Subsurface Wiping Plug Bypass Mechanism for Cementing
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Solution Overview
Problem
Conventional cementing systems for well drilling operations are limited by the larger diameter of conventional plugs, which restricts the number of sleeves that can be used and results in unreliable cement wiping from the surface to the toe of the well due to diameter changes between drill pipes, liner hanger assemblies, and casings.
Innovation Solution
The subsurface wiping plug apparatus features a ported case with a slidable sleeve and plug capsule, eliminating the internal bore to accommodate smaller diameters, and utilizes a bypass mechanism with front and rear ports to direct fluid flow around the plug capsule, along with a release device and shear pins to control plug release and reestablish fluid flow, enabling effective cement wiping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional plugs with internal bores are used, then fluid can flow through the plug, but the plug diameter becomes larger which limits the number of sleeves that can be used in smaller boreholes
Solution Approach 1:
The patent removes the internal bore from the plug structure entirely. The plug is designed as a solid object without any through-flow path, extracting the harmful feature (internal bore that increases diameter) while maintaining the essential function of cement wiping and displacement.
Solution Approach 2:
The patent changes the flow path from a one-dimensional through-bore path to a three-dimensional path that flows around the external surface of the plug. Fluid enters through ports in the setting tool, flows through the annulus between the plug and casing, and exits at the top, effectively using the radial dimension to bypass the plug body.
2Reliability
If conventional plugs with larger diameter are used, then they can maintain structural integrity, but they result in unreliable cement wiping from surface to toe of well due to diameter changes
Solution Approach 1:
The patent applies different functional qualities to different parts of the system. The plug itself is small and solid for effective wiping, while the setting tool provides the necessary structural support and fluid distribution. The ports are strategically positioned to ensure proper fluid flow patterns that maintain reliability across varying diameters.
Solution Approach 2:
The system is divided into separate functional components: a small wiping plug for cement removal, a ported setting tool for fluid distribution and plug deployment, and a bypass mechanism. This segmentation allows each component to be optimized for its specific function without the compromises required in conventional integrated plug designs.
3Volume of moving object
If plugs are made smaller to fit smaller boreholes, then more sleeves can be used, but conventional plugs require internal bores that increase their diameter
Solution Approach 1:
The internal bore is completely removed from the plug structure, simplifying the plug to a solid object that is easier to manufacture. The fluid flow function is transferred to the setting tool ports and annulus, which are already part of the deployment system.
Solution Approach 2:
The setting tool with its ported case and bypass mechanism serves multiple functions: it holds the plug during deployment, distributes fluid during cementing, provides the flow path that would otherwise require an internal bore, and enables plug release. This multi-functionality eliminates the need for complex internal plug structures.
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 solution allows for the use of smaller plugs in smaller boreholes, enhances the reliability of cement wiping operations by bypassing the plug capsule, and efficiently pushes the wiping plug downhole to remove cement, overcoming the limitations of conventional systems.
Implementation Method 1
a bypass mechanism with front and rear ports to direct fluid flow around the plug capsule
Implementation Method 2
a release device and shear pins to control plug release
Data Source
AI summary
In some embodiments, a subsurface wiping plug apparatus includes an internal bore that extends for less than a length of the apparatus. A ported case encloses internal components of the apparatus such that each port of the case is configured to couple the internal bore to an external side of the case. A plug capsule is coupled to an end of the ported case. The plug capsule contains an internal wiping plug that is releasable by internal pressure.