Two-Part Restriction Element for Large-Bore Downhole Isolation
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Solution Overview
Problem
Existing downhole tools face challenges in sealing large-bore plugs efficiently, as they require a large restriction element that can be set while the setting tool is inside the well, using minimal fluid for pumping, and current methods are either limited by the size of the restriction element or are time-consuming and fluid-intensive.
Innovation Solution
A two-part restriction element system where a primary restriction element is seated in a corresponding seat of the large-bore plug, and a secondary restriction element is seated within the primary element to seal the plug, allowing for efficient sealing without the need for a mandrel and reducing fluid usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single large restriction element is used to seal a large-bore plug, then the plug can be sealed effectively, but the setting tool cannot accommodate the large restriction element inside the wellbore
Solution Approach 1:
The restriction element is divided into two separate components: a first restriction element and a second restriction element. The first restriction element is deployed from the setting tool to seal the plug, while the second restriction element is pumped separately to provide additional sealing. This segmentation allows each component to be smaller and more manageable, fitting within the constraints of the setting tool and wellbore geometry.
Solution Approach 2:
The second restriction element is designed to be pumped inside the first restriction element. This nesting arrangement allows the second element to travel through the wellbore within the confines of the first element, maximizing space utilization and enabling deployment of dual sealing elements without requiring the setting tool to accommodate both simultaneously.
2Reliability
If the setting tool is removed from the well to release a large ball for plugging, then a large restriction element can be used, but the operation becomes time-consuming and fluid-intensive
Solution Approach 1:
The first restriction element is pre-loaded into the setting tool before the plug is deployed into the wellbore. This preliminary action allows the setting tool to remain in place and immediately deploy the first restriction element to seal the plug, eliminating the need to retrieve the setting tool and pump a large ball from the surface, thereby significantly reducing operation time and fluid consumption.
3Strength
If a mandrel is used in the plug, then the plug structure is supported, but the internal diameter of the plug is reduced
Solution Approach 1:
The invention eliminates the mandrel from the plug design entirely. Instead of using a central mandrel to provide structural support, the plug relies on its outer casing and the sealing action of the two restriction elements. This extraction of the mandrel component maximizes the internal diameter of the plug, allowing for greater fluid flow capacity while maintaining structural integrity through alternative design features.
Data Source
AI summary
A downhole isolation system for sealing a well, the downhole isolation system including a setting tool having an internal chamber; a first restriction element placed within the internal chamber; and a second restriction element placed within the internal chamber, separate from the first restriction element.