Tubular Expansion Bottom Plug Segmentation

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Solution Overview

Problem

Conventional wellbore expansion assemblies face issues with the bottom packer being a massive device that can come loose during drilling, potentially damaging drill bits or milling tools due to its complex components.

Innovation Solution

An assembly comprising a primary expander, a bottom plug with tubular clad elements for sealing and anchoring, and a secondary expander that radially expands the clad element, reducing the number of components and minimizing the risk of damage during drilling out.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional bottom packer with many components is used, then sealing and anchoring functions are achieved, but the device complexity increases and components may come loose during drilling out causing damage

Engineering Contradiction:

Improvesealing and anchoring reliabilityVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The bottom plug is segmented into distinct functional components: sealing means with elastomeric elements for sealing, anchoring means with expandable elements for anchoring, and a simplified structural body. This segmentation allows each component to perform its specific function independently, reducing overall complexity while maintaining reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention extracts and eliminates the complex setting mechanism from the bottom plug design. The setting mechanism that was present in conventional packers is completely removed, leaving only the essential sealing means and anchoring means that can be set by simple radial expansion without additional mechanical components.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If a massive bottom packer with many components is used, then sealing and anchoring functions are achieved, but the ease of manufacture decreases due to complex assembly requirements

Engineering Contradiction:

Improvesealing and anchoring reliabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The sealing means and anchoring means are merged into a single integrated bottom plug structure. Both functions are combined in one component that can be manufactured as a single unit or pre-assembled module, eliminating the need for complex field assembly of multiple separate components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bottom plug is designed as a multi-functional universal component that provides both sealing and anchoring capabilities in a single device. This universal design simplifies manufacturing by consolidating multiple functions into one standardized component rather than requiring separate specialized components for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If a simplified bottom plug with fewer components is used, then ease of manufacture and drilling out improve, but sealing and anchoring reliability may be compromised

Engineering Contradiction:

Improveassembly simplicityVSAvoidsealing and anchoring reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The bottom plug incorporates local quality enhancements through the use of elastomeric sealing elements and specifically designed anchoring features at critical locations. These localized high-performance components ensure reliable sealing and anchoring functions are achieved at the precise points where they are needed, compensating for the overall simplification of the device.

Inventive Principle:

Principle #3Local quality

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 simplified assembly allows for easy drilling out of the bottom plug with fewer components, reducing the risk of damage to drill bits or milling tools and maintaining stability in the wellbore expansion process.

Implementation Method 1

a primary expander for radially expanding a tubular element by axial movement of the primary expander through the tubular element

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

a secondary expander for radially expanding the clad element in the downhole end portion of the tubular element by axial movement of the secondary expander through the clad element

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 3

the clad element comprising sealing means for sealing the clad element to the downhole end portion of the tubular element

Methodology Applied

Scientific EffectSealing:

Data Source

PatentUS10036235B2Assembly and method for expanding a tubular element

Publication Date: 2018.07.31 SHELL USA INC

AI summary

In an expansion assembly (1), an expandable bottom plug (10) is arranged below a primary expander (6) for expanding a tubular element (2). The expandable bottom plug (10) includes an expandable tubular clad element with a sealing section for sealing the expanded clad element to a lower portion of the expanded tubular element (2), and an anchoring section for anchoring the expanded clad element to the lower portion of the expanded tubular element. A secondary expander (22) is provided for radially expanding the clad element in the lower portion of the expanded tubular element by axial movement of the secondary expander through the clad element.