Expandable Frac Plug for Single-Run Zonal Isolation
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Solution Overview
Problem
Conventional frac plugs require complex operations and additional tools for setting and removal, limiting the inner diameter and increasing costs and time consumption, and existing solutions do not allow for a single-run frac plug with a larger inner diameter and efficient wellbore zonal isolation.
Innovation Solution
A dissolvable frac plug with an expandable element that expands from a first inner diameter to a second inner diameter, allowing an object to be positioned across the inner diameter without the need for additional downhole tools, and includes a setting sleeve and expandable element to form a seal and facilitate one-way fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional frac plugs use slips and seals via packing elements or O-rings, then wellbore zonal isolation can be achieved, but the operations become complex and require additional tools
Solution Approach 1:
The patent extracts the setting operation complexity by using a ball-on-seat mechanism that sets the frac plug automatically when the ball reaches the seat, eliminating the need for complex slip-setting operations and additional setting tools. The plug body is designed with an integrated seat that receives the ball, providing simple and reliable zonal isolation.
Solution Approach 2:
The frac plug design enables self-service setting through the ball-on-seat mechanism. When the ball is dropped from surface, it automatically seats on the plug's integrated seat, triggering the setting action without requiring external setting tools or complex operational procedures. The plug sets itself through this simple ball-reception mechanism.
2Ease of operation
If conventional frac plugs use running tools with pockets for balls, then balls can be positioned, but the downhole real estate occupied reduces the inner diameter
Solution Approach 1:
The patent removes the running tool and pocket structure from the system entirely. Instead of using a running tool with pockets to position balls, the design allows balls to be dropped directly from surface through the drill hole. The frac plug itself contains an integrated seat that receives the ball, eliminating the need for additional downhole tools and maximizing the inner diameter.
Solution Approach 2:
The frac plug design integrates multiple functions into a single device: it provides zonal isolation, contains the ball-receiving seat, and eliminates the need for separate running tools. This multi-functionality reduces the overall system complexity and maximizes the available inner diameter by removing redundant components.
3Ease of operation
If smaller balls are run in hole within pockets of a running tool, then balls can land on the frac plug, but thicker frac plugs with smaller inner diameters are required
Solution Approach 1:
The patent extracts the ball delivery system from the downhole environment by allowing balls to be dropped directly from surface through the existing drill hole. The frac plug contains an integrated seat that receives these balls, eliminating the need for running tools with pockets and thick-walled structures, thereby maximizing the inner diameter.
Solution Approach 2:
The frac plug is designed with a pre-positioned seat that is ready to receive the ball immediately upon its arrival from surface. This preliminary preparation of the seat eliminates the need for complex ball delivery mechanisms and allows for larger inner diameter while maintaining easy ball delivery operation.
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 wellbore zonal isolation and communication via reverse flow with a larger inner diameter frac plug, reducing operational complexity and costs by eliminating the need for additional downhole tools and operations.
Implementation Method 1
the expandable element is configured to expand from a first inner diameter to a second inner diameter to allow the object to be positioned across an inner diameter of the shorty plug
Implementation Method 2
the slips may radially expand outward to form a seal across an annulus
Implementation Method 3
The breakable threads and/or the shear pins may be configured to selectively and temporarily couple the running tool and the frac plug together
Data Source
AI summary
A frac plug with an object run in hole within a collet. Responsive to activating the collet or expandable element, the collet may slide out of the frac plug and expand to allow the object to be positioned across an inner diameter of the shorty plug, wherein the frac plug includes a bottom, and the expandable element is directly and temporarily coupled to the bottom.