Segmented Cone Frac Plug for High Radial Expansion
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Solution Overview
Problem
Conventional frac plug devices face limitations in radial expansion, making it difficult to seal wide wellbores and casings effectively, as the expansion is restricted by the dimensions of the cone and slip device.
Innovation Solution
The frac plug device incorporates a segmented cone and a segmented cap member, along with a core cone and core cap member, to achieve a multiple stage full expansion configuration, allowing for maximum radial expansion and stable sealing in larger wellbores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional cone and slip device configuration is used, then the device structure is simple, but the radial expansion is limited and cannot seal wide wellbores effectively
Solution Approach 1:
The cone is divided into multiple segments (first cone segment, second cone segment, third cone segment) that can expand independently. Each segment has its own tapered surface that interacts with corresponding slip segments, allowing the slip device to achieve greater radial expansion than a single cone configuration. This segmentation enables the frac plug to seal wider wellbores while maintaining a manageable structural complexity through modular design.
2Strength
If the cone diameter is increased to achieve greater radial expansion, then the expansion diameter increases, but the device cannot pass through narrow wellbores during deployment
Solution Approach 1:
The frac plug device transitions from a compact run-in configuration during deployment to an expanded set configuration at the target location. The cone segments and slip segments are designed to remain compact when not in use, allowing passage through narrow wellbores. Upon activation, the cone segments expand radially to engage the slip segments, which then expand further to seal the wellbore. This dynamic transformation enables the device to overcome the size constraint during deployment while achieving the required expansion diameter at the setting position.
3Strength
If a single stage expansion configuration is used, then the device structure is simple, but the expansion is insufficient for wide setting positions
Solution Approach 1:
The expansion process is divided into multiple stages through the segmented cone design. First, the cone segments expand to engage the slip segments. Then, the slip segments continue to expand radially to achieve full sealing diameter. This multi-stage expansion allows the device to achieve the required expansion diameter for wide setting positions while distributing the mechanical stress across multiple stages, reducing the complexity of any single expansion mechanism.
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 configuration enables the frac plug device to achieve high expansion at setting positions in larger diameter portions of the wellbore, ensuring stable sealing and reducing the risk of misalignment and collapse.
Implementation Method 1
The inner surface of the slip device has a first tapered surface and the outer surface of the cone has a second tapered surface. The first tapered surface and the second tapered surface are in sliding engagement with one another.
Implementation Method 2
As the thicker portion of the wedge enters into the slip, the slip expands in diameter to reach the borehole wall.
Data Source
AI summary
The frac plug device is a wedge type or ramp type frac plug that can seal at a setting position in a large diameter portion of the borehole. The thickness, taper angle, and dimensions of components for passing through the narrowest portion of the borehole during deployment no longer limit the radial expansion. The frac plug device includes a core cone, a segmented cone, a slip device, a segmented cap member, and a core cap member. A simplified setting action sets the high expansion of the slip device by the core cone and the segmented cone. The segmented cone and the segmented cap member increase expansion of the slip device, and the segmented cap member and the core cap member lock the slip device around the core cone in the final expansion configuration at the maximum radial expansion for large diameter portions of the borehole.