Frac Dart Counting System for Wellbore Sequencing
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Solution Overview
Problem
In the resource recovery industry, the introduction of objects like balls and darts into a string can lead to production delays due to size discrepancies and incorrect sequencing, causing portions of the wellbore to become temporarily unreachable, resulting in costly production interruptions.
Innovation Solution
A frac dart with a sleeve counting system that includes a cutter support, a moveable cutter, and a counter support, which counts and registers each frac sleeve passed, preventing further passage after a selected number, ensuring correct alignment and reducing installation errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple objects are dropped into the string to activate downhole devices, then the ability to activate multiple devices is improved, but the risk of size discrepancies and incorrect sequencing increases, causing portions of the wellbore to become temporarily unreachable
Solution Approach 1:
The frac dart incorporates a counting system that provides feedback on the number of frac sleeves passed. A counter member with indicia (such as windows or openings) displays the count, allowing operators to monitor progress in real-time. This feedback mechanism ensures correct sequencing by confirming that the dart has passed through the intended number of sleeves before activating the next device.
Solution Approach 2:
The patent replaces manual counting and tracking methods with an automated mechanical counting system. The counter member mechanically advances with each frac sleeve passed, and indicators automatically display the current count. This substitution eliminates human error in tracking and ensures accurate sequencing without requiring manual intervention.
2Productivity
If objects are dropped into the string, then downhole devices can be activated, but production delays occur due to incorrect sequencing or size issues requiring removal and reinstallation
Solution Approach 1:
The counting system is pre-configured on the frac dart before deployment. The counter member and indicia are installed in advance, allowing operators to know exactly how many sleeves have been passed and what the correct sequencing should be. This preliminary preparation prevents delays by eliminating the need to stop and determine the correct sequence during the operation.
Solution Approach 2:
The frac dart self-monitors its own progress through the string via the counting system. The counter automatically tracks the number of sleeves passed and displays the information, allowing the device to provide its own sequencing information without requiring external tracking or manual counting. This self-service capability prevents delays by providing real-time status information.
3Ease of operation
If a seat is out of order or an object is dropped out of sequence, then portions of the wellbore become temporarily unreachable, but removing portions of the string and restarting increases complexity and time loss
Solution Approach 1:
The counting system provides continuous feedback on the dart's position relative to frac sleeves. By displaying the number of sleeves passed, operators can determine whether the dart is at the correct position without needing to physically inspect or manipulate the string. This feedback maintains wellbore accessibility by providing clear positional information.
Solution Approach 2:
The indicia on the counter member may use visual changes such as color differences, transparent vs. opaque sections, or differently colored windows to indicate the current count and status. These visual changes provide immediate, easy-to-interpret information about the dart's position and whether it has passed through the correct number of sleeves, maintaining operational simplicity.
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
The frac dart system simplifies the introduction of objects into the wellbore by ensuring correct sequencing and uniformity of frac sleeves, reducing production delays and rig time by preventing incorrect seating and allowing for easy removal or modification of the frac dart.
Implementation Method 1
The cutter is operable to sever a portion of the counter
Data Source
AI summary
A frac dart includes a body having an outer surface and an end including at least one opening. A cutter support is mounted at the end adjacent the at least one opening. A cutter is moveably mounted at the cutter support. A counter support is slideably mounted on the outer surface, and a counter is arranged between the counter support and the cutter support. The cutter is operable to sever a portion of the counter.