Patent Publication Number: US-11047227-B1

Title: Testable indexing plug

Description:
BACKGROUND 
     In the resource recovery industry wellbores may be formed in a resource bearing formation. After forming the, a tubular may be installed to stabilize the wellbore. In some cases, cement is placed between the tubular and the formation. In such cases, cement is introduced into the tubular, flowed downward toward a toe of the wellbore. Upon reaching the toe, the cement begins to flow upwardly between an outer surface of the tubular and an inner surface of the wellbore. After the cementing a communication path is established between the tubular and the formation. 
     The communication path may be formed by a tubing conveyed perforation (TCP) system that includes a coil tubing rig and explosives. The explosives are conveyed to a targeted depth and activated to perforate the tubular establishing a communication pathway. In other cases, the communication path a shifting sleeve may be installed uphole of a landing collar. The shifting sleeve may shift open one, or have a delay or cycling mechanism that allows operators to perform a pressure test of the wellbore between establishing the communication path. 
     Prior to performing the pressure test, a wiper plug is run into the wellbore toward the toe. The wiper plug removes residual cement from the inner surface of the tubular and isolate the toe. After the pressure test, the wiper plug is removed in order to re-establish a communication path to the toe. Removing the wiper plug takes time and adds extra trips into the wellbore. Accordingly, the industry would welcome a device that isolates the toe for a pressure test and which could be subsequently reopened without the need for extra coil tubing or other tool trips into the wellbore. 
     SUMMARY 
     Disclosed is a testable indexing plug including a body having an outer surface, an inner surface defining a flow path, a first end, a second end, and an intermediate portion extending between the first end and the second end. A valve chamber extends from the first end into the intermediate portion. A valve member is arranged in the valve chamber. The valve member includes a first end portion, a second end portion including an opening, and an intermediate section including one or more ports fluidically connected with the opening. An indexing system shifts the valve member between a first position, wherein the one or more ports are arranged in the valve chamber and a second position, wherein the one or more ports are exposed outside of the valve chamber following a defined number of pressure applications to the valve member. 
     Also disclosed is a resource exploration and recovery system including a first system and a second system extending into a formation. The second system includes a tubular fluidically connected to the first system. A testable indexing plug is arranged in the tubular. The testable indexing plug includes a body having an outer surface, an inner surface defining a flow path, a first end, a second end, and an intermediate portion extending between the first end and the second end. A valve chamber extends from the first end into the intermediate portion. A valve member is arranged in the valve chamber. The valve member includes a first end portion, a second end portion including an opening, and an intermediate section including one or more ports fluidically connected with the opening. An indexing system shifts the valve member between a first position, wherein the one or more ports are arranged in the valve chamber and a second position, wherein the one or more ports are exposed outside of the valve chamber following a defined number of pressure applications to the valve member. 
     Further disclosed is a method of selectively fluidically connecting a first system with a toe of a wellbore through a testable indexing plug includes applying a test pressure to a valve member of the testable indexing plug, shifting the valve member in a valve body of the testable indexing plug from a first position to a second position with the test pressure, releasing the test pressure allowing the valve member to shift back to the first position completing a first cycle, completing a selected number of cycles, applying a final test pressure, shifting the valve member in a valve body of the testable indexing plug from the first position to the second position with the final test pressure, and releasing the test pressure allowing the valve member to shift from the second position to a third position fluidically exposing the first system with the toe of the wellbore through the testable indexing plug. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike: 
         FIG. 1  depicts a resource exploration and recovery system including a testable indexing plug having an indexing system, in accordance with an exemplary embodiment; 
         FIG. 2  depicts the testable indexing plug of  FIG. 1  illustrating a valve member in a first position, in accordance with an exemplary embodiment; 
         FIG. 3  depicts the testable indexing plug of  FIG. 2  illustrating the valve member in a second position, in accordance with an exemplary embodiment; 
         FIG. 4  depicts the testable indexing plug of  FIG. 2  illustrating the valve member in a third position, in accordance with an exemplary embodiment; 
         FIG. 5  depicts a partial glass drawing of the testable indexing plug showing the indexing system in a start position; 
         FIG. 6  depicts a partial glass drawing of the testable indexing of  FIG. 5  showing the indexing system in an intermediate position; and 
         FIG. 7  depicts a partial glass drawing of the testable indexing plug of  FIG. 6  Showing the indexing system in an end position in which a flow path is opened. 
     
    
    
     DETAILED DESCRIPTION 
     A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures. 
     A resource exploration and recovery system, in accordance with an exemplary embodiment, is indicated generally at  10 , in  FIGS. 1 and 2 . Resource exploration and recovery system  10  should be understood to include well drilling operations, completions, resource extraction and recovery, CO 2  sequestration, and the like. Resource exploration and recovery system  10  may include a first system  14  which, in some environments, may take the form of a surface system  16  operatively and fluidically connected to a second system  18  which, in some environments, may take the form of a downhole system. 
     First system  14  may include a control system  23  that may provide power to, monitor, communicate with, and/or activate one or more downhole operations as will be discussed herein. Surface system  16  may include additional systems such as pumps, fluid storage systems, cranes and the like (not shown). Second system  18  may include a casing tubular  30  that extends into a wellbore  34  formed in a formation  36 . Casing tubular  30  includes an inner surface  37  and an outer surface (not separately labeled). Wellbore  34  includes an annular wall  38  which may be spaced from the outer surface of casing tubular  30 . An amount of cement  40  is provided between annular wall  38  and the outer surface of casing tubular  30 . Cement  40  and casing tubular  30  support wellbore  34 . 
     In accordance with an exemplary embodiment, a testable indexing plug  50  is landed in casing tubular  30  at a select depth. Testable indexing plug  50  fluidically isolates first system  16  from a toe  52  of wellbore  34 . As shown in  FIG. 2 , testable indexing plug  50  includes a body  60  having a first end  62 , a second end  64 , and an intermediate portion  66  extending between the first end  62  and second end  64 . Body  60  also includes an outer surface  68  and an inner surface  70  that defines a flow path  72 . A valve chamber  80  is defined at first end  62 . Valve chamber  80  includes an increased diameter portion (not separately labeled) that extends from first end  62  partially along intermediate portion  66  to a base section  82 . Testable indexing plug  50  includes a seal  84  mounted to outer surface  68 . Seal  84  includes a plurality of wiper members, one of which is indicated at  86 . Wiper members  86  seal against inner surface  37  of casing tubular  30 . 
     In further accordance with an exemplary embodiment, testable indexing plug  50  includes a valve member  90  arranged in valve chamber  80 . Valve member  90  is selectively shiftable (through the application and removal of fluid pressure) between a first position as shown in  FIG. 2 , a second position as shown in  FIG. 3 , and a third position as shown in  FIG. 4 . Valve member  90  includes a first end portion  92 , a second end portion  94 , and an intermediate section  95  extending between first end portion  92  and second end portion  94 . 
     A cap element  97  is provided at first end portion  92 . Cap element  97  may define a radially outwardly extending projection (not separately labeled). Second end portion  94  includes an opening  98  that exposes a passage  100  extending through intermediate portion  95 . Valve member  90  includes a plurality of ports, one of which is indicated at  102 , that project radially outwardly from intermediate portion  95  and fluidically connect with passage  100 . A return spring  106  is arranged in valve chamber  80 . Return spring  106  extends between base section  82  and second end  94  of valve member  90 . Return spring  106  axially biases valve member  90  away from first end  62  of body  60 . As shown for example in  FIG. 5 , valve member  90  may also include a first recess  107  that receives one or more shear screws  108  and a second recess  109  that receives an O-ring (not separately labeled). 
     In accordance with an exemplary embodiment, valve member  90  may selectively fluidically connect first system  14  and toe  52  of wellbore  34 . That is, through a predetermined number of pressure cycles, valve member  90  may transition between the first and second positions and, at a selected cycle move to the third position. In an embodiment, the first or neutral position represents a pressure off configuration. An application of fluid pressure in casing tubular  30  forces valve member  90  to shift axially in a first direction toward second end  64  of body  60 . Travel of valve member  90  is constrained by a travel stop such as base section  82  in valve chamber  80 . Letting off fluid pressure in casing tubular  30  allows valve member  90  to transition back to the first position. 
     In an embodiment, testable indexing plug  50  includes an indexing system  110  that may be configured to allow valve member  90  to transition from the second position to the third position at a selected pressure off cycle. As best shown in  FIGS. 5-7 , indexing system  110  includes a guide track  120  having a start position  122  ( FIG. 5 ), a plurality of intermediate positions, two of which is shown at  124  and  126  in  FIG. 6 , and an end position  128  such as shown in  FIG. 7 . Guide track  120  received a guide pin  140  that extends across valve chamber  80  through valve member  90 . 
     Each application and removal of pressure in casing tubular  30  a shifting and relaxation of valve member  90  allowing guide pin  140  to traverse from start position, through intermediate positions  124 , and  126 . Of course, it should be understood that the number of intermediate positions may vary. At a nth cycle, which may be defined by the number of intermediate positions  124  and  126  or the location of start position  122 , a removal of pressure allows guide pint  140  to pass into end position  128  thereby allowing return spring  106  to shift valve member  90  from the second position to the third position. At this point, it should be understood that the start position may be set at one of the intermediate positions. With this arrangement, the testable indexing plug may isolates the toe of the wellbore for a pressure test and then be opened without the need for any additional tool runs. 
     Set forth below are some embodiments of the foregoing disclosure: 
     Embodiment 1. A testable indexing plug comprising: a body including an outer surface, an inner surface defining a flow path, a first end, a second end, and an intermediate portion extending between the first end and the second end; a valve chamber extending from the first end into the intermediate portion; a valve member arranged in the valve chamber, the valve member including a first end portion, a second end portion including an opening, and an intermediate section including one or more ports fluidically connected with the opening; and an indexing system that shifts the valve member between a first position, wherein the one or more ports are arranged in the valve chamber and a second position, wherein the one or more ports are exposed outside of the valve chamber following a defined number of pressure applications to the valve member. 
     Embodiment 2. The testable indexing plug according to any prior embodiment, further comprising: a seal including a plurality of wiper members mounted to and extending outwardly of the outer surface. 
     Embodiment 3. The testable indexing plug according to any prior embodiment, wherein the second end portion of the valve member includes a cam portion and the inner surface of the body includes a stop portion, at least one of the cam portion and the stop portion including a selected number of landing zones that maintain the one or more ports in the flow path and at least one release zone that enables the valve member to shift axially outwardly of the body fluidically connecting the one or more ports and the second end. 
     Embodiment 4. The testable indexing plug according to any prior embodiment, further comprising: a return spring extending about a portion of the valve member. 
     Embodiment 5. The testable indexing plug according to any prior embodiment, wherein the first end portion of the valve member includes a radially outwardly projecting lip, the return spring includes a first end arranged at the radially outwardly projecting lip and a second end abutting the first end of the body. 
     Embodiment 6. A resource exploration and recovery system comprising: a first system; a second system extending into a formation, the second system including a tubular fluidically connected to the first system; and a testable indexing plug arranged in the tubular, the testable indexing plug comprising: a body including an outer surface, an inner surface defining a flow path, a first end, a second end, and an intermediate portion extending between the first end and the second end; a valve chamber extending from the first end into the intermediate portion; a valve member arranged in the valve chamber, the valve member including a first end portion, a second end portion including an opening, and an intermediate portion including one or more ports fluidically connected with the opening; and an indexing system that shifts the valve member between a first position, wherein the one or more ports are arranged in the valve chamber and a second position, wherein the one or more ports are exposed outside of the valve chamber following a defined number of pressure applications to the valve member. 
     Embodiment 7. The resource exploration and recovery system according to any prior embodiment, further comprising: a plurality of wiper seals mounted to and extending outwardly of the outer surface. 
     Embodiment 8. The resource exploration and recovery system according to any prior embodiment, wherein the second end portion of the valve member includes a cam portion and the inner surface of the body includes a stop portion, at least one of the cam portion and the stop portion including a selected number of landing zones that maintain the one or more ports in the flow path and at least one release zone that enables the valve member to shift axially outwardly of the body fluidically connecting the one or more ports and the second end. 
     Embodiment 9. The resource exploration and recovery system according to any prior embodiment, further comprising: a return spring extending about a portion of the valve member. 
     Embodiment 10. The resource exploration and recovery system according to any prior embodiment, wherein the first end portion of the valve member includes a radially outwardly projecting lip, the return spring includes a first end arranged at the radially outwardly projecting lip and a second end abutting the first end of the body. 
     Embodiment 11. A method of selectively fluidically connecting a first system with a toe of a wellbore through a testable indexing plug comprising: applying a test pressure to a valve member of the testable indexing plug; shifting the valve member in a valve body of the testable indexing plug from a first position to a second position with the test pressure; releasing the test pressure allowing the valve member to shift back to the first position completing a first cycle; completing a selected number of cycles; applying a final test pressure; shifting the valve member in a valve body of the testable indexing plug from the first position to the second position with the final test pressure; and releasing the test pressure allowing the valve member to shift from the second position to a third position fluidically exposing the first system with the toe of the wellbore through the testable indexing plug. 
     Embodiment 12. The method according to any prior embodiment, further comprising: introducing the testable indexing plug into the wellbore; and guiding the testable indexing plug to a selected depth, wherein guiding the testable indexing plug includes wiping internal surfaces of the wellbore with a plurality of wipers extending from the testable indexing plug. 
     The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. 
     The terms “about” and “substantially” are intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” and/or “substantially” can include a range of ±8% or 5%, or 2% of a given value. 
     The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and/or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc. 
     While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited.