High-Expansion Bridge Plug Setting Tool Wireline Core Bit
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Solution Overview
Problem
Current methods for setting bridge plugs in boreholes require multiple drill rod trips, leading to increased costs, loss of borehole integrity, inefficiency, and risk of formation damage due to over-torqueing, and lack of sufficient expansion ratio to fit through drill rods and expand to open hole diameter.
Innovation Solution
A high-expansion bridge plug (HEBP) system that uses a setting tool with a step-up gearbox to apply torque gradually, allowing the HEBP to be set through a core bit without initial rod trips, utilizing a wireline to lower the setting tool and HEBP, and recording pressure versus time data for verification of correct setting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a bridge plug is sized to fit through drill rods, then it can be installed through existing drill rod infrastructure, but it cannot expand sufficiently to seal the open hole diameter
Solution Approach 1:
The bridge plug transitions from a compressed state during installation to an expanded state during operation. The plug is introduced in a compressed configuration that allows it to pass through the core bit and drill rods, then expands radially to seal against the open hole wall, achieving both small initial diameter and large final sealing diameter
Solution Approach 2:
The physical parameters of the bridge plug are changed during the setting process. The plug material properties and dimensional parameters are transformed from a compact installable state to an expanded sealing state, enabling the plug to fit through narrow openings and then expand to seal larger diameters
2Reliability
If multiple drill rod trips are performed to set the bridge plug, then the plug can be properly installed and set, but operational efficiency decreases and non-productive time increases
Solution Approach 1:
The introduction and setting operations are merged into a single continuous operation. The bridge plug is introduced through the core bit and set in the open hole without requiring the drill rods to be tripped out and back in, combining multiple separate operations into one efficient process
Solution Approach 2:
The bridge plug is prepared and positioned in advance through the drill rod string, ready for setting when the drill rod is tripped out once. This preliminary positioning eliminates the need for additional trips, as the plug is already in place and ready to be set on the first opportunity
3Reliability
If rotational energy from drill rods is used to torque the bridge plug, then setting can be achieved, but formation damage occurs due to over-torqueing
Solution Approach 1:
The mechanical torque application system is replaced with a controlled setting mechanism. Instead of relying on rotational energy from the drill rods which is difficult to control, a dedicated setting tool applies axial force or controlled torque directly to the bridge plug, eliminating the harmful over-torqueing effect while ensuring reliable setting
Solution Approach 2:
A setting tool or setting mechanism acts as an intermediary between the drill rod and the bridge plug. This intermediary component provides controlled force application and decouples the bridge plug setting from the rotational drilling operations, preventing formation damage while ensuring proper plug setting
4Manufacturing precision
If the bridge plug dimensions exceed the inner diameter of drill rods, then the plug can be properly sized for the open hole, but multiple drill rod trips are required for installation
Solution Approach 1:
The bridge plug dimensions are segmented into two distinct phases: a small introduction diameter for passing through the core bit and drill rods, and a large operating diameter for sealing the open hole. This dimensional segmentation allows the plug to fit through narrow openings and then expand to the required sealing size
Solution Approach 2:
The bridge plug is nested within the drill rod string during introduction. The plug is contained within the drill rod bore in a compressed state, allowing it to be transported to the target location without requiring the drill rods to be removed and reinstalled multiple times
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
Reduces the number of rod trips needed to set a bridge plug to one, increases operational efficiency, minimizes equipment wear and operator risk, and ensures accurate plug placement with reduced non-productive time and cost.
Implementation Method 1
A setting tool can be used to engage a step up gearbox to gradually and smoothly apply torque to a bridge plug (BP)
Implementation Method 2
A high-expansion BP (HEBP) with a run-in-hole (RIH) diameter with half of the full expansion diameter
Data Source
AI summary
A setting tool and bridge plug that are run-in-hole on wireline through a core bit while drill rods are in place can be used to plug a borehole. A setting tool can be sized to have a same or smaller diameter as a drill rod. A bridge plug can have a run-in configuration of a diameter that is smaller than an inner diameter of a core bit. The bridge plug can have a set configuration that can respond to the setting tool pulling uphole. The bridge plug can be positioned below a drill bit of the drill rod in the set configuration, and the diameter of the bridge plug in the set configuration can be greater than the diameter of the drill rod.