Extrudable Plug for Sequential Downhole Tool Activation
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Solution Overview
Problem
In the resource recovery industry, existing tool strings in wellbores require different plugs for each tool with distinct activation pressures, necessitating a specific order for plug deployment, which complicates downhole operations.
Innovation Solution
A method and system where a single plug is used to activate multiple tools with different activation pressures by employing ball seats with unique geometric parameters, allowing the plug to be seated and activated at varying pressures, enabling sequential activation of tools within the tool string.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different plugs are used for each tool with different activation pressures, then each tool can be activated at its specific pressure, but the complexity of plug deployment and the number of plugs required increases
Solution Approach 1:
The plug is designed with a compliant body that can adapt to multiple ball seats with different geometric parameters, allowing a single plug to activate multiple tools with different activation pressures. This multi-functional design eliminates the need for different plugs for each tool, reducing deployment complexity while maintaining reliable activation.
Solution Approach 2:
The ball seats are designed with different geometric parameters (opening angles, seat diameters) that correspond to different activation pressures. The compliant plug material allows it to deform and seal effectively against these varying geometries, enabling a single plug to function across multiple pressure thresholds through parameter variation in the ball seats rather than requiring different plugs.
2Device complexity
If a single plug is used to activate multiple tools, then the number of plugs required is reduced, but ensuring proper sealing and activation at different pressures becomes more difficult
Solution Approach 1:
The ball seats utilize different geometric parameters (opening angles ranging from 30 to 60 degrees, different seat diameters) that create distinct pressure thresholds. The compliant plug material deforms to match these varying geometries, ensuring reliable sealing at each ball seat despite the different activation pressures required.
Solution Approach 2:
Each ball seat is designed with localized geometric characteristics (specific opening angles, seat diameters) that are optimized for its particular activation pressure requirement. The plug's compliant nature allows it to conform to these local geometric variations, ensuring effective sealing and activation at each specific location along the tool string.
3Reliability
If plugs must be dropped in a specific order to match activation pressures, then proper tool activation is ensured, but the time and complexity of the operation increases
Solution Approach 1:
The single plug is designed to activate multiple tools with different activation pressures in sequence as it travels down the wellbore. This eliminates the need to drop multiple plugs in a specific order, as one plug naturally progresses through the tool string and activates tools sequentially based on the hydraulic pressure generated, significantly reducing deployment time.
Solution Approach 2:
The ball seats are pre-configured with different geometric parameters along the tool string to create a predetermined sequence of activation pressures. When the single plug is dropped, it naturally encounters these pre-arranged pressure thresholds in sequence, ensuring proper tool activation order without requiring coordinated timing or multiple plug drops.
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
This approach simplifies downhole operations by allowing a single plug to activate multiple tools with different activation pressures, reducing the complexity of plug deployment and hydraulic pressure requirements, while maintaining effective tool activation.
Implementation Method 1
the plug at the first ball seat blocks a fluid pressure at the second tool
Implementation Method 2
a plug is extruded through the first ball seat when a fluid pressure is applied to the plug above an extrusion pressure of the first ball seat
Data Source
AI summary
A work string and method of performing a downhole operation is disclosed. The work string includes a first tool having a first ball seat configured to activate when a first activation pressure is applied to a plug seated at the first ball seat, and a second tool having a second ball seat configured to activate when a second activation pressure is applied to the plug when seated at the second ball seat, wherein the first activation pressure is different than the second activation pressure. A plug is dropped through a string in a wellbore. The first activation pressure is applied when the plug is at the first tool to activate the first tool. The second activation pressure is applied when the plug is at the second tool to activate the second tool.