Patch Plug Assembly Sealing Sequence for High-Pressure 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 benefits.
Innovation Solution
The proposed solution involves a patch plug assembly comprising a shaft, a wedge, a slip, a plug with protrusions of different radii, and a ferrule, where the slip is pushed against the tubular, followed by the plug and ferrule being sealed, and the swage surfaces are used to push the protrusions against the tubular surface, creating a sealing configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing patch plug assemblies are used to seal tubulars, then the sealing function is provided, but the sealing efficacy is insufficient and fluid ingress occurs under high pressure
Solution Approach 1:
The plug is divided into multiple protrusions (first protrusion, second protrusion, third protrusion) with different radii, each making contact with the tubular at different locations. This segmentation allows the sealing force to be distributed across multiple contact points, enhancing sealing efficacy and preventing fluid ingress under high pressure conditions.
Solution Approach 2:
Different protrusions have different radii (first radius, second radius, third radius) to create localized contact points with specific pressure distribution. The ferrule and swage surfaces are designed with specific geometries to concentrate force at critical sealing locations, providing enhanced sealing where needed most while maintaining overall system reliability.
2Reliability
If the plug is pushed against the ferrule and wedge sequence is followed, then the sealing configuration is achieved, but the device complexity increases with multiple components
Solution Approach 1:
The ferrule integrates multiple functions into a single component: it provides sealing contact with the plug, structural support for the wedge, and force transmission pathways. The swage surfaces are integrated into the assembly to simultaneously push multiple protrusions against the tubular. This merging reduces the number of separate parts while maintaining the reliable sealing configuration.
Solution Approach 2:
The ferrule serves multiple purposes: sealing, structural support, and force distribution. The wedge both anchors the assembly and transmits force to the slip and ferrule. Each component is designed to perform multiple functions, reducing overall device complexity while achieving reliable sealing configuration through the coordinated sequence of operations.
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 deforming the ferrule and plug components, effectively inhibiting fluid ingress and providing a reliable seal, even under high pressures.
Implementation Method 1
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
Implementation Method 2
pushing the slip against the tubular
Implementation Method 3
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.