials, such as a solution-structured galvanic material. An example of a solution-structured galvanic material is zirconium (Zr) containing a magnesium (Mg) alloy, where different domains within the alloy contain different percentages of Zr. This may lead to a galvanic coupling between these different domains, which causes micro-galvanic corrosion and degradation. Micro-galvanically corrodible magnesium alloys could also be solution-structured with other elements such as zinc, aluminum, nickel, iron, carbon, tin, silver, copper, titanium, rare earth elements, et cetera. Micro-galvanically corrodible aluminum alloys could be in solution with elements such as nickel, iron, carbon, tin, silver, copper, titanium, gallium, et cetera.
In some embodiments, blends of certain degradable materials may also be suitable as the degradable material for at least a portion of the zonal isolation device 200. One example of a suitable blend of degradable materials is a mixture of PLA and sodium borate. Another example may include a blend of PLA and boric oxide. The choice of blended degradable materials may depend, at least in part, on the conditions of the well (e.g., wellbore temperature). For instance, lactides have been found to be suitable for lower temperature wells, including those within the range of 60° F. to 150° F., and PLAs have been found to be suitable for wellbore temperatures above this range. In addition, PLA may be suitable for higher temperature wells. Some stereoisomers of poly(lactide) or mixtures of such stereoisomers may be suitable for even higher temperature applications. Dehydrated salts may also be suitable for higher temperature wells. Other blends of degradable materials may include materials that include different alloys including using the same elements but in different ratios or with a different arrangement of the same elements.
In some embodiments, a degradable material may include a material that has undergone different heat treatments and exhibits varying grain structures or precipitation structures. As an example, in some magnesium alloys, the beta phase can cause accelerated corrosion if it occurs in isolated particles. Homogenization annealing for various times and temperatures causes the beta phase to occur in isolated particles or in a continuous network. In this way, the corrosion behavior may be different for the same alloy with different heat treatments.
In some embodiments, all or a portion of the outer surface of at least a portion of the zonal isolation device 200 may be treated to impede degradation. For example, a surface of the zonal isolation device 200 may undergo a treatment that aids in preventing the degradable material (e.g., a galvanically-corrodible metal) from galvanically-corroding. Treatments suitable for certain embodiments of the present disclosure include, but are not limited to, an anodizing treatment, an oxidation treatment, a chromate conversion treatment, a dichromate treatment, a fluoride anodizing treatment, a hard anodizing treatment, and any combination thereof. Some anodizing treatments may result in an anodized layer of material being deposited on the surface. The anodized layer may comprise materials such as, but not limited to, ceramics, metals, polymers, epoxies, elastomers, or any combination thereof and may be applied using any suitable processes known to those of skill in the art. Examples of suitable processes that result in an anodized layer include, but are not limited to, soft anodize coating, anodized coating, electroless nickel plating, hard anodized coating, ceramic coatings, carbide beads coating, plastic coating, thermal spray coating, high velocity oxygen fuel (HVOF) coating, a nano HVOF coating, a metallic coating, and any combination thereof.
In some embodiments, all or a portion of an outer surface of the zonal isolation device 200 may be treated or coated with a substance configured to enhance degradation of the degradable material. For example, such a treatment or coating may be configured to remove a protective coating or treatment or otherwise accelerate the degradation of the degradable material of the zonal isolation device 200. In some embodiments, a galvanically-corroding metal material is coated with a layer of PGA. In this example, the PGA may undergo hydrolysis and cause the surrounding fluid to become more acidic, which may accelerate the degradation of the underlying metal.
In some embodiments, the degradable material may be made of dissimilar metals that generate a galvanic coupling that either accelerates or decelerates the degradation rate of the zonal isolation device 200. As will be appreciated, such embodiments may depend on where the dissimilar metals lie on the galvanic potential. In at least one embodiment, a galvanic coupling may be generated by embedding a cathodic substance or piece of material into an anodic structural element. For instance, the galvanic coupling may be generated by dissolving aluminum in gallium. A galvanic coupling may also be generated by using a sacrificial anode coupled to the degradable material. In such embodiments, the degradation rate of the degradable material may be decelerated until the sacrificial anode is dissolved or otherwise corroded away.
An embodiment of the present disclosure is a zonal isolation device, comprising: a tubular body having a fluid communication pathway formed along a longitudinal axis comprising: a sealing element comprising a deformable material and an inner bore forming at least a portion of the fluid communication pathway; an expansion ring disposed within the bore of the sealing element; a wedge engaged with a downhole end of the sealing element; and an anchoring assembly engaged with the wedge.
In one or more embodiments described in the preceding paragraph, the tubular body further comprises an end element adjacent the anchoring assembly. In one or more embodiments described above, the sealing element is radially expandable into sealing engagement with a downhole surface. In one or more embodiments described above, the anchoring assembly comprises a plurality of arcuate-shaped slip segments for locking engagement with a downhole surface. In one or more embodiments described above, at least two of the plurality of arcuate-shaped slip segments are interconnected by a shearable link. In one or more embodiments described above, the shearable link shears upon axial expansion. In one or more embodiments described above, longitudinal compression of the tubular body radially expands the sealing element and radially expands the anchoring assembly. In one or more embodiments described above, the sealing element is coupled to the wedge and the wedge is coupled to the anchoring assembly. In one or more embodiments described above, the wedge is coupled to the sealing element by a compression fit, an interference fit, or a bonding agent.
Another embodiment of the present disclosure is a method comprising: inserting into a wellbore a zonal isolation device disposed on a setting tool adapter kit comprising a mandrel, wherein the zonal isolation device comprises: a sealing element comprising a deformable material and an inner bore; an expansion ring movably disposed within the inner bore of the sealing element; a wedge engaged with a downhole end of the sealing element; an anchoring assembly engaged with the wedge; and an end element adjacent the anchoring assembly and detachably coupled to the mandrel; and actuating to pull upwardly on the mandrel, wherein the upward movement of the mandrel longitudinally compresses the zonal isolation device, causing the expansion ring to axially move relative to the sealing element and radially expand the sealing element into a sealing engagement with a downhole surface.
In one or more embodiments described in the preceding paragraph, the upward movement of the mandrel engages the anchoring assembly with the wedge, radially expanding the anchoring assembly into a locking engagement with the downhole surface. In one or more embodiments described above, the method further comprises shearing a shear device coupling the mandrel to the end element. In one or more embodiments described above, the method further comprises removing the setting tool adapter kit and the mandrel from the wellbore. In one or more embodiments described above, one or more components of the zonal isolation device comprises a pump-down ring. In one or more embodiments described above, the method further comprises seating a sealing ball on the expansion ring. In one or more embodiments described above, the anchoring assembly comprises a plurality of arcuate-shaped slip segments for locking engagement with the downhole surface. In one or more embodiments described above, upon sufficient movement of the wedge relative to the plurality of arcuate-shaped slip segments, at least two of the plurality of arcuate-shaped slip segments slip segments are separated from each other by shearing a shearable link joining the at least two slip segments.
Another embodiment of the present disclosure is a zonal isolation system, comprising: a setting tool adapter kit comprising a mandrel; a sealing element disposed on the mandrel for sealing engagement with a downhole surface; an expansion ring movably disposed on the mandrel and engaged with the sealing element; a wedge disposed on the mandrel; and an anchoring assembly disposed around the mandrel for locking engagement with a downhole surface.
In one or more embodiments described in the preceding paragraph, the system further comprises an end element coupled to the mandrel. In one or more embodiments described in the preceding sentence, the end element is detachably coupled to the mandrel by a shearing element.
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In embodiments, the rotatable sealing component 400 of the zonal isolation device 200 can be selected from a group consisting of a flapper valve (comprising a flapper 425 as shown in
In embodiments, the rotatable sealing component 400 remains at an axially fixed distance from the support ring 190 as a result of attachment of the rotatable sealing component 400 to the support ring 190 such that they move together (e.g., as an integrated or unified component) in an axial direction during setting of the zonal isolation device 200, which is further illustrated by the relative positioning of the rotatable sealing component 400 to the support ring 190 in the unset configuration of
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In embodiments, the method as disclosed herein employs a zonal isolation device 200 comprising: a sealing element 100 comprising a deformable material and an inner bore 105; an support ring 190 (also referred to as a frustum having a conical shape) movably disposed within the inner bore 105 of the sealing element 100; a rotatable sealing component 400 directly or indirectly connected to the uphole end of the support ring 190, wherein the rotatable sealing component blocks fluid flow through the zonal isolation device 200 in a closed position and allows fluid flow through the zonal isolation device 200 in an open position and wherein a mandrel 161 of a setting tool is engaged with and holds the rotatable sealing component 400 in the open position while the zonal isolation device 200 is inserted into the wellbore; a wedge 180 engaged with a downhole end of the sealing element 100; an anchoring assembly 215 engaged with the wedge 180; and an end element 170 (e.g., a mule shoe) adjacent the anchoring assembly 215 and detachably coupled to the mandrel 161.
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Disclosed herein is a method (e.g., a method of hydraulic fracturing) comprising: inserting into a cased wellbore the zonal isolation device (e.g., a zonal isolation device with a flapper coupled to and supported by a support ring or a zonal isolation device with a flapper coupled to and supported by a mandrel) with a propping component as disclosed herein (e.g., a flapper propped open as shown in any of
In embodiments, the method as disclosed herein further comprises: sending a trigger signal to the one or more replacement perforating guns; and forming a plurality of perforations through the casing and into the surrounding formation in a wellbore zone located above the set zonal isolation device. In embodiments, the method further comprises: removing the setting tool assembly, the one or more perforating guns coupled to the setting tool assembly, and the one or more replacement perforating guns from the wellbore.
Referring to
In embodiments, the propping component 448 comprises a degradable material, an erodible material, or an abradable material and is structurally compromised via contact with a flowing wellbore fluid that removes all or a portion of the degradable material, the erodible material, or the abradable material.
In embodiments, the propping component 448 comprises a dissolvable material or a corrodible material and is structurally compromised via contact with a wellbore fluid (e.g., via chemical decomposition of the strut, dissolution of the strut, etc.).
In embodiments, the propping component 448 comprises a temperature-sensitive material (e.g., a fusible alloy) and is structurally compromised via change in ambient temperature in the wellbore proximate the set zonal isolation plug. In embodiments, the change in ambient temperature is controlled by adjusting (e.g., halting) a flow of fluid in the wellbore, thereby allowing the temperature in the wellbore proximate the set zonal isolation plug to increase and soften the temperature-sensitive material.
In embodiments, the propping component 448 comprises a frangible material and is structurally compromised via contact with a pressure wave. In embodiments, the pressure wave is produced via a fluid pulse from the surface or from firing of a perforating gun (e.g., a shock wave).
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In embodiments, the method as disclosed herein referring to
Also, disclosed herein is a method (e.g., a method of hydraulic fracturing) comprising: inserting into a cased wellbore the zonal isolation device with a propping component as disclosed herein (e.g., a flapper propped open as shown in any of
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One advantage of the disclosure is to be able to avoid the act of pumping a ball onto the frac plug for sealing purpose to divert the fracturing fluid into the perforations and surrounding formation. The pumping of the ball increases the water usage and increases the operating time for each stage of fracturing. Also a traditional spring loaded ball does not work with a bottom-set plug because the ball blocks the usage of the setting tool. By avoiding the usage of the ball, the disclosure saves water and operating time for each stage of fracturing, and can be used with a bottom-set plug. Another advantage is that the disclosure simplifies the design, reduces the leak paths, and reduces the cost of the frac plug, by attaching a rotatable flow restrictor (a rotatable sealing component 400) at an axially fixed distance with respect to the frustum of the frac plug that supports the sealing surface. There are no other frac plugs, especially dissolvable frac plugs, that have a rotatable flow restrictor at an axially fixed distance with respect to the frustum of the frac plug that supports the sealing surface. This disclosure can be applied to a dissolvable frac plug, such as the Sprire™ frac plug, which is commercially available from Halliburton Energy Services, Inc. Another advantage is that there is no mandrel in the frac plug in this disclosure after the plug is set. The feature of no mandrel simplifies the design, thus reduces the amount of material used which aids in dissolution or milling, and lowers the cost of the plug. Another advantage is that the mule shoe (the end element 170) of this design falls away after the setting process. The lack of a mandrel and the removal of the mule shoe provides for increased surface area for contact with a wellbore fluid, which allows for a more controlled (e.g., faster) dissolution process.
ADDITIONAL DISCLOSUREThe following enumerated aspects of the present disclosure are provided as non-limiting examples.
A first embodiment, which is a zonal isolation device 200 comprising a sealing element 100 comprising a deformable material and an inner bore 105, a support ring 190 (also referred to as an expansion ring, for example a frustum having a conical shape) movably disposed within the inner bore 105 of the sealing element 100, a rotatable seal connected to the support ring 190 and configured to engage a sealing surface (e.g., face or seat) of support ring 190, wherein the flapper is configured to restrict fluid flow through the zonal isolation device 200 in a closed position, is configured to minimally restrict fluid flow through the zonal isolation device 200 in a fully open position.
A second embodiment, which is a zonal isolation device comprising a mandrel having a bore extending axially there through, an anchoring assembly (e.g., slip) circumferentially disposed about the mandrel and configured to expand and engage with a downhole surface, a sealing element circumferentially disposed about the mandrel and configured to compress and create a seal with the downhole surface, and a flapper coupled to the mandrel and configured to engage a sealing surface (e.g., face or seat) of an end of the mandrel and seal the bore of the mandrel, wherein the flapper blocks fluid flow through the zonal isolation device in a fully closed position, allows unrestricted fluid flow through the zonal isolation device in a fully open position, and allows restricted fluid flow through the zonal isolation device when held by a propping component (also referred to as a propping member) in an intermediate or partially open position.
A third embodiment, which is the device of the first or the second embodiment, wherein the propping component comprises a spring (427 and/or 445).
A fourth embodiment, which is the device of the third embodiment, wherein the spring is a torsion spring 427 (e.g., a flat spiral spring or a clock spring), wherein the torsion spring is positioned adjacent a hinged end of the flapper and wherein the torsion spring holds the flapper in the intermediate position when the torsion spring is in a neutral or equilibrium (e.g., non-compressed and non-stretched) state/condition, thereby allowing fluid flow via a gap formed between flapper end 432 and the sealing surface as indicated by flow arrow 446.
A fifth embodiment, which is the device of the third embodiment, wherein the spring is a coil spring 445, wherein a first end of the coil spring is received within a recess 441 in the uphole end of the support ring 190 and a second end of the coil spring 445 contacts flapper end 432, wherein the coil spring holds the flapper in the intermediate position when the coil spring is in a neutral or equilibrium (e.g., non-compressed and non-stretched) state/condition, thereby allowing fluid flow via a gap formed between flapper end 432 and the sealing surface as indicated by flow arrow 446.
A sixth embodiment, which is the device of the first or the third embodiment, wherein the propping component comprises a strut 448.
A seventh embodiment, which is the device of the sixth embodiment, wherein a first end of the strut 448 is received within a recess 441 in the uphole end of the support ring 190 and a second end of the strut 448 contacts flapper end 432, wherein the strut holds the flapper in the intermediate position, thereby allowing fluid flow via a gap formed between flapper end 432 and the sealing surface as indicated by flow arrow 446.
An eighth embodiment, which is the device of the seventh embodiment, wherein the strut comprises a dissolvable material, a degradable material, an erodible material, an abradable material, a temperature-sensitive material (e.g., a fusible alloy), a corrodible material, a frangible material, or combinations thereof and is configured such that the strut loses structural integrity when subjected to contact with a wellbore fluid (e.g., downhole fluid flow), downhole ambient conditions (e.g., temperature and/or pressure), or both, thereby allowing the flapper to transition from the intermediate position to the fully closed position.
A ninth embodiment, which is the device of any of the first through the eighth embodiments, wherein the flapper further comprises a rupture disk 435 (also referred to as a burst disk or burst diaphragm), which optionally may be protected by one or more coating layers 437. The coating layers 437 are for protection only and do not prevent application of pressure on the rupture disk or otherwise hinder operation of the rupture disk.
A tenth embodiment, which is the device of the ninth embodiment, wherein the rupture disk is disposed within a circumferential groove on an interior face of a hole or bore passing through the flapper.
An eleventh embodiment, which is the device of any of the first through the tenth embodiments, wherein the flapper further comprises a releasable hinge configured to decouple an end of the flapper proximate the releasable hinge.
A twelfth embodiment, which is the device of the eleventh embodiment, wherein the releasable hinge comprises a pivot pin and wherein the end of the flapper proximate the releasable hinge comprises a u-shaped recess 438 receiving the pivot pin and a clip 442 (e.g., a pinch clip) engaging the pivot pin, wherein the flapper is configured to decouple from the releasable hinge via application of a releasing force sufficient to overcome a retaining force applied to the releasable hinge by the clip 442, for example a releasing force applied via flow of wellbore fluid as represented by flow arrows 440.
A thirteenth embodiment, which is a zonal isolation device 200 comprising a sealing element 100 comprising a deformable material and an inner bore 105, a support ring 190 (also referred to as a frustum having a conical shape) movably disposed within the inner bore 105 of the sealing element 100, a flapper connected to an uphole end of the support ring 190 and configured to engage a sealing surface (e.g., face or seat) of support ring 190, wherein the flapper blocks fluid flow through the zonal isolation device 200 in a fully closed position and allows unrestricted fluid flow through the zonal isolation device 200 in a fully open position and wherein the flapper further comprises a rupture disk 435 (also referred to as a burst disk or burst diaphragm), which optionally may be protected by one or more coating layers 437, a wedge 180 engaged with a downhole end of the sealing element 100, an anchoring assembly 215 engaged with the wedge 180, and an end element 170 (e.g., a mule shoe) adjacent the anchoring assembly 215.
A fourteenth embodiment, which is a zonal isolation device comprising a mandrel having a bore extending axially there through, an anchoring assembly (e.g., slip) circumferentially disposed about the mandrel and configured to expand and engage with a downhole surface, a sealing element circumferentially disposed about the mandrel and configured to compress and create a seal with the downhole surface, and a flapper coupled to the mandrel and configured to engage a sealing surface (e.g., face or seat) of an end of the mandrel and seal the bore of the mandrel, wherein the flapper blocks fluid flow through the zonal isolation device in a fully closed position and allows unrestricted fluid flow through the zonal isolation device in a fully open position and wherein the flapper further comprises a rupture disk 435 (also referred to as a burst disk or burst diaphragm), which optionally may be protected by one or more coating layers 437.
A fifteenth embodiment, which is the device of the thirteenth or the fourteenth embodiment, wherein the rupture disk is disposed within a circumferential groove on an interior face of a hole passing through the flapper.
A sixteenth embodiment, which is a zonal isolation device 200 comprising a sealing element 100 comprising a deformable material and an inner bore 105, a support ring 190 (also referred to as a frustum having a conical shape) movably disposed within the inner bore 105 of the sealing element 100, a flapper connected to an uphole end of the support ring 190 and configured to engage a sealing surface (e.g., face or seat) of support ring 190, wherein the flapper blocks fluid flow through the zonal isolation device 200 in a fully closed position and allows unrestricted fluid flow through the zonal isolation device 200 in a fully open position and wherein the flapper further comprises a releasable hinge configured to decouple an end of the flapper proximate the releasable hinge, a wedge 180 engaged with a downhole end of the sealing element 100, an anchoring assembly 215 engaged with the wedge 180, and an end element 170 (e.g., a mule shoe) adjacent the anchoring assembly 215.
A seventeenth embodiment, which is a zonal isolation device comprising a mandrel having a bore extending axially there through, an anchoring assembly (e.g., slip) circumferentially disposed about the mandrel and configured to expand and engage with a downhole surface, a sealing element circumferentially disposed about the mandrel and configured to compress and create a seal with the downhole surface, and a flapper coupled to the mandrel and configured to engage a sealing surface (e.g., face or seat) of an end of the mandrel and seal the bore of the mandrel, wherein the flapper blocks fluid flow through the zonal isolation device in a fully closed position and allows unrestricted fluid flow through the zonal isolation device in a fully open position and wherein the flapper further comprises a releasable hinge configured to decouple an end of the flapper proximate the releasable hinge.
An eighteenth embodiment, which is the device of the sixteenth or the seventeenth embodiment, wherein the releasable hinge comprises a pivot pin and wherein the end of the flapper proximate the releasable hinge comprises a u-shaped recess 438 receiving the pivot pin and a clip 442 (e.g., a pinch clip) engaging the pivot pin, wherein the flapper is configured to decouple from the releasable hinge via application of a releasing force sufficient to overcome a retaining force applied to the releasable hinge by the clip 442, for example a releasing force applied via flow of wellbore fluid as represented by flow arrows 440.
A nineteenth embodiment, which is a method comprising inserting into a cased wellbore the zonal isolation device of any of the first through the twelfth embodiments, actuating the zonal isolation device to provide a set zonal isolation device, detaching a setting tool assembly from the set zonal isolation device, moving the setting tool assembly uphole from the set zonal isolation device, wherein the setting tool assembly is coupled to one or more perforating guns located uphole from the setting tool assembly, sending a trigger signal to the one or more perforating guns, and upon failure of at least one of the perforating guns to fire, pumping one or more replacement perforating guns down the wellbore to a desired location, wherein during the pumping the propping component holds the rotatable sealing component (e.g., flapper) in the intermediate position and provides for restricted flow of a wellbore fluid through the zonal isolation device.
A twentieth embodiment, which is the method of the nineteenth embodiment, further comprising sending a trigger signal to the one or more replacement perforating guns, and forming a plurality of perforations through the casing and into the surrounding formation in a wellbore zone located above the set zonal isolation device.
A twenty-first embodiment, which is the method of the twentieth embodiment, further comprising removing the setting tool assembly, the one or more perforating guns coupled to the setting tool assembly, and the one or more replacement perforating guns from the wellbore.
A twenty-second embodiment, which is the method of the twenty-first embodiment, further comprising structurally compromising the propping component such that the rotatable sealing component (e.g., flapper) can transition to the fully closed position, whereby a wellbore zone below the set zonal isolation device is isolated from fluid flow from the wellbore zone above the set zonal isolation device.
A twenty-third embodiment, which is the method of the twenty-second embodiment, wherein the propping component comprises a degradable material, an erodible material, or an abradable material and is structurally compromised via contact with a flowing wellbore fluid that removes all or a portion of the degradable material, the erodible material, or the abradable material.
A twenty-fourth embodiment, which is the method of the twenty-second embodiment, wherein the propping component comprises a dissolvable material or a corrodible material and is structurally compromised via contact with a wellbore fluid (e.g., via chemical decomposition of the strut, dissolution of the strut, etc.).
A twenty-fifth embodiment, which is the method of the twenty-second embodiment, wherein the propping component comprises a temperature-sensitive material (e.g., a fusible alloy) and is structurally compromised via change in ambient temperature in the wellbore proximate the set zonal isolation plug.
A twenty-sixth embodiment, which is the method of the twenty-fifth embodiment, wherein the change in ambient temperature is controlled by adjusting (e.g., halting) a flow of fluid in the wellbore, thereby allowing the temperature in the wellbore proximate the set zonal isolation plug to increase and soften the temperature-sensitive material.
A twenty-seventh embodiment, which is the method of the twenty-second embodiment, wherein the propping component comprises a frangible material and is structurally compromised via contact with a pressure wave.
A twenty-eighth embodiment, which is the method of the twenty-seventh embodiment, wherein the pressure wave is produced via a fluid pulse from the surface or from firing of a perforating gun (e.g., a shock wave).
A twenty-ninth embodiment, which is the method of the twenty-first embodiment, further comprising applying a closing force on the rotatable sealing component (e.g., flapper) that is greater than a spring force applied by spring 427 and/or spring 445 to transition the rotatable sealing component (e.g., flapper) from the intermediate position to the fully closed position, wherein the closing force results from contact with fluid flowing into the wellbore.
A thirtieth embodiment, which is the method of any of the twenty-second through the twenty-ninth embodiments, further comprising pumping fluid (e.g., a fracturing fluid such as a slickwater, a gel fluid, a proppant-laden fluid) from the surface down the wellbore and into the formation via the plurality of perforations in the wellbore zone above the set zonal isolation device and fracturing the formation, wherein a sealing device such as a ball is not required to be pumped from the surface in order to prevent fluid flow through the zonal isolation device and divert the fluid into the perforations and surrounding formation.
A thirty-first embodiment, which is the method of the thirtieth embodiment, where the rotatable sealing component (e.g., flapper) comprises a rupture disk, rupturing the rupture disk to provide for fluid flow through the set zonal isolation device, wherein the fluid flow enhances the dissolution rate of one or more dissolvable components of the zonal isolation device.
A thirty-second embodiment, which is the method of the thirtieth embodiment, where the rotatable sealing component (e.g., flapper) comprises a releasable hinge, decoupling an end of the rotatable sealing component (e.g., flapper) proximate the releasable hinge to remove the rotatable sealing component (e.g., flapper) from contact with the sealing surface to provide for fluid flow through the set zonal isolation device, wherein the fluid flow enhances the dissolution rate of one or more dissolvable components of the zonal isolation device.
A thirty-third embodiment, which is a method comprising inserting into a cased wellbore the zonal isolation device of any of the first through the twelfth embodiments, actuating the zonal isolation device to provide a set zonal isolation device, detaching a setting tool assembly from the set zonal isolation device, moving the setting tool assembly uphole from the set zonal isolation device, wherein the setting tool assembly is coupled to one or more perforating guns located uphole from the setting tool assembly, sending a trigger signal to the one or more perforating guns, forming a plurality of perforations through the casing and into the surrounding formation in a wellbore zone located above the set zonal isolation device, removing the setting tool assembly and the one or more perforating guns coupled to the setting tool assembly from the wellbore, either (i) structurally compromising the propping component such that the rotatable sealing component (e.g., flapper) can transition to the fully closed position, whereby a wellbore zone below the set zonal isolation device is isolated from fluid flow from the wellbore zone above the set zonal isolation device, wherein the propping component is structurally compromised in accordance with any of the twenty-third through the twenty-eighth embodiments or (ii) applying a closing force on the rotatable sealing component (e.g., flapper) that is greater than a spring force applied by spring 427 and/or spring 445 to transition the rotatable sealing component (e.g., flapper) from the intermediate position to the fully closed position, wherein the closing force results from contact with fluid flowing into the wellbore, and pumping fluid (e.g., a fracturing fluid such as a slickwater, a gel fluid, a proppant-laden fluid) from the surface down the wellbore and into the formation via the plurality of perforations in the wellbore zone above the set zonal isolation device and fracturing the formation, wherein a sealing device such as a ball is not required to be pumped from the surface in order to prevent fluid flow through the zonal isolation device and divert the fluid into the perforations and surrounding formation.
A thirty-fourth embodiment, which is the method of the thirty-second embodiment, where the rotatable sealing component (e.g., flapper) comprises a rupture disk, rupturing the rupture disk to provide for fluid flow through the set zonal isolation device, wherein the fluid flow enhances the dissolution rate of one or more dissolvable components of the zonal isolation device.
A thirty-fifth embodiment, which is the method of the thirty-second embodiment, where the rotatable sealing component (e.g., flapper) comprises a releasable hinge, decoupling an end of the rotatable sealing component (e.g., flapper) proximate the releasable hinge to remove the rotatable sealing component (e.g., flapper) from contact with the sealing surface to provide for fluid flow through the set zonal isolation device, wherein the fluid flow enhances the dissolution rate of one or more dissolvable components of the zonal isolation device.
A thirty-sixth embodiment, which is a method comprising inserting into a cased wellbore the zonal isolation device of any of the thirteenth through the fifteenth embodiments, actuating the zonal isolation device to provide a set zonal isolation device, wherein the rotatable sealing component (e.g., flapper) transitions to the fully closed position and a wellbore zone below the set zonal isolation device is isolated from fluid flow from a wellbore zone above the set zonal isolation device, detaching a setting tool assembly from the set zonal isolation device, moving the setting tool assembly uphole from the set zonal isolation device, wherein the setting tool assembly is coupled to one or more perforating guns located uphole from the setting tool assembly, sending a trigger signal to the one or more perforating guns, forming a plurality of perforations through the casing and into the surrounding formation in a wellbore zone located above the set zonal isolation device, removing the setting tool assembly and the one or more perforating guns coupled to the setting tool assembly from the wellbore, pumping fluid (e.g., a fracturing fluid such as a slickwater, a gel fluid, a proppant-laden fluid) from the surface down the wellbore and into the formation via the plurality of perforations in the wellbore zone above the set zonal isolation device and fracturing the formation, wherein a sealing device such as a ball is not required to be pumped from the surface in order to prevent fluid flow through the set zonal isolation device and divert the fluid into the perforations and surrounding formation, and rupturing the rupture disk to provide for fluid flow through the set zonal isolation device, wherein the fluid flow enhances the dissolution rate of one or more dissolvable components of the zonal isolation device.
A thirty-seventh embodiment, which is a method comprising inserting into a cased wellbore the zonal isolation device of any of the sixteenth through the eighteenth embodiments, actuating the zonal isolation device to provide a set zonal isolation device, wherein the rotatable sealing component (e.g., flapper) transitions to the fully closed position and a wellbore zone below the set zonal isolation device is isolated from fluid flow from a wellbore zone above the set zonal isolation device, detaching a setting tool assembly from the set zonal isolation device, moving the setting tool assembly uphole from the set zonal isolation device, wherein the setting tool assembly is coupled to one or more perforating guns located uphole from the setting tool assembly, sending a trigger signal to the one or more perforating guns, forming a plurality of perforations through the casing and into the surrounding formation in a wellbore zone located above the set zonal isolation device, removing the setting tool assembly and the one or more perforating guns coupled to the setting tool assembly from the wellbore, pumping fluid (e.g., a fracturing fluid such as a slickwater, a gel fluid, a proppant-laden fluid) from the surface down the wellbore and into the formation via the plurality of perforations in the wellbore zone above the set zonal isolation device and fracturing the formation, wherein a sealing device such as a ball is not required to be pumped from the surface in order to prevent fluid flow through the set zonal isolation device and divert the fluid into the perforations and surrounding formation, and decoupling an end of the rotatable sealing component (e.g., flapper) proximate the releasable hinge to remove the rotatable sealing component (e.g., flapper) from contact with the sealing surface to provide for fluid flow through set zonal isolation device, wherein the fluid flow enhances the dissolution rate of one or more dissolvable components of the zonal isolation device.
A thirty-eighth embodiment, which is a zonal isolation device 200 comprising: a sealing element 100 comprising a deformable material and an inner bore 105; a support ring 190 (also referred to as a frustum having a conical shape) movably disposed within the inner bore 105 of the sealing element 100; a rotatable seal connected to the support ring 190 and configured to engage a sealing surface (e.g., face or seat) of support ring 190, wherein the flapper is configured to restrict fluid flow through the zonal isolation device 200 in a closed position, is configured to minimally restrict fluid flow through the zonal isolation device 200 in a fully open position an end element 170 (e.g., a mule shoe) adjacent the anchoring assembly 215.
A thirty-ninth embodiment, which is the zonal isolation device of the thirty-eighth embodiment wherein the rotatable member allows restricted fluid flow through the zonal isolation device 200 when held by a propping component (also referred to as a propping member) in an intermediate or partially open position.
A fortieth embodiment, which is a zonal isolation device 200 comprising: a sealing element 100 comprising a deformable material and an inner bore 105; a support ring movably disposed within the inner bore 105 of the sealing element 100; a rotatable sealing component 400 coupled to the support ring 190 and configured to engage a sealing surface of the support ring 190, wherein the rotatable sealing component blocks fluid flow through the zonal isolation device 200 in a fully closed position, allows unrestricted fluid flow through the zonal isolation device 200 in a fully open position, and allows restricted fluid flow through the zonal isolation device 200 when held by a propping component in an intermediate or partially open position.
A forty-first embodiment, which is the device of the fortieth embodiment, wherein the rotatable sealing component 400 is a flapper valve.
Therefore, the present disclosure is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. While numerous changes may be made by those skilled in the art, such changes are encompassed within the spirit of the subject matter defined by the appended claims. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure. In particular, every range of values (e.g., “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood as referring to the power set (the set of all subsets) of the respective range of values. The terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee.
Claims
1. A zonal isolation device comprising:
- a sealing element comprising a deformable material and an inner bore;
- a support ring movably disposed within the inner bore of the sealing element;
- a flapper coupled to the support ring and configured to engage a sealing surface of support ring, wherein the flapper blocks fluid flow through the zonal isolation device in a fully closed position and allows unrestricted fluid flow through the zonal isolation device in a fully open position and wherein the flapper further comprises a rupture disk;
- a wedge engaged with a downhole end of the sealing element;
- an anchoring assembly engaged with the wedge; and
- an end element adjacent the anchoring assembly.
2. The device of claim 1, wherein the rupture disk is disposed within a circumferential groove on an interior face of a hole passing through the flapper.
3. The device of claim 1, wherein the rupture disk comprises one or more coating layers.
4. The device of claim 1, wherein the flapper further comprises a releasable hinge configured to decouple an end of the flapper proximate the releasable hinge.
5. The device of claim 2, wherein the flapper further comprises a releasable hinge configured to decouple an end of the flapper proximate the releasable hinge.
6. The device of claim 5, wherein the end of the flapper proximate the releasable hinge comprises a u-shaped recess receiving the pivot pin and a clip engaging the pivot pin.
7. The device of claim 6, wherein the flapper is configured to decouple from the releasable hinge via application of a releasing force sufficient to overcome a retaining force applied to the releasable hinge by the clip.
8. A method comprising:
- inserting into a cased wellbore the zonal isolation device of claim 1;
- actuating the zonal isolation device to provide a set zonal isolation device, wherein the flapper transitions to the fully closed position and a wellbore zone below the set zonal isolation device is isolated from fluid flow from a wellbore zone above the set zonal isolation device;
- detaching a setting tool assembly from the set zonal isolation device;
- moving the setting tool assembly uphole from the set zonal isolation device, wherein the setting tool assembly is coupled to one or more perforating guns located uphole from the setting tool assembly;
- sending a trigger signal to the one or more perforating guns;
- forming a plurality of perforations through the casing and into the surrounding formation in a wellbore zone located above the set zonal isolation device;
- removing the setting tool assembly and the one or more perforating guns coupled to the setting tool assembly from the wellbore;
- pumping fluid from the surface down the wellbore and into the formation via the plurality of perforations in the wellbore zone above the set zonal isolation device and fracturing the formation; and
- rupturing the rupture disk to provide for fluid flow through the set zonal isolation device.
9. The method of claim 8, wherein the fluid flow through the set zonal isolation device enhances the dissolution rate of one or more dissolvable components of the zonal isolation device.
10. The method of claim 9, wherein a sealing device such as a ball is not required to be pumped from the surface in order to prevent fluid flow through the set zonal isolation device and divert the fluid into the perforations and surrounding formation.
11. The method of claim 10, wherein the fluid is slickwater, a gelled fluid, or a proppant-laden fluid.
12. The method of claim 8, wherein the flapper further comprises a releasable hinge configured to decouple an end of the flapper proximate the releasable hinge and further comprising decoupling an end of the flapper proximate the releasable hinge to remove the flapper from contact with the sealing surface to provide for fluid flow through set zonal isolation device.
13. A zonal isolation device comprising:
- a sealing element comprising a deformable material and an inner bore;
- a support ring movably disposed within the inner bore of the sealing element;
- a flapper coupled to the support ring and configured to engage a sealing surface of support ring, wherein the flapper blocks fluid flow through the zonal isolation device in a fully closed position and allows unrestricted fluid flow through the zonal isolation device in a fully open position and wherein the flapper further comprises a releasable hinge configured to decouple an end of the flapper proximate the releasable hinge;
- a wedge engaged with a downhole end of the sealing element;
- an anchoring assembly engaged with the wedge; and
- an end element adjacent the anchoring assembly.
14. The device of claim 13, wherein the releasable hinge comprises a pivot pin.
15. The device of claim 14, wherein the end of the flapper proximate the releasable hinge comprises a u-shaped recess receiving the pivot pin and a clip engaging the pivot pin.
16. The device of claim 15, wherein the flapper is configured to decouple from the releasable hinge via application of a releasing force sufficient to overcome a retaining force applied to the releasable hinge by the clip.
17. A method comprising:
- inserting into a cased wellbore the zonal isolation device;
- actuating the zonal isolation device to provide a set zonal isolation device, wherein the flapper transitions to the fully closed position and a wellbore zone below the set zonal isolation device is isolated from fluid flow from a wellbore zone above the set zonal isolation device;
- detaching a setting tool assembly from the set zonal isolation device;
- moving the setting tool assembly uphole from the set zonal isolation device, wherein the setting tool assembly is coupled to one or more perforating guns located uphole from the setting tool assembly;
- sending a trigger signal to the one or more perforating guns;
- forming a plurality of perforations through the casing and into the surrounding formation in a wellbore zone located above the set zonal isolation device;
- removing the setting tool assembly and the one or more perforating guns coupled to the setting tool assembly from the wellbore;
- pumping fluid from the surface down the wellbore and into the formation via the plurality of perforations in the wellbore zone above the set zonal isolation device and fracturing the formation; and
- decoupling an end of the flapper proximate the releasable hinge to remove the flapper from contact with the sealing surface to provide for fluid flow through set zonal isolation device.
18. The method of claim 17, wherein the fluid flow through the set isolation device enhances the dissolution rate of one or more dissolvable components of the zonal isolation device.
19. The method of claim 18, wherein a sealing device such as a ball is not required to be pumped from the surface in order to prevent fluid flow through the set zonal isolation device and divert the fluid into the perforations and surrounding formation.
20. The method of claim 19, wherein the fluid is slickwater, a gelled fluid, or a proppant-laden fluid.
Type: Application
Filed: Jan 12, 2022
Publication Date: May 5, 2022
Inventors: Matthew Taylor NICHOLS (Carrollton, TX), Nin M. NGUYEN (Carrollton, TX), Zachary William WALTON (Edmond, OK), Michael Linley FRIPP (Carrollton, TX)
Application Number: 17/573,851
