Frac Plug Anchor Slips Radial Expansion Thermal Assembly
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Solution Overview
Problem
Current frac plugs used in hydrocarbon recovery operations face challenges such as high costs and inefficiencies in zonal isolation and multi-zone hydraulic fracturing, requiring improved designs for effective hydrocarbon flow and reduced operational expenses.
Innovation Solution
A novel frac plug design featuring a shoe, lower and upper anchor slip assemblies with independently expanding anchors, a load ring, and a tubular mandrel that allows for radial expansion of anchor slips, enabling efficient zonal isolation and hydrocarbon flow without the need for machining, thereby reducing costs and enhancing operational efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional frac plugs are used with machining requirements, then manufacturing precision can be achieved, but production costs increase and manufacturing complexity increases
Solution Approach 1:
The patent replaces traditional mechanical machining processes with a heated assembly process. The anchor slips are expanded radially through thermal expansion and mechanical activation within the heated assembly tool, eliminating the need for precision machining operations while achieving the required dimensional accuracy and functional performance.
Solution Approach 2:
The patent utilizes thermal parameter changes by heating the assembly to expand the anchor slips radially. This thermal expansion allows the anchor slips to achieve their final dimensions and configurations without traditional machining, thereby reducing manufacturing complexity and cost while maintaining precision.
2Reliability
If anchor slips are expanded radially with heated assembly, then zonal isolation efficiency improves, but device complexity increases
Solution Approach 1:
The patent divides the anchor slip assembly into multiple independent segments that can expand radially independently. This segmentation allows each anchor slip to be activated and expanded individually through the heated assembly process, achieving effective zonal isolation while managing overall device complexity through modular design.
3Adaptability or versatility
If multiple independent anchor slips are used, then zonal isolation capability improves, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent designs the anchor slips as universal components that can function in multiple zones and configurations. Each anchor slip assembly is designed to perform the same isolation function in different well zones, allowing the same component design to be replicated throughout the device, thereby reducing overall complexity despite having multiple anchor slips.
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 enhances zonal isolation and hydrocarbon flow efficiency while reducing operational costs by eliminating the need for machining and allowing for self-centering and secure locking within the well bore casing, facilitating effective hydraulic fracturing processes.
Implementation Method 1
linear movement of the tubular mandrel causes movement of the upper anchor slip assembly to expand a set of upper anchor slips in a radial direction and linear movement of the tubular mandrel is further configured to expand a set of lower anchor slips in a radial direction
Data Source
AI summary
Plugs for use in hydrocarbon recovery operations having lower and upper anchor slip assemblies with individual anchors, upper and lower elements, a shoe and tubular mandrel.