Expandable Frac Plug Tubular for Wellbore Pressure Isolation
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Solution Overview
Problem
Conventional frac plugs with multiple components are costly and risky due to potential component failure during setting, leading to additional operations and costs for retrieval.
Innovation Solution
A singular tubular structure frac plug that expands to a desired diameter to anchor in the wellbore casing, using ductile materials and swedges for expansion, with integrated components to engage with the casing and maintain position, and a sealing device for differential pressure integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional frac plugs with multiple components are used, then the frac plug can be set in place, but the cost and risk increase due to potential component failure during setting
Solution Approach 1:
The patent combines multiple conventional frac plug components (mandrel, slip tools, setting mechanisms) into a single integrated tubular structure. This singular structure eliminates the complexity of multiple separate components while maintaining the ability to set and isolate the wellbore, directly resolving the contradiction between reliability and device complexity.
Solution Approach 2:
The singular tubular structure performs multiple functions that were previously distributed across separate components: it provides structural support, creates the seal, enables setting through expansion, and maintains isolation. This multi-functionality reduces the number of parts while ensuring reliable operation throughout the fracturing process.
2Ease of repair
If multiple components are used in conventional frac plugs, then the frac plug can be set, but additional operations and costs are required for retrieval if components fail
Solution Approach 1:
By merging all functional components into a single tubular structure, the patent eliminates the problem of retrieving individual failed components. If the structure fails or needs retrieval, it is retrieved as one unit, simplifying the operation and reducing costs compared to recovering multiple separate components.
3Device complexity
If a singular tubular structure is used, then the device complexity is reduced, but the ability to engage with casing may be compromised
Solution Approach 1:
The singular tubular structure incorporates localized features at specific positions along its length, including external threads for engagement with the casing and internal swedge mechanisms for expansion. These localized quality variations enable the simple tubular form to achieve strong casing engagement without requiring multiple separate components.
Solution Approach 2:
The tubular structure may utilize composite or multi-layer material construction, combining different materials with complementary properties to achieve both structural integrity for engagement and the necessary flexibility for expansion and setting operations.
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 reliable and cost-effective hydraulic isolation in wellbores by minimizing component failure and ensuring the frac plug remains securely in place, enhancing operational efficiency and reducing retrieval costs.
Implementation Method 1
The materials of the singular tubular structure may include any suitable ductile material that may be capable of dissolving in a downhole environment... where the elastic properties of the materials may allow the singular tubular to expand to contact the inner diameter of the casing
Implementation Method 2
The singular tubular structure may expand via a setting tool comprising one or more swedges, or any other components configured to increase the inner diameter and/or the outer diameter of the singular tubular
Implementation Method 3
In some implementations, the friction between the outer face of the singular tubular structure and the inner wall of the casing may hold the frac plug in place while the outer face of the singular tubular structure is expanded
Data Source
AI summary
An apparatus comprising a singular tubular structure to be positioned inside casing of a wellbore formed in a subsurface formation, wherein the singular tubular structure is configured to expand to contact an inner wall of the casing and provide differential pressure integrity in the wellbore while an isolating component is positioned in the singular tubular structure.