Ball-Energized Frac Plug Radial Sealing Mechanism
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Solution Overview
Problem
Conventional frac plugs require a large axial setting force and have long axial lengths, leading to increased drilling time to access the full bore of the casing after operation completion.
Innovation Solution
A frac plug design featuring a ball member that shortens the plug length upon setting, utilizing a button ring and ratchet mechanism for gripping and a seal member that moves into sealing contact with the wellbore, facilitated by a setting tool and a ball member to block fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional frac plugs use an element package squeezed between two members, then a seal can be created inside the wellbore casing, but a large axial setting force is required and the seal element projects radially outside the outside diameter of the frac plug
Solution Approach 1:
The patent transitions from axial compression (one-dimensional force application) to radial expansion (dimensional change) by using a ball member that forces the seal member to expand radially outward into sealing contact with the wellbore casing. This dimensional change eliminates the need for large axial setting forces while maintaining reliable sealing capability.
Solution Approach 2:
Instead of compressing the seal element axially between two members as in conventional designs, the patent inverts the approach by expanding the seal member radially outward using a ball member. This inversion of the sealing mechanism eliminates the need for large axial forces and prevents seal element projection beyond the plug's outside diameter.
2Reliability
If conventional frac plugs are designed to create a secure seal, then pressure isolation during fracturing is achieved, but the axial length of the plug increases
Solution Approach 1:
The patent achieves pressure isolation by expanding the seal member radially outward into the wellbore casing rather than requiring a long axial compression distance. This dimensional change from axial to radial sealing action significantly reduces the axial length of the plug while maintaining effective pressure isolation during fracturing operations.
3Reliability
If conventional frac plugs have long axial lengths to ensure proper sealing, then reliable pressure containment is achieved, but increased drilling time is required to drill out the plug after operation
Solution Approach 1:
By transitioning to radial expansion sealing, the patent achieves reliable pressure containment with a significantly shortened axial length. This reduces the drilling time required to remove the plug after fracturing operations, eliminating the time loss associated with drilling through long conventional plugs.
4Length of moving object
If a ball member mechanism is used to energize the frac plug, then the plug length is shortened upon setting, but the device complexity increases
Solution Approach 1:
The ball member mechanism is deployed through the casing and automatically energizes the frac plug by forcing the seal member into radial expansion. The setting tool applies a pull force to move the button ring radially outward, and the ball member subsequently moves the seal member into sealing contact. This self-service mechanism shortens the plug length upon setting while maintaining operational simplicity through automated activation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces drilling time to access the full bore after fracturing operations by shortening the plug length and ensuring a secure, efficient seal for pressure isolation during fracturing and stimulation.
Implementation Method 1
a ball seat formed about the inner circumference of the mandrel and configured to receive a ball member... moving the frac plug into a set and sealed position by dropping a ball member into the frac plug to move a seal member radially outward into sealing contact with the surrounding wellbore
Implementation Method 2
a button ring having one or more buttons disposed about the upper mandrel, wherein the lower mandrel is movable relative to the upper mandrel to move the button ring along the tapered outer surface and force the buttons into gripping contact with a surrounding wellbore
Implementation Method 3
a lower end portion comprising one or more ratchet members having teeth formed on the outer surface of the mandrel
Data Source
AI summary
A frac plug that is energized by a ball member, the frac plug comprising an upper mandrel having a tapered outer surface, a seal member coupled to the upper mandrel, and a lower mandrel coupled to the upper mandrel. A button ring having one or more buttons is disposed about the upper mandrel. The lower mandrel is movable relative to the upper mandrel to move the button ring along the tapered outer surface and force the buttons into gripping contact with a surrounding wellbore. The seal member is movable into sealing contact with the surrounding wellbore by the ball member.