Frangible Plug Assembly Shear Ring Mechanism
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Solution Overview
Problem
Existing plug assemblies for petroleum well boreholes are not robust enough and often have many moving parts, which increases the risk of malfunction in harsh well conditions with high pressure and corrosive fluids, and they lack a reliable mechanism for controlled and predictable opening.
Innovation Solution
A plug assembly with a frangible disc that can be opened by a controlled pressure differential, featuring a shear ring mechanism that shears to allow axial movement of a seat and breaker object, ensuring the plug breaks predictably and safely, with safety measures to prevent accidental actuation and ensure the plug breaks into small fragments that do not enter the wellbore.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a plug assembly with many moving parts is used to enable opening mechanism, then the plug can be opened after use, but the risk of malfunction increases in harsh well conditions
Solution Approach 1:
The invention removes all moving parts from the plug assembly by extracting the opening mechanism entirely. Instead of using mechanical components that can fail, the plug is designed to be broken open using a simple breaker tool applied externally, eliminating the source of potential malfunction while maintaining the ability to open the plug after use.
Solution Approach 2:
The plug body is designed as a disposable frangible structure that is intended to be broken and discarded after single use. This eliminates the need for complex reusable opening mechanisms, as the entire plug is replaced rather than opened and reused, significantly improving reliability in harsh well conditions.
2Ease of manufacture
If a frangible disc is used as the fluid blocking part, then the plug can be easily destroyed to open the assembly, but the plug may break into small pieces that could pose problems in the well
Solution Approach 1:
The invention applies local quality by creating a specific frangible zone in the plug body with controlled weakness characteristics. This localized frangible section is designed to break in a controlled manner when subjected to a breaker tool, allowing easy opening while ensuring that fragmentation occurs in a predictable location and pattern that minimizes harmful debris dispersion into the wellbore.
3Strength
If metal plugs are used for robustness, then the plug can withstand high pressure and temperature, but removal damages the tubing and creates debris
Solution Approach 1:
The invention uses composite materials combining a frangible disc (glass or ceramic) for the sealing function with a housing structure that provides mechanical support. The frangible disc material is specifically chosen to withstand high pressure and temperature while being designed to break cleanly into small, non-harmful fragments, eliminating tubing damage during opening while maintaining strength during operation.
4Ease of operation
If dissolvable materials are used for the plug, then removal is achieved without mechanical intervention, but the conditions for dissolution must be precisely controlled allowing no deviation in time schedule
Solution Approach 1:
The invention replaces the chemical dissolution mechanism with a simple mechanical breaking action. Instead of relying on controlled chemical reactions that require precise temperature, pressure, and time conditions, the plug is opened by applying a breaker tool that physically breaks the frangible section, providing a reliable opening method that is insensitive to well conditions and allows flexible scheduling.
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
The plug assembly maintains a fluid-tight seal until broken, then fully opens without partial opening, restoring the tubular's inner diameter for unrestricted fluid flow, and its design minimizes the risk of components entering the wellbore or malfunctioning.
Implementation Method 1
the shear ring is arranged such that when a threshold pressure differential is applied to a surface of the plug, the shear ring shears and allows for axial movement of the seat
Implementation Method 2
when a threshold pressure differential is applied to a surface of the plug
Data Source
AI summary
A plug assembly arranged in a housing including: a plug, a breaker object, a seat, a shear ring and an assembly retainer. The plug is supported by the seat and the shear ring prevents the seat from moving in an axial direction. The shear ring is arranged such that when a threshold pressure differential is applied to a surface of the plug, the shear ring shears and allows for axial movement of the seat. The assembly retainer provides axial support to the breaker object, seat, or shear ring. A plug assembly arranged in a plug tubular. The plug tubular made of a single continuous piece.