Frangible Glass Frac Plug for Wellbore Sealing and Removal
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Solution Overview
Problem
Existing oil well plugs lack a reliable method for temporary or permanent sealing and easy removal without damaging the wellbore, which complicates the process of re-establishing flow.
Innovation Solution
A frac plug made of frangible glass material with a ball valve mechanism that disintegrates upon activation, allowing for pressure sealing and easy removal by disintegration, utilizing a tapered design and actuator system for secure placement and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a frac plug is used to seal the wellbore, then pressure sealing and flow control are improved, but removal and re-establishment of flow become complex and time-consuming
Solution Approach 1:
The frac plug body is constructed from frangible glass material that changes its mechanical properties under different stress conditions. During installation, the glass material maintains structural integrity to provide reliable pressure sealing. For removal, the glass material is designed to disintegrate when subjected to specific mechanical actions (such as impact from a ball or chemical treatment), enabling rapid flow re-establishment without complex retrieval operations
Solution Approach 2:
The glass frac plug is designed as a disposable component that serves its sealing function temporarily and then is easily discarded through disintegration. This eliminates the need for complex retrieval operations and allows for quick re-establishment of flow by simply introducing a disintegration mechanism (ball or chemical agent) that breaks down the glass material into small particles that can be flushed out
2Reliability
If a traditional plug is used for wellbore sealing, then sealing function is achieved, but wellbore damage during removal occurs
Solution Approach 1:
The glass material of the frac plug is designed to change from a solid, structurally-intact state during sealing to a disintegrated, particle-state during removal. This parameter change ensures that when the plug is removed (either by mechanical impact or chemical treatment), it breaks down into small fragments that can be easily flushed out without causing damage to the wellbore formation or equipment
Solution Approach 2:
The potential harm of having a solid plug that must be forcibly removed is converted into a benefit by designing the plug from frangible glass material. The material's inherent brittleness, which might seem like a weakness, becomes advantageous during removal as it allows the plug to disintegrate easily into harmless particles under controlled conditions, eliminating the risk of wellbore damage associated with mechanical retrieval operations
3Ease of operation
If a glass material is used for the frac plug, then easy removal through disintegration is achieved, but structural strength for secure placement may be compromised
Solution Approach 1:
The glass material is engineered to exhibit different strength characteristics under different conditions. During placement and sealing operations, the glass maintains sufficient structural strength to withstand wellbore pressures and mechanical handling. For removal, the glass is designed to be sensitive to specific triggers (mechanical impact from a ball or chemical agents) that cause it to disintegrate into small particles, transforming it from a strong sealing structure to easily removable fragments
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 secure temporary or permanent sealing and easy removal of the frac plug without damaging the wellbore, facilitating efficient re-establishment of flow by disintegrating the glass portion when needed.
Implementation Method 1
the frac plug and frac ball may be mostly made from a glass or other frangible material. When it is desired to remove the plug from the pipe, it is only necessary to disintegrate the glass portion of the plug, enabling it to fall away to reestablish flow through the pipe
Data Source
AI summary
A frac plug is configured to seal a pipe of a downhole well. The frac plug includes a cylindrical plug member comprising a glass body made of a tempered or high-compression glass. The plug member has axial opposite ends with a tapered outer diameter surface extending along its length between the ends. The frac plug further includes a seal of compressible material extending substantially around the plug member outer diameter. The seal has opposite axial ends corresponding to the axial ends of the plug member. The seal is movable axially relative to, and compressible against, the plug member outer diameter surface, thus allowing the seal expand radially outward to engage the bore of the pipe. The frac plug is anchored in the pipe bore with clamping portions on axially opposite ends of the plug member. The clamping portion may include bore engagement portions that are arcuate or radially expanding fingers.