Multi-Set Frac Plug Isolation With Slip and Extrusion Prevention
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Solution Overview
Problem
Downhole operations in oil and gas exploration require multiple consumable frac plugs, leading to significant time, effort, and expense for plug removal, as each stage of a wellbore typically necessitates a new plug, with potential damage from extrusion and deformation of elastomer elements under high pressure.
Innovation Solution
A multi-set frac plug system featuring a rod, elastomer element, guardian rings, and receptacles that allow for repeated use, preventing elastomer extrusion and requiring no ball drop for sealing, utilizing guardian rings to create a metal-to-metal seal and allowing for hydraulic activation and retraction without shearing, enabling multiple settings and re-settings in a wellbore.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If consumable frac plugs are used for each stage of wellbore, then reliable sealing under high pressure is achieved, but significant time, effort, and expense are required for plug removal and replacement
Solution Approach 1:
The elastomer element is designed to be recovered and reused multiple times instead of being discarded after single use. The guardian ring prevents elastomer extrusion during high-pressure operations, allowing the same elastomer element to be recovered, inspected, and reused across multiple frac stages, thereby eliminating the need for continuous replacement and reducing time loss.
2Reliability
If consumable frac plugs are used for each stage of wellbore, then sealing function is provided, but drill-out operations are required to remove plugs
Solution Approach 1:
The plug system is designed to be self-contained and reusable without requiring external drill-out operations for removal. The guardian ring and elastomer element combination allows the plug to be set, used, recovered, and reused through hydraulic activation and retraction mechanisms, making the system self-sufficient and eliminating the need for additional drill-out operations to remove consumable plugs.
3Reliability
If elastomer element is used under high pressure, then sealing is achieved, but extrusion and deformation occur
Solution Approach 1:
The guardian ring is positioned to prevent elastomer extrusion before it can occur during high-pressure operations. By providing a protective barrier in advance, the guardian ring counteracts the extrusion force that would otherwise deform or damage the elastomer element, maintaining its structural integrity and sealing capability throughout the high-pressure frac operation.
4Reliability
If multiple plugs are used at various locations in wellbore, then complete wellbore isolation is achieved, but cumulative expense increases
Solution Approach 1:
The plug system is designed as a universal, multi-functional component that can be reused across multiple frac stages and wellbore locations. The same elastomer element and guardian ring assembly can be deployed at different stages, eliminating the need to purchase and install multiple separate consumable plugs, thereby reducing cumulative material costs while maintaining complete wellbore isolation.
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 system reduces the need for consumable plugs, eliminates drill-out operations, and ensures reliable sealing under high pressure, maintaining the integrity of the wellbore by preventing elastomer extrusion and casing damage, thus reducing operational costs and time.
Implementation Method 1
an elastomer element that interfaces with the uphole coupling... the elastomer element may expand to contact and interact with the inside diameter of the casing, in turn creating a seal
Implementation Method 2
a guardian ring disposed about a portion of the receptacle... the guardian ring comprises a split ring that prevents extrusion of the elastomer element when the apparatus is positioned in a downhole location
Data Source
AI summary
An example apparatus includes a rod, an uphole coupling through which the rod extends, an expansion ring positioned on the rod below the uphole coupling, an elastomer element positioned on the rod below the expansion ring, a receptacle positioned on the rod below the elastomer element and configured to receive a portion of the elastomer element, a guardian ring positioned on the rod below the receptacle, and a portion of the receptacle is received in the guardian ring, a cap positioned on the rod and arranged for contact with the guardian ring, and a barrel to which the cap is connected, wherein the rod is partially received in the barrel, and one of the barrel and the rod is movable with respect to the other of the barrel and the rod to exert a compression load on the elastomer element.