Through Tubing Bridge Plug Radial Expansion for Large Casing Ratios
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Solution Overview
Problem
Conventional through tubing bridge plugs are limited to wells with small expansion ratios and cannot anchor effectively for cement curing, and they struggle with large expansion ratios required in some wells, limiting their operational capability.
Innovation Solution
A through tubing bridge plug system with a downhole power unit, actuation rod, anchor assembly, and packing assembly that allows for longitudinal movement to radially expand and establish a gripping and sealing engagement with the casing, enabling operation in wells with large expansion ratios and allowing cement to cure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional through tubing bridge plugs are used, then they can provide temporary separation of zones, but they are limited to wells with small expansion ratios and cannot anchor effectively for cement curing
Solution Approach 1:
The bridge plug employs dynamic components including slip arms that can transition from a retracted running configuration to an expanded set configuration, and packing elements that can be compressed longitudinally to expand radially. This dynamic transformation allows the plug to adapt to large expansion ratios while maintaining reliable anchoring and sealing capabilities during cement curing operations
Solution Approach 2:
The bridge plug is divided into multiple functional segments including an anchor assembly with multiple slip arms, a separate packing assembly with compressible packing elements, and a compression assembly. This segmentation allows each component to be optimized independently for its specific function while working together to achieve both high expansion ratio capability and reliable anchoring for cement curing
2Adaptability or versatility
If the bridge plug is designed for large expansion ratios, then it can be installed in more wells, but the structural complexity increases
Solution Approach 1:
The bridge plug design nests multiple components within each other to minimize the running profile while maintaining large expansion capability. The packing elements are nested within the packing assembly, which is contained within the compression assembly. The slip arms are stored in a retracted position within the anchor assembly during run-in, then deployed outward to engage the casing wall. This nesting allows the plug to achieve large expansion ratios without proportionally increasing overall structural complexity
Solution Approach 2:
The compression assembly serves multiple functions: it compresses the packing elements radially outward to create the seal, it provides the mechanical force to deploy the slip arms for anchoring, and it maintains compression force during cement curing. This multi-functionality reduces the need for separate dedicated components for each function, thereby managing structural complexity while achieving large expansion ratios
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
The system effectively isolates pressure between well zones, anchors within the casing for cement curing, and operates in wells with large expansion ratios, enhancing the operational flexibility and reliability of through tubing bridge plugs.
Implementation Method 1
longitudinally compressing the packing assembly with the compression assemblies to establish the sealing engagement with the casing
Implementation Method 2
radially expand the packing assembly to establish a sealing engagement with the casing
Implementation Method 3
radially expanding the anchor assembly to establish the gripping engagement with the casing
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A through tubing bridge plug (200) for providing a gripping and sealing engagement with a casing string of a wellbore. The bridge plug (200) includes an actuation rod (208), an anchor assembly (212), a pair of compression assemblies, each including a support assembly (216, 242) and an anti extrusion assembly (220, 238) and a packing assembly (224) disposed about the actuation rod (208) between the compression assemblies. Responsive to longitudinal movement of the actuation rod (208), the anchor assembly (212) establishes the gripping engagement with the casing string, the compression assemblies are radially deployed such that the anti extrusion assemblies (220, 238) are supported by the support assemblies (216, 242) and the packing assembly (224) establishes the sealing engagement with the casing string. The anti extrusion assembly comprises a plurality of petals (554) and a plurality of webbing elements (560) attached to the petals and extending radially past the petals.