Disintegrating Plug for Subterranean Fracturing
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Solution Overview
Problem
Existing barrier plugs for subterranean fracturing treatments require milling out after use, leaving residues and not fully addressing the need for complete disintegration and minimal leakage tolerance.
Innovation Solution
A disintegrating plug design using external ribs made from degradable materials for frictional contact and optional o-ring seals with hardened inserts for anchoring, allowing for complete removal and minimal residue post-use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional barrier plugs with hardened inserts and rubber seals are used, then reliable sealing and anchoring are achieved, but complete removal is difficult and residues remain
Solution Approach 1:
The plug is divided into two distinct segments: a biodegradable body that disintegrates after use and a retained component (hardened insert or metal fragment) that remains in the tubular. This segmentation allows the plug body to be removed through biodegradation while leaving a minimal residual structure that maintains structural integrity during the treatment process.
Solution Approach 2:
The plug body material undergoes parameter changes by using biodegradable materials that change their physical and chemical properties over time. The material transitions from a stable, load-bearing state during treatment to a degrading state after treatment, ultimately disintegrating into removable or soluble components. This parameter change enables automatic removal without mechanical intervention.
2Ease of manufacture
If degradable materials are used for the plug body, then complete disintegration is achieved, but sealing capability and wall penetration are reduced
Solution Approach 1:
The plug employs composite material construction combining biodegradable materials for the main body with non-biodegradable materials (hardened inserts, metal fragments, or rubber seals) for critical sealing and anchoring functions. This composite approach allows the degradable portion to provide structural support and sealing while the retained portion ensures long-term anchoring reliability and prevents complete disintegration until the desired treatment period has elapsed.
Solution Approach 2:
Different regions of the plug have different material properties tailored to their specific functions. The main body uses biodegradable material for temporary support and sealing, while localized areas (such as the ball seat region or external surface) incorporate hardened inserts or metal fragments that resist degradation and provide permanent anchoring. This local quality differentiation resolves the contradiction between overall disintegration and localized retention.
3Reliability
If hardened inserts are used for enhanced wall penetration, then anchoring grip is improved, but complete disintegration is prevented
Solution Approach 1:
The hardened insert or metal fragment is extracted as a separate, retained component from the biodegradable plug body. During the treatment process, the hardened insert provides enhanced wall penetration and anchoring grip. After treatment, the biodegradable body disintegrates and is removed, leaving only the small hardened insert residual that can be easily retrieved or left in place without preventing subsequent operations. This extraction principle allows the system to achieve both strong anchoring during treatment and ease of removal afterward.
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
Enables efficient and complete removal of the plug after fracturing operations with reduced residue and tolerance for some leakage, enhancing operational efficiency and safety by using fully disintegrating materials.
Implementation Method 1
A disintegrating plug uses a setting tool to push a swage into the plug body that has external ribs that contact the wall of the surrounding tubular. The ribs retain the body to the surrounding tubular wall with frictional contact.
Implementation Method 2
hardened materials, while having a benefit to enhance wall penetration into the surrounding tubular for enhanced grip
Implementation Method 3
one or more o-rings are used to seal while anchoring is assisted by the hardened insert(s)
Implementation Method 4
A disintegrating plug uses a setting tool to push a swage into the plug body that has external ribs that contact the wall of the surrounding tubular... allowing for complete removal and minimal residue post-use... using fully disintegrating materials
Data Source
AI summary
A disintegrating plug uses a setting tool to push a swage into the plug body that has external ribs that contact the wall of the surrounding tubular. The ribs retain the body to the surrounding tubular wall with frictional contact. Some leakage may ensue but in fracturing some leakage does not matter if enough volume under the right pressure reaches the formation. The sheared member during the setting comes out with the mandrel that is part of the setting tool. In an alternative embodiment one or more o-rings are used to seal while anchoring is assisted by the hardened insert(s) that can be snap fitted in using rib flexing or that can be a c-ring that is expanded and snapped in. The o-ring(s) are axially spaced from the insert(s).