Frac Plug Rod Retainer for Flowback Fluid Control

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Solution Overview

Problem

In the resource recovery industry, frac plugs struggle to maintain control over fluid flow during flowback, as the ball used to redirect fluid flow can be pushed away from the plug, losing control over fluid direction.

Innovation Solution

A frac plug system is introduced, comprising a plug member that sets the frac plug in the wellbore and controls fluid flow, using a frangible connection to secure the plug member during deployment and a retainer to maintain it within the frac plug during flowback, ensuring the plug member remains in place to manage fluid flow effectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a ball is dropped onto a ball seat to redirect fluid flow, then fluid flow direction is controlled, but flowback can push the ball out of the ball seat to a distance far from the frac plug, losing control over fluid flow

Engineering Contradiction:

Improvefluid flow controlVSAvoidball position

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The system divides the ball into segments: a ball body and a ball retainer component. The ball retainer acts as a separate element that engages with the ball and prevents it from being pushed away during flowback, while allowing the ball to remain on the ball seat for flow control.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A ball retainer serves as an intermediary component between the ball and the frac plug body. This retainer engages with the ball and provides a mechanical constraint that prevents the ball from being displaced during flowback, while still allowing the ball to function on the ball seat.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the plug member is used to control fluid flow, then directional control is achieved, but the plug member may be carried away during flowback without proper retention

Engineering Contradiction:

Improvefluid flow controlVSAvoidplug member position

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The ball retainer is pre-positioned and configured to engage with the ball before flowback occurs. This preliminary positioning ensures that when flowback happens, the retainer is already in place to prevent ball displacement, eliminating the need for reactive measures.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The ball retainer is designed to provide preliminary resistance against the forces that would push the ball away during flowback. By being in place beforehand, it counteracts the harmful flowback forces before they can displace the ball.

Inventive Principle:

Principle #9Preliminary anti-action

Data Source

PatentUS11746616B2Frac plug with rod plug

Publication Date: 2023.09.05 BAKER HUGHES OILFIELD OPERATIONS LLC

AI summary

A frac plug system for use in a wellbore, including a frac plug; and a plug member configured to set the frac plug in the wellbore and to control a flow of fluid through the frac plug once the frac plug is set in the wellbore. A method of controlling a flow of fluid within a wellbore, including conveying a frac plug system in the wellbore, the frac plug system including a frac plug and a plug member; setting the frac plug in the wellbore using the plug member; and control the flow of fluid through the frac plug using the plug member once the frac plug is set in the wellbore.