Frac Plug Initiator Switch for Surface Set Confirmation
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Solution Overview
Problem
Current methods for confirming the setting of frac plugs in wellbores are time-consuming and unreliable, particularly in deep or offshore operations, as they rely on manual tension measurements and indirect indicators, which can lead to inefficiencies and increased costs.
Innovation Solution
A system with a setting tool and initiator that includes a housing, piston, and igniter switch, where the igniter switch is positioned in close proximity to the igniter to ensure direct communication of combustion products, automatically disabling the switch upon activation, providing a clear surface indication of plug setting, and maintaining high-pressure forces for effective plug actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual tension measurements and indirect indicators are used to confirm plug setting, then the method is simple to implement, but the confirmation is time-consuming and unreliable
Solution Approach 1:
The patent replaces manual mechanical tension measurements with an electrical signaling system. The initiator switch automatically opens upon plug setting, sending an electrical signal to the surface that provides immediate and reliable confirmation of plug setting, eliminating the time-consuming and unreliable manual tension measurement process.
2Reliability
If the igniter switch is positioned away from the igniter, then the switch can be protected from combustion products, but direct communication of combustion products is compromised
Solution Approach 1:
The patent introduces a protective bulkhead as an intermediary element. The bulkhead is positioned between the igniter switch and the igniter, allowing combustion products to be communicated to the switch for reliable activation confirmation while simultaneously protecting the switch from direct exposure to harmful combustion products.
3Loss of information
If the igniter switch is exposed to combustion products for direct communication, then activation confirmation is improved, but the switch may be damaged by high-pressure forces
Solution Approach 1:
The protective bulkhead serves as a mediator that transmits the activation signal (combustion products) to the igniter switch while shielding it from the harmful high-pressure forces that could damage the switch structure. This allows reliable activation confirmation without compromising switch integrity.
4Reliability
If a signal interrupter is added to provide surface indication of plug setting, then confirmation reliability is improved, but device complexity increases
Solution Approach 1:
The initiator switch automatically opens upon plug setting, self-activating the signaling function without requiring additional complex control mechanisms. This self-service approach provides reliable surface indication while minimizing the increase in device complexity.
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
Enables rapid and reliable confirmation of plug setting, reducing operational time and costs by providing a direct surface indication of plug actuation, while ensuring the plug is fully set and sealed, thus enhancing wellbore completion efficiency.
Implementation Method 1
an igniter energetic element configured to activate, in response to receiving an ignition signal from the igniter switch, and thereby activate the setting tool energetic element
Implementation Method 2
a setting tool energetic element configured, upon activation, to displace the piston axially relative to the housing and shift the plug in the wellbore from a run-in configuration permitting fluid flow within the wellbore around the plug to a set configuration restricting fluid flow in the wellbore around the plug
Implementation Method 3
the initiator comprises a signal interrupter connected between the igniter switch and the igniter assembly and configured to shift automatically from a first state in which signal communication is provided through the signal interrupter between the igniter switch and the igniter assembly to a second state in which signal communication is restricted through the signal interrupter between the igniter switch and the igniter assembly in response to exposing the initiator to a predefined toolstring condition
Data Source
AI summary
A system for setting a plug in a wellbore includes a setting tool configured, upon activation, to displace the shift the plug in the wellbore from a run-in configuration permitting fluid flow within the wellbore around the plug to a set configuration restricting fluid flow in the wellbore around the plug, an initiator including an igniter switch and an igniter assembly including an igniter energetic element, the initiator including a signal interrupter configured to shift automatically from a first state in which signal communication is provided through the signal interrupter between the igniter switch and the igniter assembly to a second state in which signal communication is restricted through the signal interrupter between the igniter switch and the igniter assembly in response to exposing the initiator to a predefined toolstring condition and whereby a surface indication is provided of the shifting of the plug to the set configuration.