Hydraulic Frac Plug Setting Tool
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Solution Overview
Problem
The existing methods for setting frac plugs and other seals in boreholes are complex and costly, often requiring explosive charges and multiple tools, increasing operational complexity and cost.
Innovation Solution
A downhole tool with an actuator mechanism and a setting member featuring an angled side portion, a collet member, and a seal member, which uses fluid force to set the seal by shifting the seal member along the angled surface and expanding radially, allowing for efficient sealing without the need for explosive charges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If explosive charges and multiple tools are used to set seals, then the seal setting capability is achieved, but the operational complexity and cost increase
Solution Approach 1:
The patent combines the setting member, seal member, and actuator mechanism into a single integrated downhole tool assembly. The setting member with angled side portion and the seal member work together in one tool, eliminating the need for separate explosive charge deployment tools and multiple sequential operations, thereby reducing operational complexity while maintaining seal setting capability
Solution Approach 2:
The patent replaces explosive charges with a hydraulic actuator mechanism that uses fluid pressure to set the seal. The actuator mechanism receives hydraulic fluid through a conduit and uses the resulting force to move the setting member and engage the seal member, providing a safer and operationally simpler alternative to explosive methods
2Reliability
If explosive charges are used to set seals, then the seal can be set, but the operational cost increases
Solution Approach 1:
The patent substitutes expensive and hazardous explosive charges with a hydraulic actuation system. The actuator mechanism uses readily available hydraulic fluid under pressure to generate the necessary force for seal setting, significantly reducing material costs and eliminating the need for specialized explosive handling procedures and safety equipment
Solution Approach 2:
The downhole tool assembly is designed to set its own seal using its internal hydraulic actuator, eliminating the need for separate explosive charge deployment tools and multiple service operations. The single integrated tool performs both the setting and sealing functions, reducing overall operational costs
3Reliability
If multiple tools are used for seal setting, then the seal can be set, but the time required increases
Solution Approach 1:
The patent integrates the setting member, seal member, and actuator mechanism into a single downhole tool assembly that performs all seal setting operations in one deployment. This eliminates the need for multiple sequential tool deployments and operations, significantly reducing the time required to set the seal while ensuring reliable seal engagement
Solution Approach 2:
The seal member is pre-positioned and ready to engage with the setting member within the integrated tool assembly. When hydraulic fluid is supplied to the actuator, the seal setting action occurs immediately without requiring additional tool deployments or preparatory steps, reducing operational time
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
This method simplifies the sealing process by using fluid force to set the seal, reducing operational complexity and cost, while ensuring effective sealing for frac plug operations.
Implementation Method 1
delivering a metered flow of fluid onto a setting member (93)
Implementation Method 2
A setting member (93) is arranged at a terminal end (66) in the passage and includes a side portion (124) that is angled inwardly from a first end portion (98) to a second end portion (99)
Data Source
AI summary
A downhole tool includes a setting tool having an outer surface, an inner surface defining a passage and a terminal end. An actuator mechanism is arranged in the passage. A setting member is arranged at the terminal end in the passage. The setting member includes a side portion that is angled radially inwardly from a first end portion to a second end portion. A collet member extends over the setting member, and a seal member is operatively connected to the collet member at the second end portion of the setting member.