Downhole tool and method of use

• US 9,976,382 B2
• Filed: 05/29/2015
• Issued: 05/22/2018
• Est. Priority Date: 08/22/2011
• Status: Active Grant

• Current Assignee: The WellBoss Company
• Original Assignee: Downhole Technology LLC (Berndorf AG)
• Inventors: VanLue, Duke
• Primary Examiner(s): Wallace, Kipp C
• Application Number:
  US14/725,079
• Publication Number:
  US 20150267502A1
• Time in Patent Office: 1,089 Days
• 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

A downhole tool useable for isolating sections of a wellbore, the downhole tool having: a mandrel made of composite material, a metal slip, a seal element, a composite slip, a first cone, and a lower sleeve. The first cone is disposed around the mandrel, and proximately between an underside of the composite slip and an end of the seal element. The first cone has a completely smooth circumferential conical surface engaged with the underside of the composite slip.

Claims

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

a mandrel made of composite material, the mandrel further comprising;

a proximate end having a first outer diameter;

a distal end having a second outer diameter;

an external side having an angled linear transition surface; and

a flowbore extending from the proximate end to the distal end;

a metal slip disposed about the composite mandrel, the metal slip comprising;

a circular metal slip body;

an outer surface comprising columns of serrated teeth; and

an inner surface configured for receiving the mandrel,

a seal element;

a composite slip disposed about the mandrel, the composite slip further comprising a circular composite slip body having one-piece configuration with at least partial connectivity around the entire circular composite slip body, and an at least two slip grooves disposed therein, wherein the composite slip body further comprises a composite slip outer surface and a composite slip inner surface, wherein at least one of the at least two slip grooves forms a lateral opening in the composite slip body that is defined by a first portion of slip material at a first slip end, a second portion of slip material at a second slip end, and a depth that extends from the composite slip outer surface to the composite slip inner surface;

a first cone disposed around the mandrel, and proximately between an underside of the composite slip and an end of the seal element; and

a lower sleeve disposed around the mandrel and proximate an end of the metal slip.

2. The downhole tool of claim 1, wherein the metal slip is made from cast iron, wherein the metal slip is heat treated, and wherein the circular metal slip body comprises a plurality of longitudinal holes.

3. The downhole tool of claim 2, 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 inner surface comprises a plurality of grooves.

4. The downhole tool of claim 1, 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, wherein the mandrel is made from filament wound material.

5. The downhole tool of claim 1, wherein the metal slip is formed of hardened cast iron, and wherein the metal slip is configured with a low-density material disposed therein.

6. The downhole tool of claim 1, wherein the composite slip comprises a circular composite slip inner surface, wherein the mandrel comprises a cylindrical outer surface proximately adjacent to where the composite slip is disposed therearound.

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

a mandrel made of composite material, the mandrel further comprising;

a distal end;

a proximate end; and

an outer surface, wherein the outer surface comprises a first outer diameter at the distal end, a second outer diameter at the proximate end, and an angled linear transition surface therebetween;

a bearing plate disposed around the mandrel, the bearing plate comprising an angled inner plate surface configured for engagement with the angled linear transition surface;

a metal slip disposed about the mandrel, the metal slip comprising an outer metal slip surface further comprising columns of gripping elements;

a sealing element disposed around the mandrel;

a composite one-piece slip disposed about the mandrel, the composite slip further comprising a circular composite slip body having one-piece configuration with at least partial connectivity around the entire circular composite slip body, and an at least two slip grooves disposed therein;

a first cone disposed around the mandrel, and proximately between an underside of the composite slip and an end of the seal element, the first cone having a completely smooth circumferential conical surface engaged with the underside of the composite slip; and

a lower sleeve engaged with the mandrel,

wherein the composite slip body further comprises a composite slip outer surface and a composite slip inner surface, wherein at least one of the at least two slip grooves forms a lateral opening in the composite slip body that is defined by a first portion of slip material at a first slip end, a second portion of slip material at a second slip end, and a depth that extends from the composite slip outer surface to the composite slip inner surface.

8. The downhole tool of claim 7, wherein at least a portion of the outer metal slip surface is heat treated, and wherein the gripping elements comprise serrated teeth.

9. The downhole tool of claim 8, wherein the metal slip is surface hardened, wherein the metal slip has a hardness profile defined by the outer metal slip surface having a Rockwell hardness in the range of about 40 to about 60, and the inner surface having a Rockwell hardness in the range of about 10 to about 25, and wherein the metal slip is made from cast iron.

10. The downhole tool of claim 9, wherein the inner surface is configured with a plurality of substantially symmetrically arranged grooves disposed therein, wherein the metal slip is made from cast iron, and wherein the metal slip comprises a one-piece configuration.

11. The downhole tool of claim 10, the downhole tool further comprising a composite member disposed around the mandrel and proximate to the sealing element, the composite member having a deformable portion with one or more member grooves disposed therein.

12. The downhole tool of claim 10, wherein the second outer diameter is greater than the first outer diameter.

13. The downhole tool of claim 7, wherein the composite slip comprises a circular composite slip inner surface and a composite slip outer surface, wherein the mandrel comprises a cylindrical outer surface proximately adjacent to the circular composite slip inner surface where the composite slip is disposed therearound.

14. A downhole tool for use in a wellbore, the downhole tool comprising:

a mandrel made of a composite material, the mandrel further comprising;

a distal end having a first outer diameter;

a proximate end having a second outer diameter;

an outer surface;

a flowbore extending from the proximate end to the distal end; and

an angled linear transition surface on the outer surface between the distal and the proximate end,

wherein the second outer diameter is larger than the first outer diameter;

a bearing plate disposed around the mandrel, the bearing plate comprising an angled inner plate surface configured for engagement with the angled linear transition surface;

a metal slip disposed around the mandrel proximate to the distal end, the metal slip further comprising;

an outer metal slip surface configured with columns of gripping elements; and

a one-piece metal slip body comprising a plurality of longitudinal holes disposed therein;

a seal element;

a composite one-piece slip disposed about the mandrel, the composite slip further comprising a composite slip body having one-piece configuration with at least partial connectivity around the entire composite slip body, and an at least two slip grooves disposed therein, wherein the composite slip body further comprises a composite slip outer surface and a composite slip inner surface, wherein at least one of the at least two slip grooves forms a lateral opening in the composite slip body that is defined by a first portion of slip material at a first slip end, a second portion of slip material at a second slip end, and a depth that extends from the composite slip outer surface to the composite slip inner surface;

a first cone disposed around the mandrel, and proximately between an underside of the composite slip and an end of the seal element; and

a lower sleeve coupled to the mandrel, and proximate to the metal slip.

15. The downhole tool of claim 14, wherein the metal slip is surface hardened, wherein the outer metal slip surface has a Rockwell hardness in the range of about 40 to about 60, and wherein the metal slip is made from cast iron.

16. The downhole tool of claim 15, wherein the metal slip comprises an inner surface configured with a plurality of grooves disposed therein, and wherein the inner surface has a Rockwell hardness in the range of about 10 to about 25.