Downhole Plug Shear Mechanism for Rapid Drill-Out
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Solution Overview
Problem
Existing downhole tools, such as bridge plugs and packers, face challenges during removal due to binding with drill bits, leading to long drill-out times and excessive casing wear, and there is a need for tools that can effectively seal wellbores and be quickly and reliably removed, with uncertainty in the types and numbers of plugs required causing fiscal inefficiencies and field delays.
Innovation Solution
The development of a plug with a lower shear mechanism that engages a setting tool and releases it under a predetermined stress, allowing for efficient removal without breaking the plug body, and anti-rotation features to prevent plug rotation during drill-out, enabling faster and more reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If non-retrievable plugs are constructed of brittle materials such as cast iron or ceramics to perform sealing functions, then the plug can effectively seal the wellbore, but the plug binds upon the drill bit during removal, resulting in extremely long drill-out times and excessive casing wear
Solution Approach 1:
The plug is divided into two distinct segments: a soft, easily-drillable body portion and a separate hard seal element. The seal element is positioned within a cavity in the plug body, allowing the soft body to be quickly drilled away while the seal element remains to maintain wellbore isolation. This segmentation resolves the contradiction by enabling fast removal of the main plug body while preserving sealing effectiveness through the retained seal element.
2Strength
If non-retrievable plugs are constructed of hard materials to maintain structural integrity and sealing, then the plug can withstand wellbore conditions, but the plug rotates within the casing string during drill-out, causing excessive casing wear
Solution Approach 1:
The plug structure separates the structural function from the sealing function. The soft body provides structural integrity and anti-rotation properties, while the separate seal element provides the sealing function. This segmentation allows the soft body to prevent rotation and casing wear, while the hard seal element maintains structural integrity for sealing under wellbore conditions.
Solution Approach 2:
Different parts of the plug have different material properties optimized for their specific functions. The body is made of soft, easily-drillable material with anti-rotation features, while the seal element is made of hard material to withstand wellbore conditions and maintain sealing. This local quality differentiation resolves the contradiction between structural integrity and casing wear prevention.
3Adaptability or versatility
If multiple types and numbers of plugs are purchased to cover various completion and production activities, then the well can be properly equipped for different zones, but fiscal inefficiencies occur due to over-purchase and under-purchase of appropriate plug types
Solution Approach 1:
The plug design provides multi-functionality through a universal soft body configuration that can accommodate different seal elements for various sealing requirements. The standardized body with consistent anti-rotation and drill-out characteristics can be combined with different seal elements to create plugs suitable for bridge plugging, frac plugging, and other completion activities, reducing the need to purchase multiple specialized plug types.
Solution Approach 2:
The invention allows for parameter changes in the seal element while maintaining a consistent body design. By varying the seal element properties (material, dimensions, sealing mechanism) while keeping the body standardized, the system can adapt to different well completion requirements without requiring completely different plug designs, thereby improving fiscal efficiency.
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 solution enables quick and reliable sealing and removal of downhole tools, reducing drill-out times and casing wear, and improves operational efficiency by allowing for the use of softer, more easily drillable materials and minimizing stress on the plug body, thus addressing the inefficiencies and delays associated with traditional plug removal.
Implementation Method 1
The lower shear or shearable mechanism is adapted to engage a setting tool and deform when exposed to a predetermined stress that is sufficient to deform the lower shear or shearable mechanism to release the setting tool
Data Source
AI summary
A plug for isolating a wellbore. The plug can include a body having a first end and a second end, wherein the body is formed from one or more composite materials and adapted to receive a setting tool through the first end thereof, at least one malleable element disposed about the body, at least one slip disposed about the body, at least one conical member disposed about the body, and one or more shearable threads disposed on an inner surface of the body, adjacent the second end thereof, wherein the one or more shearable threads are adapted to receive at least a portion of a setting tool that enters the body through the first end thereof, and wherein the one or more shearable threads are adapted to engage the setting tool when disposed through the body and adapted to release the setting tool when exposed to a predetermined axial force.