Frac Pump Isolation Safety System

Abstract

The improved system allows an operator overseeing a well stimulation hydraulic fracturing operation to bring frac pumps online and offline as necessary. A control panel allows the operator to remain at a safe distance from high-pressure equipment, including the frac pumps and respective remotely actuated isolation valves, yet allows monitoring and operation of same. The operating condition of the frac pumps and the isolation valves is monitored by an automated processing device, which prevents operation of same during certain pump and valve conditions. A wireless operator interface is also provided.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]Not ApplicableSTATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT[0002]Not ApplicableTHE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT[0003]Not ApplicableINCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC[0004]Not ApplicableBACKGROUND OF THE INVENTION[0005]1. Field of the Invention[0006]The present invention relates to a system for safe remote monitoring and operation of high-pressure and high-volume industrial fluid delivery system and, more specifically, to a system for remote monitoring and control of hydraulic fracturing equipment in a well stimulation operation.[0007]2. Description of Related Art including information disclosed under 37 CFR 1.97 and 1.98[0008]Horizontal drilling and well stimulation processes have revolutionized the oil and gas industry with regard to the optimization of hydrocarbon extraction. Shale areas once thought unreachable are now within range of the horizontal drilling techno...

AI Technical Summary

Benefits of technology

[0016]Described herein is an industrial high-pressure fluid delivery system having a plurality of fluid pumps in fluid communication with a manifold to provide high fluid pressures and high fluid volumes, the system comprising: an isolation valve in a fluid circuit between each of a plurality of fluid pumps and a fluid manifold, the isolation valve capable of substantially isolating the fluid pump discharge from the manifold, the isolation valve adapted to allow for remote actuation; and a remote operator control panel, the control panel in signal communication with each isolation valve and its respective pump, the control panel adapted to monitor at least one valve condition and at least one respective pump condition, the isolation valve operable in response to a signal from the operator control panel. Supplementary elements forming additional embodiments include wired and / or wireless operator interfaces, alternate means of isolation valve actuation, and various system condition monitoring inputs.

[0017]Also described herein is a hydraulic fracturing pump isolation safety system, the system comprising: a plurality of remotely actuated isolation valves, each isolation valve in fluid communication with the fluid head of a hydraulic fracturing pump, the plurality of isolation valves in further fluid communication with a manifold through which fracturing fluid is provided to a well head; and a control panel located remotely from the plurality of isolation valves and the hydraulic fracturing pumps, the control panel in signal communication with the plurality of isolation valves and the hydraulic fracturing pumps, the control panel comprising an operator interface for monitoring by an operator of at least one valve condition and at least one respective pump condition, wherein the control panel is adapted to allow the operator to remotely monitor and control each valve and / or pump in response to the monitored conditions. Supplementary elements forming additional embodiments include wired and / or wireless operator interfaces, alternate means of isolation valve actuation, and various system condition monitoring inputs.

Problems solved by technology

Rock pressures beneath the earth's surface are quite extreme, especially given the depths to which the well holes must be drilled to reach the pay zones.

If these stimulation operations are halted before sufficient amounts of proppant are introduced into the fissures, the fissures can close and negate any progress made to that point.

Because the frac fluid is abrasive and often corrosive, maintenance of frac pumps must occur regularly.

Also, because of the great strains on the frac pumps, breakdowns can occur, hence the need for redundancy.

However, extra precaution must be taken when isolating a frac pump—given the extreme operating pressures involved.

However, with all of the other pumps running, the extreme environment due to the cacophony of noise and the mechanical vibrations of the equipment can make it exceedingly difficult for the operator to determine which valve to operate, or whether the respective frac pump is in a safe condition.

If the wrong valve is closed on an operating frac pump, an essentially instantaneous overpressure and explosion of the valve hardware, lines, and / or fluid head of the pump can occur, possibly leading to equipment destruction, operation and production time losses, operator injury, and attendant costs.

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