Ball Release Tool for Frack Plug Object Retention
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Solution Overview
Problem
In plug and perforate systems, if perforating guns misfire, the replacement guns cannot be delivered through the isolation device using pressure or flow assist due to the frack plug object obstructing the passage, leading to costly and time-consuming alternative methods like coiled tubing or tractors, especially in horizontal wellbores.
Innovation Solution
A ball release tool is placed near the frack plug, retaining the object until the guns fire, allowing it to be released by the pressure spike, keeping the passage open for replacement gun delivery if misfires occur, and enabling larger objects and passages for faster replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the object is delivered with the isolation device, then the passage is closed quickly, but replacement guns cannot be delivered with pressure or flow assist if guns misfire
Solution Approach 1:
The object is preliminarily positioned in the launch tube adjacent to the isolation device, ready for immediate release. The launch tube is pre-installed in the BHA with the object contained within, so that upon gun firing, the object can be rapidly released into the passage to close it. This preliminary positioning enables both quick passage closure and maintains the ability to deliver replacement guns if needed, as the object release is triggered only after successful gun firing.
2Adaptability or versatility
If the object is pumped from the surface to the seat, then the passage remains open for replacement guns, but it takes time and additional fluid displacement
Solution Approach 1:
The object delivery function is extracted from the surface pumping operation and integrated into the bottom hole assembly. The object is loaded into the launch tube at the surface, but the actual delivery and release occur downhole adjacent to the isolation device. This extraction eliminates the need to pump the object from the surface through thousands of meters of wellbore, saving time and fluid displacement while maintaining passage openness for replacement gun delivery until the object is released.
3Ease of operation
If a ball release device is placed above the guns, then the object can be released after firing, but the object may not fit in the annular space or may be damaged by gun burrs
Solution Approach 1:
The launch tube serves as an intermediary structure between the object and the wellbore annulus. The object is contained within the protected environment of the launch tube during delivery, avoiding contact with gun burrs and sharp edges. The launch tube provides a controlled release mechanism where the object is ejected directly into the isolation device passage, bypassing the constrained annular space above the guns. This intermediary structure eliminates the harmful effects of annular space constraints and physical damage from gun imperfections.
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
Enables efficient delivery of replacement guns using wireline flow assist by maintaining an open passage in the isolation device, reducing operational costs and time, and allowing the fracturing process to continue even if initial guns misfire.
Implementation Method 1
retaining the object until the guns fire, allowing it to be released by the pressure spike
Data Source
AI summary
In a fracking context the object that will ultimately block a passage in an isolation device is introduced into the zone with the bottom hole assembly. The object is not released until the guns fire to create a pressure spike in the borehole that triggers the object retaining device to release the object. The retaining device is placed in close proximity to the isolation device and its setting tool to allow a larger object and passage in the isolation device to be used. If the guns misfire, the object is not released and comes out with the guns. The replacement guns can be pumped in because the passage in the isolation device has stayed open during the misfire. Direct and indirect object release in response to pressure created from the firing of the guns is contemplated.