Frac Plug Bypass Port Axial Shift Mechanism
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Solution Overview
Problem
Existing plug and perf operations in wellbores require significant fluid to circulate a ball or plug for pressure barrier creation, which is inefficient and may fail if perforating guns do not fire as intended, necessitating a different method to set and close off the wellbore for fracturing fluid injection.
Innovation Solution
A frac plug with a central mandrel and locking portion, including a packer and slip assemblies, that can be set without a ball or plug, allowing fluid communication initially for tool removal and subsequent closure using axial compression and bypass ports for efficient fracturing fluid injection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ball or plug is circulated into the wellbore to create a pressure barrier, then the wellbore can be closed off for fracturing fluid injection, but a significant amount of water or fluid is needed which is inefficient and may fail if perforating guns do not fire
Solution Approach 1:
The invention extracts the ball or plug from the system entirely. Instead of circulating a ball down the flowbore to create a pressure barrier, the frac plug itself is designed with an internal flow blockage that creates the pressure barrier without requiring any ball or additional fluid circulation. This eliminates the need for significant fluid volumes while maintaining reliable pressure containment.
Solution Approach 2:
The pressure barrier capability is built into the frac plug structure beforehand through the internal flow blockage. The plug is pre-configured with the blocking mechanism that will create the pressure barrier immediately upon setting, rather than requiring a separate action of circulating a ball afterward. This preliminary configuration ensures reliability without fluid waste.
2Reliability
If a ball or plug is circulated to pressurize the flowbore behind it, then the wellbore can be closed off, but the process is inefficient and time-consuming
Solution Approach 1:
The invention removes the time-consuming ball circulation step entirely. The internal flow blockage in the frac plug creates the pressure barrier instantly when the plug is set, eliminating the need to circulate a ball down the flowbore and wait for it to create the barrier. This dramatically reduces operation time while ensuring reliable wellbore closure.
Solution Approach 2:
The pressure barrier mechanism is pre-built into the plug structure with the internal flow blockage. When the plug sets, the barrier is immediately in place without requiring any additional time for ball circulation or pressurization steps. The system is prepared in advance to create the barrier instantly.
3Ease of operation
If the central mandrel is designed with bypass ports for fluid communication, then tool removal is enabled, but the mandrel structure becomes more complex
Solution Approach 1:
The bypass ports are designed to be dynamically controllable rather than permanently open or closed. The ports can be opened or closed based on operational requirements - opened during tool removal to allow fluid communication and closed during fracturing to maintain pressure barrier. This dynamic capability provides operational flexibility without requiring complex additional mechanisms.
Solution Approach 2:
The bypass ports serve multiple functions: they enable tool removal by allowing fluid communication when needed, and they can be closed to maintain pressure barrier during fracturing operations. This multi-functionality simplifies the overall system design by using a single structural feature for multiple operational purposes rather than requiring separate mechanisms for each function.
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 setting and closure of the wellbore for fracturing fluid injection without the need for a ball or plug, ensuring fluid communication for tool retrieval and pressurization, thereby improving the plug and perf operation's efficiency and reliability.
Implementation Method 1
The locking portion can include a locking device in the form of a packer and/or one or more slip assemblies which are set by axial compression relative to the central mandrel
Implementation Method 2
a packer and slip assemblies, that can be set without a ball or plug, allowing fluid communication initially for tool removal and subsequent closure using axial compression
Implementation Method 3
Pressurizing the annulus will shift the central mandrel within the locking portion to close off fluid communication across the frac plug
Data Source
AI summary
A frac plug for use in a plug and perf arrangement to within a wellbore. The frac plug includes a central mandrel and locking portion which can be set within the wellbore. A bypass port is disposed through the central mandrel and is unblocked to fluid flow during setting of the plug assembly. Thereafter, the central mandrel is axially shifted within the set locking portion to block fluid communication across the frac plug.