Spalling Material Frac Plug for Thermal Removal

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Solution Overview

Problem

Downhole barriers used in the oil and gas industry face challenges in withstanding high pressures and forces during operation, making them difficult to remove once their purpose is fulfilled, as they are designed to be permanent and lack cost-effective, high compressive strength, and easy removability.

Innovation Solution

Incorporating spalling materials in critical components of downhole barriers, which self-destruct upon reaching a threshold temperature, allowing for easy removal by destabilizing the barrier, utilizing materials like Ultra High Performance Concrete with ductility modifying agents and functionalized fillers to manage thermal stress and enhance structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If barriers are designed to withstand high pressures and forces during operation, then structural integrity is improved, but removal difficulty increases

Engineering Contradiction:

Improvestructural integrityVSAvoidremoval difficulty

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The barrier components are designed to undergo parameter changes through thermal exposure. When exposed to high temperatures (such as from a fire or intentional heating), the material properties of the barrier change, causing it to weaken and eventually fail. This allows the barrier to maintain high strength during normal operation but become easy to remove when thermal parameters change.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention converts the harmful effect of high temperature exposure into a beneficial removal mechanism. Instead of the heat damaging the barrier during operation, the heat is intentionally applied after operation to trigger controlled failure and removal of the barrier components, transforming a potential harm into a useful function.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Reliability

If barriers use materials with high compressive strength to withstand setting loads, then reliability is improved, but cost increases

Engineering Contradiction:

Improvewithstand setting loadsVSAvoidcost effectiveness

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The barrier utilizes common, cost-effective materials that undergo parameter changes when exposed to thermal conditions. Instead of requiring expensive high-strength materials throughout, the design uses materials that can be heated to trigger failure, allowing the use of more economical materials that would otherwise be insufficient for the application.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The barrier is designed as a disposable component that serves its purpose during operation and then fails in a controlled manner when exposed to heat. This approach uses cost-effective materials for a single-use application, eliminating the need for expensive, durable materials that would be required if the barrier needed to be reused or permanently installed.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If barriers are designed to be permanent with high structural integrity, then reliability during operation is improved, but removability after operation deteriorates

Engineering Contradiction:

Improveoperational reliabilityVSAvoidtool life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The barrier maintains its structural integrity during normal operation but is designed to undergo parameter changes when exposed to thermal conditions. This allows the barrier to be reliable during its intended service life while providing a clear end-of-life removal mechanism through controlled thermal failure.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The barrier transitions from a static, permanent structure during operation to a dynamic failure mode when exposed to heat. The material properties and structural behavior change dynamically in response to thermal exposure, enabling controlled removal after the barrier has fulfilled its operational purpose.

Inventive Principle:

Principle #15Dynamics

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 spalling material-based downhole barriers effectively manage high operational forces and pressures, ensuring easy removal and extended tool life while maintaining structural integrity, addressing the need for cost-effective, high compressive strength solutions.

Implementation Method 1

Incorporating spalling materials in critical components of downhole barriers, which self-destruct upon reaching a threshold temperature

Methodology Applied

Scientific EffectExplosive spalling: Thermal Shock

Data Source

PatentUS11293247B2Frac plug and method for fracturing a formation

Publication Date: 2022.04.05 BAKER HUGHES CO

AI summary

A downhole barrier having a component thereof comprising a spalling material.