Composite Frac Plug Elastomeric Gripper Assembly
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Solution Overview
Problem
Existing composite frac plugs used in staged wellbore completion are time-consuming to drill out after well stimulation, due to their durability requirements under extreme fluid pressures.
Innovation Solution
A novel composite frac plug design featuring a shorter and lighter structure with an elastomeric gripper assembly and a single slip assembly, which includes circumferentially spaced inserts and slips to grip the well casing, facilitating quicker milling out by reducing the number of components and enhancing ease of removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If composite frac plugs are constructed with durable materials to withstand extreme fluid pressures, then reliability is improved, but the time required to drill out the plugs increases
Solution Approach 1:
The frac plug is divided into two distinct segments: a durable upper portion (mandrel and sealing elements) that withstands extreme pressures, and a removable lower portion (gripper assembly with inserts) that is optimized for quick removal. This segmentation allows each part to be optimized for its specific function - the upper portion for durability and the lower portion for ease of removal.
Solution Approach 2:
The lower gripper assembly with its inserts is designed as a disposable component that is easily drilled out and discarded after serving its temporary function of gripping the casing during setting. This allows the use of less durable, easier-to-remove materials in the lower portion while maintaining overall system reliability through the durable upper portion.
2Reliability
If multiple slips are used to grip the casing, then setting reliability is improved, but device complexity increases
Solution Approach 1:
The patent merges the gripping function into a single integrated elastomeric gripper assembly that contains multiple inserts working together. Instead of having separate slip assemblies at different locations, all gripping elements are combined into one assembly that sets simultaneously, reducing the number of moving parts and potential failure points while maintaining reliable gripping.
Solution Approach 2:
The elastomeric gripper assembly serves multiple functions: it grips the casing to set the plug, provides structural support during the fracturing operation, and is designed to be easily removed during drilling out. This multi-functionality reduces the need for separate components for each function.
3Strength
If a longer and heavier frac plug design is used to ensure durability, then strength is improved, but productivity decreases
Solution Approach 1:
The plug is segmented into a durable upper portion and a removable lower portion, allowing the upper portion to be stronger and more robust while the lower portion is minimized for quick removal. This segmentation enables the overall plug to be optimized for both strength and removal speed.
Solution Approach 2:
Different portions of the plug have different structural qualities optimized for their specific functions. The upper mandrel and sealing elements are constructed with high strength materials and robust geometry to withstand extreme pressures, while the lower gripper assembly is designed with lighter construction and fewer inserts to facilitate rapid drilling out.
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 new design significantly reduces the time and cost associated with well completion by being more quickly and efficiently milled out of the wellbore, while maintaining durability and sealing integrity.
Implementation Method 1
an elastomeric gripper assembly mounted to a composite mandrel... having an insert groove in an outer periphery thereof with a plurality of circumferentially spaced-apart inserts in the insert groove that respectively bite and grip a casing
Data Source
AI summary
A composite frac plug has an elastomeric gripper assembly in place of an up-hole set of slips. The elastomeric gripper assembly permits the composite frac plug to be shorter and lighter and more rapidly drilled out after fracking is completed.