Patch Plug Assembly Sequencing for Leak-Tight Tubular Sealing
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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 in sealing and potential fluid leakage.
Innovation Solution
The proposed solution involves a patch plug assembly comprising a shaft, a wedge, a slip, a plug, and a ferrule, where the slip is pushed against the tubular, followed by the plug being pushed against the ferrule, and then the ferrule against the wedge, with specific protrusions and swage surfaces used to achieve a sealing configuration that includes the plug being pushed against the tubular's inner surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing patch plug assemblies are used for sealing tubulars, then the sealing process can be performed, but fluid leakage occurs and sealing efficacy is insufficient
Solution Approach 1:
The sealing system is divided into multiple functional components: a plug with sealing elements, a setting tool with swage surfaces, and a tubular interface. Each component has specific protrusions and surfaces designed to create multiple sealing contact points, ensuring comprehensive sealing coverage and preventing fluid leakage through segmented sealing zones.
Solution Approach 2:
The plug incorporates localized sealing elements with specific geometric features (protrusions with radii) that concentrate sealing force at critical contact points with the tubular. The setting tool has swage surfaces with specific radii designed to deform and shape the plug's protrusions into optimal sealing configurations, creating high-quality local sealing zones where needed most.
2Reliability
If the plug is pushed against the ferrule and ferrule against the wedge, then the sealing configuration is achieved, but the process requires multiple sequential steps increasing complexity
Solution Approach 1:
The setting tool combines multiple functions into a single integrated device: it houses both the ferrule and wedge components, and performs both the deformation of the plug protrusions and the positioning of sealing elements in one operational sequence. This merging reduces the number of separate tools and steps needed while maintaining reliable multi-stage sealing.
Solution Approach 2:
The plug protrusions are pre-formed with specific radii before insertion, and the setting tool swage surfaces are pre-configured with matching radii. This preliminary preparation ensures that when the plug is pushed against the ferrule and wedge, the deformation follows a predetermined path to achieve the correct sealing geometry, reducing the complexity of real-time adjustment during the sealing process.
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 secure and effective seal, reducing fluid leakage and improving the reliability of the sealing process.
Implementation Method 1
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
Implementation Method 2
pushing the slip against the tubular
Implementation Method 3
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
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.