U.S. patent application number 11/644443 was filed with the patent office on 2007-07-05 for deformable release device for use with downhole tools.
Invention is credited to Douglas J. Lehr, Gabriel A. Slup, James Van Lue.
Application Number | 20070151722 11/644443 |
Document ID | / |
Family ID | 38068726 |
Filed Date | 2007-07-05 |
United States Patent
Application |
20070151722 |
Kind Code |
A1 |
Lehr; Douglas J. ; et
al. |
July 5, 2007 |
Deformable release device for use with downhole tools
Abstract
A deformable release device is disclosed to be used with
downhole setting tools. The deformable release device may provide a
releasable detachment to any customary setting tool, such as
electric line, hydraulic, hydrostatic, and mechanical setting
tools, used to set a downhole packer-type device. The deformable
release device allows for the automatic release of downhole setting
tools at the application a predetermined force, similar to a shear
pin or shear stud. However, since the deformable release device
deforms rather than shears or breaks, the releasing device
minimizes the debris or remnants of the device left in the
wellbore.
Inventors: |
Lehr; Douglas J.; (The
Woodlands, TX) ; Slup; Gabriel A.; (Spring, TX)
; Van Lue; James; (Tomball, TX) |
Correspondence
Address: |
HOWREY LLP
C/O IP DOCKETING DEPARTMENT
2941 FAIRVIEW PARK DRIVE, SUITE 200
FALLS CHURCH
VA
22042-7195
US
|
Family ID: |
38068726 |
Appl. No.: |
11/644443 |
Filed: |
December 22, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60755358 |
Dec 30, 2005 |
|
|
|
Current U.S.
Class: |
166/123 ;
166/181; 166/387 |
Current CPC
Class: |
E21B 23/06 20130101 |
Class at
Publication: |
166/123 ;
166/181; 166/387 |
International
Class: |
E21B 33/129 20060101
E21B033/129 |
Claims
1. A system for selectively releasing from a set downhole tool
having an inner diameter, the system comprising: a deformable
device having an opening, the deformable device being connected
with the downhole tool; a stinger having an upper end and a lower
end; a plunger on the lower end of the stinger, wherein a portion
of the plunger is larger than the opening in the deformable device;
wherein the deformable device selectively retains the portion of
the plunger functionally associated the stinger and plunger with
the set downhole tool; and wherein the deformable device deforms
under a predetermined load releasing the portion of the
plunger.
2. The system of claim 1 wherein the stinger is connected to a
setting tool or a running tool.
3. The system of claim 2 wherein the stinger is threadably
connected to the setting tool or the running tool.
4. The system of claim 3 further comprising a spring position
between the stinger and the setting tool or the running tool.
5. The system of claim 1 wherein the opening in the deformable
device is circular.
6. The system of claim 1 wherein the deformable device is a
circular plate.
7. The system of claim 1 wherein the deformable device includes a
bevel adjacent the opening.
8. The system of claim 1 wherein the deformable device includes at
least one slot extending from the opening in the deformable
device.
9. The system of claim 8 wherein the deformable device includes at
least four slots extending from the opening in the deformable
device.
10. The system of claim 1 further comprising a bumper, the bumper
being connected to the plunger.
11. The system of claim 10 wherein the bumper is nylon.
12. The system of claim 1 wherein the deformable device is
connected to a mandrel of the downhole tool.
13. The system of claim 1 wherein the opening in the deformable
device is non-circular.
14. The system of claim 1 wherein the deformable device is a
non-circular plate.
15. The system of claim 1 wherein the deformable device is
metal.
16. A system for selectively releasing from a downhole tool, the
system comprising: a deformable device having an opening, the
deformable device being connected to the downhole tool; and a
member having a first end and a second end, the first end being
connected to a second tool and the second end being retained by the
deformable device, wherein the deformable device deforms under a
predetermined load releasing the second end of the member.
17. The system of claim 16 the member including a protrusion,
wherein the protrusion is larger than the opening in the deformable
device.
18. The system of claim 17 wherein the deformable device deforms to
allow the protrusion to pass through the deformable device.
19. The system of claim 18 wherein the protrusion has a leading
edge and a trailing edge, wherein the trailing edge is tapered.
20. A method of setting a downhole tool, the method comprising:
connecting a deformable device to a mandrel of the downhole tool,
the deformable device including an opening; preventing a portion of
a plunger from passing through the opening of the deformable
device, the plunger being connected to a lower end a stinger;
applying a force on a setting tool, the setting tool being
connected to an upper end of the stinger, wherein the deformable
device prevents movement of the setting tool; and increasing the
force on the setting tool to a predetermined force, wherein the
deformable device deforms; and releasing the running tool from the
downhole tool.
21. The method of claim 20 wherein the downhole tool is a packer
assembly.
22. An apparatus of selectively releasing a setting tool from a
downhole assembly, the apparatus comprising: a stinger having an
upper end and a lower end, the stinger positioned within a bore of
the downhole assembly; a plunger having an upper end and a lower
end also positioned within the bore of the downhole assembly, the
upper end of the plunger being connected to the lower end of the
stinger; means for connecting the upper end of the stinger to the
setting tool; means for preventing upward movement of the plunger
with respect to the downhole assembly, wherein the means for
preventing upward movement is connected to the downhole assembly;
and means for allowing upward movement of the plunger with respect
to the downhole assembly upon the application of a predetermined
force on the setting tool, wherein the means for preventing upward
movement remains connected to the downhole assembly.
23. The apparatus of claim 22 further comprising means for
preventing the accidental detachment of the stinger from the
setting tool.
24. The apparatus of claim 22 further comprising means for
preventing the accidental detachment of the plunger from the
stinger.
25. The apparatus of claim 22 further comprising means for
minimizing damage to downhole components, wherein the means for
minimizing damage is connected to the lower end of the plunger.
26. An apparatus for releasing a downhole tool having an inner
diameter, comprising: a stinger passing through the inner diameter
of the downhole tool; a plunger functionally associated with the
stinger; a deformable device on a lower end of the downhole tool,
the deformable device having an inner diameter less than the inner
diameter of the downhole tool; the plunger having a protruding
section with a diameter greater than the inner diameter of the
deformable device, wherein the diameter of the protruding section
is less than the inner diameter of the downhole tool; and wherein
when a predetermined upward force is applied on the stinger, the
protruding section of the plunger deforms the deformable device to
allow the stinger and plunger to pass upwardly through the diameter
of the downhole tool.
27. The apparatus of claim 26 wherein the plunger is an integral
part of the stinger.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a Non-provisional application claiming
benefit of U.S. Provisional Application Ser. No. 60/755,358,
entitled, "Deformable Release Device for Use with Downhole Tools,"
by Douglas J. Lehr, Gabriel A. Slup, and James Van Lue, filed Dec.
30, 2005, hereby incorporated by reference in its entirety
herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to a release device
that may be used with downhole setting tools. Specifically, the
release device of the present disclosure deforms to provide a
releasable detachment mechanism for a setting tool used to set a
downhole tool, such as a Python Frac Plug from BJ Services Company
of Houston, Tex. A deformable release device may provide a
releasable detachment to any customary setting tool used to set a
downhole packer-type device, for example. As would be appreciated
by one of ordinary skill in the art having the benefit of this
disclosure, customary setting tools include electric line,
hydraulic, hydrostatic, and mechanical setting tools or other
setting tool designs that use a combination of these methods for
actuating a packer-type device in a subterranean well.
[0004] 2. Description of the Related Art
[0005] Many types, sizes, brands and models of packer devices are
used to isolate a portion of a well bore. Each type of packer is
run into the wellbore and then set. Typically a setting tool is
used to run and set the packer. A number of different setting tools
used to run and set a packer are available, but typically the lower
end of the setting tool has different dimensions than the packer.
Thus, regardless of the type of packer and setting tool used, an
"adapter kit" is used to adapt the setting tool to the packer. The
adapter kit also enables the detachment of the setting tool from
the packer once the packer is set in the wellbore. Hence adapter
kits are intermediate devices, inserted between the setting tool
and the packer, which adapt the connection between the setting tool
and the packer and allow for the detachment of the two after the
packer is set.
[0006] Many different methods can be used to convey the setting
tool, adapter kit, and packer device into a wellbore, to set the
packer, and to detach the setting tool and adapter kit from the
packer. One method may use jointed pipe, whereas other methods may
use coiled tubing, wireline, or slick line, for example. The method
selected to run and set the packer depends on a number of
variables, such as time constraints, costs, deviation of the
wellbore, or which part of the servicing cycle the well is in. Due
to the number of methods to run and set a packer, many different
adapter kits are utilized in the oil and gas industry, such as
mechanical, hydraulic, or wireline adapter kits.
[0007] One such adapter kit, a wireline adapter kit ("WLAK"), is
used to temporarily adapt or connect a wireline setting tool to a
wireline packer device and also to enable the disengagement of the
setting tool from the packer. An adapter kit used with a mechanical
setting tool might utilize a simple coarse screw thread, such as an
acme thread running around the perimeter of the lower end of the
adapter kit, to connect the setting tool to the packer. The packer
has mating threads to engage the threads of the adapter kit. The
relatively simple coarse screw thread also allows the setting tool
to be rotationally disengaged from the packer device once the
packer device has been set. However, in some situations, such as in
horizontal wells, it can be relatively difficult to rotate the
setting tool and adapter kit.
[0008] Another means for disengaging the adapter kit from the
packer device is a design that includes a portion of the connection
adapted to release when subjected to a predetermined mechanical
load. Designs that release under a predetermined mechanical load
may be designed to release either automatically or manually. An
automatic release occurs during the setting sequence, once the
packer/adapter kit connection is subjected to a load above a
predetermined limit. A manual release requires the application of
the predetermined load to the adapter kit after the setting
sequence. Examples of a manual release are rotational releases, as
described above, or merely pulling tension into the adapter
kit.
[0009] One type of adapter kit that automatically releases under a
mechanical load is a wireline adapter kit. The release of a
wireline setting tool adapter kit may be accomplished by
mechanically failing a component of the adapter kit such as a
"release stud," shear screw(s), a shear ring, or shear pin(s) with
a known amount of force. Such components fail with the application
of a predetermined amount of a tensile or axial force. The Baker
Model B WLAK is an example of an adapter kit that uses a device,
specifically a release stud, that automatically fails with a known
axial force, which in one size is approximately 33,000 lbs, when
applied to the adapter kit.
[0010] One potential problem with using release devices that fail
under a designated mechanical force, such as a release stud or
shear pin, is that debris from the release device remains in the
well bore after the device has released. This debris can accumulate
on top of packing elements. Additionally, the debris may accumulate
on or in a moving part of a downhole tool possibly causing the
downhole tool to malfunction. A malfunction of the downhole tool
increases the normal operating costs of the well. Further, the
downhole tool or packer may need to be removed from the wellbore to
clear the debris, to correct a malfunction, or to replace the
downhole tool or packer itself due to a malfunction.
[0011] Another disadvantage of using shear pins, or other
mechanically failing devices, is that a hole for the insertion of a
shear screw or shear pin is typically drilled in a component, such
as the packer. The drilling of a hole into the packer may weaken
the overall strength of the packer, especially if the hole is
drilled into a brittle material such as cast iron, possibly leading
to premature failure of the component.
[0012] Other adapter kits and mechanical release devices are
generally rather complex in design. This complexity increases the
manufacturing and assembly costs for the system. Generally,
mechanical release devices that release by failing a mechanical
component, such as shear screws, leave remnants of those components
in the wellbore, as discussed above. A build up of these remnants
in the wellbore may require the milling out or drilling out of the
wellbore, which adds to the cost of production and leads to delays
in production from the well.
[0013] In light of the foregoing, it would be desirable to provide
a release device for an adapter kit that does not leave remnants or
debris in the wellbore. Additionally, it would be desirable to
provide a release device for an adapter kit that reduces the need
to drill holes into the packer assembly and the adapter kit. It
would also be desirable to provide a release device that simplifies
the manufacturing of the adapter kit as well as the assembly of the
adapter kit and packing assembly, thus reducing costs. It would
further be desirable to provide a release device that decreases
well servicing time, such as drilling out downhole debris.
[0014] The present invention is directed to overcoming, or at least
reducing the effects of, one or more of the issues set forth
above.
SUMMARY OF THE INVENTION
[0015] The present application discloses a deformable release
device for use in releasing a downhole tool after setting a
wellbore plug. The deformable release device is designed to
minimize the likelihood of breaking or shearing release components,
thus minimizing debris in the wellbore. The deformable release
device may deform to release a downhole tool connection. In one
embodiment, the deformable release device may be a circular plate
having a central circular opening. The deformable release device
may be metallic, but may be comprised of any material that
sufficiently deforms under a designated axial load as would be
recognized by one of ordinary skill in the art having the benefit
of this disclosure. Likewise, the geometrical shape of the
deformable release device may be one of a various shapes as would
be appreciated by one of ordinary skill in the art having the
benefit of this disclosure.
[0016] The deformable release device may be connected to the lower
end of the mandrel of a packer assembly. An opening of the
deformable releasing device may enclose a central portion of a
plunger that may be connected to a release stinger. The release
stinger may be connected to a setting tool. The plunger may be
substantially circular in cross-section and include an upper
portion and a lower portion. The outer diameter of the upper
portion of the plunger may be smaller than the diameter of the
central opening of the deformable release device. The outer
diameter of the lower portion of the may be larger than the
diameter of the central opening of the deformable release device.
The deformable release device may be adapted to pass the lower
portion of the plunger with the application of a known axial
force.
[0017] In one embodiment, a deformable release device having an
opening may be located substantially at the bottom of a downhole
tool mandrel, and may be located between a release stinger and a
plunger. When a requisite upward axial force is applied to the
release stinger, the plunger may be pulled through the deformable
release device deforming the opening of the deformable release
device. By modifying the material, thickness, and other dimensions
of the deformable release device and the plunger, the force
required for the plunger to pull through the deformable release
device can be predetermined. The force required to deform the
deformable release device is resisted by the downhole tool, and is
thereby converted into the setting force.
[0018] In one embodiment, the deformable release device may enable
the automatic disengagement of the setting tool from the plug.
Specifically, once the requisite axial upward force is applied to
the release stinger, the plunger is pulled through the deformable
release device. Alternatively, the deformable release device may be
used in a manual detachment of the setting tool, such as in a
mechanical adapter kit to set a cast iron bridge plug run into the
wellbore with a mechanical setting tool on jointed pipe. The
deformable release device could also be used in a wireline adapter
kit for setting permanent packers using a wireline pressure setting
assembly such as a Baker Model E-4. However, the deformable release
device of the present disclosure may be used with various adapter
kits, setting tools, and downhole assemblies as would be recognized
by one of ordinary skill in the art having the benefit of this
disclosure.
[0019] In one embodiment, the deformable release device is used
with a wireline adapter kit that includes an adapter sleeve and a
release stinger used to connect a setting tool to a downhole tool.
The adapter sleeve may be threaded onto the wireline pressure
setting assembly and extend down to the plug assembly. One end of
the release stinger may be threaded onto the downhole end of the
wireline pressure setting assembly. A torsional spring may prevent
the release stinger from unintentionally unthreading from the
wireline pressure setting assembly. A plunger may be threaded onto
the downhole end of the release stringer. A coiled spring may
retain the plunger against the release stinger. During the process
of setting the plug, the release stinger and the plunger pull up on
the deformable release device connected to the bottom of mandrel of
the downhole tool. Pins may secure the deformable release device to
the mandrel. Once the upward force reaches the deformation strength
of the deformable release device, the plunger is pulled through the
deformable release device, thus deforming the opening of the
deformable release device and releasing the adapter kit and setting
tool from the downhole tool.
[0020] In one embodiment of the present disclosure the upper end of
the plunger is adapted to connect to a release stinger. The upper
end of the plunger may be adapted to fit through an opening of the
deformable release device. The lower end of the plunger may be
larger than the diameter of the deformable release device opening.
Additionally, the plunger may include a protrusion positioned lower
than the deformable release device that has a larger outer diameter
than the diameter of the opening. Alternatively, the cross-section
of the plunger and the deformable release device opening may be
non-circular as would be recognized by one of ordinary skill in the
art having the benefit of this disclosure.
[0021] In one embodiment, a bumper may be connectable to the bottom
of the plunger. As would be appreciated by one of ordinary skill in
the art having the benefit of this disclosure, after the plunger is
pulled through the deformable release device there may be a
tendency for the wireline adapter kit to bounce up and down due to
the large force exerted on the assembly, which was previously
countered by the deformable release device. Thus, the bumper may be
comprised of any material, such as nylon, that would minimize
damage of downhole components due to the impact of the bumper as
the wireline adapter kit bounces up and down in the wellbore as
would be appreciated by one of ordinary skill in the art having the
benefit of this disclosure.
[0022] As discussed above, the material, thickness, and other
dimensions of the deformable release device and the plunger can be
used to determine the amount of upward force required to pull the
plunger through the deformable release device. Generally the
setting force for a plug or packer is known. The upward force
required to deform the deformable release device can be set above
the requisite setting force by adapting the material, thickness,
and geometry of the deformable release device and plunger. In one
embodiment, the deformable release device may be relatively flat
and may be generally circular having a circular, central opening.
Alternatively, the deformable release device may be generally
circular in shape, but the central portion of the device may be
beveled and include a centrally located circular opening. The
beveled portion may reduce the force needed to deform the
deformable release device. Other configurations may provide the
desired function as would be realized by those of skill in the art
having the benefit of this disclosure.
[0023] In one embodiment, the shape of the central opening in the
deformable release device may be adapted to reduce the requisite
deforming force as well as to control the deformation of the
deformable release device. For example, two slots connected to the
central opening may be cut into the deformable release device. The
location of the slots can be adapted to control the deformation of
the deformable release device. For example, the slots may be placed
at the top and bottom of the opening along the vertical axis of the
opening encouraging the deformable release device to deform and
separate circumferentially. In another embodiment, four slots
connected to the central opening may be cut into the deformable
release device. The slots may be located along the vertical axis
and the horizontal axis of the deformable release device. The
shape, number, and location of the slots connected to the opening
of the deformable release device could be modified to better
control the deformation force caused by the plunger as would be
recognized by one of ordinary skill in the art having the benefit
of this disclosure.
[0024] In one embodiment, an apparatus is disclosed for selectively
releasing a setting tool from a downhole assembly. The apparatus
may include means, such as an adapter kit, to connect a stinger to
the setting tool. The lower end of the stinger may be connected to
a plunger. The apparatus may include means for preventing upwards
movement of the plunger with respect to the downhole assembly, such
as a deformable device connected to the downhole assembly. The
deformable device may be located between the stinger and the
plunger preventing the movement of the stinger and the plunger.
Alternatively, a portion of the plunger may be sized to prevent the
passage of the plunger through a central opening in the deformable
device. The stinger and the plunger may be integral or the stinger
may include a portion larger than the central opening of the
deformable device as would be appreciated by one of ordinary skill
in the art having the benefit of this disclosure. The apparatus may
further include means, such as deforming the deformable device,
that allows the movement of the plunger with respect to the
downhole assembly. Because the deformable device deforms rather
than shears or breaks it may remain connected to the downhole
assembly rather than falling into the wellbore. The apparatus may
further include means, such as a torsional spring, for preventing
the accidental detachment of the stinger from the setting tool or
the plunger from the stinger. The apparatus may further include
means for minimizing damage to downhole components due to the
bouncing of the setting tool, the stinger, and the plunger after
being released from the downhole assembly. The means for minimizing
damage may be a nylon bumper connected to the bottom of the
plunger, for example.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 shows a cross-section of a setting tool, adapter kit,
and packer wherein the packer is retained on the adapter kit by the
deformable release device of the present disclosure.
[0026] FIG. 2 shows the cross-section of one embodiment of the
plunger of the present disclosure.
[0027] FIG. 3A is the cross-section of one embodiment of the
present disclosure of a deformable release device prior to
deformation and corresponding plunger prior.
[0028] FIG. 3B is the cross-section of one embodiment of the
present disclosure of a deformable release device prior to
deformation and corresponding plunger having a beveled portion that
deforms the deformable release device.
[0029] FIG. 3C is the cross-section of one embodiment of the
present disclosure of a deformable release device prior to
deformation having a beveled portion that deforms and corresponding
plunger having a beveled portion that deforms the deformable
release device.
[0030] FIGS. 4A-4C show one embodiment of the deformable release
device of the present disclosure in use with an adapter kit and
plug assembly. Specifically, FIG. 4A shows the assembly being run
into the wellbore, FIG. 4B shows the assembly as the plug is set
against the well bore, and FIG. 4C shows the removal of the adapter
kit is removed from the well bore after the deformable release
device has been deformed releasing the adapter kit.
[0031] FIG. 5 is the top view of one embodiment of the present
disclosure of a deformable release device.
[0032] FIG. 6 is the top view of one embodiment of the present
disclosure of a deformable release device having longitudinal slots
in addition to a central opening.
[0033] FIG. 7 is the top view of one embodiment of the present
disclosure of a deformable release device having longitudinal and
horizontal slots in addition to a central opening.
[0034] FIGS. 8A-8F and 9A-9J show the cross-section and top view of
various embodiments of the deformable release device of the present
disclosure.
[0035] While the invention is susceptible to various modifications
and alternative forms, specific embodiments have been shown by way
of example in the drawings and will be described in detail herein.
However, it should be understood that the invention is not intended
to be limited to the particular forms disclosed. Rather, the
intention is to cover all modifications, equivalents and
alternatives falling within the spirit and scope of the invention
as defined by the appended claims.
DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0036] Illustrative embodiments of the invention are described
below as they might be employed in the use of designs for
deformable release devices to be used with downhole setting tools.
In the interest of clarity, not all features of an actual
implementation are described in this specification. It will of
course be appreciated that in the development of any such actual
embodiment, numerous implementation-specific decisions must be made
to achieve the developers' specific goals, such as compliance with
system-related and business-related constraints, which will vary
from one implementation to another. Moreover, it will be
appreciated that such a development effort might be complex and
time-consuming, but would nevertheless be a routine undertaking for
those of ordinary skill in the art having the benefit of this
disclosure.
[0037] Further aspects and advantages of the various embodiments of
the invention will become apparent from consideration of the
following description and drawings.
[0038] FIG. 1 shows a wireline pressure setting assembly 10,
specifically a 10 E-4 wireline pressure assembly as commercially
offered by Baker Hughes, Inc. of 3900 Essex Lane, Houston, Tex.
Although shown in use with a BJ Services Company wireline adapter
kit 20 and a wireline pressure setting assembly 10 from Baker
Hughes, Inc., the deformable release device 30 of the present
disclosure may be used with various adapter kits and setting tools
as would be recognized by one of ordinary skill in the art.
[0039] The wireline adapter kit 20 of FIG. 1 includes an adapter
sleeve 40 and a release stinger 50. The adapter sleeve 40 is
threaded onto the wireline pressure setting assembly 10 and extends
down to the packer assembly 70, such as a Python Frac Plug Assembly
offered by BJ Services Company of Houston, Tex. One end of the
release stinger 50 is threaded onto the downhole end of the
wireline pressure setting assembly 10. A torsional spring 60
prevents the release stinger 50 from accidentally unthreading from
the wireline pressure setting assembly 10 due to vibrations or load
cycling exerted on the release stinger 50. A plunger 80 is threaded
onto the downhole end of the release stringer 50. A coiled spring
90 prevents the plunger 80 from unintentionally unthreading from
the release stinger 50 due to vibrations or cyclic loading. A
bumper 100 is attached to the end of the plunger 80.
[0040] The packer assembly 70 includes an upper cap 71, an upper
slip 72, an upper cone 73, an elastomeric packing element .74, a
lower cone 75, a lower slip 76, a lower cap 77, and a mandrel 78.
The mandrel 78, which is wrapped around a brass core 79, provides
the general support for each of the components of the packer
assembly 70. The present invention is adapted to be used with
various types of packer assemblies. For the purposes of
illustration, a packer assembly 70 will be described herein.
However, other packer assemblies could be set and used with the
release device of this disclosure as would be appreciated by one of
ordinary skill in the art.
[0041] To set the packer assembly 70, a downward force is applied
to the packer assembly 70 causing the upper slip 72 to move up the
upper cone 73. As the upper slip 72 traverse the upper cone 73, the
tapered shape of the upper cone 73 moves the upper slip 72 outward
and the upper slip 72 engages the casing wall, thus locking the
packer assembly 70 in place within the well. Once the packer
assembly 70 is locked within the well, the upward force moves the
lower portion of the packer assembly 70 (i.e., lower cap 77, lower
cone 75, and lower slip 76) upward toward the upper portion of the
packer assembly 70. Because the upper portion is anchored against
the wall of the casing, the movement of the lower portion axially
compresses the elastomeric packing element 74.
[0042] Further application of the axial force compresses the
elastomeric packing element 74, driving the packing element 74
outwardly to contact and seal against the wellbore. The axial
compression of the elastomeric packing element 74 causes the
packing element 74 to expand radially against the well casing
creating a sealing barrier that isolates a portion of the well.
Once the elastomeric packing element 74 has been compressed and
radially expanded, the upward force causes the lower slip 76 to
traverse the lower cone 75.
[0043] The tapered shape of the lower cone 75 moves the lower slip
76 outward until it engages the well casing, thus locking the lower
portion of the packer assembly 70 in place within the well. The
downward force applied to set the packer assembly 70 causes an
upward force on the release stinger 50, which is held in place by
the deformable release device 30 resting on the protruding section
83 of the plunger 80. The plunger 80 is attached to the lower end
of the release stinger 50.
[0044] During the process of setting the plug, a deformable release
device 30 retains the packer assembly 70 on the release stinger 50.
The deformable release device 30 contacts the protruding section 83
of the plunger 80, which is attached to the lower end of the
release stinger 50. Pins 31 secure the deformable release device 30
to the mandrel 78 of the packer assembly 70. As described above,
the force applied by the setting tool causes an upward force on the
release stinger 50. The release stinger 50 is held in place by the
deformable release device until the upward force becomes greater
than the force required to deform the deformable release device.
Once the force exceeds this amount, the plunger 80 is pulled
through the deformable release device 30, which deforms the
deformable release device 30. The deformation of the release device
30 allows for the automatic release of the setting tool 10 and
adapter kit 20 without any debris falling into the wellbore.
Although the deformable release device 30 is shown in use with a
wireline adapter kit 20 and a packer assembly 70, the deformable
release device may be used with various adapter kits and plugs or
packers or various downhole tool assemblies as would be appreciated
by one of ordinary skill in the art having the benefit of this
disclosure.
[0045] As shown in FIG. 1, a bumper 100 may be attached to the
bottom of the plunger 80. The purpose of the bumper 100 is to
minimize damage to the downhole components after the plunger 80 has
been pulled through the deformable release device 30. Once the
plunger 80 is pulled through the deformable release device 30 there
may be a tendency for the assembly of the setting tool 10 and the
wireline adapter kit 20 to bounce up and down due to the large
force that has been exerted to set the plug assembly and pull the
plunger through the deformable release device. The force was
previously countered by the deformable release device 30, but once
the release device 30 deforms the force may cause the wireline
adapter kit 20 to bounce up and down. The bumper 100 may be
comprised of nylon to minimize damage to the downhole components
that the bottom of the assembly may strike. The bumper could be
comprised of any material that would minimize damage due to impact
as would be appreciated by one of ordinary skill in the art having
the benefit of this disclosure.
[0046] FIG. 2 shows the cross-section of the plunger 80 of one
embodiment of the present disclosure. One end 81 of the plunger 80
is adapted to connect to a release stinger. The end 81 of the
plunger 80 is also sized to fit through the opening of the
deformable release device. The plunger 80 may include a protruding
portion 83 that has larger outer diameter than the diameter of the
opening of the deformable release device. Alternatively the outer
perimeter of the entire downhole portion 82 of plunger 80 may be
larger than the opening in the deformable release device 30. The
downhole portion 82 of the plunger includes a structure 84 adapted
to retain a bumper 100.
[0047] The protruding portion 83 of the plunger 80 may have a
leading edge 85 adapted to deform the deformable release device 30.
For example, the leading edge 85 may extend upward from the upper
portion 81 of the plunger at 100 degrees. As would be appreciated
by one of ordinary skill in the art, increasing the angle between
the leading edge 85 and the upper portion 81 would decrease the
initial deformation by the plunger. The outer diameter of the
plunger 80, at is greatest width, may determine whether the plunger
deforms the deformable release device 30 and to what extent the
release device 30 is deformed. The trailing edge 86 of the
protruding portion 83 may be tapered to enable passage of the
plunger 80 through the deformable release device 30 after
deformation. For example, the trailing edge 86 may be tapered away
from the protrusion at 135 degrees. The geometry depicted in FIG. 2
is only one embodiment of a plunger. However, a plunger of various
geometries may be used to deform a deformable release device to
release a downhole tool as would be appreciated by one of ordinary
skill in the art having the benefit of this disclosure.
[0048] FIG. 3A shows a cross-section of a deformable release device
30 and plunger 80 of one embodiment of the present disclosure prior
to the deformation of the deformable release device 30. The
deformable release device 30 may be circular in shape and fairly
flat with a circular opening centrally located. The deformable
release device 30 is retained against the mandrel 78 by retaining
pins 31. The plunger 80 may be circular with an uphole portion 81
that is connected to the release stinger 50 and that is sized to
fit through a central opening of the deformable release device 30.
The remaining portion 82 of the plunger 80 may have an outer
diameter larger than the central opening of the deformable release
device 30. When an upward force large enough to deform the release
device 30 is applied to the plunger 80, the plunger is pulled
through the deformable release device 30. The lower portion 82 of
the plunger 80 deforms the deformable release device 30 allowing
for the release of the adapter kit--and setting tool--from the
plug. As discussed above, the force required to deform the
deformable release device 30 can be set by modifying the material,
size, and shape of the deformable release device 30 as well as the
plunger 80. The use of a plunger 80 and deformable release device
30 decreases the manufacturing costs of adapter kits and downhole
tools as compared to using other mechanically releasing devices
such as shear pins and shear screws.
[0049] FIG. 3B shows a cross-section of a deformable release device
30 and plunger 80 of one embodiment of the present disclosure prior
to the deformation of the deformable release device 30. The
deformable release device 30 may be circular in shape and fairly
flat with a circular opening centrally located. The deformable
release device 30 is retained against the mandrel 78 by retaining
pins 31. The plunger 80 may be circular with an uphole portion 81
connected to the release stinger 50 and is sized to fit through the
opening of the deformable release device 30. The plunger 80 may
have a protruding portion 83 that has an outer diameter larger than
the central opening of the deformable release device 30. When a
predetermined upward force is applied to the plunger 80, the
protruding portion 83 of the plunger 80 deforms the deformable
release device 30 allowing for the release of the plunger 80. The
deformation of the release device 30 minimizes the chance that
debris from the release device will be left in the wellbore.
[0050] FIG. 3C shows a cross-section of a deformable release device
30 and plunger 80 of one embodiment of the present disclosure prior
to the deformation of the deformable release device 30. The
deformable release device 30 may be generally circular in shape
with a beveled portion 32. The beveled portion 32 of the deformable
release device 30 includes circular opening centrally located. The
deformable release device 30 is retained against the mandrel 78 by
retaining pins 31. The plunger 80 may be circular with an uphole
portion 81 is connected to the release stinger 50 and is sized to
fit through the opening of the deformable release device 30. The
plunger 80 may have a protruding portion 83 having an outer
diameter larger than the central opening of the deformable release
device 30. When a predetermined upward force is applied to the
plunger 80, the protruding portion 83 of the plunger 80 deforms the
beveled portion 32 of the deformable release device 30 allowing for
the release of the plunger 80. The beveled portion 32 of the
deformable release device 30 may decrease the amount of force
required to release the plunger.
[0051] FIGS. 4A-4C show an adapter kit and plug assembly using a
deformable release device being run into the wellbore, setting the
plug, and removing the adapter kit from the well bore.
Specifically, FIG. 4A shows a running plug assembly attached to a
setting tool via an adapter kit into a well bore. As the plug is
conveyed into the wellbore, the deformable release device 30
retains the plug assembly on the adapter kit 20.
[0052] Once the plug assembly is positioned at the proper depth in
the wellbore, the setting tool 10 applies a downward force 110 to
the plug assembly 70 through the adapter sleeve 40. As discussed
above, the downward force 110 applied to the plug assembly sets the
slips 72, 76 against the well casing and expands the elastomeric
packing elements 74 against the well casing creating a seal. FIG.
4B shows the plug assembly being set in the bore as indicated by
the expanded elastomeric packing elements 74 as well as the slips
72, 76 being set against the well casing. However, the plunger 80
shown in FIG. 4B has not yet been pulled through the deformable
release device 30.
[0053] The application of a downward force 110 through the adapter
sleeve 40 also causes an upward force 120 on the release stinger 50
and attached plunger 80. The deformable release device 30 counters
the upward force 120 and retains the release stinger 50 and plunger
80 in place relative to the plug assembly. As the plug assembly is
being set, the downward force 110 continues to increase, which also
increase the upward force 120 on the release stinger 50 and plunger
80.
[0054] During the process of setting the plug 70, a deformable
release device 30 retains the plug assembly 70 on the release
stinger 50. Pins 31 secure the deformable release device 30 to the
mandrel 78 of the plug assembly 70. As described above, the force
applied by the setting tool causes an upward force on the release
stinger 50. The release stinger 50 is held in place by the
deformable release device 30 until the upward force becomes greater
than the force required to deform the deformable release device 30.
Once the force exceeds this amount, the plunger 80 is pulled
through the deformable release device 30, which deforms the
deformable release device 30. The deformation of the release device
30 allows for the automatic release of the adapter kit 20--and
setting tool 10--while minimizing the risk of debris from the
release left in the wellbore.
[0055] FIG. 4C shows plug assembly 70 set against the well casing
and the deformable release device 30 after the adapter kit 20--and
downhole tool--has been released by the deformable release device
30. The plunger 80 has been pulled through the deformable release
device 30 deforming in against the mandrel 78 of the plug assembly
70. The deformation of the deformable release device allows for the
release of the adapter kit 20 from the plug assembly 70. Once the
adapter kit 20 has been pulled from the plug assembly 70, a valve
130, such as a flapper valve, may close off the axial passage
within the mandrel 78. This disclosure reduces the likelihood that
the release of an adapter kit will create debris in the
wellbore.
[0056] FIG. 5 shows the top view of one embodiment of the
deformable release device 30. The deformable release device 30 is
substantially circular in cross-section with a circular central
opening 33. FIGS. 6 and 7 show alternative embodiments of the
deformable release device 30 have a central opening 33 with slots
34 cut into the opening. The addition and location of the slots 34
allows for the better control of how the plunger 80 deforms the
deformable release device 30. The addition of slots 34 in the
deformable release device 30 also provides that the release device
30 may deform at a lower force. Thus, deformable release device 30
of FIG. 7 may deform at a lower force than the embodiment of FIG.
6, if both are comprised of the same material. Likewise, the
embodiment of FIG. 6 may most likely deform at a lower force than
the release device 30 shown in FIG. 5.
[0057] FIGS. 8A-8F and 9A-9J illustrate a number of various
embodiments of the deformable release device of the present
disclosure. As discussed above, the size, shape, and material of
the deformable release device may be modified to change the force
required to deform the deformable release device, thus releasing
the adapter kit. If the deformable release device is used with a
packer assembly, the deformation force needs to be greater than the
setting force required to set packer as would be appreciated by one
of ordinary skill in the art. The necessary deformation force may
range between 27,900 lbs. and 7,500 lbs for the embodiments shown
in FIGS. 8A-8F. As discussed above, the amount of force required to
deform the release device can be predetermined by the material used
as well as the overall dimensions and shape of the deformable
release device. For example, the addition of slots, tapering the
device, or enlarging the opening decreases the requisite
deformation force as would be appreciated by one of ordinary skill
in the art.
[0058] Typically, a force of 50,000 lbs. is required to set a plug
having an outer diameter of 51/2 inches. A force of 30,000-33,000
lbs. is generally required to set a plug with an outer diameter of
41/2 inches. Plugs having an outer diameter of 27/8 inches or less
typically require a setting force of 9,000-11,000 lbs. As would be
appreciated by one of ordinary skill in the art, the embodiments
shown in FIGS. 8A-8F and 9A-9J are only examples of some of the
shapes and dimensions of the deformable release device. As
discussed above, the required deformation force to release an
adapter kit may be may be varied depending on the material of the
deformable release device as well as the configuration of the
deformable release device and the plunger.
[0059] Although various embodiments have been shown and described,
the invention is not so limited and will be understood to include
all such modifications and variations as would be apparent to one
skilled in the art.
* * * * *