Atmosphere-to-Pressure Ball Drop Apparatus for Hydraulic Fracturing
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Solution Overview
Problem
Existing ball drop injection assemblies for hydraulic fracturing operations require manual handling of frac balls, which is time-consuming and hazardous, and struggle with storing and injecting frac balls of varying sizes without increasing the assembly height or requiring temperature control.
Innovation Solution
A ball drop apparatus with a pressure equalization section and seal packs that allows for dry storage and flexible injection of frac balls of varying sizes, using an atmosphere-to-pressure ball injection chamber and injection ram assembly to manage pressure and fluid flow, enabling sequential injection without height increase or temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual handling of frac balls is used, then flexibility in ball injection is maintained, but time consumption and safety hazards increase
Solution Approach 1:
The ball drop assembly automatically feeds frac balls from a storage container through the wellhead without requiring manual handling. The system uses gravity and mechanical components to self-feed balls into the wellbore, eliminating the need for personnel to manually place balls while maintaining operational flexibility
Solution Approach 2:
A mechanical ball feeding mechanism acts as an intermediary between the ball storage container and the wellbore. This intermediary system automatically transfers balls without direct human contact, reducing both time consumption and safety hazards associated with manual handling
2Reliability
If frac balls are stored in fluid with temperature control, then ball integrity is maintained, but system complexity and operational requirements increase
Solution Approach 1:
The patent changes the storage parameters from fluid-based with temperature control to dry atmospheric storage. Dissolvable frac balls are stored in a dry container at atmospheric pressure and temperature, eliminating the need for temperature control systems while maintaining ball integrity through proper material selection and storage design
Solution Approach 2:
The patent extracts the temperature control requirement and fluid storage system from the ball storage process. By using dissolvable balls that can be stored dry at atmospheric conditions, the complex temperature control infrastructure is completely removed, simplifying the overall system
3Productivity
If balls of similar sizes are injected sequentially, then injection efficiency is improved, but assembly height must be increased
Solution Approach 1:
The ball feeding mechanism is designed to be adjustable and dynamic, allowing it to accommodate balls of similar sizes in sequence without requiring fixed positioning for each ball size. The mechanism can adapt its feeding position and geometry to handle sequential injection of substantially similar ball sizes without increasing assembly height
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
Facilitates safe, efficient, and flexible injection of frac balls, maintaining the integrity of dissolvable balls by storing them dry and under atmospheric pressure, reducing manual labor and assembly height, while ensuring consistent results.
Implementation Method 1
the pressure equalization apparatus then applies pressure to the pressure equalization section, causing the pressure within the section to increase until it reaches at or near wellbore pressure
Implementation Method 2
The atmosphere-to-pressure ball injection chamber and frac ball are then pushed through a first seal pack and into the pressure equalization section by hydraulics connected to the injection ram assembly
Data Source
AI summary
An improved ball drop apparatus including an atmosphere-to-pressure frac ball injection chamber. A ball is first inserted into the atmosphere-to-pressure ball injection chamber from a ball feeding apparatus. The ball is then pushed into a pressure equalization section through a first seal pack. In a preferred embodiment, the pressure equalization section is connected to a pressure equalization apparatus and also to the wellbore through a second seal pack. Once the ball is injected into the pressure equalization section, the pressure equalization apparatus applies pressure, thereby causing the pressure of the pressure equalization section to increase until it reaches close to wellbore pressure. Once the pressures of the pressure equalization section and the wellbore are close, the atmosphere-to-pressure frac ball injection chamber and the frac ball are pushed through the second seal pack and into the wellbore, where the frac ball can be pumped downhole. The atmosphere-to-pressure ball injection chamber is then retracted into the pressure equalization section. The pressure equalization section can then be returned to atmospheric or close to atmospheric pressure by the pressure equalization apparatus. The ball injection chamber is then returned to a ball loading position where it may again be loaded by a ball feeding apparatus.