IP Library Granted Patent US 10,626,697
Granted Patent B2
US 10,626,697 · App. 16/119,423 · Granted Apr 21, 2020

Frac plug with bi-directional gripping elements

Inventor: Robert Dirocco (Humble, TX)
Assignee: FORUM US, INC.
E21B33/1293E21B33/128
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Quick Facts
Patent No.
US 10,626,697
App. No.
16/119,423
Granted
Apr 21, 2020
Kind
B2
Abstract

A frac plug for use in a wellbore includes an upper mandrel with an axis extending therethrough and a lower mandrel that moves axially along the axis and towards the upper mandrel. The frac plug further includes a sealing element and a grip ring that move radially outward from the axis and into engagement with the wellbore. The grip ring includes a first gripping element positioned at a first rake angle with respect to the axis to prevent upward movement of the grip ring with respect to the wellbore when in gripping engagement with the wellbore, and a second gripping element positioned at a second rake angle with respect to the axis that is different from the first rake angle to prevent downward movement of the grip ring with respect to the wellbore when in gripping engagement with the wellbore.

Claims (79)

1. A frac plug, comprising:

an upper mandrel comprising an axis extending therethrough;

a lower mandrel configured to move axially along the axis and towards the upper mandrel, wherein the lower mandrel is configured to move towards the upper mandrel from a lower position to an upper position;

a sealing element configured to move radially outward from the axis and into sealing engagement with a wellbore, wherein the sealing element is configured to move radially outward from the axis from a disengaged sealing position when the lower mandrel is in the lower position to an engaged sealing position when the lower mandrel is in the upper position; and

a grip ring positioned between the upper mandrel and the lower mandrel and configured to move radially outward from the axis and into gripping engagement with the wellbore as the lower mandrel moves axially towards the upper mandrel, wherein the grip ring is configured to move radially outward from the axis from a disengaged gripping position when the lower mandrel is in the lower position to an engaged gripping position when the lower mandrel is in the upper position, wherein the grip ring comprises:

a first gripping element positioned at a first rake angle with respect to the axis to prevent upward movement of the grip ring with respect to the wellbore when in gripping engagement with the wellbore; and

a second gripping element positioned at a second rake angle with respect to the axis that is different from the first rake angle to prevent downward movement of the grip ring with respect to the wellbore when in gripping engagement with the wellbore.

2. The frac plug of claim 1 , wherein:

the first gripping element comprises a first plurality of gripping elements in axial alignment with each other and equally distributed about the axis; and

the second gripping element comprises a second plurality of gripping elements in axial alignment with each other and equally distributed about the axis.

3. The frac plug of claim 1 , wherein:

the second gripping element is positioned between two first gripping elements.

4. The frac plug of claim 1 , wherein:

the grip ring comprises a ring body;

the first gripping element comprises a first button positioned within the ring body of the grip ring;

the second gripping element comprises a second button positioned within the ring body of the grip ring; and

the second button is larger in diameter than the first button.

5. The frac plug of claim 1 , wherein the first gripping element and the second gripping element extend substantially the same height above a ring body of the grip ring.

6. The frac plug of claim 1 , wherein the grip ring comprises a ring body that is configured to separate into a plurality of segments when the grip ring moves radially outward from the axis.

7. The frac plug of claim 1 , wherein:

the first rake angle of the first gripping element is between about −5 degrees and about −30 degrees; and

the second rake angle of the second gripping element is between about 5 degrees and about 30 degrees.

8. A frac plug, comprising:

an upper mandrel comprising an axis extending therethrough, an inner housing, and a cap coupled to the inner housing;

a lower mandrel configured to move axially along the axis and towards the upper mandrel;

a sealing element positioned between the upper mandrel and the lower mandrel and configured to move radially outward from the axis and into sealing engagement with a wellbore, the cap comprising a tapered outer surface and the sealing element comprising a tapered inner surface with the tapered inner surface of the sealing element configured to move along the tapered outer surface of the cap for the sealing element to move radially outward from the axis; and

a grip ring positioned between the upper mandrel and the lower mandrel and configured to move radially outward from the axis and into gripping engagement with the wellbore as the lower mandrel moves axially towards the upper mandrel, wherein the grip ring comprises:

a first gripping element positioned at a first rake angle with respect to the axis to prevent upward movement of the grip ring with respect to the wellbore when in gripping engagement with the wellbore; and

a second gripping element positioned at a second rake angle with respect to the axis that is different from the first rake angle to prevent downward movement of the grip ring with respect to the wellbore when in gripping engagement with the wellbore.

9. A frac plug, comprising:

an upper mandrel comprising an axis extending therethrough;

a lower mandrel configured to move axially along the axis and towards the upper mandrel;

a sealing element configured to move radially outward from the axis and into sealing engagement with a wellbore;

a grip ring positioned between the upper mandrel and the lower mandrel and configured to move radially outward from the axis and into gripping engagement with the wellbore as the lower mandrel moves axially towards the upper mandrel, wherein the grip ring comprises:

a first gripping element positioned at a first rake angle with respect to the axis to prevent upward movement of the grip ring with respect to the wellbore when in gripping engagement with the wellbore; and

a second gripping element positioned at a second rake angle with respect to the axis that is different from the first rake angle to prevent downward movement of the grip ring with respect to the wellbore when in gripping engagement with the wellbore; and

a cone positioned between the upper mandrel and the lower mandrel, wherein the cone comprises a tapered outer surface and the grip ring comprises a tapered inner surface with the tapered inner surface of the grip ring configured to move along the tapered outer surface of the cone for the grip ring to move radially outward from the axis.

10. A frac plug, comprising:

an upper mandrel comprising an axis extending therethrough;

a lower mandrel configured to move axially along the axis and towards the upper mandrel;

a sealing element configured to move radially outward from the axis and into sealing engagement with a wellbore;

a grip ring positioned between the upper mandrel and the lower mandrel and configured to move radially outward from the axis and into gripping engagement with the wellbore as the lower mandrel moves axially towards the upper mandrel, wherein the grip ring comprises:

a first gripping element positioned at a first rake angle with respect to the axis to prevent upward movement of the grip ring with respect to the wellbore when in gripping engagement with the wellbore; and

a second gripping element positioned at a second rake angle with respect to the axis that is different from the first rake angle to prevent downward movement of the grip ring with respect to the wellbore when in gripping engagement with the wellbore; and

an engagement interface positioned between the upper mandrel and the lower mandrel to enable the upper mandrel and the lower mandrel to move axially towards each other and prevent the upper mandrel and the lower mandrel from moving axially away each other.

11. The frac plug of claim 10 , wherein:

the upper mandrel comprises an inner housing positioned within and coupled to a cap;

the lower mandrel comprises a guide shoe positioned within and coupled to an outer housing; and

the engagement interface is formed between the inner housing and the outer housing.

12. A frac plug, comprising:

an upper mandrel comprising an axis extending therethrough;

a lower mandrel configured to move axially along the axis and towards the upper mandrel, wherein the lower mandrel is configured to move towards the upper mandrel from a lower position to an upper position;

a sealing element configured to move radially outward from the axis, wherein the sealing element is configured to move radially outward from the axis from a disengaged sealing position when the lower mandrel is in the lower position to an engaged sealing position when the lower mandrel is in the upper position; and

a grip ring positioned between the upper mandrel and the lower mandrel and configured to move radially outward from the axis, wherein the grip ring is configured to move radially outward from the axis from a disengaged gripping position when the lower mandrel is in the lower position to an engaged gripping position when the lower mandrel is in the upper position, the grip ring comprising:

a single ring body;

a first button positioned within the single ring body at a first rake angle with respect to the axis; and

a second button positioned within the single ring body at a second rake angle with respect to the axis that is different from the first rake angle.

13. The frac plug of claim 12 , wherein:

the second button is larger in diameter than the first button; and

the first button and the second button extend substantially the same height above the single ring body of the grip ring.

14. The frac plug of claim 12 , wherein:

the first button comprises a first plurality of buttons in axial alignment with each other and equally distributed about the axis; and

the second button comprises a second plurality of buttons in axial alignment with each other and equally distributed about the axis.

15. The frac plug of claim 12 , wherein the second button is positioned between two first buttons.

16. A method of setting a frac plug within a wellbore, comprising:

lowering the frac plug into the wellbore, the frac plug comprising an upper mandrel comprising an axis extending therethrough, and a lower mandrel;

moving the lower mandrel axially along the axis and towards the upper mandrel from a lower position to an upper position;

moving a grip ring radially outward with respect to an axis of the frac plug from a disengaged gripping position when the lower mandrel is in the lower position to an engaged gripping position when the lower mandrel is in the upper position such that a first gripping element positioned at a first rake angle and a second gripping element positioned at a second rake angle that is different from the first rake angle grippingly engage the wellbore; and

moving a sealing element radially outward with respect to the axis of the frac plug from a disengaged sealing position when the lower mandrel is in the lower position to an engaged sealing position when the lower mandrel is in the upper position such that the sealing element sealingly engages the wellbore.

17. The method of claim 16 , further comprising:

applying an upward force to the frac plug;

preventing upward movement of the frac plug within the wellbore through the gripping engagement of the first gripping element with the wellbore;

applying a downward force to the frac plug; and

preventing downward movement of the frac plug within the wellbore through the gripping engagement of the second gripping element with the wellbore.

18. The method of claim 16 , wherein:

the grip ring comprises a ring body;

the first gripping element comprises a first button positioned within the ring body of the grip ring;

the second gripping element comprises a second button positioned within the ring body of the grip ring; and

the second button is larger in diameter than the first button.

Assignments (7)
RELEASE OF SECOND LIEN SECURITY INTEREST IN PATENTS RECORDED AT REEL 066565/FRAME 0968 Recorded Nov 12, 2024
From: GLAS USA LLC
To: FORUM ENERGY TECHNOLOGIES, INC.; FORUM US, INC.; GLOBAL TUBING, LLC; VARIPERM ENERGY SERVICES INC.
Reel/Frame 069338/0131 →
RELEASE OF PATENT SECURITY AGREEMENT RECORDED AT REEL 053399/FRAME 0930 Recorded Nov 11, 2024
From: U.S. BANK NATIONAL ASSOCIATION
To: FORUM ENERGY TECHNOLOGIES, INC.; FORUM US, INC.; GLOBAL TUBING, LLC
Reel/Frame 069318/0330 →
ASSIGNMENT AND ASSUMPTION OF SECOND LIEN TERM LOAN INTELLECTUAL PROPERTY SECURITY AGREEMENTS Recorded Sep 27, 2024
From: VARIPERM ENERGY SERVICES PARTNERSHIP, AS RESIGNING COLLATERAL AGENT AND ASSIGNOR
To: GLAS USA LLC, AS SUCESSOR AGENT AND ASSIGNEE
Reel/Frame 069067/0317 →
SECURITY INTEREST Recorded Jan 5, 2024
From: FORUM ENERGY TECHNOLOGIES, INC.; FORUM US, INC.; GLOBAL TUBING, LLC; VARIPERM ENERGY SERVICES INC.
To: VARIPERM ENERGY SERVICES PARTNERSHIP
Reel/Frame 066565/0968 →
SECURITY INTEREST Recorded Nov 30, 2021
From: FORUM US, INC.; GLOBAL HEAT TRANSFER ULC
To: WELLS FARGO BANK
Reel/Frame 058290/0868 →
SECURITY INTEREST Recorded Aug 4, 2020
From: FORUM ENERGY TECHNOLOGIES, INC.; FORUM US, INC.; GLOBAL TUBING, LLC
To: US BANK, NATIONAL ASSOCIATION
Reel/Frame 053399/0930 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Aug 31, 2018
From: DIROCCO, ROBERT
To: FORUM US, INC.
Reel/Frame 046769/0831 →