Resettable Frac Plug With Magnetic Closure

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Solution Overview

Problem

Existing frac plugs in borehole environments require large volumes of pumped fluid for operation and do not allow for efficient replacement of perf guns without removing the plug, as they remain closed without fluid flow, hindering the replacement process during fracturing operations.

Innovation Solution

A resettable plug with a closure member assembly that holds open a flapper-style closure member using a magnetic catch or spring, allowing it to close with a selected hydrodynamic force and automatically reset upon reversed fluid flow, enabling indefinite open operation and easy reopening without removing the plug from the borehole.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional frac plug with ball-seat closure is used, then the plug can effectively seal the borehole, but large volumes of pumped fluid are required to convey balls to their seats and recirculate them back out

Engineering Contradiction:

Improvesealing effectivenessVSAvoidfluid volume required

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent replaces the mechanical ball-seat closure system with a magnetic closure mechanism. The closure member is held in the open position by a magnetic catch mechanism rather than requiring physical balls to be pumped to a seat. This substitution eliminates the need for large volumes of fluid to transport and recirculate balls, while maintaining reliable sealing when the closure member is in the closed position.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a magnetic field as an intermediary mechanism to hold the closure member in the open position. Instead of relying on fluid-driven balls to mechanically open the plug, the magnetic catch acts as an intermediary that maintains the open state without requiring continuous fluid flow or ball circulation, thereby reducing fluid volume requirements.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a conventional frac plug remains closed without fluid flow, then sealing is maintained, but perf gun replacement requires removing the plug entirely

Engineering Contradiction:

Improvesealing maintenanceVSAvoidperf gun replacement capability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent makes the closure member dynamically controllable through the magnetic catch mechanism. The closure member can be easily transitioned between open and closed states by adjusting fluid flow rates that interact with the magnetic mechanism, rather than being permanently fixed in one state. This dynamic control allows the plug to remain open for perf gun replacement and then automatically close to maintain sealing, eliminating the need to remove the plug entirely.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The plug system performs self-service by automatically resetting the closure member to the closed position after perf gun replacement using flowback fluid. The magnetic catch mechanism responds to fluid flow automatically, closing the plug without requiring manual intervention or removal of the plug device, thereby maintaining sealing while enabling operational flexibility.

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If a flapper-style closure member with magnetic catch is used, then the plug can remain open indefinitely and reset automatically, but the mechanism adds structural complexity

Engineering Contradiction:

Improveopen operation durationVSAvoidclosure assembly structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent extracts the complex mechanical components of traditional closure mechanisms (balls, seats, complex springs) and replaces them with a simplified magnetic catch mechanism. By taking out the unnecessary mechanical complexity and retaining only the essential magnetic holding and release functionality, the system achieves indefinite open operation capability while minimizing the added structural complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

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

Enables efficient fluid flow management during fracturing operations by allowing perf gun replacement without ancillary activities, as the plug automatically resets with flowback fluid, reducing fluid requirements and operational complexity.

Implementation Method 1

A resettable plug with a closure member assembly that holds open a flapper-style closure member using a magnetic catch or spring

Methodology Applied

Scientific EffectMagnetic catch: Magnetism

Implementation Method 2

A resettable plug with a closure member assembly that holds open a flapper-style closure member using a magnetic catch or spring

Methodology Applied

Scientific EffectSpring: Spring

Implementation Method 3

the hold open being configured to release the closure member upon a selected hydrodynamic force upon the closure member

Methodology Applied

Scientific EffectHydrodynamic force: Hydraulic Press

Data Source

PatentUS11359456B2Plug with a resettable closure member

Publication Date: 2022.06.14 BAKER HUGHES OILFIELD OPERATIONS LLC

AI summary

A plug with a closure member including a body defining a flow bore and a closure member seat, a closure assembly connected to the body, the assembly including a closure member, and a hold open feature to hold the closure member in an open position, the hold open being configured to release the closure member upon a selected hydrodynamic force upon the closure member.