Ball Injector for Frac Tree with Horizontal Cartridge
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Solution Overview
Problem
Current ball launch systems for hydrocarbon well stimulation are prone to mechanical failure, operator error, and are costly and complex, leading to inefficient well treatment operations and safety concerns due to their height, weight, and high-pressure exposure.
Innovation Solution
A ball injector system that connects to a frac tree, featuring a pressure-containing injector housing with a ball cartridge assembly and valve members to sequentially deliver balls through a main axial passageway, allowing for remote operation and pressure isolation to ensure safe and efficient ball launch, reducing the overall height and complexity of the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional ball launch systems are used, then balls can be launched into the frac tree, but the systems are prone to mechanical failure and operator error
Solution Approach 1:
The ball launch system is segmented into modular components: a ball cartridge assembly containing multiple balls, a ball launcher with separate valve members for each ball, and a frac tree. This segmentation allows independent operation and reduces the complexity of the overall system while improving reliability through redundancy.
Solution Approach 2:
Balls are pre-loaded into the ball cartridge assembly before the fracing operation begins. The valve members are pre-positioned to control each ball's launch sequence. This preliminary preparation eliminates the need for manual ball loading during high-pressure operations, reducing operator error and mechanical failure risks.
2Reliability
If tall ball launch systems are used, then balls can be delivered to the frac tree, but safety concerns arise due to height, weight, and high-pressure exposure
Solution Approach 1:
The ball cartridge assembly is oriented with balls arranged horizontally rather than vertically stacked. This dimensional change allows the system to maintain ball storage capacity while reducing the vertical height and overall system profile, improving safety by lowering the center of gravity and reducing exposure to high-pressure zones.
Solution Approach 2:
The ball launcher is integrated directly into the frac tree structure, with the ball cartridge assembly positioned within or adjacent to the existing frac tree components. This nesting eliminates the need for separate tall ball launch structures, reducing system height while maintaining functionality.
3Productivity
If sequential ball delivery is implemented, then well treatment operations become more efficient, but system complexity increases
Solution Approach 1:
The valve members are designed to automatically control the sequential release of balls based on pressure differentials and flow conditions within the frac tree. Once activated, the system self-regulates the ball delivery sequence without requiring complex external control mechanisms, maintaining simplicity while achieving efficient sequential operation.
Solution Approach 2:
The system incorporates pressure sensors and flow indicators that provide feedback on the position and status of each ball in the launch sequence. This feedback mechanism allows the control system to adjust valve operation timing and ensure proper ball delivery without requiring complex manual coordination, improving efficiency while keeping the control system relatively simple.
Data Source
AI summary
A ball injector for connecting below the frac head of a frac tree to accommodate and sequentially drop a ball into the axial passageway of the frac tree. The ball injector has an axial passage of an injector housing aligned with the axial passageway of the frac tree. A ball cartridge assembly stores one or more balls and sequentially delivers one ball to a port in the ball cartridge assembly. A ball launch side arm extends from the injector housing and forms a ball launch passageway communicating between the ball cartridge port and the axial passage. A first valve member in the ball launch passageway is opened to pass the ball into the axial passage, and is closed to isolate the ball cartridge assembly from a pressure in the axial passage. A second valve member between the first valve member and the ball cartridge assembly may be included to form a pressure isolation chamber between the valve members. Embodiments of ball cartridge assemblies to horizontally store a plurality of balls is provided. Also provided is a method of delivering a ball into a frac tree below the frac head, and a method of delivering and monitoring a ball progression into the frac tree, for example with a camera.