`
`(12) United States Patent
`(10) Patent No.:
`US 8,459,346 B2
`
`Frazier
`(45) Date of Patent:
`*Jun. 11, 2013
`
`(54) BOTTOM SET DOWNHOLE PLUG
`
`2,160,228 A
`2,286,126 A
`
`5/1939 Pustmueller
`7/1940 Thornhill
`
`(75)
`
`Inventor: W. Lynn Frazier, Corpus Christi, TX
`(US)
`
`2/1941 Basslnger
`22303147 A *
`2,331,532 A * 10/1943 Bassmger
`2,376,605 A
`5/1945 Lawrence
`
`~~~~~~~~~~~~~~~~~~~~~ 166/128
`..................... 166/139
`
`(73) Assignee: Magnum Oil Tools International Ltd,
`corpus Chm“ 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.
`
`GB
`WO
`
`(Continued)
`FOREIGN PATENT DOCUMENTS
`
`914030
`2010127457
`
`12/1962
`11/2010
`
`OTHER PUBLICATIONS
`
`This patent is subject to a terminal dis-
`claimer.
`
`(21) Appl. No.: 13/329,077
`
`(22)
`
`Filed:
`
`Dec. 16, 2011
`
`(65)
`
`Prior Publication Data
`US 2012/0145378 A1
`Jun. 14 2012
`
`Related US. Application Data
`
`“Teledyne Merla Oil T001s-Products-Services,” Teledyne Merla,
`Aug. 1990 (40 Pages).
`
`.
`(Continued)
`
`Primary Examiner 7 Shane Bomar
`Assistant Examiner 7 Robert E Fuller
`(74) Attorney, Agent, or Firm 7 Edmonds & Nolte, P.C.
`
`(63) Continuation of application No. 13/194,871, filed on
`Jul. 29, 2011, now Pat. No. 8,079,413, which is a
`
`(57)
`
`ABSTRACT
`
`5 1
`
`(
`
`)
`
`continuation-in-part 0f application NO- 12/311497:
`filed on Dec. 23: 2008'
`I t Cl
`£1213 3'3/129
`E213 23/06
`(52) U S Cl
`1 66/124. 1 66/135
`USPC '
`’
`(58) Field 0fClass1ficat10n Search......
`USPC
`166/123 124 135 138
`See application file foriicioiniplete search hisfory ’
`.
`
`(2006 01)
`(200601)
`'
`
`(56)
`
`References Cited
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`
`A plug for isolating a wellbore. The plug can include a body
`having a first 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 first 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 ofa setting tool that enters
`the body through the first 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.
`
`38 Claims, 7 Drawing Sheets
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`MOTI Ex. [2001] p. 1
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`
`
`US 8,459,346 B2
`
`Page2
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`MOTI Ex. [2001] p. 2
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`MOTI Ex. [2001] p. 2
`
`
`
`US 8,459,346 B2
`
`Page 3
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`
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`
`MOTI EX. [2001] p. 3
`
`B2
`B2
`B2
`B2
`B2
`B2
`B2
`B2
`
`B2
`B2
`B2
`B2
`B2
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`
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`
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`B2
`B1
`S
`
`7,055,632
`7,069,997
`7,107,875
`7,124,831
`7,128,091
`7,150,131
`7,168,494
`7,281,584
`D560,109
`7,325,617
`7,337,847
`7,350,582
`7,353,879
`7,363,967
`7,373,973
`7,428,922
`7,527,104
`7,552,779
`D597,110
`7,600,572
`7,604,058
`7,637,326
`7,644,767
`7,644,774
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`7,673,677
`7,690,436
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`7,735,549
`7,740,079
`7,775,286
`7,775,291
`7,784,550
`7,798,236
`7,810,558
`D629,820
`7,866,396
`7,878,242
`7,886,830
`7,900,696
`7,909,108
`7,909,109
`D635,429
`7,918,278
`7,921,923
`7,921,925
`7,926,571
`8,074,718
`8,079,413
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`8,127,856
`D657,807
`
`MOTI Ex. [2001] p. 3
`
`
`
`US. Patent
`
`Jun. 11,2013
`
`Sheet 1 of7
`
`US 8,459,346 B2
`
`100 \‘
`
`140
`
`144
`
`142
`
`
`
`FIG. 1A
`
`114
`
`110
`
`
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`
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`210
`
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`295
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`225
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`FIG. 18
`
`FIG. 2A
`
`MOTI Ex. [2001] p. 4
`
`MOTI Ex. [2001] p. 4
`
`
`
`US. Patent
`
`Jun. 11,2013
`
`Sheet 2 of 7
`
`US 8,459,346 B2
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`200
`
`255
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`255
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`MOTI EX. [2001] p. 5
`
`MOTI Ex. [2001] p. 5
`
`
`
`US. Patent
`
`Jun. 11,2013
`
`Sheet 3 of7
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`US 8,459,346 B2
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`
`MOTI EX. [2001] p. 6
`
`MOTI Ex. [2001] p. 6
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`U.S. Patent
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`Jun. 11, 2013
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`Sheet 4 of 7
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`US 8,459,346 B2
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`200
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`MOTI Ex. [2001] p. 7
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`MOTI Ex. [2001] p. 7
`
`
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`
`MOTI Ex. [2001] p. 8
`
`
`
`US. Patent
`
`Jun. 11,2013
`
`Sheet 6 of7
`
`US 8,459,346 B2
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`
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`
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`FIG.6
`
`
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` FIG.5
`
`MOTI EX. [2001] p. 9
`
`MOTI Ex. [2001] p. 9
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`
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`U.S. Patent
`
`Jun. 11, 2013
`
`Sheet 7 of 7
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`US 8,459,346 B2
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`MOTI Ex. [2001] p. 10
`
`MOTI Ex. [2001] p. 10
`
`
`
`
`1
`BOTTOM SET DOWNHOLE PLUG
`
`CROSS-REFERENCE TO RELATED
`APPLICATIONS
`
`This application is continuation of US. patent application
`having Ser. No. 13/194,871, which is a continuation-in-part
`of US. patent application having Ser. No. 12/317,497, filed
`Dec. 23, 2008, the entirety of which is incorporated by refer-
`ence 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 fluid
`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 fluid is prevented from
`flowing from one side of the bridge plug to the other. On the
`other hand, drop ball plugs allow for the temporary cessation
`of fluid flow in one direction, typically in the downhole direc-
`tion, while allowing fluid flow 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 five 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 fiscal inefliciencies and/or field delays.
`There is a need, therefore, for a downhole tool that can
`effectively seal
`the wellbore at wellbore conditions; be
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`US 8,459,346 B2
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`quickly, easily, and/or reliably removed from the wellbore;
`and configured in the field to perform one or more functions.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`Non-limiting, illustrative embodiments are depicted in the
`drawings, which are briefly described below. It is to be noted,
`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 ofthe insert for use with a plug for downhole
`use, according to one or more embodiments described.
`FIG. 2A depicts a partial section view ofan illustrative plug
`configured with the insert of FIG. 1, according to one or more
`embodiments described.
`
`FIG. 2B depicts a partial section view of the illustrative
`plug configured with the insert of FIG. 1 and a flapper 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 first 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 first 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 flats
`and slots that serve as anti-rotation features to interact and/or
`
`engage between a first plug and a second plug in series,
`according to one or more embodiments described.
`FIG. 8 depicts another illustrative, complementary set of
`flats and slots that serve as anti-rotation features to interact
`
`and/or engage between a first 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
`
`MOTI Ex. [2001] p. 11
`
`MOTI Ex. [2001] p. 11
`
`
`
`US 8,459,346 B2
`
`3
`when exposed to a predetermined stress that is sufficient to
`deform the shearable threads to release the setting tool but is
`less than a stress sufficient 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
`
`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 first 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 fluid flow 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 fluid flow
`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 ofthe 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 first 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
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`4
`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 ofboth 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,
`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
`ofthe 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 ofthreads 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
`
`to
`right-handed and/or left-handed threads. For example,
`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 first 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
`
`first end that is substantially flat, abutting the second diameter
`142, a second end that gradually slopes or transitions to the
`first 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,
`dezincification resistant brass, gilding metal, high brass,
`leaded brass, lead-free brass, low brass, manganese brass,
`
`MOTI Ex. [2001] p. 12
`
`MOTI Ex. [2001] p. 12
`
`
`
`US 8,459,346 B2
`
`5
`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.), fiberglass, wood, composite materials (such as
`ceramics, wood/polymer blends, cloth/polymer blends, etc.),
`and plastics (such as polyethylene, polypropylene, polysty-
`rene, polyurethane, polyethylethylketone (PEEK), polytet-
`rafluoroethylene (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 (AB8)),
`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 ofan illustrative plug
`200 configured 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 first 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 first end 207 ofthe 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, first 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 flat or substantially flat,
`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 flapper
`member 215 (shown in FIG. 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
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`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 first section or second end ofthe
`conical members 230, 235 has a sloped surface adapted to rest
`underneath a complementary sloped inner surface ofthe slips
`240, 245. As explained in more detail below, the slips 240,
`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 firs