Integrated Frac Plug Setting Cone and Anchor Mechanism
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Solution Overview
Problem
The existing methods for setting frac plugs and fracturing formations in boreholes are complex and costly, involving multiple steps and the use of explosive charges, which increase operational complexity and cost.
Innovation Solution
A downhole tool system featuring a setting cone with a taper and an anchor, along with a mandrel and actuation chamber, allows for the controlled engagement and sealing of the frac plug against the casing, enabling a single-step deployment and subsequent fracturing without the need for explosive charges, using a wireline-connected system for operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If explosive charges and drop balls are used to set frac plugs and fracture formations, then the sealing and fracturing functions can be achieved, but the operational complexity and cost increase
Solution Approach 1:
The patent combines the setting tool and frac plug into a single integrated device. The setting cone with taper is integrated directly with the frac plug body, eliminating the need for separate setting tools and multiple deployment steps. This merging of functions directly reduces operational complexity while maintaining reliable sealing through the anchor mechanism that engages with the taper.
2Reliability
If multiple steps are used for plugging and perforating the casing and fracturing the formation, then the frac plug can be set and formation can be fractured, but the time and cost increase
Solution Approach 1:
The frac plug is pre-positioned and integrated with the setting cone before deployment. The anchor mechanism is pre-configured to engage with the taper upon deployment, eliminating the need for separate plugging and perforating steps. This preliminary configuration allows the formation to be fractured immediately upon deployment, reducing operational time while ensuring reliable fracturing function.
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
This solution simplifies the process of setting frac plugs and fracturing formations by reducing the number of steps and eliminating the need for explosive charges, thereby lowering operational costs and complexity while ensuring effective sealing and fracturing.
Implementation Method 1
A force, initiated by the explosive charge, may urge a setting member into a seal
Implementation Method 2
A portion of the conduit defines an actuation chamber
Data Source
AI summary
A downhole tool has a setting cone including a body having an outer surface having a first end, a second end. At least a portion of the body includes a taper at the second end. A passage extends through the body. The passage includes a first portion having a first diameter and a second portion having a second diameter that is less than the first diameter. An anchor is arranged at the second end of the setting cone. The anchor includes a central passage that aligns with the passage through the setting cone. A mandrel extends through the passage of the setting cone and the central passage of the anchor. The mandrel includes a first end portion, a second end portion and an intermediate section. A conduit extends from the first end portion toward the second end portion. A portion of the conduit defines an actuation chamber.