Frac Plug Setting Mandrel with Fluid Bypass Slots
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Solution Overview
Problem
Conventional pre-set frac plug systems risk accidental triggering and sealing in the wrong location due to the complexity of borehole geometry, making them difficult to remove and increasing the risk of incorrect fluid delivery and recovery in wellbore operations.
Innovation Solution
A frac plug system with a setting mandrel and sleeve member that allows for multiple stages of setting, including fluid bypass slots and a cone assembly, enabling the system to be pre-set without a frac ball, allowing for easy removal by transitioning between configurations under fluid pressure, and the option to inject strong acid for removal if incorrectly positioned.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pre-set frac plug system is used to seal the zone immediately when set in position, then the sealing efficiency is improved and no frac ball is needed, but the risk of accidental triggering increases and the difficulty of removal increases
Solution Approach 1:
The setting process is divided into two distinct stages: first setting the plug in position with the setting mandrel, and second activating the seal with fluid pressure. This segmentation allows the plug to be positioned without immediately sealing, enabling removal if accidentally triggered while maintaining sealing efficiency when properly deployed.
Solution Approach 2:
The plug is preliminarily set in position using the setting mandrel before the sealing action is activated. This preliminary positioning allows the plug to be in place but not yet sealed, reducing accidental triggering risk while maintaining the ability to seal efficiently when fluid pressure is applied.
2Loss of time
If a pre-set frac plug system is used to seal the zone immediately when set in position, then the operation time is reduced, but the difficulty of removal increases
Solution Approach 1:
The setting and sealing operations are segmented into separate stages. The plug can be set in position quickly without immediate sealing, and if removal is needed, the unsealed plug can be retrieved by reversing the setting process through the fluid bypass slots, reducing both operation time and removal difficulty.
Solution Approach 2:
The system transitions from a static pre-set design to a dynamic two-stage process where the seal activation can be controlled and reversed. The fluid bypass slots enable dynamic control of the setting process, allowing quick removal by injecting fluid to reverse the setting action before final sealing occurs.
3Ease of operation
If fluid bypass slots are added to enable multi-stage setting and easy removal, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The fluid bypass slots serve multiple functions: they allow the setting mandrel to be removed after initial setting, enable reversal of the setting process for easy removal, and provide a pathway for fluid injection to control seal activation. This multi-functionality adds ease of operation without proportionally increasing 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
The system effectively isolates zones in a wellbore with a pre-set seal, reducing the risk of accidental triggering and enabling easy removal by allowing multiple stages of setting and fluid pressure control, ensuring accurate fluid delivery and recovery operations.
Implementation Method 1
The setting mandrel has a first configuration without fluid flow through the packer system and a second configuration with fluid connection through the frac plug system
Data Source
AI summary
The frac plug system includes a setting mandrel, a sleeve member, a sealing member, a cone assembly, and a slip device. The setting mandrel includes a plurality of fluid bypass slots. The sleeve member includes a sleeve body with an abutment end. The setting mandrel has a first configuration without fluid flow through the frac plug system, and a second configuration with fluid flow through the frac plug system. The methods of the present invention include running the frac plug system in the first configuration and the sealing member in an extended position for a first setting stage, moving the setting mandrel to the second configuration with the sealing member in an expanded position, and then returning the setting mandrel to the first configuration for a second setting state. If the placement is wrong, the method includes removing the frac plug system in the first setting stage.