Tunable Down-Hole Stimulation Array for Vibration Control
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Solution Overview
Problem
Conventional frac pumps experience high failure rates due to fatigue-related damage from mechanical shocks and vibration-induced resonance, particularly in high-pressure applications, leading to inefficient well stimulation and reduced productivity in unconventional formations.
Innovation Solution
The implementation of tunable stimulation systems that alter check valve closure mechanics to reduce mechanical shock and shift vibration spectra, combined with closed-loop control of down-hole stimulators to tailor impulse-generated vibration for optimized geologic fracturing and fluid flow, utilizing programmable controllers and frac diagnostics for real-time feedback and adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional high-pressure frac pumps are used for hydraulic stimulation, then well stimulation can be performed, but fatigue-related damage from mechanical shocks and vibration-induced resonance causes high fluid end failure rates
Solution Approach 1:
The patent applies dynamics by making the check valve closure mechanics adjustable and tunable. The valve design allows dynamic adjustment of closure characteristics to reduce mechanical shock and control vibration spectra, transforming a static failure-prone system into a dynamically controllable one that adapts to minimize harmful vibrations while maintaining pumping function.
Solution Approach 2:
The patent changes physical parameters of the check valve system, specifically modifying closure mechanics and vibration characteristics. By altering valve closure parameters and vibration spectra through tunable designs, the system reduces mechanical shock intensity and shifts vibration frequencies away from resonant conditions, thereby reducing fatigue damage and improving reliability.
2Adaptability or versatility
If broad-spectrum impulse-generated vibration is used for stimulation, then a range of vibration frequencies are produced, but this excites destructive resonances in fluid end components leading to fatigue-related cracking
Solution Approach 1:
The patent makes the vibration spectrum dynamically tunable by adjusting check valve closure mechanics. The system can adapt the vibration frequency spectrum in real-time to match or avoid resonant conditions in fluid end components, transforming a static broad-spectrum problem into a dynamically controllable one that selectively excites or suppresses specific frequencies as needed.
Solution Approach 2:
The patent applies mechanical vibration principles by using impulse-generated vibration for stimulation while controlling the vibration spectra through tunable valve designs. The system generates controlled mechanical vibrations to achieve stimulation objectives while suppressing harmful resonances through strategic frequency tuning and vibration spectrum management.
3Productivity
If high down-hole hydraulic pressures are applied for rock fracturing, then channels are opened in the rock, but vibration-induced cracking is exacerbated without controlled vibration
Solution Approach 1:
The patent converts harmful vibration into beneficial stimulation by using controlled impulse-generated vibration to enhance rock fracturing. The tunable vibration system transforms what would be destructive random vibrations into controlled mechanical energy that promotes channel formation and proppant generation, turning a harmful factor into a productive tool for well stimulation.
Solution Approach 2:
The patent applies mechanical vibration to enhance hydraulic fracturing by superimposing controlled vibration frequencies on the high-pressure stimulation process. This combination of hydraulic pressure and tuned vibration accelerates rock fracturing and channel opening, improving stimulation efficiency while the tunable system prevents harmful resonances from causing unwanted cracking.
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 approach enhances frac pump reliability, increases well productivity, and achieves more efficient and localized stimulation by minimizing vibration-induced cracking and optimizing energy distribution for effective rock fracturing and proppant generation, leading to improved hydraulic fracturing outcomes.
Implementation Method 1
a hammer element responsive to the driver element for striking the fluid interface and rebounding therefrom during a corresponding adjustable rebound cycle time to transmit a corresponding vibration burst comprising a plurality of transmitted frequencies via the hydraulic environment
Implementation Method 2
A driver element reversibly seals the second end, and a hammer element is longitudinally movable within the housing between the driver element and the fluid interface
Data Source
AI summary
Tunable down-hole stimulation arrays feature closed-loop control of spatial arrays comprising several connected stimulators. Each stimulator is responsive to a timed activation signal. Stimulators periodically transmit bursts comprising a plurality of vibration frequencies, each burst having an adjustable power spectral density (PSD) that is tunable via an adjustable rebound cycle time. Rebound cycle times also affect vibration interference among array stimulators, while simultaneous or sequential timed activation signals from a programmable controller affect directional propagation of combined vibration wave fronts from an array. Stimulator PSD's are adjusted for resonance excitation and fracturing of adjacent geologic materials. Closed-loop feedback control incorporates backscatter vibration from stimulated geologic material. As fracturing proceeds to smaller (proppant-sized) fragments having higher resonant frequencies, PSD's are up-shifted, increasing relative power in higher vibration frequencies. Progressive geologic stimulation is optimized, with inherent potential for plain-water fracs completed with self-generated proppant.