DOWNHOLE TOOL AND METHOD OF USE

• US 20130048272A1
• Filed: 08/22/2012
• Published: 02/28/2013
• Est. Priority Date: 08/22/2011
• Status: Active Grant

• Current Assignee: The WellBoss Company
• Original Assignee: Downhole Technology LLC (Berndorf AG)
• Inventors: VanLue, Duke
• Granted Patent: US 8,955,605 B2
• Time in Patent Office: Days
• US Class Current: 166/118
• CPC Class Codes: E21B 2200/04 Ball valves
• CPC Class Codes: E21B 23/01 for anchoring the tools or the like E21B23/02 - E21B23/06 take precedence; anchoring of drives in the borehole E21B4/18
• CPC Class Codes: E21B 23/06 for setting packers
• CPC Class Codes: E21B 33/1208 characterised by the construction of the sealing or packing means E21B33/1277 takes precedence
• CPC Class Codes: E21B 33/124 Units with longitudinally-spaced plugs for isolating the intermediate space
• CPC Class Codes: E21B 33/128 with a member expanded radially by axial pressure E21B33/122, E21B33/124 take precedence
• CPC Class Codes: E21B 33/129 with mechanical slips for hooking into the casing E21B33/122, E21B33/124 take precedence
• CPC Class Codes: E21B 33/1291 anchor set by wedge or cam in combination with frictional effect, using so-called drag-blocks E21B33/1295 takes precedence
• CPC Class Codes: E21B 33/1292 with means for anchoring against downward and upward movement
• CPC Class Codes: E21B 33/1293 with means for anchoring against downward and upward movement E21B33/1291, E21B33/1295 take precedence
• CPC Class Codes: E21B 33/134 Bridging plugs
• CPC Class Codes: E21B 34/06 in wells
• CPC Class Codes: E21B 34/16 Control means therefor being outside the borehole control systems for submerged well heads E21B33/0355

Abstract

Embodiments of the disclosure pertain to a mandrel for a downhole tool that may include a body having a proximate end with a first outer diameter and a distal end with a second outer diameter; a first set of threads disposed on the distal end; and a transition region formed on the body between the proximate end and the distal end. In aspects, the mandrel may be made from filament wound composite material.

Claims

1. A downhole tool useable for isolating sections of a wellbore, the downhole tool comprising:

a composite mandrel having at least one set of rounded threads;

a composite member disposed about the mandrel and in engagement with a seal element also disposed about the mandrel, wherein the composite member is made of a first material and comprises a first portion and a second portion; and

a slip disposed about the mandrel,

wherein setting of the downhole tool in the wellbore includes at least a portion of the slip in gripping engagement with a surrounding tubular, and the seal element sealingly engaged with the surrounding tubular.

2. The downhole tool of claim 1, wherein the second portion comprises an angled surface and the first portion comprises at least one groove, wherein a second material is bonded to the first portion and at least partially fills into the at least one groove, and wherein the slip comprises a one-piece configuration and is configured with at least one groove disposed therein.

5. The downhole tool of claim 1, wherein the downhole tool comprises an axis, wherein the composite mandrel is coupled with a sleeve configured with corresponding threads that mate with the at least one set of rounded threads, and wherein setting of the tool distributes load forces along the rounded threads at an angle that is directed away from the axis.

6. The downhole tool of claim 5, wherein the first portion comprises an outer surface, an inner surface, a top edge, a bottom edge, wherein a depth of the at least one groove extends from the outer surface to the inner surface, wherein at least one groove is formed from about the bottom edge to about the top edge, wherein upon setting the downhole tool, the first portion expands in a radial direction away from the axis, wherein the composite member and the seal element compress together to form a reinforced barrier therebetween, and wherein the composite mandrel and the first material each consist of filament wound drillable material.

3. The downhole tool of 1, wherein the composite mandrel comprises a distal end, a proximate end, and a bore formed therein, wherein the composite mandrel is configured with a second set of threads disposed along a surface of the bore at the proximate end, wherein the rounded threads are disposed along an external mandrel surface at the distal end, wherein the composite mandrel consists of filament wound material, and wherein the second set of threads comprise shear threads.

4. The downhole tool of claim 3, wherein the composite mandrel is coupled with an adapter configured with corresponding threads that mate with the shear threads, and wherein application of a load to the mandrel is sufficient enough to shear the second set of threads.

7. A downhole tool for isolating zones in a well comprising:

a composite mandrel having a first set of threads for mating with a setting tool and a second set of threads for coupling to a lower sleeve;

a seal element disposed around the mandrel, the seal element configured to buckle and expand radially in response to application of force on the seal element; and

a composite member disposed around the composite mandrel and proximate to the sealing element, the composite member comprising a deformable portion having one or more grooves disposed therein.

8. The downhole tool of claim 7, the downhole tool further comprising:

a first cone disposed around the composite mandrel and proximate a second end of the seal element;

a metal slip disposed around the composite mandrel and engaged with an angled surface of the first cone;

a bearing plate disposed around the composite mandrel, wherein the bearing plate is configured to transfer load from a setting sleeve to the metal slip; and

a composite slip having a one-piece configuration, the composite slip disposed around the composite mandrel and adjacent an external tapered surface of a second cone,

wherein the lower sleeve is disposed around the composite mandrel and proximate a tapered end of the metal slip.

9. The downhole tool of claim 7, wherein the composite mandrel comprises a flow path formed therein, and wherein the first set of threads are shear threads disposed on an inner surface of the composite mandrel.

10. The downhole tool of claim 9, wherein the shear threads are configured to shear when exposed to a predetermined axial force, resulting in disconnect between the downhole tool and the setting tool.

11. The downhole tool of claim 13, wherein the predetermined force is greater than the force required to set the downhole tool, but less than the force required to part the body of the tool.

12. The downhole tool of claim 9, wherein the composite mandrel is configured with a seal surface to receive a ball that restricts fluid flow in at least one direction through the flow passage.

13. The downhole tool of claim 12, the downhole tool comprising a predetermined failure point configured to shear at a predetermined axial force greater than the force required to set the tool but less than the force required to part the body of the tool.

14. The downhole tool of claim 7, wherein the second set of threads comprise round threads, wherein the metal slip is formed of or from hardened cast iron, and wherein the metal slip is configured with a low density material disposed therein.

15. The downhole tool of claim 14, wherein the low density material is glass bubble filled epoxy.

16. The downhole tool of claim 14, wherein the downhole tool is selected from the group consisting of a frac plug, a bridge plug, a bi-directional bridge plug, and a kill plug.

17. The downhole tool of claim 16, the downhole tool further comprising a sleeve housing engaged with a body.

18. The downhole tool of claim of claim 8, wherein the metal slip further comprises:

a slip body;

an outer surface comprising gripping elements; and

an inner surface configured for receiving a mandrel;

wherein the slip body comprises at least one hole formed therein, and wherein a buoyant material is disposed in the hole.

19. The downhole tool of claim 18, wherein the metal slip is made from cast iron and is surface hardened, wherein the outer surface has a Rockwell hardness in the range of about 40 to about 60, wherein the inner surface has a Rockwell hardness in the range of about 10 to about 25, and wherein the buoyant material is selected from the group consisting of polyurethane, light weight beads, epoxy, and glass bubbles.

20. The downhole tool of claim 8, wherein the composite slip further comprises a circular slip body with at least partial connectivity therearound, and at least one groove disposed therein.

21. The downhole tool of claim 20, wherein the composite slip further comprises two or more alternatingly arranged grooves disposed therein.

22. A mandrel for a downhole tool, the mandrel comprising:

a body having a proximate end with a first outer diameter and a distal end with a second outer diameter;

a set of rounded threads disposed on the distal end;

a transition region formed on the body between the proximate end and the distal end.

23. The mandrel of claim 22, wherein the mandrel is made from composite material, and wherein the first outer diameter is larger than the second outer diameter.

24. The mandrel of claim 23, wherein the composite material is filament wound, and wherein the mandrel further comprises a flowbore.

25. The mandrel of claim 24, wherein the flowbore extends from the proximate end to the distal end.

26. The mandrel of claim 25, wherein the flowbore comprises a ball check valve.

27. The mandrel of claim 25, wherein the mandrel comprises an outer surface along the body, and an inner surface along the flowbore, wherein the rounded threads are formed on the outer surface, and a set of shear threads are formed on the inner surface.

28. The mandrel of claim 22, wherein the mandrel comprises an outer surface along the body, and wherein a circumferential taper is formed on the outer surface near the proximate end, and wherein the proximate end comprises a ball seat configured to receive a drop ball.

29. A mandrel for a downhole tool, the mandrel comprising:

a body having a proximate end comprising shear threads and a first outer diameter, and a distal end comprising rounded threads and a second outer diameter, wherein the mandrel is made from composite filament wound material, and wherein the first outer diameter is larger than the second outer diameter.

30. The mandrel of claim 29 further comprising a transition region formed on the body between the proximate end and the distal end.

31. The mandrel of claim 30 further comprising a flowbore disposed between the proximate end and the distal end.

32. The mandrel of claim 31, wherein the flowbore comprises a ball check valve.

33. The mandrel of claim 31, wherein the mandrel comprises an outer surface along the body, and an inner surface along the flowbore, wherein the rounded threads are formed on the outer surface, and a set of shear threads are formed on the inner surface.

34. The mandrel of claim 33, wherein the mandrel comprises an outer surface along the body, and wherein a taper is formed on the outer surface near the proximate end.

35. The mandrel of claim 29, wherein the transition region comprises an angled transition surface, and wherein the proximate end comprises a ball seat configured to receive a drop ball.

36. A composite mandrel comprising an inner shear thread profile, wherein the shear threads are configured to shear when exposed to a predetermined axial force, resulting in disconnect between a setting tool and downhole tool comprising, wherein the shear threads are configured to shear at a predetermined axial force greater than the force required to set the downhole tool, but less than the force required to part the body.

37. The composite mandrel of claim 36, the mandrel further comprising a proximate end having a first outer diameter, and a distal end comprising rounded threads and a second outer diameter, wherein the mandrel is made from composite filament wound material, and wherein the first outer diameter is larger than the second outer diameter.

38. A downhole tool useable for isolating sections of a wellbore, the downhole tool comprising:

a composite mandrel comprising;

a body having a proximate end and a distal end;

a set of rounded threads disposed on the distal end; and

a transition region formed on the body between the proximate end and the distal end, and having an angled transition surface;

a composite member disposed about the mandrel and in engagement with a seal element also disposed about the mandrel, wherein the composite member is made of a first material and comprises a first portion and a second portion; and

a bearing plate disposed around the mandrel and engaged with the angled transition surface,

wherein setting of the downhole tool comprises the composite member and the seal element at least partially engaged with a surrounding tubular.

39. The downhole tool of claim 38, wherein the proximate end comprises shear threads and a first outer diameter, and the distal end comprises a second outer diameter, wherein the composite mandrel is made from filament wound material, and wherein the first outer diameter is larger than the second outer diameter.

40. The downhole tool of claim 39, wherein the mandrel further comprises a flowbore that extends from the proximate end to the distal end.

41. The downhole tool of claim 40, wherein the flowbore comprises a ball check valve.

42. The downhole tool of claim 40, wherein the mandrel comprises an outer surface along the body, and an inner surface along the flowbore, wherein the rounded threads are formed on the outer surface, and a set of shear threads are formed on the inner surface at the proximate end.

43. The downhole tool of claim 39, wherein the mandrel comprises an outer surface along the body, and wherein a circumferential taper is formed on the outer surface near the proximate end.

44. The downhole tool of claim 43, wherein the transition region is configured to distribute forces as a result of compression between the mandrel and the bearing plate.

45. The downhole tool of claim 43, wherein the transition region is configured to distribute shear forces along an angle to an axis of the mandrel.

46. The downhole tool of claim 43, wherein the proximate end comprises a ball seat configured to receive a drop ball.

47. The downhole tool of claim 42 further comprising a one-piece composite slip disposed around the mandrel.

48. The downhole tool of claim 47 further comprising a one-piece heat treated metal slip disposed around the mandrel.

49. A method of setting a downhole tool in order to isolate one or more sections of a wellbore, the method comprising:

running the downhole tool into the wellbore to a desired position, the downhole tool comprising;

a composite mandrel configured with a set of rounded threads and a set of shear threads;

a composite member disposed about the mandrel and in engagement with a seal element also disposed about the mandrel, wherein the composite member is made of a first material and comprises a deformable portion and a resilient portion;

placing the composite mandrel under a tensile load that causes the seal element to buckle axially and expand outwardly, and also causes the seal element to compress against the composite member, wherein the deformable portion expands radially outward and the seal element engages a surrounding tubular; and

disconnecting the downhole tool from a setting device coupled therewith when the tensile load is sufficient to shear the set of shear threads.

50. The method of claim 49, wherein the downhole tool further comprises:

a slip comprising a one-piece configuration and having two or more alternatingly arranged grooves disposed therein, the second slip disposed proximate to and in engagement with the second end of the cone, wherein setting of the downhole tool further comprises at least a portion of the second slip in gripping engagement with a surrounding tubular.

51. The method of claim 49, further comprising injecting a fluid from the surface into the wellbore, and subsequently into at least a portion of subterranean formation in proximate vicinity to the wellbore, wherein the downhole tool further comprises a cone disposed about the mandrel and having a first end and a second end, and wherein the first end is configured for engagement with the seal element.

52. The method of claim 51, wherein the mandrel comprises a distal end and a proximate end with a bore formed therebetween, wherein the shear threads are disposed along a surface of the bore at the proximate end, and wherein the rounded threads are disposed along an external mandrel surface at the distal end.

53. The method of claim 52, wherein the fluid is a frac fluid, and wherein the frac fluid is injected into at least a portion of the subterranean formation that surrounds the first section of the wellbore.

54. The method of claim 53, the method further comprising:

running a second downhole tool into the wellbore after the downhole tool is set;

setting the second downhole tool;

performing a fracing operation; and

drilling through the downhole tool and the second downhole tool.

55. The method of claim 49, wherein the downhole tool comprises an axis, wherein the mandrel is coupled with a sleeve configured with corresponding threads that mate with rounded threads, and wherein setting of the tool distributes load forces along the rounded threads at an angle that is directed away from the axis.