Frac Plug with Collapsible Plug Body Having Integral Wedge and Slip Elements

Abstract

A frac plug apparatus has a plug body that comprises a central bore and separable elements. The central bore extends axially through the plug body. The separable elements are joined by relatively weak bridging portions adapted to break in a controlled manner, the separable elements thereby forming an integral component comprised of the separable elements. The separable elements comprise a wedge element and an array of slip elements. The slip elements are joined to the wedge element by first bridging portions.

Claims

1. A frac plug apparatus, said plug comprising a plug body, wherein said plug body comprises: (a) a central bore extending axially through said plug body; and (b) separable elements joined by relatively weak bridging portions adapted to break in a controlled manner, said separable elements thereby forming an integral component comprised of said separable elements, wherein said separable elements comprise: i) a wedge element; and ii) an array of slip elements joined to said wedge element by first bridging portions.

2. The frac plug apparatus of claim 1, wherein said plug may be set by applying along the primary axis of said plug body a first compressive force across said first bridging portions, said first compressive force being effective to break said first bridging portions and shift said slip elements and said wedge into overlapping engagement such that said slip elements are displaced radially.

3. The frac plug apparatus of claim 1, wherein: (a) said wedge element has a tapered outer surface and said slip elements have a complimentarily tapered inner surface; and (b) said first bridging portions joining said wedge element and said slip elements are situated at the lower end of said wedge element and the upper end of said slip elements.

4. The frac plug apparatus of claim 1, wherein said slip elements are configured generally as lateral segments of an open cylinder, said slip elements being separated by longitudinal slits extending through said plug body.

5. The frac plug apparatus of claim 4, wherein said slits comprise a first set of slits originating at the upper end of said slip elements and terminating proximate the lower end of said slip elements and a second set of slits originating at the lower end of said slip elements and terminating proximate the upper end of said slip elements.

6. The frac plug apparatus of claim 3, wherein said first bridging portions shear generally along an annular plane aligned with said tapered surfaces of said wedge element and said slip elements.

7. The frac plug apparatus of claim 1, wherein said wedge element comprises first and second ramping surfaces.

8. The frac plug apparatus of claim 1, wherein: (a) said separable elements comprise a setting ring element joined to said slip elements by second bridging portions; and (b) wherein said plug may be set by applying along the primary axis of said plug body a second compressive force across said second bridging portions, said second compressive force being effective to break said second bridging portions and shift said slip elements and said setting ring element into abutment.

9. The frac plug apparatus of claim 8, wherein said first compressive force is greater than said second compressive force whereby said second bridging portions break before said first bridging portions break.

10. (canceled)

11. (canceled)

12. (canceled)

13. (canceled)

14. The frac plug apparatus of claim 1, wherein said plug body is fabricated from a wound-fiber resin blank.

15. The frac plug apparatus of claim 1, wherein said plug body is fabricated from a dissolvable metal.

16. (canceled)

17. (canceled)

18. (canceled)

19. (canceled)

20. (canceled)

21. (canceled)

22. (canceled)

23. (canceled)

24. (canceled)

25. (canceled)

26. (canceled)

27. (canceled)

28. The frac plug apparatus of claim 1, wherein: (a) said wedge element has i) an outer surface that tapers radially inward in a downhole direction to provide an inverted truncated conical lower ramping surface; and ii) an outer surface that tapers radially inward in an uphole direction to provide a truncated conical upper ramping surface; (b) said slip elements have a tapered inner surface complimentary to said wedge lower ramping surface; (c) said first bridging portions joining said wedge element and said slip elements are situated at the lower end of said wedge element and the upper end of said slip elements; and (d) said plug comprises a radially expandable seal ring carried on said upper ramping surface; and (e) said seal ring comprises an annular ring body having a tapered inner surface complimentary to said wedge upper ramping surface.

29. The frac plug apparatus of claim 28, wherein: (a) said ring body of said seal ring is fabricated from a sufficiently ductile material such that said ring body can expand radially without breaking from an unset condition, in which said seal ring has a nominal outer diameter, to a set condition, in which said seal ring has an enlarged outer diameter; and (b) said plug may be set by applying along the primary axis of said plug a third compressive force between said wedge element and said seal ring, said third compressive force being effective to shift said seal ring up said upper ramping surface from an unset position to a set position and to expand said seal ring radially-outward from said unset condition to said set condition.

30. The frac plug apparatus of claim 28, wherein said seal ring is fabricated from a plastically deformable plastic.

31. (canceled)

32. (canceled)

33. The frac plug apparatus of claim 28, wherein said seal ring comprises an outer elastomeric seal received in a groove provided in the outer surface of said ring body

34. The frac plug apparatus of claim 28, wherein said plug comprises a seal backup ring carried on said upper ramping surface of said wedge element below said seal ring and adapted to burst when said third compressive force is applied.

35. The frac plug apparatus of claim 34, wherein said seal backup ring is fabricated from plastic.

36. An oil and gas well comprising a liner, wherein the frac plug apparatus of claim 1 has been installed by driving said wedge element into said slip elements.

37. A method of setting a plug in a liner, said method comprising: (a) running said plug into said liner to a location to be plugged, wherein said plug is in an unset state comprises a plug body; (b) applying along the primary axis of said plug body a first compressive force across a wedge element of said plug body and an array of slip elements of said plug body; (c) breaking, by the application of said first compressive force, first bridging portions of said plug body joining said wedge element and said slip elements; (d) driving said wedge element into said slip elements to radially expand said slip elements into engagement with said liner and anchor said plug in said liner.

38. The method of claim 37, wherein said method comprises: (a) applying along the primary axis of said plug body a second compressive force across said slip elements and a setting ring element of said plug body; (b) breaking, by the application of said second compressive force, second bridging portions of said plug body joining said slip elements and said setting ring element; and (c) driving said setting ring into abutment with said slip elements; (d) applying said first compressive force to break said first bridging portions and drive said wedge element into said slip elements.

39. (canceled)

40. (canceled)

41. (canceled)

42. (canceled)

43. The method of claim 37, wherein said method comprises: (a) applying said first compressive force to drive a first ramping surface of said wedge element into said slip elements; (b) applying along the primary axis of said plug a third compressive force across a seal ring and said wedge element, said seal ring being carried on a second ramping surface of said wedge element; and (c) driving said seal ring up said second ramping surface to radially expand said seal ring into engagement with said liner.

44. The method of claim 43, wherein said method comprises applying said third compressive force compressive force to break a backup ring carried on said second ramping surface downhole of said seal ring and then to drive said seal ring and said backup ring up said second ramping surface.

45. (canceled)

46. (canceled)

47. (canceled)

48. (canceled)

49. (canceled)

50. (canceled)

51. (canceled)

52. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0080] FIG. 1 (prior art) is a schematic depiction in approximate scale of an oil and gas well 1 having a vertical extension 1v and a horizontal extension 1h.

[0081] FIG. 2A is a schematic illustration of an early stage of a plug and perf fracturing operation which shows a wireline tool string 20 deployed through a wellhead assembly 8 into a liner assembly 10, where tool string 20 includes a perf gun 21, a setting tool 22, an adaptor 23, and a frac plug 30a.

[0082] FIG. 2B is a schematic illustration of liner assembly 10 after completion of the plug and perf fracturing operation, but before removal of plugs 30 from liner 10.

[0083] FIG. 3 is an isometric view, taken from above, from the lower end, and to the side of a first preferred embodiment 30 of the novel frac plugs of the subject invention.

[0084] FIG. 4 is an isometric view, similar to the view of FIG. 3, of a plug body 31 of frac plug 30.

[0085] FIG. 5 is an isometric view of a cup seal 32 of frac plug 30.

[0086] FIG. 6 is a side elevational view of frac plug 30 shown in FIG. 3, the upper end of frac plug 30 being on the left and the lower end being on the right.

[0087] FIG. 7 is an isometric, axial cross-sectional view of frac plug 30 shown in FIGS. 3-4 and 6.

[0088] FIG. 8A is an axial, cross-sectional view of frac plug 30 shown in FIGS. 3-4, which view shows frac plug 30 in its unset state in liner 10.

[0089] FIG. 8B is an axial, cross-sectional view of frac plug 30 in a partially set state.

[0090] FIG. 8C is an axial, cross-sectional view of frac plug 30 in its set state.

[0091] FIG. 8D is an axial, cross-sectional view of frac plug 30 in its set, pressurized state.

[0092] FIG. 9 is a radial, cross-sectional view of frac plug 30 taken generally across the lower end of cup seal 32.

[0093] FIG. 10 is an isometric view, taken from an angle as in FIG. 3, of a second preferred embodiment 130 of the novel frac plugs of the subject invention.

[0094] FIG. 11 is an exploded isometric view of frac plug 130 shown in FIG. 10, showing the components thereof in isometric views.

[0095] FIG. 12 is a side elevational view of frac plug 130 shown in FIGS. 10-11, the upper end of frac plug 130 being on the left and the lower end being on the right.

[0096] FIG. 13 is an axial, cross-sectional view of frac plug 130.

[0097] FIG. 14 is a side elevational view of a first preferred embodiment 100 of the novel tool assemblies of the subject invention, tool assembly 100 comprising novel frac plug 130 and a first preferred embodiment 160 of the novel setting tool adaptors of the subject invention.

[0098] FIG. 15 is an axial, cross-sectional view of tool assembly 100 shown in FIG. 12, the view of FIG. 15 being rotated axially 90.sup.0 relative to the elevational view of FIG. 14.

[0099] FIG. 16 is an isometric view, taken from an angle as in FIGS. 3 and 10, of a third preferred embodiment 230 of the novel frac plugs of the subject invention.

[0100] FIG. 17 is an exploded isometric view of frac plug 230 shown in FIG. 16, showing the components thereof in isometric views.

[0101] FIG. 18 is an axial, quarter-sectional view of frac plug 230 shown in FIGS. 16-17, the upper end of plug 230 being on the left and the lower end being on the right.

[0102] FIG. 19A is an axial, cross-sectional view of frac plug 230 shown in FIGS. 16-18, which view shows frac plug 230 in its unset state in liner 10.

[0103] FIG. 19B is an axial, cross-sectional view of frac plug 230 in a partially set state.

[0104] FIG. 19C is an axial, cross-sectional view of frac plug 230 is a more complete, but still partially set state where plug 230 is anchored, but not yet sealed.

[0105] FIG. 19D is an axial, cross-sectional view of frac plug 230 in its fully set state where plug 230 is anchored and sealed.

[0106] FIG. 20 is an axial, quarter-sectional view of a second preferred embodiment 200 of the novel tool assemblies of the subject invention, tool assembly 200 comprising novel frac plug 230 and a second preferred embodiment 260 of the novel setting tool adaptors of the subject invention.

[0107] FIG. 21 is an axial, cross-sectional view of a third preferred embodiment 300 of the novel tool assemblies of the subject invention, tool assembly 300 comprising novel frac plug 230 and a third preferred embodiment 360 of the novel setting tool adaptors of the subject invention.

[0108] FIG. 22 is an axial, cross-sectional view of tool assembly 300 shown in FIG. 21, the view of FIG. 22 being rotated axially 45° from the view of FIG. 21.

[0109] In the drawings and description that follows, like parts are identified by the same reference numerals. The drawing figures also are not necessarily to scale. Certain features of the embodiments may be shown exaggerated in scale or in somewhat schematic form and some details of conventional design and construction may not be shown in the interest of clarity and conciseness. For example, certain features and components of the embodiments shown in the figures have been omitted to better illustrate the remaining components.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0110] The invention, in various aspects and embodiments, is directed generally to plugs that may be used to isolate a portion of a well, and more particularly, to plugs that may be used in fracturing or other processes for stimulating oil and gas wells. In general, the novel plugs have plug bodies with separable elements and other features that allow the plug to self-assemble in a controlled sequence as compressive forces collapse the plug during installation.

[0111] Various specific embodiments will be described below. For the sake of conciseness, however, all features of an actual implementation may not be described or illustrated. In developing any actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve a developer's specific goals. Decisions usually will be made consistent within system-related and business-related constraints. Specific goals may vary from one implementation to another. Development efforts might be complex and time consuming and may involve many aspects of design, fabrication, and manufacture. Nevertheless, it should be appreciated that such development projects would be routine effort for those of ordinary skill having the benefit of this disclosure.

Overview of Fracturing Operations

[0112] The complexity and challenges of completing and producing a well perhaps may be appreciated by reference to FIG. 1. FIG. 1 shows a well 1 approximately to scale. Well 1 includes a vertical portion 1v and a horizontal portion 111. Schematic representations of the Washington Monument, which is 555 feet tall, and the Capital Building are shown next to a derrick 10 to provide perspective. Well 1 has a vertical depth of approximately 6,000 feet and a horizontal reach of approximately 6,000 feet. Such wells are typical of wells in the Permian Basin, an oil-rich basing located mostly in Texas. Deeper and longer wells, however, are constructed both in the Permian and elsewhere. While neither the vertical portion 1v or the horizontal portion 1h of well 1 necessarily run true to vertical or horizontal, FIG. 1 provides a general sense of what is involved in oil and gas production. Well 1 is targeting a relatively narrow hydrocarbon-bearing formation 2, and all downhole equipment must be installed and operated far away from the surface.

[0113] FIG. 2 illustrate schematically a conventional “plug and perf” job employing a first preferred embodiment 30 of the novel frac plugs. As shown in FIG. 2A, the upper portion of a well 1 is provided with a casing 3, while the lower portion is an open bore 4 extending generally horizontally through a hydrocarbon bearing formation 5.

[0114] A liner assembly 10 has been suspended from casing 3 by a liner hanger 11. Liner assembly 10 extends through open bore 4 and includes various tools, such as a “toe” or “initiator” valve 12 and a float assembly 13. Float assembly 13 typically includes various tools that assist in running liner 10 into well 1 and cementing it in bore 4, such as a landing s collar 14, a float collar 15, and a float shoe 16.

[0115] Liner 10 has been cemented in bore 4 and the initial stage of a frac job has been completed. That is, cement 6 completely fills the annulus between liner 10 and bore 4. Toe valve 12, having been run in on liner 10 in its shut position, has been opened. Fluid has been pumped through a wellhead assembly 8, down liner 10, and into formation 5 via open toe valve 12. The fluid has created fractures 9 extending from toe valve 12 in a first zone near the bottom of well 1.

[0116] A typical frac job will proceed in stages from the lowermost zone in a well to the uppermost zone. Thus, FIG. 2A shows a “plug and perf” tool string 20 that has been run through wellhead assembly 8 and into liner 10 on a wireline 24. Tool string 20 comprises a perf gun 21, a setting tool 22, a setting tool adaptor 23, and a first novel frac plug 30a. Tool string 20 is positioned in liner 10 such that frac. plug 30a is uphole from toe valve 12. Frac plug 30a is coupled to setting tool 22 by adaptor 23 and will be installed in liner 10 by actuating setting tool 22 via wireline 24. Once plug 30a has been installed, setting tool 22 and adaptor 23 will be released from plug 30a. Perf gun 21 then will be fired to create perforations 17a in liner 10 uphole from plug 30a. Perf gun 21 and setting tool 22 then will be pulled out of well 1 by wireline 24.

[0117] A frac ball (not shown) then will be deployed onto plug 30a to restrict the downward flow of fluids through plug 30a. Plug 30a, therefore, will substantially isolate the lower portion of well 1 and the first fractures 9 extending from toe valve 12. Fluid then can be pumped into liner 10 and forced out through perforations 17a to create fractures 9 (shown in FIG. 1B) in a second zone. After fractures 9 have been sufficiently developed, pumping is stopped and valves in wellhead assembly 8 will be closed to shut in the well 1. After a period of time, fluid will be allowed to flow out of fractures 9, through liner 10 and casing 3, to the surface.

[0118] Additional plugs 30b to 30z then will be run into well 1 and set, liner 10 will be perforated at perforations 17b to 17z, and well 1 will be fractured in succession as described above until, as shown in FIG. 2B, all stages of the frac job have been completed and fractures 9 have been established in all zones. Once the fracturing operation has been completed, plugs 30 typically will be removed from liner 10. Production equipment then will be installed in the well and at the surface to control production from well 1.

True Plug 30

[0119] A first embodiment 30 of the novel frac plugs is shown in greater detail in FIGS. 3-9. As may be seen therein, frac plug 30 generally comprises a plug body 31 and a cup seal 32. Plug body 31 has a profiled, somewhat elongated, generally open cylindrical shape. A central bore 51 extends axially through plug body 31. Bore 51 provides a conduit to allow fluids to flow through plug 30. As described further below, however, after plug 30 has been installed in liner 10, bore 51 may be plugged to shut off flow through plug 30 and isolate lower portions of liner 10 from fluids pumped into well 1.

[0120] Plug body 31 is a unitary or integral component having defined, separable elements joined by relatively weak bridging portions. The weak bridging portions are adapted to break in a controlled fashion and allow the elements to separate and self-assemble as plug body 31 is collapsed during setting of plug 30. That controlled breaking of the bridging portions and self-assembly process is described in detail below.

[0121] Preferably, as exemplified by plug 30, plug body 31 defines an array of seal backup elements 33, a wedge element 34, an array of slip elements 35, and a setting ring element 36. Backup elements 33 are bridged to wedge element 34 by an array of bridging portions 43. Wedge element 34 is bridged to slip element 35 by portions 44. Slip elements 35 are bridged to setting ring element 36 by portions 45. It will be appreciated from the discussion that follow that the geometry and dimensions of those bridging portions 43/44/45 provide them with significantly less shear strength along the axis of plug 30 and/or significantly less expansive hoop strength than possessed by the adjoining plug elements 33/34/35/36.

[0122] Seal backup elements 33 may be described in general terms as collectively having a generally annular or flattened ring shape. That collective shape is profiled, as described further below, to allow cup seal 32 to be assembled to plug body 31 and to provide backup for cup seal 32 while the well is being fractured. More specifically, bore 51 of plug body 31 has an annular groove 52 at the lower end, i.e., the downhole end of backup elements 33 adjacent the upper end, i.e., the uphole end of wedge element 34. The upper end of backup elements 33 has internal and external bevels. The lower end of cup seal 32 is profiled to fit within groove 52 and backup elements 33.

[0123] Backup elements 33 are breakaway elements designed to break apart into one or more separate backup segments, for example, as many as ten separate backup segments. s Prior to installation, backup elements 33 are joined to each other and to wedge element 34 by weakened portions. For example, as seen best in FIGS. 3-5, individual backup elements 33 are largely, but not entirely separated by longitudinal slits 47. Slits 47 extend radially through the wall of plug body 31. They extend axially from the upper end of backup elements 33, through annular groove 52, and stop at the upper end of wedge element 34. Slits 47 leave relatively thin, weak bridging portions 43 joining each individual backup element 33 to wedge 34. When frac plug 30 is set and fluids are flowed into liner 10, as described further below, expansion of cup seal 32 will break bridging portions 43 allowing individual backup segments 33 to separate from each other and move radially outward.

[0124] Wedge element 34 is situated generally between backup elements 33 and slip elements 35. It may be described in general terms as having a generally tapered, annular or open cylindrical shape. Wedge element 34 is profiled, as described further below, to provide a bearing surface upon which adaptor 23 will bear as plug 30 is set, a ramping surface that will drive slip elements 35 radially outward into engagement with liner 10, and a seat 54 for a plug member.

[0125] More particularly, the upper portion of bore 51 extends through wedge element 34. Ball seat 54 is provided in wedge bore 51 by a shallow-angle, upward facing tapered reduction in its inner diameter. Ball seat 54 preferably is situated axially below the upper end of wedge element 34. More preferably, as seen best in FIG. 8, ball seat 54 is situated well below the upper end of wedge element 34, in its midsection. Thus, when plug 30 is set as described further below, ball seat 54 will be situated well below the axial midpoint of slips 35.

[0126] The outer surface of wedge element 34 in large part tapers radially inward from top to bottom. More specifically, the outer diameter of wedge element 34 decreases from at or near its upper end to at or near its lower end, thus providing wedge element 34 with a generally inverted truncated conical outer surface. As will be appreciated from the description below, when plug 30 is set, wedge element 34 will provide the structural core of plug 30.

[0127] Slip elements 35 are situated generally between wedge element 34 and setting ring element 36. They may be described in general terms as collectively forming a generally tapered annular or open cylindrical shape. That collective shape is profiled, as described further below, to provide a plurality of slips 35 that will engage liner 10 and anchor plug 30 therein.

[0128] More specifically, the outer surface of slip elements 35 is generally cylindrical, while the inner surface in large part tapers radially inward from top to bottom. That is, the inner diameter of slip elements 35 decreases from the upper end of slip elements 35 to proximate its lower end, thus providing the major portion of slip elements 35 with a generally inverted truncated conical inner surface. The tapered inner surface of slip elements 35 is generally complementary to the tapered outer surface of wedge element 34 in both its angle and length. The upper end of slip element 35 projects axially into, and overlaps a short distance over the outer surface of wedge element 34. A relatively short lower portion of slip elements 35 generally defines a substantially uniform, non-tapered inner diameter.

[0129] Like backup elements 33, slip elements 35 also are breakaway elements. They are designed to break apart into separate elements, for example, ten separate slips 35. Prior to installation, slip elements 35 are joined by weakened portions. For example, as seen best in FIGS. 3-5, individual slips 35 are largely, but not entirely separated by alternating, longitudinal sets of slits 48a and 48b. Slits 48 extend radially through the wall of plug body 31 except proximate wedge element 34 at the upper end of slip elements 35 and proximate setting ring 36 at the lower end of slip elements 35. They run axially through the major portion of slip elements 35. Slits 48a run from the upper end of slip elements 35 stopping proximate the lower end of slip elements 35. Slits 48b run from the lower end of slip elements 35 stopping proximate the upper end of slip elements 35.

[0130] Slip elements 35 overlap slightly at their upper end with wedge element 34 and at their lower end with setting ring element 36. That slight overlap, along with slits 48a and 48b leave relatively thin, weak bridging portions 44 along the upper end of slip elements 35 and bridging portions 45 along the lower end of slip elements 35. Upper bridging portions 44 join slip elements 35 to wedge 34 and join adjacent slip elements 35 together. Lower bridging portions 45 join slip elements 35 to setting ring element 36 and join adjacent slip elements 35 together. When frac plug 30 is installed, as described further below, bridging portions 44 and 45 will break allowing individual slip elements 35 to separate from each other and move axially over wedge element 34 and radially outward into contact with liner 10.

[0131] The outer surface of slip elements 35 preferably is provided with features to assist slip elements 35 in engaging and gripping liner 10 when frac plug 30 is set. Thus, for example, slip elements 35 may be provided with high-strength or hardened particles, grit, or inserts, such as buttons 55. Buttons 55 may be mounted in suitable bottomed holes in the outer surface of slip elements 35. They may be fabricated from, for example, a ceramic material containing aluminum, such as a fused alumina or sintered bauxite, or zirconia, such as CeramaZirc available from Precision Ceramics. Buttons 55 also may be fabricated from heat treated steel or cast iron, fused or sintered metals and other high-strength materials, or carbides such as tungsten carbide. The precise number and arrangement of buttons 55 or other such components may be varied. The outer surface of slip elements 35 also may be provided with teeth or serrations in addition to or in lieu of buttons or other gripping features.

[0132] Setting ring element 36 is situated generally below slip elements 35 at the lower end of plug body 31. As noted above, it is joined to slip elements 35 by bridging portions 45. It has a generally annular or open cylindrical shape that is profiled, as described further below, to allow setting ring element 36 to cooperate with a setting tool in setting plug 30 and to protect plug 30 as it is am into liner 10.

[0133] More specifically, the upper end of setting ring 36 has a dramatically reduced outer diameter, that lower diameter being somewhat less than the inner diameter of the lower end of slip elements 35. Thus, the upper portion of setting ring element 36 forms a short, thin annular nipple extending axially from the main portion of setting ring element 36 into the lower end of slip elements 35.

[0134] Setting ring element 36 also has radial openings 56 extending through the walls of its main, lower portion. Radial openings 56 allow setting ring element 36 to be releasably connected to adaptor 23 by, for example, shear screws, shear pins, or other shearable connectors (not shown). The shearable connectors will allow frac plug 30 to separate from adaptor 23 and setting tool 22 once it is set.

[0135] The lower end or “nose” of setting ring element 36 has an annular bevel or taper that assists in guiding plug 30 as it is deployed through liner 10. The outer surface of setting ring element 36 also has a maximum diameter portion in its mid-section. The maximum diameter portion of setting ring element 36 preferably has a diameter somewhat greater than the outer diameter of backup elements 33, wedge element 34, and slip elements 35. Setting ring element 36 thus can serve as a gauge ring and can protect the upper elements of plug body 31, especially slip element 35, from catching on debris, protrusions, and the like that might cause them to deploy prematurely as plug 30 is run into position in liner 10. In addition, adaptor 23 connecting setting tool 22 and plug 30 will comprise a protective tube or sheath into which the upper end of cup seal 32 may be carried in a somewhat compressed state. The seal sheath may provide an additional gauge surface. In any event, it will protect cup seal 32 from damage and prevent it from hanging up as frac plug 30 is deployed.

[0136] Plug 30 may be deployed and installed in a well by coupling it to a wireline tool string, such as tool string 20 on wireline 24. In general, wedge element 34 will be driven into slip elements 35 forcing them to expand radially into gripping contact with liner 10. More specifically, once plug 30 is deployed to the desired location in liner 10, setting tool 22 will be actuated to generate a force linearly compressing plug 30 along its major axis. The axial, compressive force will be transmitted through adaptor 23 and applied between wedge element 34 and setting ring element 36 of plug 30. A downward force will bear on an upper surface of wedge element 34, such as an annular beveled surface 53 at the upper end of wedge element 34. An upward force will be transmitted to setting ring element 36. Once a predetermined level of compressive force is generated by setting tool 22, the connection between slip elements 35 and setting ring 36 provided by bridging portions 45 will break, allowing those elements 35/36 to separate. For example, bridging portions 45 may shear generally along an annular plane aligned with the lower, inner cylindrical surface of slip elements 35 and the upper, outer cylindrical surface of setting ring 36. The nipple at the upper end of setting ring 36 then will shift upward into the lower end of slip elements 35 as shown in FIG. 8B. That shift allows the upward-facing shoulder formed by the enlarged diameter portion of setting ring 36 to butt against the lower surface of slip elements 35.

[0137] As increasing axial compressive force is generated by setting tool 22, the connection between wedge element 34 and slip elements 35 provided by bridging portions 44 will break, allowing wedge 34 to be driven downward into the bore of slip elements 35. For example, bridging portions 44 may shear generally along an annular plane aligned with the outer tapered surface of wedge 34 and the inner tapered surface of slip elements 35. As wedge 34 travels axially downward, the complementary conical surfaces on wedge 34 and slips 35 allow wedge 34 to ride under slip elements 35.

[0138] As wedge 34 continues downward, it generates radial load on slip elements 35. The connections between adjacent slip elements 35 provided by bridging portions 44 and 45 will break, allowing slip elements 35 to separate from each other. For example, slip elements 35 may separate along burst lines generally aligned with slits 48a and 48b and extending through bridging portions 44 and 45. Ideally, each slip element 35 will separate completely, but as a practical matter, some slip elements 35 may remain connected to other slip elements 35. In any event, as shown in FIG. 8C, separated slips 35 eventually will move radially outward into contact with liner 10 such that slips 35 and wedge 34 largely overlap.

[0139] Thus jammed between the outer conical surface of wedge 34 and liner 10, slips 35 are able to anchor plug 30 within liner 10. Preferably, the taper angles will be such that wedge 34 and slips 10 are self-locking. Thus, for example, when plug body 31 is fabricated from a composite, such as a wound fiber resin blank, the tapered outer surface of wedge 35 and the tapered inner surface of slips 35 are provided with a taper from about 1° to about 10° off center so as to provide a self-locking taper fit between them.

[0140] As noted above, setting tool 22 is connected through adaptor 23 to setting ring 36 by shearable connectors (not shown). When wedge 34 has been fully driven into slips 35, they will have been shifted radially outward into contact with liner 10. At that point, the shear forces across the shearable connectors will increase rapidly. When those forces exceed a predetermined limit, the connectors will shear, relieving any further compressive force on plug 30. Shearing of the connectors also releases setting tool 22 from setting ring 36. Setting tool 22 then can be pulled out of plug 30 and liner 10 via wireline 24.

[0141] Plug 30 then will be fully installed as depicted schematically in FIG. 1B and will be ready to receive a frac ball (not shown in FIG. 1B). Once deployed, the frac. ball will land on seat 54 in bore 51 of wedge 34 as shown in FIG. 8D. Seat 54 has a beveled surface that allows the ball to substantially restrict or preferably to shut off entirely fluid flow through plug 30. Preferably, seat 54 is located in wedge 34 such that, when plug 30 is installed and wedge 34 is fully inserted into slips 35, seat 54 will be positioned between the upper and lower ends of slips 35, and more preferably, well below the axial midpoint of slips 35. When fluid pressure is generated above the frac ball, therefore, it will create radial load on wedge 34 and slips 35. That radial load will further support the engagement between slips 35 and liner 10 and allow the use of softer materials, such as composites, having relatively lower radial yield strengths.

[0142] Cup seal 32 has a generally annular or open cylindrical shape. Its lower portion is provided with an annular lip or flange. The flange extends into the annular groove in the lower end of seal backup elements 33 and may be secured therein by suitable adhesives. The inner surface of the upper portion of cup seal 32 tapers radially inward. The upper end of cup seal 32, therefore, flares radially outward such that when plug 30 in installed, it will contact liner 10 under some compression. A section of cup seal 32 near its upper end has a uniform outer diameter, thus providing an extended contact surface. After installation, but before pumping frac fluids into well 1, cup seal 32 provides a light seal between frac plug 30 and liner 10.

[0143] Once pumping commences, however, increasing fluid pressure above frac plug 30 will cause cup seal 32 to “balloon” out, swelling it into an increasingly more robust seal with liner 10. Frac fluid will be unable to flow past frac plug 30 and will be diverted through perforations in liner 10 to create fractures 9.

[0144] As cup seal 32 balloons out, the fluid pressure within cup seal 32 will break bridging portions 43 between backup elements 33 and wedge 34. The fluid pressure, for example, will apply load to bridging portions 43, including load in an outward radial direction. That radial load will break the connections between individual backup elements 33, for example, along longitudinal burst lines. Ideally, each backup element 33 will separate completely, but as a practical matter, some backup elements 33 may remain connected to other backup elements 33. In any event, as shown in FIG. 8D, backup segments 33 then will be pushed radially outward into contact with liner 10 and into a position where they will impede downward extrusion of cup seal 32. Bridging portions 43, to the extent they connect individual backup elements 33 to wedge element 34, preferably will not break entirely, but will allow the uphole end of backup elements 33 to pivot radially outward into contact with liner 10. If there is complete separation between backup elements 33 and wedge element 34, however, groove 52 provides a downward facing shoulder that can catch on the upper end of wedge 34, providing a stop to limit downward shifting of backup elements 33 a cup seal 32 is pressurized.

[0145] It will be appreciated that novel plug 30 and other embodiments having a unitary or integral plug body that comprises defined, separable elements joined by relatively weak bridging portions offer significant advantages over prior art plugs. The weak bridging portions are adapted to break in a controlled sequence and allow the elements to separate and self-assemble as the plug body is collapsed during installation of the plug.

[0146] For example, the wedge element and slip elements are joined by weak bridging portions. The design specifications of the wedge and slip elements may be more precisely matched and controlled more easily than when those components are fabricated as separate components. Thus, it is more likely that the strength of engagement with the liner will be is more uniform from slip to slip. The controlled breaking and self-assembly also allows more precise control over the sequence and timing of setting of the slips, even when the plug is made of softer materials such as composites. It is believed, therefore, that the novel plugs will be anchored more reliably and securely than prior art plugs, especially those fabricated from composites.

Frac Plug 130 and Setting Tool Adaptor 160

[0147] A second preferred embodiment 130 of the novel frac plugs is shown in greater detail in FIGS. 10-15. As may be seen most easily in the exploded view of FIG. 11, frac plug 130 generally comprises a plug body 131, a cup seal 132, a seal backup ring 133, and a thrust ring 137. Plug body 131 is similar in many respects to plug body 31 of plug 30. It has a profiled, somewhat elongated, generally open cylindrical shape. A central bore 151 extends axially through plug body 131.

[0148] Plug body 131, like plug body 31 of novel plug 30, is an integral component having defined elements joined by relatively weak bridging portions. As in plug 30, the weak bridging portions are adapted to break in a controlled fashion and allow the elements to separate and self-assemble as plug body 131 is collapsed during setting of plug 130.

[0149] Preferably, as exemplified by plug 130, plug body 131 defines a wedge element 134, an array of slip elements 135, and a setting ring element 136. As seen best in FIG. 12, wedge element 134 is bridged to slip element 135 by portions 144. Slip elements 135 are bridged to setting ring element 136 by portions 145. It will be appreciated from the discussion that follow that the geometry and dimensions of those bridging portions 144/145 provide them with significantly less shear strength along the axis of plug 130 than possessed by the adjoining plug elements 134/135/136.

[0150] Wedge element 134 generally comprises the upper portion of plug body 131 and is situated above slip elements 135. It may be described in general terms as having an annular or open cylindrical shape with two tapered surfaces as best appreciated from the cross-sectional view of FIG. 12. Wedge element 134 is profiled, as described further below, to provide a lower ramping surface 134a that will drive slip elements 135 radially outward into engagement with liner 10, an upper ramping surface 134b that will drive cup seal 132 and seal backup ring 133 radially outward to provide a reinforced seal with liner 10, and a seat 154 for a plug member.

[0151] Ball seat 154 is provided in wedge bore 151 by a shallow-angle, upward facing tapered reduction in its inner diameter. Ball seat 154 preferably is situated axially below the upper end of wedge element 134. More preferably, as seen best in FIG. 13, ball seat 154 is situated well below the upper end of lower ramping surface 134a of wedge element 134, in its midsection. Thus, when plug 130 is set as described further below, ball seat 154 will be situated well below the axial midpoint of slips 135.

[0152] The outer surface of wedge element 134 in large part comprises lower ramping surface 134a and upper ramping surface 134b. Lower ramping surface 134a tapers radially inward from top to bottom. More specifically, the outer diameter of wedge element 134 decreases from the upper end of ramping surface 134a to the lower end thereof. Upper ramping surface 134b tapers radially inward from bottom to top. That is, the outer diameter of wedge element 134 decreases from the lower end of ramping surface 134b to the upper end thereof. Thus, wedge element 134 is provided with two truncated conical surfaces. One, lower ramping surface 134a, is inverted and faces downward. The other, upper ramping surface 134b, faces upward. As will be appreciated from the description below, when plug 130 is set, wedge element 134 will provide the structural core of plug 130.

[0153] Slip elements 135 are situated generally between wedge element 134 and setting ring element 136. Slip elements 135 are substantially similar to slip elements 35 of plug 30. Thus, they may be described in general terms as collectively forming a generally tapered annular or open cylindrical shape. That collective shape is profiled, as described further below, to provide a plurality of slips 135 that will engage liner 10 and anchor plug 130 therein.

[0154] More specifically, the outer surface of slip elements 135 is generally cylindrical, while the inner surface in large part tapers radially inward from top to bottom. The tapered inner surface of slip elements 135 is generally complementary to lower ramping surface 134a of wedge element 134 in both its angle and length. Like slip elements 35, slip elements 135 also are breakaway elements designed to break apart into separate slips 135.

[0155] Prior to installation, slip elements 135 are joined by weakened portions. For example, individual slip elements 135 are largely separated by longitudinal slits 148, but they overlap slightly at their upper end with wedge element 134 and at their lower end with setting ring 136. Those slight overlaps leave relatively thin, weak bridging portions 144 along the upper end of slip elements 135 and bridging portions 145 along the lower end of slip elements 135. Upper bridging portions 144 join slip elements 135 to wedge 134 and join the upper ends of adjacent slip elements 135 together. Lower bridging portions 145 join slip elements 135 to setting ring element 136 and join the lower ends of adjacent slip elements 135 together. When frac plug 130 is set, as described further below, bridging portions 144 and 145 will break allowing individual slip elements 135 to separate from each other and move axially over wedge element 134 and radially outward into contact with liner 10.

[0156] The outer surface of slip elements 135 preferably is provided with features to assist slip elements 135 in engaging and gripping liner 10 when frac plug 130 is set. For example, as with slip elements 35 of plug 30 and seen best in the isometric views of FIG. 10-11, they may be provided with high-strength or hardened particles, grit, or inserts, such as buttons that may be mounted in bottomed holes 155. The outer surface of slip elements 135 also may be provided with teeth or serrations in addition to or in lieu of buttons or other gripping features.

[0157] Setting ring element 136 is substantially identical to setting ring element 36 of plug 30 and is situated generally below slip elements 135 at the lower end of plug body 131. As noted above, it is joined to slip elements 135 by bridging portions 145. The upper portion of setting ring element 136 forms a short, thin annular nipple extending axially from the main portion of setting ring element 136 into the lower end of slip elements 135. The lower end or “nose” of setting ring element 136 has an annular bevel or taper that assists in guiding plug 130 as it is deployed through liner 10. The outer surface of setting ring element 136 also has a maximum diameter portion in its mid-section that preferably allows setting ring element 136 to serve as a protective gauge ring.

[0158] Cup seal 132, seal backup ring 133, and thrust ring 137, as described further below, cooperate to provide a pressure seal between liner 10 and plug 130. As best appreciated by comparing FIGS. 11 and 13, thrust ring 137 has a generally annular, ring shape having a profiled, but generally trapezoidal cross-section. it is coupled to the upper end of plug body 131 and its lower end abuts cup seal 132. For example, thrust ring 137 may be provided with a downward extending annular rim that extends around and engages an upward extending rim on the upper end of plug body 131. The upper face of thrust ring 137 preferably is provided with a profile, such as an annular notch, that facilitates axial engagement with an adaptor kit 160 as described further below. The lower end of the outer surface of thrust ring 137 has a bevel that provides a downward facing, inward taper that abuts the upper face of cup seal 132. The bevel will provide a ramping surface to radially expand cup seal 132 as plug 130 is set.

[0159] Cup seal 132 is carried in part on upper ramping surface 134b of plug body 131 and in part on thrust ring 137. It has a generally annular, ring shape also having a profiled, but generally trapezoidal cross-section. The lower portion of its inner surface is beveled to provide cup seal 132 with a downward facing, outwardly tapered surface that is complimentary to the upward facing taper of upper ramping surface 1341. The lower portion of its outer surface is beveled to provide another downward facing tapered surface which engages seal backup ring 133. Upper face of cup seal 132 is beveled to provide an upward facing, inward taper on cup seal 132 that is generally complimentary to the downward facing taper on thrust ring 137.

[0160] Seal backup ring 133 is carried on upper ramping surface 134b of plug body 131. It may be described in general terms as collectively having a generally annular or ring shape with a generally triangular cross-section. Equivalently, the lower and upper faces of seal backup ring 133 may be viewed as beveled. Backup ring 132 thus is provided with a downward facing taper at its lower end that is complimentary to the upward facing tapered surface 134b on wedge 134 and an upward facing taper at its upper end that is complimentary to the outer, downward facing taper on cup seal 132.

[0161] Seal backup ring 133 comprises breakaway elements designed to break apart into separate backup segments, for example, ten separate backup segments 133. Prior to installation, backup elements 133 are joined by weakened portions. For example, as seen best in FIGS. 10-12, individual backup elements 133 are largely, but not entirely separated by longitudinal slits 147. Slits 147 extend radially through seal backup ring 133. They extend axially from the upper end of seal backup ring 133 and stop proximate the lower end of seal backup ring 133. Slits 147 leave relatively thin, weak bridging portions 143 joining each individual backup element 133 in seal backup ring 133. When frac plug 130 is set, as described further below, radial expansion of seal backup ring 133 will break bridging portions 143 allowing individual backup segments 133 to break away and move radially outward.

[0162] Plug 130 may be deployed and installed in a well as described above in reference to plug 30. Plug 130, for example, preferably will be installed by a first preferred embodiment 100 of the novel tool assemblies. Tool assembly 100 will be coupled to wireline, such as wireline 24 shown schematically in FIG. 2A. As may be seen in FIGS. 14-15, tool assembly 100 also is coupled to plug 130 and generally comprises a setting tool 122 and a first preferred embodiment 160 of the novel setting tool adaptors. Once plug 130 is deployed to the desired location in liner 10, setting tool 122 will be actuated to generate axial compressive forces that will be transmitted through adaptor 160 to plug 130, The compressive forces will be applied between thrust ring 137 and setting ring element 136 to linearly compress plug 130 along its major axis. As described in further detail below, lower ramping surface 134a of wedge element 134 of plug 130 will be driven into slip elements 135 forcing them to expand radially into gripping contact with liner 10. Cup seal 132 will be driven up upper ramping surface 134b of wedge element 134 to seal plug 130 in liner 10.

[0163] A variety of setting tools and adapter kits may be used to install the novel plugs. For example, setting tool 122 is a pyrotechnic “Baker Style” setting tool similar to the E-4 series pyrotechnic setting tools sold by Baker Hughes. It has combustible powder charges which are electrically ignited through a wireline. Ignition of the charges generates pressure that will actuate the tool. Other pyrotechnic setting tools, however, may be used, such as the Compact wireline setting tools sold by Owen Oil Tools, the GO-style setting tools available from The Wahl Company, and the Shorty series tools available from Halliburton. Disposable setting tools, such as the DB10 and DB20 setting tools available from Diamondback Industries, also may be used. Likewise:, other types of setting tools may be used. For example, electrohydraulic setting tools, such as Weatherford's DPST setting tool, may be used. Hydraulic setting tools, such as Schlumberger's Model E setting tool, or ball activated hydraulic setting tools, such as Weatherford's HST setting tool and American Completion Tools Fury 20 setting tools, also may be used. If hydraulic setting tools are used, the tools will be run in a coiled tubing or a pipe string.

[0164] Details of the construction and operation of such setting tools are well known in the art and will not be expounded upon. Suffice it to say, however, that setting tool 122 includes an activatable outer push drive 123 and an activatable inner pull drive 124, as may be seen in FIG. 15. When setting tool 122 is actuated, outer push drive 123 moves downward relative to inner pull drive 124 transmitting axial, compressive force through adapter 160 to plug 130.

[0165] Likewise, various adaptor kits may be used with the novel plugs, the specific design of which will be tailored to a particular setting tool. The novel adaptors have an outer push member adapted for releasable connection to the plug, an inner pull member adapted for releasable connection to the plug, and a seal sheath. The seal sheath is coupled to the inner pull member by a connector extending through the outer push member. When the tool is connected to the plug in an unset position, the seal sheath is in a first position extending annularly around and substantially covering the outer surface of the plug seal. When the inner pull member moves upward relative to the outer push member, it moves the seal sheath from the first position covering the seal to a second position uncovering the seal.

[0166] Adaptor 160, for example, generally comprises an outer connector 161, an inner connector 162, an outer push sleeve 163, an inner pull mandrel 164, a seal sheath 165, and a sheath connector 166 as shown in FIG. 15. Outer connector 161 has a profiled, generally cylindrical shape. Outer connector 161 is assembled at its upper end to push drive 123 on setting tool 122, for example, by a threaded connection. The lower end of outer connector 161 is assembled to outer push sleeve 163, for example, by a threaded connection.

[0167] Push sleeve 163 has a profiled, generally cylindrical shape. It is provided with a pair of slots 171. Slots 171 extend longitudinally through a substantial portion of push sleeve 163. They extend parallel to each other on opposite sides of push sleeve 163, i.e., they are separated radially by 180°. The lower end of push sleeve 163 engages the upper face of thrust ring 137 of plug 130.

[0168] Inner connector 162 has a profiled, generally cylindrical shape and is assembled at its upper end to pull drive 124 on setting tool 122, for example, by a threaded connection. The lower end of inner connector 162 is assembled to inner pull mandrel 164, for example, by a threaded connection. Pull mandrel 164 has a generally cylindrical shape. The lower end of pull mandrel 164 is releasably connected to setting ring element 136. For example, pull mandrel 164 may be releasably connected to setting ring element 136 by threaded shear screws, shear pins, or other shearable connectors (not shown) passed through radial holes 156 in setting ring element 136 and into bottomed holes in inner pull mandrel 164. The shearable connectors will allow frac plug 130 to separate from adaptor 160 and setting tool 122 once it is set.

[0169] Seal sheath 165 has a profiled, generally cylindrical shape. It is slidably received around the lower end of outer push sleeve 163 and extends downward a distance sufficient to extend around and cover cup seal 132. Thus positioned, it will protect cup seal 132 from damage as tool assembly 100 and plug 130 are run into liner 10. Seal sheath 165 is coupled at its upper end to inner pull mandrel 164 so that, as described further below, it may be withdrawn to allow setting of cup seal 132.

[0170] For example, seal sheath 165 is coupled to inner pull mandrel 164 by sheath connector 166. More specifically, sheath connector 166 extends between opposing inner surfaces of seal sheath 165, passing through slots 171 in outer push sleeve 163 and a passage in pull mandrel 164 defined by a pair of transversely aligned holes. Sheath connector 166 is connected to seal sheath 165, for example, by threaded connectors (not shown) passing through openings 172 in sheath 166 and into threaded bottomed holes 173 in sheath connector 166. Thus, as inner pull mandrel 164 is pulled upwards, seal sheath 165 will slide upwards over outer pull sleeve 263.

[0171] Preferably, tool assembly 100 will have shearable connectors (not shown) that releasably secure the push components of setting tool 122 and adaptor 160 (push drive 123, outer connector 161, and outer push sleeve 163) and the pull components (pull drive 124, inner connector 162, and inner pull mandrel 164), immobilizing them from moving relative to each other. As described herein, setting of plug 130 is accomplished by applying compressive force along the axis of plug 130. Thus, if the components are not immobilized, plug 130 may set partially or otherwise jam as it is run into liner 10.

[0172] Setting tool 122 will generate a downward force through push drive 123 that will be transmitted through adaptor outer connector 161 and outer push sleeve 163 and bear on thrust ring 137 of plug 130. The lower face of push sleeve 163 and upper face of thrust ring 137 have mating profiles to provide more secure engagement between the components. is An upward force will be generated through setting tool pull drive 124 and transmitted through adaptor inner connector 162 and inner pull mandrel 164 to setting ring element 136 of plug 130.

[0173] Once a predetermined level of compressive force is generated by setting tool 122 any shearable connectors immobilizing the components of setting tool 122 and setting tool adaptor 160 will be sheared and shear forces will be generated throughout plug body 131. Once a predetermined level of shear force is reached, the connection between slip elements 135 and setting ring 136 provided by bridging portions 145 will break, allowing those elements 135/136 to separate. For example, bridging portions 145 may shear generally along an annular plane 145 aligned with the lower, inner cylindrical surface of slip elements 135 and the upper, outer cylindrical surface of setting ring 136.

[0174] At that point, inner pull mandrel 164 of adaptor 160 will begin to move upwards relative to outer push sleeve 163, pulling setting ring 136 along with it. The nipple at the upper end of setting ring 136 will shift axially upward into the lower end of slip elements 135. That shift allows the upward-facing shoulder formed by the enlarged diameter portion of setting ring 136 to butt against the lower surface of slip elements 135.

[0175] As increasing axial force is generated by setting tool 122, the connection between wedge element 134 and slip elements 135 provided by bridging portions 144 will break, allowing wedge 134 to be driven downward into the bore of slip elements 135. For example, bridging portions 144 may shear generally along an annular plane 144 aligned with the outer tapered surface of wedge 134 and the inner tapered surface of slip elements 135. As wedge 134 travels axially downward, the complementary conical surfaces on lower ramping surface 134a of wedge 134 and slips 135 allow the lower portion of wedge 134 to ride under slip elements 135.

[0176] As wedge 134 continues downward, it generates radial load on slip elements 135. The connections between adjacent slip elements 135 provided by bridging portions 144 and 145 will break, allowing slip elements 135 to separate from each other. For example, slip elements 135 may separate along burst lines aligned with slits 148. Separated slips 135 eventually will move radially outward into contact with liner 10. Thus, jammed between the outer conical surface of wedge 134 and liner 10, slips 135 are able to anchor plug 130 within liner 10.

[0177] As inner pull mandrel 164 moves axially upward, it not only shifts setting ring 136 and slips 135 upward, but being coupled to sheath connector 166, it also carries with it seal sheath 165. Thus, by the time slips 135 engage liner 10, seal sheath 165 has slid upwards across outer pull sleeve 163 a sufficient distance to uncover segmented seal backup 133 and cup seal 132. Once the lower portion of wedge 134 has been fully driven into slips 135 and slips 135 have shifted radially outward into contact with liner 10, shear forces across thrust ring 137 will increase rapidly. When those forces exceed a predetermined limit, thrust ring 137 will shear along lines generally co-extensive with the outer radial limits of the abutment between thrust ring 137 and wedge 134 and the inner radial limits of the abutment between thrust ring 137 and outer push sleeve 163.

[0178] Once thrust ring 137 shears, its radial outer portion will be driven downward by outer push sleeve 163 of adaptor 160. Cup seal 132 and segmented seal backup 133 then will be driven across upper tapered surface 134a of wedge 134. Having been uncovered, as they move downward on upper tapered surface 134a, cup seal 132 and seal backup ring 133 will expand radially. Segmented seal backup ring 133 will break apart into individual backup segments 133a and will expand radially into contact with liner 10. Thrust ring 137 also will expand the upper lip of cup seal 132 radially outward into contact with liner 10.

[0179] As noted above, setting tool 122 and setting tool adaptor 160 are connected to plug 130 by shearable connectors extending between setting ring 136 and inner pull mandrel 164. When the lower portion of wedge 134 has been fully driven into slips 135, and cup seal 132 and seal backup segments 133a have ridden up the upper portion of wedge 134 and into sealing engagement with liner 10, the shear forces across the shearable connectors will increase further. When those forces exceed a predetermined limit, the connectors will shear, relieving any further compressive force on plug 130. Shearing of the connectors also releases setting tool adaptor 160 from setting ring 136. Setting tool 122 and setting tool adaptor 160 then can be pulled out of plug 130 and liner 10 via wireline 24.

[0180] Plug 130 then will be fully installed and will be ready to receive a frac ball (not shown). Once deployed, the frac ball will land on seat 154 in the bore of wedge 134. Preferably, seat 154 is located in wedge 134 such that, when plug 130 is installed and the lower portion of wedge 134 is fully inserted into slips 135, seat 154 will be positioned between the upper and lower ends of slips 135, and more preferably, well below the axial midpoint of slips 135. When fluid pressure is generated above the frac ball, therefore, it will create radial load on wedge 134 and slips 135. That radial load will further support the engagement between slips 135 and liner 10.

[0181] Increasing fluid pressure above the frac ball also will cause cup seal 132 to further expand radially outward, creating an increasingly more robust seal with liner 10. Backup segments 133, having been radially expanded outward into contact with liner 10, will impede downward extrusion of cup seal 132. Frac fluid will be unable to flow past frac plug 130 and will be diverted through perforations in liner 10 to create fractures 9.

[0182] It will be appreciated that novel plug 130 offers further advantages over prior art plugs. Plug 130 and other embodiments that have a unitary or integral plug body comprising a wedge element with an upper and lower ramping surface allow further control over the sequence and timing of anchoring and sealing plug 130. The compressive forces required to anchor the plug, that is to break the bridging portions between the wedge and slip elements and drive the slip elements up the lower ramping surface, and to seal the plug, that is, to initiate expansion of the seal by driving it up the upper ramping surface, may be separately controlled. The compressive force required for anchoring the plug may be set lower than that required to seal the plug, thus helping to ensure that the plug is both properly anchored and sealed.

[0183] Control over the sequence and timing of plug collapse and setting in conventional plugs typically is determined largely through the taper angles provided on the components, for example, the taper angles of the wedge and slips. In the novel plugs, such control also is provided by the design of the bridging portions and is not nearly as sensitive to variations in material properties from blank to blank. The integral plug body and the bridging portions incorporated therein will be made from the same blank. Thus, even if there is considerable variation from blank to blank, the relative strength of the bridging portions will be consistent from plug to plug. It is believed, therefore, that the novel plugs can be installed more reliably even when they are fabricated from softer materials, such as composites.

Frac Plug 230 and Setting Tool Adaptor 260

[0184] A third preferred embodiment 230 of the novel frac plugs is shown in greater detail in FIGS. 16-20. As seen best in the exploded view of FIG. 17, frac plug 230 generally comprises plug body 231, a seal ring 232, and a seal backup ring 233. Plug body 231 is substantially identical to plug body 131 of plug 130 described above. As in plug body 131, plug body 231 of plug 230 comprises a wedge element 234 having a lower ramping surface 234a and an upper ramping surface 234b, a plurality of slip elements 235, and setting ring element 236. Wedge element 234 is bridged to slip elements 235 by portions 244. Slip elements 235 are bridged to setting ring element 236 by portions 245. It will be noted, however, that slip elements 235 are provided with circumferential grooves 249 as well as slits 248. Grooves 249 help reduce the likelihood that relatively large pieces of slips 235 are left over after drilling plugs 230 out of liner 10 once the fracturing operation is completed.

[0185] Seal ring 232 and seal backup ring 233, as described further below, cooperate to provide a pressure seal between liner 10 and plug 230. Seal ring 232 is carried on upper ramping surface 234b of plug body 231. It has an annular ring body 238. The inner surface of ring body 238 is beveled to provide seal ring 232 with a downward facing tapered surface that is complimentary to the upward facing taper of upper ramping surface 234b. Lower face of seal ring body 238 bears on an upper face of seal backup ring 233. Seal backup ring 233 also is carried on upper ramping surface 234b of plug body 231. It also has a generally annular, ring shape. its inner surface also is beveled to provide seal backup ring 233 with a downward facing tapered surface that is complimentary to the upward facing taper of upper ramping surface 234b.

[0186] When frac plug 230 is set, as described further below, radial expansion of seal backup dug 233 will cause it to split, allowing seal ring body 238 and seal backup ring 233 to travel downward over upper ramping surface 234b of wedge 234 and move radially outward. Accordingly, seal ring body 238 is fabricated from a sufficiently ductile material it to expand radially into contact with liner 10 without breaking. The outer circumference of seal ring body 238 preferably has an annular groove in which an elastomeric O-ring 239 is mounted. As seal ring 232 expands radially, seal ring body 238 and O-ring 239 seal against liner 10. Seal ring 232 is thus able to provide a seal between plug 230 and liner 10. If desired, an elastomeric band may be used instead of O-ring 239. Similarly, an elastomeric O-ring or other elastomeric material may be provided on the inner surface of seal ring body 238 to enhance the seal with wedge 234.

[0187] Plug 230 also may be deployed and installed in a well as described above in reference to plugs 30 and 130. Plug 230, for example, preferably will be installed by a second preferred embodiment 200 of the novel tool assemblies. Tool assembly 200 will be coupled to wireline, such as wireline 24 shown schematically in FIG. 2A. As may be seen in FIG. 20, tool assembly 200 also is coupled to plug 230 and generally comprises setting tool 122 and a second preferred embodiment 260 of the novel setting tool adaptors. Once plug 230 is deployed to the desired location in liner 10, setting tool 122 will be actuated to generate axial compressive forces that will be transmitted through adaptor 260 to plug 230. The compressive forces will be applied between seal ring 232 and setting ring element 236 to linearly compress plug 230 along its major axis.

[0188] As may be seen in FIG. 20, adaptor 260 generally comprises an outer connector 261, an inner connector 262, an outer push sleeve 263, and an inner pull mandrel 264. Outer connector 261 has a profiled, generally cylindrical shape. Outer connector 261 is assembled at its upper end to push drive 123 on setting tool 122, for example, by a threaded connection. The lower end of outer connector 261 is assembled to outer push sleeve 263, for example, by a threaded connection. Push sleeve 263 has a profiled, generally cylindrical shape. The lower end of push sleeve 263 engages the upper face of seal ring 232 of plug 230.

[0189] Inner connector 262 has a profiled, generally cylindrical shape and is assembled at its upper end to pull drive 124 on setting tool 122, for example, by a threaded connection.

[0190] The lower end of inner connector 262 is assembled to inner pull mandrel 264, for example, by a threaded connection. Pull mandrel 264 has a generally cylindrical shape. The lower end of pull mandrel 264 is releasably connected to setting ring element 236. For example, pull mandrel 264 may be releasably connected to setting ring element 236 by threaded shear screws 257 passed through radial holes 256 in setting ring element 236 and into bottomed holes in inner pull mandrel 264. Other shearable or frangible connections, however, may be used.

[0191] Setting tool 122 will generate a downward force through push drive 123 that will be transmitted through adaptor outer connector 261 and outer push sleeve 263 and bear on seal ring 232 of plug 230. An upward force will be generated through setting tool pull drive 124 and transmitted through adaptor inner connector 262 and inner pull mandrel 264 to setting ring element 236 of plug 230.

[0192] Setting of plug 230 will be initiated generally as described above in reference to plug 130. Once shear forces across plug 230 reach a predetermined level, bridging portions 245 between slip elements 235 and setting ring 236 will break, allowing setting ring 236 to move upward and butt into the lower end of slip elements 235 as shown in FIG. 19B.

[0193] As shear across plug 230 increases, bridging portions 244 between wedge element 234 and slip elements 235 will break, allowing wedge 234 to be driven downward into the bore of slip elements 235. As wedge 234 is driven downward it generates radial load on slip elements 235. Slip elements 235 will separate and move radially outward into contact with liner 10. Thus jammed between wedge 234 and liner 10, slips 235 are able to anchor plug 230 within liner 10 as shown in FIG. 19C.

[0194] Once wedge 234 has been fully driven into slips 235 and slips 235 have shifted radially outward into contact with liner 10, the axial load on seal ring 232 and seal backup ring 233 will increase rapidly. As that load increases to a predetermined limit, seal backup ring 233 will burst. Seal backup ring 233 preferably is provided with a radial hole 243. Radial hole 243 allows seal backup ring to burst along predetermined lines. Sizing of radial hole 243 also allows more precise control over the level of radial force required to burst seal backup ring 233.

[0195] Once seal backup ring 233 has burst, seal ring 232 and seal backup ring 233 will be driven downward and across upper tapered surface 234b by outer push sleeve 263 of adaptor 260. As they move downward on upper tapered surface 234b, seal ring 232 and seal backup ring 233 will expand radially into contact with liner 10 as shown in FIG. 19D. More specifically, ring body 238 of seal ring 232 has a nominal outer diameter when it is in its unset condition and positioned toward the upper end of upper ramping surface 134b as shown in FIGS. 19A-C. As it is pushed up upper ramping surface 134b to its set position in the mid-section of upper ramping surface 134b as shown in FIG. 19D, it has an enlarged outer diameter sufficient to bring it into sealing engagement with liner 10.

[0196] When wedge 234 has been fully driven into slips 235, and seal ring 232 and seal backup ring 233 have been set, the shear forces across shear screws 257 will increase. Shear screws 257 will shear releasing setting tool adaptor 260 from setting ring 236. Plug 230 then will be fully installed and will be ready to receive a frac bail. Once deployed, the frac ball will land on seat 254 in the bore of wedge 234 as shown in FIG. 191). As with seat 154 in plug body 131, seat 254 preferably is located in wedge 234 such that, when plug 230 is installed and wedge 234 is fully inserted into slips 235, seat 254 will be positioned between the upper and lower ends of slips 235, and more preferably, well below the axial midpoint of slips 235.

Setting Tool Adaptor 360

[0197] Plug 230 also may be deployed and installed in a well by a third preferred embodiment 300 of the novel tool assemblies. Tool assembly 300 will be coupled to wireline, such as wireline 24 shown schematically in FIG. 2A. As may be seen in FIGS. 21-22, tool assembly 300 also is coupled to plug 230 and generally comprises setting tool 122 and a third preferred embodiment 360 of the novel setting tool adaptors. Once plug 230 is deployed to the desired location in liner 10, setting tool 122 will be actuated to generate axial compressive forces that will be transmitted through adaptor 360 to plug 230. The compressive forces will be applied between seal ring 232 and setting ring element 236 to linearly compress plug 230 along its major axis.

[0198] As may be seen in FIGS. 21-22, adaptor 360 generally comprises an outer connector 361, an inner connector 362, an outer push sleeve 363, an inner pull mandrel 364, a seal sheath 365, and a sheath connector 366. Outer connector 361 has a profiled, generally cylindrical shape. Outer connector 361 is assembled at its upper end to push drive 123 on setting tool 122, for example, by a threaded connection. The lower end of outer connector 361 is assembled to outer push sleeve 363, for example, by a threaded connection.

[0199] Push sleeve 363 has a profiled, generally cylindrical shape. It is provided with four slots 371. Slots 371 extend longitudinally through a substantial portion of push sleeve 363. They extend parallel to each other and are separated radially by 90°. The lower end of push sleeve 363 engages the upper face of seal ring 232 of plug 230.

[0200] Inner connector 362 has a profiled, generally cylindrical shape and is assembled at its upper end to pull drive 124 on setting tool 122, for example, by a threaded connection. The lower end of inner connector 362 is assembled to inner pull mandrel 364, for example, by a threaded connection. Pull mandrel 364 has a generally cylindrical shape. The lower end of pull mandrel 364 is releasably connected to setting ring element 236. For example, pull mandrel 364 may be releasably connected to setting ring element 236 by threaded shear screws 257 passed through radial holes 256 in setting ring element 236 and into bottomed holes in inner pull mandrel 364. Other shearable or frangible connections, however, may be used. The shearable connectors will allow frac plug 230 to separate from adaptor 360 and setting tool 122 once it is set.

[0201] Seal sheath 365 has a profiled, generally cylindrical shape and is slidably received around the lower end of outer push sleeve 363. Seal sheath 365 also extends around and covers seal ring 232, but is coupled to inner pull mandrel 364 so that it can be slid upward to allow seal ring 232 to be expanded radially into contact with liner 10.

[0202] For example, as shown in FIG. 21, seal sheath 365 may be coupled to pull mandrel 364 by four sheath connectors 366. Each sheath connector 366 extends radially inward through an opening in seal sheath 365, through its respective slot 371 in outer push sleeve 263, and into a hole provided in a coupling ring 367. Coupling ring 365 is an annular body that is carried around a reduced outer diameter portion at the upper end of inner pull mandrel 364. Sheath connectors 366, for example, may be roll pins that will frictionally engage the openings in seal sheath 365 and coupling ring 367. Other connectors, however, such as threaded connectors or other types of pins may be used. Similarly, coupling ring 367 may be eliminated or fabricated integrally with inner pull mandrel 364 and connector holes may be provided in inner pull mandrel 364 if desired.

[0203] Preferably, setting tool adaptor 360 will have shearable connectors that releasably secure and immobilize its push components (outer connector 361 and outer push sleeve 363) and pull components (inner connector 362 and inner pull mandrel 364). For example, as shown in FIG. 22, adaptor 360 may be provided with shear screws 368 that are passed through holes in seal sheath 365, into threaded holes in outer push sleeve 363, and thence into holes in coupling ring 367. Shear screws 368 will help prevent premature setting or jamming of plug 230 as it is run into liner 10.

[0204] Plug 230 may be set with adaptor 360 generally as described above. Setting tool 122 will generate a downward force through push drive 123 that will be transmitted through adaptor outer connector 361 and outer push sleeve 363 and bear on seal ring 232 of plug 230. An upward force will be generated through setting tool pull drive 124 and transmitted through adaptor inner connector 362 and inner pull mandrel 364 to setting ring element 236 of plug 230. Once that force exceeds a predetermined level, shear screws 368 will shear, generating compressive forces along the axis of plug 230.

[0205] Plug 230 then will set by sequential breaking and shearing of bridging portions 244/245 and seal backup ring 233 as described above and shown in FIG. 19. Bridging portions 245 will break and setting ring 236 to move upward and butt into the lower end of slip elements 235. Bridging portions 244 will break and wedge 234 will be driven downward, separating slip elements 235 and shifting them radially outward into contact with liner 10. As inner pull mandrel 364 moves axially upward, it carries with it seal sheath 365. Thus, by the time slips 235 engage liner 10, seal sheath 365 has shifted upwards a sufficient distance to uncover seal ring 232.

[0206] Seal backup ring 233 then will burst, allowing seal ring 232 and seal backup ring 233 to be driven downward across upper tapered surface 234b of plug body 231. Seal ring 232 and seal backup ring 233 will expand radially into contact with liner 10. Shear screws 257 will shear releasing setting tool adaptor 260 from setting ring 236.

[0207] It will be appreciated that novel adaptors 160 and 360 and similar embodiments provide important advantages over conventional setting tools. As discussed herein, the seals of frac plugs typically are fabricated from softer materials, such as elastomers and plastics. While gauge surfaces and the like provide some protection, the seals nevertheless can be easily be damaged as the plug is run into a liner. Such damage may mean that an effective pressure seal cannot be established when the plug is installed. By providing the novel setting tool assemblies with a retractable seal sheath, the seals may be protected until the plug is at proper depth in the liner, thus helping to ensure that a robust seal is formed when the plug is installed.

[0208] It also will be appreciated that certain functions and operations of the novel adaptors have been exemplified as being performed by subassemblies of separate parts. Separate parts often facilitate fabrication and assembly of the adaptors. At the same time, however, they may be assembled from fewer components. For example, adaptors 160/260/360 all comprise outer connectors 161/261/361 and outer push sleeves 163/263/363. Those separate components, however, may be fabricated as a single, unitary push member. The same is true of inner connectors 162/262/362 and inner pull mandrels 164/264/364. They may be fabricated as a single, unitary pull member.

[0209] Moreover, and as discussed above, economics of scale in the industry generally dictate that commercially available setting tools will be used in combination with an adaptor. The setting tool generates the compressive force required for installation of the novel plugs, while the adaptor transmits the compressive force to the plug. The setting tool typically has standard connections, while the adaptor is specifically configured for a particular plug or other downhole tool, in much the same way that a set of different sized sockets are used with a ratchet wrench. If desired, however, the novel setting tools can include force generating mechanisms as are commonly used in conventional, standardized setting tools. In other words, the setting tool and adaptor may be combined into a single tool, although as noted that generally will not be cost effective.

[0210] Plug bodies 31, 131, and 231 may be fabricated from materials typically used in plugs of this type. Such materials may be relatively hard metals, but typically would be relatively soft, or more brittle, more easily drilled metals, such as cast iron. More preferably, plug bodies 31/131/231 may be fabricated from non-metallic materials commonly used in plugs, such as fiberglass and carbon fiber resinous composite materials. When composites are used, plug bodies 31/131/231 may be molded, but more typically will be machined from wound fiber resin blanks, such as a wound fiberglass cylinder. Wound fiber resin blanks can be machined readily to provide the various elements and Such materials will allow the plug to be drilled more easily once fracturing is completed.

[0211] Plug bodies 31/131/231 also may be made from dissolvable metals, that is, metals that will dissolve, soften, disintegrate, or otherwise break down wholly or partially in the presence of existing or controlled conditions in the well by any mechanism. Such dissolvable metals typically are magnesium or aluminum alloys that may be dissolved, for example, with a plug of an acid solution. Other dissolvable metals include metal matrices, such as magnesium-graphite and magnesium-calcium matrices. The dissolvable metal may also be coated with materials that provide complimentary properties. Coatings may be used, for example, to protect the base metal prior to deployment of the plug, to strengthen it, or to control its rate of dissolution.

[0212] As readily appreciated by workers in the art, refinements in the basic design of the plug body will be dictated by the choice of materials. Metal being generally stronger, for example, the plug body may be made somewhat thinner and shorter when it is fabricated from metal instead of composites. In general, the taper angles for the wedge elements will provide a self-locking taper fit between the wedge and slips. The taper angle of the wedge element and slip elements thus may be less acute in metal plug bodies, for example, from about 10° to about 30°.

[0213] The choice of material also will determine in large part the geometry and other design criteria of the bridging portions joining the elements within the plug body. A cylindrical blank of wound fiber resin composites, for example, has much greater hoop strength than shear strength. Is essence, the windings create shear planes extending axially through the cylinder, while tending to absorb outward radial force. in contrast, the crystalline structure of most metals is sufficiently complex that the material strength is relatively constant regardless of the direction force is applied.

[0214] Thus, the manner, stress points, and nature of the break in the bridging portions will vary somewhat. Depending on the material used and the direction of the break, the break may be a relatively clean, distinct severing of the elements. In other instances, the break may be more of a rough tear. The object is simply that the bridging portions break sufficiently to allow independent movement of the once joined elements. That may be accomplished by scoring, thinning, perforating the material or in other conventional ways. Likewise, while the bridging portions in plug bodies 31/131/231 have been described as being broken by the application of axial or radial force, bridging portions may be broken by other mechanisms. For example, when the plug body is made from dissolvable metals, disintegration of the bridging portions may contribute to or create the “break” and allow separation of the joined elements.

[0215] Cup seals 32/132 may be made from elastomeric materials typically used for sealing elements in plugs of this type, such as nitrile butadiene rubber (NBR) and hydrogenated nitrile butadiene rubber (HNBR). Preferably, cup seals 32/132 may be made of a dissolvable elastomer, that is, an elastomer that will dissolve, soften, disintegrate, or otherwise break down wholly or partially in the presence of existing or controlled conditions in the well by any mechanism. The elastomer may be degraded, for example, by chemical or biological action. Dissolvable elastomers made for formed, for example, by elastomeric polymers carried in a dissolvable resin matrix. Similarly, the frac balls deployed onto the novel plugs may be made from dissolvable materials.

[0216] As noted, seal ring 232 of plug 230 preferably is fabricated from a sufficiently ductile material so as to allow the ring to deform plastically and expand radially into contact with a liner without breaking. For example, seal ring 232 may be fabricated from aluminum, bronze, brass, brass, copper, mild steel, or magnesium and magnesium alloys. Alternately, the ring body may be made of hard, elastomeric rubbers, such as butyl rubber.

[0217] Preferably, however, the seal ring is fabricated from a plastic material. Plastic components are more easily drilled, and the resulting debris more easily circulated out of a well. Engineering plastics, that is, plastics having better thermal and mechanical properties than more commonly used plastics, are preferred. Engineering plastics that may be suitable for use include polycarbonates and Nylon 6, Nylon 66, and other polyamides, including fiber reinforced polyamides such as Reny polyamide. “Super” engineering plastics, such as polyether ether ketone (PEEK) and polyetherimides such as Ultem®, are especially preferred. Mixtures and copolymers of such plastics also may be suitable. Preferred materials generally will have useful operating temperatures of at least 250° F., and preferably at least 350° F., and a tensile strength of a least 5,000 psi, preferably at least about 1,500 psi. Such preferred materials also generally will provide the ring body with an elongation factor of at least 10%, and preferably at least 30%.

[0218] As noted above, the seal ring may be provided with elastomeric O-ring, bands, or other elastomeric material around its outer or inner surface. Such elastomeric materials include those commonly employed in downhole tools, such as butyl rubbers, hydrogenated nitrile butadiene rubber (HNBR) and other nitrile rubbers, and fluoropolymer elastomers such as Viton.

[0219] As should be apparent from the foregoing discussion, references to “upper,” “lower,” “upward,” “downward,” and the like in describing the relative location or orientation of plug features are made contemplating an installed plug. Thus, an “upper” and “lower,” and variants thereof, would be synonymous with, respectively, “uphole” and “downhole.”

[0220] Plugs 30/1301230 and other embodiments also have been described as installed in a liner and, more specifically, a production liner used to fracture a well in various zones along the wellbore. A “liner,” however, can have a fairly specific meaning within the industry, as do “casing” and “tubing.” In its narrow sense, a “casing” is generally considered to be a relatively large tubular conduit, usually greater than 4.5″ in diameter, that extends into a well from the surface. A “liner” is generally considered to be a relatively large tubular conduit that does not extend from the surface of the well, and instead is supported within an existing casing or another liner. In essence, a “liner” is a “casing” that does not extend from the surface. “Tubing” refers to a smaller tubular conduit, usually less than 4.5″ in diameter. The novel plugs, however, are not limited in their application to liners as that term may be understood in its narrow sense. They may be used to advantage in liners, casings, and perhaps even in smaller conduits or “tubulars” as are commonly employed in oil and gas wells. A reference to liners shall be understood in context as a reference to all such tubulars.

[0221] Likewise, while the exemplified plugs are particularly useful in fracturing a formation and have been exemplified in that context, they may be used advantageously in other processes for stimulating production from a well. For example, an aqueous acid such as hydrochloric acid may be injected into a formation to clean up the formation and ultimately increase the flow of hydrocarbons into a well. In other cases, “stimulation” wells may be drilled in the vicinity of a “production” well. Water or other fluids then would be injected into the formation through the stimulation wells to drive hydrocarbons toward the production well. The novel plugs may be used in all such stimulation processes where it may be desirable to create and control fluid flow in defined zones through a well bore. Though fracturing a well bore is a common and important stimulation process, the novel plugs are not limited thereto.

[0222] It also will be appreciated that the description references frac balls. Spherical balls are preferred, as they generally will be transported though tubulars and into engagement with downhole components with greater reliability. Other conventional plugs, darts, and the like which do not have a spherical shape, however, also may be used to occlude the wedge bore in the novel plugs. The configuration of the “ball” seats necessarily would be coordinated with the geometry of such devices. “Balls” as used herein, therefore, will be understood to include any of the various conventional closure devices that are commonly pumped down a well to occlude plugs, even if such devices are not spherical. “Ball” seat is used in a similar manner. Moreover, as used herein in reference to the novel plugs, the term “bore” is only used to indicate that a passage exists and does not imply that the passage necessarily was formed by a boring process.

[0223] While this invention has been disclosed and discussed primarily in terms of specific embodiments thereof, it is not intended to be limited thereto. Other modifications and embodiments will be apparent to the worker in the art.