Pre-positioned Plug Insert for Frac Plugs
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Solution Overview
Problem
Current hydraulic fracturing operations face inefficiencies due to the need for additional fluid and time to place a frac plug ball after positioning a frac plug tool, and increased costs from potential incorrect placement requiring milling out or relocation of the tool.
Innovation Solution
A plug insert for frac plug tools, comprising a plug top, plug body, and elastomeric O-ring, which can be used to eliminate the need for additional fluid and time to place a frac plug ball, and allows for easy removal or relocation of the tool by dissolving or dislodging the insert, facilitating correct placement and reducing operational costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If additional fluid is pumped to transport the frac plug ball to the tool, then the frac plug ball can be positioned at the target location, but fluid expenditure and time consumption increase
Solution Approach 1:
The frac plug ball is pre-positioned inside the frac plug tool assembly at the surface before being deployed into the wellbore. This preliminary placement eliminates the need to pump additional fluid to transport the ball to the tool location, as the ball is already in position when the tool is set in the wellbore.
Solution Approach 2:
The frac plug ball is integrated into the frac plug tool assembly as a combined unit, with the ball housed within a cage or chamber on the tool. This merging of components allows the ball to be deployed simultaneously with the tool, eliminating separate transportation steps and reducing both time and fluid expenditure.
2Productivity
If the frac plug tool with pre-positioned ball is used, then time and fluid expenditure are reduced, but if the tool is mistakenly placed, milling out is required increasing costs
Solution Approach 1:
The frac plug ball is housed within a removable cage or chamber on the frac plug tool, allowing it to be extracted or released from the tool assembly. This design enables the ball to be deployed independently if needed, or the tool to be retrieved and repositioned without requiring milling out, thereby maintaining operational efficiency while providing placement flexibility.
3Reliability
If conventional frac plug tools are used, then isolation barriers can be created, but additional fluid and time are required to place the frac plug ball after tool positioning
Solution Approach 1:
The frac plug ball is pre-positioned inside the frac plug tool assembly at the surface before deployment. This preliminary placement ensures the ball is ready for immediate deployment when the tool reaches the target location, eliminating the need to pump additional fluid to transport the ball and reducing overall fluid expenditure while maintaining reliable isolation barrier creation.
Data Source
AI summary
A plug insert for use in a frac plug tool comprising a plug top, a plug body and an elastomeric O-ring, The plug top is shaped to rest on a seat of an upper end of a mandrel of the frac plug tool and the plug body is shaped to fit in a flow passage of the mandrel wherein the plug body includes a shear pin opening. The elastomeric O-ring is locatable around a portion of the plug body and sized to block fluid flow through the flow passage of the mandrel when the plug body is located in the flow passage. A frac plug tool for use in a well comprising the plug insert and a shear pin to hold that insert above the mandrel seat of the tool and method of assembling the tool are also disclosed.