Integrated Cement Plug Assembly with Sensor Sub
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Solution Overview
Problem
The process of cementing wells, particularly in subsea and deep well applications, is time-consuming and costly due to the sequential running and setting of tools, which increases rental expenses for rigs.
Innovation Solution
A plug assembly comprising a bottom wiper plug, a top wiper plug, a bridge plug with a sensor sub for detecting a gate in the well, and a setting tool that allows for autonomous setting of the bridge plug upon detection, reducing the need for manual intervention and optimizing tool deployment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sequential tool running and setting is used for cementing, then proper cement placement and isolation are achieved, but operational time and rig rental costs increase
Solution Approach 1:
The patent combines multiple tools (bottom wiper plug, top wiper plug, and bridge plug) into a single integrated assembly that is run into the wellbore together. This merging eliminates the need for sequential tool runs, reducing operational time while maintaining the functional reliability of proper cement placement and isolation through the coordinated action of all plugs within the single assembly.
Solution Approach 2:
The bridge plug is pre-positioned on top of the wiper plugs within the assembly before running into the wellbore. The sensor sub is also pre-installed to detect the gate magnet. This preliminary configuration allows the entire system to be deployed in one operation, eliminating subsequent tool runs and setting operations that would otherwise be required sequentially.
2Measurement precision
If manual intervention is required for bridge plug setting, then precise placement can be achieved, but operational complexity and time increase
Solution Approach 1:
The bridge plug is equipped with a sensor sub that automatically detects the gate magnet's position and triggers the setting mechanism when the gate is detected. This self-service capability eliminates the need for manual intervention or external monitoring, allowing the plug to set itself at the precise location automatically. The system maintains placement precision through the magnetic detection mechanism while reducing operational complexity by removing the need for human operators to monitor and trigger the setting sequence.
Solution Approach 2:
The sensor sub provides real-time feedback by detecting the magnetic field of the gate magnet as the assembly descends into the wellbore. This feedback mechanism automatically triggers the bridge plug setting when the gate is detected, ensuring precise placement without requiring manual intervention. The feedback loop closes the control system, allowing autonomous operation while maintaining accuracy.
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 solution streamlines the cementing process by enabling the bridge plug to be set automatically upon reaching the gate, reducing operational time and costs associated with rig rentals, while ensuring effective sealing and minimizing the risk of incomplete setting.
Implementation Method 1
a sensor sub coupled to the bridge plug and configured to detect a gate in the well
Data Source
AI summary
A plug assembly for a cementing operation in a well includes a bottom wiper plug configured to land in or near the toe of a well and receive a cement slurry therethrough, a top wiper plug releasably coupled to the bottom wiper plug and configured to land on the bottom wiper plug after the cement slurry is received through the bottom wiper plug, a bridge plug coupled to the top wiper plug and configured to move toward the bottom wiper plug with the top wiper plug after the bottom wiper plug is landed in or near the toe of the well, and a sensor sub coupled to the bridge plug and configured to detect a gate in the well.