Expandable Plugging Device for Hydraulic Fracturing
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Solution Overview
Problem
The complexity of stimulation valve systems in hydraulic fracturing processes, particularly in multi-stage fracking, is increased by the need for various ball sizes, leading to complications in assembly and control of fracturing fluid flow along the wellbore.
Innovation Solution
A plugging device with an expandable member, counter, and actuator is deployed, which counts the number of restrictions in a conduit and expands to prevent passage through a target restriction, simplifying the process by using a single size ball and ratcheting mechanism to control fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If progressively smaller ball seats are used in stimulation valves to enable selective actuation by progressively larger balls, then selective sealing of stimulation valves is achieved, but the design complexity increases due to requiring many different valve sizes
Solution Approach 1:
Instead of using progressively smaller ball seats with progressively larger balls, the invention inverts the approach by using progressively larger ball seats with progressively smaller balls. This allows the same single-size ball to be used throughout the wellbore while achieving selective actuation, thereby reducing device complexity while maintaining selective sealing capability
Solution Approach 2:
The invention changes the parameter of ball seat size progression from decreasing to increasing, and changes the ball size from variable to uniform. This parameter transformation enables the use of a single ball size for multiple stages while maintaining selective actuation through the expanded ball seat design
2Ease of operation
If multiple ball sizes are used to actuate stimulation valves at different depths, then selective control of fracturing fluid flow is achieved, but the assembly and control complexity increases
Solution Approach 1:
The invention makes the ball universal by designing it to perform the same function at multiple different depths and valve locations. A single ball size can actuate multiple stimulation valves throughout the wellbore, eliminating the need for different ball sizes and simplifying both assembly and control operations
Solution Approach 2:
The invention introduces dynamic expansion of the ball seat that occurs in response to ball passage. The ball seat expands progressively as the ball passes through, enabling a single ball to selectively actuate multiple valves at different depths without requiring pre-configured different ball sizes
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
This solution reduces the complexity of valve systems by allowing a single-size ball to be used across multiple stages, enhancing control and efficiency in fracturing fluid distribution and preventing fluid flow through specific points in the wellbore.
Implementation Method 1
an expandable member configured to expand from a first, retracted position to a second, expanded position
Implementation Method 2
a counter configured to count a number of restrictions in a conduit that the plugging device passes through
Data Source
AI summary
A plugging device, apparatus, and method. The plugging device includes an expandable member configured to move from a first, retracted position to a second, expanded position, a counter configured to count a number of restrictions in a conduit that the plugging device passes through, and an actuator configured to move the expandable member from the first position to the second position in response to the counter counting a predetermined number of restrictions. The expandable member in the expanded position prevents the plugging device from passing through a target restriction.