Composite Plug Bypass Mechanism for Controlled Fluid Leak
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Solution Overview
Problem
Plugs used in well perforating and fracturing operations tend to fail when fully sealed and can leak fluid unpredictably, necessitating a solution for controlled fluid bypassing.
Innovation Solution
A composite plug with a mandrel and a built-in bypass mechanism, such as conduits or deformable balls, allows a controlled amount of fluid to pass through, ensuring reliable sealing and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plug is fully sealed to prevent fluid leakage, then sealing reliability is improved, but the plug becomes more prone to failure and cannot accommodate controlled fluid bypass needs
Solution Approach 1:
The plug is segmented into multiple sealing elements (first sealing element and second sealing element) that can independently function. The first sealing element provides the primary seal while the second sealing element works in conjunction with the bypass mechanism to enable controlled bypass flow, thus maintaining reliability while adding adaptability.
Solution Approach 2:
The plug transitions from a static fully-sealed state to a dynamic state where fluid flow can be controlled through the bypass mechanism. The system can adjust between different flow regimes (full seal, controlled bypass, or full open) based on operational requirements, enhancing versatility without compromising sealing reliability.
2Productivity
If a plug is designed with an internal bore to allow fluid passage, then fluid flow capability is improved, but the plug leaks fluid in an unknown and unpredictable manner
Solution Approach 1:
A bypass mechanism acts as an intermediary component between the fluid source and the plug interior. This mechanism includes a bypass conduit and bypass valve that mediate the fluid flow, providing a controlled pathway that enables precise measurement and regulation of bypass flow rate, eliminating unpredictable leakage.
Solution Approach 2:
The system enables precise control of fluid flow parameters through the bypass valve, which can adjust the bypass flow rate to specific desired values. This transforms the unpredictable leakage into a controllable parameter that can be precisely measured and regulated according to operational needs.
3Adaptability or versatility
If a bypass mechanism is added to the plug to enable controlled fluid bypass, then adaptability is improved, but device complexity increases
Solution Approach 1:
The bypass mechanism is designed to be integrated into the existing plug structure, where components like the bypass conduit and valve serve multiple functions. The bypass system not only enables controlled fluid bypass but also provides a means for pressure equalization and can be used for testing or maintenance purposes, justifying the added complexity through multi-functionality.
4Reliability
If multiple sealing elements are used to enhance sealing reliability, then sealing performance is improved, but device complexity increases
Solution Approach 1:
Multiple sealing elements are merged into a coordinated system where the first and second sealing elements work together with the bypass mechanism. Rather than being separate independent components, they are integrated such that the sealing elements and bypass components form a unified system that achieves both reliable sealing and controlled bypass capability without excessive complexity.
Data Source
AI summary
A composite plug for sealing a well includes a mandrel having an internal bore, the mandrel having a first end and a second end, opposite to the first end, and the bore extending from the first end to the second end; plural elements distributed along the mandrel in a given order and configured to seal the well; and a bypass mechanism, different from the bore, built into the composite plug and configured to allow a controlled leak of a fluid from the well, past the composite plug.