Actuatable Plug Cone and Slips Design for Well Casing Seal
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Solution Overview
Problem
The existing plug systems for hydrocarbon wells, such as bridge plugs and frac plugs, have complex and costly assemblies that can be difficult to utilize in certain environments, particularly due to the complexity of backup systems and other elements required for sealing and securing the plug against the well casing.
Innovation Solution
The system employs a flexible element slidably mounted on a cone with tapered surfaces cooperating with movable slips, allowing for actuation to a radially expanded configuration without an expandable backup ring, using a combination of upper and lower cones with tapered surfaces and slips to secure and seal against the well casing, reducing component complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a backup system and other elements are used to prevent extrusion of the rubber element and maintain seal integrity, then seal reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the expandable backup ring from the plug assembly, extracting the problematic component that caused complexity and cost issues while maintaining seal integrity through the simplified cone and slips design
Solution Approach 2:
The patent combines the functions of the backup system into the cone and slips assembly, where the tapered surface of the cone and the movable slips work together to provide both sealing and backup functions in a unified, simpler structure
2Reliability
If a complex assembly with backup system is used, then seal integrity is maintained, but ease of manufacture and deployment deteriorates
Solution Approach 1:
By removing the backup ring component entirely, the patent simplifies the manufacturing process and reduces assembly steps while maintaining the essential sealing function through the cone and slips mechanism
Solution Approach 2:
The cone and slips assembly is designed to perform multiple functions simultaneously - sealing against the wellbore, preventing extrusion, and maintaining structural integrity - eliminating the need for separate dedicated backup components
3Reliability
If traditional plug components are used, then seal integrity is maintained, but device complexity increases making it difficult to utilize in certain environments
Solution Approach 1:
By extracting the backup ring component, the patent creates a more adaptable plug design that can be deployed in environments where the complex traditional assembly would be difficult to handle or deploy, while maintaining sealing reliability
Solution Approach 2:
The patent employs movable slips that can dynamically adjust and bite into the wellbore casing, providing adaptability to different well environments and conditions while maintaining seal integrity through the flexible element and tapered cone surface
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 simplifies the assembly and operation of plugs, reduces component count, and maintains seal integrity across various temperatures, enabling efficient deployment and operation in diverse well environments, including high-temperature applications.
Implementation Method 1
the plug utilizes a rubber element to provide a seal against the surrounding well casing
Implementation Method 2
The upper cone comprises a tapered surface which works in cooperation with upper slips movably secured to the upper cone. The lower cone having a lower tapered surface which works in cooperation with lower slips
Data Source
AI summary
A technique facilitates deployment and operation of actuatable plugs, e.g. frac plugs or bridge plugs. According to one embodiment, the plug comprises a flexible element slidably mounted on a portion of a cone, e.g. an upper cone. The upper cone comprises a tapered surface which works in cooperation with upper slips movably secured to the upper cone. The bridge plug also comprises a lower cone which comprises a lower tapered surface which works in cooperation with lower slips movably secured to the lower cone. Depending on the application, the plug may be constructed with each of these features combined into an overall assembly or with a portion of these features to facilitate plug operation in a specific environment and operation.