Moled foam plugs, plug systems and methods of using same

BACKGROUND

0001The present invention relates generally to subterranean well construction, and more particularly to plugs, plug systems, and methods for using these plugs and systems in subterranean wells.

0002Cementing operations may be conducted in a subterranean formation for many reasons. For instance, after (or, in some cases, during) the drilling of a well bore within a subterranean formation, pipe strings such as casings and liners are often cemented in the well bore. This usually occurs by pumping a cement composition into an annular space between the interior wall of the well bore and the exterior surface of the pipe string disposed therein. Generally, the cement composition is pumped down into the well bore through the pipe string, and up into the annular space. Prior to the placement of the cement composition into the well bore, the well bore is usually full of fluid, e.g., a drilling mud or fluid. Oftentimes, an apparatus known as a cementing plug may be employed and placed in the fluid ahead of the cement composition to separate the cement composition from the drilling fluid as the cement slurry is placed in the well bore. The cementing plug also wipes drilling fluid from the inner surface of the pipe string as it travels through the pipe string, thereby preventing contamination of the cement slurry by the drilling fluid as it is pumped downhole. Once placed in the annular space, the cement composition is permitted to set therein, thereby forming an annular sheath of hardened substantially impermeable cement therein that substantially supports and positions the pipe string in the well bore and bonds the exterior surface of the pipe string to the interior wall of the well bore.

0003In some circumstances, a pipe string will be placed within the well bore by a process comprising the attachment of the pipe string to a tool (often referred to as a “casing hanger and run-in tool” or a “work string”) which may be manipulated within the well bore to suspend the pipe string in a desired location. In addition to the pipe string, a sub-surface release cementing plug system comprising a plurality of cementing plugs may also be attached to the casing hanger and run-in tool. Such cementing plugs may be selectively released from the run-in tool at desired times during the cementing process. Additionally, a check valve, typically called a float valve, will be installed near the bottom of the pipe string. The float valve may permit the flow of fluids through the bottom of the pipe string into the annulus, but not the reverse. A cementing plug will not pass through the float valve.

0004When a first cementing plug (often called a “bottom plug”) is deployed from a sub-surface release cementing plug system and arrives at the float valve, fluid flow through the float valve is stopped. Continued pumping results in a pressure increase in the fluids in the pipe string, which indicates that the leading edge of the cement composition has reached the float valve. Operations personnel then increase the pump pressure to rupture a rupturable member, within the bottom plug. Said rupturable member may be in the form of a pressure sensitive disc, rupturable elastomeric diaphragm, or detachable plug (stopper) portion which may or may not remain contained within the bottom plug. After the rupturable member has failed, the cement composition flows through the bottom plug, float valve and into the annulus. When the top plug contacts the bottom plug which had previously contacted the float valve, fluid flow is again interrupted, and the resulting pressure increase indicates that all of the cement composition has passed through the float valve. It is important that all of the desired cement composition be pumped into the annulus from the pipe string. If not, the cement remaining in the pipe string will have to be drilled out before any further activities can take place. Furthermore, the annulus might not be properly filled with cement, and undesirable formation-fluid migration or failure of the pipe string may result. On the other hand, if the cement is overdisplaced, a lower portion of the annulus might not be properly filled with cement, and undesirable formation-fluid migration or failure of the pipe string could result. Overdisplacement of the cement is considered a worse problem than underdisplacement, as it can be more difficult to correct.

0005Conventional cementing plugs are formed with wiper fins on their exterior surface, which function to wipe the pipe string as they travel downhole. Conventional cementing plugs used to wipe large diameter casing strings (18⅝ and larger) are by their very nature expensive to make, both heavy and bulky to handle, and require additional time to drill out due to the sheer volume of drillable materials to be removed. Under some conditions it may be advantageous to the well operator to run casing strings consisting of two or more pipe sizes, with the larger pipe size being at the shallowest depth and progressively tapering to the minimum pipe size. These casing configurations are typically known as “tapered strings” and require specially designed cementing plugs to wipe the different pipe diameters involved.

0006<figref idref="DRAWINGS">FIG. 1</figref> illustrates a typical cementing plug used to wipe a tapered string consisting of two different pipe sizes. Especially when three more pipe sizes are to be wiped, the plugs become overly long to fit in conventional plug containers and due to the long, flexible wiper segments used to wipe the larger pipe sizes the plugs may be generally unbalanced, or unstable, such that they may not clean the pipe wall and separate fluids with the desired efficiency. As can be seen from this drawing, the cementing plug has a complex design. In particular, it is formed of two or more distinct body sections that have been joined together end to end. The front body section contains a set of wiper fins that project radially outward a first diameter. The rear body section contains a separate set of wiper fins that project radially outward a second diameter, which is greater than the first diameter. The wiper fins of the front body section operate to wipe the section of the pipe string having the smallest diameter, which is the section of the pipe string that penetrates deepest into the well bore. The wiper fins of the rear body section operate to wipe the section(s) of the pipe string having the greatest diameter(s), which is the section of the pipe string that penetrates into the shallow section of the well bore. Both body sections are machined so that they can be threadably engaged. Accordingly, conventional cementing plugs are fairly complex devices that are relatively time-consuming and thus expensive to manufacture, difficult to use, and are more costly to drill out due to the increased plug length and/or material content.

0007In addition, cementing plugs may be required to pass through internal restrictions designed into special tools which may be incorporated into the pipe string, such as the seats in a plug operated multiple stage cementing device. The specially designed cementing plugs required to pass through these types of internal restrictions must both effectively wipe the casing ID and pass through the internal restrictions with minimal pressure increase to avoid prematurely activating the tool. In these instances, it is generally impossible to place the special devices in tapered strings unless the device is located in the largest pipe size due to the increased pressure that would otherwise be required to force the mass of the larger wiper segments through the restrictions.

0008Thus, there is a need for a new type of cementing plug capable of wiping multiple pipe diameters and/or easily passing through small internal restrictions that is more efficient, less costly, more user friendly, and be at least partially comprised of easily removed materials.

SUMMARY

0009The present invention relates generally to subterranean well construction, and more particularly, to cementing plugs, plug systems, and methods for using these plugs and systems in subterranean wells.

0010In one embodiment, the present invention is directed to an improved plug for separating successively introduced fluids into a wellbore, in particular a casing string. The plug comprises a cylindrically-shaped inner mandrel that has a hollow inner passage through which fluids may pass and an outer elastomeric foam sleeve secured thereto. The outer elastomeric foam sleeve may be generally cylindrically shaped or contain a series of ribs or similar geometric shapes forming its outer longitudinal profile. The plug has a nose profile formed at the lower end of the inner mandrel and an internal upset formed at the upper end having a bore larger than the ID of the inner mandrel at that end. A recess is also formed within the nose profile. In one embodiment, a high pressure disc is secured within the recess formed in the upper end. In another embodiment, a rupturable member is secured within the recess formed in the upper end.

0011In another embodiment, the elastomeric foam outer body may be attached to a solid inner mandrel comprising a nose section designed to perform a specific function, such as seat and/or seal into a special profile such as a first stage baffle/baffle adapter typically used in multiple stage cementing operations using plug operated multiple stage cementing devices. As described below, the inner mandrel may take many different forms.

0012In another embodiment, the present invention is directed to a plug system for separating fluids successively introduced into a passage. The plug system comprises an assembly of at least two plugs of the type described immediately above. In one embodiment, two plugs linearly aligned in a top and bottom configuration are provided. The plugs are placed into the casing string with the nose portions facing down. The top plug is formed with the high pressure disk and the bottom plug is formed with the rupturable member, which mates with the nose portion of the top plug. The plug system according to the present invention may further comprise a float valve, which is designed to be installed inside the casing string at the end disposed at the bottom of the well bore. The recess in the nose of the inner mandrel of the bottom plug is fitted with a flat face seal ring that is adapted to mate with, and seal against, the top face of the float valve.

0013In yet another embodiment, the present invention is directed to a method of separating fluids successively introduced into a subterranean well bore. The method comprises the steps of suspending an assembly comprising a plurality of plugs within a casing string, wherein at least one of the plugs comprises an inner mandrel and an outer elastomeric foam sleeve secured thereto; introducing a first fluid into the well bore through the casing string; introducing a second fluid into the well bore behind the first fluid such that an interface between the two fluids is formed; and deploying at least one plug within the casing string at the interface of the first and second fluids. The assembly preferably includes a top and bottom plug of the type described immediately above.

0014In one embodiment, the first fluid is a drilling fluid, the second fluid is a cement slurry and the bottom plug wipes the inside of the casing string clean of the drilling fluid as it travels down the casing string. The cement slurry is pumped downhole until the bottom plug lands against the uppermost float valve, the rupturable member fails at which point the cement slurry is displaced through the bottom plug, float valve(s), casing shoe and into the annulus formed between the casing string and the inside of the well bore. The top plug is deployed behind the cement slurry and wipes the inside of the casing string clean of the cement slurry as it travels downhole. Once the top plug engages the bottom plug at the bottom of the well bore the only cement left inside the casing is between the upper float valve and the casing shoe. The top plug prevents the cement slurry from being overdisplaced. After the cement slurry has cured, the top and bottom plugs and the float valve may be drilled out of the casing string, if required.

0015The features and advantages of the present invention will be readily apparent to those skilled in the art upon a reading of the description of the preferred embodiments, which follows.

BRIEF DESCRIPTION OF THE DRAWINGS

0016A more complete understanding of the present disclosure and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawing, wherein:

0017<figref idref="DRAWINGS">FIG. 1</figref> is an elongational cross-sectional view of a prior art cementing plug.

0018<figref idref="DRAWINGS">FIG. 2</figref> is an elongational cross-sectional view of a top plug of a plug system in accordance with the present invention.

0019<figref idref="DRAWINGS">FIG. 3</figref> an elongational cross-sectional view of a bottom plug of a plug system in accordance with the present invention.

0020<figref idref="DRAWINGS">FIG. 4</figref> illustrates a plug in accordance with the present invention as it travels downhole through the inside of a telescoping casing string.

0021<figref idref="DRAWINGS">FIG. 5</figref> illustrates the deformation of the outer foam sleeve of the plug of <figref idref="DRAWINGS">FIG. 4</figref> as it passes into a restriction in the casing string.

0022<figref idref="DRAWINGS">FIG. 6</figref> illustrates the engagement of the bottom plug of a two plug system with a float valve in accordance with the present invention.

0023<figref idref="DRAWINGS">FIG. 7</figref> illustrates engagement of the top plug with the bottom plug of the two plug system shown in <figref idref="DRAWINGS">FIG. 6</figref>.

0024<figref idref="DRAWINGS">FIG. 8</figref> is an elongational cross-sectional view of an alternate embodiment of a plug in accordance with the present invention.

0025<figref idref="DRAWINGS">FIG. 9</figref> is another embodiment of a plug in accordance with the present invention similar to that of <figref idref="DRAWINGS">FIG. 8</figref>, except that its outer sleeve is formed with ribs.

0026<figref idref="DRAWINGS">FIG. 10</figref> is an elongational cross-sectional view of another alternate embodiment of a plug in accordance with the present invention.

0027<figref idref="DRAWINGS">FIG. 11</figref> is another embodiment of a plug in accordance with the present invention similar to that of <figref idref="DRAWINGS">FIG. 10</figref>, except that its outer sleeve is formed with ribs.

0028<figref idref="DRAWINGS">FIG. 12</figref> is an elongational cross-sectional view of an alternate embodiment of a plug system in accordance with the present invention.

0029<figref idref="DRAWINGS">FIG. 13</figref> is another embodiment of a plug system in accordance with the present invention similar to that of <figref idref="DRAWINGS">FIG. 12</figref>, except that the outer sleeves of the plugs are formed with ribs.

0030<figref idref="DRAWINGS">FIG. 14</figref> is an elongational cross-sectional view of an yet another alternate embodiment of a plug system in accordance with the present invention.

0031<figref idref="DRAWINGS">FIG. 15</figref> is another embodiment of a plug system in accordance with the present invention similar to that of <figref idref="DRAWINGS">FIG. 14</figref>, except that the outer sleeves of the plugs are formed with ribs.

DESCRIPTION

0032The details of the present invention will now be described with reference to the figures. Turning to <figref idref="DRAWINGS">FIG. 2</figref>, a plug in accordance with the present invention is shown generally by reference numeral <b>10</b>. The plug <b>10</b> is formed of two basic components, an inner mandrel <b>12</b> and an outer sleeve <b>14</b>.

0033The inner mandrel <b>12</b> is preferably generally cylindrical in shape and formed of a suitable drillable material such as, but not limited to, aluminum, high strength plastic, glass fiber composite, and other materials having similar properties. The inner mandrel <b>12</b> preferably has a hollow cylindrically-shaped interior region through which drilling muds and fluids, cementing slurries and the like may flow uninhibited. The inner mandrel <b>12</b> could also be made of a solid elastomeric material. The inner mandrel <b>12</b> also has a nose portion <b>16</b> formed at one of its ends. Preferably, the combined length of the inner mandrel <b>12</b> and nose portion <b>16</b> has a minimum length equal to the largest pipe OD that the plug is designed to wipe. This length-to-pipe diameter relationship is necessary to prevent the plugs from inverting in the largest pipe diameter. The foam outer body may or may not encompass the entire mandrel length.

0034The nose <b>16</b> may be disc-shaped. In one preferred certain embodiment, the nose <b>16</b> is removably attached to the inner mandrel <b>12</b> so that different noses may be attached for different applications. There is a recess <b>18</b> formed within the lower end of the inner mandrel <b>12</b>. An elastomeric flat face seal ring <b>19</b> is disposed within the recess <b>18</b>, which is adapted to mate with the top end of another plug and/or the face of a float valve or other similar device. In an alternate embodiment, the entire nose <b>16</b> may be formed of rubber.

0035The inner mandrel <b>12</b> also has a recess <b>20</b> formed in the upper end. The recess <b>20</b> is adapted to receive either a high pressure disc <b>22</b>, as shown in <figref idref="DRAWINGS">FIG. 2</figref>, or a rupturable member such as a rupture disc <b>24</b>, as shown in <figref idref="DRAWINGS">FIG. 3</figref>. As those of ordinary skill in the art will recognize, there are many other ways in which the discs <b>22</b> and <b>24</b> can be attached to the upper end of the inner mandrel <b>12</b>. As but one example, they could be formed into a cap that slips over and seals on the end of the mandrel. As those of ordinary skill in the art will further recognize, the overall size of the plug <b>10</b> and thus the diameter of the inner mandrel <b>12</b> will be a function of the diameter of the pipe into which it will be inserted as well as the particular application that the plug will be used in.

0036The high pressure disc <b>22</b> is designed to withstand high pressures and preferably will resist failing when exposed to pressures up to approximately 9,000 psi. Of course, higher pressure devices may be used in its place. In one preferred application, the high pressure disc <b>22</b> is used to bridge the top plug mandrel ID with a high pressure bridge. The entire top plug stops fluid flow upon landing upon a suitable seat. The high pressure disc <b>22</b> can either be cemented into the recess <b>20</b> using a two-part epoxy or other similar adhesive known in the art; integrally formed into the body of the inner mandrel <b>12</b>; or otherwise secured to the inner mandrel by means known in the art.

0037The rupture disc <b>24</b> is designed to fail at a predetermined pressure, e.g.; approximately 750 psi and above. Of course, the rupture disc <b>24</b> can be designed to fail at any desired pressure. The rupture disc <b>24</b> can either be cemented into the recess <b>20</b> using a two-part epoxy or other similar adhesive known in the art; integrally formed into the body of the inner mandrel <b>12</b>; or otherwise secured to the inner mandrel by means known in the art.

0038The outer sleeve <b>14</b> is preferably generally cylindrical or rib shaped and formed of a compressible elastomeric foam. It is preferably formed of an open cell polyurethane foam. However, as those of ordinary skill in the art will appreciate, other foamable elastomers may be used instead. The outer sleeve <b>14</b> is coaxially disposed around the outer surface of the inner mandrel <b>12</b>. The outer sleeve <b>14</b> is preferably molded to the inner mandrel <b>12</b> by any suitable molding process, such as injection molding, cold pour molding, or other similar known process.

0039<figref idref="DRAWINGS">FIGS. 8-11</figref> illustrate additional embodiments of the plug <b>10</b> in accordance with the present invention. <figref idref="DRAWINGS">FIG. 8</figref> illustrates an alternate embodiment of the plug (<b>210</b>), wherein the inner mandrel <b>212</b> is formed of a solid material, i.e., it is not formed with an internal flow passage. Furthermore, in this embodiment the nose <b>216</b> is integrally formed with the inner mandrel <b>212</b>. The outer sleeve <b>214</b> is similar to outer sleeve <b>14</b> in that it is preferably formed of a foam or similar material and generally cylindrical in shape. <figref idref="DRAWINGS">FIG. 9</figref> illustrates an alternate embodiment of the plug <b>210</b>′ shown in <figref idref="DRAWINGS">FIG. 8</figref>. The only difference in this embodiment is that the outer sleeve <b>214</b>′ contains a series of ribs <b>221</b>.

0040<figref idref="DRAWINGS">FIG. 10</figref> illustrates an alternate embodiment of the plug (<b>310</b>), wherein the inner mandrel <b>312</b> is formed of a tubular member having a nose <b>316</b> integrally formed within its lower end and a recess <b>320</b> formed within its upper end. A high pressure disc or rupturable member such as a rupture disc (not shown) can be inserted within the recess <b>320</b>, as described above. The outer sleeve <b>314</b> is similar to outer sleeve <b>14</b> in that it is preferably formed of a foam or similar material and generally cylindrical in shape. <figref idref="DRAWINGS">FIG. 11</figref> illustrates an alternate embodiment of the plug <b>310</b>′ shown in <figref idref="DRAWINGS">FIG. 10</figref>. The only difference in this embodiment is that the outer sleeve <b>314</b>′ contains a series of ribs <b>321</b>.

0041Referring now to <figref idref="DRAWINGS">FIGS. 4 and 5</figref>, the flow of the plug <b>10</b> inside of a casing string <b>50</b> is illustrated. In particular, <figref idref="DRAWINGS">FIG. 4</figref> shows plug <b>10</b> traveling through the large diameter section <b>52</b> of the casing string <b>50</b>. As can be seen in that figure, the outer foam sleeve <b>14</b> is sized so as to come into contact with the inside surface of the large diameter section <b>52</b> of the casing string <b>50</b>. Indeed, the outer foam sleeve <b>14</b> of plug <b>10</b> wipes the inside surface of the large diameter section <b>52</b> of the casing string <b>50</b> clean as it travels through that section of the casing string. <figref idref="DRAWINGS">FIG. 5</figref> illustrates how the outer foam sleeve <b>14</b> of plug <b>10</b> conforms to the inner surface of the casing string <b>50</b> as it encounters a restriction <b>54</b>, which is where the inside of the casing string narrows in its diameter. The compressible nature of the foam forming the outer sleeve <b>14</b> enables the plug <b>10</b> to conform to the changing diameter within the casing string <b>50</b>. Complex devices of the type shown in <figref idref="DRAWINGS">FIG. 1</figref>, which employ multi-diameter fins, were previously needed to wipe clean the inner surface of a multi-diameter casing string.

0042A simple plug system in accordance with the present invention is shown generally in <figref idref="DRAWINGS">FIG. 6</figref> by reference numeral <b>100</b>. It comprises plug <b>110</b>, which is a plug of the type shown in <figref idref="DRAWINGS">FIG. 3</figref>, i.e., a plug that has a rupture disc <b>24</b> at the upper end. However, as those of ordinary skill in the art will recognize, any of the above described embodiments of the plug may be employed. The plug system <b>100</b> further comprises a float valve <b>112</b>, which is mounted within the casing string <b>50</b> proximate the bottom of the well bore. The nose <b>16</b> of the plug <b>110</b> is designed to mate with the top face of the float valve <b>112</b>.

0043The float valve <b>112</b> comprises a collar valve housing encased in cement <b>114</b> and a linearly moveable plunger <b>116</b>. The plunger <b>116</b> includes a central shaft, which has a disc attached to it at one end and a partially ball-shaped member attached to it at the other end. It also includes a spring, which biases the plunger <b>116</b> into a position where the ball-shaped member seats itself into a partially spherically-shaped recess formed within the collar. The plug <b>110</b> is designed to seat against the top face of the float valve <b>112</b>. The float valve <b>112</b> is a one way check valve, and therefore prevents fluid below the valve from flowing up hole.

0044Fluid flows down hole through the float valve <b>112</b> as follows. Once the downward fluid pressure exceeds the threshold of the rupture disc of the plug <b>110</b>, the fluid flows through the hollow region of the plug and acts on the plunger <b>116</b> and ball-shaped member. The fluid pressure then pushes the plunger <b>116</b> downward, which in turn unseats the partially ball-shaped member from the partially spherical recess, which in turn allows the fluid to flow through the float valve <b>112</b>. As those of ordinary skill in the art will appreciate, the exact design of the float valve <b>112</b> is not critical to the present invention. Other equivalently functioning devices may be employed in its place.

0045The plug system <b>100</b> may include a second plug <b>118</b>, which is formed with a high pressure disc at its upper end. The plug <b>118</b> is designed to engage and mate with plug <b>110</b>. More particularly, the upper end of plug <b>110</b> mates with the nose portion of plug <b>118</b>. For ease of reference, plug <b>110</b> will be referred to as the bottom plug and plug <b>118</b> will be referred to as the top plug. As those of ordinary skill in the art will appreciate, plug system <b>100</b> may include any number of plugs. At least two plugs are generally required, however, for most cementing applications.

0046A method of separating fluids successively introduced into a subterranean well bore according to the present invention will now be described. A plug assembly containing a top and bottom plug are run in a casing string to the desired depth and suspended therein. A first fluid, generally a drilling mud used to drill the hole, is introduced into the well bore through casing string <b>50</b>. Next, a second fluid, generally comprising a cement slurry, is introduced into the well bore behind the first fluid such that an interface between the two fluids is formed. Simultaneously, the bottom plug <b>110</b> is released from the assembly and deployed within the casing string at the interface of the first and second fluids. As the bottom plug <b>110</b> travels downhole between the first and second fluids, it wipes the inside of the casing string <b>50</b> removing it of any residue left behind by the first fluid. Once the bottom plug <b>110</b> reaches the bottom of the casing string <b>50</b>, it seats into the float valve <b>112</b> in the manner described above.

0047The slurry is continuously pumped into the casing string <b>50</b> until the desired amount is reached. The volume of slurry required is a function of drilled hole size, casing OD and the amount of fillup that is desired in the annulus. It is quite common for the bottom plug <b>110</b> still to be traveling down the pipe when the desired volume of cement is pumped and the top plug <b>118</b> released. Both plugs with the cement (and spacer fluid if pumped on top of the bottom plug) trapped in between are displaced by a third fluid, which can be, but does not have to be, the same as the first fluid used to circulate the hole initially, until the bottom plug <b>110</b> lands and the rupture disk <b>24</b> (or other rupturable member) fails. Displacement continues until such time as the top plug <b>118</b> lands on top of the bottom plug <b>110</b> (as shown in <figref idref="DRAWINGS">FIG. 7</figref>), or float valve <b>112</b> in a top plug only application) wherein a pressure increase signals that the top plug has landed and final displacement is finished.

0048As the top plug <b>118</b> travels downhole behind the second fluid, it also wipes the inside of the casing string <b>50</b> removing it of any residue left behind by the second fluid. Once the top plug <b>118</b> reaches the bottom of the casing string <b>50</b>, it seats into the bottom plug <b>110</b> in the manner described above and shown in <figref idref="DRAWINGS">FIG. 7</figref>. The high pressure disc <b>22</b> of the top plug <b>118</b> is designed to preclude any further displacement of the second fluid into the well bore. Indeed, the timing of the release of the bottom and top plugs <b>110</b>, <b>118</b>, respectively, as well as the monitoring of the precise amount of the second fluid being pumped into the casing string <b>50</b> are important in avoiding under and overdisplacement of the second fluid. This is particularly important wherein the second fluid is a cementing slurry used to cement the casing string to the inside of the well bore.

0049<figref idref="DRAWINGS">FIG. 12</figref> shows two alternate plugs, top plug <b>410</b> and bottom plug <b>510</b>, which together form alternate plug system <b>400</b>. Top plug <b>410</b> is formed with a solid inner mandrel <b>412</b>, which has a threaded lower end. A taper-shaped nose <b>416</b> attaches to the threaded lower end of the inner mandrel <b>412</b>. However, as those of ordinary skill in the art will appreciate, the nose <b>416</b> can take any desired form and may be integrally formed with the inner mandrel <b>412</b>. The outer sleeve <b>414</b> is similar to outer sleeve <b>14</b> in that it is generally cylindrically shaped and formed of a foam or other similar material.

0050The bottom plug <b>510</b> is formed with a generally tubular-shaped inner mandrel <b>512</b>, which has a hollow interior for channeling fluids. The bottom plug <b>510</b> has a funnel-shaped tapered upper end adapted for engagement with the taper-shaped nose <b>416</b> of the top plug <b>410</b>. The outer sleeve <b>514</b> is identical to outer sleeve <b>414</b> of the top plug <b>410</b>. A nose <b>516</b> is integrally formed at the lower end of inner mandrel <b>512</b>. A flow stopper plug <b>524</b> is temporarily secured to the nose <b>516</b> with one or more shear pins or other securing means. The flow stopper plug <b>524</b> is formed of a high strength thermoplastic or other similar material. As those of ordinary skill in the art will appreciate, the nose <b>516</b> may be removable. Furthermore, as those of ordinary skill in the art will appreciate, the release pressure of the flow stopper plug <b>524</b> may be adjustable.

0051<figref idref="DRAWINGS">FIG. 13</figref> illustrates an alternate embodiment of the plugs <b>410</b>′ and <b>510</b>′ shown in <figref idref="DRAWINGS">FIG. 12</figref>. The only difference in this embodiment is that the outer sleeves <b>414</b>′ and <b>514</b>′ contain a series of ribs <b>421</b> and <b>521</b>, respectively.

0052<figref idref="DRAWINGS">FIG. 14</figref> illustrates another embodiment of a plug system (<b>600</b>). Plug system <b>600</b> includes a top plug <b>610</b> and a bottom plug <b>710</b>. The top plug <b>610</b> includes a generally tubular-shaped inner mandrel <b>612</b> having a taper-shaped nose <b>616</b> integrally formed at its lower end. The inner mandrel <b>612</b> is simply open at its upper end. As a consequence of its tubular design the inner mandrel has an internal flow channel, through which fluids may travel. Holes are formed in the nose <b>616</b> for inserting pins, which attach a flow stopper plug <b>670</b> to the internal flow channel of the plug <b>610</b>. The flow stopper plug <b>670</b> is preferably formed of a high strength thermoplastic material and is designed to stop the flow of fluids through the internal flow channel. The number and strength of the pins holding the flow stopper plug <b>670</b> in place within the internal flow channel are selected so that the flow stopper plug <b>670</b> is forced out of the plug <b>610</b> at the desired pressure, which is dependent upon the particular application. A pair of elastomeric rings <b>672</b> are also provided to seal the flow stopper plug <b>670</b> to the inside wall of the internal flow channel, so that no fluid is allowed to seep past the flow stopper plug <b>670</b>. The outer sleeve <b>614</b> is similar to outer sleeve <b>14</b> in that it is generally cylindrically shaped and formed of a foam or other similar material.

0053Bottom plug <b>710</b> includes an inner mandrel <b>712</b>, which is generally tubular in shape having an internal flow channel, through which fluids may pass. The bottom plug <b>710</b> further includes a nose <b>716</b>, which is generally taper-shaped and integrally formed with the inner mandrel <b>712</b> at its lower end. Holes are formed in the nose <b>716</b> for inserting pins, which attach a flow stopper plug <b>770</b> to the internal flow channel of the plug <b>710</b>. The flow stopper plug <b>770</b> is preferably formed of a high strength thermoplastic material and is designed to stop the flow of fluids through the internal flow channel. The number and strength of the pins holding the flow stopper plug <b>770</b> in place within the internal flow channel are selected so that the flow stopper plug <b>770</b> is forced out of the plug <b>710</b> at the desired pressure, which is dependent upon the particular application. An elastomeric ring <b>772</b> is also provided to seal the flow stopper plug <b>770</b> to the inside wall of the internal flow channel, so that no fluid is allowed to seep past the flow stopper plug <b>770</b>. The bottom plug <b>710</b> has a funnel-shaped tapered upper end <b>774</b> adapted for engagement with the taper-shaped nose <b>616</b> of the top plug <b>610</b>. The outer sleeve <b>714</b> is similar to outer sleeve <b>14</b> in that it is generally cylindrically shaped and formed of a foam or other similar material.

0054<figref idref="DRAWINGS">FIG. 15</figref> illustrates an alternate embodiment of the plugs <b>610</b> and <b>710</b> shown in <figref idref="DRAWINGS">FIG. 12</figref>. The only difference in this embodiment is that the outer sleeves <b>614</b>′ and <b>714</b>′ of plugs <b>610</b>′ and <b>710</b>′ comprise a plurality of ribs <b>621</b> and <b>721</b>, respectively.

0055The function, operation and advantages of the plug systems <b>600</b> and <b>600</b>′ illustrated in <figref idref="DRAWINGS">FIGS. 14 and 15</figref> over conventional plug systems will now be described. As can be seen in <figref idref="DRAWINGS">FIGS. 14 and 15</figref>, the bottom plug <b>710</b>, <b>710</b>′ is equipped with a sealing nose, which optionally may incorporate a latch down feature, and which may optionally be formed as an integral part of the bottom plug mandrel. The bottom plug <b>710</b>, <b>710</b>′ is capable of being pumped down into a baffle profile (not shown) located above the upper most float valve assembly. The nose <b>716</b>, <b>716</b>′ seals against the minimum ID of the baffle profile and resists further downward movement. Both of the profiles of the bottom plug nose <b>716</b>, <b>716</b>′ and the baffle (not shown) are designed such that they will be capable of sustaining high pressure loads applied from above at high temperatures. Upon landing in the baffle profile, increased pressure will shear the rupturable member(s) retaining the plug <b>770</b>, <b>770</b>′ in the nose of the bottom plug <b>710</b>, <b>710</b>′, thereby allowing circulation to continue. A catching device located above the top float valve (not shown) would be provided to catch the nose plug to keep the plug from interfering with the float valves.

0056After displacing the top plug <b>610</b>, <b>610</b>′, with its tapered nose piece <b>616</b>, <b>616</b>′, to a shut-off against the funnel shaped seat profile built into the top of the bottom plug mandrel <b>712</b>, <b>712</b>′, further application of pressure will shear the plug pinned in the ID of the top plug mandrel <b>612</b>, <b>612</b>′. As the major ID's of both the top and bottom plug mandrels will be the same, the plug <b>670</b>, <b>670</b>′ in the top plug <b>610</b>, <b>610</b>′ will, after shearing free, continue to pass, in sealing engagement, through the major ID of the bottom plug mandrel <b>712</b>, <b>712</b>′ until it is restrained by the internal restriction indicated near the lower end of the bottom plug nose <b>716</b>, <b>716</b>′. At this point, the only components that will be subjected to high pressure testing are the baffle profile, the bottom plug nose <b>716</b>, <b>716</b>′, and the nose plug <b>616</b>, <b>616</b>′ from the top plug <b>610</b>, <b>610</b>′, no further loading will be imposed on either the top or bottom plug mandrels, <b>612</b>, <b>612</b>′; <b>712</b>, <b>712</b>′, respectively. The only strength requirements for the bottom plug mandrel <b>712</b>, <b>712</b>′, including the plug seat built into its top, is that it be strong enough to resist the forces imposed by pressuring up against the top plug <b>610</b>, <b>610</b>′ to shear out its nose <b>616</b>, <b>616</b>′. The top plug mandrel <b>612</b>, <b>612</b>′ has no special strength requirements other than the nose <b>616</b>, <b>616</b>′ be capable of supporting the loads imposed in shearing out its nose plug <b>670</b>, <b>670</b>′. The nose plug <b>770</b>, <b>770</b>′ shear pinned inside the bottom plug mandrel <b>712</b>, <b>712</b>′ may be pinned to shear at a pressure valve that makes sense in view of job conditions. The plug <b>670</b>, <b>670</b>′ shear pinned in the nose <b>616</b>, <b>616</b>′ of the top plug <b>610</b>, <b>610</b>′ also may be pinned to an appropriate value as the nose plug will remain pressure balanced until such time as the top plug is landed.

0057As those of ordinary skill in the art should recognize, the inner mandrels <b>612</b>, <b>612</b>′ and <b>712</b>, <b>712</b>′ of the plugs <b>610</b>, <b>610</b>′ and <b>710</b>, <b>710</b>′ need only be strong enough to resist the forces/loads imposed to land the plugs <b>610</b>, <b>610</b>′ and <b>710</b>, <b>710</b>′ and release the nose plugs <b>670</b>, <b>670</b>′ from the top plugs <b>610</b>, <b>610</b>′, as discussed in the preceding paragraph.

0058While the use of the cementing plugs of the present invention in sub-surface release applications has been described, other embodiments of the present invention may advantageously employ these cementing plugs as conventional surface-release plugs and or as subsurface released plugs as well.

0059Therefore, the present invention is well-adapted to carry out the objects and attain the ends and advantages mentioned as well as those which are inherent therein. While the invention has been depicted, described, and is defined by reference to exemplary embodiments of the invention, such a reference does not imply a limitation on the invention, and no such limitation is to be inferred. The invention is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those ordinarily skilled in the pertinent arts and having the benefit of this disclosure. The depicted and described embodiments of the invention are exemplary only, and are not exhaustive of the scope of the invention. Consequently, the invention is intended to be limited only by the spirit and scope of the appended claims, giving full cognizance to equivalents in all respects.