CA2914395A1 - Apparatus for ball catching - Google Patents

Abstract

There is provided an apparatus for ball catching and a system including the apparatus. The apparatus includes a means for receiving and delivering fluid, a means for receiving a ball, a means for preventing passage of the ball and a plunger. The apparatus is generally configured to collect balls while preventing the passage of the at least one ball during collection of balls from the chamber and allow for removal of collected balls without disrupting the fluid flow. The system includes a frac tree configured to connect to a wellhead, a ball catcher, and downstream equipment.

Description

APPARATUS FOR BALL CATCHING
Cross-Reference to Related Applications This application claims priority from Canadian Patent Application 2,876,608, filed Jan. 6, 2015, the contents all of which are incorporated herein by reference.
Technical Field [0001]
This disclosure relates in general to an apparatus for oil and gas recovery and, in particular, to an improved apparatus for ball catching during oil and gas recovery operations.
Background of the Disclosure

[0002]
Hydraulic fracturing (also referred to as fracking) is a technique used to improve recovery rates in oil and gas wells. Typically, fracking involves pumping a fluid containing a proppant (e.g. sand, ceramic beads) down the well and into the formation from which oil or gas is to be recovered. The fluid creates or enlarges fissures in the formation, and the proppant prevents the fissures from closing when pumping of the fluid ceases. After the pumping of fracking fluid down the well ceases, well fluid, which may contain oil or gas, is allowed to flow up the well for recovery.

[0003]
In some well operations, it is desirable to isolate different zones of the formation through which the well extends before pumping fracturing fluid down the well, in order to fracture only a particular zone. The above-mentioned isolation is often achieved by inserting frac balls into the well. The frac balls, carried down the well by the fracturing fluid, seal against seats within the well casing, and actuate devices which restrict the fracturing fluid contact to only the desired portion or stage of the well. Once the fracking operation is complete, the well fluid flowing up the well carries the frac balls with it.

[0004]
When the well fluid and frac balls reach the frac tree connected to the top of the well, they are directed to a ball catcher mechanism, which generally includes a horizontal member extending from the well, and a vertical chamber depending from the horizontal member. The well fluid and frac balls flow from the well through the horizontal member, and the frac balls fall into the vertical chamber while well fluid flows to downstream equipment. The ball catcher can then be isolated from the horizontal member and the balls can be recovered.

[0005]
In known solutions of separating debris and/or balls from a fluid flow, a screen or filter is used within the flow line to catch the debris and/or balls. This screen or filter may be designed with holes that are small enough to prevent debris and/or balls from passing and thus removing the debris and/or balls from the fluid flow. Some prior art designs exist which allow for removal of debris and/or balls from the screen without stopping the fluid flow.

[0006]
For example, U.S. Patent No. 2,977,616 discloses a pig ball receiver 10 adapted to receive or recover a pig ball 11 from a flow line 12 as shown in FIGS. 1 and 2. The principal purpose of the pig ball 11 is to remove deposits from the walls of the flow line 12. FIG. 1 shows the pig ball receiver 10 with a valve 13 in a first position for receiving the pig ball 11. FIG. 2 shows the pig ball receiver 10 with the valve 13 in a second position for preventing flow into a receiver housing 14 to allow for removal of the pig ball 11.

[0007]
As another example, Canadian patent 2,635,852 discloses a ball catcher 15 fluidly connected to a wellhead port 16 to receive well bore fluids and balls 17 carried therewith, as shown in FIG. 3. The ball catcher 15 includes an isolation valve 18 to isolate the ball recovery chamber 19 temporarily from the catcher body 20 for servicing.

[0008] Examples of a disadvantage with known techniques is that designs using a plunger, such as the one illustrated in FIGS. 1 and 2, expose the internal components, such as the thread of the valve, to the fluid flow. Other embodiments, such as the one shown in Figure 3, are generally more complicated and involve increased expense, and weight.
Summary

[0009]
In an aspect, there is provided an apparatus for ball catching. The apparatus includes a body having an inlet for receiving fluid and at least one ball, a fluid outlet for permitting fluid to exit the body, and a ball-collection outlet for accommodating at least one ball. In addition, the apparatus includes a chamber in communication with the ball-collection outlet, the chamber for receiving the at least one ball. Furthermore, the apparatus includes a blockage disposed within the fluid outlet, the blockage configured to prevent the passage of at least one ball through the fluid outlet and encourage at least one ball toward the ball-collection outline and configured to permit the passage of fluid through the fluid outlet. The apparatus also includes a plunger moveable between an open position and a closed position, wherein the closed prevents at least one ball and fluid from entering the ball-collection outlet, prevents at least one ball from entering the fluid outlet, and permits fluid to exit the body through the fluid outlet.
The apparatus provides a means for sealing the chamber while preventing the passage of the at least one ball during collection of balls from the chamber.

[0010] In certain embodiments, the apparatus may include a wing valve connected to the body for controlling flow of the fluid.

[0011] In certain embodiments, the wing valve may be connected upstream from the body.

[0012] In certain embodiments, the apparatus may include a drain valve connected to the chamber, the drain valve for relieving pressure within the chamber.

[0013] In certain embodiments, the chamber may include a cleanout port for removing at least one ball from the chamber.

[0014] In certain embodiments, the plunger may be perforated.

[0015] In certain embodiments, the plunger may be configured to allow fluid to flow from the inlet, around at least a portion of the plunger, and through the fluid outlet.

[0016] In certain embodiments, the apparatus may include a non-rising valve stem

[0017] In certain embodiments, the non-rising valve stem may include a thread, the thread isolated from the fluid flowing through the body to reduce wear.

[0018] In certain embodiments, the plunger may be configured to discourage fluid from contacting the non-rising valve stem.

[0019] In certain embodiments, the plunger may include at an upper seal and a lower seal.

[0020] In certain embodiments, the blockage may be welded to the body.

[0021] In certain embodiments, the blockage may include a screen that includes holes for allowing the fluid and at least some debris to pass through the screen.

[0022] In another aspect, there is provided an apparatus for ball catching.
The apparatus includes means for receiving fluid and at least one ball at an inlet. In addition, the apparatus includes means for permitting fluid to exit the body via a fluid outlet.
Furthermore, the apparatus includes means for permitting at least one ball to enter a chamber via a ball-collection outlet, the chamber in communication with the ball-collection outlet. The apparatus further includes means for preventing the passage of the at least one ball through the fluid outlet.
The apparatus also includes a plunger moveable between an open position and a closed position, wherein the closed position prevents at least one ball and fluid from entering the ball-collection outlet, prevents at least one ball from entering the fluid outlet, and permits fluid to exit the body through the fluid outlet. The apparatus provides a means for sealing the chamber while preventing the passage of the at least one ball during collection of balls from the chamber.

[0023] In certain embodiments, the apparatus may further include means for controlling flow of the fluid.

[0024] In certain embodiments, the means for controlling flow of the fluid may be connected upstream from the body.

[0025] In certain embodiments, the apparatus may further include means for relieving pressure within the chamber.

[0026] In certain embodiments, the apparatus may further include means for the fluid to flow through the body and through the fluid outlet.

[0027] In certain embodiments, the apparatus may further include non-rising control means for controlling the plunger.

[0028] In certain embodiments, the apparatus may further include means for discouraging fluid from contacting the non-rising control means to reduce wear.

[0029] In certain embodiments, the plunger may be configured to prevent fluid from contacting the non-rising valve stem when the plunger is in the closed position.

[0030] In certain embodiments, the apparatus may further include means for supporting the plunger at an upper seal and a lower seal when the plunger is in the closed position.

[0031] In certain embodiments, the apparatus may further include means for fixing the screen to the body.

[0032] In certain embodiments, the apparatus may further include means for allowing the fluid and at least some debris to pass through the fluid outlet.

[0033] In another aspect, there is provided a system for hydraulic fracturing of a well. The system includes a frac tree configured to connect to a wellhead of the well and configured to receive fluid and at least one ball from the wellhead. The system also includes a ball catcher connected to the frac tree. The ball catcher includes a body having an inlet for receiving the fluid and at least one ball from the frac tree, a fluid outlet for accommodating, and a ball-collection outlet for delivering the at least one ball; a chamber in communication with the ball-collection outlet, the chamber for receiving the at least one ball; a blockage disposed within the fluid outlet, the blockage configured to prevent the passage of at least one ball through the fluid outlet and encourage at least one ball toward the ball collection outlet and configured to permit the passage of fluid through the fluid outlet; and a plunger moveable between an open position and a closed position, wherein the closed position prevents at least one ball and fluid from entering the ball-collection outlet, prevents at least one ball from entering the fluid outlet, and permits fluid to exit the body through the fluid outlet. The system further includes downstream equipment connected to the fluid outlet of the ball catcher, the downstream equipment configured to process fluid. The system connects to a wellhead and provides a means for collecting balls with the ball catcher during hydraulic fracturing.

[0034]
Other aspects, features, and advantages will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, which are a part of this disclosure and which illustrate, by way of example, principles of the inventions disclosed.
Description of the Figures

[0035] The accompanying drawings facilitate an understanding of the various embodiments:

[0036] FIG 1 is a schematic representation of an example of a prior art apparatus in an open position;

[0037] FIG 2 is a schematic representation of the prior art apparatus of FIG.
1 in an closed position;

[0038] FIG 3 is a schematic representation of another example of a prior art apparatus in an open position;

[0039] FIG 4 is a schematic representation of an apparatus in an open position in accordance with an embodiment;

[0040] FIG 5 is a schematic representation of the apparatus of FIG. 4 in a closed position;

[0041] FIG 6 is a schematic representation of an apparatus in an open position in accordance with another embodiment;

[0042] FIG 7 is a schematic representation of the apparatus of FIG. 6 in a closed position;

[0043] FIG 8a is a front view of a screen of the apparatus of FIG. 6;

[0044] FIG 8b is a side view of a screen of the apparatus of FIG. 6;

[0045] FIG 9 is a schematic representation showing the assembly of the apparatus of FIG. 6 in accordance with an embodiment;

[0046] FIG 10 is a schematic representation of an apparatus in an open position in accordance with another embodiment;

[0047] FIG 11 is a schematic representation of the apparatus of FIG. 10 in a closed position;

[0048] FIG 12 is a schematic representation of the front cross sectional view of the apparatus of FIG. 10 in a closed position;

[0049] FIG 13 is a schematic representation of an apparatus in an open position in accordance with another embodiment;

[0050] FIG 14 is a schematic representation of the apparatus of FIG. 13 in a closed position;

[0051] FIG 15a is a schematic representation of the apparatus of FIG. 13 in a partially open position;

[0052] FIG 15b is a zoomed view of the plunger of FIG. 15a;

[0053] FIG 16 is a schematic representation of the apparatus of FIG. 13 in another partially open position; and

[0054] FIG 17 is a schematic representation of a system for hydraulic fracturing in accordance with an embodiment.
Detailed Description

[0055] Referring now to FIG. 4, an apparatus for ball catching is shown generally at 50. It is to be understood that the apparatus 50 is purely exemplary, and that variations are contemplated.
The apparatus 50 includes a body 52, a chamber 54, a plunger 56, and a screen 58.

[0056] In the present embodiment, the body 52 includes an inlet 60 for receiving fluid flow A
and at least one ball 90 carried by the fluid. It is to be appreciated that the fluid flow A is not particularly limited and can be a liquid or gas and can contain solids, such as debris or proppant.
The body 52 also includes a fluid outlet 62 for permitting fluid to exit body 52. In the present embodiment, the frac ball 90 is separated from fluid that exits body 52, and fluid that exits body 52 is generally delivered to testers or any other piece of downstream equipment. The body 52 further includes a ball-collection outlet 64 for accommodating a ball 90 that, for example, has been separated from fluid that exits body 52. During operation, one or more balls 90 are carried by fluid flowing into the inlet 60.

[0057] The chamber 54 is in communication with the ball-collection outlet 64.
In the present embodiment, the chamber 54 is configured to receive balls 90 via the ball-collection outlet 64.

The chamber 54 can be constructed of any material or from any design that can provide sufficient mechanical properties to sustain the pressure. In the present embodiment, the chamber also optionally includes a drain valve 66 generally configured to relieve pressure within the chamber 54. The chamber further optionally includes a cleanout port 68 generally configured to allow for removal of the ball 90 from the chamber 54.

[0058] The plunger 56 is disposed within the body 52 and generally configured to be moveable between an open position (as shown in FIG. 4) and a closed position (as shown in FIG. 5). The manner by which the plunger 56 is moved is not particularly limited. In the present embodiment, the plunger 56 is part of a plunger valve. The plunger valve can be controlled by a user, such as by turning a handle 57, to move the plunger 56 between the open position and the closed position via a non-rising valve stem 59. As another example, the plunger valve can be automated and controlled using a motor. In other embodiments, the non-rising valve stem 59 can be modified to be another type of valve stem.

[0059] Screen 58 is disposed within the outlet 62 and generally configured to prevent the passage of the ball 90 while allowing fluid to flow through screen 58. In the present embodiment, the screen 58 is configured to enourage the ball 90 toward the chamber 54 through the outlet 64. The screen 58 can be integral (i.e. non-removable, such as welded), or it can be removably attached to a component of apparatus 50 such that it is in the stream. In addition, any other part or blockage can be used to prevent the passage of the ball 90 through the outlet 62 while allowing the passage of fluid through outlet 62.

[0060] Screen 58 can encourage the movement of the ball 90 within the apparatus 50 (e.g., toward outlet 62). For example, when the plunger 56 is in the open position as illustrated in FIG.

4, the apparatus 50 is configured to receive the ball 90 along with fluid via the inlet 60 such that the fluid passes through the apparatus 50 and exits the outlet 62, and the ball 90 is encouraged by screen 58 to enter chamber 54 via the outlet 64. Accordingly, apparatus 50 operates to separate the ball 90 from the fluid exiting body 52 through outlet 62, which permits ball 90 to be collected while fluid moves to downstream equipment.

[0061] In the present embodiment, the apparatus 50 also optionally includes a wing valve 74 for controlling the flow of the fluid. The wing valve 74 is generally disposed upstream of the body 52 and can be used to limit or stop the flow of fluid into the body 52.

[0062] Referring to FIG. 5, the apparatus 50 is illustrated with the plunger 56 in a closed position for preventing the ball 90 from passing through the apparatus 50 and isolating the chamber 54 by forming a seal 72 between the plunger 56 and the outlet 64. The manner by which the seal 72 is formed is not particularly limited. For example, the diameter of plunger 56 can be substantially the same size as or slightly smaller than the diameter of outlet 64 such that fluid and/or ball 90 are prevented from entering outlet 64. As another example, the plunger 56 can be made from a resiliently deformable material, such as a suitable plastic or more malleable metal, to enhance sealing. As another example, the outlet 64 can include a feature, such as a seat (not shown), configured to mate with the plunger 56. The seat can include an inlay or insert to enhance sealing. The inlay or insert is not particularly limited and can be made from an erosion and/or corrosion resistant material.

[0063] In the present embodiment, the plunger 56 includes a perforated section 76 to allow the fluid to flow from the inlet 60 to the outlet 62 while plunger 56 is in a closed position and fluid is prevented from entering outlet 64. It is to be appreciated that the perforated section 76 is not particularly limited and the perforated section is generally configured to prevent a ball from passing through to the fluid outlet 62. In some embodiments, the perforated section 76 includes passages through the plunger 56. In other embodiments the perforated section 76 can allow fluid to flow around the plunger 56 within the body 52. For example, the plunger 56 can be sized to allow the fluid to pass around plunger 56 while preventing the ball 90 from passing between the space formed by the inner wall of the body 52 and the plunger 56.

[0064] In the embodiment shown in FIG. 5, the plunger 56 prevents the ball 90 from passing through the body 52 to any of the outlets 62 or 64. Furthermore, fluid flows directly from the inlet 60 to the outlet 62. Therefore, because the chamber 54 is isolated from the fluid flow, the chamber 54 can be opened at the cleanout port to remove any balls therein without stopping the flow of fluid.

[0065] Referring to FIG. 6, another embodiment of an apparatus for ball catching is shown generally at 50a. Like components of the apparatus 50a bear like reference to their counterparts in the apparatus 50, except followed by the suffix "a". The apparatus 50a includes a body 52a, a chamber 54a, a plunger 56a, and a screen 58a.

[0066] In the present embodiment, the body 52a includes an inlet 60a for receiving fluid flow A' and at least one ball 90 and / or other debris (not shown) carried by the fluid. The body 52a also includes an outlet 62a for permitting fluid to exit body 52a, which can include at least some debris. In the present embodiment, the ball 90 is separated from fluid that exits body 52a, and fluid that exits body 52a is generally delivered to testers or any other piece of downstream equipment. The body 52a further includes an additional outlet 64a for accommodating ball 90 that, for example, has been separated from fluid that exits body 52a.

[0067] As described above, the chamber 54a is in communication with the outlet 64a. In the present embodiment, the chamber 54a is configured to receive the ball 90 and /
or other debris via the outlet 64a. The chamber 54a can be constructed of any material or from any design that can provide sufficient mechanical properties to sustain the pressure, such as steel or another alloy. In the present embodiment, the chamber 54a also includes a drain valve 66a generally configured to relieve pressure within the chamber 54a. The chamber 54a includes a cleanout port 68a configured to facilitate removal of the ball 90 and/or debris from the chamber 54a.

[0068] The plunger 56a is disposed within the body 52a and generally configured to be moveable between an open position (as shown in FIG. 6) and a closed position (as shown in FIG. 7). In the present embodiment, the plunger 56a is part of a plunger valve. The plunger valve can be controlled by a user, such as by turning a handle 57a, to move the plunger 56a between the open position and the closed position via a non-rising valve stem 59a. In particular, the non-rising valve stem 59a is configured to rotate about an axis to move the plunger 56a along the axis without having the non-rising valve stem 59a move along the axis. One advantage of using the non-rising valve stem 59a in the present embodiment is that the handle 57a does not move along the axis of rotation to facilitate manual rotation of the handle 57a. In addition, as shown in FIG. 7, when the plunger 56a is in the closed position, the plunger 56a forms another seal 73a at the top of the plunger to substantially isolate the thread controlling the plunger 56a from the fluid. In addition, the plunger 56a includes a perforated section 76a to allow the fluid to flow from the inlet 60a to the outlet 62a while sealing the outlet 64a and preventing the ball 90 from passing through. Accordingly, the thread of the non-rising valve stem 59a is subjected to less wear, and the plunger 56a is supported in the body 52a at both the seal 72a and the seal 73a when in the closed position. It is to be appreciated that the manner by which the seal 72a and the seal 73a are formed is not particularly limited and can include manners discussed above in connection with the seal 72.

[0069] As shown in FIGS. 6 and 7, the screen 58a is disposed within the outlet 62a and generally configured to prevent the passage of the ball 90 and / or other debris while allowing fluid and at least some debris to flow through screen 58a. In the present embodiment, the screen 58a is configured to prevent the ball 90 from entering the outlet 62a and to encourage the ball 90 to enter the chamber 54a through the outlet 64a. Furthermore, in the present embodiment, the screen 58a is welded onto the sidewall of the outlet 62a using a weld joint 70a. Any other part or blockage can be used to prevent the passage of the ball 90 through the outlet 62a while allowing the passage of fluid through outlet 62a.

[0070] Referring to FIGS. 8a and 8b, the screen 58a is shown in greater detail. It is to be understood that the screen 58a is purely exemplary, and a variety of screens are contemplated for the present embodiment as well as other embodiments. The screen 58a includes a face 100a, a side 105a and a base 110a. In the present embodiment, the screen 58a is a unitary body;
however, it is to be appreciated that variations are contemplated. For example, the screen 58a can be constructed from separate pieces that are welded or otherwise attached together.

[0071] The face 100a is generally configured to allow fluid and at least some debris to pass through face 100a. In the present embodiment, the face 100a includes a plurality of circular holes 115a dimensioned to prevent the ball 90 as well as larger pieces of debris from passing through face 100a. It is to be understood that the face 100a is not particularly limited to any material and that several different types of materials are contemplated. In the present embodiment, the face 100a is a steel plate of sufficient thickness to stop the ball 90 in the fluid flow. The minimum thickness of face 100a can depend, for example, on the material of the face 100a.

[0072] The side 105a is generally configured to allow fluid and at least some debris to continue along the fluid path and to support the face 100a within the outlet 62a. In the present embodiment, the side 105a includes a plurality of slots 120a dimensioned to allow fluid and small debris to pass through slots 120a. In particular, each slot 120a extends almost the length of the side 105a from the face 100a to the base 110a. It is to be understood that the side 105a is not particularly limited to any material and that several different types of materials are contemplated.
In the present embodiment, the side 105a is made from steel. In other embodiments, side 105a can be replaced or supplemented by a plurality of support rods for supporting the face 100a while allowing fluid and debris to pass between adjacent rods. In the present embodiment, the side 105a is configured to allow substantially all debris to pass through via the slot 120a so that debris does not build up in the annular chamber formed between the screen 58a and the sidewall of the outlet 62a. However, some further embodiments can be configured to prevent larger debris from passing through the side 105a of the screen 58a.

[0073] The base 110a is generally configured to support the screen 58a within the outlet 62a.
In particular, the base 110a is configured to be welded to the sidewall of the outlet 62a using a weld joint 70a to increase the rigidity of the body 52a. It is to be understood that the base 110a is not particularly limited to any material and that several different types of materials are contemplated. In the present embodiment, the base 110a is an annular steel ring.

[0074] The marmer by which the screen 58a is welded into the outlet 62a of the body 52a is not particularly limited. To encourage ball 90 to enter outlet 64a, for example, the face 100a can be positioned substantially close to an end of the outlet 62a in the present embodiment.

[0075] The manner by which the screen 58a is positioned during assembly of the ball catcher prior to welding is not particularly limited. For example, FIG. 9 shows one manner by which the face 100a is to be positioned substantially close to the end of the entry of the outlet 62a within the body 52a. During assembly of the apparatus 50a, a pipe 200 is inserted through the body 52a passing through the outlet 64a. The screen 58a is subsequently inserted into the body 52a until the face 100 abuts against the pipe 200. The screen 58a is then welded to the sidewall of the passage 62a, and the pipe 200 is removed from the body 52a and assembly of the remainder of the apparatus 50a is carried out accordingly.

[0076] Referring to FIG. 10, another embodiment of an apparatus for ball catching is shown generally at 50b. Like components of the apparatus 50b bear like reference to their counterparts in the apparatus 50, except followed by the suffix "b". The apparatus 50b includes a body 52b, a chamber 54b, a plunger 56b, and a screen 58b.

[0077] In the present embodiment, the body 52b includes an inlet 60b for receiving fluid flow A" and at least one ball 90 and / or other debris (not shown) carried by the fluid. The body 52b also includes an outlet 62b for permitting fluid to exit body 52b, which can include at least some debris. In the present embodiment, the fluid can be delivered to testers or to any other piece of downstream equipment. The body 52b further includes an additional outlet 64b for accommodating ball 90 that, for example, has been separated from fluid that exits body 52b.

[0078] As described above, the chamber 54b is in communication with the outlet 64b. In the present embodiment, the chamber 54b is configured to receive the ball 90 and /
or other debris delivered via the outlet 64b. In the present embodiment, the chamber 54b also includes a drain valve 66b generally configured to relieve pressure within the chamber 54b. The chamber 54b includes a cleanout port 68b configured to facilitate removal of the ball 90 and/or debris from the chamber 54b.

[0079] The plunger 56b is disposed within the body 52b and generally configured to be moveable between an open position (as shown in FIG. 10) and a closed position (as shown in FIG. 11). In the present embodiment, the plunger 56b is part of a plunger valve. The plunger valve can be controlled by a user, such as by turning a handle 57b, to move the plunger 56b between the open position and the closed position via a non-rising valve stem 59b. In particular, the non-rising valve stem 59b is configured to rotate about an axis to move the plunger 56b along the axis without having the non-rising valve stem 59b move along the axis. In the present embodiment, the plunger 56b includes a guide member 55b configured to frictionally engage the inside wall of the body 52b. The guide member 55b can be any protrusion dimensioned to fit within the body 52b. In the present embodiment, the body 52b further includes a stop 53b for stopping the plunger 56b from any further axial motion. It is to be appreciated with the benefit of the specification that the guide member 55b interacts with the stop 53b by abutting against the stop 53b to prevent the plunger 56b from travelling any further into the outlet 64b or from disengaging the stem 59b and from excessive travel of the plunger 56b.

[0080] As shown in FIG. 11, when the plunger 56b is in the closed position, the plunger 56b forms another seal 73b at the top of the plunger to isolate the thread controlling the plunger 56b from the fluid. Accordingly, it is to be appreciated by a person of skill in the art with the benefit of this description that the thread of the non-rising valve stem 59b is subjected to less wear than other embodiments and that the plunger 56b is supported in the body 52b at both the seal 72b and the seal 73b when in the closed position. It is to be appreciated that the manner by which the seal 72b and the seal 73b are formed is not particularly limited and can include manners discussed above in connection with the seal 72.

[0081] In the present embodiment, the plunger 56b is configured to be narrower in the center portion to form passages 76b within the plunger 56b such that, if the plunger 56b is in the closed position, fluid can flow from the inlet 60b to the outlet 62b and ball 90 is prevented from flowing through outlet 62b. It is to be appreciated that the passages 76b are not particularly limited and are generally dimensioned to prevent a ball 90 from passing through passage 76b. In the present embodiment, the passages 76b include single slot shaped passages on either side of and passing through the plunger 56b as shown in FIG. 12.

[0082] As shown in FIGS. 10 to 12, the screen 58b is disposed within the outlet 62b and generally configured to prevent the passage of the ball 90 and / or other debris while allowing fluid and at least some debris to flow through screen 58b. In the present embodiment, the screen 58b is configured to prevent the ball 90 from entering the outlet 62b and to encourage the ball 90 to enter the chamber 54b through the outlet 64b. Furthermore, in the present embodiment, the screen 58b is welded onto the sidewall of the outlet 62b using a weld joint 70b. Any other part or blockage can be used to prevent he passage of the ball 90 through the outlet 62b while allowing the passage of fluid through outlet 62b.

[0083] Referring to FIG. 13, another embodiment of an apparatus for ball catching is shown generally at 50c. Like components of the apparatus 50c bear like reference to their counterparts in the apparatus 50, except followed by the suffix "c". The apparatus 50c includes a body 52c, a chamber 54c, a plunger 56c, a seal 82c, and a screen 58b.

[0084] In the present embodiment, the body 52c includes an inlet 60c for receiving fluid flow A" and at least one ball 90 and / or other debris (not shown) carried by the fluid. The body 52c also includes an outlet 62c for permitting fluid to exit body 52c, which can include at least some debris. In the present embodiment, the fluid can be delivered to testers or to any other piece of downstream equipment. The body 52c further includes an additional outlet 64c for accommodating ball 90 that, for example, has been separated from fluid that exits body 52c.

[0085] Similar to the apparatus 50a, the chamber 54c is in communication with the outlet 64c.
In the present embodiment, the chamber 54c is configured to receive the ball 90 and / or other debris delivered via the outlet 64c. In the present embodiment, the chamber 54c also includes a drain valve 66c generally configured to relieve pressure within the chamber 54c. The chamber 54c includes a cleanout port 68c configured to facilitate removal of the ball 90 and/or debris from the chamber 54c.

[0086] In the present embodiment, the plunger 56c is disposed within the body 52c and generally configured to be moveable between an open position (as shown in FIG.
13) and a closed position (as shown in FIG. 14). In the present embodiment, the plunger 56c is part of a plunger valve. The plunger valve can be controlled by a user, such as by turning a handle 57c, to move the plunger 56c between the open position and the closed position via a non-rising valve stem 59c. In particular, the non-rising valve stem 59c is configured to rotate about an axis to move the plunger 56c along the axis without having the non-rising valve stem 59c move along the axis. In the present embodiment, the plunger 56c includes a guide member 55c configured to frictionally engage the inside wall of the body 52c. The guide member 55c can be any protrusion dimensioned to fit within the body 52c. In the present embodiment, the body 52c further includes a stop 53c for stopping the plunger 56c from any further axial motion. It is to be appreciated with the benefit of the specification that the guide member 55c interacts with the stop 53c by abutting against the stop 53c to prevent the plunger 56c from travelling any further into the outlet 64c or from disengaging the stem 59c and from excessive travel of the plunger 56c.

[0087] The seal 82c is generally configured to create a seal 72c within the body 52c between the ball-collection outlet 64c and a protrusion 80c of the plunger 56c when in the closed position.
The seal 82c can be constructed of any material that can provide a seal between the protrusion 80c and the outlet 64c of the body 52c. In the present embodiment, the seal 82c is a metal ring.
In other embodiments, the seal 82c can be made of a rubber or plastic material. In the closed position (as shown in FIG. 14), the seal 82c rests at the opening of the outlet 64c and the protrusion 80c is positioned within a central opening of the seal 82c.
Accordingly, the seal 82c and the protrusion 80c prevent fluid from entering the outlet 64c.
Furthermore, the plunger 56c also forms another seal at the top of the plunger 56c to isolate valve stem 59c and other components of the apparatus from the fluid when in the closed position.
100881 Referring to FIG. 15a, the plunger 56c is shown in a partially open position. It is to be appreciated ,that, as the plunger 56c is raised from the closed position shown in FIG. 14, the protrusion 80c is initially lifted to separate from the seal 82c to allow fluid to enter the outlet 64c via the small gap created. Since the protrusion 80c has a smaller diameter than the opening of the outlet 64c, less torque would need to be applied at the handle 57c to break the seal 72c and raise plunger 56c. Once fluid enters the outlet 64c via the gaps below the plunger 56c (as shown in FIG. 15b), the pressure is balanced above and below to provide for easier unseating of the seal 82c. In the present embodiment, a snap ring 84c is disposed on the protrusion 80c below the seal 82c. The snap ring 84c is configured to engage the seal 82c to lift and completely unseat the seal 82c as the plunger 56c is raised as shown in a partially open position in FIG.
16. In other embodiments, the snap ring 84c can be replaced by another means to lift the seal 82c, such as an additional protrusion extending from the protrusion 80c or a pin.
[00891 In the present embodiment, the seal 82c has an outer diameter of approximately 4.06 inches and an inner diameter of approximately 2 inches. The protrusion 80c is generally tapered and forms a flow channel of approximately 0.036 inches in the position shown in FIG. 15. However, it is to be appreciated that the dimensions of the seal 82c and the plungers 56c are not particularly limited. For example, the inner diameter can be smaller to further decrease the amount of torque required to move the plunger 56c from the closed position shown in FIG. 14 to the partially opened position shown in FIG. 15. For example, seal 82c can have a larger outer diameter (e.g., 5 inches, 6 inches, or more), a smaller outer diameter (e.g., 3 inches, 2 inches, or less), a larger inner diameter (e.g., 3 inches, 4 inches, or more), or a smaller inner diameter (e.g., 1.5 inches, 1 inch, or less).
[00901 Referring to FIG. 17, a system for hydraulic fracturing of a well is shown at 500 including the apparatus 50. It is to be understood that the system 500 is purely exemplary and it will be apparent to those skilled in the art that a variety of configurations are contemplated. For example, as an example of a variation, the apparatus 50 can be substitute or the apparatus 50a.
The system 500 further includes a frac tree 508 and downstream equipment 512.
The downstream equipment 512 can include, for example, any combination of pipes, testing devices, storage vessels and the like. The fi-ac tree 508 is connected, at a wellhead end 516, to a well 517 extending through a ground surface 518 to the underground formations from which the recovery of oil or gas is desired.
100911 In the foregoing description of certain embodiments, specific terminology has been resorted to for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes other technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as "left" and right", "front" and "rear", "above" and "below" and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.
[0092] In this specification, the word "comprising" is to be understood in its "open" sense, that is, in the sense of "including", and thus not limited to its "closed" sense, that is the sense of "consisting only of'. A corresponding meaning is to be attributed to the corresponding words "comprise", "comprised" and "comprises" where they appear.
[0093] In addition, the foregoing describes only some embodiments of the invention(s), and alterations, modifications, additions and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive.
Furthermore, invention(s) have described in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention(s). Also, the various embodiments described above may be implemented in conjunction with other embodiments, e.g., aspects of one embodiment may be combined with aspects of another embodiment to realize yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment.

Claims (34)

WHAT IS CLAIMED IS:

1. An apparatus for ball catching, the apparatus comprising:
a body having an inlet for receiving fluid and at least one ball, a fluid outlet for permitting fluid to exit the body, and a ball-collection outlet for accommodating at least one ball;
a chamber in communication with the ball-collection outlet, the chamber for receiving the at least one ball;
a blockage disposed within the fluid outlet, the blockage configured to prevent the passage of at least one ball through the fluid outlet and encourage at least one ball toward the ball-collection outline and configured to permit the passage of fluid through the fluid outlet;
and a plunger moveable between an open position and a closed position, wherein the closed position prevents at least one ball and fluid from entering the ball-collection outlet, prevents at least one ball from entering the fluid outlet, and permits fluid to exit the body through the fluid outlet.

2. The apparatus of claim 1, further comprising a wing valve connected to the body for controlling flow of the fluid.

3. The apparatus of claim 2, wherein the wing valve is connected upstream from the body.

4. The apparatus of any one of claims 1 to 3, further comprising a drain valve connected to the chamber, the drain valve for relieving pressure within the chamber.

5. The apparatus of any one of claims 1 to 4, wherein the chamber includes a cleanout port for removing at least one ball from the chamber.

6. The apparatus of any one of claims 1 to 5, wherein the plunger is perforated.

7. The apparatus of any one of claims 1 to 5, wherein the plunger is configured to allow fluid to flow from the inlet, around at least a portion of the plunger, and through the fluid outlet.

8. The apparatus of any one of claims 1 to 7, further comprising a non-rising valve stem.

9. The apparatus of claim 8, wherein the non-rising valve stem comprises a thread, the thread isolated from the fluid flowing through the body to reduce wear.

10. The apparatus of claim 9, wherein the plunger is configured to discourage fluid from contacting the non-rising valve stem .

11. The apparatus of claim 10, wherein the plunger comprises an upper seal and a lower seal.

12. The apparatus of any one of claims 1 to 11, wherein the blockage is welded to the body.

13. The apparatus of any one of claims 1 to 12, wherein the blockage comprises a screen that comprises holes for allowing the fluid and at least some debris to pass through the screen.

14. The apparatus of any one of claims 1 to 13, further comprising an inlay disposed within the ball-collection outlet, the inlay configured to mate with the plunger to enhance sealing.

15. The apparatus of claim 14, wherein the inlay comprises a corrosion resistant material.

16. The apparatus of any one of claims 1 to 13, further comprising an insert disposed within the ball-collection outlet, the inlay configured to mate with the plunger to enhance sealing.

17. The apparatus of claim 16, wherein the insert comprises a corrosion resistant material.

18. An apparatus for ball catching, the apparatus comprising:
means for receiving fluid and at least one ball at an inlet into a body;
means for permitting fluid to exit the body via a fluid outlet;
means for permitting at least one ball to enter a chamber via a ball-collection outlet, the chamber in communication with the ball-collection outlet;
means for preventing the passage of the at least one ball through the fluid outlet; and a plunger moveable between an open position and a closed position, wherein the closed position prevents at least one ball and fluid from entering the ball-collection outlet, prevents at least one ball from entering the fluid outlet, and permits fluid to exit the body through the fluid outlet.

19. The apparatus of claim 18, further comprising means for controlling flow of the fluid.

20. The apparatus of claim 19, wherein the means for controlling flow of the fluid is connected upstream from the body.

21. The apparatus of any one of claims 18 to 20, further comprising means for relieving pressure within the chamber.

22. The apparatus of any one of claims 18 to 21, further comprising means for removing at least one ball from the chamber.

23. The apparatus of any one of claims 18 to 22, wherein the plunger comprises means for permitting the fluid to flow through the inlet, around at least a portion of the plunger, and through the fluid outlet.

24. The apparatus of any one of claims 18 to 23, further comprising means for the fluid to flow through the body and through the fluid outlet.

25. The apparatus of any one of claims 18 to 24, further comprising non-rising control means for controlling the plunger.

26. The apparatus of claim 25, further comprising means for discouraging fluid from contacting the non-rising control means to reduce wear.

27. The apparatus of claim 26, wherein the plunger is configured to prevent fluid from contacting the non-rising control means when the plunger is in the closed position.

28. The apparatus of claim 27, further comprising means for supporting the plunger at an upper seal and a lower seal when the plunger is in the closed position.

29. The apparatus of any one of claims 18 to 28, wherein the means for preventing the passage of at least one ball within the fluid outlet is fixed to the body.

30. The apparatus of any one of claims 18 to 29, further comprising means for allowing the fluid and at least some debris to pass through the fluid outlet.

31. The apparatus of any one of claims 18 to 30, further comprising means for mating the ball-collection outlet with the plunger to enhance sealing.

32. The apparatus of claim 31, wherein the means for mating the ball-collection outlet with the plunger comprises a corrosion resistant inlay.

33. The apparatus of claim 31, wherein the means for mating the ball-collection outlet with the plunger comprises a corrosion resistant insert.

34. A system for hydraulic fracturing of a well, the system comprising:
a frac tree configured to connect to a wellhead of the well and configured to receive fluid and at least one ball from the wellhead;
a ball catcher connected to the frac tree, wherein the ball catcher comprises:
a body having an inlet for receiving the fluid and at least one ball from the frac tree, a fluid outlet for permitting fluid to exit the body, and a ball-collection outlet for accommodating at least one ball;
a chamber in communication with the ball-collection outlet, the chamber for receiving the at least one ball;
a blockage disposed within the fluid outlet, the blockage configured to prevent the passage of at least one ball through the fluid outlet and encourage at least one ball toward the ball collection outlet and configured to permit the passage of fluid through the fluid outlet; and a plunger moveable between an open position and a closed position, wherein the closed position prevents at least one ball and fluid from entering the ball-collection outlet, prevents at least one ball from entering the fluid outlet, and permits fluid to exit the body through the fluid outlet; and downstream equipment connected to the fluid outlet of the ball catcher, the downstream equipment configured to process fluid.