Cement Plug System with Pass-Through Catching Mechanism
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Solution Overview
Problem
In oil and gas well construction, the deployment of two or more plugs requires the use of progressively larger obstruction members, which can lead to errors and blockages, especially if the larger plug is inadvertently deployed first.
Innovation Solution
A cement plug system comprising a first plug with a seat for a first obstruction member and a second plug positioned adjacent to the first plug, where the second plug has a pass-through configuration to allow the first obstruction member to pass through and a catching configuration to catch a second obstruction member, with the first plug actuatable from a locked to an unlocked configuration in response to axial force, allowing the plugs to separate and the second plug to transition to a catching configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If progressively larger obstruction members are used for two or more plugs, then the plugs can be deployed in sequence, but the risk of error increases if the larger plug is inadvertently deployed first, blocking access to the bottom plug
Solution Approach 1:
The system segments the plugs into distinct components with unique identification features. Each plug has a specific configuration (e.g., different collar orientations, unique obstruction member sizes) that acts as a code, allowing operators to visually identify and deploy plugs in the correct sequence without confusion
Solution Approach 2:
The plugs are pre-configured with identification features and deployment controls before entering the wellbore. The system prepares the correct sequence of plugs with appropriate obstruction members and collar orientations in advance, eliminating the need for complex real-time decision-making during deployment
2Reliability
If the second plug is configured to catch the first obstruction member, then deployment accuracy improves, but the device complexity increases due to additional configurations
Solution Approach 1:
The second plug is designed with multi-functionality, capable of operating in two distinct modes: pass-through configuration for deploying the first obstruction member, and catching configuration for retaining the second obstruction member. This universal design consolidates multiple functions into a single component rather than requiring separate specialized plugs
Solution Approach 2:
The second plug incorporates dynamic reconfigurability through movable collars that can transition between different positions. The collars can be adjusted to create either a pass-through pathway or a catching configuration, allowing the plug to adapt its function based on deployment requirements without changing the physical plug itself
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
This system prevents errors by ensuring that the larger obstruction member is not deployed first, allowing for accurate deployment of cement plugs and reducing the risk of blockages, thereby enhancing the efficiency of wellbore cementing operations.
Implementation Method 1
the first plug being actuatable from the locked configuration to the unlocked configuration in response to an axial force transmitted to the first plug by the first obstruction member
Implementation Method 2
increasing the pressure in the well causes the first plug to actuate into an unlocked configuration, which releases a shifting sleeve to press a second seat of the second plug radially inwards such that the second plug is actuated to a catching configuration
Data Source
AI summary
A cement plug system includes a first plug configured to catch a first obstruction member and actuatable from a locked configuration to an unlocked configuration in response to an axial force transmitted to the first plug by the first obstruction member, and a second plug adjacent to the first plug and configured to catch a second obstruction member, the second plug having a pass-through configuration in which the first obstruction member passes through the second plug, and a catching configuration in which the second plug catches the second obstruction member, the first obstruction member is at least as large as the second obstruction member. The second plug actuates from the pass-through configuration to the catching configuration in response to the first plug shifting from the locked configuration to the unlocked configuration, and the first plug in the unlocked configuration separates from the second plug.