Rapid Development and Deployment of a High Expansion Retrievable V0 Bridge Plug

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Abstract This paper presents the rapid development of a high expansion retrievable V0-rated bridge plug that effectively leveraged engineering simulation and additive manufacturing to design, optimize, and qualify the new plug in accordance with the ISO14310 and API11D1 standards. This technology was mobilized for deployment into a customer well within less than 12 months. For this project, a major Norwegian continental shelf (NCS) operator required a high expansion wireline retrievable bridge plug with a small outside diameter (OD) that was capable of gas-tight zonal isolation in 7 in. tubing while meeting the ISO14310 and API 11D1 V0 classifications. To address this challenge, several design concepts were developed using computer-aided design (CAD) and simulated using finite element analysis (FEA) to determine the optimal design and to establish the design factor of safety. Initial prototype testing showed unexpected failures of the mechanical backup system as a result of non-uniform loading from the rubber element, which had been assumed to be evenly distributed for the initial FEA. Leveraging FEA to verify the failure mode increased its fidelity and enabled successful generation of alternate solutions with an alternate material, in this case nickel alloy 718. A revised mechanical backup system was manufactured within three weeks using internal direct metal additive manufacturing capability; it was successfully validated within an additional two weeks. The final V0 trials were successfully completed a month later with additively manufactured components, and the technology was mobilized for deployment into the operator’s well within less than 12 months. The successful design, development, and mobilization of the 7-in. high expansion V0-rated bridge plug within only 12 months demonstrates how FEA modeling and additive manufacturing can be successfully leveraged to reduce development timelines while identifying and producing innovative solutions. Speed to market and the delivery of robust solutions on time are becoming more critical in the cost-constrained oil market; consequently, tools such as FEA and additive manufacturing are increasingly becoming fundamental methods for meeting these new challenges, as demonstrated by the 7-in. high expansion V0 bridge plug project. This paper shows how leveraging FEA in conjunction with fundamental testing failure analysis can be critical to overcoming technical challenges. Furthermore, combining these capabilities with additive manufacturing can accelerate timelines and increase the probability of project success and operator satisfaction.