Configurable Composite Bridge Plug Conversion
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Solution Overview
Problem
Existing oil and gas extraction methods require multiple types and numbers of plugs for isolation and treatment, leading to inefficiencies due to the need for separate parts and complex assembly, and lack a single piece bridge plug that can be easily converted into frac plug variants in the field.
Innovation Solution
A configurable composite bridge plug system that includes a cylindrical hollow mandrel with upper and lower threaded ends, a release ring, upper and lower restriction elements, a stand-off pin, a ball seat, and a cage retainer, allowing conversion into caged, ball-in-place, and ball-drop frac plugs by removing and re-installing specific components, enabling a single shipping package solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple types and numbers of plugs are used for isolation and treatment, then the isolation and treatment operations can be performed, but the need for separate parts and complex assembly leads to inefficiencies
Solution Approach 1:
The bridge plug is designed with multiple functional components (restriction elements, ball seats, cages, check valves) that can be selectively installed or removed to convert the single plug into different configurations (bridge plug, frac plug, ball-in-place frac plug, caged frac plug). This multi-functional design allows one plug to perform multiple isolation and treatment operations that previously required several different plug types.
Solution Approach 2:
The plug is divided into modular components including the body, restriction elements, ball seats, cages, and check valves that can be independently installed, removed, or reconfigured. This segmentation enables flexible conversion between different plug types by selectively assembling or disassembling specific components based on operational requirements.
2Adaptability or versatility
If multiple types and numbers of plugs are used for isolation and treatment, then the isolation and treatment operations can be performed, but the need for separate parts and complex assembly increases time and resource requirements
Solution Approach 1:
The plug is shipped as a complete kit with all necessary components (restriction elements, ball seats, cages, check valves) pre-assembled or pre-packaged together. This preliminary preparation eliminates the need to source and assemble multiple separate plugs in the field, significantly reducing assembly time and resource requirements while maintaining full operational versatility.
3Strength
If high strength materials are used for the bridge plug body, then pressure resistance is improved, but the cost and weight increase
Solution Approach 1:
The plug body is constructed from composite materials that provide high strength-to-weight ratio, achieving the necessary pressure resistance without excessive weight. The composite structure allows the plug to withstand downhole pressures while maintaining a lighter weight compared to traditional solid metal constructions.
Solution Approach 2:
The plug body incorporates hollow internal structures and chambers that reduce material usage and weight while maintaining structural integrity and pressure resistance. The segmented design with internal cavities allows the plug to achieve sufficient strength with less material, reducing both weight and cost.
Data Source
AI summary
A configurable composite bridge plug apparatus and method for converting bridge plugs into frac plugs in the field of operation is disclosed. The bridge plug apparatus includes a body with a cylindrical hollow inner mandrel, an upper threaded end and a lower threaded end. A release ring with threads disposed on an outer surface is attached to the upper threaded end. An upper restriction element and a lower restriction element plug both ends of the hollow inner mandrel so that flow is restricted in either directions. A stand-off pin holds the lower restriction element in place. A ball seat inserted proximally to the upper restriction element towards the upper threaded end. A cage retainer is attached to the ball seat with a ball. The configurable bridge plug transformed to a frac plug by removing the upper restriction element and the lower restriction element from the bridge plug.