Flapper on Frac Plug That Allows Pumping Down a New Plug

Abstract

A zonal isolation device conveyed into the wellbore with a propped flapper valve. The zonal isolation device comprises a deformable sealing element and a support ring movably disposed within the inner bore of the sealing element. A flapper valve coupled to the support ring is configured to engage a sealing surface of support ring. The flapper valve blocks fluid flow through the zonal isolation device in a fully closed position, allows unrestricted fluid flow through the zonal isolation device in a fully open position, and allows restricted fluid flow through the zonal isolation device when held by a propping component in an intermediate or partially open position. The zonal isolation device is anchored to the wellbore by an anchoring assembly engaged with a wedge coupled to the downhole end of the sealing element.

What is claimed is: 
     
         1 . A zonal isolation device comprising:
 a sealing element comprising a deformable material and an inner bore;   a support ring movably disposed within the inner bore of the sealing element;   a flapper coupled to the support ring and configured to engage a sealing surface of support ring, wherein the flapper blocks fluid flow through the zonal isolation device in a fully closed position and allows unrestricted fluid flow through the zonal isolation device in a fully open position and wherein the flapper further comprises a rupture disk;   a wedge engaged with a downhole end of the sealing element;   an anchoring assembly engaged with the wedge; and   an end element adjacent the anchoring assembly.   
     
     
         2 . The device of  claim 1 , wherein the rupture disk is disposed within a circumferential groove on an interior face of a hole passing through the flapper. 
     
     
         3 . The device of  claim 1 , wherein the rupture disk comprises one or more coating layers. 
     
     
         4 . The device of  claim 1 , wherein the flapper further comprises a releasable hinge configured to decouple an end of the flapper proximate the releasable hinge. 
     
     
         5 . The device of  claim 2 , wherein the flapper further comprises a releasable hinge configured to decouple an end of the flapper proximate the releasable hinge. 
     
     
         6 . The device of  claim 5 , wherein the end of the flapper proximate the releasable hinge comprises a u-shaped recess receiving the pivot pin and a clip engaging the pivot pin. 
     
     
         7 . The device of  claim 6 , wherein the flapper is configured to decouple from the releasable hinge via application of a releasing force sufficient to overcome a retaining force applied to the releasable hinge by the clip. 
     
     
         8 . A method comprising:
 inserting into a cased wellbore the zonal isolation device of  claim 1 ;   actuating the zonal isolation device to provide a set zonal isolation device, wherein the flapper transitions to the fully closed position and a wellbore zone below the set zonal isolation device is isolated from fluid flow from a wellbore zone above the set zonal isolation device;   detaching a setting tool assembly from the set zonal isolation device;   moving the setting tool assembly uphole from the set zonal isolation device, wherein the setting tool assembly is coupled to one or more perforating guns located uphole from the setting tool assembly;   sending a trigger signal to the one or more perforating guns;   forming a plurality of perforations through the casing and into the surrounding formation in a wellbore zone located above the set zonal isolation device;   removing the setting tool assembly and the one or more perforating guns coupled to the setting tool assembly from the wellbore;   pumping fluid from the surface down the wellbore and into the formation via the plurality of perforations in the wellbore zone above the set zonal isolation device and fracturing the formation; and   rupturing the rupture disk to provide for fluid flow through the set zonal isolation device.   
     
     
         9 . The method of  claim 8 , wherein the fluid flow through the set zonal isolation device enhances the dissolution rate of one or more dissolvable components of the zonal isolation device. 
     
     
         10 . The method of  claim 9 , wherein a sealing device such as a ball is not required to be pumped from the surface in order to prevent fluid flow through the set zonal isolation device and divert the fluid into the perforations and surrounding formation. 
     
     
         11 . The method of  claim 10 , wherein the fluid is slickwater, a gelled fluid, or a proppant-laden fluid. 
     
     
         12 . The method of  claim 8 , wherein the flapper further comprises a releasable hinge configured to decouple an end of the flapper proximate the releasable hinge and further comprising decoupling an end of the flapper proximate the releasable hinge to remove the flapper from contact with the sealing surface to provide for fluid flow through set zonal isolation device. 
     
     
         13 . A zonal isolation device comprising:
 a sealing element comprising a deformable material and an inner bore;   a support ring movably disposed within the inner bore of the sealing element;   a flapper coupled to the support ring and configured to engage a sealing surface of support ring, wherein the flapper blocks fluid flow through the zonal isolation device in a fully closed position and allows unrestricted fluid flow through the zonal isolation device in a fully open position and wherein the flapper further comprises a releasable hinge configured to decouple an end of the flapper proximate the releasable hinge;   a wedge engaged with a downhole end of the sealing element;   an anchoring assembly engaged with the wedge; and   an end element adjacent the anchoring assembly.   
     
     
         14 . The device of  claim 13 , wherein the releasable hinge comprises a pivot pin. 
     
     
         15 . The device of  claim 14 , wherein the end of the flapper proximate the releasable hinge comprises a u-shaped recess receiving the pivot pin and a clip engaging the pivot pin. 
     
     
         16 . The device of  claim 15 , wherein the flapper is configured to decouple from the releasable hinge via application of a releasing force sufficient to overcome a retaining force applied to the releasable hinge by the clip. 
     
     
         17 . A method comprising:
 inserting into a cased wellbore the zonal isolation device;   actuating the zonal isolation device to provide a set zonal isolation device, wherein the flapper transitions to the fully closed position and a wellbore zone below the set zonal isolation device is isolated from fluid flow from a wellbore zone above the set zonal isolation device;   detaching a setting tool assembly from the set zonal isolation device;   moving the setting tool assembly uphole from the set zonal isolation device, wherein the setting tool assembly is coupled to one or more perforating guns located uphole from the setting tool assembly;   sending a trigger signal to the one or more perforating guns;   forming a plurality of perforations through the casing and into the surrounding formation in a wellbore zone located above the set zonal isolation device;   removing the setting tool assembly and the one or more perforating guns coupled to the setting tool assembly from the wellbore;   pumping fluid from the surface down the wellbore and into the formation via the plurality of perforations in the wellbore zone above the set zonal isolation device and fracturing the formation; and   decoupling an end of the flapper proximate the releasable hinge to remove the flapper from contact with the sealing surface to provide for fluid flow through set zonal isolation device.   
     
     
         18 . The method of  claim 17 , wherein the fluid flow through the set isolation device enhances the dissolution rate of one or more dissolvable components of the zonal isolation device. 
     
     
         19 . The method of  claim 18 , wherein a sealing device such as a ball is not required to be pumped from the surface in order to prevent fluid flow through the set zonal isolation device and divert the fluid into the perforations and surrounding formation. 
     
     
         20 . The method of  claim 19 , wherein the fluid is slickwater, a gelled fluid, or a proppant-laden fluid.