Composite Reconfigurable Downhole Tool Adapter Design
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Solution Overview
Problem
Current pressure isolation tools in oil and gas wellbores, such as frac plugs and bridge plugs, lack ease of conversion between configurations and high run-in speeds, necessitating improved designs for efficient operation.
Innovation Solution
A drillable composite tool with a mandrel and adaptable configurations, including standard frac plug, caged ball frac plug, and bridge plug settings, utilizing interchangeable adapters and expandable sealing elements, allowing for efficient conversion and high-speed deployment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional frac plugs and bridge plugs are used separately, then each tool performs its specific function reliably, but the complexity of operations increases and conversion between configurations is difficult
Solution Approach 1:
The tool incorporates a universal mandrel design that can accept different adapters (frac plug adapter with flow passage and bridge plug adapter without flow passage), allowing a single base tool to perform multiple functions as either a frac plug or bridge plug by simply changing the adapter component
Solution Approach 2:
The tool is divided into separable components including the mandrel, adapters, and sealing elements. The adapters can be independently removed and replaced, enabling easy conversion between configurations without replacing the entire tool assembly
2Productivity
If traditional pressure isolation tools are deployed, then pressure isolation function is achieved, but run-in speed is limited and deployment efficiency is reduced
Solution Approach 1:
The tool is pre-configured with the mandrel and sealing elements during manufacturing, and adapters are designed for quick attachment. This preliminary preparation allows the tool to be deployed rapidly into the wellbore without requiring complex assembly operations downhole
Solution Approach 2:
The tool design allows dynamic reconfiguration between frac plug and bridge plug modes by simply changing the adapter in the field, enabling rapid adaptation to different operational requirements without time-consuming configuration changes
3Adaptability or versatility
If a single tool design is used for both frac plug and bridge plug functions, then adaptability improves, but the structural complexity and manufacturing difficulty increase
Solution Approach 1:
The tool is segmented into a standardized mandrel body and separate interchangeable adapters. This segmentation allows each component to be manufactured independently using standard processes, simplifying production while enabling multiple configurations through adapter selection
Solution Approach 2:
The universal mandrel design with standardized connection interfaces allows the same base component to support multiple adapter types, reducing the need for multiple specialized tool designs and simplifying the overall manufacturing process
Data Source
AI summary
A downhole tool for use in a well is configurable as a frac plug, a caged ball frac plug or a bridge plug. The tool has a mandrel with a threaded neck. The mandrel has an expandable sealing element disposed thereabout. An adapter, which may be selected from multiple configurations of adapters, is threaded to the neck of the mandrel. The adapter may comprise a sleeve, or a cap with one open end and one closed end. The adapter has threads on an outer surface thereof to which a threaded setting mandrel may be attached. The setting mandrel when actuated will move the tool to a set position in the well and once the tool is moved to the set position the threads on the adapter will shear so that the setting mandrel may be retrieved. The tool will thus remain in the hole and will act as either a frac plug, a caged ball frac plug or a bridge plug depending upon the configuration of the selected adapter.