Frack Plug Sleeve with Temporary Wall Support
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Solution Overview
Problem
Existing fracturing technologies face challenges in providing adequate compressive strength against external pressures during fracturing while ensuring a larger flow diameter for subsequent production, as existing solutions either compromise collapse resistance or incur significant costs and time due to the need for expansion or exotic materials.
Innovation Solution
A tubular insert made of controlled electrolytic materials (CEM) is used, which provides collapse resistance during fracturing and can be removed to increase the flow diameter post-fracturing, without the need for expansion, using a sleeve that secures the mandrel and disappears when loading diminishes, allowing for a larger bore diameter for production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a thin-walled mandrel is used to maximize flow diameter, then the flow path diameter is increased, but the collapse resistance under external pressures during fracturing is insufficient
Solution Approach 1:
A removable insert is nested within the thin-walled mandrel to provide temporary collapse resistance during fracturing. The insert fits inside the mandrel bore and can be removed after fracturing to restore the full flow diameter, effectively nesting a support structure within the flow path only when needed.
Solution Approach 2:
The mandrel system transitions from a static thin-walled structure to a dynamic configuration by adding a removable insert. The insert can be installed before fracturing to provide strength, then removed after fracturing to maximize flow, making the structural properties dynamic rather than fixed.
2Strength
If a thick-walled mandrel is used to provide collapse resistance during fracturing, then the compressive strength is improved, but the flow path diameter is reduced and production efficiency decreases
Solution Approach 1:
The support function is segmented from the permanent mandrel structure and provided by a separate removable insert. This allows the mandrel to remain thin-walled for optimal flow, while the insert provides temporary support during fracturing only when needed, separating the support function from the flow path structure.
Solution Approach 2:
The insert is discarded after serving its temporary purpose of providing collapse resistance during fracturing. By removing the insert after fracturing, the full flow diameter is recovered, maximizing production efficiency while maintaining adequate support during the critical fracturing operation.
3Area of stationary object
If expansion is used to increase the flow bore diameter after fracturing, then the flow diameter is increased, but the device complexity and operational time increase
Solution Approach 1:
Instead of expanding the mandrel to increase flow diameter, the invention inverts the approach by using a removable insert that is taken out after fracturing. This achieves the same goal of maximizing flow diameter but through removal rather than expansion, simplifying the device and reducing operational 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
This solution effectively addresses the need for compressive strength during fracturing and enhances flow diameter post-fracturing, reducing costs and operational time by using a material that selectively disappears or changes shape in response to environmental conditions, resulting in a more than 20% increase in passage diameter.
Implementation Method 1
The preferred material is controlled electrolytic materials but other materials that can disappear when the anticipated loading is diminished can also be used. The disappearing can be motivated chemically or thermally among other contemplated methods.
Data Source
AI summary
In a fracturing application a packer for a given zone to be fractured is reinforced during fracturing with an insert that is preferably a sleeve. During times of high collapse pressure loading, the sleeve provides the needed support. When fracking is over the liner sleeve is caused to disappear. The preferred material is controlled electrolytic materials but other materials that can disappear when the anticipated loading is diminished can also be used. The disappearing can be motivated chemically or thermally among other contemplated methods. As a result, there is a larger available bore when production is ready to start.