Expandable Fracture Plug Seat with Elastomeric Seal
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Solution Overview
Problem
Conventional expandable fracture plug seats in subterranean well fracturing operations face issues such as debris lodging in radial slits, erosion during high-pressure frac slurry injection, and stress-induced deformation, which compromise sealing capability.
Innovation Solution
A specially designed expandable fracture ball seat structure featuring an annular configuration with rigid metal segments and a resilient elastomeric material, allowing diametric expansion and contraction while preventing debris lodging and withstanding abrasive conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If radial slits are formed in the ball seat to permit diametrical expansion, then the seat can expand to allow fracture balls to pass through, but debris can lodge in the widened slits preventing proper closure and compromising sealing capability
Solution Approach 1:
The ball seat incorporates a resilient elastomeric material that forms a flexible membrane capable of diametrical expansion when a fracture ball passes through, yet returns to its original configuration to maintain sealing. The elastomeric material acts as a thin film that can deform elastically without creating permanent gaps where debris could lodge.
Solution Approach 2:
The ball seat uses a composite structure combining rigid metal segments with resilient elastomeric material. The metal segments provide structural support while the elastomeric material provides the flexible sealing surface that expands and contracts without debris accumulation.
2Productivity
If the plug seat is exposed to high-pressure frac slurry injection, then fracturing operations can proceed, but the seat undergoes abrasive blasting causing erosion and lessening plug sealing ability
Solution Approach 1:
The elastomeric material forms a resilient protective layer that absorbs and distributes the impact of abrasive frac slurry, preventing erosion of the underlying metal structure. The flexible nature of the elastomer allows it to deform under slurry impact and return to its original shape, maintaining sealing capability.
Solution Approach 2:
The composite structure of rigid metal segments covered with resilient elastomeric material provides both structural integrity and erosion resistance. The elastomeric outer layer acts as a protective barrier against abrasive blasting while the metal core maintains structural strength.
3Power
If driving pressure is exerted on ball plugs during high-pressure injection, then fracturing can proceed, but stress concentrations deform the balls and reduce sealing capability of the associated ball seat
Solution Approach 1:
The elastomeric material provides a compliant sealing surface that can deform to accommodate variations in ball plug shape and size. This flexibility allows the seat to maintain sealing even when ball plugs experience stress-induced deformation during high-pressure injection.
Solution Approach 2:
The combination of rigid metal segments with resilient elastomeric material creates a seat structure that can withstand high injection pressures while maintaining sealing capability. The elastomeric material absorbs stress concentrations and prevents ball deformation from compromising the seal.
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 design ensures reliable sealing, resistance to erosion, and effective expansion control, maintaining sealing integrity and preventing debris entry, even under high-pressure frac operations.
Implementation Method 1
a resilient portion formed from an elastomeric material... allowing diametric expansion and contraction
Implementation Method 2
resistance to erosion, and effective expansion control, maintaining sealing integrity and preventing debris entry, even under high-pressure frac operations
Data Source
AI summary
An annular seat structure, for use in subterranean well stimulation operations, is operative in conjunction with associated expansion control structure to permit a predetermined number of fracture plug members to axially pass therethrough. In an illustrated embodiment thereof, the annular seat structure is movable between a retracted position having a first interior diameter, and a resiliently expanded position having a second, larger interior diameter. The seat structure has an annular array of rigid ring segments interdigitated with annular gaps that receive radially outwardly projecting portions of an annular resilient liner secured to radially inner surfaces of the rigid ring segments, the outwardly projecting liner portions being secured to circumferentially facing surfaces of the rigid ring segments. An annular spring member coaxially circumscribes the rigid ring segment array, is received in notches formed in the rigid segments, and resiliently biases the seat structure toward its retracted position.