US20260022621A1
2026-01-22
19/341,701
2025-09-26
Smart Summary: A bottom set frac plug is designed to control the flow of fluids in oil and gas wells. It has a special blocking device inside it that can create a seal to stop fluid from passing through. This device can also be moved to allow fluid to flow again when needed. If the fluid flows in a different direction, the device can be permanently removed to stop any flow. This technology helps manage fluid flow more effectively during drilling operations. 🚀 TL;DR
A bottom set frac plug including an object with an embedded blocking device, wherein the embedded blocking device is configured to form an initial seal across the object, allow communication through the object, be repositioned across the object to once again restrict communication through the object based on fluid flowing in a first direction, and be permanently disengaged from the object based on fluid flowing in a second direction.
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E21B34/063 » CPC main
Valve arrangements for boreholes or wells in wells Valve or closure with destructible element, e.g. frangible disc
E21B33/129 » CPC further
Sealing or packing boreholes or wells in the borehole; Packers; Plugs with mechanical slips for hooking into the casing
E21B2200/04 » CPC further
Special features related to earth drilling for obtaining oil, gas or water Ball valves
E21B2200/05 » CPC further
Special features related to earth drilling for obtaining oil, gas or water Flapper valves
E21B2200/06 » CPC further
Special features related to earth drilling for obtaining oil, gas or water Sleeve valves
E21B34/06 IPC
Valve arrangements for boreholes or wells in wells
Examples of the present disclosure relate to a downhole tool. More specifically, embodiments are directed towards a bottom set frac plug including an object with an embedded blocking device, wherein the embedded blocking device is configured to form an initial seal across the object, allow communication through the object, be repositioned across the object to once again restrict communication through the object based on fluid flowing in a first direction, and be permanently disengaged from the object based on fluid flowing in a second direction.
Conventionally, after cementing a well and to achieve frac/zonal isolation for a frac operation, a frac plug, and perforation guns on a wireline or other conveying methods are pushed or pumped downhole to a desired depth. Then, the frac plug is set across an annulus, internally sealed, and the perforation guns are fired above to create a conduit to frac fluid above the frac plug.
After an operation involving the downhole plug is complete, the plug and the internal seal must be removed from the wellbore or otherwise disposed of through milling or drilling. However, these operations can also be complex, time-consuming, and expensive.
Further, running a bottom-set frac plug may not allow running a ball on a seat. For example, once the frac plug is set, a ball must be dropped from the surface to form the internal seal. This requires additional time, increases the amount of fluid necessary to pump the ball downhole, and requires additional mechanical parts downhole.
To this end, these conventional processes consume frac fluid, time, and costs. Moreover, these conventional frac plugs with balls do not have a contingency operation if the perforation guns do not fire, where it would be desirable to reestablish communication instantly through the downhole tool without additional milling or waiting time for dissolvable material to dissolve.
Accordingly, needs exist for systems and methods for a single-run frac plug that utilizes a shearable plug embedded within an object, which allows for multiple seals to be created within the frac plug while also allowing for reestablishing communication through the frac plug.
Embodiments disclosed herein describe systems and methods for selectively restricting fluid through a downhole tool, wherein the downhole tool may be a bottom set frac plug, wiper, or another mandrel. The downhole tool may be configured to initially operate as a check valve to provide wellbore zonal isolation in multistage stimulation treatments. Specifically, the downhole tool may be configured to isolate a lower zone during stimulation, while always allowing communication via reverse flow and later always allowing bi-directional fluid flow. Embodiments may utilize a blocking device initially embedded within an object, wherein the object and the embedded blocking device form the initial, primary, seal across the mandrel. Responsive to flowing fluid in a second direction, the embedded blocking device may allow communication through the object. Later, the embedded blocking device is configured to reestablish the seal or form a secondary seal within the object by flowing fluid in the first direction. A pressure differential across the blocking device may shear the embedded blocking device from the object and remove the ability of the embedded blocking device to reestablish the seal across the object, wherein subsequent reverse flowing of the fluid may move the embedded blocking device up hole and allowing bi-directional flow of fluid through the object.
The system associated with the downhole tool may include a setting sleeve, mandrel, retainer, cone, slips, and object with an embedded blocking device. However, one skilled in the art may appreciate that the object with the embedded blocking device may be configured to selectively restrict communication through any mandrel, passageway, or downhole tool, such as a frac plug, wiper plug, etc.
The setting sleeve may be configured to move in the first direction to directly apply mechanical forces against the cone, which may drive the cone downhole to radially expand the slips. The setting sleeve may move in the first direction while the mandrel stays relatively fixed in place along a longitudinal axis of the downhole tool. Alternatively, while the setting sleeve moves in the first direction, the mandrel may move in a second direction along the longitudinal axis of the downhole tool.
The mandrel may be a tubular that runs through a central axis of the downhole tool and extends through the cone, slips, and retainer. The mandrel may have a threaded distal end, wherein breakable threads positioned on an outer diameter of the mandrel are configured to temporarily interface with threads positioned on an inner diameter of the retainer. These corresponding threads may allow the retainer to be substantially fixed in place to allow relative movement between the cone and slips across an annulus. In other embodiments, these threads may be replaced by a no-go profile, shear screws, or any other mechanism that limits relative axial movement. When the downhole tool is run in a hole, the mandrel may be configured to prop open the object, and not allow the object to extend across the central axis of the downhole tool. However, responsive to pulling the mandrel out of the hole, after the slips have radially expanded and broken the breakable threads, the mandrel may no longer restrict the rotation of the object. Once the mandrel is pulled out of the hole, the object with the embedded blocking device may form a primary seal across the downhole tool. In embodiments, the mandrel may run through a central axis of the tool, which may assist in more evenly distributing forces to the retainer when setting the frac plug.
The retainer may be positioned on the distal end of the frac plug. The retainer may have a threaded inner diameter that is configured with breakable or shearable threads that interface with the outer diameter of the mandrel to lock the relative movement of the mandrel and the retainer together. The retainer may be configured to be relatively fixed in place along a longitudinal axis of the frac plug while the setting sleeve moves in the first direction. This may allow the cone to radially expand the slips by the retainer receiving a load from the slips.
The cone may be positioned between the distal end of the setting sleeve and the slips. The cone may be configured to slide towards the retainer of the frac plug to radially expand the slips. More specifically, the cone may slide under the slips while the slips stay fixed in place along a longitudinal axis of the frac plug to drive the slips outward. When the slips radially expand, the outer diameter of the slips may extend across an annulus and grip an inner diameter of the casing to secure the frac plug in place.
The cone may include a first seat and a second seat. The first seat may be positioned above the second seat along a longitudinal axis of the cone, and the first seat may have a first inner diameter. The second seat may be positioned below the first seat along the longitudinal axis of the cone, and the second seat may have a second inner diameter that is smaller than the first inner diameter. The first seat may be configured to receive an outer diameter of the object to limit the downward rotation or movement of the object. Responsive to the object landing on the first seat, the object with the embedded blocking device may form a primary seal across the first inner diameter of the cone. The second seat may be configured to receive an outer diameter of the blocking device responsive to shearing the blocking device from the object. Responsive to the second seat receiving the blocking device while the object remains in place across the first seat, a second seal may be formed across the second inner diameter of the cone.
The object may be a flapper, ball, disc, or any other object that is configured to operate as a check valve in a first mode of operation, which restricts fluid from flowing in a first direction and allows fluid to flow in a second direction. In a second mode of operation, an embedded blocking device may be removed from the object allowing fluid may freely flow through the object in either the first direction or the second direction. In embodiments, the object may be a housing that extends across the downhole tool and may not be configured to rotate. For example, the object may be a housing extending across an inner diameter of a frac plug, wiper plug, etc.
The embedded blocking device may be a plug configured to initially form a seal or restrict communication across an inner diameter of the object and subsequently form a secondary seal across the cone. In further embodiments, the embedded blocking device may be configured to selectively form the seal across the inner diameter of the object, wherein the blocking device may be configured to be positioned and repositioned across the object to selectively restrict communication across the object. Specifically, the blocking device may be configured to be positioned away from the mandrel by flowing fluid in an uphole direction, and the object is configured to be positioned across the mandrel by flowing fluid in a downhole direction.
The downhole device may transition from the first mode to the second mode without moving the object along a longitudinal axis of the cone and/or without the object rotating. When run in a hole, the object may be restricted from forming a primary seal across the first seat within the cone by the mandrel, wherein a lower surface of the embedded blocking device or object may contact an outer diameter of the mandrel when run in the hole. After the mandrel is pulled out of the hole, the object may rotate or move to be positioned on the first seat, and form the primary seal across the first inner diameter of the cone.
Responsive to flowing fluid through an inner diameter of the cone in the first direction, the flowing fluid may apply pressure against the upper surface of the object and/or embedded blocking device to maintain the primary seal. Responsive to flowing fluid through an inner diameter of the cone in a second direction, the flowing fluid may apply forces against the lower surface of the object and/or embedded blocking device to move the object up hole a limited distance or rotate the object and the embedded blocking device upward, which may no longer form the seal across the first inner diameter of the cone.
In the first mode of operation, the blocking device may be embedded within a hollow passageway through a short axis of the object. The blocking device may have an outer diameter that is positioned directly adjacent to the inner diameter of the object, wherein seals positioned on the outer diameter of the blocking device may not allow or restrict communication through the short axis of the object. When in the first mode of operation, the object and blocking device may form the primary seal across the cone. Subsequently, flowing fluid in the first direction above the cone may increase the pressure within the inner diameter of the cone to shear the blocking device from the object. Responsive to shearing the blocking device, the blocking device may travel downhole within the cone to be positioned on the second seat within the cone, and form a secondary seal across the cone. When positioned on the second seat, the seals on the outer diameter of the blocking device may be positioned directly adjacent to the walls of the inner diameter of the cone above the second seat to form a secondary seal. When the blocking device is positioned on the second seat, the blocking device may maintain pressure integrity to allow a fracturing operation above the blocking device.
Furthermore, when the blocking device is positioned on the second seat, fluid may flow in the second direction to dislodge the blocking device from the second seat, allowing the blocking device to flow away from the cone. After the blocking device is moved away from the cone, fluid may permanently flow bidirectionally through the inner diameter of the object and cone. In contrast, the object is maintained on the first seat. This may permit the next wireline tool string to be pumped downhole without a fluid lock. In further embodiments, the blocking device may not be sheared from the object by flowing fluid in the second direction due to the object rotating in the second direction responsive to flowing fluid in the first direction. Alternatively, the blocking device may not be sheared from the object by flowing fluid in the second direction due to the object being able to axially move a stroke length relative to the object. Moving the blocking device up the hole may expose communication chambers between the outer diameter of the blocking device and the inner diameter of the object. These communication chambers may limit the ability of a required pressure differential to shear the blocking device from the object due to the flowing fluid in the second direction.
A second embodiment of a bottom set shorty frac plug may similarly include a setting sleeve, mandrel, retainer, cone, slips, and object. These embodiments may also include a communication conduit, control chamber, and shearing device.
The communication conduit may be a hollow passageway extending from the inner diameter of the cone to the outer diameter of the cone. The communication conduit may be configured to establish communication between an area positioned below the object when the object forms a seal across the cone and a lower surface of the shearing device within the control chamber. Specifically, the communication conduit may allow the pressure below the shearing device within the control chamber to be equal to the downhole pressure below the object or the frac plug. This may allow for a pressure differential across the shearing device to break the shearing device. Accordingly, embodiments may be used in multiple implementations, which would not be possible if the area below the shearing device was not in communication with downhole pressure, such as if portions of the control chamber were an atmospheric chamber.
The control chamber may be a chamber, opening, etc. positioned between an inner diameter and outer diameter of the cone. A proximal end of the control chamber may be exposed to the first area above the object when the object forms a seal across the cone, and a distal end of the control chamber may be exposed to a second area below the object via the communication conduit. This relative communication within the control chamber may allow the pressure differential between the first area and the second area to act upon the shearing device. A diameter across the distal end of the chamber may be smaller than a diameter across the proximal end of the chamber, this may allow the shearing device to be inserted within the chamber, but only be able to travel a given distance within the control chamber.
The shearing device may be a device that is configured to shear, break, separate, etc. based on a pressure differential being applied across the shearing device, wherein the pressure differential is associated with the first area and the second area. Additionally, when the shearing device is intact, the shearing device may restrict the longitudinal movement of the object. However, when the shearing device is broken, the shearing device may allow for the longitudinal movement of the object in a second, uphole, or above frac plug, direction.
The shearing device may include a lower portion, an upper portion, and breakable portions. The lower portion of the shearing device may be configured to form a seal across a distal end of the control chamber, wherein the seal may be a metal-to-metal seal, o-ring seal, or any other type of seal. Additionally, the lower portion may act as a piston to receive pressure from the first area and pressure from the second area. Responsive to the pressure differential between the first area and the second area being greater than a pressure differential, the lower portion may break the breakable portions, and slide in a first direction, while maintaining the seal within the control chamber.
The upper portion of the shearing device may be positioned above the hole from the lower portion of the shearing device. The upper portion may have a slot configured to receive the shaft of the object. When the shearing device is intact, the slot may restrict the relative longitudinal movement of the shearing device and the object via the shaft. Accordingly, while the shearing device is intact, the reverse flow back of fluids through the inner diameter of the cone will not cause the object to flow up the hole and away from the cone due to the shaft being inserted through both the shearing device and the object.
The breakable portions of the shearing device may be positioned longitudinally between the upper portion and the lower portion of the shearing device. The breakable portions may include a pin slot that is configured to receive a retaining pin, wherein the retaining pin is configured to secure the shearing device within the control chamber when the shearing device is intact. The breakable portions may include weak points, windows, etc., that are configured to shear based on a pressure differential applied across the shearing device.
Responsive to breaking the breakable portions of the shearing device, the lower portion may slide in the first direction within the control chamber, decoupling the upper portion from the lower portion. This may enable the upper portion to move in the second direction outside of the control chamber and uphole. Furthermore, after the upper portion of the shearing device is separated from the lower portion, the shaft may no longer extend within the slot, which may allow the upper portion and the object to independently move along the longitudinal axis of the downhole tool. This may enable the object and the upper portion to simultaneously flow in the second direction after the shearing device is broken.
In further embodiments, a ball or secondary object may be subsequently positioned across the inner diameter of the cone to form a secondary seal, while the lower portion of the shearing device retains the seal across the control chamber. These, and other, aspects of the invention will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. The following description, while indicating various embodiments of the invention and numerous specific details thereof, is given by way of illustration and not of limitation. Many substitutions, modifications, additions, or rearrangements may be made within the scope of the invention, and the invention includes all such substitutions, modifications, additions, or rearrangements.
Non-limiting and non-exhaustive embodiments of the present invention are described concerning the following figures, wherein reference numerals refer to like parts throughout the various views unless otherwise specified.
FIG. 1 depicts a system associated with a downhole tool or frac plug, according to an embodiment.
FIG. 2 depicts a downhole tool being run in a hole, according to an embodiment.
FIG. 3 depicts a downhole tool after a mandrel has been pulled out of the hole, according to an embodiment.
FIG. 4 depicts a downhole tool with an object in the first mode forming the primary seal across the cone, according to an embodiment.
FIG. 5 depicts a downhole tool with an object in the second mode, and the blocking device 155 is forming a secondary seal within the cone, according to an embodiment.
FIG. 6 depicts a downhole tool with an object in the second mode and a blocking device no longer forming a secondary seal within the cone, according to an embodiment.
FIG. 7 depicts a downhole tool, according to an embodiment.
FIG. 8 depicts a downhole tool, according to an embodiment.
FIG. 9 depicts a downhole tool, according to an embodiment.
FIGS. 10-11 depict a downhole tool, according to an embodiment.
FIGS. 12-13 depict a downhole tool, according to an embodiment.
FIG. 14 depicts a downhole tool, according to an embodiment.
FIG. 15 depicts a method for deploying a frac plug or downhole sealing system, according to an embodiment.
FIG. 16 depicts a method for removing a frac plug or downhole sealing system, according to an embodiment.
Corresponding reference characters indicate corresponding components throughout the several views of the drawings. Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of various embodiments of the present disclosure. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted to facilitate a less obstructed view of these various embodiments of the present disclosure.
In the following description, numerous specific details are outlined to provide a thorough understanding of the present invention. It will be apparent, however, to one having ordinary skill in the art that the specific detail need not be employed to practice the present invention. In other instances, well-known materials or methods have not been described in detail to avoid obscuring the present invention.
FIG. 1 depicts a system 100 associated with a downhole tool or frac plug, according to an embodiment. System 100 may be a bottom set frac plug having an object 150 with an embedded blocking device 155 that makes it possible to form a secondary seal within cone 120 while permanently opening a passageway through the object 150 by applying higher pressure. After the blocking device 155 is sheared from object 150 and the passageway is exposed, the blocking device 155 may land on a downhole seat 124 within the downhole tool, allowing for pressure integrity during a fracturing operation requiring up to 10,000 PSI in a first direction. After pressure is released, fluid may flow in a reverse direction, removing the blocking device 155 from the second seat, allowing bi-directional fluid flow through the passageway of the object 150. This will allow fluid to be pumped through the downhole tool and the object 150, without the object 150 ever moving from its initial position along a longitudinal axis of the downhole tool, to position wireline tools downhole.
Downhole tool 100 may include a setting sleeve 105, mandrel 110, retainer 140, cone 120, slips 130, and object 150 with an embedded blocking device 155.
Setting sleeve 105 may be configured to move in a first direction to directly apply mechanical forces against cone 150 to radially expand the slips 130. Setting sleeve 105 may move in the first direction while the mandrel 110 may stay relatively fixed in place along a longitudinal axis of the downhole tool 100. Alternatively, while setting sleeve 105 moves in the first direction, mandrel 110 may move in a second direction along the longitudinal axis of the downhole tool 100. In other words, setting sleeve 105 may be a tubular with a hollow passageway. Setting sleeve 105 may be configured to apply forces against the cone 120 towards slips 130, moving the cone 120 under the slips 130, causing slips 130 and seal ring 132 to radially expand. In embodiments, a distal end of the setting sleeve 105 may be directly coupled to a proximal end of the cone 120. The distal end of setting sleeve 105 may be interfaced with the proximal end of cone 120 via an anti-rotational lock, such as castling or a series of projections and grooves. This may rotationally lock cone 120 with setting sleeve 105.
Mandrel 110 may be a tubular that runs through a central axis of the downhole tool 100, and extends through the cone 120, slips 130, and retainer 140. Mandrel 110 may have a threaded distal end 112. The threads positioned on the inside of the retainer 140 may be breakable threads that temporarily interface to an outer diameter of mandrel 110. These temporarily interfacing threads may allow the retainer 140 to be relatively fixed in place to allow the relative movement between the cone 120 and slips 130 to set the frac plug and allow the radial expansion of the slips 130. In other embodiments, the retainer 140 threads may be replaced by a no-go, shear pins, or other temporary coupling mechanism that shears after the expansion of slips 130. During the entirety of running the downhole tool 100 from the surface, mandrel 110 may be configured to prop open object 150, and not allow object 150 to extend across the inner diameter of the cone 120 or the downhole tool 100. However, responsive to pulling the mandrel 110 out of the hole along with setting sleeve 105, after the slips 130 have radially expanded and breaking the breakable threads, mandrel 110 may no longer restrict the rotation of object 150, and object 150 may form a seal across the cone 120 or downhole tool 100. In embodiments, mandrel 110 may run through a central axis of the downhole tool 100, which may assist in more evenly distributing forces to retainer 140 when setting the frac plug.
Retainer 140 may be positioned on the distal end of the downhole tool 100. Retainer 140 may have a threaded inner diameter with shearable threads that are configured to interface with the threads on the outer diameter of mandrel 110 to lock the relative movement of the mandrel and the retainer together. Retainer 140 may be configured to be relatively fixed in place along a longitudinal axis of downhole tool 100 as setting sleeve 105 moves in the first direction. This may allow cone 120 to radially expand slips 130 by receiving a load from slips 130 when restricting the movement of slips 130 in the first direction. In other embodiments, the retainer 140 thread may be replaced by a no-go, shear pins, or other temporary coupling mechanism that shears after the expansion of slips.
Cone 120 may be positioned between the distal end of setting sleeve 105 and slips 130. Cone 120 may be configured to slide towards retainer 140 while slips 130 do not move along the longitudinal axis of downhole tool 100 to radially expand slips 130 and seal ring 132. More specifically, cone 120 may slide under slips 130 and seal ring 132 while slips 130 and seal ring 132 stay fixed in place along a longitudinal axis to drive slips 130 and seal ring 132 outward. When slips 130 and seal ring 132 radially expand, the outer diameter of slips 130 and seal ring 132 may increase to extend across an annulus and grip and seal an inner diameter of the well casing to secure the frac plug in place. In implementations, after slips 130 and seal ring 132 have radially expanded mandrel 110 and setting sleeve 105 may be pulled out of the hole together. In contrast, cone 120, slips 130, seal ring 132, and retainer 140 remain downhole to expose a continuous passageway through a central axis of cone 120, slips 130, seal ring 132, and retainer 140. In embodiments, the continuous passageway may be initially blocked by object 150 with embedded blocking device 155 and subsequently blocked by blocking device 155 alone.
Cone 120 may be a single unitary piece formed of a single material. In other embodiments, cone 120 may include a first seat 122 and a second seat 124. First seat 122 may be positioned above second seat 124 along a longitudinal axis of the cone 120, and the first seat 122 may have a first inner diameter. Second seat 124 may be positioned below the first seat 122 along the longitudinal axis of cone 120, and second seat 124 may have a second inner diameter that is smaller than the first inner diameter.
First seat 122 may be configured to receive an outer diameter of object 150 to limit the downward rotation or movement of object 150. Responsive to object 150 landing on the first seat 122, object 150 may form a primary seal across the first inner diameter of cone 120 at a first location within cone 120. Second seat 124 may be configured to receive an outer diameter of the blocking device 155 responsive to shearing the blocking device 155 from the object 150. Responsive to the second seat 124 receiving the blocking device 155, a second seal may be formed across the second inner diameter of cone 120 at a second location within cone 120. Furthermore, once blocking device 155 is disengaged from object 150, object 150 may no longer be able to form the primary seal across the first inner diameter of cone 120 or at any other location due to having a permanently open hollow passageway.
Object 150 may be a flapper, ball, disc, or any other object that is configured to operate as a check valve in a first mode of operation. In implementations, object 150 may be coupled to cone 120 via a shaft 152, pin, etc. that extends through the body of cone 120 and object 150. In embodiments, shaft 152 may include a spring or other means of force that is configured to position object 150 on first seat 122 if no other forces are applied to object 150. In other embodiments, shaft 152 may be a net-neutral shaft that does not exert a rotational force against object 150.
In implementations, object 150 may be configured to rotate about shaft 152. Due to the passageway holding shaft 152 through cone 120 potentially allowing communication between the outer diameter of cone 120 and the hollow passageway within cone 120, shaft 152 may be positioned above seal ring 132 on the outer diameter of slips 130 before and after slips 130 are activated. In other embodiments, shaft 152 may be located on the same plane or lower than seal ring 132. In further embodiments, second seat 122 may also be positioned above sealing location 132 before and after slips 130 are activated. In other embodiments, shaft 152 does not penetrate cone 120 and only resides within cartridge 125.
In the first mode of operation, object 150 with embedded blocking device 155 restricts fluid from flowing in the first direction while allowing fluid to flow in a second direction. In a second mode of operation, blocking device 155 may no longer be embedded within blocking device 155 such that fluid may freely flow through object 150 in either the first direction or the second direction. Downhole tool 100 may transition from the first mode to the second mode without object 150 moving along a longitudinal axis of the cone 120, without object 150 rotating, and/or positioning additional tools downhole. More specifically, when run in a hole, object 150 may be restricted from forming a primary seal across the first seat within the cone 120 by mandrel 110, wherein a lower surface of object 150 may contact an outer diameter of mandrel 110 when run in the hole. After mandrel 110 is pulled out of the hole, object 150 may rotate or move to be positioned on the first seat, and object 150 and blocking device 155 may form the primary seal across the first inner diameter of 120. Specifically, after mandrel 110 is removed from cone 120, object 150 may be moved to a closed position by the force of a biased spring. Responsive to flowing fluid through an inner diameter of the cone 120 in the first direction, the flowing fluid may apply force against the upper surface of object 150 to seat object 150 on seat 122 and maintain the primary seal. Responsive to flowing fluid through an inner diameter of the cone 120 in a second direction, the flowing fluid may apply force against the lower surface of object 150 to move or rotate object 150 and embedded blocking device 155 upward, which may no longer form the seal across the first inner diameter of the cone 120 and seat 122.
When downhole tool 100 is in its first mode of operation, a blocking device 155 may be embedded within a hollow passageway through a short axis of object 150. Blocking device 155 may have an outer diameter that is positioned directly adjacent to an inner diameter of the hollow passageway within object 150, wherein seals 210 positioned on the outer diameter of blocking device 155 may not allow communication through the short axis of object 150. When downhole tool 100 is in its first mode of operation and object 150 and blocking device 155 form the primary seal across cone 120, fluid flowing in the first direction above cone 120 may increase the pressure within the inner diameter of cone 120 to shear blocking device 155 from object 150. This may transition the downhole tool 100 to the second mode of operation. When in the second mode of operation, object 150 and blocking device 155 may no longer form the primary seal.
However, responsive to the shearing blocking device 155, the blocking device 155 may travel downhole within cone 120 to be positioned on the second seat 124. This movement may allow blocking device 155 to form a secondary seal across second seat 124 within cone 120. Specifically, blocking device 155 may form the second seal within cone 120 directly after being sheared from object 150 without moving through any other element within downhole tool 100. When blocking device 15 is positioned on the second seat 124, the seals 210 on the outer diameter of blocking device 155 may be positioned directly adjacent to the walls of the inner diameter of the cone 120 above the second seat 124. Furthermore, when blocking device 155 is positioned on the second seat 124, fluid may flow in the second direction to dislodge blocking device 155 from the second seat 124, allowing blocking device 155 to flow away from the cone 120.
After blocking device 155 is moved away from cone 120, fluid may permanently flow bidirectionally through the inner diameter of object 150 and cone 120, while object 150 is positioned on the first seat. This may permit the next wireline tool string to be pumped downhole without a fluid lock.
FIG. 2 depicts downhole tool 100 being run in a hole, according to an embodiment. Elements depicted in FIG. 2 may be described above, and for the sake of brevity, a further description of these items may be omitted.
As depicted in FIG. 2, when mandrel 110 is positioned through a central axis of cone 120, mandrel 110 may restrict the rotation of object 150 and blocking device 155. Specifically, in embodiments where object 150 is a flapper, a lower surface of blocking device 155 may contact and be positioned against an outer diameter of mandrel 110 when run in a hole. This contact may limit the downward rotation of the flapper.
As further depicted in FIG. 2, a lower surface of object 150 may include a tapered rim 220, and a lower surface of blocking device 155 may include a tapered rim 230. The tapered rims 220, 230 may be configured to allow for mandrel 110 to be pulled out of the hole more easily. Additionally, tapered rim 230 may have a distal end that is positioned further downhole than the distal end of tapered rim 220. This may allow tapered rim 230 to contact mandrel 110 while tapered rim 230 of object 150 does not contact mandrel 110. This may ensure the integrity of the lower surface of object 150, while also positioning a contact point between tapered rim 230 and mandrel 110 below seals 210.
FIG. 3 depicts downhole tool 100 after mandrel 110 has been pulled out of the hole, according to an embodiment. Elements depicted in FIG. 3 may be described above, and for the sake of brevity, a further description of these items may be omitted.
As depicted in FIG. 3, responsive to pulling mandrel 110 out of the hole, the object 150 may freely rotate within cone 120. Specifically, object 150 may rotate about shaft 152, wherein shaft 152 extends in an axis orthogonal to the central axis of cone 120.
In embodiments, shaft 152 may be configured to apply a net neutral force against object 150 to allow object 150 to freely rotate. This may allow fluid to move object 150 in the first mode or the second mode. However, in alternative embodiments, shaft 152 may be configured to be equipped with a biased spring or other means of force, which may be biased to seat object 150 on first seat 122 when no external forces are applied to object 150.
FIG. 4 depicts downhole tool 100 with an object in the first mode forming the primary seal across cone 120, according to an embodiment. Elements depicted in FIG. 4 may be described above, and for the sake of brevity, a further description of these items may be omitted.
After mandrel 110 has been pulled out of the hole and fluid flows through an inner diameter of cone 120 in a first direction, the fluid may interface with an upper surface 430 of object 150 to seat object on first seat 122
Once object 150 is positioned on first seat 122, the tapered lower surface 220 of object 150 may be positioned directly on seat 122, and bodies of object 150 and embedded blocking device 155 may form a seal across an inner diameter of cone 150. This primary seal may not allow communication in an area below object 150 to an area above object 150 within cone 120.
As further depicted in FIG. 4, an upper surface 430 of blocking device 155 may be a bulbous surface, and a lower surface 435 of blocking device 155 may be a bulbous surface, wherein the bulbous surfaces increase the thickness of blocking device 155. This increase in thickness may allow the bulbous surfaces of the blocking device 155 to either contact the mandrel 110 when run in a hole or the inner diameter of cone 120 if fluid is flowing in a second direction. To this end, the upper surface or lower surface of object 150 may not have to contact mandrel 110 or the inner surface of cone 120 due to the bulbous surfaces of blocking device 155 contacting other surfaces within cone 120. Furthermore, the bulbous lower surface 435 of blocking device 155 may increase the surface area of blocking device 155 and assist in forming a secondary seal when positioned on second seat 124.
In the first mode, blocking device 155 may have a projection 410 that radially extends away from the body of blocking device 155 and is positioned on a ledge 420 of object 150. Responsive to flowing fluid in a first direction, pressure applied to projection 410 may cause projection 410 to shear due to a thickness across projection being a minimum thickness of blocking device 155. When blocking device 155 is sheared, blocking device 155 may immediately or soon after form a second seal within cone 120. In embodiments, blocking device 155 may shear from object 150 due to an initial fracturing operation, such as perforation guns firing.
FIG. 5 depicts downhole tool 100 with object 150 in the second mode, and blocking device 155 is forming a secondary seal within cone 120, according to an embodiment. Elements depicted in FIG. 5 may be described above, and for the sake of brevity, a further description of these items may be omitted.
As depicted in FIG. 5, responsive to flowing fluid in the first direction, projection 410 may shear, allowing the body of the blocking device 155 to move in the first direction and be positioned on the second seat 124 without object 150 moving. When blocking device 155 is positioned on second seat 124, blocking device 155 may form a secondary seal within cone 120, wherein the secondary seal may be formed by seals 210 being positioned adjacent to an inner diameter of cone 120. This secondary seal may allow for a secondary fracturing operation to occur above object 150.
In embodiments, blocking device 155 may be disengaged from object 150 by flowing fluid below a fracturing pressure through cone 120. This may allow fracturing after blocking device 155 is disengaged from the object, while also allowing blocking device 155 to be disengaged from object 150 without reaching a fracturing pressure. For example, a shearing threshold to shear blocking device 155 from object 150 may be 2,500 PSI while blocking device 155 may retrain pressure integrity up to 10,000 PSI associated with a fracturing operation.
FIG. 6 depicts downhole tool 100 with object 150 in the second mode and blocking device 155 no longer forming a secondary seal within cone 120, according to an embodiment. Elements depicted in FIG. 6 may be described above, and for the sake of brevity, a further description of these items may be omitted.
As depicted in FIG. 6, after blocking device 155 has been disengaged from object 150, flowing fluid in the second direction will cause blocking device 155 to be disengaged from second seat 124, where it can wash away. After blocking device 155 is removed from cone 120, object 150 may have an open hollow passageway that allows for bi-directional fluid flow through cone 120.
FIG. 7 depicts a downhole tool 700, according to an embodiment. Elements depicted in downhole tool 700 may be described above, and for the sake of brevity, a further description of these elements may be omitted. Specifically, one skilled in the art may understand that elements utilized in downhole tool 100 may also be utilized in downhole tool 700, and vice versa.
Downhole tool 700 may be a bottom set shorty frac plug. In embodiments, downhole 700 may include similar elements as downhole tool 700. However, object 720 may be mounted and/or positioned in a different manner than object 150 of downhole tool 100. Downhole tool 700 includes casing 705, mandrel 110, slips 130, retainer 140, cone 710, object 720, shaft 730, and shearing device 740.
Communication conduit 712 may be a hollow passageway extending from an inner diameter of cone 710 to an outer diameter of cone 710. In embodiments, cone 710 may be any tubular structure that may be symmetrical or asymmetrical with a hollow internal passageway. Communication conduit 712 may be positioned longitudinally below a seal formed by object 720 across cone 710 to allow communication below object 720 into control chamber 716. In embodiments, communication conduit 712 may be configured to allow communication of pressure below object 720 into a distal end of control chamber 716, which will allow downhole pressure to form the pressure differential that shears shearing device 740. In embodiments, communication conduit 712 may extend in a direction perpendicular to the hollow passageway through cone 710. When run in the hole and after slips 130 are activated, communication conduit 712 may be positioned longitudinally below a seal 132 on the outer diameter of slips 130. Additionally, once slips 130 are activated, an inner surface of slips 130 may form a seal against an outer surface of conduit 712, wherein an inner surface of communication conduit 712 may still be in communication with the hollow passageway within cone 710.
Channel 714 may form a portion of the distal end of control chamber 716, and may be configured to be in fluid communication with communication conduit 712. Channel 714 may extend in a direction parallel to the hollow passageway through cone 710, which may assist in positioning communication conduit 712 below object 720.
Control chamber 716 may be a chamber, opening, etc., positioned between the inner diameter and outer diameter of cone 710. The proximal end of control chamber 716 may be configured to be in communication with the first area of the well above object 720, and the distal end of control chamber 716 may be configured to be in communication with a second area of the well below the object 720. This relative communication within Control chamber 716 may allow a pressure differential between the first area and the second area to act upon the shearing device 740. Furthermore, control chamber 716 may be radially offset from the hollow passageway extending through cone 710. Furthermore, a diameter across a distal end of control chamber 716 may be smaller than a diameter across a proximal end of control chamber 716. This may allow the shearing device 740 to be inserted within the control chamber 716, but only be able to travel a given distance within the control chamber 716.
Object 720 may be a flapper, ball, disc, or any other object that is configured to operate as a check valve in a first mode of operation. In embodiments where object 720 is a flapper, object 720 may be configured to rotate about shaft 730, wherein shaft 730 may be aligned with a central axis of control chamber 716. After mandrel 110 is removed from the downhole tool 700, object 720 may rotate about shaft 730 to be seated across seat 722, which may isolate a first area above object 720 from a second area below object 720. Responsive to flowing fluid up a hole within the hollow passageway in cone 710, object 720 may rotate about shaft 730 away from first seat 722 to allow communication through downhole tool 700 in the uphole direction. Flowing fluid downhole may cause object 720 to rotate about shaft 730 to once again be seated on seat 722. In embodiments, object 720 may be secured in place along a longitudinal axis via a shaft 730 that extends through both the object 720 and the shearing device 740. However, after the shearing device 740 has broken, the shaft 730 may no longer restrict the longitudinal movement of the object 720.
Shearing device 740 may be a device that is configured to shear, break, separate, etc., based on a pressure differential being applied across shearing device 740. Additionally, when shearing device 740 is intact, shearing device 740 may restrict the movement of the object 720, such that the entirety of object 720 may not move up the hole while shearing device 740 is intact. However, when the shearing device 740 is broken, the shearing device 740 may allow for the movement of the object 720 in a second, up-hole direction. Shearing device 740 may include a lower portion 746, an upper portion 744, and breakable portions 742.
Lower portion 746 may be configured to form a seal across a distal end of the control chamber 716, wherein the seal may be a metal-to-metal seal, o-ring seal, or any other type of seal. Additionally, the lower portion 746 may act as a piston to receive pressure from the first area and pressure from the second area. Responsive to the pressure differential between the first area and the second area being greater than a pressure differential, lower portion 746 may slide in a first direction, maintaining the seal within the control chamber 716, and breaking the breakable portions 742.
Upper portion 744 may be positioned up the hole from the lower portion 746, and upper portion 744 may have a slot 745 configured to receive the shaft 730. When the shearing device 740 is intact, and the shaft 730 is inserted through the slot 745, longitudinal movement of the shearing device 740 and object 720 may be locked together. To this end, the upper portion 744 may act as a stopper to limit the upward movement of object 720 and shaft 730 when shearing device 740 is intact. Accordingly, while the shearing device 740 is intact, the reverse flow back of fluids through the inner diameter of the cone 710 will not cause the object 720 to flow uphole and away from the cone 710. However, responsive to decoupling the upper portion 744 from the lower portion 746, shaft 730 and object 720 may independently move up the hole.
Breakable portions 742 may be positioned between the upper 744 portion and the lower portion 746. Breakable portions 742 may include weak points, windows, etc., that are configured to shear based on a pressure differential applied across the shearing device 740. In other embodiments, breakable portions 742 may have a reduced thickness, no thickness, or other geometrical properties that allow breakable portions 742 to become the weak point and shear before the lower portion 746 and/or upper portion 744 shear. Responsive to breaking breakable portions 742, the lower portion 746 may slide in the first direction within the control chamber 716. In embodiments, while lower portion 746 moves in the first direction, upper portion 744 may initially not move. However, the upper portion 744 may subsequently move in the second direction outside of the control chamber 716.
Breakable portions 742 may include a retaining pin slot that is configured to receive a retaining pin 750. In embodiments, retaining pin 750 may extend into a body of breakable portions 742 to form a stopper to limit the longitudinal movement of shearing device 740, which may secure lower portion 747 within the control chamber 716 when the shearing device 740 is intact or not. In embodiments, the retaining pin slot may allow communication in an area within the control chamber 716 above the lower portion 746 and an area outside of cone 710. In other words, in embodiments, retaining pin 750 may not form a seal within the retaining pin slot. Furthermore, in other embodiments, retaining ring 750 may be replaced by a no-go, shear pins, or other temporary coupling mechanism that shears.
In further embodiments, a ball or secondary object may be subsequently positioned across the inner diameter of cone 710 to form a secondary seal, while the lower portion 746 retains the seal across the control chamber 716.
In further embodiments, shaft 730 may be a hinge that is configured to allow object 720 to rotate about it, wherein the axis of rotation is offset from a central axis of the cone 710. After the shearing device 740 is broken, the hinge may no longer retain or allow the object 720 to rotate about. Additionally, in other embodiments, the downhole forces may activate shaft 730 by breaking shaft 730, wherein the activation may be caused by the downhole movement of lower portion 746 or the downhole forces directly interfacing with shaft 730 to activate shaft 730.
FIG. 8 depicts downhole tool 700, according to an embodiment. Elements depicted in FIG. 8 may be described above, and for the sake of brevity, a further description of these elements is omitted.
As depicted in FIG. 8, an upper surface of cone 710 may include a shaft slot 810 that is configured to receive shaft 730, wherein shaft slot 810 is configured to extend along a lateral axis of cone 710. The length of the shaft slot 810 and the shaft 730 may be longer than the first end of the object 720. This may enable the first end of shaft 730 to be positioned in a first groove on the first side of object 720, and the second end of shaft 730 to be positioned on a second side of object 730. However, in embodiments, shaft slot 730 may not extend across into the outer diameter of cone 710.
In embodiments, before being positioned within cone 710, slot 745 positioned within the shearable device 740 may be aligned with shaft holes on the first end of object 720. Then, shaft 730 may be inserted into slot 745, and the shaft holes within object 720. The unified shaft 730, object 720, and shearing device 740 may be inserted into the control chamber 716.
After positioning the unified shaft 730, object 720, and shearing device 740 within control chamber 716, retaining pin 750 may be inserted through the radial rim of cone 710, through shearing device 740, and into control chamber 716. In embodiments, retaining pin 750 may extend in an axis that is perpendicular or angled relative to the hollow passageway within cone 710 and the central axis of shaft 730. This may lock the unified shaft 730, object 720, and shearing device 740 within the control chamber 716 until shearing device 740 is broken.
After securing the shearing device within cone 710 via retaining pin 750, cone 710 may be run down a hole.
FIG. 9 depicts downhole tool 700, according to an embodiment. Elements depicted in FIG. 9 may be described above, and for the sake of brevity, a further description of these elements is omitted.
As depicted in FIG. 9, after mandrel 110 is pulled out of the hole and slips 130 are set, the hollow passageway through cone 710 may be unobstructed. This may allow object 720 to freely rotate inward about shaft 730.
Additionally, once slips 130 are set, an outer end of communication passageway 712 may be sealed or positioned directly adjacent to the inner surface of slips 130, which may limit communication into the outer end of communication passageway 712 into control chamber 716. However, communication passageway 712 may still be in communication with control chamber 716 via an inner end of communication passageway 712.
FIGS. 10-11 depict downhole tool 700, according to an embodiment. Elements depicted in FIGS. 10-11 may be described above, and for the sake of brevity, a further description of these elements is omitted.
As depicted in FIGS. 10-11, after pulling mandrel 110 out of the hole, object 720 may rotate inward about shaft 730 to be seated on seat 722. This may form a seal isolating a first area above object 720 from a second area below object 720. Furthermore, because shaft 740 extends through portions of object 720 and shearing device 740, there can be no relative longitudinal movement between object 720 and shearing device 740 while shearing device 740 is intact. Additionally, while shearing device 740 is intact, shearing device 740 may be secured within control chamber 716 via retaining pin 750.
When object 720 is forming a seal across seat 722, an upper surface of lower portion 746 may be exposed to the first area above object 720. The upper surface of the lower portion 746 may be exposed to the via area via an open upper surface of the control chamber 716 or through the opening housing retaining pin 750. Additionally, when object 720 is forming a seal across seat 722, a lower surface of lower portion 746 of shearing device 740 may be exposed to the second area below object 720. The lower surface of the lower portion 746 may be in communication with the second area via communication port 712. A pressure differential between the upper surface and lower surface of the lower portion 746 may allow for the shearing of the shearing device 740.
FIGS. 12-13 depict downhole tool 700, according to an embodiment. Elements depicted in FIGS. 12-13 may be described above, and for the sake of brevity, a further description of these elements is omitted.
In embodiments, when object 720 is seated across seat 722, a pressure differential may be applied across lower portion 746, wherein the pressure differential is created by a pressure difference between the first area and the second area. When the pressure differential increases past a pressure threshold, breakable portions 742 may break to decouple lower portion 746 and upper portion 744.
Due to the breakable portions 742 breaking, the upper portion 744 and lower portion 746 may no longer be coupled together. This may allow the upper portion 744 to move in the second direction and travel up the hole while a seal is maintained within chamber 716 and across seat 722. As the upper portion 744 travels up the hole, shaft 730 may no longer be inserted through slot 750. This may enable the relative movement of the upper portion 744 and object 750. In embodiments, when the upper portion 744 travels up the hole, the pressure differential applied to object 720 and lower portion 742 may be sufficient to maintain object 720 across seat 722.
Furthermore, due to the pressure differential, lower portion 742 may travel downhole within control chamber 716, while retaining a seal across control chamber 716, with lower portion 742 being positioned on seat 1310, wherein seat 1310 restricts the movement of lower portion 742 in a first direction. In embodiments, even after the shearing device 740 is broken, the retaining pin 750 may still be inserted into the control chamber 716 to limit the movement of the lower portion 742 in a second direction, allowing it to continue to seal.
FIG. 14 depicts downhole tool 700, according to an embodiment. Elements depicted in FIG. 14 may be described above, and for the sake of brevity, a further description of these elements is omitted.
As depicted in FIG. 14, a reverse flow of fluid caused by flowing fluid in a second direction may move object 720 away from seat 722, and object 720 may travel in the second direction. More specifically, due to the upper portion 744 no longer being coupled to lower portion 746, the longitudinal movement of shaft 730 may no longer be restricted by shearing device 740 due to the shaft slot 810 no longer existing. This may enable shaft 730 to move in the second direction independently from upper portion 744, while lower portion 746 retains its seal across control chamber 716.
Embodiments are also directed towards systems and methods to remove sealing elements or frac plugs from the inside by eroding an inner diameter of the sealing elements or frac plugs. This may eliminate the need to mill out downhole elements and/or reduce the amount of debris downhole. This is different than prior art techniques that either required frac plugs to be milled out and leave material downhole, or used dissolvable material frac plugs that requires specific temperature, or salinity coupled with time to dissolve.
Systems and methods for frac plugs to be eroded from the inner diameter towards the outer diameter by systems 100 and/or 700 initially create a seal downhole that allows for a fracturing operation to take place. Subsequently, a blocking element may be disengaged across the inner diameter of a housing by reverse flow, wherein the geometry of the housing and the blocking element may not make it possible for the blocking element to reform the seal across the inner diameter of the housing. After the inner diameter of the housing is exposed, sand, slurry, eroding fluids, or other coarse materials may be pumped through the inner diameter of the housing. The coarse material may erode, scour, or gradually wear away the housing from the inside of the inner diameter of the frac plug while the slips or gripping elements of the frac plug are still extended and engaged with the casing.
Therefore, the coarse material may erode the frac plug without eroding the inner diameter of the casing because the frac plug is eroded from the inside out in an outward radial direction. This is different than prior art techniques used to fail frac plugs or other blocking devices set inside the casing that relied on pressure cycles in an attempt to fail the scaling between the casing and the frac plug (blocking device) and required pumping fluid between the slips and the casing that cause the slips to fail, which causes the erosion of the casing or piping as it did so due to higher jetting velocity of the coarse/eroding fluid.
FIG. 15 depicts a method 1500 for deploying a frac plug or downhole sealing system, according to an embodiment. The operations of method 1500 presented below are intended to be illustrative. In some embodiments, method 1500 may be accomplished with one or more additional operations not described, and/or without one or more of the operations discussed. Additionally, the order in which the operations of method 1500 are illustrated in FIG. 15 and described below is not intended to be limiting. Method 1500 may be performed utilizing systems 100, 700, or any other scaling system.
At operation 1510, a frac plug or other sealing system may be pumped downhole in a first direction. In embodiments, the frac plug may be a bottom set frac plug, wherein an object that is configured to be a blocking device is pumped downhole in an open position.
At operation 1520, a first operation may be performed above the frac plug. The first operation may include flowing fluid in a first (downhole) direction to fracture a wellbore, setting perforation guns, etc. This first operation may cause a force in the first direction against the object, which may cause the object to become activated. The activation of the object may cause the object to become decoupled from the housing.
At operation 1530, after activating the object, the force applied against the object may cause the object to move in the first direction while the object retains a seal on the housing.
At operation 1540, a second operation may occur, creating a downhole force against the upper surface of the object while the object retains the seal on the housing.
At operation 1550, fluid may flow in a second direction against a lower surface of the object, which may disengage the object from the housing.
At operation 1560, the object may flow in the second direction away from the housing to permanently expose the inner diameter of the housing, and allow bidirectional flow of fluid through the inner diameter of the housing.
At operation 1570, a coarse fluid may flow in the first direction and interface with the inner diameter of the housing, which may erode the housing from the inside out. This may cause the inner diameter of the housing to get bigger and the frac plug material left in the hole to be reduced in volume, and gradually eliminate the housing. Hence, the erosion of the entirety of the downhole tool may occur from the inside to the outside while sealing elements, such as slips, are still engaged at the beginning. The coarse fluid may be pumped in the first direction until the downhole tool fails and the sealing elements and or the slips are no longer engaged with the casing.
FIG. 16 depicts a method 1600 for removing a frac plug or downhole sealing system, according to an embodiment. The operations of method 1600 presented below are intended to be illustrative. In some embodiments, method 1600 may be accomplished with one or more additional operations not described, and/or without one or more of the operations discussed. Additionally, the order in which the operations of method 1600 are illustrated in FIG. 16 and described below is not intended to be limiting. Method 1600 may be performed utilizing systems 100, 700, or any other sealing system.
At operation 1610, a frac plug or other sealing system may be pumped downhole in a first direction. In embodiments, the frac plug may be a bottom-set frac plug. While being run in a hole and after being set, a blocking object may not restrict communication across a housing and then restrict it respectively.
At operation 1620, a first operation may be performed above the frac plug. The first operation may include flowing fluid in the first direction to fracture a wellbore, setting perforation guns, etc. This first operation may cause a force in the first direction against the blocking object and a breakable portion positioned within a control chamber. In embodiments, the breakable portion may be, or include, a hinge wherein the blocking object may rotate about.
At operation 1630, the downhole tool may be activated by the force breaking the breakable portion within the control chamber. After the downhole tool is activated, relative movement between the breakable portion and the blocking object may be allowed. Even after the breakable portion is activated, the blocking object retains a seal within the housing. Furthermore, after activating the downhole tool, the distal end of the breakable portion may travel in the first direction while the blocking object remains stationary and holds the seal across the housing.
At operation 1640, a second fracturing operation may occur, creating a downhole force against the upper surface of the blocking object while the blocking object retains the seal across the housing.
At operation 1650, fluid may flow in a second direction against a lower surface of the blocking object, which may disengage the blocking object from the housing and cause the blocking object and a proximal end of the breakable portion to travel uphole in the second direction.
At operation 1660, the blocking object may flow in the second direction away from the housing and the distal end of the breakable portion to permanently expose the inner diameter of the housing, and allow bidirectional flow of fluid through the inner diameter of the housing. In embodiments, the distal end of the breakable portion may maintain the seal across the control chamber after the blocking object moves in the second direction.
At operation 1670, a coarse fluid may flow in the first direction and interface with the inner diameter of the housing, which may erode the housing from the inside out. This may cause the inner diameter of the housing to get bigger and reduce the volume of the frac plug material left in, and gradually eliminate the housing. Hence, the erosion of the entirety of the downhole tool may occur from the inside to the outside while sealing elements, such as slips, are still engaged at the beginning. The coarse fluid may be pumped in the first direction until the downhole tool fails, and the sealing elements and or the slips are no longer engaged with the casing.
Furthermore, the entire frac plug or downhole tool described in FIGS. 15 and 16 may be eroded from the inside out, including the slips, retainer, etc. The erosion of the entirety of the downhole tool may occur while sealing elements, such as slips, are still engaged and expanded. Reference throughout this specification to “one embodiment”, “an embodiment”, “one example” or “an example” means that a particular feature, structure, or characteristic described in connection with the embodiment or example is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment”, “in an embodiment”, “one example” or “an example” in various places throughout this specification are not necessarily all referring to the same embodiment or example. Furthermore, the particular features, structures, or characteristics may be combined in any suitable combinations and/or sub-combinations in one or more embodiments or examples. In addition, it is appreciated that the figures provided herewith are for explanation purposes to persons ordinarily skilled in the art and that the drawings are not necessarily drawn to scale.
Although the present technology has been described in detail for illustration based on what is currently considered to be the most practical and preferred implementations, it is to be understood that such detail is solely for that purpose and that the technology is not limited to the disclosed implementations, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present technology contemplates that, to the extent possible, one or more features of any implementation can be combined with one or more features of any other implementation.
1. A downhole tool comprising:
an object configured to selectively form a seal across a passageway within a tubular to isolate communication between a first area and a second area during a first procedure that flows fluid in a first direction, the object maintains the seal across the passageway after being activated, and the object being configured to release the seal after activating the object by flowing fluid in a second direction, wherein the first procedure activates the object;
a control chamber with a proximal end in communication with the first area and a distal end in communication with the second area;
a device positioned within the control chamber, the device being configured to limit movement of the object when the device is intact and allow movement of the object when the device is broken;
wherein the device includes a lower portion, an upper portion, the device being configured to break between the lower portion and the upper portion.
2. The downhole tool of claim 1, wherein the device is a unitary piece before shearing, and
the device breaks into to at least two pieces after being sheared.
3. The downhole tool of claim 1, wherein the device is a shaft being configured to allow the object to rotate before activating the object.
4. The downhole tool of claim 1, wherein the object is a flapper.
5. The downhole tool of claim 1, wherein the control chamber is radially offset from the passageway.
6. The downhole tool of claim 1, wherein the lower portion is configured to form the seal across the control chamber before and after the device is broken.
7. The downhole tool of claim 6, wherein the breakable portions are configured to break based on a pressure differential between the first area and the second area.
8. The downhole tool of claim 7, wherein the upper portion is configured to be positioned within control chamber when the device is intact, and the upper portion can freely move in second direction after the device is broken.
9. The downhole tool of claim 1, wherein an entirety of the object and the shaft can freely move uphole after the device is broken.
10. The downhole tool of claim 9, wherein coarse fluid is configured to flow through the inner diameter of the downhole tool to erode the downhole tool from the inside out after the sharable device is broken and the object moves uphole.
11. The downhole tool of claim 10, wherein the downhole tool is a frac plug with slips that are configured to engage casing.
12. The downhole tool of claim 1, further comprising:
a first seat positioned within the tubular and a second seat positioned within the tubular, the first seat having a first inner diameter, and the second seat having a second inner diameter, the second inner diameter being smaller than the first inner diameter;
an embedded blocking device positioned within the object, wherein the object and the embedded blocking device are configured to form the seal across the first seat.
13. The downhole tool of claim 12, wherein the embedded blocking device is configured to be sheared from the object to form a second seal across the second seat.
14. The downhole tool of claim 13, wherein the embedded blocking device is configured to be sheared based on a pressure differential between the first area and the second area.
15. The downhole tool of claim 14, wherein the embedded blocking device is configured to be removed from the second seat based on fluid flowing a second direction.
16. A downhole tool comprising:
an object configured to selectively form a seal across a passageway within a tubular to isolate communication between a first area and a second area during a first procedure in which fluid flows in a first direction;
a control chamber having a proximal end in communication with the first area and a distal end in communication with the second area; and
an element within the control chamber, the element being configured to restrict movement of the object when intact and to allow movement of the object element when the element is broken or activated;
wherein the control chamber is configured to transition from a sealed state to an unsealed state without requiring removal of the downhole tool from the wellbore.
17. The tool of claim 16, further comprising:
a communication conduit extending between the passageway and the distal end of the control chamber, the conduit configured to communicate pressure from below the object or valve element into the control chamber to apply a differential across the element.
18. The tool of claim 16, wherein the control chamber comprises a proximal portion with a larger diameter and a distal portion with a smaller diameter, the element being positioned to travel within the distal portion upon breaking.
19. The tool of claim 16, wherein the element is configured to break at a first pressure differential and thereafter maintain pressure integrity up to a higher second pressure to allow a fracturing operation.
20. The tool of claim 16, wherein the object comprises a flapper, disc, ball, or sleeve, configured to form a primary seal across a first seat and to allow bi-directional flow after the shearing device is broken.