US008079413B2
`
`(12) Ulllted States Patent
`Frazier
`
`(10) Patent N0.:
`(45) Date of Patent:
`
`US 8,079,413 B2
`*Dec. 20, 2011
`
`(54) BOTTOM SET DOWNHOLE PLUG
`
`.
`-
`-
`(75) Inventor: W. Lynn Frazier, Corpus Christi, TX
`(Us)
`
`(73) Assignee: W. Lynn Frazier, Corpus Christi, TX
`(Us)
`
`( * ) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`This patent is subject to a terminal dis-
`claimer.
`
`(21) Appl- N05 13/194,871
`
`(22) Filed:
`
`Jul. 29, 2011
`
`(65)
`
`Prior Publication Data
`
`Us 2011/0277987 A1
`
`NOV' 17’ 2011
`
`2,593,520 A 10/ 1945 Baker et ?l~
`2,616,502 A
`3/1948 LenZ
`2,756,827 A
`6/1948 F
`2,737,242 A
`8/1952 B25:
`2,640,546 A
`6/1953 Baker et a1.
`2,833,354 A
`2/1955 Sailers
`3,054,453 A
`3/1955 Bonner
`2,713,910 A
`7/1955 Baker et a1.
`(Continued)
`
`GB
`
`FOREIGN PATENT DOCUMENTS
`914030
`12/1962
`(Continued)
`
`OTHER PUBLICATIONS
`
`“Halliburton Services, Sales & Service Catalog No. 43,” Halliburton
`C ., 1985 202
`.
`O
`(
`pages)
`
`(Continued)
`
`Primary Examiner * Shane Bomar
`Assistant Examiner * Robert E Fuller
`
`Related US Application Data
`
`(74) Attorney, Agent, or Firm * Edmonds & Nolte, PC
`
`(63) Continuation-in-part of application No. 12/317,497,
`?led on Dec. 23, 2008.
`
`(51) Int CL
`(2006 01)
`E213 33/129
`166/124 165/133_ 165/135
`(52) U 5 Cl
`h ’
`’166/123
`""
`58
`F,‘ I'd
`assl ca Ion earc
`138 193’
`0
`(
`)
`1e
`See a lication ?le for Com lete Search hist’o
`’
`pp
`p
`1y‘
`References Cited
`
`(56)
`
`US. PATENT DOCUMENTS
`RE17,217 E
`2/1929 Burch
`2,040,889 A
`5/1933 Whinnen
`2,223,602 A 10/1938 Cox
`2,286,126 A
`7/1940 Thornhill
`2,376,605 A
`5/1945 Lawrence
`
`ABSTRACT
`(57)
`.
`.
`.
`A plug for isolating a Wellbore. The plug can 1nclude a body
`having a ?rst end and a second end, Wherein the body is
`formed from one or more composite materials and adapted to
`receive a setting tool through the ?rst end thereof, at least one
`malleable element disposed about the body, at least one slip
`disposed about the body, at least one conical member dis
`posed about the body, and one or more shearable threads
`disposed on an inner surface of the body, adjacent the second
`end thereof, Wherein the one or more shearable threads are
`adapted to receive at least a portion of a setting tool that enters
`the body through the ?rst end thereof, and Wherein the one or
`more shearable threads are adapted to engage the setting tool
`When disposed through the body and adapted to release the
`setting tool When exposed to a predetermined axial force.
`
`20 Claims, 7 Drawing Sheets
`
`(it
`
`245 /
`
`290 i
`
`MEGCO Ex. 1003
`
`

`
`US 8,079,413 B2
`Page2
`
`U.S. PATENT DOCUMENTS
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`2714932 A
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`’
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`ge
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`0
`’
`’
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`1
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`’
`’
`‘1° er
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`A 13%;: EH9
`’
`’
`‘S
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`M979 Rro‘c‘l’n
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`M980 Hea.
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`’
`’
`‘Wm
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`g?ggj gockreclll
`31
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`’
`’
`Wm“
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`t 1
`’
`’
`‘Pussye a'
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`’
`’
`Ya.
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`5/1989 Blackwell etal.
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`1
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`M992 Glam
`l
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`M992 Masflr
`a1
`5,154,228 A “M992 Gueberet‘llq
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`M993 Pam ertogloet '
`’
`’
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`2/1993 Echols, 111 etal.
`.
`5,207,274 A
`5/1993 Strelch etal.
`“993 C1 d d1
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`M993 S Ye; ael
`’
`’
`“61° at”
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`5234 052 A
`8/1993 C
`tal
`5,253,705 A “M993 ci’oneeal'
`’
`’
`.aryet ~
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`115888 Win in
`'
`e
`e
`’
`’
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`6,725,935 B2
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`6,769,491 B2
`8/2004 Zimmermanetal.
`6,796,376 B2
`9/2004 Frazier
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`6’834’717 B2 12,2004 Bland
`6’851’489 B2
`2,2005 Hinds
`6,902,006 B2
`6/2005 Myerleyetal.
`7/2005 Dallas
`6,918,439 B2
`6,938,696 B2
`9,2005 Dallas
`7,021,389 B2
`4/2006 Bishop etal.
`7,040,410 B2
`5/2006 McGuireetal.
`7,055,632 B2
`6/2006 Dallas
`7,069,997 B2
`7/2006 Coyesetal.
`7,107,875 B2
`9/2006 Haugenetal.
`7,128,091 B2 10/2006 Istre, Jr.
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`7325 617 B2
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`9/2010 McKeachnieetal.
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`7,878,242 B2
`2/2011 Gray
`7,886,830 B2
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`7909108 B2
`30011 Swor et a1
`7’909’109 B2
`30011 An ane'tal
`7’918’278 B2
`4,2011 Bari‘;
`'
`7’92l’923 B2
`40011 McGuire
`7,921,925 B2
`4/2011 Maguire etal.
`7926 571 B2
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`’
`’
`2003/0024706 A1
`2/2003 Allamon
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`-
`2007/0051521 A1
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`-
`5/2007 Valdya etal.
`2007/0107908 A1
`-
`2008/0060821 A1
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`2008/0110635 A1
`2009/0114401 A1
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`2009/0211749 A1
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`2010/0084146 A1
`4/2010 Roberts
`2010/0101807 A1
`4/2010 Greenleeetal.
`2010/0132960 A1
`6/2010 Shkurtietal.
`2010/0155050 A1
`6/2010 Frazier
`-
`2010/0252252 A1 10/2010 Harrlsetal.
`-
`2010/0263876 A1 10/2010 FraZler
`2010/0276159 A1 11/2010 Mailandetal.
`2010/0288503 A1 11/2010 Cuiperetal.
`-
`-
`2011/0036564 A1
`2/2011 Wllllamson
`2011/0061856 A1
`3/2011 Kellneretal.
`2011/0088915 A1
`4/2011 Stanojcic etal.
`2011/0103915 A1
`5/2011 Tedeschi
`
`FOREIGN PATENT DOCUMENTS
`
`W0 WO 2010127457
`
`11/2010
`
`OTHER PUBLICATIONS
`
`“Alpha Oil Tools Catalog,” Alpha Oil Tools, 1997(136 pages).
`“Teledyne Merla Oil Tools-Products-Services,” Teledyne Merla,
`Aug'199°<4°PageS>'
`“78/79 Catalog: Packers-Plugs-Completions Tools,” Pengo
`Id t.
`I
`19781979 12
`“I1 “We? 11°"
`'
`(” Pages);
`MAPO1lToolsInc.Catalog, MAPO1lTools,Apr. 1999 (46pages).
`“Lovejoy-Where the World turns for couplings,” Lovejoy, Inc., Dec.
`2000 (30 pages).
`
`MEGCO Ex. 1003
`
`

`
`US 8,079,413 B2
`Page 3
`
`“Halliburton Services, Sales & Service Catalog,” Halliburton Ser
`vices, 1970-1971 (2 pages).
`“1975-1976 Packer Catalog,” GearhaIt-OWen Industries Inc., 1975
`1976 (52 pages).
`“Formation Damage Control Utilizing Compo site-Bridge Plug Tech
`nology for Monobore, MultiZone Stimulation Operations,” Gary
`Gar?eld, SPE, May 15, 2001 (8 pages).
`“Composite Bridge Plug Technique for MultiZone Commingled Gas
`Wells,” Gary Gar?eld, SPE, Mar. 24, 2001 (6 pages).
`
`“Composite Research: Composite bridge plugs used in multi-Zone
`Wells to avoid costly kill-Weight ?uids,” Gary Gar?eld, SPE, Mar. 24,
`2001 (4 pages).
`“It’s About TimeiQuick Drill Composite Bridge Plug,” Baker Oil
`Tools, Jun. 2002 (2 pages).
`“Baker HughesiBaker Oil ToolsiWorkover Systems4QUIK
`Drill Composite Bride Plug,” Baker Oil Tools, Dec. 2000 (3 pages).
`“Baker Hughes 100 Years of Service,”Baker Hushes in Depth, Spe
`cial Centennial Issue, Publication COR-07-13127, vol. 13, No. 2,
`Baker Hughes Incorporated, Jul. 2007 (92 pages).
`
`* cited by examiner
`
`MEGCO Ex. 1003
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`

`
`US. Patent
`
`Dec. 20, 2011
`
`Sheet 1 017
`
`US 8,079,413 B2
`
`130
`
`112
`
`FIG. 1A
`
`1005 \
`
`130
`
`112
`
`///////)r’\ 160
`
`FIG. 1B
`
`FIG. 2A
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`MEGCO Ex. 1003
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`

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`US. Patent
`
`Dec. 20, 2011
`
`Sheet 2 of7
`
`US 8,079,413 B2
`
`FIG. 28
`
`FIG. 2C
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`MEGCO Ex. 1003
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`

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`US. Patent
`
`Dec. 20, 2011
`
`Sheet 3 of7
`
`US 8,079,413 B2
`
`FIG. 3A
`
`FIG. 3B
`
`MEGCO Ex. 1003
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`

`
`U.S. Patent
`
`Dec. 20, 2011
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`Sheet 4 of 7
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`US 8,079,413 B2
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`200
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`295
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`210
`
`280
`
`240
`
`236
`
`245
`
`242
`
`100
`
`290
`
`200
`
`295
`
`216
`
`210
`
`280
`
`240
`
`236
`
`245
`
`242
`
`100
`
`290
`
`300
`
`320
`
`228
`
`255
`
`230
`
`250
`
`235
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`270
`
`275
`
`285
`
`315
`
`A 300
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`215
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`228
`
`255
`
`230
`
`250
`
`235
`
`270
`
`275
`
`285
`
`315
`
`FIG. 3C
`
`FIG. 3D
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`MEGCO EX. 1003
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`MEGCO Ex. 1003
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`

`
`US. Patent
`
`Dec. 20, 2011
`
`Sheet 5 of7
`
`US 8,079,413 B2
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`Q”
`
`/
`
`~
`
`\
`
`210
`255
`
`280
`
`240
`
`_— 230
`
`250
`
`\ 235
`
`FIG. 4
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`MEGCO Ex. 1003
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`US. Patent
`
`Dec. 20, 2011
`
`Sheet 6 of7
`
`US 8,079,413 B2
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`300
`
`285
`
`FIG. 5
`
`0'0
`050)
`NN
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`MEGCO Ex. 1003
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`US. Patent
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`Dec. 20, 2011
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`Sheet 7 of7
`
`US 8,079,413 B2
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`05
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`MEGCO Ex. 1003
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`

`
`US 8,079,413 B2
`
`1
`BOTTOM SET DOWNHOLE PLUG
`
`CROSS-REFERENCE TO RELATED
`APPLICATIONS
`
`This application is a continuation-in-part of US. patent
`application having Ser. No. 12/317,497, ?led Dec. 23, 2008,
`the entirety of Which is incorporated by reference herein.
`
`BACKGROUND
`
`1. Field
`Embodiments described generally relate to doWnhole
`tools. More particularly, embodiments described relate to
`doWnhole tools that are set Within a Wellbore With a loWer
`shear mechanism.
`2. Description of the Related Art
`Bridge plugs, packers, and frac plugs are doWnhole tools
`that are typically used to permanently or temporarily isolate
`one Wellbore Zone from another. Such isolation is often nec
`essary to pressure test, perforate, frac, or stimulate a Zone of
`the Wellbore Without impacting or communicating With other
`Zones Within the Wellbore. To reopen and/or restore ?uid
`communication through the Wellbore, plugs are typically
`removed or otherWise compromised.
`Permanent, non-retrievable plugs and/or packers are typi
`cally drilled or milled to remove. Most non-retrievable plugs
`are constructed of a brittle material such as cast iron, cast
`aluminum, ceramics, or engineered composite materials,
`Which can be drilled or milled. Problems sometimes occur,
`hoWever, during the removal or drilling of such non-retriev
`able plugs. For instance, the non-retrievable plug components
`can bind upon the drill bit, and rotate Within the casing string.
`Such binding can result in extremely long drill-out times,
`excessive casing Wear, or both. Long drill-out times are
`highly undesirable, as rig time is typically charged by the
`hour.
`In use, non-retrievable plugs are designed to perform a
`particular function. A bridge plug, for example, is typically
`used to seal a Wellbore such that ?uid is prevented from
`?oWing from one side of the bridge plug to the other. On the
`other hand, drop ball plugs alloW for the temporary cessation
`of ?uid ?oW in one direction, typically in the doWnhole direc
`tion, While alloWing ?uid ?oW in the other direction. Depend
`ing on user preference, one plug type may be advantageous
`over another, depending on the completion and/ or production
`activity.
`Certain completion and/or production activities may
`require several plugs run in series or several different plug
`types run in series. For example, one Well may require three
`bridge plugs and ?ve drop ball plugs, and another Well may
`require tWo bridge plugs and ten drop ball plugs for similar
`completion and/or production activities. Within a given
`completion and/or production activity, the Well may require
`several hundred plugs and/or packers depending on the pro
`ductivity, depths, and geophysics of each Well. The uncer
`tainty in the types and numbers of plugs that might be
`required typically leads to the over-purchase and/or under
`purchase of the appropriate types and numbers of plugs
`resulting in ?scal ine?iciencies and/or ?eld delays.
`There is a need, therefore, for a doWnhole tool that can
`effectively seal the Wellbore at Wellbore conditions; be
`quickly, easily, and/or reliably removed from the Wellbore;
`and con?gured in the ?eld to perform one or more functions.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`Non-limiting, illustrative embodiments are depicted in the
`draWings, Which are brie?y described beloW. It is to be noted,
`
`20
`
`25
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`2
`hoWever, that these illustrative draWings illustrate only typi
`cal embodiments and are not to be considered limiting of its
`scope, for the invention can admit to other equally effective
`embodiments.
`FIG. 1A depicts a partial section vieW of an illustrative
`insert for use With a plug for doWnhole use, according to one
`or more embodiments described.
`FIG. 1B depicts a partial section vieW of another illustra
`tive embodiment of the insert for use With a plug for doWnhole
`use, according to one or more embodiments described.
`FIG. 2A depicts a partial section vieW of an illustrative plug
`con?gured With the insert of FIG. 1, according to one or more
`embodiments described.
`FIG. 2B depicts a partial section vieW of the illustrative
`plug con?gured With the insert of FIG. 1 and a ?apper valve,
`according to one or more embodiments described.
`FIG. 2C depicts a partial section vieW of another illustra
`tive plug With a loWer shear mechanism disposed directly on
`the plug body, according to one or more embodiments.
`FIG. 3A depicts a partial section vieW of the plug of FIG.
`2A located Within a casing prior to installation, according to
`one or more embodiments described.
`FIG. 3B depicts a partial section vieW of the plug of FIG.
`2B located Within the casing prior to installation, according to
`one or more embodiments described.
`FIG. 3C depicts a partial section vieW of the plug of FIG.
`2A located in an expanded or actuated position Within the
`casing, according to one or more embodiments described.
`FIG. 3D depicts a partial section vieW of the plug of FIG.
`2B located in an expanded or actuated position Within the
`casing, according to one or more embodiments described.
`FIG. 4 depicts a partial section vieW of the expanded plug
`depicted in FIGS. 3C and 3D, according to one or more
`embodiments described.
`FIG. 5 depicts an illustrative, complementary set of angled
`surfaces that function as anti-rotation features to interact and/
`or engage betWeen a ?rst plug and a second plug in series,
`according to one or more embodiments described.
`FIG. 6 depicts an illustrative, dog clutch anti-rotation fea
`ture, alloWing a ?rst plug and a second plug to interact and/or
`engage in series according to one or more embodiments
`described.
`FIG. 7 depicts an illustrative, complementary set of ?ats
`and slots that serve as anti-rotation features to interact and/ or
`engage betWeen a ?rst plug and a second plug in series,
`according to one or more embodiments described.
`FIG. 8 depicts another illustrative, complementary set of
`?ats and slots that serve as anti-rotation features to interact
`and/or engage betWeen a ?rst plug and a second plug in series,
`according to one or more embodiments described.
`
`DETAILED DESCRIPTION
`
`A plug for isolating a Wellbore is provided. The plug can
`include one or more loWer shear or shearable mechanisms for
`connecting to a setting tool. The loWer shear or shearable
`mechanism can be located directly on the body of the plug or
`on a separate component or insert that is placed Within the
`body of the plug. The loWer shear or shearable mechanism is
`adapted to engage a setting tool and release the setting tool
`When exposed to a predetermined stress that is su?icient to
`deform the shearable threads to release the setting tool but is
`less than a stress su?icient to break the plug body. The term
`“stress” and “force” are used interchangeably, and are
`intended to refer to a system of forces that may in include
`axial force, radial force, and/or a combination thereof. The
`terms “shear mechanism” and “shearable mechanism” are
`
`MEGCO Ex. 1003
`
`

`
`US 8,079,413 B2
`
`10
`
`3
`used interchangeably, and are intended to refer to any com
`ponent, part, element, member, or thing that shears or is
`capable of shearing at a predetermined stress that is less than
`the stress required to shear the body of the plug. The term
`“shear” means to fracture, break, or otherwise deform thereby
`releasing tWo or more engaged components, parts, or things
`or thereby partially or fully separating a single component
`into tWo or more components/pieces. The term “plug” refers
`to any tool used to permanently or temporarily isolate one
`Wellbore Zone from another, including any tool With blind
`passages, plugged mandrels, as Well as open passages extend
`ing completely therethrough and passages that are blocked
`With a check valve. Such tools are commonly referred to in the
`art as “bridge plugs,” “frac plugs,” and/or “packers .”And such
`tools can be a single assembly (i.e. one plug) or tWo or more
`assemblies (i.e. tWo or more plugs) disposed Within a Work
`string or otherWise connected thereto that is run into a Well
`bore on a Wireline, slickline, production tubing, coiled tubing
`or any technique knoWn or yet to be discovered in the art.
`FIG. 1A depicts a partial section vieW of an illustrative,
`shearable insert 100 for a plug, according to one or more
`embodiments. The insert 100 can include a body 102 having
`a ?rst or upper end 112 and a second or loWer end 114. A
`passageWay or bore 110 can be completely or at least partially
`formed through the body 102. One or more threads 120 can be
`disposed or formed on an outer surface of the body 102. The
`threads 120 can be disposed on the outer surface of the body
`102 toWard the upper end 112. As discussed in more detail
`beloW With reference to FIGS. 2A-2C and FIGS. 3A-D, the
`threads 120 can be used to secure the insert 100 Within a
`surrounding component, such as another insert 100, setting
`tool, tubing string, plug, or other tool.
`FIG. 1B depicts a partial section vieW of an alternative
`embodiment of the illustrative, shearable insert 100B for a
`plug. The insert 100B can include any combination of fea
`tures of insert 100, and additionally, a ball 150 or other solid
`impediment can seat against either or both ends of the bore
`110 to regulate or check ?uid ?oW therethrough. As depicted
`in FIG. 1B, the body 102 can include a shoulder 155 formed
`in, coupled to, or otherWise provided, Which can be siZed to
`receive the ball 150 and to seal thereWith. Accordingly, the
`ball 150 can seat against the shoulder 155 to restrict ?uid ?oW
`through the bore 110 from beloW the insert 100B. An adapter
`pin 160 can be inserted through the body 102 to cage the ball
`150 or other solid impediment in the bore 110, betWeen the
`pin 160 and the shoulder 155.
`One or more shearable threads 130 can be disposed or
`formed on an inner surface of the body 102. The shearable
`threads 130 can be used to couple the insert 100, 100B to
`another insert 100, 100B, setting tool, tubing string, plug, or
`other tool. The shearable threads 130 canbe located anyWhere
`along the inner surface of the body 1 02, and are not dependent
`on the location of the outer threads 120. For example, the
`location of the shearable threads 130 can be located beneath
`or above the outer threads 120; toWard the ?rst end 112 of the
`insert 100, 100B, as depicted in FIGS. 1 and 1B; and/or
`toWard the second end 114 of the insert 100, 100B.
`Any number of shearable threads 130 can be used. The
`number, pitch, pitch angle, and/or depth of the shearable
`threads 130 can depend, at least in part, on the operating
`conditions of the Wellbore Where the insert 100, 100B Will be
`used. The number, pitch, pitch angle, and/ or depth of the
`shearable threads 130 can also depend, at least in part, on the
`materials of construction of both the insert 100, 100B and the
`component, e.g., another insert 100, 100B, a setting tool,
`another tool, plug, tubing string, etc., to Which the insert 100,
`100B is connected. The number of threads 130, for example,
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`4
`can range from about 2 to about 100, such as about 2 to about
`50; about 3 to about 25; or about 4 to about 10. The number of
`threads 130 can also range from a loW of about 2, 4, or 6 to a
`high of about 7, 12, or 20. The pitch betWeen each thread 130
`can also vary depending on the force required to shear, break,
`or otherWise deform the threads 130. The pitch betWeen each
`thread 13 0 can be the same or different. For example, the pitch
`betWeen each thread 13 0 can vary from about 0.1 mm to about
`200 mm; 0.2 mm to about 150 mm; 0.3 mm to about 100 mm;
`or about 0.1 mm to about 50 mm. The pitch betWeen each
`thread 130 can also range from a loW of about 0.1 mm, 0.2
`mm, or 0.3 mm to a high ofabout 2 mm, 5 mm or 10 mm.
`The shearable threads 130 can be adapted to shear, break,
`or otherWise deform When exposed to a predetermined stress
`or force, releasing the component engaged Within the body
`102. The predetermined stress or force can be less than a
`stress and/ or force required to fracture or break the body 102
`of the insert 1 00, 1 00B. Upon the threads 130 shearing, break
`ing, or deforming, the component engaged Within the body
`102 can be freely removed or separated therefrom.
`Any number of outer threads 120 can be used. The number
`of outer threads 120, for example, can range from about 2 to
`about 100, such as about 2 to about 50; about 3 to about 25; or
`about 4 to about 10. The number of threads 120 can also range
`from a loW of about 2, 4, or 6 to a high of about 7, 12, or 20.
`The pitch betWeen each thread 120 can also vary. The pitch
`betWeen each thread 120 can be the same or different. For
`example, the pitch betWeen each thread 120 can vary from
`about 0.1 mmto about 200 mm; 0.2 mmto about 150 mm; 0.3
`mm to about 100 mm; or about 0.1 mm to about 50 mm. The
`pitch betWeen each thread 120 can also range from a loW of
`about 0.1 mm, 0.2 mm, or 0.3 mm to a high ofabout 2 mm, 5
`mm or 10 mm.
`The threads 120 and the shearable threads 130 can be
`right-handed and/or left-handed threads. For example, to
`facilitate connection of the insert 100, 100B to a setting tool
`When the setting tool is coupled to, for example, screWed into
`the insert 100, 100B, the threads 120 can be right-handed
`threads and the shearable threads 130 can be left-handed
`threads, or vice versa.
`The outer surface of the insert 100, 100B can have a con
`stant diameter, or its diameter can vary, as depicted in FIGS.
`1A and 1B. For example, the outer surface can include a
`smaller ?rst diameter portion or area 140 that transitions to a
`larger, second diameter portion or area 142, forming a ledge
`or shoulder 144 therebetWeen. The shoulder 144 can have a
`?rst end that is substantially ?at, abutting the second diameter
`142, a second end that gradually slopes or transitions to the
`?rst diameter 140, and can be adapted to anchor the insert into
`the plug. The shoulder 144 can be formed adjacent the outer
`threads 120 or spaced apart therefrom, and the outer threads
`120 can be above or beloW the shoulder 144.
`The insert 100, 100B and/or the shearable threads 130 can
`be made of an alloy that includes brass. Suitable brass com
`positions include, but are not limited to, admiralty brass,
`Aich’s alloy, alpha brass, alpha-beta brass, aluminum brass,
`arsenical brass, beta brass, cartridge brass, common brass,
`deZinci?cation resistant brass, gilding metal, high brass,
`leaded brass, lead-free brass, loW brass, manganese brass,
`MuntZ metal, nickel brass, naval brass, Nordic gold, red brass,
`rich loW brass, tonval brass, White brass, yelloW brass, and/or
`any combinations thereof.
`The insert 100, 100B can also be formed or made from
`other metallic materials (such as aluminum, steel, stainless
`steel, copper, nickel, cast iron, galvaniZed or non-galvanized
`metals, etc.), ?berglass, Wood, composite materials (such as
`ceramics, Wood/polymer blends, cloth/polymer blends, etc.),
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`MEGCO Ex. 1003
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`

`
`US 8,079,413 B2
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`5
`and plastics (such as polyethylene, polypropylene, polysty
`rene, polyurethane, polyethylethylketone (PEEK), polytet
`ra?uoroethylene (PTFE), polyamide resins (such as nylon 6
`(N6), nylon 66 (N66)), polyester resins (such as polybutylene
`terephthalate (PBT), polyethylene terephthalate (PET), poly
`ethylene isophthalate (PEI), PET/PEI copolymer) polynitrile
`resins (such as polyacrylonitrile (PAN), polymethacryloni
`trile, acrylonitrile-styrene copolymers (AS), methacryloni
`trile-styrene copolymers, methacrylonitrile-styrene-butadi
`ene copolymers; and acrylonitrile-butadiene-styrene (ABS)),
`polymethacrylate resins (such as polymethyl methacrylate
`and polyethylacrylate), cellulose resins (such as cellulose
`acetate and cellulose acetate butyrate); polyimide resins
`(such as aromatic polyimides), polycarbonates (PC), elas
`tomers (such as ethylene-propylene rubber (EPR), ethylene
`propylene-diene monomer rubber (EPDM), styrenic block
`copolymers (SBC), polyisobutylene (PIB), butyl rubber, neo
`prene rubber, halobutyl rubber and the like)), as Well as mix
`tures, blends, and copolymers of any and all of the foregoing
`materials.
`FIG. 2A depicts a partial section vieW of an illustrative plug
`200 con?gured With the insert 100, 100B and adapted to
`receive a ball type impediment or another type of impedi
`ment, according to one or more embodiments. The plug 200
`can include a mandrel or body 210 having a ?rst or upper end
`207 and a second or loWer end 208. A passageWay or bore 255
`can be formed at least partially through the body 210. The
`body 210 can be a single, monolithic component as shoWn, or
`the body 210 can be or include tWo or more components
`connected, engaged, or otherWise attached together. The body
`210 serves as a centraliZed support member, made of one or
`more components or parts, for one or more outer components
`to be disposed thereon or thereabout.
`The insert 100, 100B can be threaded or otherWise dis
`posed Within the plug 200 at a loWer end 208 ofthe body 210.
`A setting tool, tubing string, plug, or other tool can enter the
`bore 255 through the ?rst end 207 of the body 210 and can be
`threaded to or otherWise coupled to and/or disposed Within
`the insert 100. As further described herein, the shearable
`threads 130 on the insert 100 can be sheared, fractured, or
`otherWise deformed, releasing the setting tool, tubing string,
`plug, or other tool from the plug 200.
`The bore 255 can have a constant diameter throughout, or
`its diameter can vary, as depicted in FIG. 2A. For example, the
`bore 255 can include a larger, ?rst diameter portion or area
`226 that transitions to a smaller, second diameter portion or
`area 227, forming a seat or shoulder 228 therebetWeen. The
`shoulder 228 can have a tapered or sloped surface connecting
`the tWo diameter portions or areas 226, 227. Although not
`shoWn, the shoulder 228 can be ?at or substantially ?at,
`providing a horiZontal or substantially horiZontal surface
`connecting the tWo diameters 226, 227. As Will be explained
`in more detail beloW, the shoulder 228 can serve as a seat or
`receiving surface for plugging off the bore 255 When a ball
`(shoWn in FIG. 3C) or other impediment, such as a ?apper
`member 215 (shoWn in FIGS. 3D), is placed Within the bore
`255.
`At least one conical member (tWo are shoWn: 230, 235), at
`least one slip (tWo are shoWn: 240, 245), and at least one
`malleable element 250 can be disposed about the body 210.
`As used herein, the term “disposed about” means surrounding
`the component, e.g., the body 210, alloWing for relative
`movement therebetWeen (e. g., by sliding, rotating, pivoting,
`or a combination thereof). A ?rst section or second end of the
`conical members 230, 235 has a sloped surface adapted to rest
`underneath a complementary sloped inner surface of the slips
`240, 245. As explained in more detail beloW, the slips 240,
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`6
`245 travel about the surface of the adjacent conical members
`230, 235, thereby expanding radially outWard from the body
`210 to engage an inner surface of a surrounding tubular or
`borehole. A second section or second end of the conical
`members 230, 235 can include tWo or more tapered pedals or
`Wedges adapted to rest about an adjacent malleable element
`250. One or more circumferential voids 236 can be disposed
`Within or betWeen the ?rst and second sections of the conical
`members 230, 235 to facilitate expansion of the Wedges about
`the malleable element 250. The Wedges are adapted to hinge
`or pivot radially outWard and/ or hinge or pivot circumferen
`tially. The groove or void 236 can facilitate such movement.
`The Wedges pivot, rotate, or otherWise extend radially out
`Ward, and can contact an inner diameter of the surrounding
`tubular or borehole. Additional details of the conical mem
`bers 230, 235 are described in Us. Pat. No. 7,762,323.
`The inner surface of each slip 240, 245 can conform to the
`?rst end of the adjacent conical member 230, 235. An outer
`surface of the slips 240, 245 can include at least one out
`Wardly-extending serration or edged tooth to engage an inner
`surface of a surrounding tubular, as the slips 240, 245 move
`radially outWard from the body 210 due to the axial move
`ment across the adjacent conical members 230, 235.
`The slips 240, 245 can be designed to fracture With radial
`stress. The slips 240, 245 can include at least one recessed
`groove 242 milled or otherWise formed therein to fracture
`under stress alloWing the slips 240, 245 to expand outWard
`and engage an inner surface of the surrounding tubular or
`borehole. For example, the slips 240, 245 can include tWo or
`more, for example, four, sloped segments separated by
`equally-spaced recessed grooves 242 to contact the surround
`ing tubular or borehole.
`The malleable element 250 can be disposed betWeen the
`conical members 230, 235. A three element 250 system is
`depicted in FIG. 2A, but any number of elements 250 can be
`used. The malleable element 250 can be constructed of any
`one or more malleable materials capable of expanding and
`sealing an annulus Within the Wellbore. The malleable ele
`ment 250 is preferably constructed of one or more synthetic
`materials capable of Withstanding high temperatures and
`pressures, including temperatures up to 4500 E, and pressure
`differentials up to 15,000 psi. Illustrative materials include
`elastomers, rubbers, TEFLON®, blends and combinations
`thereof.
`The malleable element(s) 250 can have any number of
`con?gurations to effectively seal the annulus de?nedbetWeen
`the body 210 and the Wellbore. For example, the malleable
`element(s) 250 can include one or more grooves, ridges,
`indentations, or protrusions designed to alloW the malleable
`element(s) 250 to conform to variations in the shape of the
`interior of the surrounding tubular or borehole.
`At least one component, ring, or other annular member 280
`for receiving an axial load from a setting tool can be disposed
`about the body 210 adjacent a ?rst end of the slip 240. The
`annular member 280 for receiving the axial load can have ?rst
`and second ends that are substantially ?at. The ?rst end can
`serve as a shoulder adapted to abut a setting tool (not shoWn).
`The second end can abut the slip 240 and transmit axial forces
`therethrough.
`Each end of the plug 200 can be the same or different. Each
`end of the plug 200 can include one or more anti-rotation
`features 270, disposed thereon. Each anti-rotation feature 270
`can be screWed onto, formed thereon, or otherWise connected
`to or positioned about the body 210 so that there is no relative
`motion betWeen the anti-rotation feature 270 and the body
`210. Alternatively, each anti-rotation featu