MODULAR ASSET CONTROL UNIT OF A MODULAR CONTROL SYSTEM WITH UMBILICAL DEPLOYMENT, SYSTEM COMPRISING IT AND CONNECTION METHOD

Abstract

A control unit includes a hydraulic fluid system, a lubricant system, at least one sensor cable, and an electronic module communicating with the hydraulic fluid system and the lubricant system. A control unit housing contains the hydraulic fluid system, the lubricant system, the sensor cables, and the electronic module.

Description

MODULAR CONTROL SYSTEM WITH UMBILICAL DEPLOYMENT BACKGROUND

[0001] Drilling and well systems typically employ several different equipment units, which may require a number of different operating systems. For example, a wellhead, also called a Christmas tree, may include an assembly of valves, spools, and fittings connected to the top of a well to direct and control the flow of fluids from the well. Wellheads may be installed, for example, in wells for fracturing operations (called a fracturing wellhead), in a production well (called a production wellhead), or in a subsea well (for example, a horizontal wellhead designed to minimize the mounting height and reduce sway from surrounding water currents). The valves used with wellheads may be actuated using hydraulic pressure, which can be supplied by a hydraulic pressure unit (HPU).These valves are supplied with hydraulic pressure using a hydraulic system, which can also supply hydraulic pressure to other valves and equipment units. Control of a main hydraulic system may also include the use of electrical wiring to send and receive electrical signals and instructions to monitor and control the operation of each component using hydraulic pressure.

[0002] In addition, valves and other components of well equipment units can be lubricated periodically to ensure their proper operation. The lubricant (e.g., grease) can be pumped to the valve or other well equipment component from a central lubrication system through lubrication hoses.

[0003] Master control units are often used to control the operation of one or more systems in a well operation. For example, a control unit can be used to operate sub-controllers for different systems in the well operation, such as a sub-controller for a hydraulic system and a sub-controller for a lubrication system. Control units may include automatic programming to perform one or more 1941186 of 24 functions under a pre-established condition, or the control units can be operated on a case-by-case basis.

[0004] Figure 1 shows an example of a convection well system 100 that has multiple fracturing trees 110 mounted at a well site. Each fracturing tree 110 may include multiple valves 112 (e.g., more than 8 valves), connections, and flow lines to direct and control fluid flow in the well. The valves 112 on a fracturing tree 110 may be hydraulically actuated using hydraulic pressure supplied by a centrally located HPU 120. In addition, each valve actuator 112 may include two piston chambers connected to the HPU 120 via separate hydraulic hoses 122 (hoses that carry hydraulic fluid). Therefore, according to the number of hydraulically operated valves 112 on each fracturing tree 110, dozens of hydraulic hoses 122 may be required to connect all the valve actuators on a single fracturing tree 110 to the HPU 120.Additional fracturing trees 110 can also utilize additional HPUs 120 and hydraulic hoses 122 to provide hydraulic actuation to the valves 112 on the additional fracturing trees 110.

[0005] In addition, an automatic lubrication system (AGS) can be provided at the well site to keep the valves 112 lubricated. The AGS may include, for example, a grease pump 130, which may be mounted on a trailer 135 with an air compressor 132 for pump operation, a central controller 134, individual lubrication units 136, and grease lines 138 that seamlessly connect the components of the AGS.

[0006] A master control unit 140 can be used to control the operation of one or more systems at the well site, including the hydraulic system and the AGS. As shown, electrical cables 144 can be provided between the master control unit 140, the AGS central controller 134, and a controller for the HPUs 120 to the different fracturing trees 110 to send communication signals between the different systems (e.g., signals that include instructions for the operation of one or more components in the systems). In addition, sensors 150 can be placed in various locations in 1941186 of 24 the well site to monitor operations, where sensor data can be processed by the master control unit 140.

[0007] By providing a centralized system for each function, such as a centralized hydraulic system and a centralized lubrication system, a single master control system can be used to monitor and operate the well site. However, in typical well systems, such as those shown in FIG. 1, hundreds of feet of hydraulic hoses 122, grease lines 138, and electrical cables 144 are often used for system operation, which can lead to complications during well system installation, dismantling, and maintenance when it comes to tracing which line goes where. SYNTHESIS

[0008] This summary is provided to introduce a selection of concepts that are described later in the detailed description. This summary is not intended to identify the key or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

[0009] In one aspect, the embodiments described herein relate to control units comprising a hydraulic fluid system, a lubricant system, at least one sensor cable, an electronic module communicating with the sensor cable, the hydraulic fluid system, and the lubricant system, and a housing containing the hydraulic fluid system, the lubricant system, the sensor cable, and the electronic module. The hydraulic fluid system may include a hydraulic fluid flow line extending between a main hydraulic inlet and a main hydraulic outlet, a plurality of hydraulic fluid valves located along the hydraulic fluid flow line, and a plurality of hydraulic fluid ports, wherein each hydraulic fluid port is fluidly connected to one of the hydraulic fluid valves.The lubricant system may include a lubricant flow line extending between a main lubricant inlet and a main lubricant outlet, a plurality of lubricant valves located along the lubricant flow line, and a plurality of lubricant ports, wherein. 1941186 of 24 Each lubricant port connects seamlessly to one of the lubrication valves. The sensor cable can be extended between a sensor port and the electronic module.

[0010] In another aspect, the embodiments described herein relate to systems that include a modular asset control unit, a well equipment unit comprising at least one valve, and an umbilical connecting the modular asset control unit to the at least one valve of the well equipment unit. The modular asset control unit may include a hydraulic fluid system, a lubricant system, at least one sensor cable, an electronic module, and a housing containing the hydraulic fluid system, the lubricant system, the sensor cable, and the electronic module. The umbilical may have at least one hydraulic hose fluidly connecting the hydraulic fluid system to the valve and one lubricant hose fluidly connecting the lubricant system to the valves.

[0011] In yet another aspect, the embodiments described herein relate to methods that include providing multiple units of well equipment at a well site, connecting multiple modular asset control units to the well equipment unit in a one-to-one relationship with the well equipment unit using at least one umbilical, such that each of the modular asset control units connects to one of the well equipment units, connecting the multiple modular asset control units together in series using a connecting supply umbilical, connecting a first modular asset control unit of the multiple modular asset control units to a distribution center with the connecting supply umbilical,and provide hydraulic pressure and lubricant to at least one valve in the well equipment unit from the distribution center through the connecting supply umbilical, the modular asset control units, and the umbilical.

[0012] Other aspects and advantages of the claimed subject matter will be evident from the following description and the accompanying claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1 shows a schematic of a conventional well system. 1941186 of 24

[0014] FIG. 2 shows a well system according to the embodiment of the present description.

[0015] FIG. 3 shows a connection between a valve and an ACU according to the embodiments of the present description.

[0016] FIG. 4 shows a schematic of an ACU according to the embodiments of the present description.

[0017] FIG. 5 shows one side of the ACU valve in FIG. 4.

[0018] FIG. 6 shows one side of the ACU power port in the FIG 4 and 5.

[0019] FIG. 7 shows a partial perspective view of the ACU in FIG. 4-6.

[0020] FIG. 8 shows a method in accordance with the ways of realizing the present description. DETAILED DESCRIPTION

[0021] The embodiments described herein include modular asset control units (ACUs) that can be deployed per asset, where a single ACU can be used to control, monitor, and / or maintain the asset's valves. In systems using multiple assets with valves, an ACU, according to the embodiments described herein, can be provided for each asset, or in some embodiments, one ACU can be provided for fewer than all assets in a system. The ACUs can be connected in series with a master control center to distribute valve control functionality from the master control center to each connected asset. In this way, the ACUs can be used to control the valves of an entire system using a hydrodynamic connection system.Furthermore, the ACUs described herein can be modularized, so that an ACU can be deployed with different types of assets for different operational tasks.

[0022] An asset may include well equipment units with valves, such as a tree, missile, rack manifold, fracturing manifold, other well equipment used in fracturing operations, manifolds having one or more valves, well equipment units used to drill a well (in well drilling operations), well equipment units used in backflow operations, well equipment units used in other completion operations, and other well equipment having one or more valves, as well as control choke manifolds, trash reclaimers, and other well equipment units used in drilling and / or production operations. Well equipment units used in well operations often use a valve configuration to direct or stop the flow of fluids used in the well operation.In some well operations, such as hydraulic fracturing, hydraulically actuated valves can be used to control the flow of high-pressure fluids. For example, a manifold includes a set of valves and flow lines that allows low-pressure fracturing fluid to enter, where it can be directed to the fracturing pumps for pressurization. The high-pressure fluid then returns to the manifold to be directed to a well or fracturing manifold. A rack manifold may include a set of fracturing valves and can be used to direct treatment fluid from a manifold to multiple fracturing trees.

[0023] According to the embodiments described herein, valve control and monitoring systems in an ACU, such as a hydraulic fluid system, a lubricant system, and a sensor and electronics system, may be connected to one or more, or all, of the valves in a well equipment unit (asset) to control, monitor, and / or maintain the valves. Additionally, the ACUs described herein may be connected to the valves in one or more well equipment units at a well site in a one-to-one ratio, such that multiple ACUs may control and monitor the valves in a corresponding number of well equipment units. The ACUs described herein may be used to control and monitor different types of valves, including, for example, hydraulically actuated valves, electronically actuated valves, and manual valves. 1941186 of 24

[0024] FIG. 2 shows an example of a well site system 200 according to the embodiments of the present description, wherein the well equipment units (210a, 210b, 210c, 210d, collectively referred to as 210) used at the well site may each be connected to an ACU (220a, 220b, 220c, 220d, collectively referred to as 220). An ACU 220 according to the embodiments of the present description may contain valve control and monitoring systems, such as a hydraulic fluid system, a lubricant system, a sensor system, and an electronic module. An ACU 220 can be connected to a well equipment unit 210 by connecting the valve control and monitoring systems in the ACU 220 to one or more or all of the valves 212 in the well equipment unit 210 using an umbilical 230.An umbilical connecting an ACU to an asset (well equipment unit) can collectively house hydraulic hoses, lubricant hoses, and other lines for connecting components on the asset to the ACU. For example, umbilical 230 may include at least one hydraulic hose seamlessly connecting a hydraulic fluid system in ACU 220 to a hydraulically actuated valve 212, one lubricant hose seamlessly connecting a lubricant system in ACU 220 to the valve 212, and / or one sensor line connecting a sensor cable in ACU 220 to one or more sensors 214 on the valve 212.

[0025] Multiple cables, lines, or hoses (for example, hydraulic fluid hoses, lubricant hoses, and electrical or other sensor lines) can be bundled into a single umbilical 230 to provide a standardized umbilical 230 that can be used to connect ACU 220s to multiple different types of valves on different types of well equipment units 210. When an ACU 220 is connected to a valve 212 that does not utilize one or more valve control and monitoring systems (for example, valves that do not have a sensor or valves that are not hydraulically actuated), the corresponding line in the umbilical 230 can be capped. For example, in some embodiments, the umbilical 230 can be used to connect an ACU 220 to a valve that is not hydraulically actuated (for example, a manual valve or an electronic valve). In such cases, the hydraulic hoses in the umbilical 230 1941186 7 of 24 may be covered, while other cables, lines or hoses may be connected to valve 212.

[0026] For example, FIG. 3 shows a schematic of an example connection between an ACU 220 according to the embodiments of the present description and a hydraulically actuated valve 212 (which may be provided in a well equipment unit 210, shown in FIG. 2) using an umbilical 230. The umbilical 230 may include a lubricant hose 232, which can fluidly connect a lubricant system in the ACU 220 to a valve gate or other lubricated component in the valve 212. The umbilical 230 may also include two hydraulic hoses, including a hydraulic pressure hose 234 and a hydraulic return hose 235, which can be fluidly connected between a hydraulic fluid system in the ACU 220 and a double-acting hydraulic actuator in the valve 212.In some embodiments, a hydraulic pressure hose 234 may be seamlessly connected to a single-acting hydraulic valve, while a hydraulic return hose 235 may be capped or not provided at the umbilical 230. The umbilical 230 may also include a sensor line 236 for connecting a sensor 214 (for example, a position sensor) at the valve 212 to a sensor cable at the ACU 220.

[0027] In some embodiments, umbilical 230 may optionally include a heat trace line 239, which can be connected to a heat trace cable at ACU 220. A heat trace system, including the heat trace line 239, can be used to maintain a temperature (or temperature range) of the piping or vessels. A heat trace line and / or cable may include a conductive element running the length of the line that heats up as current passes through it. A power source, such as a generator, can supply current through the heat trace line to heat it. A thermostat and controller can also be used to monitor and control the amount of heat emitted by the heat trace line.The operating components of the heat tracing, such as the power source and controller, can be located away from the 210 well equipment units and the 220 ACUs and can be connected to them. 1941186 of 24 heat tracing lines 239 in the umbilical 230 through the heat tracing cables connected through the ACU 220.

[0028] Hoses and lines 232, 234, 235, 236 can be grouped in a sleeve 238, which can keep the hoses and lines together and organized. In embodiments having a heat tracing line 239 provided in the umbilical 230, the heat tracing line 239 can be grouped with the remaining hoses and lines 232, 234, 235, 236 in the sleeve 238. In other embodiments, the heat tracing line 239 can be integrated with the sleeve 238 to provide overall heat tracing to the grouped hoses and lines. For example, the conductive elements of a heat tracing line 239 can pass through one or more layers of polymeric materials (for example, a thermoplastic layer or other insulating material) forming the sheath 238 along the length of the sheath 238, where appropriate power connections to the conductive elements can be provided at the axial ends of the sheath 238.

[0029] Furthermore, by grouping the hoses and lines of a 230 umbilical together, the 230 umbilical can be wound onto a reel 231 for ease of assembly and disassembly. In some embodiments, a large reel 231 can hold up to 400 ft or more of the 230 umbilical and can be used to provide 230 umbilicals for between 5 and 10 (or more) connections between an ACU 220 and a valve 212.

[0030] As mentioned previously, 230 umbilicals can be standardized, where the same type of umbilical (including the same bundled lines) can be used for multiple different connections. The standardized 230 umbilical can be stored on a 231 reel and unspooled and used for assembling a 210 well equipment unit. When one or more hoses or lines on the standardized umbilical are not needed for connection to a valve, the unused hose / line can be capped. In this way, standardized 230 umbilicals can be used to connect multiple 220 ACUs to each of their associated 210 well equipment units, regardless of whether the same types of valves are connected.

[0031] With reference again to FIG. 2, an ACU 220 can distribute valve control and monitoring functionality to and from a 9-unit center 1941186 of 24 distribution 240. A distribution center 240 may provide the primary source of power, fluids, and other components used for proper valve operation, including, for example, a power source 241 (for example, one or more generators), a master control unit 242 (which may include one or more computer systems used to control and monitor the operations of one or more systems at the well site 200), a lubricant system 243 (for example, which includes a lubricant source and one or more pumps), an HPU (hydraulic pressure unit) 244 (which may include a hydraulic fluid source and one or more pumps), a valve control system 245, and a distribution system 246 to direct selected quantities of fluids or power to the ACU 220.A distribution center 240 may have its components and systems provided in a single trailer 247 in a compact and / or modular configuration, as shown in FIG. 2. In other embodiments, the components and systems of a distribution center may be provided separately from each other.

[0032] The distribution center 240 may be located at a distance from the ACUs and well equipment units 210. For example, in some embodiments, the distribution center 240 may be located outside a red zone 201, while the ACUs 220 are connected to the equipment units 210 within the red zone 201, where the red zone 201 may define a safety zone or area around the pressurized well equipment units 210, which poses a hazard to persons entering while the pressurized well equipment units 210 are operating. In some embodiments, the distribution center 240 may be located outside a zone ranging from approximately a radius of 20 to 60 feet around the well equipment units 210 of an active well operation.

[0033] The 250 connection supply umbilicals can be used to connect the 240 distribution hub to the 220 ACUs in series. For example, a 250 main connection supply umbilical can connect a first 220a ACU to the 240 distribution hub, a second 220b ACU to the first 220a ACU, a third 220c ACU to a second 220b ACU, and so on, in a daisy-chain configuration to connect all the 220 ACUs in the 1941186 of 24 system 200 to distribution center 240. In this way, multiple ACU 220s can be connected in series with a distribution center 240 to distribute valve control functionality from the distribution center 240 to each of the connected assets

[0034] The connection supply umbilical 250 may include, for example, two hydraulic supply hoses (for example, a hydraulic pressure hose and a hydraulic return hose), which may be seamlessly connected to the HPU 244 at the distribution center 240, a lubricant supply hose, which may be seamlessly connected to the lubricant system 243 at the distribution center 240, at least one power cable, such as an electrical cable connected to the power source 241 and / or the valve control system 245 at the distribution center 240, and a communication cable, such as an Ethernet cable. Similar to umbilical 230, the connection supply umbilical 250 may be standardized and bundled to include the same hoses and lines.Since the main connection supply umbilical 250 can supply hydraulic fluids and grease to multiple active units 210 in series, the supply and return hoses for each respective connection supply umbilical 250 must be of sufficient size to provide the required flow volumes. Therefore, in some embodiments, the connection supply umbilical 250 may have a larger diameter than the umbilical 230 that connects the ACU 220 to the valves.

[0035] Each ACU 220 may have a housing 222 that contains the ACU components, for example, a hydraulic fluid system, a lubricant system, at least one sensor cable, and an electronic module. In some embodiments, the ACU 220s can be modularized so that each ACU 220 has the same configuration, for example, the same shape and size of housing 222 and the same components therein. By modularizing the ACU 220s, they can be interchangeable for use with different wellhead equipment units and at different well sites. Furthermore, modularization of the ACU 220s can allow for easier connection assemblies. For example, a modularized ACU 220 can be designed to have main system inlets (for example, a main hydraulic inlet and a main lubricant inlet) located on one inlet side of the housing 222. 1941186 of 24 the main outlets to the systems (for example, a main hydraulic outlet and a main lubricant outlet) located on one outlet side of the housing 222, and / or feed ports to each of the systems (for example, hydraulic fluid ports, lubricant ports, and sensor ports) located on the other side of the housing 222. In other embodiments, the main inlets, main outlets, and / or feed ports may be provided in other configurations around the ACU housing 222, but may be located in the same location on each ACU 220a, 220b, 220c, 220d, so that connection points can be easily found for connecting the umbilicals 230 and the connection supply umbilicals 250.

[0036] For example, in some embodiments, a first ACU 220ase can be connected to the distribution hub 240 by connecting a connection supply umbilical 250 from the distribution hub 240 to an input side of the first ACU 220a. A connection supply umbilical 250 can also be used to connect an output side of the first ACU 220a to an input side of a second ACU 220b; to connect an input side of a third ACU 220c to the output side of the second ACU 220b; and so on. The connection supply umbilicals 250 for each connection can be standardized to have the same components. Furthermore, the input sides of the first, second, and third ACUs 220a, 220b, and 220c can have the same configuration, which may allow for faster connection assembly.

[0037] A first well equipment unit 210a may be connected to the first ACU 220a through an umbilical 230, wherein the umbilical 230 may be connected between one or more valves 212 in the first equipment unit 210a and a side of the feed port of the first ACU 220a. A second well equipment unit 210b may be connected to the second ACU 220b through an umbilical 230, wherein one segment of the umbilical 230 may be connected between a first valve 212a in the second equipment unit 210b and a side of the feed port of the second ACU 220b, and wherein another segment of the umbilical 230 may be connected between a second valve 212b in the second well equipment unit 210b and the side of the feed port of the second ACU 220b. Similarly, a connection of the 230 umbilical between the 1941186 of 24 third ACU 220c and third well equipment unit 210c may include the connection of umbilical 230 from a valve in the third equipment unit 210c to a feed port side of the third ACU 220c. While the system shown in FIG. 2 shows umbilical connections between a single ACU and a valve (e.g., in the first, third, and fourth equipment units 210a, 210c, 210d) and umbilical connections between a single ACU and two valves (212a, 212b in the second equipment unit 210b), umbilical connections can be made between a single ACU 220 and multiple valves (including more than two valves) in one equipment unit. In this way, the hydraulic, lubrication, monitoring, and control systems can be connected to each valve of an asset as required.In addition, the 230 umbilical can be standardized to have the same components, and the power port sides of each ACU 220 can have the same configuration to allow for faster connection assembly.

[0038] With reference now to FIG. 4-7, FIG. 4 shows a schematic of an example of an ACU 300 according to the embodiments of the present description, FIG. 5 shows a perspective view of one side of the valve of the ACU 300, FIG. 6 shows a perspective view of one side of the feed port of the ACU 300, and FIG. 7 shows an enlarged view of part of the ACU 300.

[0039] According to the embodiments described herein, an ACU 300 may include multiple valve control and monitoring systems housed in a 301 enclosure. The 301 enclosure may be an open frame, a box with windows for access to the systems thereon, or another frame and wall configuration,

[0040] The ACU 300 may have a hydraulic fluid system that includes a hydraulic fluid flow line 310 (e.g., a hydraulic pressure line) extending between a main hydraulic inlet 311 and a main hydraulic outlet 312, a plurality of hydraulic fluid valves 313 located along the hydraulic fluid flow line 310, and a plurality of hydraulic fluid ports 314, wherein each hydraulic fluid port 314 can be fluidly connected to one of the hydraulic fluid valves 313 (e.g., by means of hydraulic port lines 315). 1941186 13 of 24

[0041] In some embodiments, the hydraulic fluid system in the ACU 300 may also include a secondary hydraulic fluid flow line, for example, a hydraulic return line, extending between a second main hydraulic inlet (not shown) and a second main hydraulic outlet (316). A plurality of secondary hydraulic fluid ports 317 may be fluidly connected to the secondary hydraulic fluid flow line by means of at least one valve.In some embodiments, a hydraulic fluid valve 313 may be located along the primary hydraulic fluid flow line 310 and the secondary hydraulic fluid flow line, wherein a hydraulic fluid valve 313 may selectively permit the flow of hydraulic fluid from the primary hydraulic fluid flow line 310 to a hydraulic fluid port 314 and from the secondary hydraulic fluid flow line to the secondary hydraulic fluid ports 317. In other embodiments, hydraulic fluid valves 313 may selectively permit the flow of hydraulic fluid from the primary hydraulic fluid flow line 310 to the hydraulic flow ports 314, and, in different embodiments, secondary hydraulic fluid valves may selectively permit the flow of hydraulic fluid between the secondary hydraulic fluid flow line and the secondary hydraulic flow ports 317.

[0042] Hydraulic fluid valves can have various configurations that can provide hydraulic fluid flow through ACUs connected in series (e.g., as shown in FIG. 2) while also controlling the flow of hydraulic fluid to and from connected assets as required to operate the valves of the associated asset according to instructions. Therefore, hydraulic fluid valves (e.g., 313) can be provided along hydraulic fluid flow lines in such a way that the operation of one hydraulic fluid valve does not affect the flow of hydraulic fluid to other ACUs connected in series.

[0043] The ACU 300 may also have a lubricant system that includes a lubricant flow line 320 extending between a main lubricant inlet 321 and a main lubricant outlet 322, a plurality of lubricant valves 323 located along the lubricant flow line 320, and a plurality of lubricant ports 324, wherein each lubricant port 324 is 1941186 of 24 can be smoothly connected to one of the lubricating valves 323 (for example, by means of lubricating lines 325).

[0044] Similar to hydraulic fluid valves, lubricant valves can have various configurations that can provide lubricant flow through ACUs connected in series (e.g., as shown in FIG. 2) while also controlling lubricant flow to and from connected assets as required to lubricate the valves of the associated asset according to instructions. Therefore, lubricant valves 323 can be provided along the lubricant flow line 320 in a configuration that allows the operation of the lubricant valves without impeding lubricant flow to other ACUs connected in series.

[0045] The ACU 300 may also include at least one sensor cable 330 extending between at least one sensor port 334 and an electronic module 340 on the ACU 300. When the ACU 300 is connected to a valve having at least one sensor, the sensor cable 330 and the connected sensor ports 334 can receive and transmit data captured by the valve's sensors, such as valve positioning, pressure sensing, and equipment monitoring.

[0046] The ACU 300 may also include an electronic module 340 in communication with the sensor cables 330, the hydraulic fluid valves 313, and the lubricant valves 323. The electronic module may include, for example, a controller and other computer hardware capable of sending and receiving signals to open or close a valve, transmitting sensor data, and sending / receiving signals to turn switches on and off (e.g., power switches). The electronic module 340 may send and receive signals from a distribution center (e.g., a master control unit in the distribution center) wirelessly or via cables in a connecting supply umbilical (e.g., 250 in FIG. 2).For example, a power cable and a communication cable extending through a connection supply umbilical can power and send signals to the electronic module 340, and the electronic module 340 can then send signals to operate the valve. When the ACU 300 is connected to a valve that has at least one sensor, the sensor cable 330 and the connected sensor port 334 can receive and transmit data captured by the valve's sensors to the module. 1941186 of 24 electronic 340, where the electronic module 340 can transmit sensor data via a network or data cable at the connection supply umbilical (or transmit wirelessly) to a master control unit at the distribution center. Therefore, the electronic module 340 in the ACU 300 can act as a central communication point for the connected asset.

[0047] In some embodiments, an ACU 300 may also include a heat tracing cable 350 extending from a heat tracing power input 351 to a heat tracing power output 352 and a plurality of heat tracing ports 354 in communication with the heat tracing cable 350 by means of heat tracing lines 355.

[0048] In addition, in some embodiments, the ACU 300 may include remote bypass lines 360, 362 that can be used to shut down the ACU 300 if necessary. The remote bypass lines can provide a way to bypass the ACU 300, for example, in an emergency situation, and actuate a valve within the ACU. For instance, an ACU may include one or more bypass lines branching off to one or more hydraulic ports, which can be seamlessly connected to one or more valves designated as bypass valves. Outside the red zone (or safety zone) around the well equipment unit, a manually operated control manifold or valve may be provided and connected to the bypass valve via the bypass lines, where the control manifold or valve can be manually operated to send hydraulic power directly to the bypass valve.In this way, the override lines and the manifold / control valve can allow the connected override valves to be controlled from outside a red zone without going through the control communications via the 340 electronic module in the ACU (for example, in the event of an ACU problem or failure).

[0049] According to the embodiments of the present description, the inlets, outlets, and ports to the systems within the ACU 300 may be arranged in selected positions around the housing 301 to facilitate assembly for connection with other ACUs and valves and to provide modularization. For example, in some embodiments, the inlets to the systems of the ACU 300 may be located on an inlet side 302 of the housing 301 of the 1941186 of 24 The ACU, and the outlets to the ACU 300 systems, can be located on an outlet side 303 of the ACU housing 301. In the embodiment shown, the main hydraulic inlet 311 and the main lubricant inlet 321 can be located on an inlet side 302 of the housing 301. In some embodiments, one or more connections (for example, a heat tracing power inlet 351, a secondary hydraulic fluid port 316, and / or a remote override inlet) to other systems in the ACU 300 can also be located on the inlet side 302 of the housing 301. In addition, the main hydraulic outlet 312 and the main lubricant outlet 322 can be located on an outlet side 303 of the housing 301, opposite the inlet side 302.

[0050] As shown in FIG. 5. The valves of the ACU 300 can be arranged on the same side of the ACU 300 (for example, on one side of valve 305 of the ACU), which can allow easier access to the valves of the ACU 300. For example, the lubricant valves 323 and the hydraulic fluid valves 313 can be provided on the valve side of the ACU 300. In addition, in some embodiments, the ports to the systems within the ACU 300 can be arranged on one side of the feed port 304 of the ACU 301 housing. For example, in the embodiment shown, the hydraulic fluid ports 314, the lubricant ports 324, and the sensor ports 334 can be located on the same side of the ACU 300. Other ports, such as the heat tracing ports 354 and the ports of secondary hydraulic fluid 317.In some embodiments, the ACU 300 feed port 304 side (which has the ACU systems ports arranged on it) may be on an opposite side of the ACU to the ACU valve 305 side (which has the ACU systems valves arranged on it).

[0051] According to the embodiments described herein, the ports of different systems in the ACU 300 can be grouped into banks 370 and 372. Banks 370 and 372 of ports can be provided as a consolidated group of ports to allow easier connection of an umbilical to a valve on an asset. Since each port bank can be associated with a label or mark, controls and systems can be similarly associated with that bank, thereby enabling the association of a valve on an asset. 1941186 of 24 connected with the appropriate ports on the ACU. In this way, in addition to ease of assembly and connection, the control of the asset valves can be facilitated through plug-and-play connectivity with the banks and associated connections.

[0052] For example, a hydraulic fluid port 314, optionally a secondary hydraulic fluid port 317, a lubricant port 324, a sensor port 334, and optionally a heat tracing port 354 can be grouped together in one bank 370. According to the embodiments of the present description, multiple banks 370 can be provided in an ACU 300 (for example, at least 2, at least 8, or more banks) for connection to multiple valves, sensors, and other equipment of an asset.

[0053] In some embodiments, a group of ports that do not include hydraulic fluid ports can be grouped into a bank for connection to a non-hydraulically actuated valve (e.g., a manual valve or an electrically actuated valve). For example, a lubricant port 324, a sensor port 334, and optionally a heat tracer port 354 can be grouped into a non-hydraulic bank 372. According to the embodiments of the present description, an ACU 300 may contain at least one non-hydraulic bank, may contain multiple non-hydraulic banks (e.g., four non-hydraulic banks 372 as shown in FIG. 6), or may contain no non-hydraulic banks.

[0054] By grouping these ports into banks 370, 372, an umbilical can be easily connected to the ports of a bank 370, 372 at one end and to a valve at the other. Separating the ports into groups that can then be connected to individual valves also allows the connecting lines between the ports and valves to remain organized by valve. For example, according to the embodiments of the present description, a well equipment unit can have multiple hydraulic valves and, optionally, at least one non-hydraulic valve. The umbilical segments can be connected at one end to different banks 370, 372 in the ACU 300 and at the other end to the different valves of the equipment unit and the hydraulically actuated valve. 1941186 of 24

[0055] Furthermore, by grouping valve connections according to banks 370, 372 in the ACU 300, connected valves can be assigned by bank 370, 372 using the electronic module 340. For example, a connection to a first bank 370, 372 in the ACU 300 can be tagged in the electronic module 340. As different operations related to the first bank connection occur (e.g., sensor data received from a connected valve, hydraulic fluid valve operations, and lubricant valve operations), such actions can be transmitted from the electronic module 340 to the distribution center, which can then be processed in relation to the overall well site operation.

[0056] The embodiments described herein may permit easier assembly and disassembly of well systems, as well as simplified valve control and monitoring of the valves used in the well system. Whereas conventionally arranged well systems may have included multiple lines connecting each valve to different centralized systems and individual assignments for each valve, the methods and systems according to the embodiments described herein include providing a type of sub-control system that controls multiple systems (via the ACUs) on a per-asset basis for the well equipment units in a well system.

[0057] Figure 8 shows an example of a Method 400 according to the embodiments of the present description for assembling a well site using the ACUs, as described herein. The well site may include multiple well equipment units (for example, a tree, rack, utility skid, other hydraulic fracturing well equipment, drilling equipment, backflow equipment, or other well completion equipment) provided around at least one well (Stage 410). The multiple modular ACUs according to the embodiments of the present description may be connected to the well equipment units in a one-to-one ratio (Stage 420), such that each of the modular ACUs is connected to one of the well equipment units. Each ACU may be connected to a corresponding well equipment unit. 1941186 of 24 by connecting segments of the ACU umbilical to one or more valves in the well equipment unit.

[0058] Modular ACUs can be connected in series with a distribution center (stage 430) using a connecting supply umbilical, where the distribution center can include a hydraulic pressure unit, a lubricant source and pump, a master control unit, a power source, and other components that can be used for the control and monitoring of equipment units at the well site. For example, a distribution center can be connected to a first modular ACU using a first segment of the connecting supply umbilical, a second modular ACU can be connected to the first modular ACU using a second segment of the connecting supply umbilical, and so on until each of the ACUs is connected.

[0059] As an example, the distribution center may be connected to a first ACU, which connects the distribution center's electronic and control system to the first ACU. Since the ACUs are connected to the well equipment units (which include the well equipment units' valves, sensors, etc.), the particular asset and its valve can be assigned in the distribution center's main control and monitoring system in the same way the well equipment units are connected. Alternatively, multiple assets (e.g., fracturing trees) can be connected to one ACU in an organized manner (e.g., the asset's main valve to ACU bank #1, the asset's wing valve to ACU bank #2, etc.), so that assignments in the main control system can be easily configured.The specific order of connection of the distribution center, ACUs and assets may vary, but it can be done in a way that facilitates the allocation of connected assets within the main control system of the distribution center.

[0060] Once the ACUs are connected to the well equipment units and the distribution center, the ACUs can control and monitor the valves of the well equipment units, for example, by providing hydraulic pressure and a lubricant to the valves from the distribution center through the connection supply umbilical, the modular ACUs and the umbilical. 1941186 of 24

[0061] The provision of ACUs on an asset-by-asset basis with well equipment units, where each connected well equipment unit can be controlled using its corresponding ACU, allows the well equipment units to operate independently if one of the well equipment units fails or needs to be shut down. For example, with reference to the well system example shown in FIG. 2, a first well equipment unit 210a can be shut down, for example, for maintenance, while continuing to operate (for example, providing hydraulic pressure and / or lubricant) to at least one valve in the remaining well equipment units 210b, 210c, and 210d.

[0062] In some embodiments, a label can be assigned to each valve on the well equipment units connected to the ACUs, and a well equipment unit type can be assigned to each well equipment unit connected to an ACU. The valve type and well equipment unit assignments can be stored in the connected ACUs, which can then be used to operate the valves and equipment units from the distribution center. For example, signals can be sent from a sensor on a valve in a well equipment unit through an umbilical to a connected ACU, where the valve type and equipment unit can be assigned. The signal with the corresponding valve type and equipment unit assignments can then be sent through a connecting supply umbilical to the distribution center, where the signal can be processed as belonging to the assigned valve type and equipment unit.

[0063] In embodiments having ACUs provided with an integrated heat tracing system, the well system may have a winterizing option integrated with the assembly. For example, multiple ACUs having a heat tracing system in the same may be connected together in series with an HPU (e.g., including a hydraulic fluid source and hydraulic pumps), a lubricant source, and a lubricant pump, which may be provided at a distribution center or other location. A connecting supply umbilical may be used to connect the ACUs in series, where the connecting supply umbilical may include a heat tracing cable (either as a separate line bundled within the 1941186 of 24 supply umbilical connection with other lines, or integrally formed in the lining of the supply umbilical connection) that connects the heat tracing cables in the ACUs. In addition, each ACU can be connected to a well equipment unit by means of an umbilical that includes a heat tracing cable. The heat tracing cable provided in the umbilical can be connected to the heat tracing cables in the ACUs. A power source (for example, a generator) can provide power to the heat tracing cables, which can generate heat through the connected heat tracing cables (in the supply umbilical connection, the ACUs, and the umbilical). The power source can be provided near the HPU and the lubricant source and connected in series with the ACUs, or the power source can be connected to each ACU through separate connecting lines.An integrated heat tracing system included with the ACUs and systems according to the embodiments described herein may allow the winterization of the well system without the use of additional heaters and ducts, thereby simplifying winterization and reducing costs.

[0064] Additionally, the modular ACUs described herein can allow for easy scalability, reorganization, or other changes to a well system on a work basis. For example, adding an additional well equipment unit to a well system may involve connecting an additional ACU to the additional well equipment unit and connecting that additional ACU to a final ACU in the well system. In this way, the ACUs described herein and the methods of using ACUs to assemble a well system can enable the implementation of a scalable system to accommodate any future completion program. The ACUs described herein can also allow for standardized and simplified connections, which can reduce the site footprint and decrease assembly time and costs.

[0065] Although only some exemplary embodiments have been described in detail, those skilled in the art will readily appreciate that many modifications to the exemplary embodiments are possible without materially departing from this invention. Accordingly, all these modifications 1941186 of 24 are intended to be included within the scope of this description as defined in the following claims. 1941186 of 24 ARIEL JUAN IBAÑEZ - 20232572532 Digitally signed by PORTALTRAMITES - INPI Date: 2022.09.01 11:25:36 -03:00 Reason: Digitally Signed by the INPI Location: Buenos Aires, Argentina 1941186

Claims

1. A modular asset control unit of a modular control system with umbilical deployment, comprising: a hydraulic fluid system, comprising: a hydraulic fluid flow line extending between a main hydraulic inlet and a main hydraulic outlet; a plurality of hydraulic fluid valves located along the hydraulic fluid flow line; and a plurality of hydraulic fluid ports, wherein each hydraulic fluid port is fluidly connected to one of the hydraulic fluid valves; characterized in that: a hydraulic fluid return flow line extending between a main hydraulic return inlet and a main hydraulic return outlet, and a plurality of hydraulic fluid return ports fluidly connected to the hydraulic fluid return flow line;A lubricant system comprising: a lubricant flow line extending between a main lubricant inlet and a main lubricant outlet; a plurality of lubricant valves located along the lubricant flow line; and a plurality of lubricant ports, wherein each lubricant port is fluidly connected to one of the lubricant valves; at least one sensor cable extending between at least one sensor port and an electronic module, wherein the electronic module is in communication with the at least one sensor cable, the plurality of hydraulic fluid valves, and the plurality of lubricant valves; and a housing containing the hydraulic fluid system, the lubricant system, the at least one sensor cable, and the electronic module. Eighteen claims follow;