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<p>In unconventional oil and gas wells at great depths, casing deformation occurs frequently and to a significant degree, posing high demands on the passability, expansibility, and anchoring capability of soluble bridge plugs. Most existing bridge plug products have a diameter of 70&#xa0;mm or more, with a maximum expansion rate of no more than 40%. Therefore, an ultra-small diameter all-metal soluble bridge plug suitable for casing deformation wells with severe deformation has been proposed. Based on clamp ring fracture mechanics and slip anchoring mechanics analysis, indoor tests on anchoring, releasing, and pressure-bearing capabilities of the ultra-small diameter all-metal soluble bridge plug were conducted. The failure behaviors of the spiral slip seat and clamp ring fracture were analyzed. The numerical simulation method was used to optimize the structure. Then the feasibility of the structural principle of the ultra-small diameter all-metal soluble bridge plug was verified by laboratory tests. The research results indicate: (1) The maximum outer diameter of the ultra-small diameter all-metal soluble bridge plug is only 50&#xa0;mm, which has excellent passability and expansibility. After expansion, it can effectively block off a casing with an inner diameter of 114.3&#xa0;mm, achieving an expansion rate of over 128%. (2) The structure principle of the ultra-small diameter all-metal soluble bridge plug is reliable, the spiral slip seat expands evenly, the anchoring force can reach 56.8&#xa0;kN. It can withstand a pressure of 200&#xa0;kN without failure. (3) The recommended pitch of expansion cone III is 140&#xa0;mm. The recommended pitch of the spiral slip seat is 80&#xa0;mm. The number of spiral circles is 1.5. The use of tungsten carbide bonding technology for the spiral slip seat can prevent failure in the anchoring area, thereby enhancing the anchoring performance of ultra-small diameter soluble bridge plug. The research results can provide theoretical guidance and reference for the design and development of ultra-small diameter bridge plugs.</p>

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Failure Analysis and Development of Ultra-Small Diameter All-Metal Soluble Bridge Plug for Severely Casing Deformation Wells

  • 期刊论文

  • 发表日期：

    2026年1月22日

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  • Changshuai Shi,
  • Ao Wang,
  • Xiaohua Zhu,
  • Wenzhe Li,
  • Chenggang Yu

摘要

In unconventional oil and gas wells at great depths, casing deformation occurs frequently and to a significant degree, posing high demands on the passability, expansibility, and anchoring capability of soluble bridge plugs. Most existing bridge plug products have a diameter of 70 mm or more, with a maximum expansion rate of no more than 40%. Therefore, an ultra-small diameter all-metal soluble bridge plug suitable for casing deformation wells with severe deformation has been proposed. Based on clamp ring fracture mechanics and slip anchoring mechanics analysis, indoor tests on anchoring, releasing, and pressure-bearing capabilities of the ultra-small diameter all-metal soluble bridge plug were conducted. The failure behaviors of the spiral slip seat and clamp ring fracture were analyzed. The numerical simulation method was used to optimize the structure. Then the feasibility of the structural principle of the ultra-small diameter all-metal soluble bridge plug was verified by laboratory tests. The research results indicate: (1) The maximum outer diameter of the ultra-small diameter all-metal soluble bridge plug is only 50 mm, which has excellent passability and expansibility. After expansion, it can effectively block off a casing with an inner diameter of 114.3 mm, achieving an expansion rate of over 128%. (2) The structure principle of the ultra-small diameter all-metal soluble bridge plug is reliable, the spiral slip seat expands evenly, the anchoring force can reach 56.8 kN. It can withstand a pressure of 200 kN without failure. (3) The recommended pitch of expansion cone III is 140 mm. The recommended pitch of the spiral slip seat is 80 mm. The number of spiral circles is 1.5. The use of tungsten carbide bonding technology for the spiral slip seat can prevent failure in the anchoring area, thereby enhancing the anchoring performance of ultra-small diameter soluble bridge plug. The research results can provide theoretical guidance and reference for the design and development of ultra-small diameter bridge plugs.