Downhole tool apparatus

Abstract: A downhole tool apparatus such as a packer or bridge plug utilises non-metallic components, eg. engineering grade plastics components. The non-metallic components may include a center mandrel (22), slips (28,54), slip wedges (32,46), slip supports (24,58) and housings, spacer rings, valve housings and valve components. These tools can be relatively easily drilled out after use without significant variations in the drilling speed and weight applied to the drill bit may be employed. Alternative drill bit types, such as polycrystalline diamond compact (PDC) bits may also be used.

Description: This invention relates to downhole tools for use in well bores and the removal of such tools out of well bores. In the drilling or reworking of oil wells, a great variety of downhole tools are used. For example, but not by way of limitation, it is often desirable to seal tubing or other pipe in the casing of the well, such as when it is desired to pump cement or other slurry down tubing and force the slurry out into a formation. It then becomes necessary to seal the tubing with respect to the well casing and to prevent the fluid pressure of the slurry from lifting the tubing out of the well. Packers and bridge plugs designed for these general purposes are well known in the art. When it is desired to remove many of these downhole tools from a well bore, it is frequently simpler and less expensive to mill or drill them out rather than to implement a complex retrieving operation. In milling, a milling cutter is used to grind the packer or plug, for example, or at least the outer components thereof, out of the well bore. Milling is a relatively slow process, but it can be used on packers or bridge plugs having relatively hard components such as erosion-resistant hard steel. One such packer is disclosed in U. S. Patent No. 4,151,875 to Sullaway, assigned to the assignee of the present invention and sold under the trademark EZ Disposal packer. Other downhole tools in addition to packers and bridge plugs may also be drilled out. In drilling, a drill bit is used to cut and grind up the components of the downhole tool to remove it from the well bore. This is a much faster operation than milling, but requires the tool to be made out of materials which can be accommodated by the drill bit. Typically, soft and medium hardness cast iron are used on the pressure bearing components, along with some brass and aluminum items. Packers of this type include the Halliburton EZ Drill® and EZ Drill SV® squeeze packers. The EZ Drill SV® squeeze packer, for example, includes a lock ring housing, upper slip wedge, lower slip wedge, and lower slip support made of soft cast iron. These components are mounted on a mandrel made of medium hardness cast iron. The EZ Drill® squeeze packer is similarly constructed. The Halliburton EZ Drill® bridge plug is also similar, except that it does not provide for fluid flow therethrough. All of the above-mentioned packers are disclosed in Halliburton Services Sales and Service Catalog No. 43, pages 2561-2562, and the bridge plug is disclosed in the same catalog on pages 2556-2557. The EZ Drill® packer and bridge plug and the EZ Drill SV® packer are designed for fast removal from the well bore by either rotary or cable tool drilling methods. Many of the components in these drillable packing devices are locked together to prevent their spinning while being drilled, and the harder slips are grooved so that they will be broken up in small pieces. Typically, standard "tri-cone" rotary drill bits are used which are rotated at speeds of about 75 to about 120 rpm. A load of about 5,000 to about 7,000 pounds of weight is applied to the bit for initial drilling and increased as necessary to drill out the remainder of the packer or bridge plug, depending upon its size. Drill collars may be used as required for weight and bit stabilization. Such drillable devices have worked well and provide improved operating performance at relatively high temperatures and pressures. The packers and plug mentioned above are designed to withstand pressures of about 10,000 psi and temperatures of about 425° F. after being set in the well bore. Such pressures and temperatures require the cast iron components previously discussed. However, drilling out iron components requires certain techniques. Ideally, the operator employs variations in rotary speed and bit weight to help break up the metal parts and reestablish bit penetration should bit penetration cease while drilling. A phenomenon known as "bit tracking" can occur, wherein the drill bit stays on one path and no longer cuts into the downhole tool. When this happens, it is necessary to pick up the bit above the drilling surface and rapidly recontact the bit with the packer or plug and apply weight while continuing rotation. This aids in breaking up the established bit pattern and helps to reestablish bit penetration. If this procedure is used, there are rarely problems. However, operators may not apply these techniques or even recognize when bit tracking has occurred. The result is that drilling times are greatly increased because the bit merely wears against the surface of the downhole tool rather than cutting into it to break it up. While cast iron components may be necessary for the high pressures and temperatures for which they are designed, it has been determined that many wells experience pressures less than 10,000 psi and temperatures less than 425° F. This includes most wells cemented. In fact, in the majority of wells, the pressure is less than about 5,000 psi, and the temperature is less than about 250° F. Thus, the heavy duty metal construction of the previous downhole tools, such as the packers and bridge plugs described above, is not necessary for many applications, and if cast iron components can be eliminated or minimized, the potential drilling problems resulting from bit tracking might be avoided as well. In the apparatus of the present invention, at least some of the components, including pressure bearing components, are made of non-metallic materials, such as engineering grade plastics. Such plastic components are much more easily drilled than cast iron, and new drilling methods may be employed which use alternative drill bits such as polycrystalline diamond compact bits, or the like, rather than standard tri-cone bits. More specifically, the present invention, provides a downhole apparatus for use in a well bore, said apparatus comprising: a center mandrel; and slip means disposed on said mandrel for grippingly engaging said well bore when in a set position, characterized in that said slip means comprise a slip wedge made of a non-metallic material, and that the diameter of the bore of the mandrel is less than half the outside diameter of the mandrel. The downhole tool apparatus of the present invention utilizes non-metallic materials, such as engineering grade plastics, to reduce weight, to reduce manufacturing time and labour, to improve performance through reducing frictional forces of sliding surfaces, to reduce costs and to improve drillability of the apparatus when drilling is required to remove the apparatus from the well bore. Primarily, in this disclosure, the downhole tool is characterized by well bore packing apparatus, but it is not intended that the invention be limited to such packing devices. The non-metallic components in the downhole tool apparatus also allow the use of alternative drilling techniques to those previously known. In addition to the slip wedge or wedges, the mandrel, the slips and or slip supports may be made of the non-metallic material, such as plastic. Specific preferred plastics include nylon, phenolic materials and epoxy resins. The phenolic materials may further include any of Fiberite FM4056J, Fiberite FM4005 or Resinoid 1360. The plastic components may be molded or machined. One preferred plastic material for at least some of these components is a glass reinforced phenolic resin having a tensile strength of about 18,000 psi and a compressive strength of about 40,000 psi, although the invention is not intended to be limited to this particular plastic or a plastic having these specific physical properties. The plastic materials are preferably selected such that the packing apparatus can withstand well pressures less than about 10,000 psi and temperatures less than about 425°F. In one preferred embodiment, but not by way of limitation, the plastic materials of the packing apparatus are selected such that the apparatus can withstand well pressures up to about 5,000 psi and temperatures up to about 250°F. Most of the components of the slip means are subjected to substantially compressive loading when in a sealed operating position in the well bore, although some tensile loading may also be experienced. The center mandrel typically has tensile loading applied there to when setting the packer and when the packer is in its operating position. In order that the invention may be more fully understood, some embodiments thereof will now be described by way of example only with reference to the accompanying drawings, wherein: FIG. 1 generally illustrates a downhole tool apparatus of the present invention positioned in a well bore with a drill bit disposed thereabove. FIGS. 2A and 2B show a cross section of a first embodiment of a drillable packer; FIGS 3A and 3B show a second form of drillable packer embodiment, with a poppet valve therein. FIG. 4 is a cross section of one embodiment of a drillable bridge plug made in accordance with the present invention. Referring now to FIG. 1, the downhole tool apparatus of the present invention is shown and generally designated by the numeral 10. Apparatus 10, which may include, but is not limited to, packers, bridge plugs, or similar devices, is shown in an operating position in a well bore 12. Apparatus 10 can be set in this position by any manner known in the art such as setting on a tubing string or wire line. A drill bit 14 connected to the end of a tool or tubing string 16 is shown above apparatus 10 in a position to commence the drilling out of apparatus 10 from well bore 12. Methods of drilling will be further discussed herein. Referring now to FIGS. 2A and 2B, the details of a first squeeze packer embodiment 100 of apparatus 10 will be described. The size and configuration of packer 100 is substantially the same as the previously mentioned prior art EZ Drill SV® squeeze packer. Packer 100 defines a generally central opening 104 therein. Packer 100 comprises a center mandrel 102 on which most of the other components are mounted. Mandrel 102 may be described as a thick cross-sectional mandrel having a relatively thicker wall thickness than typical packer mandrels. A thick cross-sectional mandrel may be generally defined as one in which the central opening there through has a diameter less than about half of the outside diameter of the mandrel. That is, mandrel central opening 104 in center mandrel 102 has a diameter less than half the outside of center mandrel 102. It is contemplated that a thick cross-sectional mandrel will be required if it is constructed from a material having relatively low physical properties. In particular, such materials may include phenolics and similar plastic materials. An upper support 106 is attached to the upper end of center mandrel 102 at threaded connection 108. In an alternate embodiment, center mandrel 102 and upper support 106 are integrally formed and there is no threaded connection 108. A spacer ring or upper slip support 110 is disposed on the outside of mandrel 102 just below upper support 106. Spacer ring 110 is initially attached to center mandrel 102 by at least one shear pin 112. A downwardly and inwardly tapered shoulder 114 is defined on the lower side of spacer ring 110. Disposed below spacer ring 110 are a plurality of upper slips 116. A downwardly and inwardly sloping shoulder 118 forms the upper end of each slip 116. The taper of each shoulder 118 conforms to the taper of shoulder 114 on spacer ring 110, and slips 116 are adapted for sliding engagement with shoulder 114, as will be further described herein. An upwardly and inwardly facing taper 120 is defined in the lower end of each slip 116. Each taper 120 generally faces the outside of center mandrel 102. A plurality of hardened inserts or teeth 122 preferably are molded into upper slips 116. In the embodiment shown in FIG. 2A, inserts 122 have a generally square cross section and are positioned at an angle so that a radially outer edge 124 protrudes from the corresponding upper slip 116. Outer edge 124 is adapted for grippingly engaging well bore 12 when packer 100 is set. It is not intended that inserts 122 be of square cross section and have a distinct outer edge 124. Different shapes of inserts may also be used. Inserts 122 can be made of any suitable hardened material. An upper slip wedge 126 is disposed adjacent to upper slips 116 and engages taper 120 therein. Upper slip wedge 126 is initially attached to center mandrel 102 by one or more shear pins 128. Below upper slip wedge 126 are upper back-up ring 37, upper packer shoe 38, end packer elements 40 separated by center packer element 42, lower packer shoe 44 and lower back-up ring 45. Below lower back-up ring 45 is a lower slip wedge 130 which is initially attached to center mandrel 102 by a shear pin 132. Preferably, lower slip wedge 130 is identical to upper slip wedge 126 except that it is positioned in the opposite direction. Lower slip wedge 138 is in engagement with an inner taper 134 in a plurality of lower slips 136. Lower slips 136 have inserts or teeth 138 molded therein, and preferably, lower slips 136 are substantially identical to upper slips 126. Each lower slip 136 has a downwardly facing shoulder which tapers upwardly and inwardly. Shoulders 136 are adapted for engagement with a corresponding shoulder 142 defining the upper end of a valve housing 144. Shoulder 142 also tapers upwardly and inwardly. Thus, valve housing 144 may also be considered a lower slip support 144. Referring now also to FIG. 2B, valve housing 146 is attached to the lower end of center mandrel 102 at threaded connection 146. A sealing means, such as O-ring 148, provides sealing engagement between valve housing 144 and center mandrel 102. Below the lower end of center mandrel 102, valve housing 104 defines a longitudinal opening 150 therein having a longitudinal rib 152 in the lower end thereof. At the upper end of opening 150 is an annular recess 154. Below opening 150, valve housing 144 defines a housing central opening including a bore 156 therein having a closed lower end 158. A plurality of transverse ports 160 are defined through valve housing 144 and intersect bore 156. The wall thickness of valve housing 144 is thick enough to accommodate a pair of annular seal grooves 162 defined in bore 156 on opposite sides of ports 160. Slidably disposed in valve housing 144 below center mandrel 102 is a sliding valve 164. At the upper end of sliding valve 164 are a plurality of upwardly extending collet fingers 166 which initially engage recess 154 in valve housing 144. Sliding valve 164 is shown in an uppermost, closed position in FIG. 2B. It will be seen that the lower end of center mandrel 102 prevents further upward movement of sliding valve 164. Sliding valve 164 defines a valve central opening 168 therethrough which is in communication with central opening 104 in center mandrel 102. A chamfered shoulder 170 is located at the upper end of valve central opening 168. Sliding valve 164 defines a plurality of substantially transverse ports 172 therethrough which intersect valve central opening 168. As will be further discussed herein, ports 172 are adapted for alignment with ports 160 in valve housing 144 when sliding valve 164 is in a downward, open position thereof. Rib 152 fits between a pair of collet fingers 166 so that sliding valve 164 cannot rotate within valve housing 144, thus insuring proper alignment of ports 172 and 160. Rib 152 thus provides an alignment means. A sealing means, such as O-ring 173, is disposed in each seal groove 162 and provides sealing engagement between sliding valve 164 and valve housing 144. It will thus be seen that when sliding valve 164 is moved downwardly to its open position, O-rings 173 seal on opposite sides of ports 172 in the sliding valve. Referring again to FIG. 2 A, a tension sleeve 174 is disposed in center mandrel 102 and attached thereto to threaded connection 176. Tension sleeve 174 has a threaded portion 178 which extends from center mandrel 102 and is adapted for connection to a standard setting tool (not shown) of a kind known in the art. Below tension sleeve 174 is an internal seal 180. Referring now to FIGS. 3A and 3B, a second squeeze packer embodiment is shown and generally designated by the numeral 400. As illustrated, the packer embodiment 400 incorporates the same thick cross-sectional center mandrel 102 as does the packer embodiment 100 shown in FIGS. 2A and 2B. Also, the external components positioned on center mandrel 102 are the same as in the first packer embodiment, so the same reference numerals will be used. Further, tension sleeve 174 and internal seal 180 in second embodiment 100 are also incorporated in fifth embodiment 400, and therefore these same reference numerals have also been used. The difference between the second packer embodiment 400 and first embodiment 100 is that the lower end of center mandrel 102 is attached to a lower slip support 402 at threaded connection 404. Shoulders 140 on lower slips 136 slidingly engage an upwardly and inwardly tapered shoulder 406 at the upper end of lower slip support 402. Referring now to FIG. 3B, a sealing means, such as O-ring 408, provides sealing engagement between the lower end of center mandrel 102 and lower slip support 402. Lower slip support 402 defines a first bore 410 therein and a larger second bore 412 spaced downwardly from the first bore. A tapered seat surface 414 extends between first bore 410 and second bore 412. The lower end of lower support 402 is attached to a valve housing 416 at threaded connection 418. Valve housing 416 defines a first bore 420 and a smaller second bore 422 therein. An upwardly facing annular shoulder 424 extends between first bore 420 and second bore 422. Below second bore 422, valve housing 416 defines a third bore 426 therein with an internally threaded surface 428 forming a port at the lower end of the valve housing. Disposed in first bore 420 in valve housing 416 is a valve body 430 with an upwardly facing annular shoulder 432 thereon. An elastomeric valve seal 434 and a valve spacer 436, which provides support for the valve seal, are positioned adjacent to shoulder 432 on valve body 430. A conical valve head 438 is positioned above valve seal 434 and is attached to valve body 430 at threaded connection 440. It will be seen by those skilled in the art that valve seal 434 is adapted for sealing engagement with seat surface 414 in lower slip support 402 when valve body 430 is moved upwardly. The lower end of valve body 430 is connected to a valve holder 442 by one or more pins 444. Valve holder 442 is disposed in second bore 422 of valve housing 416. A sealing means, such as O-ring 446 provides sealing engagement between valve holder 442 and valve housing 416. Above shoulder 424 in valve housing 416, valve body 430 has a radially outwardly extending flange 448 thereon. A biasing means, such as spring 450, is disposed between flange 448 and shoulder 424 for biasing valve body 430 upwardly with respect to valve housing 416. Valve holder 442 defines a first bore 452 and a smaller second bore 454 therein with an upwardly facing chamfered shoulder 456 extending therebetween. A ball 458 is disposed in valve holder 442 and is adapted for engagement with shoulder 456. Referring now to FIG. 4, a bridge plug embodiment of the present invention is shown and generally designated by the numeral 500. It comprises the same center mandrel 102 and the external components positioned thereon as does the first packer embodiment 100. Therefore, the reference numerals for these components shown in FIG. 4 are the same as in FIG. 2A. The lower end of center mandrel 102 in the bridge plug embodiment 500 is connected to a lower slip support 502 at threaded connection 504. An upwardly and inwardly tapered shoulder 506 on lower slip support 502 engages shoulders 140 on lower slips 136. As with the other embodiments, slips 136 are adapted for sliding along shoulder 506. Lower slip support 502 defines a bore 508 therein which is in communication with mandrel central opening 104 in center mandrel 102. A bridging plug 510 is disposed in the upper portion of mandrel central opening 104 in center mandrel 102 and is sealingly engaged with internal seal 180. A radially outwardly extending flange 512 prevents bridging plug 510 from moving downwardly through center mandrel 102. Above bridging plug 510 is tension sleeve 174, previously described for second packer embodiment 100. In prior art drillable packers and bridge plugs of this general type, mandrel 102 is made of a medium hardness cast iron, and the slip wedges 126, 130 and lower slip support 144 are made of soft cast iron for drillability. Most of the other components are made of aluminium, brass or rubber which, of course, are relatively easy to drill. Prior art upper and lower slips are made of hard cast iron, but are grooved so that they will easily be broken up in small pieces when contacted by the drill bit during a drilling operation. As previously described, the soft cast iron construction of prior art lock ring housings, upper and lower slip wedges, and lower slip supports are adapted for relatively high pressure and temperature conditions, while a majority of well applications do not require a design for such conditions. Thus, the apparatus of the present invention, which is generally designed for pressures lower than 10,000 psi and temperatures lower than 425°F, utilizes engineering grade plastics for at least some of the components. For example, the apparatus may be designed for pressures up to about 5,000 psi and temperatures up to about 250°F, although the invention is not intended to be limited to these particular conditions. At least some of the previously soft cast iron components of the slip means, upper and lower slip wedges and optionally the lower slip support are made of engineering grade plastics. In particular, the upper and lower slip wedges are subjected to substantially compressive loading. Since engineering grade plastics exhibit good strength in compression, they make excellent choices for use in components subjected to compressive loading. The lower slip support is also subjected to substantially compressive loading and can be made of engineering grade plastic when the packer is subjected to relative low pressures and temperatures. The upper and lower slips may also be of plastic in some applications. Hardened inserts for gripping well bore 12 when the packer is set may be required as part of the plastic slips. Such construction is discussed in more detail below. Mandrel 102 is subjected to tensile loading during setting and operation, and many plastics will not be acceptable materials therefor. However, some engineering plastics exhibit good tensile loading characteristics, so that construction of mandrel 22 from such plastics is possible. Reinforcements may be provided in the plastic resin as necessary. Example A packer was constructed in which the upper slip wedge and lower slip wedge were constructed by molding the parts to size from a phenolic resin plastic with glass reinforcement. The specific material used was Fiberite 4056J manufactured by Fiberite Corporation of Winona, Minnesota. This material is classified by the manufacturer as a two stage phenolic with glass reinforcement. It has a tensile strength of 18,000 psi and a compressive strength of 40,000 psi. Setting and Operation of the Apparatus Downhole tool apparatus 10 is positioned in well bore 12 and set into engagement therewith in a manner similar to prior art devices made with metallic components. For example, a prior art apparatus and setting thereof is disclosed in the above-referenced U.S. Patent No. 4,151,875 to Sullaway. In the setting of the packer embodiments 100 and 400, and the bridge plug embodiment 500 the setting tool is attached to tension sleeve 174. During setting, the setting tool pushes downwardly on upper slip support 110, thereby shearing shear pin 112. Upper slips 116 are moved downwardly with respect to upper slip wedge 126. Tapers 120 and upper slips 116 slide along upper slip wedge 126, and shoulders 118 on upper slips 116 slide along shoulder 114 on upper slip support 110. Thus, upper slips 116, are moved radially outwardly with respect to center mandrel 102 such that edges 124 of inserts 122 grippingly engage well bore 12. Also during the setting operation, upper slip 126 is forced downwardly, shearing shear pin 128. This in turn causes packer elements 40 and 42 to be squeezed outwardly into the sealing engagement with the well bore. The lifting on center mandrel 102 causes the lower slip support (valve housing 144 in the first packer embodiment 100, lower slip support 402 in second packer embodiment 400, and lower slip support 502 in the bridge plug embodiment 500) to be moved up and lower slips 136 to be moved upwardly with respect to lower slip wedge 130. Tapers 134 in lower slips 136 slide along lower slip wedge 130, and shoulders 140 on lower slips 136 slide along the corresponding shoulder 142, 406, or 506. Thus, lower slips 136 are moved radially outwardly with respect to center mandrel 102 so that inserts 138 grippingly engage well bore 12. Also during the setting operation, lower slip wedge 130 is forced upwardly, shearing shear pin 132, to provide additional squeezing force on packer elements 40 and 42. The engagement of inserts 122 in upper slips 116 and inserts 138 in lower slips 136 with well bore 12 prevent packers 100 and 400 and bridge plug 500 from coming unset. Once the packer 100 is set, the valve 164 therein may be actuated in a manner known in the art. In the packer embodiment 400, the valve assembly comprising valve body 432, valve seal 434, valve spacer 436, valve head 438 and valve holder 442 is operated in a manner substantially identical to that of the Halliburton EZ Drill® squeeze packer of the prior art. Drilling out the Packer Apparatus Drilling out any embodiment of downhole tool 10 may be carried out by using a standard drill bit at the end of tubing string 16. Cable tool drilling may also be used. With a standard "tri-cone" drill bit, the drilling operation is similar to that of the prior art except that variations in rotary speed and bit weight are not critical because the non-metallic materials are considerably softer than prior art cast iron, thus making tool 10 much easier to drill out. This greatly simplifies the drilling operation and reduces the cost and time thereof. In addition to standard tri-cone drill bits, and particularly if tool 10 is constructed utilizing engineering grade plastics for the mandrel as well as for slip wedges, slips, slip supports and housings, alternate types of drill bits may be used which would be impossible for tools constructed substantially of cast iron. For example, polycrystalline diamond compact (PDC) bits may be used. Drill bit 14 in FIG. 1 is illustrated as a PDC bit. Such drill bits have the advantage of having no moving parts which can jam up. Also, if the well bore itself was drilled with a PDC bit, it is not necessary to replace it with another or different type bit in order to drill out tool 10. While specific squeeze packer and bridge plug configurations of packing apparatus 10 have been described herein, it will be understood by those skilled in the art that other tools may also be constructed utilizing components selected of non-metallic materials, such as engineering grade plastics.

Claims: A downhole apparatus for use in a well bore, said apparatus comprising: a center mandrel (102); and slip means (116,126,136,130) disposed on said mandrel for grippingly engaging said well bore when in a set position, characterized in that said slip means comprise a slip wedge (126,130) made of a non-metallic material, and that the diameter of the bore (104) of the mandrel is less than half the outside diameter of the mandrel. Apparatus according to claim 1, which is a packing apparatus and comprises packing means (40,42) disposed on the mandrel (102) for sealingly engaging said wellbore when in a set position. Apparatus according to claim 2, wherein said slip means is an upper slip means (116) disposed above said packing means and further comprising a lower slip means (136) disposed below said packing means (40,42), said lower slip means comprising another slip wedge (130) made of a non-metallic material. Apparatus according to claim 1, 2 or 3, wherein said slip means (116,126,136,130) comprises a slip support (110,144) made of a non-metallic material. Apparatus according to claim 1, 2, 3 or 4, wherein said slip means comprises slips (116,136) made of a non-metallic material. Apparatus according to claim 5, further comprising a plurality of hardened inserts (122,138) molded into said material of said slips (116,136). Apparatus according to any of claims 1 to 6, wherein said mandrel (102) is made of a non-metallic material. Apparatus according to any of claims 1 to 7, wherein said non-metallic material is an engineering grade plastic. Apparatus according to claim 8, wherein said plastic is nylon, a phenolic material which is Fiberite FM4056J, Fiberite FM4005 or Resinoid 1360, or an epoxy resin. Apparatus according to any of claims 1 to 9, wherein the or each said wedge (126,130) is molded to size.

Inventors: BERSCHEIDT KEVIN T, HUSHBECK DONALD F, JACOBI RICK D, STREICH STEVEN G, BERSCHEIDT, KEVIN T., HUSHBECK, DONALD F., JACOBI, RICK D., STREICH, STEVEN G.
Applicants: HALLIBURTON CO, HALLIBURTON COMPANY
Application year: 1992
Main classification: E21B33
IPC codes: E21B33