Controlled Aperture Ball Drop for Frac Sequencing
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Solution Overview
Problem
Current frac ball drop systems for well completion and re-completion operations are prone to errors due to manual processes, which can lead to frac balls being dropped out of sequence, and they do not reliably operate in harsh environments with extreme temperatures, abrasive conditions, and high pressures.
Innovation Solution
A controlled aperture ball drop system that includes a ball cartridge with a ball rail and an aperture controller to sequentially release frac balls in a predetermined size sequence, ensuring accurate and reliable operation by controlling the size of the ball drop aperture, and is designed to withstand harsh conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual frac ball dropping is used, then操作简单性 is improved, but 可靠性 deteriorates due to balls being dropped out of sequence
Solution Approach 1:
The system uses the frac fluid pressure itself to automatically push balls out of the cartridge in sequence, eliminating the need for manual intervention while ensuring proper sequencing through the natural pressure-driven flow of the fluid stream
Solution Approach 2:
The patent replaces manual mechanical dropping with an automated system where frac fluid pressure mechanically pushes balls through a restriction orifice, converting manual operation into a pressure-driven automated process that ensures sequence reliability
2Reliability
If automated frac ball injectors are used, then 可靠性 is improved for sequence control, but 设备复杂性 increases
Solution Approach 1:
The patent extracts only the essential sequencing function by using a simple restriction orifice and pressure-driven mechanism, removing complex injector components while maintaining reliable sequence control through the natural frac fluid pressure
Solution Approach 2:
The ball cartridge system serves multiple functions: it stores balls in predetermined sequence, automatically releases them in order using frac fluid pressure, and integrates with the existing frac pump system, eliminating the need for separate complex injector devices
3Device complexity
If traditional ball drop systems are used, then 设备复杂性 is reduced, but 可靠性 deteriorates in harsh environments with extreme temperatures and high pressures
Solution Approach 1:
The system uses a flexible rubber ball design that dynamically adapts to pressure changes and environmental conditions, allowing the balls to maintain their sealing and rolling functions across extreme temperatures and high pressures without requiring complex environmental control systems
Solution Approach 2:
The patent designs the ball cartridge and restriction orifice to operate across varying pressure and temperature parameters, with the system adapting its operation based on the frac fluid conditions rather than requiring fixed operational parameters, ensuring reliability in harsh environments
Data Source
AI summary
A controlled aperture ball drop includes a ball cartridge that is mounted to a frac head or a high pressure fluid conduit. The ball cartridge houses a ball rail having a bottom end that forms an aperture with an inner periphery of the ball cartridge through which frac balls of a frac ball stack supported by the ball rail are sequentially dropped from the frac ball stack as a size of the aperture is increased by an aperture controller operatively connected to the ball rail. A control console displays a user interface that permits an operator to control the controlled aperture ball drop to drop frac balls only when desired.