Automated Ball-Seat Event Detection in Hydraulic Fracturing
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Solution Overview
Problem
Current hydraulic fracturing processes require manual detection of ball-seat events, which can lead to inefficiencies and potential damage to perforation plugs if the fracturing fluid rate is increased prematurely, or increased treatment time and material usage if detection is delayed.
Innovation Solution
An automated method and system that detect a ball-seat event by analyzing real-time data on volume ratio, slurry rate, slurry rate slope, and pressure change, using historical data comparisons to determine when the ball has seated in the perforation plug, allowing for automatic adjustment of fracturing fluid pressure for the next treatment zone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual detection of ball-seat events is used, then operational flexibility is maintained, but detection precision and reliability deteriorate due to human error and delayed response
Solution Approach 1:
The patent replaces manual visual inspection and mechanical observation methods with an automated computer vision system using cameras and image processing algorithms. This substitution enables precise, real-time detection of ball-seat events without human intervention, resolving the contradiction between detection precision and operational simplicity.
Solution Approach 2:
The system enables self-detection of ball-seat events through automated image capture and analysis. The camera system continuously monitors the wellbore environment and automatically identifies when balls seat in plugs, eliminating the need for manual detection and improving both precision and reliability.
2Productivity
If fracturing fluid rate is increased prematurely, then treatment productivity improves, but harmful effects occur due to potential damage to perforation plugs
Solution Approach 1:
The patent implements a feedback control system where the automated detection of ball-seat events triggers immediate feedback to the fracturing operation. When a ball-seat event is detected, the system automatically signals to adjust the fracturing fluid rate, ensuring productivity increases only after proper seating occurs, thus preventing plug damage while maintaining efficient treatment.
Solution Approach 2:
The system performs preliminary detection and confirmation of ball-seat events before allowing fracturing fluid rate increases. This preliminary action ensures that all necessary conditions are met before proceeding to higher productivity stages, preventing harmful effects from premature rate increases.
3Loss of time
If detection is delayed, then system simplicity is maintained, but loss of time and increased material usage occur
Solution Approach 1:
The patent replaces delayed manual detection with continuous automated video monitoring and real-time image analysis. This substitution reduces detection time significantly by operating continuously without human response delays, directly addressing the time loss issue while accepting the necessary automation level.
Solution Approach 2:
The camera system operates continuously to monitor ball movement and seating events, ensuring no detection gaps occur. This continuous useful action eliminates the intermittent nature of manual detection, reducing overall treatment time and material usage while maintaining appropriate automation.
Data Source
AI summary
This disclosure presents processes for automatically detecting a ball-seat event in a wellbore. The processes can automatically detect a ball-seat event and automatically fracture a formation at a next treatment zone once the ball-seat event has been automatically detected. The processes for automatically detecting the ball-seat event can determine a volume ratio is in a predetermined range and within a minimum and maximum bound, then determine a slurry rate is in a predetermined range and is within a minimum and maximum bound, then determine a slope of a slurry rate is in a predetermined range and within a minimum and maximum bound, and then determine a slope of a pressure change of the fracturing fluid in the wellbore is in a predetermined range and within a minimum and maximum bound.