Removable Fracturing Plug Using Granular Material in Porous Enclosure
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Solution Overview
Problem
Existing methods for isolating zones in a wellbore using sand plugs are inefficient for removal and require complex processes, and alternative designs with swelling materials do not provide sufficient sealing for fracturing applications.
Innovation Solution
A removable plug featuring a solid granular material in a porous enclosure that changes shape to set, using a setting tool to create relative movement and alter the enclosure's shape, allowing for easy removal by fluid circulation or mandrel undermining, with optional locking features to prevent reverse flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sand plugs are used to isolate zones in a wellbore, then zonal isolation is achieved, but removal requires complex jetting processes and is inefficient
Solution Approach 1:
The plug is segmented into two functional components: a porous substrate that provides the sealing surface and a granular material that forms the isolation barrier. This segmentation allows the plug to be set effectively while enabling simplified removal by targeting specifically the granular material portion through jetting or circulation, without requiring complex removal processes for the entire plug structure.
Solution Approach 2:
The granular material is extracted as a removable component from the overall plug system. The porous substrate remains in place to maintain the seal, while the granular material can be selectively removed through fluid circulation or jetting actions, simplifying the removal process compared to removing an entire monolithic plug.
2Ease of operation
If swelling material in porous enclosures is used to create relative movement, then the packer can transition from run in to set position, but sealing is insufficient for fracturing applications
Solution Approach 1:
The invention changes the physical parameters of the granular material through compression. When the plug is set, the granular material is compressed between the porous substrate and the wellbore wall, transforming it from a loose, permeable state to a compacted, low-permeability state that provides reliable sealing for fracturing applications. This parameter change (density and permeability) achieves the required sealing without requiring swelling materials.
3Reliability
If a long sand column is created with dewatering, then pressure forces sand particles together to create a barrier, but the process is time-consuming and inefficient
Solution Approach 1:
The granular material is pre-positioned within the porous enclosure before deployment into the wellbore. This preliminary action eliminates the need for time-consuming in-situ dewatering and compaction processes. The material is already in its isolation-forming configuration, requiring only placement and optional compression to achieve the barrier function, significantly reducing setting time.
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 provides effective zonal isolation with minimal material usage, allowing sufficient flow for fracturing while being easily removable, reducing interference with other tools and maintaining operational efficiency.
Implementation Method 1
a porous enclosure that changes shape to set, using a setting tool to create relative movement and alter the enclosure's shape
Implementation Method 2
Pressure is applied and the sand is dewatered. If a long enough sand column is created, the pressure applied from pumped fluid above forces the sand particles together in such a manner as to create a barrier
Implementation Method 3
The jetting action and the circulation starts to work on the compacted sand pile and eventually allows the particles to come off the cohesive plug and get lifted from the well with the circulating fluid that exits the jetting nozzles
Data Source
AI summary
The removable plug features a solid material that is housed in a porous container that has its shape changed to transition from the run in shape to the set shape. A running string and setting tool that creates relative movement deliver the plug and pull on its lower end while holding the top stationary against a backing plate. The container is pulled into itself as the radial dimension grows for the set. There can be a mandrel that remains in position and can lock to the backing plate or alternatively there can be no mandrel or a removable mandrel. The porous container can be removed in a variety of ways to let the solid material escape to be removed with fluid circulating in the wellbore. Alternatively the mandrel can be undermined to let the solid material escape for recovery.