Wellbore Plug Seal Element Folding Edge Design
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Solution Overview
Problem
Conventional plugs for oil and gas wellbores are complex and costly due to their multiple components, leading to increased operational expenses and time required for drilling out the plug after wellbore operations are complete.
Innovation Solution
A compact plug design featuring a mandrel with a gauge ring, guide shoe, cones, and a seal element that moves to fold its edge underneath, reducing the number of components and allowing for a shorter plug length, which simplifies operations and reduces costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional plug design with multiple components (five or more including extrusion limiters) is used, then sealing reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines multiple sealing functions into a single seal element that interfaces with both the mandrel and the cones. The seal element integrates the sealing actions that would traditionally require multiple separate components including extrusion limiters, thereby reducing component count while maintaining sealing effectiveness.
Solution Approach 2:
The seal element serves multiple functions simultaneously: it seals against the mandrel, seals against the cones, and provides structural support. This multi-functional design eliminates the need for separate specialized components for each function, reducing overall device complexity.
2Reliability
If conventional plug design with multiple components is used, then sealing reliability is improved, but manufacturing cost increases
Solution Approach 1:
By merging multiple sealing components into a single seal element, the patent reduces the number of parts that need to be manufactured, inventoried, and assembled. This consolidation directly reduces manufacturing costs while maintaining the required sealing reliability through the integrated design.
3Reliability
If conventional plug design with multiple components is used, then sealing reliability is improved, but plug length increases
Solution Approach 1:
The integration of multiple sealing functions into a single compact seal element positioned between the cones eliminates the need for multiple sequential components along the plug length. This consolidation significantly reduces the overall plug length while maintaining effective sealing at all necessary interfaces.
4Reliability
If conventional plug design with multiple components is used, then sealing reliability is improved, but drilling out time increases
Solution Approach 1:
The reduced component count and shorter plug length achieved by merging sealing functions into a single element directly reduce the time required to drill out the plug after wellbore operations. Fewer components mean less material to remove and a more efficient drilling out process.
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 solution results in cost savings, reduced drilling time, and enhanced sealing pressure, with the ability to withstand high stimulation pressures during fracing operations, while using nonmetallic materials for cost-effectiveness.
Implementation Method 1
The seal element is movable between a preset position and a set position, and the movement of the seal element between the preset position and the set position folds the edge of the seal element in a direction from the second end of the seal element towards the first end of the seal element and underneath an outer portion of the seal element
Implementation Method 2
a first cone disposed around the mandrel between the gauge ring and the guide shoe, a second cone disposed around the mandrel between the gauge ring and the guide shoe
Data Source
AI summary
Aspects of the present disclosure relate generally to plug apparatus and methods, and components thereof, for oil and gas wellbores. In one implementation, a plug for oil and gas wellbores includes a mandrel, and a gauge ring disposed around the mandrel. The plug also includes a guide shoe disposed around the mandrel. The plug also includes a first cone, a second cone, and a seal element between the first cone and the second cone. The seal element includes an edge that faces the second cone. The seal element is movable between a preset position and a set position, and the movement of the seal element between the preset position and the set position folds the edge of the seal element in a direction from a second end of the seal element towards a first end of the seal element and underneath an outer portion of the seal element.