Frack Plug Object Retention for Misfire Recovery
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Solution Overview
Problem
In plug and perforate systems, if perforating guns misfire, the replacement guns cannot be delivered through the isolation device using pressure or flow assist due to the obstruction by the frack plug object, leading to costly delays and inefficiencies, especially in horizontal wellbores.
Innovation Solution
A ball release tool is placed near the isolation device to retain the object until the guns fire, allowing it to be released only by the pressure spike created during firing, keeping the passage open for replacement gun delivery if the guns misfire, and enabling a larger object and passage size for easier delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the object is delivered with the isolation device, then the passage is closed quickly, but replacement guns cannot be delivered with pressure or flow assist if guns misfire
Solution Approach 1:
The object is delivered with the isolation device and held in a retained position before gun firing, ready to be deployed immediately after successful firing. This preliminary positioning allows rapid passage closure when needed while maintaining the option to deliver replacement guns if misfire occurs.
Solution Approach 2:
The system transitions from a static retained state to a dynamic deployed state based on gun firing status. The object can be held in position during gun firing, then deployed to close the passage if firing is successful, or remain retained to allow replacement gun delivery if misfire occurs.
2Ease of operation
If pressure or flow is used to deliver replacement guns, then the object is forced against the seat closing the passage, but this prevents replacement gun delivery
Solution Approach 1:
The object is pre-positioned and retained above the seat before replacement gun delivery attempts. This preliminary retention ensures the passage remains open for replacement gun insertion without requiring pressure or flow that would force the object against the seat.
Solution Approach 2:
The retained object acts as an intermediary element that can be selectively positioned to either block or allow passage. By keeping the object in a retained intermediate position, the system maintains passage openness for replacement guns while having the capability to close the passage when needed.
3Volume of moving object
If a small object is used to fit in the annular space around the gun, then the passage can be small, but this causes delays if replacement guns need to be delivered
Solution Approach 1:
The object is delivered and retained in position with the isolation device before gun firing. This preliminary action allows the use of a larger object that can quickly close a larger passage, while the retained position ensures the passage remains open for replacement gun delivery if misfire occurs, eliminating the time delay.
4Reliability
If the object is released before gun firing, then the passage is closed, but this prevents replacement gun delivery in case of misfire
Solution Approach 1:
The object is delivered and retained in a ready-but-not-deployed state before gun firing. This preliminary retention maintains passage openness for potential replacement gun delivery while having the object prepared to quickly close the passage if gun firing is successful.
Solution Approach 2:
The system uses gun firing status as feedback to determine object deployment. If guns fire successfully, the retained object is deployed to close the passage. If guns misfire, the object remains retained and the passage stays open, allowing replacement gun delivery. This feedback-based control provides adaptability to different outcomes.
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 method allows for efficient delivery of replacement guns using pressure or flow assist even if the original guns misfire, reducing operational costs and time by ensuring the passage remains open and enabling the use of larger objects and passages.
Implementation Method 1
retain the object until the guns fire, allowing it to be released only by the pressure spike created during firing
Data Source
AI summary
In a fracking context the object that will ultimately block a passage in an isolation device is introduced into the zone with the bottom hole assembly. The object is not released until the guns fire to create a pressure spike in the borehole that triggers the object retaining device to release the object. The retaining device is placed in close proximity to the isolation device and its setting tool to allow a larger object and passage in the isolation device to be used. If the guns misfire, the object is not released and comes out with the guns. The replacement guns can be pumped in because the passage in the isolation device has stayed open during the misfire. Direct and indirect object release in response to pressure created from the firing of the guns is contemplated.