Plug Releaser Pressure Differential Control

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Solution Overview

Problem

In tubular systems used for carbon dioxide sequestration and hydrocarbon recovery, existing technologies lack the ability to control the release of intermediate plugs effectively, often leading to premature rupture due to pressure differentials, which can result in unintended actuation or tool malfunction.

Innovation Solution

A plug releaser system that includes a first tubular with ports allowing fluid communication between chambers and an outside environment, featuring rupturable plugs that can be released at selected pressure differentials, and a movable piston or housing to manage pressure differentials and prevent premature rupture by equalizing pressures across the plugs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stress or pressure

If plugs are sealingly engaged in a tubular to temporarily plug an opening, then pressure can be built upstream to facilitate actuation, but pressure differential may build to a level that causes premature rupture or release of the plugs

Engineering Contradiction:

Improvepressure differential across plugsVSAvoidcontrolled release of plugs

Core Design Contradiction:

Stress or pressureVSReliability

Solution Approach 1:

A piston is introduced as an intermediary element between the plugs and the pressure system. The piston selectively blocks fluid flow paths based on pressure differential, allowing controlled communication between chambers. This mediator prevents direct pressure buildup across plugs while enabling selective plug release when desired pressure differentials are achieved.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system changes the pressure parameter distribution by using the piston to create different pressure conditions in different chambers. By moving the piston to different positions, the system can equalize pressures across plugs (preventing premature rupture) or create pressure differentials (enabling controlled release), thus dynamically controlling the pressure state.

Inventive Principle:

Principle #35Parameter changes

2Ease of operation

If a port is provided to allow fluid communication between chamber and outside, then pressure differential can be controlled, but the port must be sized to prevent pressure differential from building to rupture levels

Engineering Contradiction:

Improvecontrolled release of plugsVSAvoidpressure differential across plugs

Core Design Contradiction:

Ease of operationVSStress or pressure

Solution Approach 1:

The piston is designed to be movable rather than fixed, allowing it to dynamically respond to pressure changes. The piston can be positioned to block or allow fluid flow through ports based on the desired pressure differential, providing dynamic control over the pressure state across plugs rather than relying solely on fixed port sizing.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system uses fluid pressure (pneumatics/hydraulics) as the primary control mechanism. The piston responds to pressure differential forces and uses fluid communication through ports to control pressure distribution. This hydraulic/pneumatic system enables precise control of plug release by manipulating fluid pressure paths.

Inventive Principle:

Principle #29Pneumatics and hydraulics

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

The system effectively controls the release of plugs by maintaining pressure within the chamber at a lower value than would occur without fluid communication, preventing premature rupture and allowing for controlled actuation of tools in downhole environments.

Implementation Method 1

The at least one first port provides fluidic communication between the first chamber and an outside of both the first tubular and the second tubular and the at least one first port is sized to prevent pressure differential across the at least two plugs from building to a selected pressure differential needed to rupture or release the plugs

Methodology Applied

Scientific EffectPressure equalization: Pressure Gradient

Implementation Method 2

the at least two plugs are rupturable or releasable from the first tubular at selected pressure differentials thereacross

Methodology Applied

Scientific EffectPressure differential-induced rupture: Fracture Mechanics

Data Source

PatentUS10087702B2Plug releaser and method of limiting pressure differential across plugs

Publication Date: 2018.10.02 BAKER HUGHES CO

AI summary

A plug releaser includes, a first tubular with at least one first port through a wall thereof, at least two plugs sealingly engaged with the first tubular defining a first chamber between the first tubular and the at least two plugs. The at least two plugs are rupturable or releasable from the first tubular at selected pressure differentials thereacross, and a second tubular is in operable communication with the first tubular at locations beyond the at least two plugs. The at least one first port provides fluidic communication between the first chamber and an outside of both the first tubular and the second tubular and the at least one first port is sized to prevent pressure differential across the at least two plugs from building to a selected pressure differential needed to rupture or release the plugs in either direction for at least a period of time.