Modular Fracking Ball Assembly with Interchangeable Outer Shells
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Solution Overview
Problem
Current frac balls are not smart and cannot efficiently measure downhole conditions across various wellbore sizes, leading to high operational costs due to the need for custom manufacturing for each bore size and inadequate data acquisition methods.
Innovation Solution
A modular fracking ball assembly that includes a removable outer shell and a measurement assembly with sensors for pressure and temperature, allowing for interchangeable components to fit different well diameters and specific gravities, enabling cost-effective data collection across multiple well operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If custom manufacturing is used for each bore size, then measurement accuracy for specific well diameters is improved, but manufacturing cost and operational expense increase significantly
Solution Approach 1:
The fracking ball is divided into separate functional modules: a universal measurement assembly containing sensors and electronics, and interchangeable outer shells sized for different bore diameters. This segmentation allows the expensive measurement components to be reused across multiple well sizes while only the simpler outer shells need to be customized for each application.
Solution Approach 2:
The measurement assembly is designed as a universal component that can be paired with multiple outer shells of different sizes. This multi-functionality allows a single measurement assembly to serve multiple wellbore diameters, eliminating the need to manufacture separate complete fracking balls for each bore size and significantly reducing operational costs.
2Loss of information
If smart frac balls with sensors are implemented, then downhole data acquisition capability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The smart fracking ball separates the complex measurement assembly from the simple outer shell structure. The measurement assembly contains all sensors, power sources, and electronics in a self-contained unit, while the outer shell remains a simple protective casing. This segmentation makes the complex components easier to manufacture, test, and replace independently.
Solution Approach 2:
The measurement assembly is nested within the outer shell, with the shock-absorbing layer positioned between them. This nested structure protects the complex electronic components during deployment and retrieval while maintaining relatively simple overall device geometry that is easy to manufacture and handle.
3Adaptability or versatility
If multiple complete fracking balls for different bore sizes are manufactured, then adaptability to various well diameters is improved, but operational cost and resource consumption increase
Solution Approach 1:
A single universal measurement assembly can be paired with multiple outer shells of different diameters, allowing one measurement assembly to serve multiple wellbore sizes. This universality dramatically reduces the number of complete devices that need to be manufactured, stored, and deployed, reducing operational costs while maintaining full adaptability.
Solution Approach 2:
The reusable measurement assembly can be recovered after use with one outer shell and then paired with a different outer shell for the next well. This recovering and reusing of the expensive measurement components across multiple operations significantly reduces the quantity of materials and resources consumed compared to manufacturing complete new fracking balls for each application.
Data Source
AI summary
Embodiments of the modular fracking ball assembly can include, but are not limited to, a measurement assembly, a shock absorbing layer, and an outer shell. The shock absorbing layer can encase the measurement assembly and the outer shell can encase the shock absorbing layer and the measurement assembly. The outer shell of the modular fracking ball assembly can be replaced with another outer shell when a change in parameters of the modular fracking ball assembly is needed. For instance, an overall diameter or a specific gravity of the modular fracking ball assembly can be changed by swapping outer shells.