DOWNHOLE TOOL SYSTEM AND METHOD RELATED THERETO

• US 20140020911A1
• Filed: 07/19/2012
• Published: 01/23/2014
• Est. Priority Date: 07/19/2012
• Status: Active Grant

• Current Assignee: General Plastics & Composites LP (General Plastics & Composites)
• Original Assignee: General Plastics & Composites LP (General Plastics & Composites)
• Inventors: Martinez, Edgar
• Granted Patent: US 9,157,288 B2
• Time in Patent Office: Days
• US Class Current: 166/387
• 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 33/1204 permanent; drillable
• CPC Class Codes: E21B 33/124 Units with longitudinally-spaced plugs for isolating the intermediate space
• 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 33/1293 with means for anchoring against downward and upward movement E21B33/1291, E21B33/1295 take precedence

Abstract

A slip and cone assembly for a downhole tool that includes a composite slip having a one-piece configuration and having at least two grooves disposed therein; and a cone having a first end configured for engagement with the composite slip, wherein the composite slip and the cone are configured for application of a load therebetween that results in a fracture in material between the at least two grooves.

Claims

1. A slip and cone assembly for a downhole tool, the assembly comprising:

a composite slip comprising a one-piece configuration and having at least two grooves disposed therein; and

a cone having a first end configured for engagement with the composite slip,

wherein the composite slip and the cone are configured for application of a load therebetween that results in a fracture in material between the at least two grooves.

2. The assembly of claim 1, wherein the composite slip comprises a planar slip surface, and wherein the cone comprises a planar cone surface configured to correspond to and engage with the planar slip surface.

3. The assembly of claim 1, wherein the composite slip comprises a plurality of planar slip surfaces, and wherein the cone comprises a plurality of planar cone surfaces configured to engage with the respective plurality of planar slip surfaces.

4. The assembly of claim 3, wherein the at least two grooves are disposed proximate to an area of intersection between two planar slip surfaces.

5. The assembly of claim 3, wherein there are at least two grooves disposed proximate to an area of intersection between each of the plurality of planar slip surfaces.

6. The assembly of claim 5, wherein the configuration of each of the at least two grooves and each corresponding material therebetween is designed to induce fracture in the material upon application of the load thereagainst.

7. The assembly of claim 3, wherein the cone comprises a raised surface disposed proximate to each area of intersection between each of the plurality of planar cone surfaces.

8. The assembly of claim 1, wherein the composite slip comprises a plurality of slip segments, and each of the plurality of slip segments comprise inserts disposed therein.

9. The assembly of claim 8, wherein the load is in the range of about 1500 to about 2500 lbf.

10. The assembly of claim 9, wherein the composite slip and the cone each consist of filament wound drillable material.

11. The assembly of claim 8, wherein the slip is configured to expand in the range of about 0.00005″

to about 0.001″

before fracture occurs.

12. The assembly of claim 11, wherein the composite slip comprises an outer surface and an inner surface, wherein at least one of the grooves comprises a depth, and wherein the depth of the at least one groove is a distance from the outer surface to the inner surface.

13. The assembly of claim 8, wherein the slip comprises an inner radius of curvature, and wherein at least one slip segment has an unexpanded outer radius of curvature that is different than the inner radius of curvature.

14. The assembly of claim 13, wherein each of the plurality of slip segments has an unexpanded outer radius of curvature that is different than the inner radius of curvature.

15. The assembly of claim 8, wherein the slip comprises an inner radius of curvature, wherein each of the plurality of slip segments has an unexpanded outer radius of curvature that is different than the inner radius of curvature, and wherein each of the plurality of slip segments has an expanded radius of curvature substantially similar to the inner radius of curvature.

16. The downhole tool of claim 8, wherein the composite slip comprises cloth wrap material, and wherein the cone comprises filament wound material.

17. A slip and cone assembly for a downhole tool, the assembly comprising:

a composite slip comprising a one-piece configuration and having a grooved region disposed therein; and

a cone having a first end configured for engagement with the composite slip,

wherein the grooved region comprises a void and a portion of material, and

wherein the composite slip and the cone are configured for application of a load therebetween that results in a fracture in the portion of material.

18. The assembly of claim 17, wherein the composite slip comprises a plurality of slip surfaces, and wherein the cone comprises a plurality of cone surfaces configured to engage with the respective plurality of slip surfaces.

19. The assembly of claim 18, wherein the grooved region is disposed proximate to an area of intersection between two slip surfaces.

20. The assembly of claim 18, wherein the assembly comprises a plurality of grooved regions, and wherein there is a grooved region disposed in an area of intersection between each of the plurality of slip surfaces.

21. The assembly of claim 20, wherein the configuration of each of the grooved regions and each corresponding material therebetween is designed to induce fracture in the material upon application of the load thereagainst.

22. The assembly of claim 17, wherein the composite slip comprises an outer surface and an inner surface, wherein the void extends a distance from the outer surface to the inner surface.

23. The assembly of claim 17, wherein the composite slip comprises a plurality of slip segments, and each of the plurality of slip segments comprise inserts disposed therein, and wherein the load is in the range of about 1500 to about 2500 lbf.

24. The assembly of claim 23, wherein the composite slip and the cone each consist of filament wound drillable material.

25. The assembly of claim 22, wherein the slip comprises an inner radius of curvature offset from a slip central axis, and wherein at least one slip segment has an unexpanded outer radius of curvature based on the slip central axis.

26. The assembly of claim 25, wherein each slip segment has an unexpanded outer radius of curvature based on the slip central axis, and wherein each of the plurality of slip segments has an expanded radius of curvature offset from the slip central axis.

29. The downhole tool of claim 26, wherein the composite slip comprises a plurality of slip planar surfaces, and wherein the cone comprises a plurality of cone planar surfaces configured to engage with the respective plurality of slip planar surfaces.

30. The downhole tool of claim 29, wherein the at least two grooves are disposed proximate to an area of intersection between two slip planar surfaces.

31. The downhole tool of claim 30, wherein there are at least two grooves disposed proximate to each area of intersection between each of the plurality of slip planar surfaces.

32. The downhole tool of claim 30, wherein the cone comprises a raised surface disposed proximate to each area of intersection between each of the plurality of cone planar surfaces.

33. The downhole tool of claim 32, wherein the composite slip comprises a plurality of slip segments, and each of the plurality of slip segments comprise inserts disposed therein, and wherein during setting a complete fracture occurs between each slip segment.

34. The downhole tool of claim 29, wherein the fracture occurs at an applied load of about 1400 to about 2500 lbf.

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

a mandrel;

a composite slip disposed about the mandrel and configured for engagement with a tubular member, the composite slip comprising a one-piece configuration and having at least two grooves disposed therein;

a cone disposed about the mandrel and having a first end configured for engagement with the composite slip;

wherein setting of the downhole tool in the wellbore includes a fracture in the material between the at least two grooves, and the first slip moved into gripping engagement with the tubular member.

28. The downhole tool of claim 27, wherein the composite slip comprises a slip planar surface, and wherein the cone comprises a cone planar surface configured to correspond relative to and engage with the slip planar surface.

35. The downhole tool of claim 28, wherein at least one groove is cut at a back angle in the range of about 20 degrees to about 90 degrees as measured from the axis of the radius.

36. The downhole tool of claim 27, wherein the mandrel, the composite slip, and the cone each consist of filament wound drillable material.

37. The downhole tool of claim 27, wherein at least one of the mandrel, the composite slip, and the cone is formed by wet winding one or more fibers having a phase angle of from about 30 degrees to about 70 degrees relative to a center line of the downhole tool.

38. The downhole tool of claim 37, the one or more fibers pass through a resin bath prior to winding the fibers.

39. The downhole tool of claim 38, wherein one or more fibers comprise glass.

40. The downhole tool of claim 38, wherein one or more fibers comprise carbon.

41. The downhole tool of claim 38, wherein the one or more fibers are wound in the presence of an epoxy resin blend comprising bisphenol A, epichlorohydrin, and one or more cycloaliphatic epoxy resins.

42. The downhole tool of claim 27, wherein the mandrel, the cone, and the composite slip each comprise filament wound material wound at an angle in the range of about 0 degrees to about 90 degrees.

43. The downhole tool of claim 27, wherein the slip expands at least 0.00005″

during setting before fracture occurs.

44. The downhole tool of claim 27, wherein the slip expands in the range of about 0.00005″

to about 0.001″

before fracture.

45. The downhole tool of claim 27, wherein the composite slip comprises a plurality of slip segments, and each of the plurality of slip segments comprise inserts disposed therein.

46. The downhole tool of claim 27, wherein the downhole tool is a frac plug or a bridge plug.

47. The downhole tool of claim 46, wherein the composite slip comprises an outer surface and an inner surface, wherein at least one of the grooves comprises a depth, and wherein the depth of the at least one groove is a distance from the outer surface to the inner surface.

48. 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 mandrel;

a composite slip disposed about the mandrel and configured for engagement with a tubular member, the slip comprising a one-piece configuration and having at least two grooves disposed therein;

a cone disposed about the mandrel and having a first configured for engagement with the composite slip;

placing the tool under a load that causes the cone to forcibly engage the slip, wherein the first slip breaks in at least one spot and expands radially outward into gripping engagement with a surrounding tubular when the load exceeds a predetermined value; and

disconnecting the downhole tool from a setting device coupled therewith.

49. The method of claim 48, wherein the downhole tool comprises:

at least one of the cone, the slip, or both, formed by wet winding one or more fibers having a phase angle of from about 30 degrees to about 70 degrees relative to a center line of the tool; and

releasing the tool from the wellbore by drilling.

50. The method of claim 48, wherein the break occurs in the material between the at least two grooves.

51. The method of claim 48, 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.

52. The method of claim 51, 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.

53. The method of claim 52, the method further comprising:

performing a fracing operation;

setting a second downhole tool; and

drilling through at least one of the downhole tool, the second downhole tool, or both.

54. A method of manufacturing a slip and cone assembly, the method comprising:

forming a composite member by winding a first layer of fibers at an angle of from about 30 degrees to about 70 degrees relative to a center line of the composite member, and winding a second layer of fibers at an angle of from about 30 degrees to about 70 degrees relative to the center line over at least a portion of the first layer to provide a desired thickness;

forming a billet by using cloth wrap;

machining the composite member to form the cone; and

milling the billet to form the slip; and

placing the slip and cone together to form a separable slip and cone assembly.

55. The method of claim 54, wherein the fibers of each layer are at least substantially parallel to one another, and wherein the cloth comprises prewoven fabric comprising fibers in multiple directions.

56. The method of claim 54, wherein each layer is wet wound with an epoxy resin.

57. The tool of claim 56, wherein the epoxy resin is a blend comprising one or more cycloaliphatic epoxy resins.

58. The tool of claim 56, wherein the epoxy resin is a blend comprising bisphenol A, epichlorohydrin, and one or more cycloaliphatic epoxy resins.

59. The tool of claim 54, further comprising curing the layers using thermal energy.

60. The tool of claim 54, further comprising curing the layers using ultraviolet light.

61. The tool of claim 54, further comprising curing the layers using a high energy electron beam.