BACKGROUND

Field of the Disclosure

[0001] Embodiments disclosed herein relate generally to downhole tools. In particular, embodiments disclosed herein relate to a pressurizing device having a ball drop module for pressure activating downhole tools.

Background Art

[0002] In oilfield drilling and completion, various downhole tools in a drillstring may be pressure activated by increasing a pressure in a central bore of the drillstring. To increase the pressure in the central bore, fluid flow through the central bore may be blocked or obstructed at a particular location in the bore, which allows fluid pressure to increase above the obstruction in the bore. Ball drop devices are one such tool that may be used to obstruct the central bore by dropping a steel ball into the central bore and allowing the drilling fluid or similar liquid to carry the ball, assisted by gravity down the hole until the ball lodges in a landing seat located downhole in the bore. The dropped ball may obstruct the fluid flow through the central bore and allow the fluid pressure uphole of the ball to be increased. When activation of a particular tool is complete, the ball may be removed from the central bore, which allows fluid flow to resume through the central bore.

[0003] Removal of the ball from the central bore may be carried out in a number of ways. For example, the ball may be made of a drillable material, such that the ball is drilled through to allow the fluid to return to flow through the central bore. Alternatively, the landing seat or ball may be formed of a material such that the ball may be extruded through the seat at a high pressure to remove the ball. However, extrusion or drilling through the ball leaves a reduced diameter section of the central bore at the landing seat location (i.e. , the diameter of the central bore is reduced to a diameter of the landing seat orifice). This reduced diameter may prevent additional tools from being passed through to locations downhole of the landing seat.

l [0004] To reopen the central bore to its original diameter, release mechanisms have been incorporated into the landing seat to allow both the ball and the landing seat to be moved. For example, one such mechanism includes a landing seat having a collet finger mechanism to secure the landing seat in the bore, the collet fingers then being disengaged and the ball and seat forced downhole. However, the collet finger mechanism has proved to be difficult to position and seal properly in the bore, does not provide the ability to reliably activate the downhole tool, and often does not fail predictably when required. Further, the above mentioned mechanisms are not capable of being reused and instead are discarded and lost at a bottom of the wellbore after use.

[0005] Accordingly, there exists a need for a reusable ball drop device that may be reliably operated for activation of downhole tools.

SUMMARY OF THE DISCLOSURE

[0006] In one aspect, embodiments disclosed herein relate to a pressurizing device including a main housing having a central bore therethrough and a ball drop module removably disposed within the main housing, the ball drop module including a ball seat hingedly attached within the ball drop module and configured to receive a dropped ball, wherein the ball seat is configured to rotate about a hinge from a closed position to an open position when a pressure above the ball seat exceeds a preset limit.

[0007] In other aspects, embodiments disclosed herein relate to a method of operating a pressurizing device to activate a downhole tool, the method including circulating a fluid through an orifice in a ball seat of a ball drop module, wherein the ball seat is in a closed position, engaging a dropped ball with the orifice of the ball seat and obstructing fluid flow through the orifice, increasing a fluid pressure uphole of the ball seat to an activation pressure of the downhole tool, and increasing the fluid pressure uphole of the ball seat above a preset pressure limit to shear one or more shear pins and open the ball seat.

[0008] Other aspects and advantages of the invention will be apparent from the following description and the appended claims. BRIEF DESCRIPTION OF DRAWINGS

[0009] Figure 1 is a cross-sectional view of a pressurizing device having a ball drop module in a closed position in accordance with embodiments of the present disclosure.

[0010] Figure 2 is a detailed cross-sectional view of the ball drop module in a closed position in accordance with embodiments of the present disclosure.

[0011] Figure 3 is a cross-sectional view of the pressurizing device having the ball drop module in an open position in accordance with embodiments of the present disclosure.

[0012] Figure 4 is a detailed cross-sectional view of the ball drop module in an open position in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION

[0013] In one aspect, embodiments disclosed herein relate to a reusable pressurizing device having a ball drop module for pressure activating downhole tools and methods of using the ball drop module.

[0014] Referring to Figure 1 , a cross-sectional view of the pressurizing device 100 is shown in accordance with embodiments of the present disclosure. Pressurizing device 100 includes a main housing 103 having a central bore 101 therethrough that is comprised of a first housing 102 and a second housing 104, which may be coupled together. A ball drop module 1 10 is disposed within the main housing and held in place between first housing 102 and second housing 104. Thus, ball drop module 1 10 may be characterized as a "cartridge-type" system that is easily installed and removed from the main housing. Pressurizing device 100 may include one or more seals disposed between first and second housings 102, 104 and ball drop module 1 10 to prevent fluid leakage between the main housing and ball drop module 1 10. Although two separate housings 102 and 104 coupled together are shown, those skilled in the art will understand that, alternatively, a single integral main housing having ball drop module 1 10 disposed therein may be used.

[0015] Referring to Figures 1 and 2, ball drop module 1 10 includes a cylindrical body

11 1 in which a ball seat 1 12 having a centrally located orifice 1 16 is located. Ball seat 1 12 further includes a hinge 120 attached to housing 1 1 1 about which ball seat 1 12 is configured to rotate. As shown, a ball 1 14 is configured to engage ball seat 1 12. As shown, ball seat 1 12 is initially secured in a position perpendicular to central bore 101 by one or more shear pins 122, which are inserted radially through an outer wall of cylindrical body 11 1 and into ball seat 1 12. Further, ball drop module 1 10 includes a locking mechanism 124, which comprises a lock pin 126 and a biasing mechanism 128 (e.g., a spring) disposed within a cavity of cylindrical body 1 1 1. Lock pin 126 is configured to move in an axial direction and engage a notch 121 of hinge 120 when ball seat 1 12 rotates about hinge 120 to an open position, or parallel to central bore 101, as will be described later.

[0016] Ball seat 112 is configured to allow dropped ball 1 14 to sealingly engage orifice 1 16 when seated, and thus prevent fluid flow therethrough. Ball seat 1 12 is configured having an angled inlet surface 1 18 with which ball 114 contacts. Angled inlet surface 1 18 may be configured such that when ball seat 112 is in the closed position the angled inlet surface 1 18 is steep enough to centrally position ball 1 14 in orifice 1 16, and when ball seat 1 12 is in the open position the angled inlet surface 1 18 is shallow enough to allow ball 1 14 to fall out of and away from orifice 1 16. To allow for such movement, angle a of angled inlet surface 1 18 may vary within a range of about 90 degrees to about 150 degrees.

[0017] Methods of using ball drop module 1 10 include initially orienting ball seat 1 12 in a closed position (i.e. , perpendicular to central bore 101) and inserting one or more shear pins 122 to secure ball seat 1 12, as shown in Figures 1 and 2. The number, shape, and material of the shear pins 122 used to secure ball seat 1 12 determine a preset pressure limit at which shear pins 122 will fail and allow ball seat 1 12 to open. Thus, the pressure limit, which may be between about 1500 and 5000 psi, may be preset by securing ball seat 1 12 with a certain number or kind of shear pins 122. In certain embodiments, each shear pin may withstand up to about 500 psi. So for example, three shear pins may be inserted to set the pressure limit at 1500 psi and 10 shear pins may be inserted to set the pressure limit at 5000 psi. However, in general, those skilled in the art will understand calculating the number of shear pins required to attain failure at the preset pressure limit. [0018] After ball seat 112 is secured in the closed position, ball drop module 110 may then be installed within main housing 103 and subsequently run downhole into a wellbore, Ball drop module 1 10 may be secured within main housing 103 with threads or other known fastener mechanisms. Otherwise, ball drop module 1 10 may be secured merely by being restricted between first housing 102 and second housing 104 of main housing 103. Before ball 1 14 is dropped, fluid may flow through unobstructed orifice 1 16 of ball seat 1 12. Ball 114 may then be dropped or inserted into the fluid and allowed to travel downward through central bore 101 until it contacts angled inlet surface 1 18 of ball seat 1 12. Contact between ball 1 14 and inlet surface 1 18 may provide a complete obstruction in central bore 101 that prevents fluid from continuing past ball seat 1 12. After ball 1 14 engages ball seat 1 12, fluid pressure above ball seat 1 12 may be increased to activate certain downhole tools (not shown).

[0019] Referring now to Figures 3 and 4, cross-sectional views of ball drop module

1 10 in an open position are shown in accordance with embodiments of the present disclosure. After activation of downhole tools is complete, ball 1 14 may be removed from ball seat 1 12 to allow fluid or additional tools to pass through central bore 101 unobstructed. To remove the ball 1 14, fluid pressure above the obstructed ball seat 1 14 may be further increased to exceed the preset pressure limit (previously described) and cause the one or more shear pins 122 to fail. After the one or more shear pins 122 fail, ball seat 1 12 may rotate about hinge 120 from the closed position to the open position. Ball 1 14 may roll out of contact with angled inlet surface 1 18 of orifice 1 16 and continue downhole, where it is lost. Ball seat 1 12 may continue to rotate about 90 degrees until reaching the open position, at which point ball seat 1 12 is stored within a pocket or cavity 130 formed in a wall of cylindrical body 1 1 1 of ball drop module 1 10.

[0020] Locking mechanism 124 is configured to secure ball seat 1 12 in the open position and ensure that ball seat 1 12 remains positioned flush with the inner surface of main housing 103 and/or the inner surface of ball drop module 1 10. Locking mechanism 124 secures ball seat 1 12 with lock pin 126, which is forced by biasing mechanism (spring) 128 into engagement with notch 121 on hinge 120. With ball seat 1 12 in the open position, fluid and any additional tools may be run downhole through central bore without obstruction. Subsequently, pressurizing device 100 may be returned to the surface and ball drop module 1 10 may be quickly removed and reset with new shear pins 122 for continued use.

[0021] Advantageously, embodiments of the present disclosure provide a reusable ball drop module for used with a pressurizing device in oil and gas casing. The entire ball drop module (except for disposable dropped ball and shear pins) may be reused for pressurization multiple times with little expense or labor required. The ball drop module is simply brought to the surface, reset to the closed position with new shear pins, and run back downhole. Further, the "drop-in" installation of the cartridge-type ball drop module into the pressurizing device makes accessibility very easy, and thus, any required maintenance may require minimal time and labor.

[0022] Still further, the ball drop module may provide a reliable ball seat with which the dropped ball may engage and seal. The ball drop module is easily oriented within the main housing of the pressurizing device, thus reducing chances of undesirable failures and leaks during high pressure activation of downhole tools. In addition, the ball drop module is easily configurable for various applications requiring different downhole pressures, as the ball drop module may be configured for use at various preset pressure limits by selecting a particular number or types of shear pins. The ball drop module may also be configured to be used with a number of different liner and/or casing sizes.

[0023] 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.