U.S. patent application number 17/601091 was filed with the patent office on 2022-07-14 for voided moldable buttons.
The applicant listed for this patent is Schlumberger Technology Corporation. Invention is credited to Robert Matthew Graham.
Application Number | 20220220824 17/601091 |
Document ID | / |
Family ID | 1000006198755 |
Filed Date | 2022-07-14 |
United States Patent
Application |
20220220824 |
Kind Code |
A1 |
Graham; Robert Matthew |
July 14, 2022 |
VOIDED MOLDABLE BUTTONS
Abstract
A button includes a body including a void. The void pierces the
body completely therethrough, and the body is made of a moldable
material.
Inventors: |
Graham; Robert Matthew;
(Houston, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Schlumberger Technology Corporation |
Sugar Land |
TX |
US |
|
|
Family ID: |
1000006198755 |
Appl. No.: |
17/601091 |
Filed: |
April 3, 2020 |
PCT Filed: |
April 3, 2020 |
PCT NO: |
PCT/US2020/026502 |
371 Date: |
October 4, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62829208 |
Apr 4, 2019 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 33/1208 20130101;
E21B 33/13 20130101; E21B 33/1292 20130101 |
International
Class: |
E21B 33/13 20060101
E21B033/13; E21B 33/129 20060101 E21B033/129; E21B 33/12 20060101
E21B033/12 |
Claims
1. A button comprising: a body comprising a void, wherein the void
pierces the body completely therethrough, and wherein the body is
made of a moldable material.
2. The button of claim 1, wherein the moldable material is a powder
metal material.
3. The button of claim 1, wherein the moldable material is a
ceramic material.
4. The button of claim 1, wherein the void pierces the body through
a flat surface of the body.
5. The button of claim 2, wherein the void pierces the body through
a flat surface of the body.
6. A downhole tool comprising: a slip body; and at least one button
of claim 1 disposed in the slip body.
7. The downhole tool of 6, further comprising: at least one slip
assembly comprising a plurality of slips, each slip of the
plurality of slips comprising the slip body.
8. The downhole tool of claim 7, further comprising a sealing
element.
9. The downhole tool of claim 8, wherein the downhole tool is a
frac plug.
10. A downhole tool comprising: a slip body; and at least one
button of claim 2 disposed in the slip body.
11. The downhole tool of claim 10, further comprising: at least one
slip assembly comprising a plurality of slips, each slip of the
plurality of slips comprising the slip body.
12. The downhole tool of claim 11, further comprising a sealing
element.
13. The downhole tool of claim 12, wherein the downhole tool is a
frac plug.
14. A method comprising: deploying a downhole tool into a cased
wellbore; and anchoring the downhole tool to the cased wellbore,
wherein the downhole tool comprises: a plurality of slips, each
slip of the plurality of slips comprising: a slip body; and at
least one button disposed in the slip body, wherein the at least
one button comprises: a body comprising a void, wherein the void
pierces the body completely therethrough, and wherein the body of
the at least one button is made of a moldable material.
15. The method of claim 14, wherein the moldable material is a
powder metal material.
16. The method of claim 14, further comprising: initiating a
fracturing operation after the anchoring step; and drilling out the
downhole tool after the fracturing operation.
17. The method of claim 15, further comprising: initiating a
fracturing operation after the anchoring step; and drilling out the
downhole tool after the fracturing operation.
18. A method of manufacturing a button comprising: using a mold to
form a body comprising a void, wherein the void pierces the body
completely therethrough.
19. The method of claim 18, wherein the body is made of a powder
metal material.
20. The method of claim 18, wherein the body is made of a ceramic
material.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present document is based on and claims priority to U.S.
Provisional Application Ser. No. 62/829,208, filed Apr. 4, 2019,
which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] In a variety of well fracturing applications, a wellbore is
initially drilled and cased. A frac plug is then pumped down and
actuated to form a seal with the surrounding casing. Once the
casing is perforated, the frac plug is used to prevent fracturing
fluid from flowing farther downhole, thus forcing the fracturing
fluid out through the perforations and into the surrounding
formation. In some applications, multiple frac plugs may be
deployed to enable fracturing at different well zones. Each frac
plug includes a sealing element, which is deformed into sealing
engagement with the surrounding casing. The frac plug also includes
one or more slip assemblies having a plurality of slips. The slips
may include buttons, which are used to anchor the frac plug in the
casing. To ensure sealing and sufficient anchoring with the casing,
the frac plug tends to be formed with relatively precise and
expensive components. In addition to the expense, the construction
of such a frac plug also can lead to difficulties associated with
milling out the frac plug after completion of the fracturing
operation.
SUMMARY
[0003] According to one or more embodiments of the present
disclosure, a button includes a body comprising a void, wherein the
void pierces the body completely therethrough, and wherein the body
is made of a moldable material.
[0004] According to one or more embodiments of the present
disclosure, a method includes deploying a downhole tool into a
cased wellbore, and anchoring the downhole tool to the cased
wellbore, wherein the downhole tool includes: a plurality of slips,
each slip of the plurality of slips including: a slip body; and at
least one button disposed in the slip body, wherein the at least
one button includes: a body including a void, wherein the void
pierces the body completely therethrough, and wherein the body of
the at least one button is made of a moldable material.
[0005] According to one or more embodiments of the present
disclosure, a method of manufacturing a button includes using a
mold to form a body including a void, wherein the void pierces the
body completely therethrough.
[0006] However, many modifications are possible without materially
departing from the teachings of this disclosure. Accordingly, such
modifications are intended to be included within the scope of this
disclosure as defined in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Certain embodiments of the disclosure will hereafter be
described with reference to the accompanying drawings, wherein like
reference numerals denote like elements. It should be understood,
however, that the accompanying figures illustrate the various
implementations described herein and are not meant to limit the
scope of various technologies described herein, and:
[0008] FIG. 1 is a schematic illustration of an example of a
downhole tool deployed in a wellbore according to one or more
embodiments of the present disclosure;
[0009] FIG. 2 is a perspective view of a frac plug having voided
moldable buttons according to one or more embodiments of the
present disclosure;
[0010] FIG. 3 is the frac plug of FIG. 2 set in casing according to
one or more embodiments of the present disclosure;
[0011] FIG. 4(a) is a perspective view of a voided moldable button
according to one or more embodiments of the present disclosure;
[0012] FIG. 4(b) is a top view of a voided moldable button
according to one or more embodiments of the present disclosure;
[0013] FIG. 5(a) is a perspective view of a solid button; and
[0014] FIG. 5(b) is a top view of a solid button.
DETAILED DESCRIPTION
[0015] In the following description, numerous details are set forth
to provide an understanding of some embodiments of the present
disclosure. However, it will be understood by those of ordinary
skill in the art that the apparatus and/or method may be practiced
without these details and that numerous variations or modifications
from the described embodiments may be possible.
[0016] In the specification and appended claims: the terms "up" and
"down," "upper" and "lower," "upwardly" and "downwardly,"
"upstream" and "downstream," "uphole" and "downhole," "above" and
"below," and other like terms indicating relative positions above
or below a given point or element are used in this description to
more clearly describe some embodiments of the disclosure.
[0017] The present disclosure generally relates to an apparatus and
method for facilitating a fracturing operation. Specifically, one
or more embodiments of the present disclosure are directed to
voided buttons made out of a moldable material, such as a powder
metal material or a ceramic material, for use in a downhole tool
during a fracturing operation. Because the voided button is made
out of a moldable material, no machining of the button is required,
which provides a significant cost savings. Moreover, the voided
button exhibits improved performance during drill out.
[0018] Referring generally to FIG. 1, an embodiment of a downhole
tool 20 is illustrated deployed in a well 21. According to one or
more embodiments of the present disclosure, the downhole tool 20 is
a frac plug. For example, the frac plug 20 may be deployed in a
wellbore 22 to facilitate a fracturing operation. In the example
illustrated, the frac plug 20 is deployed in the wellbore 22 so as
to isolate a zone of the wellbore 22 so that fracturing fluid 24
may be directed through perforations 26 and into a surrounding
formation 28 uphole of the frac plug 20 for fracturing of the
surrounding formation 28. It should be noted that the frac plug 20
according to one or more embodiments of the present disclosure may
be used in many types of wellbores, such as deviated, e.g.,
horizontal, wellbores to facilitate fracturing of desired well
zones along the horizontal or otherwise deviated wellbore.
[0019] Still referring to FIG. 1, the wellbore 22 may be lined with
a casing 30, and each frac plug 20 may be actuated to grip into and
seal against the casing 30, thereby sealing or substantially
restricting flow of the fracturing fluid 24 downhole of the frac
plug 20 in the wellbore 22. As a result, during a fracturing
operation, the fracturing fluid 24 is directed through the
perforations 26 into the surrounding formation 28 while the frac
plug 20 remains anchored to the casing 30. Once the fracturing
operation is completed and a given frac plug 20 is no longer of
use, the frac plug may be milled and removed from the wellbore
22.
[0020] Referring now to FIG. 2, a perspective view of a frac plug
having voided moldable buttons according to one or more embodiments
of the present disclosure is shown. Specifically, FIG. 2 shows the
frac plug 200 in an unset position. Referring also to FIG. 3, the
frac plug 200 of FIG. 2 is shown set in the casing 30. According to
one or more embodiments, the frac plug 200 may include a mandrel
(not shown) and at least upper and lower slip assemblies 202a,
202b, upper and lower cones 204a, 204b, a sealing element 206, and
at least one barrier ring 208 disposed around the mandrel. In one
or more embodiments, the at least one barrier ring 208 is disposed
adjacent the sealing element 206, and the at least one barrier ring
208 may include a plurality of flanges 210, which may radially
expand against an inner wall of the casing 30 and create a
circumferential barrier to keep the sealing element 206 from
extruding. The frac plug 200 may also include a bottom sub 212
having a chamfered end 214 according to one or more
embodiments.
[0021] Still referring to FIGS. 2-3, the upper and lower slip
assemblies 202a, 202b of the frac plug 200 may include a plurality
of slips 216. Further, each slip 216 may include a slip body 218
and at least one voided button 220 disposed in the slip body 218.
The voided button 220 is further described below with reference to
FIGS. 4a and 4b.
[0022] When the frac plug 200 transitions from the run-in-hole
unset position of FIG. 2 to the set position of FIG. 3, the upper
slip assembly 202a ramps down the upper cone 204a, and the lower
slip assembly 202b ramps up the lower cone 204b, causing the upper
and lower slip assemblies 202a, 202b to radially expand. The radial
expansion of the upper and lower slip assemblies 202a, 202b causes
the at least one voided button 220 disposed in the slip body 218 of
a given slip 216 to grip and bite into the inner diameter of the
casing 30. Further, when the frac plug 200 is in the set position,
the sealing element 206 is deformed into sealing engagement with
the surrounding casing 30. According to one or more embodiments of
the present disclosure, the sealing element 206 may be formed of an
elastomeric material or metal material, which is deformed in a
radially outward direction until forming a permanent seal with the
inside surface of the casing 30. Due to the gripping and biting of
the at least one voided button 220 and the sealing of the sealing
element 206, the frac plug 200 is able to be effectively anchored
to the inside surface of the casing 30 when the frac plug 200 is in
the set position. The frac plug 200 may remain anchored to the
inside surface of the casing 30 during a fracturing operation, and
after the fracturing operation, the frac plug 200 may be drilled
out, as previously described.
[0023] Referring now to FIGS. 4(a) and 4(b), perspective and top
views of a voided button 220 according to one or more embodiments
of the present disclosure are shown, respectively. As shown, the
voided button 220 includes a body 222, which may be cylindrical,
for example, and a void 224 that pierces the body 222 completely
therethrough. Although the body 222 is shown as being cylindrical
in FIG. 4(a), other shapes and configurations of the body 222 are
feasible and are within the scope of the present disclosure. As
also shown in FIG. 4(b), the void 224 pierces the body 222 through
a flat surface of the body 222, according to one or more
embodiments of the present disclosure.
[0024] Still referring to FIGS. 4(a) and 4(b), the body 222 of the
voided button 220 is made out of a moldable material according to
one or more embodiments of the present disclosure. In one or more
embodiments, the moldable material may be a powder metal material
or a ceramic material, for example. That is, according to one or
more embodiments of the present disclosure, the void 224 is not
machined into the body 222 to create the voided button 220.
Instead, the voided button 220 is manufactured using powder metal
or ceramic during a molding process with the void 220 already
present in the mold. Stated another way, powder metal (or ceramic)
molding can produce the button in its current form, including
voids, without the need for machining. Further, powder metal and
ceramic materials have a requisite hardness such that the resulting
voided button 220 is sufficiently hard enough to grip and bite the
inside surface of the casing 30 when the frac plug 200 is in the
set position.
[0025] Due to the affordability of powder metal and the potential
to eliminate machine work, the powder metal molding process as
previously described may reduce the cost of the voided button 220
by up to 90%. There are commercially available powdered metals,
which have low elongation, but comparable tensile strength to 8620
steel. As appreciated by those having ordinary skill in the art,
low elongation generally indicates that a material will fracture
and mill more easily.
[0026] In other embodiments, 3D printing or additive manufacturing
are other manufacturing methods that could be used to manufacture
the voided button 220.
[0027] Still referring to FIGS. 4(a) and 4(b), the void 224
facilitates drill out of the voided button 220 and the frac plug
200 after a fracturing operation, for example. That is, the voided
buttons 220 according to one or more embodiments of the present
disclosure exhibit significantly improved performance during drill
out over the solid and un-voided prior art button 500 shown in
FIGS. 5(a) and 5(b), for example. In particular, the void 224
allows the voided button 220 to drill out faster and into smaller
pieces than the solid and un-voided prior art button 500. As
appreciated by those having ordinary skill in the art, the ability
to drill out a frac plug quickly is an extremely critical aspect of
frac plug performance. The addition of voids 224 to the buttons
220, according to one or more embodiments of the present
disclosure, make the voided buttons 220 easier to chip away at
while still anchoring the frac plug 200 in place during the
fracturing operation.
[0028] Moreover, the synergy of combining a button molded out of
powdered metal (or ceramic) with a void completely piercing the
body of the button therethrough, according to one or more
embodiments of the present disclosure, achieves superior results
and exhibits an unmistakable improvement in average fracture size
during impact testing over the solid and un-voided prior art button
of FIGS. 5(a) and 5(b), for example.
[0029] Although a few embodiments of the disclosure have been
described in detail above, those of ordinary skill in the art will
readily appreciate that many modifications are possible without
materially departing from the teachings of this disclosure.
Accordingly, such modifications are intended to be included within
the scope of this disclosure as defined in the claims.
* * * * *