Removable Downhole Plug with Frangible Coating
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Solution Overview
Problem
Multi-shifting service valves in downhole drilling operations require complex mechanical linkages and sliding sleeves to control orifices, which are cumbersome and prone to failure in corrosive environments, limiting flexibility and longevity.
Innovation Solution
A selectively removable fastener plug with a plug body and sealant coating, featuring a non-planar surface texture, is used to seal and open orifices without sliding sleeves, utilizing wellbore fluids to dissolve the coating and remove the plug, allowing for controlled access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If sliding sleeves and mechanical linkages are used to control orifices, then the valve can be actuated to open/close orifices, but the device complexity increases and reliability decreases due to mechanical failures in corrosive environments
Solution Approach 1:
The patent replaces the mechanical sliding sleeve system with a chemically responsive plug system. The orifices are sealed by plugs that dissolve or disintegrate when exposed to specific downhole fluids (such as acid or base), eliminating the need for mechanical linkages and sliding mechanisms. This substitution of chemical action for mechanical action directly resolves the contradiction by maintaining operational capability while eliminating complex mechanical components.
Solution Approach 2:
The patent utilizes downhole fluids (hydraulic/chemical agents) to trigger the opening of orifices. Instead of mechanical actuators, the system employs fluid injection of chemically reactive substances that cause the sealing plugs to dissolve or disintegrate, thereby opening the orifices. This hydraulic/chemical approach replaces the mechanical actuation system while maintaining the ability to control fluid flow through the orifices.
2Ease of operation
If sliding sleeves are used to cover orifices, then the orifices can be selectively closed, but the working volume of the basepipe is reduced and design flexibility is constrained
Solution Approach 1:
The patent extracts the sealing function from the basepipe structure itself. Instead of using a sliding sleeve that occupies space within the basepipe, the system employs separate, removable plugs that can be positioned in the orifices. These plugs can be small and precisely fitted, minimizing the volume they occupy and maximizing the working volume of the basepipe. The sealing function is taken out as a separate, exchangeable component rather than an integral part of the basepipe structure.
Solution Approach 2:
Instead of having the basepipe structure itself provide the closure mechanism (sliding sleeve), the patent inverts the approach by placing separate sealing elements (plugs) within the orifices. The plugs are inserted into the orifices to seal them, rather than having the orifices sealed by a moving wall of the basepipe. This inversion allows for more flexible space utilization and design freedom.
3Duration of action of moving object
If mechanical linkages are maintained for long periods in corrosive environments, then the valve can be repeatedly actuated, but the reliability decreases due to corrosion and wear
Solution Approach 1:
The patent employs disposable or sacrificial sealing plugs that are designed to be consumed or replaced rather than maintained. The plugs are made from materials that can be selectively dissolved or disintegrated by downhole fluids, allowing for controlled opening of orifices without the need for durable, maintainable mechanical components. This approach trades the longevity of mechanical components for the simplicity and reliability of consumable sealing elements that eliminate the need for long-term mechanical connection maintenance.
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 solution eliminates the need for complex mechanical linkages, enhances flexibility in valve design, and ensures reliable, long-term operation by using wellbore fluids to selectively open and close orifices, improving operational efficiency and reducing maintenance needs.
Implementation Method 1
exposing the selectively removable plug to a first wellbore fluid that is configured to selectively remove the sealant coating and provide a fluid access to the plug body
Implementation Method 2
exposing the selectively removable plug body to a second wellbore fluid through the fluid access that is configured to selectively remove the plug body
Implementation Method 3
using the second wellbore fluid to break the sealant coating disposed on the non-planar portion into a plurality of pieces
Data Source
AI summary
A method of opening an orifice in a downhole article includes forming a downhole article having an orifice, the orifice having a selectively removable plug sealingly disposed therein, the selectively removable plug comprising a selectively removable plug body formed of a plug body material and a selectively removable sealant coating formed of a coating material disposed on an outer surface of the plug body. The method also includes disposing the article within a wellbore. The method further includes exposing the selectively removable plug to a first wellbore fluid that is configured to selectively remove the sealant coating and provide a fluid access to the plug body. The method further includes exposing the selectively removable plug body to a second wellbore fluid through the fluid access that is configured to selectively remove the plug body and using the second wellbore fluid to break the sealant coating into a plurality of pieces.