Abstract:
The presently disclosed subject matter relates to methods and apparatus associated with a slip assembly. The slip assembly comprises a plurality of slip segments, wherein each of the plurality of slip segments and a bonding substrate. The slip segments comprise: a first end having a plurality of teeth; a second end opposite the first end; and a transition section between the first end and the second end. The bonding substrate is disposed within the transition sections. The disclosed methods pertain to the manufacture and deployment of such an apparatus.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a Continuation of U.S. patent application Ser. No. 13/361,477 filed Jan. 30, 2012, the entire disclosure of which is incorporated herein by reference. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not applicable. 
       BACKGROUND OF THE INVENTION 
       [0003]    1. Field of the Invention 
         [0004]    Embodiments disclosed herein relate to apparatuses and methods used in well operations. More specifically, embodiments disclosed herein relate to slip assemblies used in well operations. More specifically still, embodiments disclosed herein relate to cageless slip assemblies used in well operations. 
         [0005]    2. Background Art 
         [0006]    This section of this document introduces various information from the art that may be related to or provide context for some aspects of the technique described herein and/or claimed below. It provides background information to facilitate a better understanding of that which is disclosed herein. This is a discussion of “related” art. That such art is related in no way implies that it is also “prior” art. The related art may or may not be prior art. The discussion in this section is to be read in this light, and not as admissions of prior art. 
         [0007]    Slip assemblies are used in well completion operations to secure downhole tools in the well bore. For examples, slip assemblies may be run downhole on a tubular string and then radially expanded to secure packers, anchors, plugs, or other downhole tools to the sidewall of a well or well casing. 
         [0008]    Typical slip assemblies include a cage or springs that prevent the slips from contacting the annular area, thereby allowing the slip assemblies to be deployed to a specified depth without becoming stuck or prematurely setting. Once at the specified depth, the slips are released from the case or spring system using mechanical or hydraulic systems, thereby allowing the slips to radially expand into contact with the well or casing wall. Such cage and spring systems occupy annular space on the tool, thereby reducing the cross-sectional area through which a tool, such as a packer, anchor, or plug may be run. However, the cage and/or spring systems are required to prevent premature actuation of the tool. 
         [0009]    Accordingly, there exists a need for a slip assembly that may be run downhole without the requirement of a cage or spring system to prevent premature tool actuation. 
         [0010]    The present invention is directed to resolving, or at least reducing, one or all of the problems mentioned above. 
       SUMMARY OF THE DISCLOSURE 
       [0011]    In various aspects and embodiments, the disclosure herein relates to methods and apparatus associated with a slip assembly. 
         [0012]    In a first aspect, a slip assembly comprises a plurality of slip segments, wherein each of the plurality of slip segments and a bonding substrate. The slip segments comprise: a first end having a plurality of teeth; a second end opposite the first end; and a transition section between the first end and the second end. The bonding substrate is disposed within the transition sections. 
         [0013]    In a second aspect, a method of manufacturing a slip assembly comprises forming a plurality of teeth on at least one of a first end and a second end of a tubular, forming a recess on the tubular, wherein the recess is formed between the first and second ends; milling the tubular to form a plurality of slip segments; and bonding the plurality of slip segments to form an assembled slip assembly. 
         [0014]    In a third aspect, a method of deploying a downhole tool comprises: running the downhole tool comprising a slip assembly into a well, wherein the slip assembly comprises a plurality of bonded slip segments; breaking the bonds of the slip segments; radially expanding the plurality of slip segments; and engaging a wall of the well with the slip assembly. 
         [0015]    In a fourth aspect, a method of manufacturing a slip assembly comprises, the method comprising: forming a plurality of slip segments, wherein the plurality of slip segments comprise a first end, a second end, and a transition between the first and second ends, and wherein at least one of the first and second ends have a plurality of teeth; and bonding the plurality of slip segments to form an assembled slip assembly. 
         [0016]    The above presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an exhaustive overview of the invention. It is not intended to identify key or critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is discussed later. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0017]    The invention may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements, and in which: 
           [0018]      FIG. 1  is a partial cross-sectional view of a slip assembly according to embodiments of the present disclosure. 
           [0019]      FIG. 2  is a perspective view of a slip assembly according to embodiments of the present disclosure. 
           [0020]      FIG. 3  is a cross-sectional view of a slip assembly according to embodiments of the present disclosure. 
           [0021]      FIG. 4  is a perspective view of a slip assembly according to embodiments of the present disclosure. 
           [0022]      FIG. 5  is a flow chart diagram of a method of forming a slip assembly according to embodiments of the present disclosure. 
           [0023]      FIG. 6  is a flow chart diagram of a method for using a slip assembly according to embodiments of the present disclosure. 
       
    
    
       [0024]    While the invention is susceptible to various modifications and alternative forms, the drawings illustrate specific embodiments herein described in detail by way of example. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, 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. 
       DETAILED DESCRIPTION 
       [0025]    Illustrative embodiments of the invention are described below. 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&#39; 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, even if complex and time-consuming, would be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. 
         [0026]    In general, embodiments disclosed herein relate to apparatuses and methods used in well operations. More specifically, embodiments disclosed herein relate to slip assemblies used in well operations. More specifically still, embodiments disclosed herein relate to cageless slip assemblies used in well operations. 
         [0027]    As explained above, traditional slip assemblies used in downhole tools, such as packers, anchors, plugs, and the like, require use of a cage or spring system to retain slips during downhole deployment. The cage or spring systems take up valuable annular space, as the cage and/or spring systems may extend radially from the tool body. Because the cage and/or spring systems may have an outside diameter that is greater than the slips or other tool portions, the cage and/or spring systems may reduce the cross-sectional area through which the downhole tool may be deployed. 
         [0028]    Embodiments disclosed herein provide slip assemblies that do not require the use of a cage or spring system. Rather than rely on cage or spring systems to prevent the premature actuation of the slip assemblies, the slips are divided then bonded in place. The bonds are broken in a controlled fashion once the tool has reached the desired depth. 
         [0029]    Referring to  FIG. 1 , a partial cross-sectional view of a slip assembly  100  according to embodiments of the present disclosure is shown. In this embodiment, slip assembly  100  has a first end  110  and a second end  120 . As illustrated, the first end  110  and the second end  120  each have a plurality of teeth  130 . The plurality of teeth  130  extend radially from the slip assembly  100 , and are configured to engage a well or casing wall after actuation. In certain embodiments, only one of the first end  110  or second end  120  may include teeth  130 . In such an embodiment, actuation of the slip assembly may thus only cause the teeth  130  of either first end  110  or second  120  to engage a well wall. 
         [0030]    Slip assembly  100  further includes a transition section  140  located between first end  110  and second end  120 . Transition section  140  is recessed, such that the outer diameter of transition section  140  may be less than the outer diameter of first end  110  and second end  120 . In embodiments where only one of first end  110  and second end  120  have teeth  130 , the transition section may have an outer diameter that is less than the end  110 / 120  that has teeth  130 . The transition section  140  in this embodiment has a constant outside diameter, however, in alternate embodiments, the transition section  140  may have grooves or other geometric profiles. 
         [0031]    Slip assembly  100  is divided into a plurality of slip segments  150   a ,  150   b , and  105   c . The plurality of slip segments  150   a ,  150   b , and  150   c  are milled from a tubular material, so the plurality of slip segments  150   a ,  150   b , and  150   c  corresponded to one another. The manufacturing process for slip assembly  100  is described in detail below. Depending on the requirements of the operation, the number of slip segments  150  into which slip assembly  100  is divided may vary. For example, in certain embodiments, the slip assembly  100  may be divided into two, three, four, or more slip segments  150 . In such embodiments, the segments may be 180° segments, 120° segments, or 90° segments, respectively. However, in other embodiments, such as when smaller diameter casing is used, e.g., 3-6 inch casing, six to eight segments may be preferable. In other embodiments, such as when larger diameter casing is used, e.g., 12-36 inch casing, as may be used in offshore wells, the slip assembly  100  may be divided into 36 or more segments. The number of slip segments  150  that slip assembly  100  is divided into may be as many as is practical to occupy the full 360° circumference of the slip assembly  100 . The same is generally true for different diameters of so-called “open hole” wells (with no casing). 
         [0032]    Referring to  FIG. 2 , a perspective view of a slip assembly  200  according to embodiments of the present disclosure is shown.  FIG. 2  is a perspective view of the slip assembly  200  of  FIG. 1 , i.e., slip assembly  100 , and illustrates the slip assembly  200  prior to connecting individual slip segments  250  with a bonding substrate. Slip assembly  200  has a first end  210  and a second end  220 . As illustrated, the first end  210  and the second end  220  each have a plurality of teeth  230 . Slip assembly  200  further includes a transition section  240  located between first end  210  and second end  220 . 
         [0033]      FIG. 2  illustrates a slip assembly  200  that has six slip segments  250   a - f . Each slip segment  250   a - f  is 60°, so that when assembled, the slip segments  250   a - f  form a complete 360 circumference. As may be readily seen in  FIG. 2 , transition  240  extends around the entire circumference of slip assembly  200 ; however, in alternate embodiments, transition  240  may not be continuous around the entire circumference. For example, transition  240  may extend for a limited portion of the circumference, such as around the portions of slip assembly  200  where slip segments  250   a - f  are divided. 
         [0034]    Referring to  FIG. 3 , a cross-sectional view of a slip assembly  300  according to embodiments of the present disclosure is shown.  FIG. 3  illustrates slip assembly  300  after individual slip segments  350  have been bonded. Slip assembly  300  has a first end  310  and a second end  320 . As illustrated, the first end  310  and the second end  320  each have a plurality of teeth  330 . Slip assembly  300  further includes a transition section  340  located between first end  310  and second end  320 . 
         [0035]    Slip assembly  300  further includes a bonding substrate  360  disposed in transition  340 . The bonding substrate  360  may include various substances capable of bonding slip segments  350  together. Examples of bonding substrates  360  may include various elastomers and/or polymers, including polymer resins and fiber composites. The elastomer and/or polymers may be applied to transition  340  to create a laminated tubular section of slip assembly  300 . 
         [0036]    Along the internal diameter of slip assembly  300 , a secondary bonding substrate  370  may be applied to hold slip segments  350  in place during the process of connecting/bonding the individual slip segments  350 . In alternate embodiments, secondary bonding substrate  370  may be used in place of bonding substrate  360 . Depending on the requirements of the slip assembly  300 , bonding substrate  360  and secondary bonding substrate  370  may be formed of the same material, or alternatively, may be formed from different materials. For example, bonding substrate  360  may be an elastomer bond, while secondary bonding substrate  370  may be a polymer bond. Either may be reinforced with fiber in a matrix composite. 
         [0037]    Referring to  FIG. 4 , a perspective view of a slip assembly  400  according to embodiments of the present disclosure is shown.  FIG. 4  illustrates slip assembly  400  in an assembled condition, wherein individual slip segments  450  have been connected through the use of a bonding substrate  460 . 
         [0038]    Slip assembly  400  has a first end  410  and a second end  420 . As illustrated, the first end  410  and the second end  420  each have a plurality of teeth  430 . Slip assembly  400  further includes a bonding substrate  460  located between first end  410  and second end  420 .  FIG. 4  further illustrates slip assembly  400  that has six slip segments  450   a - f . Each slip segment  250   a - f  is 60°, so that when assembled, the slip segments  450   a - f  form a complete 360 circumference. 
         [0039]    In this embodiment, bonding substrate  460  is disposed in the transition portion (not shown) around the entire circumference of slip assembly  400 . Thus, individual slip segments  450   a - f  are held in place so as to form slip assembly  400 . Additionally, secondary bonding substrate  470  is disposed along the inner diameter of slip assembly  400 , thereby providing an additional connection between the slip segments  450   a - f.    
         [0040]    Referring to  FIG. 5 , a flow chart diagram of a method for manufacturing a slip assembly according to embodiments of the present disclosure is shown. In manufacturing a slip assembly, a tubular portion is selected for a particular application. Examples of types of tubular that may be used include metallic tubulars, such as steel or other metals, as well as non-metallic tubulars, such as fiberglass, carbon, or ceramics. 
         [0041]    In manufacturing the slip assembly, a first end of the tubular is formed ( 500 ) to include a plurality of teeth. The first end may be formed by, for example, milling a portion of the tubular to a selected slip profile. Similarly, a second end of the tubular is formed  510 . The second end of the tubular may be formed to include teeth, or may be formed to match an alternative slip profile. Those of ordinary skill in the art will appreciate that the plurality of teeth may be formed to include conventional tooth patterns as known in the oilfield industry. 
         [0042]    In addition to forming ( 500  and  510 ) the first and second ends, a recess is formed ( 520 ) on the tubular between the first and second ends. The depth of the recess may be selected based on the requirements of a particular slip assembly or based on operational constraints. For example, the depth of the recess may be determined based on a volume of bonding substrate that is required to hold individual slip segments in place. 
         [0043]    The method further includes milling ( 530 ) the tubular to form a plurality of slip segments. During the slip segment milling ( 530 ), the slip assembly may be divided into individual slip segments by milling linearly, or longitudinally, along the length of the tubular. As discussed above, the number of slip segments created may vary based on the requirements of the downhole operation and/or the specifics of the well, such as the diameter of the well bore or casing. In certain embodiments, an inner diameter ring may be disposed in the tubular prior to milling ( 530 ), such that the individual slip segments are held in place throughout the remainder of the manufacturing process. If used, an inner diameter ring may be removed any time after the slip segments are bonded. 
         [0044]    After the slip segments are milled ( 530 ), the plurality of slip segments may be bonded ( 540 ) to form an assembled slip assembly. The bonding process may include applying an elastomer or polymer substrate to the transition or recessed section of the slip assembly. In certain embodiments, the bonding ( 540 ) may further include applying a secondary substrate along the inner diameter of the slip assembly, such as along the area in which an inner diameter ring was previously disposed. 
         [0045]    After the slip assembly is assembled, the slip assembly may be disposed along a downhole tubular string for disposition into a well. Each slip segment has a load bearing that contacts the mandrel preventing the slip from moving upward/downward into the slip cones and expanding into the well bore or casing. The only way that the slip can be expanded is to have the slip cone hydraulically or mechanically pushed into the cageless slip causing the slip to expand over the load bearing and outward into the well bore or casing. 
         [0046]    The methods of manufacturing described herein are by way of example and illustration particular methods by which slip assemblies according to embodiments of the present disclosure may be formed. In alternative embodiments, additional steps may be undertaken or steps may be performed in different orders than expressly described herein. For example, the order that individual portions of the tubular are milled may vary and still be within the scope of the present disclosure. 
         [0047]    Alternate methods for manufacturing a slip assembly according to embodiments of the present disclosure may be used. In these embodiments, rather than form a plurality of teeth along a preformed tubular, individual slip segments are formed. The individual slip segments may be formed in a variety of ways, including, for example, casting or molding the individual slip segments. In such an embodiment, a metal or composite may be introduced into a preformed mold, allowed to set, and then the resultant product removed from the mold. 
         [0048]    Depending on the forming technique, the casting or molding material may be in liquid or solid state during introduction to the mold, and thus the introduction of the material into the mold may vary depending on the specific properties of the materials. Additionally, the types of materials used may influence the way in which the materials set or cure. In certain embodiments, the materials may be introduced after heating, and thus cooling of the materials in the mold allows the materials to set or cure. In alternative embodiments, such as with the use of thermosetting materials, the materials may be introduced to the mold, heated to a specific temperature, and then allowed to cool, thereby setting or curing the materials. 
         [0049]    The mold may include any of the various design features for the slip segments described above. For example, the mold may include a slip segment having first and second ends with a transition section therebetween, wherein at least one of the ends includes a plurality of teeth. In certain embodiments, the mold may include first and second ends with a transition section therebetween, wherein both the first and second ends have a plurality of teeth. 
         [0050]    After the slip segments have been formed, by setting or curing in the molds, the slip segments are removed from the molds. The individual slip segments may then be bonded together to form a complete assembled slip assembly. The number of slip segments used in forming the assembled slip assembly may vary according to the requirements of the completion operation as described above. In bonding the slip segments, the individual slip segments may be wrapped around a material tube, such as a metal or composite tubular, and bonded together using a bonding substrate, such as a polymer or elastomeric material. After the bonding substrate has cured, the material tube may be removed. The bonding substrate thus holds the individual slip segments together as an assembled slip assembly. 
         [0051]    In certain embodiments a bonding substrate may alternatively be applied along the inner diameter of the slip segments. In such an embodiment, rather than wrapping the slip segments around a material tube, the slip segments may be held in place from either end of the slip segments or by compressing the slip segments into place along the outer diameter of the slip segments. As explained above, in certain embodiments, a bonding substrate may be applied to both the outer diameter and the inner diameter of the slip segments when forming an assembled slip assembly. 
         [0052]    The types of composites used in manufacturing the slip assemblies described above may vary based on specific operational requirements. Examples of composite materials that may be used include carbon fiber, ceramics embedded in metal matrices, carbon/carbon materials, metal matrix composites, polymer composites, and the like. Particular resins used in either the composite materials used to form the slip segments or the bonding substrate may also vary depending on operational requirements, but may include, for example, various epoxy and epoxy derivatives, polyesters, vinlyesters, and the like. Those of ordinary skill in the art will appreciate that the aforementioned examples of composite materials and resins are not meant to be exhaustive and are not introduced as a specific limitation of the present disclosure. Rather, the above listed materials are illustrative of types of materials that may be used in forming components of the present disclosure. 
         [0053]    Referring to  FIG. 6 , a flow chart diagram of a method for using a slip assembly according to embodiments of the present disclosure is shown. During use of the slip assembly, initially, the slip assembly having a plurality of bonded slip segments is run ( 600 ) downhole. The slip assembly is lowered to a desired depth within the well, at which point the bonds holding the slip assembly segments are broken ( 610 ). The method for breaking the bonds may vary depending on the specific application for the slip assembly. For example, in certain embodiments, a hydraulic or mechanical force may be applied to the slip assembly that causes the slip segments to radially expand ( 620 ), thereby breaking/fracturing ( 610 ) the bonding substrate. In certain embodiments, the slip assembly may be self-setting. In such an embodiment, as the tool having the slip assembly is disposed into place within the well, the slip assembly self actuates. Depending on the particular embodiment in which the slip assembly is used, a separate setting tool may be disposed on the downhole tubular string; however, in certain applications, the setting tool may be an integral component of the particular tool in which the slip assembly is used. 
         [0054]    As the slip segments radially expand ( 620 ), the teeth of the slip assembly engage ( 630 ) the wall of the well or casing, thereby locking a downhole tool in place. Those of ordinary skill in the art will appreciate that, as used herein, the wall of the well corresponds to any wall tubular, substrate, casing, or the like, with which the slip assembly may engage ( 630 ). 
         [0055]    Advantageously, embodiments of the present disclosure may provide for slip assemblies that do not require the use of a cage or spring system. Because the slip assembly does not have a cage or spring system, the slip assembly provides greater radial slip extension, thereby allowing for use in larger inner diameter casing strings. 
         [0056]    Additionally, downhole tools, such as packers, anchors, plugs, and the like that include such a slip assembly, may have a smaller outer diameter, which can be run in broader ranges of casing diameters. Thus, a single size tool may advantageously be used in a variety of applications. 
         [0057]    Also advantageously, stronger tubular materials, such as steel may be used in place of low tensile ductile irons, which are used in certain applications, because the slip assembly is segmented prior to disposition downhole. Tools formed using low tensile ductile irons tend to fracture or prematurely actuate, thus, the slip assembly of the present disclosure may advantageously prevent tool damage, as well as premature actuation. 
         [0058]    While the present disclosure has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments may be devised which do not depart from the scope of the disclosure as described herein. Accordingly, the scope of the disclosure should be limited only by the attached claims.