Drill Pipe Conveyed Plug With Electronic Control
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Solution Overview
Problem
Existing downhole bridge plugs face challenges in setting and releasing due to difficulties in transferring torque and weight at great depths, especially with high wellbore deviation, and require complex mechanical force applications, leading to increased rig time and costs.
Innovation Solution
A drill pipe string conveyed retrievable plug system with an electronic control section that uses pressure and control signals to initiate the setting of slips and packer, eliminating the need for torque and weight transfer, and includes a motor-controlled selector ring and piston sleeve for controlled fluid channel activation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If torque and weight are transferred via drill pipe string to set the plug, then the plug can be set in the wellbore, but the transfer becomes difficult and unreliable at great depths with high deviation
Solution Approach 1:
The patent replaces the traditional mechanical setting system (torque and weight transfer through drill pipe) with an electronic control system. The electronic control unit receives signals from surface, detects drill pipe rotation speed and pressure, and automatically controls the setting sequence of slips and packer via electronic signals rather than mechanical force transfer.
Solution Approach 2:
The patent utilizes fluid pressure (pneumatics/hydraulics) as the medium to transmit setting forces. Pressure signals are sent through the drill pipe to activate the setting mechanism, replacing the need for mechanical torque and weight transfer. The pressure-based activation is more reliable at great depths and high deviations where mechanical transfer fails.
2Reliability
If complex mechanical force applications are used to set the plug, then the plug can be set, but rig time and operational costs increase
Solution Approach 1:
The electronic control unit is equipped with sensors that automatically detect drill pipe rotation speed and pressure conditions. The system autonomously determines when setting conditions are met and automatically executes the setting sequence without requiring complex manual operations or multiple intervention steps, thereby reducing rig time.
Solution Approach 2:
The system performs preliminary detection of setting conditions (rotation speed, pressure) before initiating the setting sequence. This ensures that setting actions are taken at the optimal moment, avoiding unnecessary delays and repeated operations that would increase rig time and costs.
3Ease of operation
If torque is applied to unscrew ratchet locks via drill string rotation, then the plug can be released, but the process becomes unreliable at great depths with high deviation
Solution Approach 1:
The patent replaces mechanical torque-based release mechanisms with electronic control. The electronic control unit receives release signals from surface and automatically activates the release sequence through pressure signals, eliminating the need for reliable torque transfer through the drill string at great depths.
4Reliability
If ball drop is used to activate the setting mechanism, then the plug can be set, but the process is time-consuming and increases rig time
Solution Approach 1:
The patent uses pressure signals transmitted through the drill pipe to activate the setting mechanism, replacing the ball drop method. Pressure can be applied immediately and controlled precisely, eliminating the time required for a ball to travel down the drill string and reach the activation point.
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 system provides a reliable and efficient setting sequence independent of ball drop and rotation, reducing operational complexity and cost by enabling pressure-based setting and controlled release of the plug, even at great depths, and allows for temporary or permanent well closure with reduced power requirements.
Implementation Method 1
an electric motor, which is arranged for transforming electrical energy to mechanical energy to turn the selector ring
Implementation Method 2
initiating the mechanical setting of slips and packer via pressure in the central bore of the drill pipe string and the plug system
Data Source
AI summary
A drill pipe string conveyed retrievable plug system has a central through bore. The plug system includes a drill pipe string; a control section; a running tool with a connector at a lower end of a drill pipe string with the control section, and a top connector on a mechanical plug section with a bridge plug. The mechanical plug section includes a mandrel with the through bore, a ball valve arranged for closing the through bore, and a packer sleeve on the mandrel with slips and a packer element. The control section includes an electric supply, an electric control unit, and sensors connected to the electric control unit. The mechanical plug section includes a motor controlled by the electrical control unit. The motor is arranged to turn a selector ring to a selected first rotational position so as for allowing a piston sleeve to slide to an axial first stop position in order for opening to fluid channels through the mandrel from the through bore to the packer sleeve. The pressure in the through bore can be set to the pressure of the packer sleeve in a surrounding casing.