Decomposable Insert for Downhole Plug Drill-Out
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Solution Overview
Problem
Existing downhole tools, such as bridge plugs and packers, face challenges during removal due to binding with drill bits, leading to long drill-out times and excessive casing wear, and there is a need for tools that can effectively seal wellbores, be quickly and reliably removed, and configured to perform multiple functions efficiently.
Innovation Solution
The development of an insert for downhole plugs that includes shear mechanisms to release setting tools under axial force, anti-rotation features to prevent plug rotation during removal, and decomposable materials for controlled fluid flow, allowing for efficient sealing and removal of wellbore zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If non-retrievable plugs are constructed of brittle material such as cast iron or ceramics, then the plugs can effectively seal the wellbore, but the plugs bind upon the drill bit during removal, resulting in long drill-out times and excessive casing wear
Solution Approach 1:
The plug body is segmented into multiple sections that can separate during drill-out. The plug includes a first section and a second section that can detach from each other, allowing the drill bit to pass through more easily and reducing drill-out time while maintaining sealing effectiveness during operation
Solution Approach 2:
The plug material properties are changed by using a composite structure with different material characteristics in different sections. The first section uses brittle material for effective sealing, while the second section uses a different material composition that facilitates easier drill-out, changing the physical parameters of the plug to resolve the contradiction
2Adaptability or versatility
If multiple different plug types are run in series for completion activities, then various wellbore functions can be achieved, but the uncertainty in types and numbers required leads to over-purchase and under-purchase, resulting in fiscal inefficiencies and field delays
Solution Approach 1:
A single plug design is made universal by incorporating configurable inserts that can be selected based on the desired function. The plug body remains the same, but different inserts (such as bridge plug inserts, frac plug inserts, or drop ball plug inserts) provide different functions, eliminating the need to stock multiple different plug types while maintaining functional versatility
Solution Approach 2:
The insert is nested within the plug body, with the insert being a smaller component placed inside the larger plug structure. This nesting allows the same plug body to accommodate different insert types, reducing inventory complexity while maintaining the ability to perform various wellbore functions
3Reliability
If plugs are designed to be permanently sealed in the wellbore, then effective zone isolation is achieved, but the plugs cannot be easily removed or restored, requiring complex drill-out or mill-out operations
Solution Approach 1:
The plug transitions from a static permanent seal to a dynamic removable seal through the inclusion of a setting mechanism. The plug can be set to provide effective isolation when needed, and then the setting tool can be released to allow for easy removal. This dynamic capability resolves the contradiction between reliable isolation and ease of removal
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 insert enables rapid and reliable removal of downhole tools, reduces drill-out times, and allows for controlled fluid flow, addressing the inefficiencies and challenges associated with existing plug removal methods.
Implementation Method 1
The upper shear or shearable mechanism is adapted to release a setting tool when exposed to a predetermined axial force that is sufficient to deform the shearable mechanism
Implementation Method 2
The insert or portions thereof can be made from one or more decomposable materials that will at least partially decompose when exposed to one or more predetermined triggers
Data Source
AI summary
A plug for isolating a wellbore. The plug can include a mandrel having a bore formed therethrough, at least one sealing element disposed about the mandrel, at least one slip disposed about the mandrel, at least one conical member disposed about the mandrel, and an insert disposed at least partially within the bore of the mandrel. The insert can include a body, at least one circumferential groove disposed on an outer surface of the body, wherein the at least one circumferential groove is adapted to retain an elastomeric seal, and at least one interface disposed on an end of the body for securing the insert into the mandrel. The body can also have a bore formed only partially therethrough or a bore formed completely therethrough with the body being adapted to receive an impediment that restricts fluid flow in at least one direction through the body. At least one of the body and the impediment can include one or more decomposable materials.