Nested Elastomer Bridge Plug for High-Expansion Wellbore Sealing
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Solution Overview
Problem
Current through-tubing bridge plugs with large expansion ratios require excessive elastomer length and setting force, posing practical challenges in hydrocarbon reservoir exploration and development, as increasing the setting force is limited by structural and geometric constraints.
Innovation Solution
A high expansion elastomer design with optimized geometric features, including nested male and female conical or cupped elements, allows for a shorter bridge plug length and reduced setting force, utilizing two stacks of elements with ID constraining features and O-rings to achieve a reliable, leak-free seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the amount of elastomer is increased to create a positive seal with large expansion ratios, then the sealing reliability is improved, but the overall length of the plug increases
Solution Approach 1:
The elastomer is configured in a nested arrangement where the first elastomer is positioned within the second elastomer, allowing both elastomers to contribute to sealing functionality while occupying minimal axial space. This nested configuration enables adequate sealing material to be present without increasing the overall plug length, thereby resolving the contradiction between sealing reliability and plug length.
2Reliability
If the amount of elastomer is increased to create a positive seal with large expansion ratios, then the sealing reliability is improved, but the required setting force increases
Solution Approach 1:
The nested elastomer configuration allows the elastomers to expand in a compact manner where the inner elastomer expands first followed by the outer elastomer. This staged expansion reduces the peak setting force required compared to a single large elastomer expanding simultaneously, while still achieving the necessary sealing pressure through the cumulative effect of both elastomers.
Solution Approach 2:
The elastomer sealing system is divided into multiple segmented elastomers (first and second elastomers) with distinct functional zones. This segmentation allows each elastomer to be optimized for specific expansion characteristics and pressure distribution, reducing the overall setting force requirement while maintaining sealing reliability through distributed pressure application.
3Reliability
If the plug length is increased to accommodate more elastomer, then the sealing capacity is improved, but the rig-up cost and time increase
Solution Approach 1:
The nested elastomer design enables adequate sealing capacity to be achieved within a compact plug length by utilizing radial and axial space efficiently. The inner elastomer nests within the outer elastomer, maximizing the sealing material density without increasing the overall plug dimensions, thereby reducing rig-up time and cost while maintaining sealing capacity.
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 new design achieves a reliable high expansion ratio seal with minimized elastomer length and setting force, enabling faster and cheaper rig-up, reduced setting time, and compatibility with various deployment methods, while maintaining a positive seal in wellbores.
Implementation Method 1
Through tubing bridge plugs are characterized by very large expansion ratios, typically ranging from 300% up to 600% or even more
Data Source
AI summary
A high expansion bridge plug comprising an elastomer element assembly and a control assembly for generating a compressive force against the elastomer element assembly. The elastomer element assembly comprises a first element stack and a second element stack with the first element stack comprising a first grouping of male and female elements and the second element stack comprising a second grouping of male and female elements. The compressive force generated causes the male element and the female element to expand and the female element to at least partially swallow the male element. The male and female elements can be conical shape, and an angle of a conical element can be between 5-25 degrees, and the length of the top female element is greater than the length of the middle or bottom male element.