Integrated Frac Plug Setting Tool with Propellant-Driven Anchor
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Solution Overview
Problem
The existing methods for setting frac plugs in boreholes are complex and costly, involving multiple steps and tools like drop balls and explosive charges, which increase operational complexity and cost.
Innovation Solution
A downhole tool comprising a setting cone, anchor, mandrel, and bottom sub, where a propellant charge in the mandrel's conduit generates pressure to drive the anchor and seal into the borehole wall, simplifying the plug-setting process and reducing the need for explosive charges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If explosive charges and drop balls are used to set frac plugs, then the plug can be set and casing can be perforated, 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, anchor, mandrel, and bottom sub are all part of one unified tool that performs both the setting and fracturing functions, eliminating the need for separate explosive charges and drop ball operations.
Solution Approach 2:
The integrated downhole tool serves multiple functions: it acts as both the setting mechanism for the frac plug and the fracturing tool. The mandrel can function as both the setting tool that drives the anchor into the casing and the fracturing tool that creates the formation fracture, reducing the number of separate operations needed.
2Reliability
If multiple steps are used to set frac plug and perforate casing, then the plug can be set and casing perforated, but the process time and operational complexity increase
Solution Approach 1:
The patent merges the setting operation and perforation operation into a single integrated tool. The same mandrel that sets the anchor also performs the fracturing function, allowing both operations to be completed in one deployment rather than requiring separate sequential operations.
Solution Approach 2:
The tool is pre-configured with all necessary components (setting cone, anchor, mandrel, bottom sub) before deployment. The anchor is already positioned on the mandrel and ready to be set, eliminating the need for separate setting and perforation operations.
3Reliability
If traditional setting tools are used, then the anchor can be set into the casing, but additional explosive charges are required increasing cost
Solution Approach 1:
The patent combines the setting tool and frac plug into a single integrated device. The setting cone, anchor, mandrel, and bottom sub are all part of one unified tool that performs both the setting and fracturing functions, eliminating the need for separate explosive charges and drop ball operations.
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 streamlines the plug-setting process, reducing operational complexity and cost by using a pressure wave from a propellant charge to set the anchor and seal, allowing for efficient and cost-effective formation fracturing.
Implementation Method 1
a propellant charge in the mandrel's conduit generates pressure to drive the anchor and seal into the borehole wall
Data Source
AI summary
A downhole tool includes a setting cone having a body including an outer surface. The body has a first end, a second end and an intermediate portion. At least a portion of the body includes a taper at the second end. A passage extends through the body from the first end to the second end. An anchor is arranged at the second end. The anchor includes a first end section receptive of the setting cone and a second end section. A mandrel extends through the passage of the setting cone and the anchor. The mandrel includes a first end portion, a second end portion and an intermediate section. A bottom sub is arranged at the second end section of the anchor. The bottom sub includes a first member fixedly mounted to the mandrel and a second member that is shiftable relative to the mandrel.