Fracturing Plug Valve Assembly for Through-Flow Zone Isolation
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Solution Overview
Problem
Conventional hydraulic fracturing plugs, such as ball drop and ball-in-place plugs, are inefficient and require time-consuming operations, and existing ball-in-place plugs do not allow fluid flow through the plug, leading to costly delays and difficulties in confirming proper placement.
Innovation Solution
A plug with a flow control subassembly that includes a mandrel, valve assembly, and anchoring subassembly, featuring a valve element secured by a frangible matrix or shear pins, allowing fluid flow until activated by pressure differential, and a sealing device to prevent flow when activated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ball drop plug is used to control fluid flow, then the plug can be set in the wellbore, but the operation becomes slow and it is difficult to confirm proper placement
Solution Approach 1:
The plug assembly is self-indicating through the pressure-sensitive indicator mechanism that automatically changes state based on downhole pressure conditions, eliminating the need for separate confirmation operations. The indicator provides immediate visual feedback on whether the plug is properly seated and isolated
Solution Approach 2:
The pressure-sensitive indicator is pre-configured to change state at a predetermined pressure differential, providing advance confirmation that the plug is properly placed before proceeding to the next operation. This preliminary indication prevents time-consuming verification steps later
2Productivity
If a ball-in-place plug is used to isolate lower zones, then the plug can be set quickly without ball drop, but fluid flow through the plug is prohibited causing costly delays
Solution Approach 1:
The valve element is designed to be dynamically controllable through the pressure-sensitive indicator mechanism, allowing the plug to transition between closed and open states. This dynamic capability enables the plug to adapt to different operational requirements - isolated during fracturing and open during pumpdown operations
Solution Approach 2:
The plug assembly serves multiple functions: it can isolate zones during hydraulic fracturing operations and simultaneously allow fluid flow during pumpdown or remedial operations. The pressure-sensitive indicator and controllable valve mechanism enable this multi-functionality, making the plug versatile for different well intervention scenarios
3Device complexity
If a simple blocking device is used as a plug, then the device is simple in structure, but it requires drilling or destruction to remove for fluid flow
Solution Approach 1:
The mechanical system requiring drilling or destruction is replaced with a pressure-sensitive mechanical indicator system and controllable valve mechanism. The plug can be opened and closed through pressure differential or wireline actuation, eliminating the need for destructive removal while maintaining structural simplicity
Solution Approach 2:
Instead of discarding the plug through drilling, the design allows the plug to be recovered and reused by actuating the valve mechanism through wireline or pressure control. The plug can be retrieved, repositioned, and redeployed, providing economic and operational advantages over single-use blocking devices
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
Enables efficient fluid flow through the plug without requiring a ball drop step, reducing production time and allowing quick reconfiguration for fluid flow or isolation as needed, enhancing operational efficiency in hydraulic fracturing.
Implementation Method 1
The valve element is secured to the housing with a frangible matrix when the valve element is in a first position and spaced apart from the valve seat
Implementation Method 2
The valve element is secured to the housing with one or more shear pins when the valve element is in a first position and spaced apart from the valve seat
Implementation Method 3
allowing fluid flow until activated by pressure differential
Data Source
AI summary
A plug and perforation system includes a plug that is configured to isolate formation zones within a wellbore that has a casing. The plug includes a flow control subassembly, an anchoring subassembly, and a sealing device. The flow control subassembly a valve assembly. The valve assembly includes a housing, a valve chamber inside the housing, a valve seat, and a valve element inside the valve chamber. In some embodiments, the valve element is secured to the housing with a frangible matrix that is manufactured as a unitary part with the valve element and the housing. The frangible matrix is designed to fail under a predetermined shearing load to allow the valve element to be pushed into the valve seat. In other embodiments, the valve element is retained by one or more shear pins or shearable threads.