Anti-extrusion slip assemblies for downhole sealing integrity
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Solution Overview
Problem
Downhole plugs used in wellbore completion operations face challenges in maintaining sealing integrity during hydraulic fracturing due to the migration of elastomeric sealing elements into arcuate gaps between slip segments, which compromises the fluid isolation between the uphole and downhole portions of the wellbore.
Innovation Solution
A slip assembly comprising first and second slip segments with arcuately extending anti-extrusion members that prevent the migration of sealing elements into these gaps, ensuring the sealing integrity by restricting relative movement between the anti-extrusion members and the second slip segments, thereby maintaining a fluid-tight boundary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If slip segments are used to affix the downhole plug to the casing string, then the plug can withstand differential pressure, but arcuate gaps form between slip segments that allow sealing elements to migrate and compromise sealing integrity
Solution Approach 1:
An anti-extrusion member is introduced as an intermediary component between the slip segments and sealing elements. This member includes an anti-extrusion surface that contacts the sealing element and prevents it from migrating into the arcuate gaps between slip segments, thereby maintaining sealing integrity while preserving the differential pressure resistance provided by the slip segments.
2Ease of operation
If multiple slip segments are used to engage the casing string, then the plug can be securely affixed, but gaps between segments create pathways for sealing element migration
Solution Approach 1:
The anti-extrusion member converts the potentially harmful effect of arcuate gaps (which allow sealing element migration) into a beneficial configuration where the anti-extrusion surface is strategically positioned to contact and contain the sealing element, preventing it from entering the gaps while maintaining the engagement functionality of the slip segments.
Data Source
AI summary
A downhole plug for plugging a tubular member. The downhole plug may include a packer and a slip assembly including a plurality of slip segments circumferentially spaced about a central axis of the slip assembly, each slip segment having a body comprising a first end, a second end longitudinally opposite the first end, an outward face with at least one engagement member for coupling to the tubular member, and sides each facing an adjacent slip segment of the plurality of slip segments. The plurality of slip segments may include a first set of slip segments and a second set of slip segments wherein each of the first set of slip segments is positioned directly between a pair of the second set of slip segments. Each of the second set of slip segments may include a pair of arcuately extending anti-extrusion members.