Ball Drop Wellhead Control Apparatus Sequence Error Prevention
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Solution Overview
Problem
Current ball-actuated frac sleeve systems require expensive remediation when frac balls are dropped out of sequence, leading to inefficient well stimulation and increased costs due to unfractured zones.
Innovation Solution
A ball drop wellhead control apparatus with a control body and control ball that obstructs frac balls from entering the fluid stream until manually released, ensuring only the correct ball is dropped and preventing sequence errors or malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a ball-actuated frac sleeve system is used to improve well stimulation efficiency, then productivity is improved, but reliability deteriorates when frac balls are dropped out of sequence requiring expensive remediation
Solution Approach 1:
A control ball is introduced as an intermediary component between the frac ball drop system and the frac sleeves. This control ball acts as a mediator that must be manually rotated to align its outlet port with the central passage, thereby controlling the release of frac balls into the fluid stream. This intermediary mechanism prevents unauthorized or premature frac ball deployment, ensuring that frac balls are only released when the control ball is properly positioned, thus maintaining both productivity and reliability
2Productivity
If automated ball drop systems are used to increase productivity, then productivity is improved, but device complexity increases leading to higher costs
Solution Approach 1:
The control ball system is designed to be manually operated rather than requiring complex automated control systems. The control ball itself serves as the control mechanism, where manual rotation of the control ball by an operator aligns the outlet port with the central passage to release frac balls. This self-service approach allows the system to maintain high productivity through rapid manual operation while avoiding the complexity and cost of automated control systems, sensors, and actuators
3Ease of operation
If frac balls are released without control to maintain continuous fluid stream operation, then ease of operation is improved, but reliability deteriorates due to sequence errors
Solution Approach 1:
The control ball is pre-positioned in a closed position where its body obstructs the central passage, preventing frac balls from entering the fluid stream. Before frac balls can be released, the operator must manually rotate the control ball to align the outlet port with the central passage. This preliminary action of manually positioning the control ball ensures that frac balls are only released when intentionally commanded, maintaining reliable sequence control while allowing continuous pumping operation to proceed without interruption
Data Source
AI summary
A ball drop wellhead control apparatus provides a control ball between a frac ball drop or frac ball injector used to drop frac balls into a frac fluid stream being pumped into a subterranean well to ensure that only frac balls intended to be dropped reach the frac fluid stream.