Frac Plug Flapper Rupture Disc Segmentation
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Solution Overview
Problem
Conventional frac plugs are difficult to remove from a wellbore, especially in horizontal sections, and lack the ability to re-establish communication for re-pumping or new perforations without consuming excessive fluid or requiring drilling/milling, which is time-consuming and inefficient.
Innovation Solution
A frac plug with a movable flapper configured to seal and unseal based on pressure differential and fluid flow, featuring a rupture disc that shears at a pre-determined pressure to allow communication across the plug, enabling fluid flow even when closed, and designed with a weak point for easy removal or re-pumping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional frac plugs are used, then the wellbore can be isolated, but the frac plug is difficult to remove and requires drilling/milling which consumes time
Solution Approach 1:
The frac plug is divided into separable components: an outer mandrel, an inner mandrel, and a flapper assembly. The inner mandrel can be detached from the outer mandrel, allowing the flapper assembly to be removed independently without milling the entire plug. This segmentation enables selective removal of only the necessary components.
Solution Approach 2:
The flapper assembly is designed to be extractable from the outer mandrel. By removing the inner mandrel first, the flapper assembly can be taken out separately, eliminating the need to mill the entire frac plug and reducing removal time and complexity.
2Ease of operation
If conventional frac plugs are used, then the wellbore can be isolated, but excessive fluid is consumed for drop and pumping operations
Solution Approach 1:
The flapper is designed as a movable component that can dynamically open or close based on operational needs. The flapper can be opened to allow fluid flow for re-pumping operations without requiring complete plug removal, reducing fluid consumption compared to conventional methods that require dropping and pumping balls.
Solution Approach 2:
The system changes the flow parameters by opening the flapper to allow bidirectional fluid flow when re-pumping is needed. This parameter change enables fluid to pass through the plug without requiring excessive pumping operations, thereby reducing fluid consumption.
3Reliability
If the flapper is closed to maintain seal, then communication is blocked, but re-pumping and new perforation cannot be established
Solution Approach 1:
The flapper serves as a dynamic valve that can switch between closed (sealing) and open (communication) positions. When sealing is needed, the flapper closes; when re-pumping or new perforation is required, the flapper opens to restore communication. This dynamic behavior provides both reliable sealing and adaptability.
Solution Approach 2:
The flapper assembly provides multiple functions: it seals the wellbore during fracturing operations, allows bidirectional fluid flow for re-pumping, and enables new perforation establishment. This multi-functionality resolves the contradiction between maintaining seal integrity and enabling communication when needed.
4Ease of operation
If milling is performed to remove the frac plug, then the plug can be removed, but the process is time-consuming and inefficient
Solution Approach 1:
By segmenting the frac plug into removable components (outer mandrel, inner mandrel, flapper assembly), the system eliminates the need for time-consuming milling operations. The components can be detached and removed sequentially, significantly improving operational efficiency while maintaining effective plug removal capability.
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
Facilitates efficient removal and re-pumping of frac plugs by allowing communication through the sheared rupture disc, reducing fluid consumption and milling time, especially in challenging horizontal well sections.
Implementation Method 1
the flapper is configured to close based on a pressure differential and/or fluid flow from a proximal end towards a distal end of the frac plug
Implementation Method 2
The frac plug may include a rupture disc that is configured to shear at a pre-determined pressure
Implementation Method 3
the flapper is configured to close based on a pressure differential and/or fluid flow from a proximal end towards a distal end of the frac plug
Implementation Method 4
the flapper is configured to open based on the pressure and/or fluid flow from the distal end towards the proximal end of the frac plug
Data Source
AI summary
A frac plug with a flapper, wherein the flapper is configured to set and unset based on a pressure differential and/or fluid flow associated with the frac plug.