Frac Plug With Integral Setting Tool Assembly
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Solution Overview
Problem
The existing process of fracturing a subsurface well requires separate assembly of a setting tool and frac plug at the well location, resulting in a long and unreliable assembly that necessitates increased manpower and time.
Innovation Solution
A combined downhole assembly comprising a plug section with a top and bottom sub, a power section with a power charge and ignitors, and a mandrel, which ignites the power charge to separate the plug and power sections, allowing for a shorter and more reliable assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate setting tool and frac plug are assembled at well location, then assembly can be customized and adjusted, but assembly length increases and reliability decreases
Solution Approach 1:
The patent combines the setting tool and frac plug into a single integrated downhole assembly. The setting tool is positioned within the plug body, with the power charge located in a cavity of the plug. This merging eliminates the need for separate assembly at well location, reducing overall assembly length and improving reliability through factory pre-assembly and testing of the integrated unit.
2Productivity
If separate setting tool and frac plug are assembled at well location, then on-site adjustment is possible, but manpower requirements increase and time consumption increases
Solution Approach 1:
The setting tool and frac plug are pre-assembled into an integrated unit at the factory before deployment to the well site. This preliminary assembly allows for quality control and testing to be performed in advance, eliminating the need for on-site assembly operations. The pre-integrated assembly reduces manpower requirements and accelerates the deployment process, as the complete assembly is simply lowered into the wellbore as a single unit.
3Loss of time
If power charge is used to separate plug and power sections, then setting operation is rapid and effective, but explosive material is required
Solution Approach 1:
The patent uses a shear pin as an intermediary mechanical separation mechanism between the power charge and the plug body. The power charge is contained in a cavity within the plug, and separation is achieved through the shearing of the pin that connects the power section to the plug body. This intermediary mechanical linkage allows for controlled separation without requiring the power charge itself to be explosive, reducing handling hazards while maintaining rapid setting 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
The solution reduces the physical length of the assembly, enhancing handling and increasing reliability by allowing the frac plug with integral setting tool to be pre-assembled, thus decreasing the time required for each operation and reducing manpower needs.
Implementation Method 1
activating the one or more ignitors, resulting in the power charge being ignited, which results in the production of gas
Implementation Method 2
the gas forces the shear pin to break, resulting in the dog separating from the mandrel
Data Source
AI summary
A system combining a setting tool and a frac plug into one assembly thus producing a much shorter and more reliable assembly. More specifically, a downhole assembly comprising a plug section, which itself comprises a top sub, a bottom sub, a slip, and an elastomeric element. The downhole assembly further comprises a power section comprising a body comprising a power charge and one or more ignitors, a firing head, a shearing pin, and a setting tool piston. Additionally, the downhole assembly comprises a check valve, wherein the check valve is positioned downhole from the power charge and inside the setting tool piston; a mandrel comprising a hydraulic chamber and a ball, wherein the mandrel is positioned inside and adjacent to the setting tool piston and the top sub; and a dog.