Modular Millable Bridge Plug Locking Mechanism
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Solution Overview
Problem
Conventional millable bridge plugs face challenges in stabilization during removal, as partially milled remnants can lodge on drill elements, hindering further drilling and being costly to remove due to metallic components' durability and complexity.
Innovation Solution
A modular millable bridge plug system with interchangeable and locking connections between bridge plugs, using composite materials and mechanical locking mechanisms to stabilize and facilitate removal, preventing remnants from interfering with subsequent drilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional millable bridge plugs with metallic components are used, then durability and structural integrity are improved, but removal complexity and cost increase significantly
Solution Approach 1:
The bridge plug is divided into multiple modular components including a mandrel, sealing member, ring members, cone assemblies, and slip devices. These segments can be independently manufactured, assembled, and removed, reducing overall removal complexity while maintaining structural integrity through standardized mechanical connections
Solution Approach 2:
The material composition parameters are changed by using composite materials with specific mechanical properties that balance durability with millability. The sealing member uses elastomeric or thermoplastic materials that provide both strength and ease of removal, while the mandrel uses millable metal alloys that maintain structural integrity during service but can be efficiently milled for removal
2Reliability
If bridge plugs are made permanent to seal entire portions of the wellbore, then sealing reliability is improved, but adaptability and removal flexibility are lost
Solution Approach 1:
The bridge plug incorporates dynamic components such as the slip devices that can engage and disengage, and the modular construction that allows for controlled decomposition during removal. The sealing member can maintain its seal under various pressure and temperature conditions while being designed for eventual removal through milling or drilling operations
Solution Approach 2:
The bridge plug design incorporates universal features that allow it to serve multiple functions: providing a reliable seal during production, allowing for controlled removal when needed, and enabling reuse of certain components. The modular design with standardized connections allows the same basic structure to be applied in different wellbore conditions and removal scenarios
3Ease of manufacture
If bridge plugs include modular ends with locking connections, then ease of assembly and interchangeability are improved, but device complexity increases
Solution Approach 1:
The bridge plug is divided into multiple modular components including a mandrel, sealing member, ring members, cone assemblies, and slip devices. These segments can be independently manufactured, assembled, and removed, reducing overall removal complexity while maintaining structural integrity through standardized mechanical connections
Solution Approach 2:
The modular components are designed to nest within each other during assembly, with the sealing member surrounding the mandrel, ring members positioned around the sealing member, and cone assemblies engaging with the slip devices. This nested arrangement simplifies assembly while maintaining structural integrity
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 modular design ensures stable connection and easy removal of bridge plugs, preventing interference and reducing the risk of damage to drill elements, thus simplifying the milling process and improving operational efficiency.
Implementation Method 1
the shearing means on the upper portion of the mandrel and the cap means on the lower portion of the mandrel are sheared by the setting tool, separating the bridge plug system from the setting tool and the positioning assembly
Implementation Method 2
the pressure of the ramming portion compresses the stack, forcing the sealing member to radially extend outward to seal against the wellbore or case
Implementation Method 3
The slip means extend radially outward and engage an inner surface of a surrounding borehole to lock the position of the bridge plug
Data Source
AI summary
A millable bridge plug system includes a mandrel having an upper portion and a lower portion, a shearing member attached at said upper portion of the mandrel, a sealing member, ring members, cone assemblies, slip devices, and a cap member at a lower portion of the mandrel. The shear member and the cap member are modular so that one bridge plug interchangeably connects to another bridge plug. The shear members are compatible with cap members of other bridge plugs. The shear member and the cap member further include a locking mechanism for rotational engagement by protrusions on the cap member being fit into the shear member and a locking mechanism for triggering a spring loaded lock into a groove on the cap member.