Automated Ball Dropper Assembly for Frac Ball Deployment
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Solution Overview
Problem
Conventional methods for dropping a frac ball or plug into a wellbore during frac operations are hazardous and non-productive, requiring manual intervention in a hazardous zone, which poses risks to workers and wastes time.
Innovation Solution
A ball dropper assembly with a main body, magazine assembly, and actuation system that includes a sealing piston and carrier piston, allowing for automated alignment and dropping of frac balls into the wellbore without manual intervention, using a main bore, angle bore, and transverse bore configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual intervention is used to drop the frac ball into the wellbore, then the worker can directly control the placement, but the worker is exposed to hazardous zones and non-productive time increases
Solution Approach 1:
The patent introduces an automated ball dropper assembly as an intermediary device between the worker and the hazardous wellbore environment. The assembly includes a magazine that holds the frac ball, a carrier piston that transports it, and a main bore that delivers it to the wellbore, eliminating the need for workers to enter hazardous zones while maintaining precise placement control
Solution Approach 2:
The patent replaces the manual mechanical system (worker physically dropping the ball) with an automated mechanical system (actuator-driven piston mechanism). The actuator controls the carrier piston to precisely position and release the frac ball through the main bore, substituting human intervention with automated mechanical operation
2Manufacturing precision
If manual intervention is used to drop the frac ball, then the worker can ensure proper placement, but non-productive time increases due to manual assembly and disassembly
Solution Approach 1:
The patent implements preliminary action by pre-loading the frac ball into the magazine before the actual dropping operation. The magazine is prepared in advance, and the actuator system is ready to deploy the ball when needed, eliminating the time-consuming manual assembly and disassembly steps while ensuring proper placement through pre-positioning
Solution Approach 2:
The automated ball dropper assembly performs self-service operations where the actuator automatically controls the carrier piston to position and release the frac ball through the main bore. The system serves itself by automating the entire deployment process, eliminating the need for manual intervention and reducing non-productive time while maintaining placement accuracy
3Productivity
If automated systems are used to deploy the frac ball, then worker safety is improved and productivity increases, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the ball dropper assembly into distinct functional modules: the magazine for holding the frac ball, the carrier piston for transport, the main bore for delivery, and the actuator for control. This modular segmentation manages device complexity by organizing components into separate, manageable units while maintaining overall automated functionality and high productivity
Data Source
AI summary
A ball dropper assembly includes a main body, a sealing piston, and a magazine assembly. The main body includes a main bore, angle bore, and transverse bore formed therethrough. The transverse bore is fluidly coupled to the main bore through the angle bore. The sealing piston is positioned within the transverse bore. Seal rings are positioned between the main body and the sealing piston on either side of the angle bore. The magazine assembly includes a magazine body and a carrier piston. The magazine body is mechanically coupled to the main body. The carrier piston has a carrier hole formed therein and is mechanically coupled to the sealing piston.