Patch Plug Assembly With Ferrule-Wedge Sealing for Tubulars
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Solution Overview
Problem
Existing patch plug assemblies and methods for sealing tubulars lack the combination of steps and features that effectively seal tubulars, leading to inefficiencies and unexpected issues.
Innovation Solution
The proposed solution involves a patch plug assembly with a shaft, wedge, slip, plug, and ferrule, where the slip is pushed against the tubular, followed by the plug and ferrule being sealed against the wedge, utilizing protrusions and swage surfaces to achieve a secure seal by deforming the plug and ferrule against the tubular surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a simple plug assembly is used, then the device complexity is reduced, but the sealing reliability deteriorates due to inability to maintain tight seal under high pressure
Solution Approach 1:
The plug assembly is divided into multiple functional components: a body portion with sealing elements, a settable portion with expandable protrusions, and a deployment mechanism. This segmentation allows each component to perform its specific function optimally while maintaining overall sealing reliability without excessive complexity.
Solution Approach 2:
The plug transitions from an initial state with protrusions in a first configuration to a set state with protrusions in a second configuration. This dynamic transformation allows the plug to adapt to different sealing requirements and maintain reliability under varying pressure conditions.
2Reliability
If protrusions are deformed against tubular surface, then the sealing efficacy is improved, but the manufacturing precision requirements increase due to specific geometric constraints
Solution Approach 1:
The protrusions are designed with specific geometric parameters (radii, tangent lines) that change during deployment. The first and second protrusions have different radii and share a tangent line parallel to the tubular surface, creating optimal sealing geometry without requiring extreme manufacturing precision.
Solution Approach 2:
The plug is pre-configured with protrusions in an initial state that facilitates easy deployment. The protrusions are positioned and oriented beforehand to ensure they will achieve the correct sealing geometry when deformed against the tubular surface, reducing the need for high-precision manufacturing.
3Reliability
If multiple components are used in the assembly, then the sealing reliability is improved, but the ease of manufacture deteriorates due to increased assembly steps
Solution Approach 1:
Multiple functional elements are merged into integrated components. The body portion incorporates sealing elements, the settable portion includes expandable protrusions, and these are combined in a single plug assembly that maintains reliability while simplifying manufacturing and assembly processes.
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 configuration enhances the sealing efficacy by ensuring a tight seal along the tubular surface, preventing fluid ingress and maintaining integrity under high pressures, thereby addressing the inefficiencies of prior methods.
Implementation Method 1
pushing the slip against the tubular
Implementation Method 2
pushing the ferrule against the wedge after the plug is pushed against the ferrule
Implementation Method 3
pushing the ferrule against the wedge
Implementation Method 4
pushing a plug portion of the plug against an inner surface of the tubular
Implementation Method 5
pushing a plug portion of the plug against an inner surface of the tubular
Implementation Method 6
pushing, with the first swage surface, the first protrusion and the second protrusion to share a tangent line parallel with a tubular surface of the tubular
Data Source
AI summary
Methods of sealing tubulars are disclosed herein, which methods may include: providing a patch plug assembly that includes: a shaft; a wedge coupled to the shaft; a slip coupled to the shaft; a plug slidably coupled to the wedge; and a ferrule disposed between the wedge and the plug; pushing the slip against the tubular; pushing the plug against the ferrule after the slip is pushed against the tubular; pushing the ferrule against the wedge after the plug is pushed against the ferrule; and pushing a plug portion of the plug against an inner surface of the tubular.