Frac Plug Wedge Slip Mechanism for Flow and Drilling
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Solution Overview
Problem
Conventional frac plugs face challenges such as restricted fluid flow, complex design, high drilling costs, and susceptibility to hydraulic pressure due to smaller diameters and materials like composite materials that lack the strength and durability of metals, leading to increased time and expense in drilling out plugs.
Innovation Solution
The development of a plug apparatus featuring an annular wedge with a tapered outer surface, a radially expandable sealing ring, and an annular slip, which can be set in a liner by axially displacing the wedge into the slip to anchor and seal the plug, allowing for a larger central bore and reduced material usage, facilitating easier deployment and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional composite materials are used for frac plugs, then the plugs can be deployed, but they lack the strength and durability to resist hydraulic pressure, leading to increased drilling time and costs
Solution Approach 1:
The patent employs composite materials comprising metal and polymer layers, where the metal provides structural strength and durability to resist hydraulic pressure, while the polymer facilitates easier drilling. This composite structure resolves the contradiction by combining materials with complementary properties, achieving both high strength and reduced drilling time.
2Loss of substance
If smaller diameter plugs are used, then material usage is reduced, but fluid flow is restricted and drilling costs increase
Solution Approach 1:
The patent utilizes a thin polymer film or coating on the plug surface that is easily removable during drilling operations. This thin film reduces material usage and allows for larger plug diameters to maintain fluid flow capacity, while the frangible nature of the polymer enables quick removal to restore full flow.
3Reliability
If complex design features are added to ensure secure sealing, then sealing reliability improves, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent achieves reliable sealing by optimizing parameters such as the friction coefficient between the plug and liner, the expansion ratio of the plug, and the material properties of the polymer and metal layers. By carefully controlling these parameters, the invention achieves secure sealing without adding complex mechanical features or multiple components.
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 design enhances fluid flow, reduces drilling time and costs, and maintains a secure seal under hydraulic pressure, while minimizing debris and material complexity, thus improving the efficiency and cost-effectiveness of frac operations.
Implementation Method 1
a radially expandable sealing ring, which can be set in a liner by axially displacing the wedge into the slip to anchor and seal the plug
Implementation Method 2
maintains a secure seal under hydraulic pressure
Implementation Method 3
an annular wedge with a tapered outer surface... by axially displacing the wedge into the slip to anchor and seal the plug
Data Source
AI summary
A plug apparatus comprises a wedge, a sealing ring, and a slip. The wedge comprises an axial wedge bore. A seat is defined in the wedge bore. The seat is adapted to receive a ball. The wedge has a tapered outer surface which decreases in diameter from the upper to the lower extent of the tapered outer surface. The sealing ring is received around the tapered outer surface of the wedge. The sealing ring has an axial ring bore and is radially expandable. The slip comprises an axial slip bore having a tapered inner surface. The tapered inner surface decreases in diameter from the upper to the lower extent of the tapered inner surface. The inner surface is adapted to receive the wedge. The wedge is adapted for displacement from an unset position generally above the slip to a set position wherein the wedge is received in the slip bore.