Conic-Section Breaker Object for Reliable Frangible Plug Opening
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Solution Overview
Problem
Existing breaker objects for frangible plugs in hydrocarbon wells face issues such as delayed breakage, misalignment, and the need for precise alignment, leading to incomplete or difficult plug opening, especially under high pressure differentials, which complicates operations and increases downtime.
Innovation Solution
The breaker object is shaped as a conical section, such as an ellipse or parabola, ensuring a point contact with the frangible plug, allowing for reliable breakage regardless of orientation and eliminating the need for precise alignment, and is designed to move relative to the plug under pressure differentials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional breaker object with a small impact area is used to break the frangible plug, then the plug can be broken under high pressure, but the breaker requires precise alignment and may cause delayed breakage or incomplete opening
Solution Approach 1:
The breaker object is designed with a conical section shape (ellipse or parabola) that creates a point contact with the frangible plug. This curved geometric form concentrates the breaking force at a specific point while the overall conical structure provides tolerance to misalignment, resolving the contradiction between needing precise alignment for reliable breakage and the practical difficulty of achieving such precision in downhole operations
2Ease of manufacture
If pressure is applied to move the breaker object relative to the plug, then the plug can be broken without explosives, but the breaking process may be delayed under high pressure differentials
Solution Approach 1:
The breaker object is pre-positioned within the plug assembly during manufacturing, ready to break the plug immediately when pressure differential is applied. The conical shape is designed to engage the frangible plug at the correct orientation and location, eliminating delays that would occur with systems requiring complex activation sequences or signal routing from the surface
3Reliability
If a point contact breaker is used to break the frangible plug, then complete breakage is achieved, but the breaker must be precisely aligned with the plug impact surface
Solution Approach 1:
The conical section shape of the breaker object creates an asymmetric geometry that naturally guides alignment. The cone's tapered form provides a self-aligning mechanism where the breaker will naturally orient itself to achieve point contact with the plug impact surface, reducing the stringency of alignment requirements while still achieving complete breakage
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 design ensures complete and efficient breakage of the frangible plug, restoring the inner diameter for unrestricted fluid flow, reducing downtime, and simplifying the opening process by eliminating the need for precise alignment and minimizing the risk of incomplete breakage.
Implementation Method 1
the movement from the first position to the second position initiated by pressure applied to the plug
Implementation Method 2
The breaker will then make contact with the frangible disc on a relatively small area, the disc impact surface
Data Source
AI summary
A plug assembly including a breaker object and a plug, having a first position in which the breaker object is not in contact with the plug and a second position where the breaker object is in contact with the plug, wherein the movement from the first position to the second position initiated by pressure applied to the plug, wherein: the breaker object includes an impact surface where the impact surface is the projection of the plug surface onto the breaker object, and the impact surface includes an impact point wherein: the impact point is the portion of the plug which makes contact with the breaker object when the plug assembly is in the second position; and the impact surface has the cross sectional shape of a portion of a conic section.