Downhole Seal Element with Dynamic Elongation for Bridge Plug Removal
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Solution Overview
Problem
The removal of bridge plugs after stimulation operations is challenging due to the high elongation properties of the seal element, which often results in clogging of surface lines with large debris chunks, requiring significant time and cost for cleanout and re-rigging.
Innovation Solution
A drillable isolation device with a seal element that has substantial elongation properties for initial sealing but reduces to less substantial elongation properties over time, allowing for easier drill-out and removal, utilizing a polymer matrix and cement additive that hardens upon exposure to wellbore constituents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the seal element is made with high elongation properties for effective sealing, then the sealing reliability is improved, but the ease of removal deteriorates
Solution Approach 1:
The seal element's elongation properties are made dynamic by incorporating a degradable material that transitions from high elongation (200-400%) during sealing to low elongation after degradation. This allows the seal to be highly elastic during operation but easily removable afterward, resolving the contradiction between sealing reliability and ease of removal.
Solution Approach 2:
The material properties of the seal element are changed over time through degradation. The seal starts with high elongation properties for effective sealing, then degrades to have reduced elongation properties, transforming it from a difficult-to-remove state to an easily drillable state. This parameter change resolves the contradiction between initial sealing performance and subsequent removability.
2Reliability
If the seal element maintains high elongation properties, then the hydraulic isolation is improved, but the productivity of removal operations deteriorates
Solution Approach 1:
The seal element transitions from a dynamic high-elongation state during hydraulic isolation to a static low-elongation degraded state for easy removal. This temporal separation allows the seal to provide reliable hydraulic isolation when needed, then easily degrade to enable rapid drill-out, resolving the contradiction between isolation reliability and removal productivity.
Solution Approach 2:
The elongation parameter of the seal element changes over time through controlled degradation. Initially, the seal maintains high elongation (200-400%) for effective hydraulic isolation, then degrades to have substantially reduced elongation, transforming it into an easily drillable material. This parameter transformation resolves the contradiction between maintaining isolation reliability and improving removal productivity.
3Reliability
If the seal element has high elongation properties, then the sealing effectiveness is improved, but the loss of time for cleanout operations increases
Solution Approach 1:
The seal element performs its sealing function with high elongation properties during the stimulation operation, then preliminarily degrades to a low-elongation state before removal is needed. This preliminary degradation action reduces the time required for subsequent cleanout operations, resolving the contradiction between sealing effectiveness and time loss for cleanout.
Solution Approach 2:
The seal element's elongation parameter changes from high (200-400%) during effective sealing to low after degradation. This parameter transformation allows the seal to maintain effectiveness during operation while becoming easily drillable afterward, significantly reducing cleanout time and resolving the contradiction between sealing effectiveness and cleanout time loss.
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 timely and efficient removal of bridge plugs without clogging surface lines, reducing production downtime and cleanout costs by breaking down into finer particulate during drill-out.
Implementation Method 1
the elongation properties of the seal element are less substantial during subsequent plug removal... utilizing a polymer matrix and cement additive that hardens upon exposure to wellbore constituents
Data Source
AI summary
An isolation device with seal element having substantial elongation properties at a time of setting and insubstantial elongation properties at time of drill out. That is, the seal element may be constructed of materials that are geared toward providing effective temporary sealing, for example to support stimulation operations. The seal is also tailored to change elongation properties over time such that upon sufficient exposure to downhole conditions the elongation properties may be substantially reduced. Thus, drillable removal of the device and seal element may be readily attained without undue concern over stretchable tearing of the element leading to an accumulation of large debris left behind in the well.