Plug Counter for Fracing Valves Using Indexing Mechanism
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fracturing systems in the drilling and completion industries are limited by the need for multiple plug sizes and tolerances due to irregular borehole shapes, making it difficult to effectively fracture discrete locations in a borehole for hydrocarbon production and CO2 sequestration.
Innovation Solution
A plug counter system that uses a single size plug for multiple actuation sequences, featuring a movable seat and indexing mechanism to allow a selected number of plugs to pass before preventing further passage, enabling the use of same-sized plugs to open and close fracing valves for isolated fracturing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple plug sizes are used to fracture discrete locations, then the fracturing operation can be performed at different zones, but the system complexity increases and tolerance requirements limit the number of usable diameters
Solution Approach 1:
The plug counter device enables a single plug size to perform multiple functions by counting and enabling sequential activation of multiple fracing valves at different zones. The universal seat design accepts plugs of a single diameter while the indexing mechanism allows the same plug size to trigger multiple discrete fracturing events throughout the borehole.
Solution Approach 2:
The fracing system is divided into multiple independently controllable valve clusters, each capable of being activated by a plug passing through its associated plug counter. This segmentation allows discrete control of different zones while using uniform plug sizing, eliminating the need for progressively larger plugs.
2Ease of operation
If a staged system with progressively larger plugs is used, then discrete locations can be accessed from toe to surface, but the tolerance requirements and irregular borehole shape further limit the number of usable diameters
Solution Approach 1:
The plug counter with its movable seat and indexing mechanism allows a single plug size to sequentially activate multiple fracing valves at different depths. The design eliminates tolerance sensitivity by using a single plug diameter that can trigger multiple discrete events, making the system robust against borehole irregularities.
Solution Approach 2:
The plug counter incorporates dynamic components including a movable seat that shifts position in response to plug passage, and an indexing mechanism that progresses through discrete positions. This dynamic behavior enables the same static plug size to trigger multiple activation events as the counter progresses through its indexing sequence.
3Adaptability or versatility
If multiple fracing valves are controlled by same sized plugs, then the system flexibility and precision are improved, but a mechanism is needed to control the number of plugs that can pass
Solution Approach 1:
The plug counter is segmented into distinct functional components: a seat for plug engagement, an indexing mechanism with discrete positions, and a control element that prevents further plug passage after a predetermined number. This segmentation provides the necessary control while maintaining system flexibility.
Solution Approach 2:
The indexing mechanism provides feedback on the number of plugs that have passed through the system. Each plug activation advances the index, and this feedback controls when the seat becomes inoperative, automatically limiting the number of fracing events without requiring external intervention.
Data Source
AI summary
A valve includes a tubular having at least one port, and a sleeve in operable communication with the tubular configured to uncover the at least one port in response to moving from a first position to a second position. The valve also has a seat that is configured to be passed a selected number of times without shifting the sleeve from the first position to the second position and is further configured to be passed one additional time after the selected number of times after shifting the sleeve from the first position to the second position.