Fracking Plug Support Ring for Seal Extrusion Control
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Solution Overview
Problem
Fracking plugs face issues such as dislodgement during conveyance due to high-pressure fluid velocity, premature setting before reaching the desired location, and seal extrusion through gaps during activation, leading to potential failure and costly remedial work.
Innovation Solution
A plug assembly with a segmented support ring interposed between a seal and an anchoring ring, where the support ring segments overlap and bridge gaps formed during activation, preventing seal extrusion and maintaining component alignment during conveyance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the plug is conveyed through the well casing using high-volume pressurized water, then the plug can reach the targeted isolation point, but the high velocity water can dislodge components within the plug assembly
Solution Approach 1:
The support ring segments are pre-positioned and locked to the anchoring ring segments before conveyance, creating a preliminary locked configuration that prevents component dislodgement during high-velocity water conveyance. The protrusions are already in place to engage with the recesses, establishing stability before the harmful conveyance forces act on the system.
Solution Approach 2:
The support ring acts as an intermediary component between the anchoring ring and the seal, providing a mechanical lock that prevents relative movement. The protrusions on the support ring segments engage with recesses in the anchoring ring segments, creating an intermediate locking mechanism that stabilizes the entire plug assembly during conveyance.
2Adaptability or versatility
If the plug assembly includes segmented components that expand during activation, then unrestricted expansion is achieved, but gaps form between segments that allow seal extrusion under high fluid pressure
Solution Approach 1:
The support ring segments act as intermediary elements between the seal and the anchoring ring segments. During activation when gaps form between anchoring ring segments, the support ring segments bridge these gaps and prevent the seal from extruding through them. The protrusions on the support ring segments engage with recesses in the anchoring ring segments to maintain this bridging function.
Solution Approach 2:
The support ring is divided into multiple segments that correspond to the segmented anchoring ring. This segmentation allows the support ring to expand along with the anchoring ring during activation while maintaining the bridging function across the gaps. Each support ring segment independently bridges the gap between adjacent anchoring ring segments.
3Reliability
If the plug assembly components are locked together during conveyance, then component dislodgement is prevented, but premature binding may occur before reaching the desired location
Solution Approach 1:
The locking mechanism is designed to be dynamic rather than permanently fixed. The support ring segments can be locked to the anchoring ring segments during conveyance to prevent dislodgement, but can be unlocked or disengaged if premature binding occurs. The protrusions and recesses provide a reversible mechanical lock that maintains stability during conveyance but allows for corrective action if needed.
Data Source
AI summary
An example plug assembly includes: a cone; a seal mounted to the cone; an anchoring ring comprising a plurality of anchoring ring segments disposed in a circular array, wherein a respective receptacle is formed between each two adjacent anchoring ring segments of the plurality of anchoring ring segments; and a support ring that is interposed between the seal and the anchoring ring, wherein the support ring comprises a plurality of support ring segments disposed in a respective circular array, such that each support ring segment partially overlaps two adjacent anchoring ring segments, and wherein each support ring segment of at least a subset of the plurality of support ring segments has a protrusion that is received within the respective receptacle.