Single-Body Expandable Frac Plug for Reliable Stage Isolation
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Solution Overview
Problem
Conventional frac plugs with multiple components are costly and risky due to potential component failure during setting, leading to increased operational costs and complexity in hydraulic fracturing operations.
Innovation Solution
A singular tubular frac plug that expands to contact the inner wall of the casing, using ductile materials and swedges to anchor in place, eliminating the need for multiple components, and incorporating isolating components for hydraulic isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional frac plugs with multiple components are used, then hydraulic isolation between stages can be achieved, but the risk of component failure and operational cost increase
Solution Approach 1:
The patent combines multiple separate components (mandrel, slips, setting mechanism) into a single integrated frac plug body. The setting mechanism is integrated directly into the tubular body, eliminating the need for separate mandrels and multiple independent components, thereby reducing failure points while maintaining hydraulic isolation functionality
Solution Approach 2:
The single tubular body performs multiple functions: it serves as the structural frame, contains the setting mechanism, provides the hydraulic seal, and anchors to the casing. This multi-functional design eliminates the need for separate specialized components, reducing overall system complexity and failure risk
2Reliability
If conventional frac plugs with multiple components are used, then hydraulic isolation can be provided, but operational cost and complexity increase
Solution Approach 1:
By merging the mandrel, setting mechanism, and seal components into a single tubular body, the patent reduces the number of parts that need to be manufactured, assembled, and handled during operations. This simplification reduces manufacturing costs and operational expenses while maintaining reliable hydraulic isolation
3Ease of operation
If multiple components are used in frac plug, then setting mechanism can be complex, but failure risk and operational complexity increase
Solution Approach 1:
The setting mechanism is merged into the tubular body as an integrated system rather than separate components. This integration simplifies the setting operation to a single action while eliminating the risk of failure between multiple independent components, making the process both simpler and more reliable
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 singular tubular frac plug effectively anchors in the wellbore, reducing failure risks and operational costs by simplifying the setting process and ensuring reliable hydraulic isolation between frac stages.
Implementation Method 1
the elastic properties of the materials may allow the singular tubular to expand to contact the inner diameter of the casing
Implementation Method 2
The one or more swedges may traverse through the inner bore of the singular tubular structure to press the singular tubular structure, expanding the singular tubular structure to contact the inner wall of the casing
Implementation Method 3
the friction between the outer face of the singular tubular structure and the inner wall of the casing may hold the frac plug in place
Data Source
AI summary
An apparatus comprising a frac plug to be positioned inside casing of a wellbore formed in a subsurface formation, wherein the frac plug is configured to expand to contact an inner wall of the casing and maintain, via one or more components coupled with the frac plug, a position while the frac plug is expanded.