Modular Ball Drop for Simultaneous Frac Injection
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Solution Overview
Problem
Current methods for hydrocarbon well stimulation require multiple size-graduated frac balls, leading to issues with small diameter frac balls being fragile and prone to getting trapped, and existing ball drops are unable to simultaneously inject multiple balls of the same diameter, affecting fluid throughput and efficiency.
Innovation Solution
A modular ball drop system with a tubular body and actuator stem lock mechanism that allows for simultaneous injection of multiple frac balls of the same diameter, featuring a ball retainer mechanism that automatically locks in the released position to prevent obstruction of subsequent drops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple size-graduated frac balls are used to stimulate multiple zones, then the stimulation process can be completed, but the diameter of the frac balls decreases and they become more fragile and prone to getting trapped
Solution Approach 1:
The invention divides the frac balls into multiple groups, where each group contains multiple balls of the same diameter. This segmentation allows the system to maintain larger, more reliable ball diameters while still stimulating multiple zones by injecting multiple groups sequentially or simultaneously.
Solution Approach 2:
The ball retainer mechanism is pre-loaded with multiple frac balls of the same diameter before injection. This preliminary preparation ensures that when the retention mechanism releases, multiple balls are injected simultaneously, eliminating the need to use progressively smaller balls for different zones.
2Productivity
If multiple frac balls of the same diameter are injected simultaneously, then fluid throughput is improved, but existing ball drops are unable to accomplish this task
Solution Approach 1:
The invention employs a dynamic ball retainer mechanism that can transition from a retained state to a released state, enabling controlled simultaneous injection of multiple balls. The actuator stem lock mechanism provides dynamic locking and release capabilities that existing static ball drops lack.
Solution Approach 2:
The actuator stem lock mechanism serves as an intermediary component that controls the release of the ball retainer mechanism. This intermediary device enables the simultaneous injection of multiple balls by mediating between the control system and the ball retention/release function.
3Adaptability or versatility
If the frac ball seat orifice is made smaller to accommodate smaller frac balls, then the stimulation of multiple zones is enabled, but the rate at which frac fluid can be pumped into the associated zone is affected
Solution Approach 1:
By segmenting the frac balls into multiple groups of the same diameter, the invention allows each ball to pass through adequately sized seat orifices, maintaining high fluid pump rates while still enabling multi-zone stimulation through the injection of multiple ball groups.
Data Source
AI summary
A modular ball drop made up of two or more identical ball drop modules that are vertically stacked in a desired number. Each ball drop module can drop one or more frac balls into a fluid stream being pumped into a well.