Composite bridge plug system

[0002] Not applicable to this application.

[0003] Not applicable to this application.

[0004] 1. Field of the Invention

[0005] The present invention relates generally to bridge plugs and more specifically it relates to a composite bridge plug system for containing a well bore with reduced drill up time.

[0006] 2. Description of the Related Art

[0007] Bridge plugs have been in use for years. Conventional bridge plugs are comprised of a metallic material which is lowered into a well bore via a wire line or steel tube. To set the conventional bridge plugs within the well bore, the user caused slips within the bridge plug to extend outwardly thereby contacting the well bore walls and an elastomeric packing element to seal to the well bore by using an electronic means or pump force.

[0008] While these devices may be suitable for the particular purpose to which they address, they are not as suitable for containing a well bore with reduced drill up time. Conventional bridge plugs are difficult to remove from a well bore by conventional drilling because they are rotated within the well bore.

[0009] In these respects, the composite bridge plug system according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in so doing provides an apparatus primarily developed for the purpose of containing a well bore with reduced drill up time.

[0010] In view of the foregoing disadvantages inherent in the known types of bridge plugs now present in the prior art, the present invention provides a new composite bridge plug system construction wherein the same can be utilized for containing a well bore with reduced drill up time.

[0011] The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new composite bridge plug system that has many of the advantages of the bridge plugs mentioned heretofore and many novel features that result in a new composite bridge plug system which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art bridge plugs, either alone or in any combination thereof.

[0012] To attain this, the present invention generally comprises an elongate mandrel, a head member attached to a lower portion of the mandrel, an upper collar positioned about an upper portion of the mandrel, and a plurality of gripping members positioned about the mandrel. The gripping members are expandable outwardly when the mandrel is pulled upwardly with an engaging tube preventing the upward movement of the upper collar thereby compressing the gripping members. The upper portion of the mandrel includes a shear portion that is breakable by pulling upwardly upon the mandrel. An engaging portion surrounds the shear portion adjacent to the upper collar that is engageable with a lower slot within a head member of a higher bridge plug thereby preventing rotation of the higher bridge plug during drilling thereof.

[0013] There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and that will form the subject matter of the claims appended hereto.

[0014] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting.

[0015] A primary object of the present invention is to provide a composite bridge plug system that will overcome the shortcomings of the prior art devices.

[0016] A second object is to provide a composite bridge plug system for containing a well bore with reduced drill up time.

[0017] Another object is to provide a composite bridge plug system that utilizes a combination of metal and non-metal components for containing a conduit.

[0018] An additional object is to provide a composite bridge plug system that may be utilized within oil or gas well bores.

[0019] A further object is to provide a composite bridge plug system that reduces milling or drill out operations of the bridge plug.

[0020] Other objects and advantages of the present invention will become obvious to the reader and it is intended that these objects and advantages are within the scope of the present invention.

[0021] To the accomplishment of the above and related objects, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated and described within the scope of the appended claims.

[0022] Various other objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:

[0023] FIG. 1 is an upper perspective view of the present invention.

[0024] FIG. 2 is a side view of the present invention.

[0025] FIG. 3 is an exploded side view of one embodiment of the present invention.

[0026] FIG. 4 is a side view of the present invention movably positioned within a conduit.

[0027] FIG. 5 is a side view of the present invention non-movably secured within the conduit.

[0028] FIG. 6 is a side cutaway view of another embodiment of the present invention movably positioned within the conduit.

[0029] FIG. 7 is a side cutaway view of the embodiment of FIG. 6 non-movably secured within the conduit.

[0030] FIG. 8 is a magnified side cutaway view of the shear portion of the mandrel.

[0031] FIG. 9 is a magnified side cutaway view of the shear portion of the mandrel after being broken.

[0032] Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, FIGS. 1 through 9 illustrate a composite bridge plug system 10, which comprises an elongate mandrel 20, a head member 30 attached to a lower portion 28 of the mandrel 20, an upper collar 40 positioned about an upper portion 24 of the mandrel 20, and a plurality of gripping members 52a-bpositioned about the mandrel 20. The gripping members 52a-bare expandable outwardly when the mandrel 20 is pulled upwardly with an engaging tube 70 preventing the upward movement of the upper collar 40 thereby compressing the gripping members 52a-b. The upper portion 24 of the mandrel 20 includes a shear portion 22 that is breakable by pulling upwardly upon the mandrel 20. An engaging portion 21 surrounds the shear portion 22 adjacent to the upper collar 40 that is engageable with a lower slot 32 within a head member 30 of a higher bridge plug thereby preventing rotation of the higher bridge plug during drilling thereof.

[0033] As shown in FIGS. 6 and 7 of the drawings, the mandrel 20 is an elongated shaft constructed of a rigid material such as but not limited to metal. The mandrel 20 preferably has a constant diameter, however the mandrel 20 may have varying diameters through the length of the mandrel 20. The length of the mandrel 20 may vary depending upon the usage required. The mandrel 20 may have various cross sectional shapes including hut not limited to circular, square and rectangular.

[0034] The mandrel 20 has an upper portion 24 which is preferably threaded for removably being engaged by a coupler 16 with an installation shaft 18 attached. There are various other structures that may be utilized for the upper portion 24 capable of securing the mandrel 20 to a coupler 16.

[0035] As shown in FIGS. 7, 8 and 9 of the drawings, the upper portion 24 of the mandrel 20 preferably includes a shear portion 22. The shear portion 22 is preferably a narrower portion of the mandrel 20 which may be broken after the composite bridge plug system 10 has been properly secured within the conduit 12. The shear portion 22 may be constructed of the same material utilized throughout the mandrel 20 or a weaker material to assist in the breaking of the shear portion 22. The shear portion 22 may be broken by a pulling and/or rotating force placed upon the mandrel 20 by the coupler 16.

[0036] As shown in FIG. 1 of the drawings, an engaging portion 21 preferably is positioned about the lower end of the shearing portion. The engaging portion 21 is shaped to receive a lower slot 32 within another head member 30 of another composite bridge plug system 10. The engaging portion 21 is preferably comprised of a rectangular or square structure which may be catchably retained within the lower slot 32. The engaging portion 21 has a height sufficient to provide adequate retaining of another composite bridge plug system 10 while it is being drilled out.

[0037] The mandrel 20 further has a middle portion 26 that extends longitudinally from the upper portion 24 as best shown in FIG. 6 of the drawings. A lower portion 28 extends from the middle portion 26 and preferably has a threaded exterior for threadably receiving a head member 30. The head member 30 may also be retained upon the lower portion 28 of the mandrel 20 utilizing various other securing mechanisms such as fasteners, welding and the like. The head member 30 preferably has a tapered lower end for guiding the composite bridge plug system 10 through the conduit 12.

[0038] The mandrel 20 and the head member 30 may have a longitudinal bore that extends through either partially or completely. A check valve or other device may be attached within this bore for performing various desired activities while the composite bridge plug system 10 is secured within the conduit 12.

[0039] As shown in FIGS. 1, 2, and 4-7 of the drawings, a center member 60 is positioned about the middle portion 26 of the mandrel 20. The upper and lower edges of the center member 60 are preferably angled as best shown in FIGS. 5 through 7 of the drawings. A pair of third members 58a-bare preferably positioned about the middle portion 26 of the mandrel 20 on opposing sides of the center member 60 as best shown in FIG. 7 of the drawings. The third members 58a-bhave outer edges that are substantially radial with respect to the mandrel 20 with the inner edges angled to correspond to the angled edges of the center member 60.

[0040] A pair of opposing second members 56a-bare preferably positioned about the outer edges of the third members 58a-bas shown in FIGS. 5 through 7 of the drawings. The second members 56a-beach have a radial inner edge that corresponds to the third members 58a-band a substantially tapered outer edge as shown in FIGS. 5 through 7 of the drawings.

[0041] A pair of first members 54a-bare preferably positioned about the middle portion 26 of the mandrel 20 upon opposing sides of the second members 56a-bas shown in FIGS. 1 through 7 of the drawings. The first members 54a-bhave an angled inner and outer edge as best shown in FIGS. 5 through 7 of the drawings.

[0042] As shown in FIGS. 1 through 7 of the drawings, a pair of gripping members 52a-bis positioned about the middle portion 26 of the mandrel 20 on opposing sides of the first members 54a-b. The portion of the lower gripping member 52badjacent to the head member 30 is formed to correspond to the shape of the head member 30. The lower gripping member 52bhas a tapered inner portion which forms a conical shape as best shown in FIGS. 5 through 7 of the drawings. The outer portion of the second gripping members 52a-bpreferably have a plurality of gripping ridges that preferably extend downwardly to engage the inner wall of the conduit 12. The gripping members 52a-bare preferably comprised of a metal that fractures along longitudinal channels when the gripping members 52a-bare forced upon the first members 54a-b. The gripping members 52a-bare preferably comprised of a material that is harder than the material utilized to construct the conduit 12.

[0043] As shown in FIGS. 1 through 7, an upper main support 50 surrounds the middle portion 26 of the mandrel 20 adjacent to the upper gripping member 52a. The lower edge of the upper main support 50 is formed to catchably engage the upper gripping member 52a. The upper inner portion of the upper main support 50 is preferably tapered outwardly in a conical shape for receiving the upper member 42. The upper member 42 is formed into a conical shape that surrounds the mandrel 20. The inner surface of the upper member 42 is preferably comprised of a gripping surface such as a plurality of ridges or teeth for engaging the mandrel 20 during compression of the composite bridge plug system 10. An upper collar 40 is positioned about upper portion 24 of the mandrel 20 adjacent to the upper member 42 and the upper main support 50 as shown in FIGS. 1 through 9 of the drawings.

[0044] The upper collar 40, first members 54a-band the head member 30 are preferably comprised of a rigid and strong material such as but not limited to steel that is resistant to bending. The second members 56a-b, third members 58a-band the center member 60 are preferably comprised of a malleable material which are capable of forming a seal within the conduit 12 when compressed and expanded such as but not limited to a polymeric material.

[0045] In use, the user utilizes the installation shaft 18 attached to the mandrel 20 via the coupler 16 to lower the composite bridge plug system 10 to the location within the conduit 12 to be sealed. The user then slides an engaging tube 70 about the installation shaft 18 adjacent to the upper collar 40 as shown in FIG. 5 in a non-movable position. The user then pulls the mandrel 20 upwardly with the installation shaft 18 while the engaging tube 70 remains stationary with respect to the conduit 12. As the mandrel 20 is drawn upwardly, the head member 30 is pulled upwardly thereby compressing the upper member 42, upper main support 50, gripping members 52a-b, first members 54a-b, second members 56a-b, third members 58a-band center member 60 between the head member 30 and the upper collar 40. The compression force first causes the center member 60, third members 58a-band second members 56a-bto expand outwardly against the inner wall of the conduit 12 which is supported within an outer wall 14 as shown in FIG. 7 of the drawings. The compression force then causes the gripping members 52a-bto expand and break apart thereby penetrating the inner wall of the conduit 12 to prevent movement of the composite bridge plug system 10 within the conduit 12. The upper member 42 is compressed about the mandrel 20 thereby preventing the mandrel 20 from falling through into the conduit 12 after the coupler 16 is removed. After the composite bridge plug system 10 has been properly seated within the conduit 12, the user then rotates the installation shaft 18 while pulling upwardly thereby breaking the shear portion 22. The upper portion 24 of the mandrel 20 is then removed from the conduit 12. When the user desires to drill out the composite bridge plug system 10 from the conduit 12, the user drills into the mandrel 20 and the upper collar 40 first. The composite bridge plug system 10 may slide downwardly and rotate within the conduit 12. As the composite bridge plug system 10 slides downwardly, the head member 30 engages the engaging portion 21 of a lower composite bridge plug system 10 within the conduit 12 within the lower slot 32 thereby preventing rotation of the composite bridge plug system 10. The composite bridge plug system 10 is then continued to be drilled or milled out as desired.

[0046] Referring to FIG. 3, a slightly different embodiment of this invention is illustrated using identical reference characters for identical elements and primed reference characters for the changed components. Instead of the third member 58ahaving a flat upper surface and the third member 58bhaving a flat lower surfaces as in FIGS. 6 and 7, the third members 58a′ and 58b′ have tapered upper and lower surfaces. This requires the second elements 56a′ and 56b′ to have tapered mating surfaces but flat opposing surfaces. This requires the first members 54a′ and 54b′ to be modified to provide complementary mating surfaces. Operation of the embodiment of FIG. 3 is essentially the same as the embodiment of FIG. 6 and FIG. 7 because the gripping members 52a-band the malleable members are expanded in response to use of the coupler 16 and shaft 18.

[0047] As to a further discussion of the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.

[0048] With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed to be within the expertise of those skilled in the art, and all equivalent structural variations and relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.

[0049] Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.