Downhole Isolation Tool Plastically Deformable Seal Mandrel Removal
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Solution Overview
Problem
Existing frac plugs with internal mandrels have a small internal diameter due to the mandrel's structural requirements, restricting fluid flow and complicating plug removal due to the mandrel's thickness and multiple composite components.
Innovation Solution
A downhole isolation tool with a plastically deformable sealing element that irreversibly deforms when swaged, eliminating the need for a mandrel and allowing for a larger internal passage and reduced component count, facilitating easier manufacturing and quicker removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mandrel is used to support the sealing element, then the structural integrity and reliability of the plug are improved, but the internal diameter is reduced and the device complexity increases
Solution Approach 1:
The patent removes the mandrel from the plug structure entirely. Instead of using a mandrel to support the sealing element, the invention uses a single slip ring that engages with the casing to provide the necessary support and positioning. This extraction of the mandrel component directly resolves the contradiction by eliminating the space-consuming internal structure while maintaining reliability through the alternative slip ring mechanism.
2Reliability
If a mandrel is used to support the sealing element, then the sealing reliability is improved, but the manufacturing complexity and removal difficulty increase
Solution Approach 1:
The mandrel is completely removed from the structure, reducing the component count from multiple parts (mandrel, sealing element, slip rings, wedges) to a simplified assembly with fewer components. The sealing reliability is maintained through the slip ring's engagement with the casing, which provides the necessary support without requiring a complex internal mandrel structure.
Solution Approach 2:
The functions of the mandrel and the slip ring are merged into a single integrated structure. The slip ring both engages with the casing for positioning and supports the sealing element, eliminating the need for a separate mandrel component. This merging reduces device complexity while maintaining the necessary sealing reliability.
3Reliability
If multiple composite components are used in the plug, then the sealing performance is improved, but the removal time increases due to milling requirements
Solution Approach 1:
The mandrel, which requires extensive milling for removal, is completely removed from the structure. The remaining components are designed to be more easily removable, significantly reducing the time required for plug removal while maintaining sealing performance through the slip ring's engagement mechanism.
4Reliability
If the sealing element is made elastically deformable, then the sealing capability is improved, but the tendency to return to initial position requires additional components to maintain seal
Solution Approach 1:
The mandrel is removed, and the sealing element is designed to work in conjunction with the slip ring without requiring the complex wedge-and-slip ring assembly of conventional plugs. This simplification reduces component count while maintaining sealing capability through the slip ring's engagement with the casing.
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 solution provides a larger bore for improved fluid flow and significantly reduces the time required to remove the plug by eliminating the need to mill out a mandrel, while simplifying the manufacturing and assembly process.
Implementation Method 1
The sealing element includes a plastically deformable material that irreversibly deforms when swaged
Data Source
AI summary
A downhole isolation tool for sealing a well, the downhole isolation tool including a sealing element having an internal surface that defines a bore of the downhole isolation tool. The sealing element includes a plastically deformable material that irreversibly deforms when swaged.