Retrievable Bridge Plug Valve Assembly for Tandem Retrieval
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Solution Overview
Problem
Conventional retrievable bridge plugs face challenges in tandem retrieval due to the inability to circulate fluid effectively, leading to debris accumulation and resetting issues, which necessitate multiple trips and result in excessive fluid loss and increased operational costs.
Innovation Solution
A bridge plug design featuring a mandrel with a valve assembly and snap ring mechanism that allows for fluid circulation to clear debris and prevent resetting, enabling simultaneous retrieval of multiple plugs in a single run with coiled or jointed tubing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional retrievable bridge plugs are used for tandem retrieval, then multiple plugs can be set in the wellbore, but fluid cannot be circulated past the topmost plug to clear debris from lower plugs
Solution Approach 1:
The bridge plug is divided into separate functional components: the main plug body with slips and packing element, and a separate tailpiece with valve assembly. This segmentation allows the tailpiece to be manipulated independently for valve operation during retrieval, enabling debris clearance functionality to be added without interfering with the plug's setting and retrieval mechanisms.
Solution Approach 2:
A retrieval valve assembly is introduced as an intermediary component between the formation and the retrieved plugs. This valve assembly, controlled by a retrieval tool, allows fluid to be circulated through the tailpiece and around the plugs to clear debris during the retrieval operation, solving the debris clearance problem while maintaining tandem retrieval capability.
2Productivity
If conventional bridge plugs are retrieved without fluid circulation, then retrieval operations can proceed, but sand and debris accumulate on the plugs preventing proper tool coupling
Solution Approach 1:
The valve assembly is pre-configured in the tailpiece to allow fluid circulation capability before retrieval begins. The retrieval tool opens the valve as a preliminary action before attempting to couple to the plug, ensuring debris is cleared in advance, which prevents coupling failures and maintains reliable operation throughout the retrieval process.
3Ease of operation
If bridge plugs are released without pressure equalization, then retrieval can begin, but differential pressure forces the plug uphole preventing proper retrieval
Solution Approach 1:
The tailpiece valve assembly acts as a mediator to control pressure equalization. By opening the valve, fluid can flow around the plug to equalize pressure between the upper and lower annuli, eliminating the differential pressure that would otherwise force the plug uphole and prevent proper retrieval operation.
4Reliability
If multiple trips are made to retrieve bridge plugs, then all plugs can be retrieved, but operational time and fluid loss increase
Solution Approach 1:
The valve assembly enables continuous fluid circulation throughout the retrieval operation. Fluid can be circulated to clear debris from multiple plugs in sequence without stopping the retrieval process, allowing all plugs to be retrieved in a single continuous operation rather than requiring multiple trips, thereby reducing operational time and fluid loss.
Data Source
AI summary
A bridge plug can be deployed downhole and retrieved using a retrieval tool disposed on jointed or coiled tubing or on another bridge plug. Internally, the bridge plug has a sleeve that is movable on a stem of the plug's tailpiece. When in a first position, the sleeve prevents fluid communication through ports in the stem so that circulated fluid from the retrieval tool can be used to clear debris from the plug during retrieval. When the retrieval tool engages the sleeve in the plug, pulling up on the tool moves the sleeve to an intermediate position in which fluid pressure is equalized across the plug. Further pulling up on the tool locks the sleeve in a further position on the stem so that circulated fluid from the retrieval tool will pass directly to the stem's ports. Movement of the sleeve by the retrieval tool also releases the engaged slips and packing element on the bridge plug's mandrel.