Isolation system for equipment maintenance during well treatment opertions

Abstract

Disclosed embodiments include systems and methods for relatively safely providing maintenance for one bank of pumps of a pressurized wellbore services system, even while one or more other bank of pumps continues to operate (e.g. at high pressures). Further, disclosed embodiments may be configured to allow for essentially continuous pumping of fluid downhole in a well, even while maintenance is being performed. Embodiments may also allow relatively safe in situ maintenance operations without the need for separate barrier protection or shielding. For example, banks of pumps may be configured and managed / operated to address red zone concerns, providing relatively safe maintenance opportunities without the need for a barrier therebetween.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority benefit under 35 U.S.C. 119 (e) of U.S. Provisional Patent Application No. 63 / 627,264 filed Jan. 31, 2024 and entitled “Isolation System for Equipment Maintenance During Well Treatment Operations,” which is incorporated by reference herein in its entirety.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not applicable.FIELD

[0003] This disclosure relates generally to the field of pumping. More particularly, this disclosure relates to the field of pumping units for wells. Still more particularly, this disclosure relates to a system allowing relatively safe and effective operation and maintenance of pumping units in situ.BACKGROUND

[0004] For the safety of maintenance personnel, conventional pumping units, such as those utilized for wellbore operations (e.g., for hydraulic fracking), typically are not serviced while the pump of the pumping unit is fluidly coupled to the well (e.g. coupled to pressurized equipment such as an active high-pressure line, which may be in fluid communication with the well). For example, when the pumping unit is coupled to pressurized equipment, the pumping unit conventionally would be disposed within the “red zone” of that pressurized equipment, which would mean that any personnel working on the coupled pumping unit would be at risk and / or in danger. So, conventionally pumping units typically would be decoupled and removed from a “red zone” of pressurized wellbore services equipment (such as one or more high-pressure line) before maintenance is performed. By removing the pumping unit from proximity to the pressurized equipment (e.g. away from the red zone of the pressurized equipment), maintenance can then be performed relatively safely on the pumping unit. Maintenance may also be performed by deenergizing the entire pumping system (e.g. all pumping units coupled to the well) to allow for maintenance, but during such time, no work would be being performed on the well (e.g. no pumping of fluids), thereby significantly reducing job efficiency.

[0005] For example, such a “red zone” may include a perimeter a defined distance adjacent pressurized equipment. Accordingly, for maintenance to be performed, either the pumping unit as a whole may typically be removed from the red zone, or the pump in question may be removed from the red zone. Either of these approaches can be a time-consuming operation, as the job must typically be halted for the time taken to rig down and move the unit. Furthermore, the delays inherent in such a system can negatively impact pumping efficiency of the wellbore services system. Additionally, there is safety risk in removing pumps or pumping units from the active site. Thus, there may be a need for improved techniques for relatively safely and / or effectively performing maintenance on pumping units, for example to significantly reduce or eliminate job downtime due to pump maintenance. There may also be a need for improved wellbore services systems, for example in order to allow for continuous pumping of fluid downhole in the well regardless of maintenance being performed (e.g. without having to halt a job during performance of maintenance).BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Embodiments of the disclosure may be better understood by referencing the accompanying drawings.

[0007] FIG. 1 is a schematic of an exemplary pumping unit, according to embodiments of this disclosure;

[0008] FIG. 2 is a schematic of an exemplary pump module, according to embodiments of this disclosure;

[0009] FIG. 3 is a schematic representation of an overview of an exemplary wellbore servicing system, according to embodiments of this disclosure;

[0010] FIG. 4 is a schematic illustration of an exemplary wellbore services system similar to that of FIG. 3, according to embodiments of this disclosure;

[0011] FIG. 5 is a schematic illustration of another exemplary wellbore services system, according to embodiments of this disclosure;

[0012] FIG. 6 is a schematic illustration of yet another exemplary wellbore services system, according to embodiments of this disclosure;

[0013] FIGS. 7A-D are schematic overhead plan views of exemplary red zones, according to embodiments of this disclosure;

[0014] FIG. 8 is an overhead schematic of exemplary rotational red zones within an exemplary pumping bank, according to embodiments of this disclosure;

[0015] FIG. 9 is a schematic elevation view of still another exemplary wellbore services system, according to an embodiment of this disclosure; and

[0016] FIGS. 10A-C are overhead schematic illustrations regarding exemplary operation of an exemplary system, for example illustrating the interaction between active pump banks with red zones and the work zone for a corresponding inactive pump bank on which maintenance can be performed.DESCRIPTION

[0017] The description that follows includes example systems, methods, techniques, and program flows that embody aspects of the disclosure. However, it is understood that this disclosure may be practiced without these specific details. For brevity, well-known steps, protocols, structures, and techniques have not been shown in detail in order not to obfuscate the description.

[0018] As noted above, there is a need for improved techniques for relatively safely, effectively, and / or efficiently operating pumps and / or performing maintenance on such pumps (e.g. of one or more pumping unit at a wellsite), for example to reduce downtime within the system during maintenance and / or to allow for continuous pumping of fluid downhole in the well regardless of maintenance being performed (e.g. without having to halt a job during performance of maintenance). As disclosed herein, utilizing a plurality of banks of pumps (e.g. two or more pump banks) and configuring the banks of pumps appropriately to address maintenance concerns, may allow for maintenance to be relatively safely, effectively, and / or efficiently performed on pumps, for example without the need to move the pump or to shut-down the entire system (e.g. the system as a whole may continue to pump fluid to the well). Before discussing the specifics of such systems and methods for improved (e.g. in situ) maintenance in detail, exemplary pumping units, pumps, and wellbore services systems, of the sort that can be used in this system, will now be set forth.

[0019] FIG. 1 illustrates schematically an exemplary pumping unit 100. While the specific exemplary pumping unit 100 shown in FIG. 1 is configured for a modular approach (allowing modular pump removal and replacement), it should be understood that the maintenance system described herein can be used with various pumping units, whether modular or not. And while the exemplary pumping unit shown in FIG. 1 is configured as a mobile skid, for example with wheels and a hook-up so that a truck can be used for transport of the pumping unit 100, it should be understood that various types of pumping units and / or various modes of transporting such pumping units are included in the disclosure herein. The pumping unit 100 of FIG. 1 can comprise a base structure 101; an electric motor 110 mounted on the base structure 101; and one or more pump modules 150. As depicted via brackets, in the embodiment of FIG. 1, the one or more pump modules 150 include two pump modules 150, comprising first pump module 150A and second pump module 150B. Each of the one or more pump modules 150 comprises a pump 120 and a pump module structure 130. The one or more pump modules 150 are configured to be removably mounted on the base structure 101 and driven by the electric motor 110.

[0020] The pumping unit 100 can further comprise at least one connector panel 102 comprising connectors 103 for electrical cables and / or hoses 104 from the one or more pump modules 150, wherein the electrical cables and / or hoses 104 are configured for supplying fluids, electric power, and / or control signals to the one or more pump modules 150, and / or to receive sensor feedback from the one or more pump modules 150. One or more of the connectors / receptacles 103 can be configured for providing / receiving electrical power to the connector panel 102.

[0021] The base structure 101 can comprise a truck, a trailer, or a skid. The electric motor 110, an electric motor drive 160 (which can include) an auxiliary electric power supply 107, or a combination thereof can be mounted on the base structure 101. A pump packing lubrication system 108 can be mounted on the base structure 101.

[0022] In embodiments, the base structure 101 can further comprise one or more mounting points / elements 115, and each of the one or more pump modules 150 can comprise one or more complementary mounting points / elements 116, configured such that each of the one or more mounting points 115 of the base structure 101 are configured to receive / align with one or more of the one or more complementary mounting elements 116 of the one or more pump modules 150, to position and / or align the pump module 150 (e.g., a driveline 135 thereof) with the electric motor 110 (e.g., with a motor shaft 111 thereof).

[0023] FIG. 2 is a schematic of an exemplary pump module 150, providing additional details about exemplary pumps 120. In embodiments, each of the one or more pump modules 150 can comprise the pump module structure 130, the pump 120, a driveline 135, and pump auxiliary systems 140. The pump auxiliary systems 140 can comprise an oil lubrication pump 141, an oil reservoir 143, one or more oil filters 144, an oil cooler 145, an oil heater 187, a sensor package 146 (e.g., comprising one or more sensors 147 for monitoring pressure, temperature, position), a driveline 135 (“driveshaft assembly”), or a combination thereof. The oil lubrication pump 141 can be powered by an auxiliary electric motor 142, in embodiments. Oil cooler 145 can comprise a heat exchanger (e.g., radiator having oil circulating therein) and a fan, in embodiments. The oil heater 187 can comprise a heat exchanger or heating element such as an electrical resistance heating element 188 disposed within the oil reservoir 143 or a heating jacket disposed around all or a portion of the oil reservoir 143. The oil cooler and / or heater can be controlled by control systems 153 responsive to temperature of the oil and / or ambient temperature sensed by one or more sensors of the sensor package 146. The pump auxiliary systems 140 can further comprise a suction manifold 148 and a discharge manifold 149 with connectors for piping, a pump packing lubrication system 151, a driveshaft clutch and / or driveshaft decoupler 152, electrical cables and / or hoses 104, control systems 153, or a combination thereof.

[0024] Each of the pump modules 150 can comprise cables and / or hoses 104 that extend to one or more connector panels 102 mounted on the base structure 101. For example, two connector panels 102 are depicted in the embodiments of FIG. 1. However, in embodiments, a single connector panel 102 can be utilized for one, two, or more pump modules 150, or a plurality of connector panels 102 can be associated with each pump module 150. In embodiments, connector panel 102 can be mounted on base structure 101 (rather than on pump module structure 130). One or more cables (e.g., electrical cables) and / or hoses 104 can connect the connector panel 102 with (e.g., components of) pump module 150. A receptacle / connector 103 of the connector panel 102 can receive electrical supply for the pumping unit 100.

[0025] Each of the one or more pump modules 150 can further comprise one or more lift components 113 configured for removal of each of the one or more pump modules 150 from the base structure 101. The lifting components 113 are not particularly limited, and can comprise, for example, one or more forklift pockets, lifting eyes, or a combination thereof.

[0026] As depicted in FIG. 2, each of the one or more pump modules 150 can further comprise guarding 114, such as configured for rotating or otherwise moving one or more components of the pump module 150; deflectors, trays, and / or tanks, such as for directing or containing fluids; or a combination thereof.

[0027] The electric motor 110 can comprise a first drive shaft 111A and a second drive shaft 111B. In such embodiments, as depicted in FIG. 1, the pumping unit 100 can comprise two pump modules 150, with a first pump module 150A and a second pump module 150B. First pump module 150A is connected to the first drive shaft 111A and second pump module 150B is connected to the second drive shaft 111B, whereby the two pump modules 150 can be driven by the single electric motor 110. The pumping unit 100 can be designed to operate with a single pump module 150 or more pump modules 150 (e.g., with exactly two pump modules 150).

[0028] As depicted in FIG. 2, each of the one or more pump modules 150 can further comprise a pump packing lubrication system 151a (e.g., a “packing grease system”), and / or can be connected to a remote pump packing grease system 151b, and have no fluid connections from the pump packing lubrication system 151 to the base structure 101.

[0029] One or more of the pump module(s) 150 can comprise a pump life monitoring system 154 that is operable to provide component identification, data processing, data storage and / or communications (e.g., internal and / or external), or a combination thereof. In this manner, life data for each pump module 150 can be monitored and tracked (e.g., independently of the life of a pumping unit 100 itself).

[0030] As noted herein, pump 120 of each pump module 150 can comprise a triplex or quintuplex plunger pump (e.g., positive displacement pump), in embodiments. Pump 120 of each of the one or more pump modules 150 can be mounted onto the pump module structure 130 of the each of the one or more pump modules 150 in a manner designed to reduce and / or prevent translation of flexure of the pump module structure 130 to the pump 120. For example, in embodiments, pump 120 of each of the one or more pump modules 150 can be mounted onto the pump module structure 130 of the each of the one or more pump modules 150 via a three-point mounting sub-structure 190 that reduces and / or prevents translation of flexure of the pump module structure 130 to the pump 120.

[0031] Additionally, or alternatively, pump 120 of one or more pump modules 150 can be a centrifugal pump. A centrifugal pump for pumping wellbore servicing fluids downhole comprises a housing having an inlet and an outlet, and a rotating impeller disposed within the housing. The impeller has a plurality of vanes extending radially outwardly from a central hub and is mounted on a shaft that is driven by the electric motor. The impeller rotates at high speed, creating a centrifugal force that propels the wellbore servicing fluid (e.g., fracturing fluid) through the pump and into the wellbore via a manifold and associate piping fluidically coupling the pump 120 to the wellbore.

[0032] Each of the one or more pump modules 150 is driven by the electric motor 110 via connection of a driveline 135 of each of the pump modules 150 with a shaft 111 of the electric motor 110. In embodiments, the driveline can comprise a driveshaft clutch and / or a driveshaft decoupler 152, whereby rotary motion can be prevented from being transmitted from the electric motor 110 to pump 120.

[0033] While the specific exemplary pumping units and / or pumps described herein may be in the context of an exemplary modular pumping unit, many of the same basic elements would be shared with conventional, non-modular pumping units, as persons of skill would understand. The discussion of exemplary pumping units is not intended to be limiting, but merely provides examples for context. The systems and method described herein can apply to both modular and non-modular pumping units.

[0034] One or more pumping units 100 can be used within a wellbore servicing system 300 (for example, as shown in FIG. 3), and examples of such systems and methods for improved (e.g. in situ) maintenance are detailed below. For example, systems to rig up a plurality of pumping units, for instance in a configuration allowing for in situ maintenance even while pumping of fluid to the well continues, and methods of operating such systems and performing maintenance on pumps or pumping units in such systems, are disclosed. In embodiments, the rig up may begin with a bank of clean pumps (e.g. configured to provide clean fluid to the system). A high-pressure discharge line from the clean pump bank may split to flow into two high-pressure lines, each of which can be isolated, for example by closing valves. In some embodiments, the valves can be manually or remotely actuated. A bank of dirty pumps (e.g. configured to provide dirty fluid, for example fluid having sand, particulates, and / or chemicals, such as a slurry) can be fluidly coupled to each high-pressure line. For normal operation, the flow from the clean pump bank may be configured to only go through one of the high-pressure lines (e.g. with the other high-pressure line and associated dirty pump bank being isolated), and the dirty pump bank associated with that active high-pressure line can add slurry to the flow, which then continues to the wellhead / wellbore. The system may be configured with adequate spacing between the two high-pressure lines for the dirty pump banks, and for adequate spacing between the high-pressure discharge line from the clean pump bank and each dirty pump bank, for example to ensure that each high-pressure line is not located in the red zone of the other high-pressure lines.

[0035] Accordingly, when a high-pressure line is isolated (e.g. no flow therethrough), it will not be located within the red zone of any active pump banks and / or other high-pressure lines, and maintenance can be performed in situ by personnel on equipment (such as one or more pumping unit) in the isolated pump bank associated with the isolated high-pressure line. During stage transitions (e.g. when an active bank of pumps needs maintenance), valves can be actuated to swap the flow to another of the pump banks (e.g. from a first dirty pump bank to a second dirty pump bank), thereby allowing relatively safe maintenance to be performed on the other (now isolated) pump bank (e.g. the first dirty pump bank). Additionally, valves can be actuated to isolate the clean pump bank, with both dirty pump banks running a conventional (e.g. non-split flow) stage in order to allow maintenance of the clean pump bank. Such an approach may allow for relatively safe in situ maintenance of pumping units within an isolated pump bank, without the need to move pumping units away from the site, since the work zone for the isolated pump bank may be out of the active red zone(s).

[0036] As used herein, “red zone” may mean a safety perimeter around pressurized equipment (such as a high-pressure line) which is pressurized and / or under active pumping operations. The perimeter may typically extend 1.5 to 2 times the swing radius of the longest discharge joint, which may delineate an area of danger (and beyond it, a relatively safe area) in the event of unexpected failure of pressurized equipment. In embodiments, the red zone may also include an area extending from a high-pressure line and / or manifold to the front of the pumping units. If a monoline is being used, an associated red zone can extend a minimum of 25-30 feet from the perimeter of the pressurized line (e.g. the red zone perimeter can be set based on at the greater of approximately 30 feet from the pressurized equipment or 1.5-2 times the swing radius of the longest discharge joint, for example the sum of these areas when overlaid). As configured, the disclosed system may provide a relatively safe “work zone” for the isolated pump bank (e.g. an area outside of the pressurized / red zone, where maintenance personnel can perform maintenance on the isolated pump bank), for example even when the other pump bank(s) are actively pumping fluid to the wellhead / wellbore. Personnel in the work zone may still wear personal protection equipment, such as hard hats, safety glasses, hearing protection, H2S monitors, and / or protective clothing (e.g. coveralls, safety boots, and / or high impact gloves), but may be available to work on pumping units 100 in the work zone of the isolated pump bank (e.g. in situ and / or without having to move the pumping unit). Examples of maintenance may include the following: replacing parts of the pumping unit, repairing parts of the pumping unit, repairing fluid coupling of the pumping unit to the high-pressure line, replacing fluid coupling of the pumping unit to the high-pressure line, inspecting the pumping units, inspecting the fluid coupling of the pumping unit to the high-pressure line, cleaning (e.g. flushing) the pumping unit, and combinations thereof.

[0037] An exemplary embodiment of a wellbore servicing system 300 and a method of servicing a wellbore / wellhead via the wellbore servicing system 300 will now be described with reference to FIG. 3, which is a schematic representation of an exemplary embodiment of a wellbore servicing system 300. For simplicity and clarity, one or more components may be omitted from FIG. 3. A method of servicing a wellbore / wellhead 324 using a pumping unit 100 can comprise fluidly coupling a pump 120 of a pumping unit 100 to a source of fluid and to the wellbore 324, and communicating fluid (e.g. treatment / wellbore servicing fluid) into the wellbore 324 via the pump 120. The pump 120 can comprise a pump fluid end and a pump power end. The pump power end can be operable to reciprocate a reciprocating element within a reciprocating element bore of the pump fluid end.

[0038] The method of servicing the wellbore can comprise connecting a fluid inlet (e.g., suction or suction manifold 148) on each of the one or more pump modules 150 to a source of fluid, connecting a fluid outlet (e.g., outlet or discharge manifold 149) on each of the one or more pump modules 150 to a well, and operating each of the one or more pump modules 150 via the electric motor 110 to pump the treatment fluid (e.g., fracturing fluid) into the wellbore 324 and surrounding formation (e.g., to fracture the subterranean formation). The method can further comprise recovering oil and / or gas (e.g., hydrocarbons) from the wellbore 324 (e.g., flowing to the wellbore via the fractured subterranean formation).

[0039] It will be appreciated that the wellbore servicing system 300 disclosed herein can be used for any purpose. In embodiments, the wellbore servicing system 200 may be used to service a wellbore 324 that penetrates a subterranean formation by pumping a wellbore servicing fluid into the wellbore and / or subterranean formation. As used herein, a “wellbore servicing fluid” or “servicing fluid” or “treatment fluid” refers to a fluid used to drill, complete, work over, fracture, repair, or in any way prepare a well bore for the recovery of materials residing in a subterranean formation penetrated by the well bore. It is to be understood that “subterranean formation” encompasses both areas below exposed earth and areas below earth covered by water such as ocean or fresh water. Examples of servicing fluids suitable for use as the wellbore servicing fluid, the another wellbore servicing fluid, or both include, but are not limited to, cementitious fluids (e.g., cement slurries), drilling fluids or muds, spacer fluids, fracturing fluids or completion fluids, and gravel pack fluids, remedial fluids, perforating fluids, diverter fluids, sealants, drilling fluids, completion fluids, gelation fluids, polymeric fluids, aqueous fluids, oleaginous fluids, etc.

[0040] In embodiments, the wellbore servicing system 300 comprises one or more pumping units 100 operable to perform oilfield and / or well servicing operations. The oilfield and / or well servicing operations may include, but are not limited to, drilling operations, fracturing operations, perforating operations, fluid loss operations, primary cementing operations, secondary or remedial cementing operations, or any combination of operations thereof. Although a wellbore servicing system is illustrated, skilled artisans will readily appreciate that the pump 120 disclosed herein may be employed in any suitable operation. Each of the one or more pumping units 100 comprises one or a plurality of pump modules 150, and each of the one or more pump modules 150 comprises one or a plurality of pumps 120 operated by an electric motor 110, as detailed hereinabove.

[0041] In FIG. 3, there are a plurality of pumping units 100, for example which may be configured to jointly provide treatment fluid to the wellbore 324. For example, the plurality of pumping units 100 may be configured as two or more pump banks (e.g. banks of pumps, with each bank of pumps having a plurality of pumping units 100). In FIG. 3, the plurality of pumping units 100 are configured as a clean pump bank 391, a first dirty pump bank 393, and a second dirty pump bank 395, with each of the pump banks comprising a plurality of pumping units 100 (although in other embodiments any number of clean and dirty pump banks may be used together as a system).

[0042] In embodiments, the wellbore servicing system 300 may be a system such as a fracturing spread for fracturing wells in a hydrocarbon-containing reservoir. In fracturing operations, wellbore servicing fluids, such as particle laden fluids, are pumped at high-pressure into a wellbore. The particle laden fluids may then be introduced into a portion of a subterranean formation at a sufficient pressure and velocity to cut a casing and / or create perforation tunnels and fractures within the subterranean formation. Proppants, such as grains of sand, are mixed with the wellbore servicing fluid to keep the fractures open so that hydrocarbons may be produced from the subterranean formation and flow into the wellbore. Hydraulic fracturing may desirably create high-conductivity fluid communication between the wellbore and the subterranean formation.

[0043] Typically, each pump bank may be configured to provide fluid under high pressure. For example, the clean pump bank 391 may be configured to provide clean fluid (e.g. water or hydraulic fluid without particulates and / or chemicals) at high pressure, and the dirty pump banks 393, 395 may be configured to provide dirty fluid (e.g. fluid with particulates, such as sand, and / or chemicals) at high pressure. In FIG. 3, high pressure lines may be configured to fluidly couple the clean pump bank 391 to the dirty pump banks 392, 395, and the dirty pump banks 391, 395 to the wellbore 324.

[0044] In the example of FIG. 3, the wellbore servicing system 300 may also include one or more piece of low-pressure equipment, for example configured to feed one or more pump bank. For example, the system 300 may include a blender 302 that is fluidly coupled to and / or configured to feed the dirty pump banks 393, 395 (e.g. mixing water, sand, and / or chemicals to provide dirty fluid). The system may also include a source of clean fluid 389, which may be fluidly coupled (e.g. via feedlines) to and / or configured to feed the clean pump bank 391. In embodiments, low-pressure lines may be used for the feedlines for low-pressure equipment. In embodiments, the low pressure of the low-pressure lines may be less than approximately 200 psi, less than approximately 100 psi, or approximately 100-200 psi.

[0045] The blender 302 can be utilized / operable to mix or otherwise combine solid and fluid components of the dirty fluid (e.g. which may form a portion of the treatment fluid ultimately provided to the wellbore 324, for example when joined, combined, and / or mixed with the clean fluid from the clean pump bank 391). As depicted, in embodiments, sand or proppant 312, water 314, and / or additives 316 can be fed into the blender 302 (e.g. via feedlines). The water 314 may be potable, non-potable, untreated, partially treated, or treated water. In embodiments, the water 314 may be produced water that has been extracted from the wellbore while producing hydrocarbons from the wellbore. The produced water may comprise dissolved and / or entrained organic materials, salts, minerals, paraffins, aromatics, resins, asphaltenes, and / or other natural or synthetic constituents that are displaced from a hydrocarbon formation during the production of the hydrocarbons. In embodiments, the water 314 may be flowback water that has previously been introduced into the wellbore during wellbore servicing operation. The flowback water may comprise some hydrocarbons, gelling agents, friction reducers, surfactants and / or remnants of wellbore servicing fluids previously introduced into the wellbore during wellbore servicing operations.

[0046] The water 314 may further comprise local surface water contained in natural and / or manmade water features (such as ditches, ponds, rivers, lakes, oceans, etc.). Still further, the water 314 may comprise water stored in local or remote containers. The water 314 may be water that originated from near the wellbore and / or may be water that has been transported to an area near the wellbore from any distance. In some embodiments, the water 314 may comprise any combination of produced water, flowback water, local surface water, and / or container stored water. In embodiments, the clean fluid 389 may be the same as or similar to the water 314 for the blender 302. In some implementations, water may be substituted by nitrogen or carbon dioxide; some in a foaming condition.

[0047] In embodiments, the blender 302 may be an Advanced Dry Polymer (ADP) blender and the additives 316 are dry blended and dry fed into the blender 302. In alternative embodiments, however, additives may be pre-blended with water using other suitable blenders, such as, but not limited to, a GEL PRO blender, which is a commercially available pre-blender trailer from Halliburton Energy Services, Inc., to form a liquid gel concentrate that may be fed into the blender 302. Alternate examples of blenders and related equipment include FB4K and ExpressSand (e.g. by Halliburton). The mixing conditions of the blender 302, including time period, agitation method, pressure, and temperature of the blender 302, may be chosen by one of ordinary skill in the art with the aid of this disclosure to produce a homogeneous blend having a desirable composition, density, and viscosity. In alternative embodiments, however, sand or proppant, water, and additives may be premixed and / or stored in a storage tank before entering a wellbore services manifold trailer 304.

[0048] In embodiments, the pump(s) 120 can pressurize fluid to a pressure suitable for delivery into a wellbore 324 or wellhead (e.g. high pressure). For example, the pumps 120 can increase the pressure of fluid to a pressure of greater than or equal to about 3,000 psi, about 5,000 psi, about 10,000 psi, about 15,000, about 20,000 psi, about 30,000 psi, approximately 3,000-20,000 psi, or approximately 5,000-15,000 psi, in embodiments. By way of example, the clean pump bank 391 may be configured to pressurize clean fluid, and the dirty pump banks 393, 395 may be configured to pressurize dirty fluid. In FIG. 3, the clean fluid flows from the clean pump bank 391 into high-pressure lines into which the dirty pump banks 393, 395 inject / pump dirty fluid, and the combination (e.g. treatment fluid) can then be jointly pumped (e.g. through flowline 326) to the wellbore 324.

[0049] The clean and dirty fluid from the pumps 120 of the pump banks may be combined so that the treatment fluid may have a total fluid flow rate through flowline 326 to the flow connector of wellbore 324 based on the needs of the specific wellbore 324 at the specific time in the operation. For example, the fluid flow rate of treatment fluid to the wellbore 324 may be between about 1 BPM to about 200 BPM, alternatively from between about 50 BPM to about 150 BPM, alternatively about 100 BPM. In embodiments, pumps 120 can discharge fluid at a fluid flow rate of between about 1 BPM to about 200 BPM, alternatively from between about 50 BPM to about 150 BPM, alternatively about 100 BPM. In embodiments, the pumps 120 can discharge fluid at a volumetric flow rate of greater than or equal to about 3, 10, or 20 barrels per minute (BPM), or in a range of from about 3 to about 20, from about 10 to about 20, or from about 5 to about 20 BPM.

[0050] In embodiments, the system 300 may also include a controller 377. The controller may be configured to interact with, instruct, control, operate, and / or adjust one or more element / component of the system 300. In some embodiments, the controller 377 may be configured to receive data from one or more sensors. In some embodiments, the controller 377 may be configured to instruct, control, operate, and / or adjust one or more element / component of the system 300 based on and / or responsive to the data. In FIG. 3, the controller 377 may be configured to instruct, control, operate, and / or adjust high-pressurize equipment (such as the clean pump bank 391 (or one or more pumping unit 100 or pump of the clean pump bank), or the dirty pump banks 393, 395 (or one or more pumping unit 100 or pump of the dirty pump banks)) or low-pressure equipment such as the blender 302 (or feed lines to the blender and / or from the blender to the dirty pump banks). For example, the controller 377 may be configured to switch between active pump banks (e.g. bring an inactive pump bank online, while isolating another pump bank based on a maintenance schedule). The controller 377 may also be configured to adjust the composition of the dirty fluid and / or the flow rate for the dirty and / or clean fluid in some embodiments (for example depending on which pump banks are pumping). In embodiments, the controller 377 may be configured to monitor the treatment fluid flowing to the wellbore 324 and / or to adjust the composition of the treatment fluid. In embodiments, the controller 377 may be configured for wellbore servicing operations, such as fracing or producing the well. In embodiments, the controller 377 may be configured for wireless communication, wired communication, or any other form of communication for effectively interacting within the system.

[0051] The controller 377 may include an information handling system (e.g. comprising one or more processor). A processor or central processing unit (CPU) of the controller 377 may be communicatively coupled to a memory controller hub (MCH) or north bridge. The processor may include, for example a microprocessor, microcontroller, digital signal processor (DSP), application specific integrated circuit (ASIC), or any other digital or analog circuitry configured to interpret and / or execute program instructions and / or process data. Processor may be configured to interpret and / or execute program instructions or other data retrieved and stored in any memory (which may for example be a non-transitory computer-readable medium, configured to have program instructions stored therein, or any other programmable storage device configured to have program instructions stored therein) such as memory or hard drive. Program instructions or other data may constitute portions of a software or application, for example application or data, for carrying out one or more methods described herein. Memory may include read-only memory (ROM), random access memory (RAM), solid state memory, or disk-based memory. Each memory module may include any system, device or apparatus configured to retain program instructions and / or data for a period of time (for example, non-transitory computer-readable media). For example, instructions from a software or application or data may be retrieved and stored in memory for execution or use by processor. In one or more embodiments, the memory or the hard drive may include or comprise one or more non-transitory executable instructions that, when executed by the processor, cause the processor to perform or initiate one or more operations or steps. The information handling system may be preprogrammed or it may be programmed (and reprogrammed) by loading a program from another source (for example, from a CD-ROM, from another computer device through a data network, or in another manner).

[0052] Data received by the controller 377 may be used to carry out operations with respect to the system 300. For example, the controller 377 may evaluate the data and determine one or more action based on the evaluation. In some embodiments, the controller 377 may automatically take action based on the evaluation.

[0053] The one or more applications may comprise one or more software applications, one or more scripts, one or more programs, one or more functions, one or more executables, or one or more other modules that are interpreted or executed by the processor. The one or more applications may include machine-readable instructions for performing one or more of the operations related to any one or more embodiments of the present disclosure. The one or more applications may include machine-readable instructions for generating a user interface or a plot. The one or more applications may obtain input data from the memory, from another local source, or from one or more remote sources (for example, via the one or more communication links). The one or more applications may generate output data and store the output data in the memory, hard drive, in another local medium, or in one or more remote devices (for example, by sending the output data via the communication link).

[0054] Memory controller hub may include a memory controller for directing information to or from various system memory components within the information handling system, such as memory, storage element, and hard drive. The memory controller hub may be coupled to memory and a graphics processing unit (GPU). Memory controller hub may also be coupled to an I / O controller hub (ICH) or south bridge. I / O controller hub can be coupled to storage elements of the information handling system, including a storage element, which may comprise a flash ROM that includes a basic input / output system (BIOS) of the computer system. I / O controller hub can also be coupled to the hard drive of the information handling system. I / O controller hub may also be coupled to an I / O chip or interface, for example, a Super I / O chip, which is itself coupled to several of the I / O ports of the computer system, including a keyboard, a mouse, a monitor (or other display) and one or more communications link. Any one or more input / output devices receive and transmit data in analog or digital form over one or more communication links such as a serial link, a wireless link (for example, infrared, radio frequency, or others), a parallel link, or another type of link. The one or more communication links may comprise any type of communication channel, connector, data communication network, or other link. For example, the one or more communication links may comprise a wireless or a wired network, a Local Area Network (LAN), a Wide Area Network (WAN), a private network, a public network (such as the Internet), a WiFi network, a network that includes a satellite link, or another type of data communication network.

[0055] Modifications, additions, or omissions may be made to the controller 377 or any components or elements thereof without departing from the scope of the present disclosure. Any suitable configurations of components may be used. For example, components of controller 377 may be implemented either as physical or logical components. Furthermore, in some embodiments, functionality associated with components of controller 377 may be implemented in special purpose circuits or components. In other embodiments, functionality associated with components of controller 377 may be implemented in configurable general-purpose circuit or components. For example, components of controller 377 may be implemented by configured computer program instructions.

[0056] Persons of ordinary skill in the art with the aid of this disclosure will appreciate that the flowlines described herein are piping that are connected together for example via flanges, clamps, collars, welds, hammer unions, etc. These flowlines may include various configurations of pipe tees, elbows, and the like. These flowlines connect together the various wellbore servicing fluid process equipment described herein.

[0057] Having discussed exemplary pumping units and wellbore servicing systems 300 as context, this disclosure turns now to describing in detail improved systems and techniques for relatively safely performing maintenance at a well site (e.g. in situ, without having to remove the pumping unit from its active location) and / or providing for continuous or uninterrupted (e.g. uninterrupted by maintenance) pumping of pressurized fluid to the wellhead / wellbore.

[0058] FIG. 4 is a schematic view illustrating an exemplary wellbore services system 300 (e.g. for pumping (e.g. treatment) fluid downhole into a well), according to embodiments of this disclosure. The system 300 may include at least two pump banks fluidly coupled to the wellbore / wellhead 324. Each pump bank can have a red zone, and each pump bank can be disposed outside the red zone of the other pump bank (e.g. to allow / provide relatively safe maintenance without a barrier therebetween). In some embodiments, the two pump banks may each be independently fluidly coupled to the wellbore 324.

[0059] In embodiments, maintenance can relatively safely be performed (e.g. by maintenance personnel at the bank) on one pump bank (of the at least two pump banks) while the other pump bank is operating / pumping, even without a barrier disposed between the pump banks or between the corresponding high-pressure line for one pump bank and another pump bank. For example, maintenance personnel can relatively safely perform maintenance at one of the pump banks while being clear of (e.g. without being in) the red zone of the other pump bank. In the embodiments, the two pump banks can be disposed (e.g. parallel to one another) with a space therebetween, and the space therebetween may be substantially open / unblocked (e.g. no barrier wall erected or disposed therebetween, for example no barrier of the sort that would address, eliminate, or reduce the red zone). In embodiments, the red zone of each of the two pump banks does not extend towards the other of the two pump banks beyond the (e.g. substantially open) space therebetween. For example, the open space therebetween can be sufficiently wide so that the red zone of each pump bank does not extend to encompass any part of the other pump bank (e.g. including to corresponding high-pressure line, in some embodiments). In some embodiments, each pump bank may be disposed outside but in proximity to (e.g. a range of approximately 1 foot to 1 yard, 1 foot to 2 yards, 1 foot to 3 yards, 1 foot to 5 yards, 1-2 yards, 1-3 yards, 1-5 yards, 2-3 yards, 3-5 yards, 2-7 yards, or 5-7 yards) the red zone of one or more other pump bank. For example, the high-pressure line associated with one pump bank may be disposed outside of the red zones for the other pump banks (e.g. including the red zone for the high-pressure lines associated with the other pump banks and / or any other high-pressure line of the system), and in some embodiments the high-pressure lines associated with one pump bank may be disposed in proximity to (e.g. abutting or adjacent to, for example within approximately 1 foot to 1 yard, 1 foot to 2 yards, 1 foot to 3 yards, 1 foot to 5 yards, 1-2 yards, 1-3 yards, 1-5 yards, 2-3 yards, 3-5 yards, 2-7 yards, or 5-7 yards of) one or more of the red zones for other pump banks and / or one or more high-pressure lines of the system. And as noted above, each of the pump banks typically comprises a plurality of pumping units. In the embodiment of FIG. 4, the at least two pump banks comprise a first dirty pump bank 393 and a second dirty pump bank 395. The first dirty pump bank 393 has a red zone 421, and the second dirty pump bank 395 has a red zone 422. In FIG. 4, the at least two pump banks also comprise a clean pump bank 391, which is fluidly coupled to the first and second dirty pump banks 393, 395. The clean pump bank 391 has a red zone 423.

[0060] In some embodiments, each of the first dirty pump bank 393 and the second dirty pump bank 395 may comprise the same number of pumping units 100 (e.g. eight pumping units, ten pumping units, twelve pumping units, more than 4 pumping units, more than six pumping units, more than 8 pumping units, more than 10 pumping units, more than twelve pumping units, less than fifteen pumping units, less than twelve pumping units, less than 10 pumping units, less than eight pumping units, 4-12 pumping units, 6-10 pumping units or 8-10 pumping units). In embodiments, the clean pump bank 391 may comprise no more (and often less) pumping units 100 than each dirty pump bank 393, 395 (e.g. no less than ½ the number of pumping units 100 as either one of the dirty pump bank). As shown in FIG. 4, in some embodiments the clean pump bank 391 may comprise the same number of pumping units 100 as each of the dirty pump banks 393, 395.

[0061] The first and second dirty pump banks 393, 395 can each be configured to be fluidly isolated from the clean pump bank 391 and / or the wellhead 324 and / or the other dirty pump bank (e.g. using one or more isolation valves 405). In some embodiments, the clean pump bank 391 can be configured to be fluidly isolated from both the first and second dirty pump banks 393, 395 simultaneously (and / or the wellhead 324) (e.g. using one or more isolation valves 405). In some embodiments, the isolation valve 405 for the clean pump bank 391 may be disposed outside the red zones of the dirty pump banks 393, 395. In some embodiments, the isolation valve 405 for the clean pump bank 391 may be disposed within the red zone for the clean pump bank. In some embodiments, the isolation valve(s) 405 associated with each of the pump banks may be disposed outside the red zone of any other pump banks. In some embodiments, the isolation valve(s) 405 associated with each pump bank may be disposed within the red zone of the corresponding pump bank.

[0062] For each pump bank in FIG. 4, the corresponding plurality of pumping units 100 can be disposed in parallel configuration (e.g. all pumping units extending outward approximately perpendicularly from the corresponding high-pressure line / manifold). In the embodiment of FIG. 4, the first and second dirty pump banks 393, 395 are disposed in parallel configuration (e.g. with the open space therebetween). The clean pump bank 391 of FIG. 4 is positioned out of line with the two parallel dirty pump banks 393, 395 (e.g. the high-pressure line between the clean pump bank 391 and the two dirty pumps banks 393, 395 includes a bend, which is approximately ninety degrees in this figure).

[0063] In embodiments, each dirty pump bank can further comprise one or more high-pressure line. For example, for each dirty pump bank 393, 395, the one or more high-pressure line may include a primary high-pressure line (e.g. high-pressure line 420a for the first dirty pump bank 393 and high-pressure line 420b for the second dirty pump bank 395), and each of the plurality of pumping units 100 can be fluidly coupled to the corresponding primary high-pressure line for the pump bank. In FIG. 4, the primary high-pressure lines 420a, 420b may be the lines to which all of the corresponding plurality of pumping units 100 for the corresponding pump bank are directly coupled and / or from which the plurality of pumping units 100 for the corresponding pump bank extend perpendicularly). In the embodiment of FIG. 4, the primary high-pressure lines 420a and 420b for the first and second dirty pump banks 393, 395 are / extend approximately parallel to each other.

[0064] In embodiments, the primary high-pressure line 420a or 420b for each dirty pump bank 393, 395 may be disposed between the corresponding plurality of pumps 100 for the corresponding dirty pump bank and the other dirty pump bank. For example, the primary high-pressure lines 420a, 420b for each dirty pump bank 393, 395 may face each other in parallel with no pumping units 100 therebetween. So in FIG. 4, the pumping units 100 of the first dirty pump bank 393 may extend outward away from the second dirty pump bank 395, with the corresponding high-pressure line 420a disposed between the pumping units 100 of the first dirty pump bank 393 and the second dirty pump bank 395; and the pumping units 100 of the second dirty pump bank 395 may extend outward away from the first dirty pump bank 393, with the corresponding high-pressure line 420b disposed between the pumping units 100 of the second dirty pump bank 395 and the first dirty pump bank 393. A substantially open space may be disposed between the two primary high-pressure lines 420a, 420b. For example, the space between the primary high-pressure lines 420a, 420b for the first and second dirty pump banks 393, 395 may be substantially open / unblocked (e.g. with no barrier wall, such as a blast shield, erected therebetween).

[0065] For each dirty pump bank 393, 395, the plurality of pumping units typically may be disposed in parallel configuration (e.g. parallel to one another) on one side (e.g. the same side) of the corresponding high-pressure line 420a or 420b (e.g. extending outward from the corresponding high-pressure line perpendicularly). In the embodiment of FIG. 4, the plurality of pumping units 100 in the first dirty pump bank 393 are disposed parallel to the plurality of pumping units 100 in the second dirty pump bank 395. In embodiments, the red zone 421 for the first dirty pump bank 393 may not extend to encompass the high-pressure line 420b corresponding to the second dirty pump bank 395, and the red zone 422 for the second dirty pump bank 395 may not extend to encompass the high-pressure line 420a corresponding to the first dirty pump bank 393. For example, in some embodiments the high-pressure line 420b for the second dirty pump bank 395 may be disposed outside but in proximity to (e.g. approximately abutting, adjacent to, and / or with substantially no space between, for example less than one meter from, less than one foot from, between one foot and one meter from, or one to two meters from) the red zone 421 for the first dirty pump bank 393, and the high-pressure line 420a for the first dirty pump bank 393 may be disposed outside but in proximity to the red zone 422 for the second dirty pump bank 395. In some embodiments, the high-pressure line / manifold from the clean pump bank 391 may be disposed outside but in proximity to the red zone for either the first dirty pump bank 393 or the second dirty pump bank 395 (or both).

[0066] For the clean pump bank 391, half of the pumping units 100 can be disposed on each opposite side of the corresponding high-pressure line / manifold (e.g. disposed on opposite sides and extend perpendicularly from the high-pressure line / manifold), as shown in FIG. 4. In the embodiment of FIG. 4, the plurality of pumping units 100 in the clean pump bank 391 are not parallel to the plurality of pumping units 100 in the dirty pump banks 393, 395 (e.g. extending perpendicularly to the plurality of pumping units 100 in the dirty pump banks 393, 395). In some embodiments, each pump bank may further comprise a manifold configured to fluidly couple the plurality of pumping units 100 to the corresponding high-pressure line. For example, the pumping units of the clean pump bank 391 may be fluidly coupled to a clean high-pressure manifold, which may in turn feed the high-pressure line between the clean pump bank 391 and the dirty pump banks 393, 395.

[0067] As shown in FIG. 4, embodiments may further comprise a high-pressure line from the clean pump bank 391 (e.g. from the clean high-pressure manifold) to both the first and second dirty pump banks 393, 395, for example with the first and second dirty banks 393, 395 fluidly coupled to the high-pressure line from the clean pump bank 391 in parallel (e.g. the high pressure line comprises one or more independent and / or fluidly parallel branch (e.g. a tee-branch), with the first dirty pump bank 393 fluidly coupled to a first branch line and the second dirty pump bank 395 fluidly coupled to a second branch line). One or more isolation valve 405 (e.g. in one or more high pressure line) may be used to provide fluid isolation (e.g. to isolate a pump bank for maintenance). For example, at least one isolation valve 405 can be fluidly disposed between each dirty pump bank 393, 395 and the clean pump bank 391. In some embodiments, at least two isolation valves 405 may be fluidly disposed between each dirty pump bank 393, 395 and the clean pump bank 391. In embodiments, the at least two isolation valves 405 may comprise at least one dirty pump bank isolation valve corresponding to each dirty pump bank and at least one clean pump bank isolation valve. For example, one or more dirty pump bank isolation valve may be disposed between the corresponding dirty pump bank 393, 395 and the tee-branch (e.g. providing parallel high-pressure flow to the two dirty pump banks 393, 395, for example from the clean pump bank 391). This may allow each dirty pump bank 393, 395 to be fluidly isolated from the clean pump bank 391. In embodiments, the at least one dirty pump bank isolation valve may comprise two dirty pump bank isolation valves corresponding to each dirty pump bank (e.g. a primary valve and a redundant / back-up valve).

[0068] As shown in FIG. 4, the at least one clean pump bank isolation valve may be disposed between the clean pump bank 391 and the tee-branch leading to the two parallel dirty pump banks 393, 395. In embodiments, the at least one clean pump bank isolation valve may comprise two clean pump bank isolation valves (e.g. a primary valve and a redundant / back-up valve). In other embodiments, there may not be a separate clean pump bank isolation valve. For example, the clean pump bank 391 may be fluidly isolated by closing dirty pump bank isolation valves between the clean pump bank 391 and both dirty pump banks 393 and 395 (e.g. so both high-pressure lines 420a and 420 be are fluidly isolated from the clean pump bank 391). And as shown in FIG. 4, at least one isolation valve 405 can be disposed between each dirty pump bank 393, 395 and the wellbore 324 (and between the two dirty pump banks 393, 395, for example between the corresponding dirty pump bank 393, 395 and a tee-branch between the parallel dirty pump banks 393, 395 and the wellbore 324). In embodiments, the at least one isolation valve 405 disposed between each dirty pump bank 393, 395 and the wellbore 324 may comprise two or more such isolation valves (e.g. a primary valve and a redundant / back-up valve). In the embodiment of FIG. 4, the clean pump bank 391 is fluidly upstream of the dirty pump banks 393, 395, and the dirty pump banks 393, 395 are fluidly upstream of the wellbore 324.

[0069] The system configuration shown in FIG. 4 may allow for two pump banks to be used to pump fluid to the wellbore 324, while a third pump bank may be fluidly isolated for maintenance. For example, the first dirty pump bank 393 may be active (e.g. in fluid communication with the clean pump bank 391 and / or the wellbore 324 and / or pumping), the second dirty pump bank 395 may be isolated, deactivated, depowered, and / or not pumping (e.g. configured for maintenance), and the clean pump bank 391 may be active (e.g. in fluid communication with the first dirty pump bank 393 and / or the wellbore 324 and / or pumping). Alternatively, the first dirty pump bank 393 may be active (e.g. in fluid communication with the wellbore 324 and / or pumping), the clean pump bank 391 may be isolated, deactivated, depowered, and / or not pumping (e.g. configured for maintenance), and the second dirty pump bank 395 may be active (e.g. in fluid communication with the wellbore 324 and / or pumping). Or alternatively, the clean pump bank 391 may be active (e.g. in fluid communication with the second dirty pump bank 395 and / or wellbore 324 and / or pumping), the first dirty pump bank 393 may be isolated, deactivated, depowered, and / or not pumping (e.g. configured for maintenance), and the second dirty pump bank 395 may be active (e.g. in fluid communication with the clean pump bank 391 and / or wellbore 324 and / or pumping).

[0070] Some embodiments may further comprise a controller 377 (see FIG. 3 for example), and the controller 377 may be configured to receive data regarding and / or control fluid communication in the system 300 (e.g. whether isolation valves 405 are opened or closed and / or whether pump banks are active or non-active / isolated). In embodiments, the controller may be configured to maintain approximately the same / constant composition of fluid to the wellbore 324 (e.g. regardless of which of the pump banks is active / pumping and / or which of the pump banks is non-active / isolated). For example, the controller may be configured to alter the composition of dirty fluid flow (e.g. slurry) to the dirty pump banks 393, 395 when (e.g. responsive to) the clean pump bank 391 is taken offline (e.g. isolated, for example for maintenance) and / or when the two dirty pump banks 393, 395 are used to pump fluid to the wellbore 324, for example to maintain approximately the same composition of fluid to the wellbore 324. The controller may also be configured to alter the composition of dirty fluid flow to one of the dirty pump banks 393 or 395 when (e.g. responsive to) the clean pump bank 391 is brought back online (e.g. into fluid communication with one of the dirty pump banks 393, 395) and the other of the dirty pump banks 393, 395 is taken offline (e.g. isolated, for example for maintenance), for example to maintain approximately the same composition of fluid to the wellbore 324.

[0071] As described with respect to FIG. 3, the system 300 may include one or more piece of low-pressure equipment (e.g. sand boxes 312, blender 302, tanks (e.g. 314, 316, and / or 389), low-pressure pumps for pumping low pressure fluid through low pressure tubing / piping and / or between low-pressure equipment and high-pressure equipment, such as the pump banks). In some embodiments, one or more piece of the low-pressure equipment may be fluidly coupled to one or more of the pump banks. In some embodiments, at least one of the one or more low-pressure equipment may have a work zone (e.g. where personnel and / or vehicles should be able to operate relatively safely to operate / interact with the corresponding low-pressure equipment). In embodiments, the work zone may not overlap the red zones of any of the pump banks. For example, the low-pressure equipment may be disposed / configured within the footprint of the overall system 300 so that there is no overlap between the work zone and the red zones of the pump banks (e.g. the work zone may be separate and distinct from, apart from, physically isolated from, segregated from, and / or does not encroach upon the red zones of the various pump banks—e.g. the clean pump bank 391 and the first and second dirty pump banks 393, 395). In some embodiments, at least some of the low-pressure equipment (e.g. tanks) can be disposed between two of the pump banks.

[0072] FIG. 5 illustrates a system 300 similar to that of FIG. 4. In FIG. 5, the clean pump bank 391 is disposed in-line with the two parallel dirty pump banks 393, 395 (e.g. the high-pressure line between the clean pump bank and two dirty pump banks (e.g. the t-branch to the two dirty pump banks) extends approximately linearly (e.g. without bend)). As in FIG. 4, the clean pump bank 391 of FIG. 5 is fluidly upstream of the dirty pump banks 393, 395, and the dirty pump banks 393, 395 are fluidly upstream of the wellhead 324. Thus, the clean pump bank 391 is configured to flow (e.g. pump) clean fluid to the high-pressure lines to which the dirty pump banks 393, 395 are fluidly coupled (e.g. to the high-pressure line for the dirty pump bank that is not fluidly isolated), and the dirty pump bank 393 or 395 that is not fluidly isolated flows (e.g. pumps) dirty fluid into the corresponding high-pressure line. The combination of clean and dirty fluid in the high-pressure line forms treatment fluid, which then flows (e.g. is pumped) to the wellbore 324.

[0073] FIG. 6 illustrates a system 300 similar to that of FIG. 5 (e.g. similar to FIG. 4, but with the clean pump bank 391 disposed in-line with the two parallel dirty pump banks 393, 395, rather than being offset). In the embodiment of FIG. 6, the dirty pump banks 393, 395 are upstream of the clean pump bank 391 and the wellhead 324 (e.g. with the clean pump bank 391 disposed between the dirty pump banks 393, 395 and the wellhead 324). In the embodiment of FIG. 6, there may be one or two dirty pump bank isolation valve between each dirty pump bank 393, 395 and the clean pump bank 391 (e.g. between each dirty pump bank 393 or 395 and the tee-branch leading to the clean pump bank 391 and the wellbore 324). And in some embodiments, there may also be one or two clean pump bank isolation valve disposed between the two parallel dirty pump banks 393, 395 and the clean pump bank 391 (e.g. between the clean pump bank 391 and the tee-branch leading to both the first and second dirty pump banks 393, 395). Thus, the dirty pump bank 393 or 395 that is not fluidly isolated flows (e.g. pumps) dirty fluid into the corresponding high-pressure line. That corresponding (dirty) high-pressure line feeds the clean manifold (e.g. clean high-pressure line), into which the clean pump bank 391 is configured to flow (e.g. pump) clean fluid. The combination of clean and dirty fluid in the high-pressure line forms treatment fluid, which then flows (e.g. is pumped) to the wellbore 324.

[0074] FIG. 7A illustrates schematically an exemplary red zone for a pump bank (e.g. configured in a manner similar to that of the red zone 423 for the clean pump bank 391 as shown in FIG. 4, although similar approaches can work for one or more dirty pump bank as well). For example, the red zone for each pump bank (e.g. red zone 423 as shown in FIG. 7A) can comprise (e.g. be formed of) a pressurized equipment red zone 705 and a rotational equipment red zone 710 (e.g. the footprint for the overall red zone for each pump bank may include the footprint of the pressurized equipment red zone 705 for all pressurized equipment in the pump bank and the footprint of the rotational equipment red zone 710 for all rotational equipment in the pump bank-some or all of which may overlap). In some embodiments, the red zone 705 for pressurized equipment in a pump bank may completely encompass the red zone 710 for any rotational equipment in the pump bank (e.g. as shown in FIG. 7A). In other embodiments, portions of the red zone 710 for any rotational equipment may extend beyond the footprint of the red zone 705 for pressurized equipment, and / or vice versa (e.g. as shown in FIG. 7B). FIGS. 7C-D similarly show exemplary red zones for a pump bank (e.g. configured in a manner similar to that of the red zone 421 for the first dirty pump bank 393 as shown in FIG. 4, although similar approaches can work for a clean pump bank as well). For example, in FIG. 7C the red zone 705 for pressurized equipment in a pump bank may completely encompass the red zone 710 for any rotational equipment in the pump bank, while in FIG. 7D portions of the red zone 710 for any one or more rotational equipment may extend beyond the footprint of the red zone 705 for pressurized equipment, and / or vice versa.

[0075] In some embodiments, the pressurized equipment red zone 705 may be the greater of 1.5 times the longest run of piping for the equipment or pump bank, 1.5-2 times the swing radius of the longest discharge joint, approximately 25-30 feet, or 30 ft. In some embodiments, the rotational equipment red zone 710 may be defined by the front of the radiator (e.g. for diesel units), the back of the cab (e.g. for duel-fuel units), and / or one or more blast shield for lateral protection (e.g. for the end units). In some embodiments, such lateral blast shield protection may not be disposed between pump banks and / or may be disposed within the pressurized equipment red zone 705 (e.g. not disposed between the overall red zone for the pump bank and another pump bank). FIG. 8 illustrates an exemplary pump bank similar to one side of the clean pump bank 391 of FIG. 4, showing an example of how rotational red zones for rotational equipment (e.g. the pumping units 100 of an exemplary pump bank) may be defined and may interact. For example, in FIG. 8, the rotational red zone associated with each pumping unit 100 of the exemplary pump bank can extend outward from the high-pressure line or manifold, for example to the back of the cab for the pumping unit (e.g. with the cab of the pumping unit (or some other portion of the pumping unit) extending out of the corresponding rotational red zone), while also extending laterally to any adjacent pumping unit(s) (e.g. so that space between a pumping unit and adjacent pumping unit(s) is included in the corresponding rotational red zone for the pumping unit-if the pumping unit has adjacent pumping units on each lateral side, then the space on both sides may be included within its rotational red zone). Typically, spacing between adjacent pumping units may be approximately 1-3 meters. For end pumping units of a pump bank (e.g. having an adjacent pumping unit on only one side), the rotational red zone may extend from the side of the pumping unit opposite the adjacent pumping unit for a greater distance than the spacing between adjacent pumping units, for example extending approximately 2-6 meters, 3-6 meters, or 4-6 meters. And as shown in the embodiment of FIG. 8, the red zones of the various pumping units 100 may overlap (e.g. with the space between adjacent pumping units being included in the rotational red zone of both of the adjacent pumping units).

[0076] For example, the rotational red zone 710b for pumping unit 100b may extend laterally to include the space between pumping unit 100b and pumping unit 100a, as well as the space between pumping unit 100b and pumping unit 100c; the rotational red zone 710c for pumping unit 100c may extend laterally to include the space between pumping unit 100c and pumping unit 100b, as well as the space between pumping unit 100c and pumping unit 100d; and rotational red zone 710d for pumping unit 100d may extend laterally to include the space between pumping unit 100d and pumping unit 100c, as well as the space between pumping unit 100d and pumping unit 100e. Thus, the space between pumping unit 100a and pumping unit 100b may be included in both rotational red zone 710a and 710b; the space between pumping unit 100b and pumping unit 100c may be included in both rotational red zone 710b and 710c; the space between pumping unit 100c and pumping unit 100d may be included in both rotational red zone 710c and 710d; and the space between pumping unit 100d and pumping unit 100e may be included in both rotational red zone 710d and 710e. For end pumping units 100a and 100e, the corresponding rotational red zone (e.g. 710a, 710e) may extend on the side opposite the corresponding adjacent pumping unit (e.g. on the open side, without an adjacent pumping unit) a distance greater than the spacing between adjacent pumping units. And as discussed above with respect to FIGS. 7A-D, in some embodiments the rotational red zones for the pumping units in a pump bank may be entirely within the pressurized red zone for the pump bank (e.g. the pressurized red zone for the pump bank may serve as the overall red zone for the pump bank), while in other embodiments the rotational red zone for at least some of the pumping units in a pump bank may extend beyond the pressurized red zone for the pump bank (e.g. the overall red zone for the pump bank may have a footprint including the extent of both the rotational and pressurized red zones—for example extending to include both rotational and pressurized red zones).

[0077] In some embodiments, one or more barriers may be used between two or more pump banks, for example to reduce the size of the red zone, to allow pump banks to be positioned even closed together, and / or to provide an additional layer of safety / protection. For example, barriers may be used to further minimize the footprint of the system in instances when the footprint of the wellsite is small (e.g. too small or oddly shaped to allow for effective spacing of pump banks). In some embodiments, any such barriers may be used in conjunction with spacing between red zones. For example, the red zones may remain unchanged (e.g. despite the use of the barrier), with pump bank placement as described above with respect to FIG. 4 (e.g. with the barrier between pump banks serving as additional safety / protection). In other example, the placement of barriers between pump banks may effectively reduce the size of the corresponding red zone(s) (although there still may be a red zone distance needed to separate a work zone from active pumping units), allowing for pump banks to be located closer together (e.g. minimizing the footprint of the system). In some embodiments, one or more barrier may be disposed within the pressurized equipment red zone 705 and / or within the overall red zone for the corresponding pump bank (e.g. configured to protect workers at a different pump bank from damage resulting from the corresponding pump bank). In some embodiments, one or more barrier may be disposed within the red zone of a pump bank and configured to protect workers in the corresponding pump bank from one or more other / different pump banks. In some embodiments, the one or more barriers may not disposed between the overall red zone for the pump bank and another pump bank (e.g. between two pump banks). For example, the barrier may provide lateral protection (e.g. with respect to rotational equipment), but may be configured and / or oriented so as to not provide protection of one pump bank from another pump bank (e.g. with respect to pressurized equipment). In some embodiments, the one or more barrier may comprise blast shielding (e.g. ballistic shielding), which may comprise one or more steel plates. For example, the one or more steel plates of the blast shielding can each comprise approximately 1 inch thick steel plates. Other materials capable of providing sufficient ballistic protection may also be used. Further, the blast shielding may be engineered so that its structure can meet the ballistic requirements of the particular system. For example, any structure engineered (for example with respect to material selection and thickness and structural element design) to meet the ballistic requirements of the system can serve as the blast shield. In embodiments, the blast shielding can comprise one or more relatively small opening, for example for flowlines.

[0078] In other embodiments, spacing / configuration of the red zones may allow for effective systems without barriers between pump banks (e.g. no blast / ballistic shielding between pump banks) and / or between the high-pressure lines for one pump bank and the work zone for another pump bank. Thus, spacing / disposition of red zones (e.g. similar to the discussion regarding FIG. 4) may allow for systems with no barrier between two or more red zones, between two or more pump banks, and / or between two or more pressurized lines associated with various pump banks of the system. In some embodiments, the system may also employ one or more indicator to identify which pump banks are active (e.g. pumping and / or pressurized), so that maintenance personnel can easily distinguish between work zones and red zones. For example, flashing indicator lights may automatically be activated when one or more pumping unit of a pump bank is pumping and / or pressurized, and such indicator lights may automatically deactivate when an entire pumping unit is not pumping (e.g. isolated and / or de-pressurized). In some embodiments, the indicator lights may be positioned (e.g. at boundaries) to delineate the red zones. In some embodiments, the controller 377 may operate the indicator lights.

[0079] In some embodiments, at least two of the pump banks may be disposed at different elevation levels at the wellsite. For example, as shown in in FIG. 9, at least one pump bank can be sunken and / or located within a hole. This approach may offer earthwork protection, thereby effectively reducing the size of the red zone in a way that may allow one or more pump bank to be located closer together (e.g. effectively reducing the size of the red zone, while allowing relatively safe maintenance on one pump bank when another pump bank is still pumping fluid). Such an approach may be useful for well sites with small overall footprints, by reducing the open space between pump banks.

[0080] In addition to the system embodiments described herein, method embodiments are also disclosed. For example, both methods of setting up a well site (e.g. setting up the system 300 at the well site) and methods of using the system 300 to pump fluid downhole into the well (e.g. and to provide relatively safe maintenance, for example while providing continuous pumping that is uninterrupted by pump maintenance) are disclosed and included herein. By way of example, embodiments may further comprise one or more methods of setting up a well site (e.g. for introduction of treatment fluid into a well). For example, a method of setting up a well site may comprise: transporting a first plurality of pumping units to the well site; transporting a second plurality of pumping units to the well site; transporting a third plurality of pumping units to the well site; arranging / disposing / positioning the first plurality of pumping units as a first dirty pump bank at a first location at the well site, wherein the first dirty pump bank comprises a first red zone; arranging / disposing / positioning the second plurality of pumping units as a second dirty pump bank at a second location at the well site, wherein the second dirty pump bank comprises a second red zone, and wherein the second dirty pump bank is disposed outside of the first red zone; arranging / disposing / positioning the third plurality of pumping units as a clean pump bank at a third location at the well site, wherein the clean pump bank comprises a third red zone, and wherein the clean pump bank is disposed outside of both the first red zone and the second red zone; fluidly coupling the clean pump bank to both the first dirty pump bank and the second dirty pump bank; and / or fluidly coupling the clean pump bank or both the first and second dirty pump banks to the well head. In embodiments, the fluid coupling is configured to allow fluid isolation of the clean pump bank from the first and second dirty pump banks for maintenance, the fluid coupling is configured to allow fluid isolation of the first dirty pump bank from the clean pump bank and the well (e.g. and the second dirty pump bank) for maintenance, and the fluid coupling is configured to allow fluid isolation of the second dirty pump bank from the clean pump bank and the well (e.g. and the first dirty pump bank) for maintenance.

[0081] In some embodiments, each pump bank (e.g. including its corresponding high-pressure line or manifold) may be positioned with respect to the other pump banks so as to not be disposed within (e.g. to be clear of) the red zone of the other pump banks. In some embodiments, the first red zone, the second red zone, and the third red zone may each be separate and distinct, apart, and / or spaced (e.g. do not overlap). In some embodiments, maintenance can be performed on the first dirty bank without personnel being in the second or third red zones, maintenance can be performed on the second dirty bank without personnel being in the first or third red zones, and maintenance can be performed on the clean bank without personnel being in the first or second red zones. In some embodiments, a substantially open space (e.g. substantially without shielding and / or barrier) can be disposed between the second dirty pump bank and the first dirty pump bank. In some embodiments, a substantially open space (e.g. substantially without shielding and / or barrier) can be disposed between the clean pump bank and the first and / or second dirty pump banks. In some embodiments, each of the pump banks may be disposed in proximity to the red zone of one or more other pump banks (e.g. minimizing the space therebetween). In some embodiments, each of the pump banks may be disposed in proximity to the red zone of two or more other pump banks. In embodiments, a pump bank disposed in proximity to a red zone of another pump bank may be approximately abutting or adjacent to the red zone (e.g. with little or no space therebetween). In embodiments, disposing a pump bank in proximity to a red zone of another pump bank of the system may comprise positioning the pump bank no more than approximately 1 foot, 1 yard, 2 yards, 3 yards, or 4 yards from the red zone, or no less than approximately 1 yard, 2 yards, 3 yards, 4 yards, 5 yards, or 6 yards from the red zone.

[0082] In some embodiments, arranging / disposing may comprise arranging / disposing the pump banks so that their red zones are in proximity (e.g. with substantially no space therebetween) (e.g. so that the outer boundary of their red zones are proximal to each other—for example, minimizing the spacing therebetween, so as to minimize the wellsite footprint). In some embodiments, arranging / disposing may comprise arranging / disposing the pump banks so that at least one of the pump banks is disposed in proximity to (e.g. with substantially no space therebetween—for example—minimizing the spacing therebetween, so as to minimize the wellsite footprint) the red zone of another of the pump banks. In some embodiments, arranging / disposing may comprise arranging / disposing the pump banks so that at least two of the pump banks are disposed in proximity to (e.g. with substantially no space therebetween—for example—minimizing the spacing therebetween, so as to minimize the wellsite footprint) the red zone of another of the pump banks. In some embodiments, arranging / disposing may comprise arranging / disposing the pump banks so that each of the pump banks is disposed in proximity to the red zone of another of the pump banks.

[0083] Some embodiments may further comprise fluidly isolating one of the first or second dirty pump banks from the clean bank (and the wellhead). Some embodiments, may further comprise pumping fluid to the wellhead using the clean bank and the non-isolated (e.g. active) dirty pump bank. In some embodiments, the first dirty pump bank and the second dirty pump bank can be fluidly coupled in parallel to the clean pump bank and / or the wellhead. In some embodiments, the first dirty pump bank and the second dirty pump bank can be spaced apart by the open space (e.g. at least approximately 30 feet). In some embodiments, arranging / disposing first, second, and third pump banks may comprise positioning to minimize overall footprint of the well site and / or configuring to fit a footprint of the well site (e.g. including low pressure equipment work zone, which no red zone should overlap with).

[0084] In some embodiments, arranging further may comprise providing sufficient area adjacent each pump bank for mobile pumping units (e.g. trucks with pumps) to maneuver in and out of position in the corresponding pump bank. In some embodiments, for each pump bank, the corresponding red zone spacing between banks may be the greater of a pressurized equipment red zone or a rotational equipment red zone. In some embodiments, for each pump bank, the footprint of its red zone comprises the joint footprint of both the pressurized equipment red zone and the rotational equipment red zone.

[0085] Some embodiments may further comprise arranging / disposing one or more low-pressure equipment at the well site, wherein at least one of the low-pressure equipment has a work zone, and wherein the work zone is separate and distinct, apart, or spaced from (e.g. does not overlap with) the red zones for any of the pump banks. In some embodiments, arranging / disposing one or more low-pressure equipment may comprise arranging / disposing the low-pressure equipment so that its work zone is in proximity to the red zone of one of the pump banks (e.g. with substantially no space therebetween) (e.g. so that the outer boundary of the work zone and the outer boundary of the red zone are proximal to each other—for example, minimizing the spacing therebetween, so as to minimize the wellsite footprint). Some method embodiments may further comprise digging at / grading / lowering at least one of the first, second, or third location, so that at least two of the pump banks are disposed at different elevation levels at the well site (e.g. at least one pump bank is sunken relative to another pump bank and / or is located within a hole).

[0086] Some embodiments may also include selecting the locations for the pump banks and in some embodiments, the low-pressure equipment and / or the high-pressure lines) at the well site. For example, selecting the locations may be based on ensuring that the pump banks are each outside of the red zone of the other pump banks, that one or more of the pump banks is in proximity to (e.g. but outside of) one or more red zone of another pump bank, that the work zone associated with one or more pump bank is disposed outside (e.g. but in proximity to) the red zone for one or more other pump bank, and / or that the work zone for low-pressure equipment is outside the red zones. In some embodiments, selecting the locations may be based on minimizing the footprint of the system and / or making the footprint of the system fit within the overall footprint of the well site. Pump banks may then be set up (e.g. by disposing the related pumping units and / or high-pressure lines) accordingly. Using a system with such a set-up, pumping of fluid into the well may operate essentially continuously, for example with pumping continuing while maintenance is being performed on a non-active pumping unit and / or while switching between pumping units for maintenance (e.g. while taking one pumping unit offline for maintenance, and bringing a previously idle non-active pumping unit online in its place). In embodiments, while switching between pumping units (e.g. taking one pumping unit offline for maintenance, and bringing a previously idle non-active pumping unit online in its place), there may be substantially no time in which pumping of fluid into the well ceases and / or in which the number of pumping units pumping fluid into the well decreases (e.g. the number of pumping units working in conjunction to pump fluid downhole may stay approximately constant throughout operation of the system).

[0087] Embodiments may also comprise one or more methods for pumping treatment fluid downhole in a well and / or relatively safely performing maintenance on pumps during pumping (e.g. using a system similar to any one of the embodiments disclosed herein). For example, a method for pumping treatment fluid downhole in a well may comprise: pumping treatment fluid into the well using a clean pump bank and a first dirty pump bank fluidly disposed in-line (e.g. in series, e.g. with the clean bank pumping clean fluid, and the first dirty bank pumping dirty / slurry fluid that mixes with the clean fluid), wherein a second dirty pump bank is fluidly isolated from the clean pump bank and / or the first dirty pump bank and / or the well (e.g. while the second dirty pump bank is isolated / idle / not pumping / having maintenance performed or configured to have maintenance performed) (e.g. operating only one of the dirty pump banks in conjunction with the clean pump bank—to add dirty / slurry flow to the clean flow); and performing (e.g. relatively safely, without maintenance personnel being in the red zone for either the clean or first dirty bank) maintenance on the isolated second dirty pump bank while both the clean pump bank and the first dirty pump bank are pumping. See for example FIG. 10A. In some embodiments, a space between the first and second dirty pump banks and / or between the second dirty pump bank and the clean pump bank may be substantially open / unblocked (e.g. without shielding therebetween). For example, maintenance may be performed on the isolated pump bank (e.g. within its work zone), despite there being no barrier between the isolated pump bank and other, active pump banks and the active pump banks operating (e.g. having high-pressure and / or rotational equipment in use). The work zone for the isolated pump bank may be located outside / beyond the red zones for the other pump banks of the system. In some embodiments, maintenance can be performed on the second dirty pump bank by maintenance personnel without such personnel entering the red zone for either the first dirty pump bank or the clean pump bank (e.g. due to disposition of the pump banks with regard to their red zones—for example with the second dirty pump bank disposed outside the red zones of the first dirty pump bank and the clean pump bank).

[0088] In embodiments, pumping treatment fluid into the well using a clean pump bank and a first dirty pump bank may comprise: pumping clean fluid using the clean pump bank; pumping dirty fluid using the first dirty pump bank; and combining / mixing the clean and dirty fluid and pumping the combination to the wellhead. Some embodiments may further comprise fluidly isolating the second dirty pump bank from the clean pump bank and / or wellhead (e.g. before pumping treatment fluid into the well using the clean pump bank and the first dirty pump bank fluidly disposed in-line). Some embodiments may further comprise (e.g. after pumping treatment fluid into the well using the clean pump bank and the first dirty pump bank fluidly disposed in-line fluidly and / or after maintenance on the second dirty pump bank is performed / completed): fluidly isolating the first dirty pump bank and (e.g. approximately simultaneously) placing the second dirty pump bank into fluid communication with the clean pump bank and / or the wellhead; pumping (e.g. continuously) treatment fluid into the well using the clean pump bank and the second dirty pump bank, while the first dirty pump bank is fluidly isolated (e.g. thereby providing approximately continuous pumping even while switching between pump banks and performing maintenance); and performing (e.g. relatively safely) maintenance on the isolated first dirty pump bank while pumping with both the clean pump bank and the second dirty pump bank (e.g. even when personnel are located in the isolated pump bank). See for example FIG. 10B. In embodiments, a space between the first and second dirty pump banks and / or between the first dirty pump bank and the clean pump bank can be substantially open / unblocked (e.g. without shielding therebetween). In embodiments, maintenance can be performed on the first dirty pump bank by maintenance personnel without such personnel entering the red zone for either the second dirty pump bank or the clean pump bank (e.g. due to disposition of the pump banks with regard to their red zones—for example with the first dirty pump bank disposed outside the red zones of the second dirty pump bank and the clean pump bank).

[0089] Some method embodiments may further comprise (e.g. after pumping treatment fluid into the well using the clean pump bank and the first dirty pump bank fluidly disposed in-line fluidly and / or after maintenance on the second dirty pump bank is performed / completed): fluidly isolating the clean bank from both the first and second dirty banks and (e.g. approximately simultaneously) placing the (e.g. previously isolated) first or second dirty pump bank into fluid communication with the wellhead (e.g. so that both the first and second dirty banks are in fluid communication with the wellhead and are pumping dirty fluid / slurry into the wellhead); pumping (e.g. continuously) treatment fluid into the well using the first and second dirty pump banks, while the clean bank is fluidly isolated (e.g. thereby providing approximately continuous pumping even while switching between pump banks and performing maintenance); and performing (e.g. relatively safely) maintenance on the clean bank while pumping with both the first dirty pump bank and the second dirty pump bank (e.g. without shielding therebetween—the space between the clean bank and the dirty banks is substantially open / unblocked). See for example FIG. 10C. In some embodiments, a space between the second dirty pump bank and the clean pump bank and / or between the first dirty pump bank and the clean pump bank can be substantially open / unblocked (e.g. without shielding therebetween—e.g. typically, substantially the only thing between one of the dirty pump banks and the clean pump bank may be the other dirty pump bank). In some embodiments, maintenance can be performed on the clean pump bank by maintenance personnel without such personnel entering the red zone for either the first or second dirty pump banks (e.g. due to disposition of the pump banks with regard to their red zones—for example with the clean pump bank disposed outside the red zones of the first and second dirty pump banks). Some embodiments may further comprise, after maintenance is performed / completed on the clean pump bank, fluidly isolating one of the dirty pump banks while (e.g. approximately simultaneously) placing the clean pump bank into fluid communication with the other dirty pump bank and the well (e.g. returning to a configuration or operation similar to that shown in FIG. 10A).

[0090] In embodiments, some portion of the pumping units at the well site (e.g. one of the pump banks) may always be idle (e.g. not pumping). For example, if the dirty pump banks and the clean pump bank all have the same number of pumping units, then ⅓ of the total pumping units at the site may be idle at any given time (e.g. the system may be designed to only use ⅔ of the pumping units at the site). Thus, the number of pumping units at the well site may be selected based on having some portion (such as ⅓) of the total pumping units of the system idle, while still providing the pressure and / or flow rate desired or expected for the wellhead. In some embodiments, there is the capability to run all pump banks at the same time (e.g. for a limited period of time in which flow rate greater than standard may be needed or desired). For example, temporarily (e.g. no more than approximately one hour, 12 hours, or one day), all pump banks may work in conjunction to pump fluid downhole into the well, thereby increasing fluid flow rate and / or pressure. This typically would not be done all of the time, however, since it may impact the ability to perform maintenance while providing continuous and / or consistent flow. In other embodiments, however, all pump banks may generally operate together except when one pump bank needs maintenance (e.g. providing higher overall flow rate, with periods of lower (but typically continuous / uninterrupted) flow rate when there is maintenance being performed).

[0091] In some method embodiments, maintenance (e.g. and / or fluidly isolating) can be performed on the first and second dirty pump banks based on a dirty pump bank maintenance schedule, and maintenance can be performed on the clean pump bank based on a clean pump bank maintenance schedule. Typically, the clean pump bank maintenance schedule may be longer (e.g. less frequent, with more time in between maintenance) than the dirty pump bank maintenance schedule. In embodiments, (e.g. timing for) switching between pump banks (e.g. fluidly isolating one pump bank while simultaneously placing another pump bank into fluid communication) is based on the clean pump bank maintenance schedule and the dirty pump bank maintenance schedule. In embodiments, the clean pump bank maintenance schedule may be 2-4 times longer than the dirty pump bank maintenance schedule (e.g. the dirty pump bank maintenance schedule is 50-60 hours runtime and / or the clean pump bank maintenance schedule is 150-200 hours runtime). In some embodiments, lines providing fluid communication between pump banks and the wellhead during pumping may be pressurized (e.g. with high pressure), and the method may further comprise, after isolating one of the pump banks, de-pressurizing (e.g. reducing pressure from high pressure to at least low pressure) the lines fluidly coupled to the isolated pump bank. In embodiments, treatment fluid can be continuously (e.g. without interruption for pump maintenance) pumped to the well, even while maintenance is performed on one of the pump banks.

[0092] Some embodiments may further comprise, responsive to the clean pump bank being offline (e.g. isolated for maintenance) and both dirty pump banks pumping fluid to the wellhead, altering the composition of the dirty fluid (e.g. slurry) supplied to the dirty pump banks, for example to maintain approximately the same composition of fluid ultimately flowing to the wellhead. Some method embodiments may further comprise, responsive to the clean pump bank being brought back online (e.g. placed into fluid communication with one of the dirty pump banks) and / or one of the dirty pump banks being taken offline (e.g. fluidly isolated for maintenance), altering the composition of the dirty fluid (e.g. slurry) supplied to the active dirty pump bank (e.g. the dirty pump bank in fluid communication with the clean pump bank and the well), for example to maintain approximately the same composition of fluid ultimately flowing to the wellhead. In some embodiments, the first and second dirty pump banks may each have the same number of pumping units available. In some embodiments, the first and second dirty pump banks and the clean pump bank may each have the same number of pumping units available. In some embodiments, the number of available pumping units (e.g. for the well) can be kept constant while performing maintenance (e.g. on one of the pump banks, for example ¼-⅓ of the total pumping units for the well). In some embodiments, not all available pumping units may run / pump at all times or at the same time.

[0093] Some method embodiments may further comprise, upon detecting an issue indicative of a need for maintenance / repair for one of the pump banks, switching (e.g. simultaneously and / or before the maintenance schedule indicates it is time) that pump bank offline (e.g. fluidly isolating that pump bank) and bringing the reserve pump bank (e.g. the pump bank that was previously fluidly isolated) online (e.g. placing it into fluid communication with the well), and then performing maintenance / repair on the offline pump bank. Some embodiments may further comprise sensing one or more parameter of the system to detect a need for maintenance / repair of one of the pump banks.

[0094] Some embodiments may further comprise operating low-pressure equipment having a work zone while pumping high-pressure treatment fluid to the well, wherein the work zone does not overlap with the red zone for any of the pump banks (e.g. no personnel or vehicle for the low-pressure equipment disposed in the red zone for any of the pump banks) (e.g. the work zone is separate and distinct, apart, and / or spaced from the red zones). Some embodiments may further comprise setting up / positioning and fluidly coupling the pump banks to the well (e.g. to the wellhead / wellbore). For example, setting up the pump banks may comprise any of the method embodiments for setting up a well site set forth herein. Some embodiments may further comprise setting up / positioning and / or fluidly coupling the low-pressure equipment (e.g. to the pump banks). These and other method embodiments relating to the system embodiments disclosed herein will be understood by persons of skill.ADDITIONAL DISCLOSURE

[0095] The following are non-limiting, specific embodiments in accordance with the present disclosure:

[0096] In a first embodiment, a system for pumping (e.g. treatment) fluid downhole into a well comprises: at least two pump banks (e.g. independently) fluidly coupled to a wellhead / wellbore, wherein each pump bank has a red zone, and each pump bank is disposed outside the red zone of the other pump bank (e.g. to allow / provide relatively safe maintenance without a barrier therebetween).

[0097] A second embodiment can include the system of the first embodiment, wherein the two pump banks are independently fluidly coupled to the wellhead (e.g. can be fluidly isolated from each other).

[0098] A third embodiment can include the system of the first or second embodiment, wherein maintenance can relatively safely be performed (e.g. by maintenance personnel at the pump bank) on one pump bank while the other pump bank is operating / pumping, even without a barrier disposed between the pump banks (wherein maintenance personnel can relatively safely perform maintenance at one of the pump banks while being clear of (e.g. without being disposed in) the red zone of the other pump bank).

[0099] A fourth embodiment can include the system of any one of the first to third embodiments, wherein the two pump banks are disposed with a space therebetween, and the space therebetween is substantially open / unblocked (e.g. no barrier wall erected or disposed therebetween).

[0100] A fifth embodiment can include the system of any one of the first to fourth embodiments, wherein the two pump banks are disposed approximately / substantially parallel to one another.

[0101] A sixth embodiment can include the system of any one of the fourth to fifth embodiments, wherein the red zone of each of the two pump banks does not extend towards the other of the two pump banks beyond the (e.g. substantially open) space therebetween (e.g, wherein the open space therebetween is sufficiently wide so that the red zone of each pump bank does not extend to encompass any part of the other pump bank).

[0102] A seventh embodiment can include the system of any one of the first to sixth embodiments, wherein each of the two pump banks comprises a plurality of pumping units.

[0103] An eighth embodiment can include the system of any one of the first to seventh embodiments, wherein the two pump banks comprise a first dirty pump bank and a second dirty pump bank.

[0104] A ninth embodiment can include the system of the eighth embodiment, wherein each of the first dirty pump bank and the second dirty pump bank comprises the same number of pumping units (e.g. eight pumping units, ten pumping units, twelve pumping units, more than 4 pumping units, more than six pumping units, more than 8 pumping units, more than 10 pumping units, more than twelve pumping units, less than fifteen pumping units, less than twelve pumping units, less than 10 pumping units, less than eight pumping units, 4-12 pumping units, 6-10 pumping units or 8-10 pumping units).

[0105] A tenth embodiment can include the system of any one of the first to ninth embodiments, further comprising a third / clean pump bank, wherein the third / clean pump bank is fluidly coupled to the first and second dirty pump banks.

[0106] An eleventh embodiment can include the system of the tenth embodiment, wherein the clean pump bank comprises a plurality of pumping units.

[0107] A twelfth embodiment can include the system of any one of the tenth to eleventh embodiments, wherein the clean pump bank comprises no more (e.g. typically less) pumping units than each dirty pump bank (e.g. no less than ½ the number of pumping units as either one of the dirty pump bank).

[0108] A thirteenth embodiment can include the system of any one of the tenth to eleventh embodiments, wherein the clean pump bank comprises the same number of pumping units as each of the dirty pump banks.

[0109] A fourteenth embodiment can include the system of any one of the tenth to thirteenth embodiments, wherein the first and second dirty pump banks are each configured to be fluidly isolated from the clean pump bank and / or the wellhead and / or the other dirty pump bank (e.g. using one or more isolation valves).

[0110] A fifteenth embodiment can include the system of any one of the tenth to fourteenth embodiments, wherein the clean pump bank is configured to be fluidly isolated from both the first and second dirty pump banks simultaneously (and / or the wellhead) (e.g. using one or more isolation valves).

[0111] A sixteenth embodiment can include the system of any one of the first to fifteenth embodiments, wherein at least one of the pump banks is disposed in proximity to the red zone of another of the pump banks (e.g. the second dirty pump bank can be disposed in proximity to the red zone of the first dirty pump bank, the first dirty pump bank can be disposed in proximity to the red zone of the second dirty pump bank, the clean pump bank can be disposed in proximity to the red zone of the first dirty pump bank, and / or the clean pump bank can be disposed in proximity to the red zone of the second dirty pump bank).

[0112] A seventeenth embodiment can include the system of any one of the seventh to sixteenth embodiments, wherein for each pump bank, the corresponding plurality of pumping units are disposed in parallel configuration.

[0113] An eighteenth embodiment can include the system of any one of the eighth to seventeenth embodiments, wherein the first and second dirty pump banks are disposed in parallel configuration (e.g. with the open space therebetween).

[0114] A nineteenth embodiment can include the system of any one of the tenth to eighteenth embodiments, wherein the clean pump bank is disposed in-line with the two parallel dirty pump banks (e.g. the high-pressure line between the clean pump bank and two dirty pump banks (e.g. the t-branch to the two dirty pump banks) extends approximately linearly (e.g. without bend)).

[0115] A twentieth embodiment can include the system of any one of the tenth to eighteenth embodiments, wherein the clean pump bank is positioned out of line with the two parallel dirty pump banks (e.g. the high-pressure line between the clean pump bank and the two dirty pumps banks includes a bend).

[0116] A twenty-first embodiment can include the system of any one of the eighth to twentieth embodiments, wherein each dirty pump bank further comprises one or more high-pressure line, wherein for each dirty pump bank, the one or more high-pressure line comprises a primary high-pressure line, and each of the plurality of pumping units is fluidly coupled to the corresponding primary high-pressure line for the pump bank.

[0117] A twenty-second embodiment can include the system of the twenty-first embodiment, wherein the primary high-pressure line (e.g. the line to which all of the corresponding plurality of pumping units are directly coupled and / or from which the plurality of pumping units extend perpendicularly) for the first and second dirty pump banks are / extend approximately parallel to each other.

[0118] A twenty-third embodiment can include the system of any one of the twenty-first to twenty-second embodiments, wherein the primary high-pressure line for each dirty pump bank is disposed between the corresponding plurality of pumps and the other dirty pump bank (e.g. the primary high-pressure lines for each dirty pump bank face each other in parallel with no pumping units therebetween).

[0119] A twenty-fourth embodiment can include the system of any one of the twenty-first to twenty-third embodiments, wherein a space between the primary high-pressure lines for the first and second dirty pump banks is substantially open / unblocked (e.g. no barrier wall erected therebetween).

[0120] A twenty-fifth embodiment can include the system of any one of the twenty-first to twenty-fourth embodiments, wherein the red zone for the first dirty pump bank does not extend to encompass the (e.g. primary) high-pressure line corresponding to the second dirty pump bank, and the red zone for the second dirty pump bank does not extend to encompass the (e.g. primary) high-pressure line corresponding to the first dirty pump bank.

[0121] A twenty-sixth embodiment can include the system of any one of the twenty-first to twenty-fifth embodiments, wherein for each dirty pump bank, the plurality of pumping units are disposed in parallel configuration (e.g. parallel to one another) on one side (e.g. the same side) of the corresponding high-pressure line (e.g. extending outward from the corresponding high-pressure line approximately or substantially perpendicularly, for example extending away from the other dirty pump bank).

[0122] A twenty-seventh embodiment can include the system of the twenty-sixth embodiment, wherein the plurality of pumping units in the first dirty pump bank are disposed approximately parallel to the plurality of pumping units in the second dirty pump bank.

[0123] A twenty-eighth embodiment can include the system of any one of the twenty-sixth to twenty-seventh embodiments, wherein for the clean pump bank, the plurality of pumping units are disposed in parallel configuration (e.g. parallel to one another).

[0124] A twenty-ninth embodiment can include the system of any one of the twenty-sixth to twenty-eighth embodiments, wherein for the clean pump bank, half of the pumping units are disposed on each opposite side of the corresponding high-pressure line / manifold (e.g. disposed on opposite sides and extending approximately or substantially perpendicularly from the high-pressure line / manifold).

[0125] A thirtieth embodiment can include the system of any one of the twenty-sixth to twenty-ninth embodiments, wherein the plurality of pumping units in the clean pump bank are not parallel to the plurality of pumping units in the dirty pump banks (e.g. extend approximately perpendicularly to the plurality of pumping units in the dirty pump banks).

[0126] A thirty-first embodiment can include the system of any one of the twenty-sixth to twenty-ninth embodiments, wherein the plurality of pumping units in the clean pump bank are approximately parallel to the plurality of pumping units in the dirty pump banks (e.g. extend approximately parallel to the plurality of pumping units in the dirty pump banks).

[0127] A thirty-second embodiment can include the system of any one of the tenth to thirty-first embodiments, further comprising a high-pressure line from the clean pump bank (e.g. clean high-pressure manifold) to both the first and second dirty pump banks, wherein the first and second dirty banks are fluidly coupled to the high-pressure line from the clean pump bank in parallel (e.g. the high pressure line comprises one or more independent and / or fluidly parallel branch (e.g. a t-branch), with the first dirty pump bank fluidly coupled to a first branch line and the second dirty pump bank fluidly coupled to a second branch line).

[0128] A thirty-third embodiment can include the system of any one of the first to thirty-second embodiments, wherein one or more isolation valve (e.g. in one or more high pressure line) may be used to fluidly isolate (e.g. to provide fluid isolation for one or more pump bank).

[0129] A thirty-fourth embodiment can include the system of the thirty-third embodiment, wherein at least one isolation valve is fluidly disposed between each dirty pump bank and the clean pump bank.

[0130] A thirty-fifth embodiment can include the system of any one of the thirty-third to thirty-fourth embodiments, wherein at least two isolation valves are fluidly disposed between each dirty pump bank and the clean pump bank.

[0131] A thirty-sixth embodiment can include the system of the thirty-fifth embodiment, wherein the at least two isolation valves comprise at least one dirty pump bank isolation valve corresponding to each dirty pump bank and at least one clean pump bank isolation valve.

[0132] A thirty-seventh embodiment can include the system of the thirty-sixth embodiment, wherein the at least one dirty pump bank isolation valve comprises two dirty pump bank isolation valves corresponding to each dirty pump bank (e.g. a primary valve and a redundant / back-up valve).

[0133] A thirty-eighth embodiment can include the system of any one of the thirty-sixth to thirty-seventh embodiments, wherein the at least one dirty pump bank isolation valve is disposed in proximity to each dirty pump bank and / or distal to the clean pump bank, for example outside the red zone of the clean pump bank).

[0134] A thirty-ninth embodiment can include the system of any one of the thirty-sixth to thirty-eighth embodiments, wherein the at least one clean pump bank isolation valve comprises two clean pump bank isolation valves (e.g. a primary valve and a redundant / back-up valve).

[0135] A fortieth embodiment can include the system of any one of the thirty-sixth to thirty-ninth embodiments, wherein the at least one clean pump bank isolation valve is disposed in proximity to the clean pump bank (e.g. distal to the dirty pump banks, for example outside the red zones for both dirty pump banks).

[0136] A forty-first embodiment can include the system of any one of the thirty-third to fortieth embodiments, wherein at least one isolation valve is disposed between each dirty pump bank and the well.

[0137] A forty-second embodiment can include the system of the forty-first embodiment, wherein the at least one isolation valve disposed between each dirty pump bank and the well comprises two or more isolation valves (e.g. a primary valve and a redundant / back-up valve).

[0138] A forty-third embodiment can include the system of any one of the forty-first to forty-second embodiments, wherein the at least one isolation valve disposed between each dirty pump bank and the well is disposed in proximity to the corresponding dirty pump bank (e.g. between the corresponding dirty pump bank, the well, and / or the other dirty pump bank).

[0139] A forty-fourth embodiment can include the system of any one of the tenth to forty-third embodiments, wherein the clean pump bank is fluidly upstream of the dirty pump banks, and the dirty pump banks are fluidly upstream of the wellhead / wellbore.

[0140] A forty-fifth embodiment can include the system of any one of the tenth to forty-third embodiments, wherein the dirty pump banks are upstream of the clean pump bank and the wellhead (e.g. with the clean pump bank disposed between the dirty pump banks and the wellhead / wellbore).

[0141] A forty-sixth embodiment can include the system of any one of the tenth to forty-fifth embodiments, wherein the first dirty pump bank is active, in fluid communication with the clean pump bank and / or the wellhead / wellbore, pressurized, and / or pumping, the second dirty pump bank is fluidly isolated (e.g. deactivated, depowered, de-pressured, not pumping, fluidly disconnected, and / or configured for maintenance), and the clean pump bank is active, in fluid communication with the first dirty pump bank and / or the wellhead / wellbore, pressurized, and / or pumping.

[0142] A forty-seventh embodiment can include the system of any one of the tenth to forty-fifth embodiments, wherein the first dirty pump bank is active, in fluid communication with the wellhead / wellbore, pressurized, and / or pumping, the clean pump bank is fluidly isolated (e.g. deactivated, depowered, de-pressured, not pumping, fluidly disconnected, and / or configured for maintenance), and the second dirty pump bank is active, in fluid communication with the wellhead / wellbore, pressurized, and / or pumping.

[0143] A forty-eighth embodiment can include the system of any one of the tenth to forty-fifth embodiments, wherein the clean pump bank is active, in fluid communication with the second dirty pump bank and / or wellhead / wellbore, pressurized, and / or pumping, the first dirty pump bank is fluidly isolated (e.g. deactivated / depowered / de-pressured, not pumping, fluidly disconnected, and / or configured for maintenance), and the second dirty pump bank is active, in fluid communication with the clean pump bank and / or wellhead / wellbore, pressurized, and / or pumping.

[0144] A forty-ninth embodiment can include the system of any one of the tenth to forty-eighth embodiments, further comprising a controller, wherein the controller is configured to receive data regarding and / or control fluid communication in the system (e.g. control the isolation valves being open or closed) (e.g. regarding which pump bank is non-active / isolated).

[0145] A fiftieth embodiment can include the system of the forty-ninth embodiment, wherein the controller is configured to maintain approximately the same / constant composition of fluid to the wellhead / wellbore (e.g. regardless of which of the pump banks is active / pumping and / or which of the pump banks is non-active / isolated).

[0146] A fifty-first embodiment can include the system of any one of the forty-ninth to fiftieth embodiments, wherein the controller further is configured to alter the composition of dirty fluid flow (e.g. slurry) to the dirty pump banks when (e.g. responsive to) the clean pump bank is offline (e.g. isolated, for example for maintenance) (e.g. when the two dirty pump banks are used to pump fluid to the wellhead), for example to maintain approximately the same composition of treatment fluid to the wellhead / wellbore.

[0147] A fifty-second embodiment can include the system of the fifty-first embodiment, wherein the controller is further configured to alter the composition of dirty fluid flow (e.g. slurry) to one of the dirty pump banks when (e.g. responsive to) the clean pump bank is brought back online (e.g. into fluid communication with one of the dirty pump banks and / or pressurized) and the other dirty pump bank is offline (e.g. isolated, for example for maintenance), for example to maintain approximately the same composition of fluid to the wellhead / wellbore.

[0148] A fifty-third embodiment can include the system of any one of the first to fifty-second embodiments, further comprising one or more low-pressure equipment (e.g. sand boxes, blender, tanks (e.g. holding fluid, water, and / or chemicals), low-pressure pumps for pumping low pressure fluid through low pressure tubing / piping and / or between low-pressure equipment and high-pressure equipment, such as the pump banks).

[0149] A fifty-fourth embodiment can include the system of the fifty-third embodiment, wherein the low-pressure equipment is fluidly coupled to at least one of the pump banks.

[0150] A fifty-fifth embodiment can include the system of any one of the fifty-third to fifty-fourth embodiments, wherein at least one of the one or more low-pressure equipment has a work zone (e.g. where personnel and / or vehicles should be able to operate relatively safely to operate / interact with the corresponding low-pressure equipment), and wherein the work zone does not overlap the red zones of any of the pump banks (e.g. the low-pressure equipment disposed / configured so that no overlap) (e.g. the work zone is separate and distinct from, apart from, physically isolated from, segregated from, and / or does not encroach upon the red zones) (in some embodiments, the work zone may abut and / or be disposed in proximity to one or more red zone).

[0151] A fifty-sixth embodiment can include the system of any one of the fifty-third to fifty-fifth embodiments, wherein at least some (e.g. at least one piece) of the low-pressure equipment (e.g. tanks) is disposed between pump banks.

[0152] A fifty-seventh embodiment can include the system of any one of the first to fifty-sixth embodiments, wherein at least two of the pump banks are disposed at different elevation levels at the wellsite (e.g. at least one pump bank is sunken and / or located within a hole).

[0153] A fifty-eighth embodiment can include the system of any one of the first to fifty-seventh embodiments, wherein the red zone for each pump bank comprises a pressurized equipment red zone and a rotational equipment red zone (e.g. the footprint for the overall red zone for each pump bank includes the footprint for the pressurized equipment red zone and the footprint for rotational equipment red zone).

[0154] A fifty-ninth embodiment can include the system of the fifty-eight embodiment, wherein the pressurized equipment red zone is the greater of 1.5 times the longest run of piping for the equipment / pump bank or 30 ft.

[0155] A sixtieth embodiment can include the system of any one of the fifty-eighth to fifty-ninth embodiments, wherein the rotational red zone is defined by a front of the radiator (e.g. for diesel units), a back of the cab (e.g. for duel-fuel units), and / or one or more blast shield positioned to provide lateral protection for end units.

[0156] In a sixty-first embodiment, a method for pumping treatment fluid downhole in a well (e.g. using a system similar to any one of claims 1-60), comprises: pumping treatment fluid into the well using a clean pump bank and a first dirty pump bank fluidly disposed in-line (e.g. in series, e.g. with the clean bank pumping clean fluid, and the first dirty bank pumping dirty / slurry fluid that mixes with the clean fluid to form treatment fluid for the well), wherein a second dirty pump bank is fluidly isolated from the clean pump bank and / or the first dirty pump bank and / or the well (e.g. while the second dirty pump bank is isolated / idle / not pumping / having maintenance performed or configured to have maintenance performed) (e.g. operating only one of the dirty pump banks in conjunction with the clean pump bank—to add dirty / slurry flow to the clean flow to form treatment fluid); performing (e.g. relatively safely, without maintenance personnel being in the red zone for either the clean or first dirty bank) maintenance on the isolated second dirty pump bank while both the clean pump bank and the first dirty pump bank are pumping; wherein a space between the first and second dirty pump banks and / or between the second dirty pump bank and the clean pump bank is substantially open / unblocked (e.g. without shielding therebetween).

[0157] A sixty-second embodiment can include the method of the sixty-first embodiment, wherein maintenance can be performed on the second dirty pump bank by maintenance personnel without such personnel entering the red zone for either the first dirty pump bank or the clean pump bank (e.g. due to disposition of the pump banks with regard to their red zones—for example with the second dirty pump bank disposed outside the red zones of the first dirty pump bank and the clean pump bank, for example adjacent / abutting at least one red zone).

[0158] A sixty-third embodiment can include the method of any one of the sixty-first to sixty-second embodiments, wherein pumping treatment fluid into the well using a clean pump bank and a first dirty pump bank comprises: pumping clean fluid using the clean pump bank; pumping dirty fluid using the first dirty pump bank; and combining / mixing the clean and dirty fluid and pumping the combination (e.g. the treatment fluid) to the wellhead.

[0159] A sixty-fourth embodiment can include the method of any one of the sixty-first to sixty-third embodiments, further comprising, fluidly isolating the second dirty pump bank from the clean pump bank and / or wellhead (e.g. before pumping treatment fluid into the well using the clean pump bank and the first dirty pump bank fluidly disposed in-line).

[0160] A sixty-fifth embodiment can include the method of any one of the sixty-first to sixty-fourth embodiments, further comprising (e.g. after pumping treatment fluid into the well using the clean pump bank and the first dirty pump bank fluidly disposed in-line fluidly and / or after maintenance on the second dirty pump bank is performed / completed): fluidly isolating the first dirty pump bank; (e.g. approximately simultaneously) placing the second dirty pump bank into fluid communication with the clean pump bank and / or the wellhead; pumping (e.g. continuously) treatment fluid into the well using the clean pump bank and the second dirty pump bank, while the first dirty pump bank is fluidly isolated (e.g. thereby providing approximately continuous pumping even while switching between pump banks and / or performing maintenance); performing (e.g. relatively safely) maintenance on the isolated first dirty pump bank while pumping with both the clean pump bank and the second dirty pump bank; wherein a space between the first and second dirty pump banks and / or between the first dirty pump bank and the clean pump bank is substantially open / unblocked (e.g. without shielding therebetween).

[0161] A sixty-sixth embodiment can include the method of the sixty-fifth embodiment, wherein maintenance can be performed on the first dirty pump bank by maintenance personnel without such personnel entering the red zone for either the second dirty pump bank or the clean pump bank (e.g. due to disposition of the pump banks with regard to their red zones—for example with the first dirty pump bank disposed outside the red zones of the second dirty pump bank and the clean pump bank, for example adjacent / abutting at least one red zone).

[0162] A sixty-seventh embodiment can include the method of any one of the sixty-first to sixty-sixth embodiments, further comprising (e.g. after pumping treatment fluid into the well using the clean pump bank and the first dirty pump bank fluidly disposed in-line fluidly and / or after maintenance on the second dirty pump bank is performed / completed and / or after pumping treatment fluid into the well using the clean pump bank and the second dirty pump bank fluidly disposed in-line fluidly and / or after maintenance on the first dirty pump bank is performed / completed): fluidly isolating the clean bank from both the first and second dirty banks and (e.g. approximately simultaneously) placing the (e.g. previously isolated) first or second dirty pump bank into fluid communication with the wellhead (e.g. so that both the first and second dirty banks are in fluid communication with the wellhead and are pumping dirty fluid / slurry into the wellhead); pumping (e.g. continuously) treatment fluid into the well using the first and second dirty pump banks, while the clean bank is fluidly isolated (e.g. thereby providing approximately continuous pumping even while switching between pump banks and / or performing maintenance); performing (e.g. relatively safely) maintenance on the clean bank while pumping with both the first dirty pump bank and the second dirty pump bank (e.g. without shielding therebetween—the space between the clean bank and the dirty banks is substantially open / unblocked); wherein a space between the second dirty pump bank and the clean pump bank and / or between the first dirty pump bank and the clean pump bank is substantially open / unblocked (e.g. without shielding therebetween—e.g. typically, substantially the only thing between one of the dirty pump banks and the clean pump bank may be the other dirty pump bank).

[0163] A sixty-eighth embodiment can include the method of the sixty-seventh embodiment, wherein maintenance can be performed on the clean pump bank by maintenance personnel without such personnel entering the red zone for either the first or second dirty pump banks (e.g. due to disposition of the pump banks with regard to their red zones—for example with the clean pump bank disposed outside the red zones of the first and second dirty pump banks, for example adjacent / abutting at least one red zone).

[0164] A sixty-ninth embodiment can include the method of any one of the sixty-seventh to sixty-eighth embodiments, further comprising, after maintenance is performed / completed on the clean pump bank, fluidly isolating one of the dirty pump banks while simultaneously placing the clean pump bank into fluid communication with the other dirty pump bank and the well.

[0165] A seventieth embodiment can include the method of any one of the sixty-first to sixty-ninth embodiments, wherein maintenance (e.g. and / or fluidly isolating) is performed on the first and second dirty pump banks based on a dirty pump bank maintenance schedule, and maintenance is performed on the clean pump bank based on a clean pump bank maintenance schedule, wherein the clean pump bank maintenance schedule is longer (e.g. less frequent, with more time in between maintenance) than the dirty pump bank maintenance schedule.

[0166] A seventy-first embodiment can include the method of the seventieth embodiment, wherein (e.g. timing for) switching between pump banks (e.g. fluidly isolating one pump bank while simultaneously placing another pump bank into fluid communication) is based on the clean pump bank maintenance schedule and / or the dirty pump bank maintenance schedule.

[0167] A seventy-second embodiment can include the method of any one of the seventieth to seventy-first embodiments, wherein the clean pump bank maintenance schedule is 2-4 times longer (e.g. the time period between scheduled maintenance is longer) than the dirty pump bank maintenance schedule (e.g. the dirty pump bank maintenance schedule is approximately 50-60 hours runtime and / or the clean pump bank maintenance schedule is approximately 150-200 hours runtime).

[0168] A seventy-third embodiment can include the method of any one of the sixty-first to seventy-second embodiments, wherein lines providing fluid communication between pump banks and the wellhead during pumping are pressurized (e.g. with high pressure), the method further comprising, after isolating one of the pump banks, de-pressurizing (e.g. reducing pressure from high pressure to at least low pressure, e.g. draining fluid / bleeding off pressure) the lines fluidly coupled to the isolated pump bank.

[0169] A seventy-fourth embodiment can include the method of any one of the sixty-first to seventy-third embodiments, wherein treatment fluid can be continuously (e.g. without interruption for pump maintenance) pumped to the well, even while maintenance is performed on one of the pump banks.

[0170] A seventy-fifth embodiment can include the method of any one of the sixty-seventh to seventy-fourth embodiments, wherein responsive to the clean pump bank being offline (e.g. isolated for maintenance) and both dirty pump banks pumping fluid to the wellhead, altering the composition of the dirty fluid (e.g. slurry) supplied to the dirty pump banks, for example to maintain approximately the same composition of (e.g. treatment) fluid ultimately flowing to the wellhead.

[0171] A seventy-sixth embodiment can include the method of the seventy-fifth embodiment, wherein responsive to the clean pump bank being brought back online (e.g. placed into fluid communication with one of the dirty pump banks) and / or one of the dirty pump banks being taken offline (e.g. fluidly isolated for maintenance), altering the composition of the dirty fluid (e.g. slurry) supplied to the active dirty pump bank (e.g. the dirty pump bank in fluid communication with the clean pump bank and the well), for example to maintain approximately the same composition of (e.g. treatment) fluid ultimately flowing to the wellhead.

[0172] A seventy-seventh embodiment can include the method of any one of the sixty-first to seventy-sixth embodiments, wherein the first and second dirty pump banks each have the same number of pumping units available.

[0173] A seventy-eighth embodiment can include the method of any one of the sixty-first to seventy-sixth embodiments, wherein the first and second dirty pump banks and the clean pump bank each have the same number of pumping units available.

[0174] A seventy-ninth embodiment can include the method of any one of the sixty-first to seventy-eighth embodiments, wherein the number of available pumping units (e.g. for the well) can be kept constant while performing maintenance (e.g. on one of the pump banks, for example ¼-⅓ of the total pumping units for the well).

[0175] An eightieth embodiment can include the method of any one of the sixty-first to seventy-ninth embodiments, wherein not all available pumping units run / pump at all times or at the same time (e.g, wherein only some of the available pumping units run / pump at the same time).

[0176] An eighty-first embodiment can include the method of any one of the sixty-first to eightieth embodiments, further comprising, upon detecting an issue indicative of a need for maintenance / repair for one of the pump banks, switching (e.g. simultaneously and / or before the maintenance schedule indicates it is time) that pump bank offline (e.g. fluidly isolating that pump bank) and bringing the reserve pump bank (e.g. the pump bank that was previously fluidly isolated) online (e.g. placing it into fluid communication with the well), and then performing maintenance / repair on the offline pump bank.

[0177] An eighty-second embodiment can include the method of the eighty-first embodiment, further comprising sensing one or more parameter of the system to detect a need for maintenance / repair of one of the pump banks.

[0178] An eighty-third embodiment can include the method of any one of the sixty-first to eighty-second embodiments, further comprising operating low-pressure equipment having a work zone while pumping high-pressure treatment fluid to the well, wherein the work zone does not overlap with the red zone for any of the pump banks (e.g. no personnel or vehicle for the low-pressure equipment disposed in the red zone for any of the pump banks) (e.g. the work zone is separate and distinct, apart, and / or spaced from the red zones).

[0179] An eighty-fourth embodiment can include the method of any one of the sixty-first to eighty-third embodiments, further comprising setting up / positioning and fluidly coupling the pump banks to the well (e.g. to the wellhead).

[0180] An eighty-fifth embodiment can include the method of the eighty-fourth embodiment, wherein setting up the pump banks comprises the method of any one of claims 87-120).

[0181] An eighty-sixth embodiment can include the method of any one of the sixty-first to eighty-fifth embodiments, further comprising setting up / positioning and / or fluidly coupling the low-pressure equipment (e.g. to the pump banks).

[0182] In an eighty-seventh embodiment, a method of setting up a well site (e.g. for introduction of treatment fluid into a well) comprises: transporting a first plurality of pumping units to the well site; transporting a second plurality of pumping units to the well site; transporting a third plurality of pumping units to the well site; arranging / disposing / positioning the first plurality of pumping units as a first dirty pump bank at a first location at the well site, wherein the first dirty pump bank comprises a first red zone; arranging / disposing / positioning the second plurality of pumping units as a second dirty pump bank at a second location at the well site, wherein the second dirty pump bank comprises a second red zone, and wherein the second dirty pump bank is disposed outside of the first red zone; arranging / disposing / positioning the third plurality of pumping units as a clean pump bank at a third location at the well site, wherein the clean pump bank comprises a third red zone, and wherein the clean pump bank is disposed outside of both the first red zone and the second red zone; fluidly coupling the clean pump bank to both the first dirty pump bank and the second dirty pump bank; fluidly coupling the clean pump bank and / or both the first and second dirty pump banks to the well head; wherein the fluid coupling is configured to allow fluid isolation of the clean pump bank from the first and second dirty pump banks for maintenance, the fluid coupling is configured to allow fluid isolation of the first dirty pump bank from the clean pump bank and the well (e.g. and the second dirty pump bank) for maintenance, and the fluid coupling is configured to allow fluid isolation of the second dirty pump bank from the clean pump bank and the well (e.g. and the first dirty pump bank) for maintenance.

[0183] An eighty-eighth embodiment can include the method of the eighty-seventh embodiment, wherein each pump bank is positioned with respect to the other pump banks so as to not be disposed within (e.g. to be clear of) the red zone of the other pump banks.

[0184] An eighty-ninth embodiment can include the method of any one of the eighty-seventh to eighty-eighth embodiments, wherein the first red zone, the second red zone, and the third red zone are each separate and distinct, apart, and / or spaced (e.g. do not overlap).

[0185] A ninetieth embodiment can include the method of any one of the eighty-seventh to eighty-ninth embodiments, wherein maintenance can be performed on the first dirty bank without personnel being in the second or third red zones, maintenance can be performed on the second dirty bank without personnel being in the first or third red zones, and maintenance can be performed on the clean bank without personnel being in the first or second red zones.

[0186] A ninety-first embodiment can include the method of any one of the eighty-seventh to ninetieth embodiments, wherein a substantially open space (e.g. substantially without shielding) is disposed between the second dirty pump bank and the first dirty pump bank; and wherein a substantially open space (e.g. substantially without shielding) is disposed between the clean pump bank and the first and / or second dirty pump banks.

[0187] A ninety-second embodiment can include the method of any one of the eighty-seventh to ninety-first embodiments, wherein arranging / disposing comprises arranging / disposing the pump banks so that their red zones are in proximity (e.g. with substantially no space therebetween) (e.g. so that the outer boundary of their red zones are proximal to each other / abut—for example, minimizing the spacing therebetween, so as to minimize the wellsite footprint).

[0188] A ninety-third embodiment can include the method of any one of the eighty-seventh to ninety-second embodiments, wherein arranging / disposing comprise arranging / disposing the pump banks so that at least one of the pump banks is disposed in proximity to (e.g. with substantially no space therebetween / abutting—for example—minimizing the spacing therebetween, so as to minimize the wellsite footprint) the red zone of another of the pump banks.

[0189] A ninety-fourth embodiment can include the method of any one of the eighty-seventh to ninety-third embodiments, wherein arranging / disposing comprise arranging / disposing the pump banks so that at least two of the pump banks are disposed in proximity to (e.g. with substantially no space therebetween / abutting—for example—minimizing the spacing therebetween, so as to minimize the wellsite footprint) the red zone of another of the pump banks.

[0190] A ninety-fifth embodiment can include the method of any one of the eighty-seventh to ninety-fourth embodiments, wherein arranging / disposing comprises arranging / disposing the pump banks so that each of the pump banks is disposed in proximity to the red zone of another of the pump banks.

[0191] A ninety-sixth embodiment can include the method of any one of the eighty-seventh to ninety-fifth embodiments, wherein each pump bank comprises a high-pressure line / manifold, and wherein arranging / disposing comprises arranging / disposing the pump banks so that at least two of the pump banks (e.g. the dirty pump banks) are disposed with their corresponding high-pressure line / manifold in proximity to (e.g. with substantially no space therebetween / abutting—for example—minimizing the spacing therebetween, so as to minimize the wellsite footprint) the red zone of another of the pump banks (e.g. the other dirty pump bank).

[0192] A ninety-seventh embodiment can include the method of any one of the eighty-seventh to ninety-fifth embodiments, wherein each pump bank comprises a high-pressure line / manifold, and wherein arranging / disposing comprises arranging / disposing the pump banks so that each of the pump banks are disposed with their corresponding high-pressure line / manifold in proximity to (e.g. with substantially no space therebetween / abutting—for example—minimizing the spacing therebetween, so as to minimize the wellsite footprint) the red zone of another of the pump banks.

[0193] A ninety-eighth embodiment can include the method of any one of the eighty-seventh to ninety-seventh embodiments, further comprising fluidly isolating one of the first or second dirty pump banks from the clean bank (and the wellhead / wellbore).

[0194] A ninety-ninth embodiment can include the method of the ninety-eighth embodiment, further comprising pumping fluid to the wellhead using the clean bank and the non-isolated (e.g. active) dirty pump bank.

[0195] A one hundredth embodiment can include the method of any one of the eighty-seventh to ninety-ninth embodiments, wherein the first dirty pump bank and the second dirty pump bank are fluidly coupled to the clean pump bank and / or the wellhead / wellbore in parallel with each other (e.g. parallel fluid coupling).

[0196] A one hundred first embodiment can include the method of any one of the eighty-seventh to one hundredth embodiments, wherein the first dirty pump bank and the second dirty pump bank are spaced apart by the open space (e.g. at least approximately 30 feet or approximately 30 feet).

[0197] A one hundred second embodiment can include the method of any one of the eighty-seventh to one hundred first embodiments, wherein arranging / disposing first, second, and third pump banks comprises positioning to minimize overall footprint of the well site and / or configuring to fit a footprint of the well site (e.g. including low pressure equipment work zone, which no red zone should overlap with).

[0198] A one hundred third embodiment can include the method of any one of the eighty-seventh to one hundred second embodiments, wherein arranging further comprises providing sufficient area adjacent each pump bank for mobile pumping units (e.g. trucks with pumps) to maneuver in and out of position in the corresponding pump bank.

[0199] A one hundred fourth embodiment can include the method of any one of the eighty-seventh to one hundred third embodiments, wherein for each pump bank, the corresponding red zone spacing between banks is the greater of a pressurized equipment red zone or a rotational equipment red zone.

[0200] A one hundred fifth embodiment can include the method of the one hundred fourth embodiment, wherein for each pump bank, the footprint of its (e.g. overall) red zone comprises the joint footprint of both the pressurized equipment red zone and the rotational equipment red zone.

[0201] A one hundred sixth embodiment can include the method of any one of the eighty-seventh to one hundred fifth embodiments, further comprising arranging / disposing one or more low-pressure equipment at the well site, wherein at least one of the low-pressure equipment has a work zone, and wherein the work zone is separate and distinct, apart, or spaced from (e.g. does not overlap with) the red zones for any of the pump banks.

[0202] A one hundred seventh embodiment can include the method of the one hundred sixth embodiment, wherein arranging / disposing one or more low-pressure equipment comprises arranging / disposing the low-pressure equipment so that its work zone is in proximity to the red zone of one of the pump banks (e.g. abutting and / or with substantially no space therebetween) (e.g. so that the outer boundary of the work zone and the outer boundary of the red zone are proximal to each other—for example, minimizing the spacing therebetween, so as to minimize the wellsite footprint).

[0203] A one hundred eighth embodiment can include the method of any one of the eighty-seventh to one hundred seventh embodiments, further comprising digging at / grading / lowering at least one of the first, second, or third location, so that at least two of the pump banks are disposed at different elevation levels at the well site (e.g. at least one pump bank is sunken relative to another pump bank and / or is located within a hole).

[0204] In a one hundred ninth embodiment, a method of setting up a well site, comprises: fluidly coupling a first dirty pump bank to a first high-pressure line; fluidly coupling a second dirty pump bank to a second high-pressure line; and fluidly coupling both the first and second high-pressure lines to a well head / wellbore and to a clean pump bank; wherein the fluid coupling is configured to allow fluid isolation of the clean pump bank from the first and second dirty pump banks for maintenance, the fluid coupling is configured to allow fluid isolation of the first dirty pump bank from the clean pump bank and the well (e.g. and the second dirty pump bank) for maintenance, and the fluid coupling is configured to allow fluid isolation of the second dirty pump bank from the clean pump bank and the well (e.g. and the first dirty pump bank) for maintenance.

[0205] A one hundred tenth embodiment can include the method of the one hundred ninth embodiment, further comprising: arranging / disposing a first plurality of pumping units as the first dirty pump bank at the well site, wherein the first dirty pump bank comprises a first red zone; arranging / disposing a second plurality of pumping units as a second dirty pump bank at the well site, wherein the second dirty pump bank comprises a second red zone; and arranging / disposing a third plurality of pumping units as the clean pump bank at the well site, wherein the clean pump bank comprises a third red zone; wherein each pump bank is positioned / arranged / disposed with respect to the other pump banks so as to not be disposed within (e.g. to be clear of) the red zone of the other pump banks.

[0206] A one hundred eleventh embodiment can include the method of the one hundred tenth embodiment, wherein arranging / disposing a second plurality of pumping units as a second dirty pump bank comprises arranging / disposing the second dirty pump bank to be disposed outside of the first red zone but in proximity to (e.g. approximately abutting) the first red zone.

[0207] A one hundred twelfth embodiment can include the method of any one of the one hundred tenth to one hundred eleventh embodiments, wherein arranging / disposing a third plurality of pumping units as the clean pump bank comprises arranging / disposing the clean bank to be disposed outside both the first red zone and the second red zone, but in proximity to (e.g. approximately abutting) at least one of the first and second red zones.

[0208] A one hundred thirteenth embodiment can include the method of any one of the one hundred tenth to one hundred twelfth embodiments, wherein the pump banks are arranged / disposed so that maintenance can be performed on the first dirty bank without personnel being in the second or third red zones, maintenance can be performed on the second dirty bank without personnel being in the first or third red zones, and maintenance can be performed on the clean bank without personnel being in the first or second red zones.

[0209] A one hundred fourteenth embodiment can include the method of any one of the one hundred tenth to one hundred thirteenth embodiments, wherein a substantially open space (e.g. substantially without shielding) is disposed between the second dirty pump bank and the first dirty pump bank; and / or wherein a substantially open space (e.g. substantially without shielding) is disposed between the clean pump bank and the first and / or second dirty pump banks.

[0210] A one hundred fifteenth embodiment can include the method of any one of the one hundred ninth to one hundred fourteenth embodiments, wherein the clean pump bank can be (e.g. is configured to be) fluidly isolated from the first and second dirty pump banks for maintenance, the first dirty pump bank can be (e.g. is configured to be) fluidly isolated from the clean pump bank and the well (e.g. and the second dirty pump bank) for maintenance, and the second dirty pump bank can be (e.g. is configured to be) fluidly isolated from the clean bank and the well (e.g. and the first dirty pump bank) for maintenance.

[0211] A one hundred sixteenth embodiment can include the method of any one of the one hundred tenth to one hundred fifteenth embodiments, wherein the first dirty pump bank and the second dirty pump bank are disposed in parallel configuration (e.g. with a substantially open space therebetween).

[0212] A one hundred seventeenth embodiment can include the method of any one of the one hundred ninth to one hundred sixteenth embodiments, wherein the first high-pressure line and the second high-pressure line are approximately parallel.

[0213] A one hundred eighteenth embodiment can include the method of any one of the eighty-seventh to one hundred seventeenth embodiments, further comprising performing maintenance on one or more pump in the isolated pump bank in situ while the one or more pump remains connected (e.g. fluidly coupled) to the corresponding high-pressure line / manifold and / or well (e.g. without removing the one or more pump from proximity to the corresponding high-pressure line / manifold or the red zone for one or more other pump banks).

[0214] A one hundred nineteenth embodiment can include the method of any one of the eighty-seventh to one hundred seventeenth embodiments, further comprising performing maintenance on all pumps in the isolated pump bank in situ while all of the pumps in the isolated pump bank remain connected (e.g. fluidly coupled) to the corresponding high-pressure line / manifold and / or well (e.g. without removing the pumps of the isolated / non-active pump bank from proximity to the corresponding high-pressure line / manifold or the red zone for one or more other pump banks).

[0215] A one hundred twentieth embodiment can include the method of any one of the eighty-seventh to one hundred nineteenth embodiments, wherein after setting up, the wellsite comprises a system similar to any one of claims 1-60.

[0216] While embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of this disclosure. The embodiments described herein are exemplary only, and are not intended to be limiting. Many variations and modifications of the embodiments disclosed herein are possible and are within the scope of this disclosure. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted or not implemented. Also, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other techniques, systems, subsystems, or methods without departing from the scope of this disclosure. Other items shown or discussed as directly coupled or connected or communicating with each other may be indirectly coupled, connected, or communicated with. Method or process steps set forth may be performed in a different order. The use of terms, such as “first,”“second,”“third” or “fourth” to describe various processes or structures is only used as a shorthand reference to such steps / structures and does not necessarily imply that such steps / structures are performed / formed in that ordered sequence (unless such requirement is clearly stated explicitly in the specification).

[0217] Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, Rl, and an upper limit, Ru, is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=Rl+k*(Ru-Rl), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . 50 percent, 51 percent, 52 percent, . . . , 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. Language of degree used herein, such as “approximately,”“about,”“generally,” and “substantially,” represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the language of degree may mean a range of values as understood by a person of skill or, otherwise, an amount that is + / −10%.

[0218] Use of broader terms such as comprises, includes, having, etc. should be understood to provide support for narrower terms such as consisting of, consisting essentially of, comprised substantially of, etc. When a feature is described as “optional,” both embodiments with this feature and embodiments without this feature are disclosed. Similarly, the present disclosure contemplates embodiments where this “optional” feature is required and embodiments where this feature is specifically excluded. The use of the terms such as “high-pressure” and “low-pressure” is intended to only be descriptive of the component and their position within the systems disclosed herein. That is, the use of such terms should not be understood to imply that there is a specific operating pressure or pressure rating for such components. For example, the term “high-pressure” describing a manifold should be understood to refer to a manifold that receives pressurized fluid that has been discharged from a pump irrespective of the actual pressure of the fluid as it leaves the pump or enters the manifold. Similarly, the term “low-pressure” describing a manifold should be understood to refer to a manifold that receives fluid and supplies that fluid to the suction side of the pump irrespective of the actual pressure of the fluid within the low-pressure manifold.

[0219] Accordingly, the scope of protection is not limited by the description set out above but is only limited by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated into the specification as embodiments of the present disclosure. Thus, the claims are a further description and are an addition to the embodiments of the present disclosure. The discussion of a reference herein is not an admission that it is prior art, especially any reference that can have a publication date after the priority date of this application. The disclosures of all patents, patent applications, and publications cited herein are hereby incorporated by reference, to the extent that they provide exemplary, procedural, or other details supplementary to those set forth herein.

[0220] Use of the phrase “at least one of” preceding a list with the conjunction “and” should not be treated as an exclusive list and should not be construed as a list of categories with one item from each category, unless specifically stated otherwise. A clause that recites “at least one of A, B, and C” can be infringed with only one of the listed items, multiple of the listed items, and one or more of the items in the list and another item not listed.

[0221] As used herein, the term “or” is inclusive unless otherwise explicitly noted. Thus, the phrase “at least one of A, B, or C” is satisfied by any element from the set {A, B, C} or any combination thereof, including multiples of any element.

[0222] As used herein, the term “and / or” includes any combination of the elements associated with the “and / or” term. Thus, the phrase “A, B, and / or C” includes any of A alone, B alone, C alone, A and B together, B and C together, A and C together, or A, B, and C together.

Claims

1. A system for pumping fluid downhole into a well, comprises:two pump banks fluidly coupled to a wellbore,wherein each of the pump banks comprises a plurality of pumping units, andwherein each pump bank has a red zone, and each pump bank is disposed outside the red zone of the other pump bank.

2. The system of claim 1, wherein the two pump banks are disposed with a space therebetween, and the space therebetween is substantially open.

3. The system of claim 2, wherein the two pump banks comprise a first dirty pump bank and a second dirty pump bank.

4. The system of claim 3, wherein each of the first dirty pump bank and the second dirty pump bank comprises the same number of pumping units.

5. The system of claim 3, further comprising a clean pump bank; wherein the clean pump bank comprises a plurality of pumping units; wherein the clean pump bank is fluidly coupled to the first and second dirty pump banks; wherein the first dirty pump bank and the clean pump bank are disposed with a space therebetween, and the space therebetween is substantially open; wherein the second dirty pump bank and the clean pump bank are disposed with a space therebetween, and the space therebetween is substantially open; and wherein at least one of the pump banks is disposed in proximity to the red zone of another of the pump banks.

6. The system of claim 5, wherein the first and second dirty pump banks are each configured to be fluidly isolated from the clean pump bank.

7. The system of claim 6, wherein the clean pump bank is configured to be fluidly isolated from both the first and second dirty pump banks simultaneously.

8. The system of claim 3, wherein each dirty pump bank further comprises one or more high-pressure line; wherein for each dirty pump bank, the one or more high-pressure line comprises a primary high-pressure line, and each of the corresponding plurality of pumping units is fluidly coupled to the corresponding primary high-pressure line for the dirty pump bank; and wherein the primary high-pressure line for the first and second dirty pump banks extend approximately parallel to each other.

9. The system of claim 8, wherein the red zone for the first dirty pump bank does not extend to encompass the primary high-pressure line corresponding to the second dirty pump bank, and the red zone for the second dirty pump bank does not extend to encompass the primary high-pressure line corresponding to the first dirty pump bank.

10. The system of claim 7, further comprising a controller, wherein the controller is configured to control fluid isolation of pump banks in the system.

11. The system of claim 3, wherein the red zone for each pump bank comprises a pressurized equipment red zone and a rotational equipment red zone.

12. A method for pumping treatment fluid downhole in a well, comprises:pumping treatment fluid into the well using a clean pump bank and a first dirty pump bank fluidly coupled in-line, wherein a second dirty pump bank is fluidly isolated from the clean pump bank;performing maintenance on the isolated second dirty pump bank while both the clean pump bank and the first dirty pump bank are pumping;wherein a space between the first and second dirty pump banks and between the second dirty pump bank and the clean pump bank is substantially open.

13. The method of claim 12, further comprising, fluidly isolating the second dirty pump bank from the clean pump bank.

14. The method of claim 12, further comprising:fluidly isolating the first dirty pump bank;placing the second dirty pump bank into fluid communication with the clean pump bank;pumping treatment fluid into the well using the clean pump bank and the second dirty pump bank, while the first dirty pump bank is fluidly isolated; andperforming maintenance on the isolated first dirty pump bank while pumping with both the clean pump bank and the second dirty pump bank.

15. The method of claim 12, further comprising:fluidly isolating the clean pump bank from both the first and second dirty pump banks and placing the second dirty pump bank into fluid communication with the well;pumping treatment fluid into the well using the first and second dirty pump banks, while the clean pump bank is fluidly isolated;performing maintenance on the clean pump bank while pumping with both the first dirty pump bank and the second dirty pump bank.

16. The method of claim 15, further comprising, after maintenance is performed on the clean pump bank, fluidly isolating one of the dirty pump banks while placing the clean pump bank into fluid communication with the other dirty pump bank and the well.

17. The method of claim 15, wherein maintenance is performed on the first and second dirty pump banks based on a dirty pump bank maintenance schedule, and maintenance is performed on the clean pump bank based on a clean pump bank maintenance schedule, wherein the clean pump bank maintenance schedule has less frequent maintenance than the dirty pump bank maintenance schedule.

18. The method of claim 15, wherein responsive to the clean pump bank being isolated for maintenance and both dirty pump banks pumping fluid to the well, altering the composition of the dirty fluid supplied to the dirty pump banks to maintain approximately the same composition of treatment fluid flowing to the well.

19. The method of claim 16, wherein responsive to the clean pump bank being placed into fluid communication with one of the dirty pump banks and one of the dirty pump banks being fluidly isolated for maintenance, altering the composition of the dirty fluid supplied to the dirty pump bank in fluid communication with the clean pump bank and the well, to maintain approximately the same composition of treatment fluid flowing to the well.

20. A method of setting up a well site, comprising:transporting a first plurality of pumping units to the well site;transporting a second plurality of pumping units to the well site;transporting a third plurality of pumping units to the well site;positioning the first plurality of pumping units as a first dirty pump bank at a first location at the well site, wherein the first dirty pump bank comprises a first red zone;positioning the second plurality of pumping units as a second dirty pump bank at a second location at the well site, wherein the second dirty pump bank comprises a second red zone, and wherein the second dirty pump bank is disposed outside of the first red zone;positioning the third plurality of pumping units as a clean pump bank at a third location at the well site, wherein the clean pump bank comprises a third red zone, and wherein the clean pump bank is disposed outside of both the first red zone and the second red zone;fluidly coupling the clean pump bank to both the first dirty pump bank and the second dirty pump bank;fluidly coupling the clean pump bank and both the first and second dirty pump banks to the well;wherein the fluid coupling is configured to allow fluid isolation of the clean pump bank from the first and second dirty pump banks for maintenance, the fluid coupling is configured to allow fluid isolation of the first dirty pump bank from the clean pump bank and the well for maintenance, and the fluid coupling is configured to allow fluid isolation of the second dirty pump bank from the clean pump bank and the well for maintenance; andwherein a substantially open space is disposed between the second dirty pump bank and the first dirty pump bank; and a substantially open space is disposed between the clean pump bank and at least one of the first and second dirty pump banks.

21. The method of claim 20, wherein positioning the pump banks comprises disposing the pump banks so that at least one of the pump banks is disposed in proximity to the red zone of another of the pump banks.

22. The method of claim 21, further comprising positioning one or more low-pressure equipment at the well site, wherein at least one of the low-pressure equipment has a work zone, wherein the work zone is separate and apart from the red zones for any of the pump banks, and wherein positioning one or more low-pressure equipment comprises disposing the low-pressure equipment so that the corresponding work zone is in proximity to the red zone of one of the pump banks.

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