Methods and systems for maintaining and swapping equipment

Abstract

Systems and methods of operating a fracturing operation include a platform having an upper surface and a channel, wherein the platform is configured to receive a carrier mounted with a pumping unit; and a conduit configured to transfer fluid to or from a manifold system, the conduit having a first end configured to be connected to the pumping unit. The channel may be configured to receive the conduit when the carrier is at least partially received on the platform. A guide member may be configured to guide the conduit into the channel and include a rounded portion and an abutment surface, wherein the conduit is configured to extend at last partially around the rounded portion, and the carrier is configured to engage the abutment surface. The systems and methods may also include a controller configured to control a braking system of the carrier when the pumping unit is actuated.

Description

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional Application No. 63 / 673,988, filed Jul. 22, 2024, the entirety of which is incorporated herein by reference.TECHNICAL FIELD

[0002] This disclosure relates generally to methods and systems for maintaining and / or swapping equipment, and more specifically, the present disclosure is directed to maintaining and / or swapping pumping equipment in a frac system during active operations.BACKGROUND

[0003] Frac pumps must be swapped out for maintenance often resulting in down time for operations. However, it is industry standard to have a safe working zone that is a specified distance from active pressurized fracturing (fracing) operations.SUMMARY

[0004] The present inventors recognize a need for methods and systems for safe continuous hydraulic fracturing operations while avoiding operator exposure to the high-pressure environment. A limiting feature on the operations is the fact that the pumps must be swapped for maintenance. No personnel working should be in the red zone according to the industry standard. The present inventors also recognize that the pumping units need to be isolated and bleed off. The present inventors contemplate solutions using standard and non-standard pumping equipment.

[0005] The foregoing needs are met by the various embodiments as disclosed herein.

[0006] A first aspect of the present disclosure is directed to a system comprising: a platform having a channel, wherein the platform is configured to receive a carrier mounted with a pumping unit; and a conduit configured to transfer fluid to or from a manifold system, the conduit having a first end configured to be connected to the pumping unit, wherein the channel is configured to receive the conduit when the carrier is at least partially received on the platform.

[0007] In some embodiments, the system of the first aspect may include one or more of the following features. The platform may have a frame defining the channel. The channel may be underneath an upper surface of the platform, wherein the upper surface is configured to support the carrier. The system may include a pivoting member underneath an upper surface of the platform and connected to a second end of the conduit; and a second conduit having a first end connected to the pivoting member and a second end connected to a valve assembly. The system may include a guide member configured to guide the conduit into the channel. The guide member may be configured to travel relative to the platform. The guide member may include a rounded portion and an abutment surface, wherein the conduit is configured to extend at last partially around the rounded portion, and the carrier is configured to engage the abutment surface. The guide member may be deflectable and configured to support the conduit. The guide member may include a plurality of articulating segments configured to deflect relative to each other to allow the guide member to bend or curl. The system may further include a valve assembly configured to isolate the pumping unit from the manifold system. The valve assembly may include a pressure intensifier configured to control pressure in the system. The pressure intensifier may be configured to perform a pressure test of the system. The system may include an intensifier valve configured to isolate the pressure intensifier.

[0008] A second aspect of the present disclosure is directed to a system comprising: a conduit configured to transfer fluid to a manifold system, the conduit having a first end configured to be connected to a pumping unit on a carrier; and a reel configured to rotate in a first direction to wind the conduit around an axis to store the first conduit when the pumping unit travels toward a manifold system and to rotate in a second direction to unwind the first conduit as the carrier travels away from the manifold system.

[0009] In some embodiments, the system of the second aspect may include one or more of the following features. The system may include a valve assembly configured to isolate the pumping unit from the manifold system. The valve assembly may include a pressure intensifier configured to control pressure in the system. The pressure intensifier may be configured to perform a pressure test of the system. The system may include an intensifier valve configured to isolate the pressure intensifier.

[0010] A third aspect of the present disclosure is directed to a system comprising: a valve assembly comprising one or more valves configured to fluidly connect a pumping unit to a manifold system; a braking assembly configured to be connected to a carrier that transports the pumping unit, wherein the braking assembly includes a valve actuator configured to control a valve between a brake and a source of pressurized fluid; and a controller configured to control the valve actuator to engage the brake and prevent movement of the carrier when the pumping unit is actuated.

[0011] In some embodiments, the system of the third aspect may include one or more of the following features. The controller may prevent manual release of the brake by an operator when the brake are engaged by the controller.

[0012] A fourth aspect of the present disclosure is directed to a method comprising: engaging, with a controller, a brake of a carrier of a pumping unit based on the pumping unit being actuated; operating, with the controller, the pumping unit to perform a fracing operation by actuating one or more valves of a valve assembly; isolating, with the controller, the pumping unit from the manifold system by actuating the one or more valves of the valve assembly; and releasing, with the controller, the brake of the carrier based on the valve assembly isolating the pumping unit from the manifold system.

[0013] In some embodiments, the method of the fourth aspect may include one or more of the following features. Releasing the brake may be by controlling a valve between the brake and a source of pressurized fluid. The method may further include preventing, with the controller, manual release of the brake by an operator when the brake are engaged by the controller. The method may further include priming, with the controller, the pumping unit based on the brake being engaged. The method may further include pressure testing, with the controller, the pumping unit based on the brake being engaged. Pressuring testing may be by actuating a pressure intensifier in the valve assembly. The method may further include moving the carrier out of the area with respect to the manifold system after the releasing the brake.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The present application is further understood when read in conjunction with the appended drawings. For the purpose of illustrating the subject matter, there are shown in the drawings exemplary embodiments of the subject matter; however, the presently disclosed subject matter is not limited to the specific methods, devices, and systems disclosed. In the drawings:

[0015] FIG. 1 illustrates a system for hydraulic fracturing and injection well.

[0016] FIG. 2 illustrates a schematic of a system for swapping pumping units according to the present disclosure.

[0017] FIGS. 3A-B illustrate a first embodiment of the system of FIG. 2.

[0018] FIGS. 4A-B illustrate an exemplary embodiment of a pivoting member according to the first embodiment of FIG. 3A-B.

[0019] FIG. 5 illustrates a second embodiment of the system of FIG. 2.

[0020] FIG. 6 illustrates a third embodiment of the system of FIG. 2.

[0021] FIGS. 7A-B illustrate a fourth embodiment of the system of FIG. 2.

[0022] FIG. 8 illustrates a valve assembly of the system of FIGS. 1-7B.

[0023] FIG. 9 illustrates a braking assembly of the system of FIGS. 1-8.

[0024] FIG. 10 illustrates a method of swapping a pumping unit with the system of FIGS. 1-9.

[0025] Aspects of the disclosure will now be described in detail with reference to the drawings, wherein like reference numbers refer to like elements throughout, unless specified otherwise.DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0026] The present disclosure is directed to methods and systems for continuous hydraulic fracturing operations with standard pumping equipment, while limiting or eliminating operator exposure to the high-pressure environment.

[0027] In some embodiments, the system may be for swapping pumping units outside of an immediate vicinity of operating by moving the necessary fracturing connections to a safe area. Thus, the pump may be connected or disconnected out of the redzone. For example, the methods and systems may be configured to remove the essential pumping unit connections outside of the redzone for safe make up and disconnection processes such that standard fracturing connections and processes can be utilized. The system may include integrated safety mechanisms so the pumping unit cannot be moved passed the safe mobilization range before the disconnection process is complete. The system may also include remote pressure testing capability that does not utilize the pumping unit to perform a pressure test or to prime the pumping unit. The system may further include an electronic safeguard for ensuring that pumping unit cannot be started or pumped without active pressure relief or an open valve.

[0028] FIG. 1 illustrates a system 100 for hydraulic fracturing. The system 100 may include a manifold system 102 and one or more pumping units 104. The one or more pumping units 104 may include a positive displacement pump, a centrifugal pump, a progressive cavity pump, and / or a hydraulic piston pump. In some embodiments, the one or more pumping units 104 may each include one or more drive rods to drive a plunger or piston to generate the pressure. The one or more pumping units 104 may have three or more separate drive rods. For example, the one or more pumping units 104 may be a triplex pump or a quintuplex pump. Each of the pumping units 104 may be attached to a carrier 106 for transportation. The carrier 106 may be configured to support the one or more pumping units 104 for transportation relative to the manifold system 102.

[0029] The system 100 may further include a blender 108 configured to mix one or more components to generate a frac fluid. The frac fluid may be one or more liquids, slurries, water, or brine. The frac fluid may include one or more additives, such as chemicals, proppants, diverter material, sand, and other additives.

[0030] The frac fluid may be pumped at a low-pressure from the blender 108 to the manifold system 102. The manifold system 102 may have various flow path segments for fluid distribution and include a low-pressure manifold 130 and a high-pressure manifold 132, as schematically illustrated in FIG. 8. The low-pressure manifold 130 may be configured to receive the low-pressure fluid from the blender 108 and distribute the low-pressure fluid to the one or more pumping units 104 through a low-pressure line. Each pumping unit 104 may be configured to receive the fluid at a low-pressure and discharge it through a high-pressure line to the high-pressure manifold 132 at a high-pressure. The high-pressure manifold 132 may be fluidly connected to a wellbore extending into the ground. The frac fluid may be used to cause fractures in a subterranean formation to enable the collection of hydrocarbons from the wellbore.

[0031] Due to the pressure of the frac fluid being generated by the one or more pumping units 104 through the manifold system 102, an area or red zone 10 exists around the manifold system 102 where entry by personnel is limited during operation of the system 100. The red zone 10 presents challenges for fracking operations. In the past, the systems often time have to be shut down in order to disconnect one of the pumping units 104 for repair and / or maintenance. Thus, in case of a failure of one or more of the pumping units 104, the operator may have to choose between continuing to run the system 100 at less power due to the inoperable pump unit(s) or depressurizing the system 100 to allow personnel to enter the red zone 10 to disconnect the inoperable pumping unit 104 for maintenance. Either operation would undesirably increase downtime reducing output of the system 100.

[0032] As illustrated in FIG. 2, each of the pumping units 104 may be connected to the manifold system 102 with a connection assembly 110 and / or a valve assembly 112. The connection assembly 110 may include one or more conduits configured to transport the fluid between the manifold system 102 and the pumping unit 104 during operation of the system 100. Each of the connection assemblies 110 may include a low-pressure conduit configured to transport the fluid at low-pressure from the manifold system 102 to the pumping unit 104 and a high-pressure conduit configured to transport the fluid at high-pressure from the pumping unit 104 to the manifold system 102. The valve assembly 112 may include one or more valves to isolate the pumping unit 104 from the manifold system 102 for decoupling. In some embodiments, the carrier 106 may be at least partially received on a platform 120 when in the red zone 10.

[0033] FIGS. 3A-B illustrate a first embodiment of a connection assembly 110. The connection assembly 110 may include the platform 120, a first conduit 122 configured to connect to the pumping unit 104, a second conduit (not shown) positioned in or on the platform 120, and a rotary member 124 coupling the first conduit 122 and the second conduit. Thus, each of the low-pressure line and high-pressure line for the pumping unit 104 may separately have a first conduit 122 configured to connect to the pumping unit 104 at the coupling 105, a second conduit (not shown) positioned in the platform 120, and a rotary member 124 coupling the first conduit 122 and the second conduit (although both high-pressure and low-pressure sides not shown in FIGS. 3A-B). As further illustrated, the pumping unit 104 may be received on a trailer 114 of the carrier 106 for transportation relative to the manifold system 102.

[0034] The connection assembly 110 may have a first configuration (as illustrated in FIG. 3A) where at least a portion of the trailer 114 is in a first position to place at least the rear end of the pumping unit 104 in the red zone 10. At least a portion of the trailer 114 may be received on the platform 120 when in the first position (FIG. 3A). The connection assembly 110 may have a second configuration (as illustrated in FIG. 3B) where at least a portion of the pumping unit 104 is in a second position outside of the red zone 10 for the conduit 122 to be disconnected from the pumping unit 104. For example, the connection assembly 110 may be configured to position the coupling 105 out of the red zone 10 in the second configuration (FIG. 3B). Thus, the pumping unit 104 may be closer to the manifold system 102 when the connection assembly 110 is in the first configuration (FIG. 3A) than when the connection assembly 110 is in the second configuration (FIG. 3B).

[0035] The coupling 105 may be configured to connect and / or disconnect the pumping unit 104 from the manifold system 102 by an operator when the pumping unit 104 is outside of the redzone (FIG. 3B). In some embodiments, the coupling 105 may be a standard connection, enabling the connection assembly 110 to be used on any type of pumping equipment using standard procedures and equipment. For example, the coupling 105 may include a threaded connection, a clamping connection, a quick-connect connection, a sleeve connection, and / or a bolted connection (e.g., with an API flange and Bolt Pattern). However, in some embodiments, the coupling 105 may not be a standard connection.

[0036] The platform 120 may include a channel 126. The channel 126 may be immovably fixed to the platform 120. The channel 126 may be defined by an interior of a frame 127 integrated or fixed in or on the platform 120. In some embodiments, the channel 126 may be underneath an upper surface 128 of the platform 120 and running in the direction to and from the manifold system 102, where the upper surface 128 is configured to support the carrier 106. In some embodiments, the frame 127 may be secured between and / or join two distinct parts of the platform 120 (as illustrated in FIGS. 5 and 6). In some embodiments, the frame 127 may be positioned over or on the upper surface 128 and beside and / or in between the pumping unit(s) 104. The channel 126 may receive at least a portion of the first conduit 122 in the first configuration (FIG. 3A). The rotary member 124 may be in or on the platform 120 and be configured to rotate relative to a lateral axis of the platform 120 to extend and retract the conduit 122. For example, the rotary member 124 may be in the channel 126 of the frame 127 and / or underneath the upper surface 128. The rotary member 124 may guide the first conduit 122 out of the channel 126 when the pumping unit 104 pulls the first conduit 122 in traveling away from the manifold system 102 out of the red zone 10 (traveling from FIG. 3A to FIG. 3B). Similarly, the rotary member 124 may guide the first conduit 122 into the channel 126 when the pumping unit 104 pushes the first conduit 122 in traveling toward from the manifold system 102 into the red zone 10 (traveling from FIG. 3B to FIG. 3A). Each of the first conduits 122 of the low-pressure line and the high-pressure line may be received in the same channel 126 or different channels 126. The channel(s) 126 may enable storage of the first conduit 122 in the first configuration while preventing the first conduit 122 from being damaged by the trailer 114 or cluttering walkway space. The rotary member 124 may be positioned away from the manifold system 102 and / or valve assembly 112, for example at least about 1 feet away from the valve assembly 112 to provide sufficient space in the channel 126 for the conduit 122 in the first configuration (FIG. 3A) and travel of the trailer 114 to the second configuration (FIG. 3B). However, in some embodiments, the rotary member 124 may be integrated into the valve assembly 112.

[0037] As illustrated in FIGS. 4A-4B, the rotary member 124 may be configured to pivot or swivel as the first conduit 122 is pulled by the pumping unit 104. A pair of rotary members 124 are illustrated in each of FIGS. 4A-B, one for each of the low-pressure line and the high-pressure line. As further illustrated, the rotary members 124 of the low-pressure line and high-pressure line may pivot together during the travel of the pumping unit 104 as illustrated in FIGS. 3A-B. Each of the rotary members 124 may have a first tubular connection 140 configured to fluidly connect to the first conduit 122 and a second tubular connection 142 configured to fluidly connect to the second conduit. The rotary member 124 may have a U-shaped configuration. The first tubular connection 140 and the second tubular connection 142 may be substantially parallel in a first configuration (FIG. 4A), such that the first conduit 122 and the second conduit are directed substantially toward the manifold system 102 and at least a portion of the pumping unit 104 may be disposed in the red zone 10, as illustrated in FIG. 3A. The first tubular connection 140 and the second tubular connection 142 of each rotary member 124 may be rotationally offset in a second configuration (FIG. 4B), such that the first conduit 122 may be directed away from the manifold system 102 and the pumping unit 104 may be disposed out of the red zone 10, as illustrated in FIG. 3B. The rotary member 124 may include a rotary coupling 144 configured to rotationally and fluidly connect the first tubular connection 140 and the second tubular connection 142. The rotary coupling 144 may be configured to allow the first tubular connection 140 to swivel relative to the second tubular connection 142 between the first configuration (FIG. 4A) and the second configuration (FIG. 4B). The rotary coupling 144 may include a fitting fixed to the second tubular connection 142 and receiving a lateral portion of the first fluid connection 140 with ball bearings or the like to reduce friction during the swiveling. The rotary coupling 144 may not impart a substantial torque, such that rotation is provided by the travel of the carrier 106. The first conduit 122 may be coupled to the first tubular connection 140 in any reasonable manner for fluid communication. Similarly, the second conduit may be coupled to the second tubular connection 142 in any reasonable manner for fluid communication.

[0038] The first conduit 122 may be flexible and be configured to deflect during the travel of the pumping unit 104, as illustrated in FIGS. 3A-B. The first conduit 122 for each of the low-pressure line and the high-pressure line have a minimum bend radius of about 30 inches (e.g., about 0.75 meters). The first conduit 122 may be made of a rubber, an elastomeric, braided, woven, and / or reinforced composite material. The connection assembly 110 may further include a guide member 150 configured to guide the deflection and prevent overbending of the first conduit 122 as the trailer 114 travels. The guide member 150 may include a rounded portion 152 having a radius configured to ensure that the first conduit 122 is not bent past a minimum radius (e.g., about 30 inches). As illustrated in FIG. 3A, the first conduit 122 may be configured to extend at least partially around the rounded portion 152 in the first configuration to prevent overbending. The guide member 150 may further include an abutment surface 154 configured to engage the trailer 114, for example at a bumper of the trailer 114. The guide member 150 may be engaged to the platform 120 for the guide member 150 (e.g., by being received in the channel 126 or other tracks) to travel in a single degree of freedom between the first configuration (FIG. 3A) and the second configuration (FIG. 3B). The guide member 150 may be a dolly. For example, the guide member 150 may have wheels engaging the platform 120 (e.g., the frame 127 and / or the upper surface 128) and be configured to reduce friction during the travel along the platform 120. Thus, the first conduit 122 may extend around the rounded portion 152 to pull the guide member 150 from the first configuration (FIG. 3A) to the second configuration (FIG. 3B) when the trailer 114 travels from the first position to the second position. The trailer 114 may abut the abutment surface 154 to push the guide member 150 from the second configuration (FIG. 3B) to the first configuration (FIG. 3A) when the trailer 114 travels from the second position to the first position. The rounded portion 152 may guide the first conduit 122 back into the channel 126 as the trailer 114 travels to the first position. The second conduit may extend between the rotary member 124 and the valve assembly 112 in or on the platform 120. The second conduit may be rigid. The guide member 150 may simultaneously guide the first conduit 122 for both of the high-pressure line and the low-pressure line with the rounded portion 152 into and out of the same channel 126.

[0039] FIG. 5 illustrates a second embodiment of the connection assembly 110′. The connection assembly 110′ may be similar to the connection assembly 110 of the first embodiment, the entire disclosure of which is incorporated herein, except when otherwise indicated. As illustrated, the connection assembly 110′ may include a guide member 150′ configured to guide the deflection and prevent overbending of the first conduit 122 as the trailer 114 travels. The guide member 150′ may include a rounded portion 152′ having a radius configured to ensure that the first conduit 122 is not bent past a minimum radius (e.g., 30 inches). The first conduit 122 may be configured to extend at least partially around the rounded portion 152′ in the first configuration to prevent overbending. As illustrated, the rounded portion 152′ may have an arc shape configured to guide bending of the first conduit 122. The rounded portion 152′ may include rollers 153′ configured to rotate and reduce friction on the first conduit 122 as the first conduit 122 travels along the rounded portion 152′. The guide member 150′ may further include an abutment surface 154′ configured to engage the trailer 114, for example at a bumper of the trailer 114. The guide member 150′ may be engaged to the platform 120 for the guide member 150 (e.g., by being received in the channel 126 or other tracks) to travel in a single degree of freedom between the first configuration (FIG. 3A) and the second configuration (FIG. 3B). The guide member 150 may be a dolly. For example, the guide member 150′ may have wheels engaging the platform 120 (e.g., the upper surface 128) and be configured to reduce friction during the travel along the platform 120. Thus, the first conduit 122 may extend around the rounded portion 152′ to pull the guide member 150′ from the first configuration (FIG. 3A) to the second configuration (FIG. 3B) when the trailer 114 travels from the first position to the second position. The trailer 114 may abut the abutment surface 154′ to push the guide member 150′ from the second configuration (FIG. 3B) to the first configuration (FIG. 3A) when the trailer 114 travels from the second position to the first position. The rounded portion 152′ may guide the first conduit 122 back into the channel 126 as the trailer 114 travels to the first position. The guide member 150′ may simultaneously guide the first conduit 122 for both of the high-pressure line and the low-pressure line with the rounded portion 152′ into and out of the same channel 126.

[0040] FIG. 6 illustrates a third embodiment of the connection assembly 110″. The connection assembly 110″ may be similar to at least one of the connection assembly 110 of the first embodiment and the connection assembly 110′ of the second embodiment, the entire disclosure of which is incorporated herein, except when otherwise indicated. The connection assembly 110″ may include a guide member 160 to extend and retract the conduit 122. The guide member 160 may be in the form of a sleeve or rail configured to receive the first conduit 122 (not shown). The guide member 160 may be deflectable and configured to support the conduit 122. For example, as illustrated, the guide member 160 may be formed by a plurality of articulating segments 162 configured to deflect relative to each other to allow the guide member 160 to bend or curl. The articulating segments 162 may be rigid and / or discrete segments connected to each other. The articulating segments 162 may be connected through a male / female connection, a pin connection, and / or a ball / socket connection to allow the articulating segments 162 to deflect relative to each other. The articulating segments 162 may limit the bending of the first conduit 122 by abutting each other when the articulating segments 162 deflect at a predetermined bend radius. The guide member 160 may be received in the channel 126 with the first conduit 122 when the trailer 114 is in the first position (as illustrated in FIG. 3A). The guide member 160 may have a length that substantially matches a length of the conduit 122. As illustrated in FIG. 5, the length of the guide member 160 may be longer than a length of the channel 126, such that the guide member 160 is bent or curled in the first configuration and the second configuration to provide a proper angle of the conduit 122 for the coupling 105 to connect to the pumping unit 104. The guide member 160 may be connected to the platform 120 away from the manifold system 102 and / or valve assembly 112, for example at least about 1 feet away from the valve assembly to provide sufficient space in the channel 126 for the conduit 122 in the first configuration (FIG. 3A) and travel of the trailer 114 to the second configuration (FIG. 3B).

[0041] FIGS. 7A-B illustrate a fourth embodiment of a connection assembly 110′″ of the system of the present disclosure. The connection assembly 110′″ may be similar to at least one of the connection assembly 110 of the first embodiment, the connection assembly 110′ of the second embodiment, and the connection assembly 110″ of the third embodiment, the entire disclosure of which is incorporated herein, except when otherwise indicated. As illustrated, the connection assembly 110′″ may include a guide member 164 configured to extend and retract the conduit 122. The guide member 164 may include a reel configured to rotate in a first direction to wind the first conduit 122 around an axis to store the first conduit 122 in a first configuration (FIG. 7A) when the pumping unit 104 is in the red zone 10. The reel 164 may configured to rotate in a second direction to unwind the first conduit 122 as the trailer 114 travels out of the redzone to a second configuration (FIG. 7B). The reel 164 may include a motor or biasing force configured to rotate the reel 164 to automatically retract the first conduit 122 in a controlled manner when the trailer 114 travels into the red zone 10. The motor may be a tension driven servo configured to reel and unreel the reel 164. In some embodiments, the motor may provide sufficient torque to the reel 164 to pull the trailer 114 and / or carrier 106 into the red zone 10 autonomously via the first conduit 122. The second conduit 123 is illustrated extending from the reel 164 to the valve assembly 112. It should be noted that in any of the embodiments, the second conduit 123 may be integrally and continuously formed with the first conduit 122 or be a separate hose or tube from the first conduit 122 and joined at a coupling.

[0042] As illustrated in FIG. 8, the valve assembly 112 may include a pressure intensifier 170, an intensifier valve 172, a relief valve 173, a high-pressure valve 174, and a low-pressure valve 175. The valve assembly 112 may further include a check valve 176 downstream of the relief valve 173 and a check valve 177 downstream of the high-pressure valve 174. The various components of the valve assembly 112 may be situated on the same or different housings, skids, and / or vehicles.

[0043] The valve assembly 112 may provide a primary flow path through a low-pressure side from the low-pressure manifold 130 past the low-pressure valve 175, through the connection assembly 110, through the pumping unit 104, back through the connection assembly 110, through the high-pressure valve 174 on a high-pressure side, and to the high-pressure manifold 132. A first pressure sensor 178 may be fluidly connected between the pressure intensifier 170 and the intensifier valve 172. A second pressure sensor 179 may be in the primary flow path downstream of the pumping unit 104 and upstream of the high-pressure manifold 132.

[0044] The pressure intensifier 170 may be configured to pressurize and depressurize the system according to methods as disclosed herein. For example, the pressure intensifier 170 may be configured to perform a pressure test of the connection assembly 110 and / or the valve assembly 112 without using the pumping unit 104. The intensifier valve 172 may be configured to isolate the pressure intensifier 170 from the primary flow path. When the intensifier valve 172 is open, the pressure intensifier 170 may be configured to pressurize and depressurize the primary flow path. The pressure intensifier 170 may be a variable volume mechanism including a piston cylinder 180 having a longitudinal bore with a first end that is closed and a second end that is open. A piston rod 181 may be positioned within the longitudinal bore of the piston cylinder 180 and be moveable along a longitudinal axis of the longitudinal bore. The piston cylinder 180 may define a hydraulic or pneumatic chamber 182 between the closed end of the longitudinal bore and the piston rod 181. Pneumatic or hydraulic fluid may be pumped into or out of the chamber 182 to move the piston rod 181 longitudinally within the piston cylinder 180 to pressurize or depressurize the valve assembly 112. In other embodiments, the piston rod 181 may be moved within the piston cylinder 180 by an electro-magnetic system, such as via electro-magnets or a coil positioned along the longitudinal bore proximate to the closed first end of the piston cylinder 180 and extending toward the open second end. Electrical impulses sent to the coil or magnetic fields generated may cause the piston rod 181 to move within the longitudinal bore.

[0045] Increasing the volume of the chamber 182, such as by pumping pneumatic or hydraulic fluid volume into the chamber 182, pushes the piston rod 181 down to increase the pressure in the primary flow path. Likewise, decreasing the volume of the chamber 182, such as by pumping pneumatic or hydraulic fluid volume out of the chamber 182, pulls the piston rod 181 up to reduce the pressure in the primary flow path. Alternatively, an electromagnetic system as described hereinabove may move the piston rod 181 through the piston cylinder 180 to affect the pressure in the primary flow path.

[0046] The relief valve 173 may be configured to prevent overpressure in the primary flow path and / or redirect fluid flow from the high-pressure side back to the low-pressure side upstream or downstream of the low-pressure valve 175, for example when the high-pressure valve 174 is closed. In some embodiments, the relief valve 173 may be a bleed valve. The relief valve 173 may be embodied by the valves for pressure relief as disclosed in U.S. Pat. No. 10,627,003 and U.S. Patent Pub. Nos. 2022 / 0300014 and 2024 / 0125401, the entire disclosures of which are expressly incorporated herein by reference. The check valve 177 may include a limit switch and / or be fluidly connected to a flow sensor configured to measure the fluid flow from the high-pressure side to the low-pressure side.

[0047] Each of the valves 172-175 may be connected to any type of actuator configured to operate the valve 172-175 from a closed position to an open position, and then back to the closed position during each of a plurality of operation cycles, or from the open position to the closed position and back. In some embodiments, each valve actuator may be a solenoid actuator, a hydraulic actuator, an electromagnetic actuator, an electric motor, pneumatic actuator, and / or other similar or different types of actuators, as desired. According to some embodiments, each valve actuator may be a pneumatic or hydraulic actuator driven by an actuator fluid. Such an embodiment may provide improved safety on extreme worksites, such as those of a standard hydraulic fracturing or wellbore completion operation (e.g., exposure to extremes temperatures and weather).

[0048] As further illustrated, a controller 184 may be configured to perform the methods as disclosed herein. The controller 184 may be configured to modulate the extension of the pressure intensifier 170 and / or the opening and closing of the valves 172-175 via the valve actuators. For example, the controller 184 may be in communication with one or more hydraulic supplies configured to actuate the various components of the valve assembly 112. The controller 184 may be configured to pump hydraulic or pneumatic fluid into and out of the chamber 182 to actuate the piston rod 181. The controller 184 may also be configured to pump hydraulic or pneumatic fluid into and out of the valve actuators for each of the valve 172-175.

[0049] The controller 184 may monitor, interpret, control, and provide user interface and / or information feedback. The controller 184 may monitor or interpret process conditions and manage the components based on user desired function or interpreting control algorithms and signals. For example, the controller 184 may automatically actuate the valve assembly 112 to prime, pressure test, operate, and / or isolate the pumping unit 104 while the system 100 is operating.

[0050] The controller 184 may include a processing unit that executes logic to control the various components. Inputs from various sensors may be relayed to the controller 184 via direct electrical connection, such as from the various sensors and actuators. The controller 184 may include a computer programmed to respond to specific sensor input to control the positions of the various valves and the piston rod. The controller 184 may further include memory, non-volatile storage, and / or a display. The display be configured to display system information or status and / or receive user input and direct the user input to the VVM control module. The controller 184 may further include a network interface that provides connection to external components via a network, such as to a client device. The connection may be used to provide instructions to the controller 184 from the client device and / or relay information from the controller to the client device, such as via a wireless connection, Bluetooth, intranet, and / or internet communication. The network interface may also provide connection to any of the sensors and / or actuators, as discussed herein.

[0051] FIG. 9 illustrates a braking assembly 190 on the carrier 106 and / or trailer 114. As illustrated, the braking assembly 190 may include a brake 192, a compressed fluid source 194, a valve 196 between the tailer brake 192 and the compressed air source 194, and a valve actuator 198 configured to control fluid paths in the valve 196. The brake 192 may require air pressure from the compressed fluid source 194 to release. The compressed fluid source 194 may include an engine driven air compressor and a reservoir that holds compressed air. The valve 196 when actuated may provide a fluid path for the compressed air from the source 194 to one or more secondary chambers to compress a power spring (not shown) to release the brake 192. The compressed air may remain in the secondary chamber to compress the power spring the entire time that the brake 192 is disengaged. The valve 196 may also release the compressed air from the secondary chambers by providing a fluid path into the atmosphere 199 to reengage the brake 192. The carrier 106 may include brakes 192 for multiple wheels.

[0052] The controller 184 may automatically control the brake 192 with the valve actuator 198. The valve actuator 198 may include a source of hydraulic fluid configured to open and close the valve 196. The valve actuator 198 may selectively open and close the fluid paths for each of the compressed fluid source 194 and the atmosphere 199. For example, the valve actuator 198 may be configured to close the fluid path of the valve 196 to the compressed fluid source 194 and open the fluid path of the valve 196 to the atmosphere 199 to bleed the secondary chamber(s) ensuring that the tailer brake 192 is engaged and set preventing the pumping unit 104 from being moved when the pumping unit 104 and / or the valve assembly 112 is pressurized. Thus, the controller 184 may monitor and automatically control the brake 192 to prevent the carrier 106 from traveling out of the red zone 10 until after the pumping unit 104 and / or the valve assembly 112 is depressurized. In some embodiments, the controller 184 may automatically engage the brake 192, additionally or alternatively, based on geolocation, for example to prevent over tension of the first conduit 122. Likewise, if any of the criteria is not met as discussed, the controller 184 may blead off the braking assembly 190 to immediately engage the trailer brake 192 to ensure fracturing conduits are not damaged. The valve actuator 198 may further prevent the operator from manually releasing the brake 192 when the brake 192 is engaged by the controller 184.

[0053] FIG. 10 illustrates a method 1000 of swapping a pumping unit 104 with the system of FIGS. 1-9. The method 1000 may begin with the pumping unit 104 outside of the red zone 10. The conduit(s) 122 may be extended, and the coupling 105 of the conduit(s) 122 may be secured to the pumping unit 104 outside of the red zone 10, for example as illustrated in FIG. 3B. The valve assembly 112 may be depressurized, such that the carrier brake 192 may be released. With the coupling 105 secured to the conduit 122, the trailer 114 may be backed into the red zone 10 and stopped at a pumping position, for example as illustrated in FIG. 1A.

[0054] In step 1002, the controller 184 may automatically engage the brake 192 to prevent movement of the trailer 114 based on the priming of step 1004 being initiated and / or once the pumping unit 104 has reached its stationary spot inside of the redzone. The controller 184 may lock out the braking assembly 190 to prevent the trailer 114 from being moved forward based on the priming of step 1004 being initiated. The valve actuator 198 may open the fluid path of the valve 196 with the atmosphere 199 and close the fluid path of the valve 196 with the source 194 to engage the brake 192. The valve actuator 198 may further prevent the operator from manually releasing the brake 192 when engaged by the controller 184. Pressurization and testing may then be performed.

[0055] In step 1004, the controller 184 may prime the pumping unit 104 when the trailer 114 is in the red zone 10. The priming of the pumping unit 104 may be according to a request by an operator. During step 1004, the intensifier valve 172 and the high-pressure valve 174 may be closed to isolate the pressure intensifier 170 and the high-pressure manifold 132. The relief valve 173 and the low-pressure valve 175 may be opened to allow fluid flow from the low-pressure manifold 130. The fluid flow may flow through the valve assembly 112 and the pumping unit 104, and through the relief valve 173. The check valve sensor may indicate flow which may be recirculated back to the low-pressure side of the valve assembly 112. With the pumping unit 104 primed, the operator may engage the pumping unit 104 as needed to prime the fluid end of the pumping unit 104.

[0056] In step 1006, the controller 184 may perform a pressure test on the valve assembly 112 and / or the pumping unit 104. The operator may input a request for the pressure testing operation and in some embodiments input a test pressure. From the configuration of the valve assembly 112 in step 1004, the controller 184 may close the relief valve 173 and open the intensifier valve 172. The controller 184 may first retract the piston rod 181 within the piston cylinder 180 to prime at the blender pressure. The controller 184 may then start to extend the piston rod 181 through the piston cylinder 180 until the inputted pressure is met as indicated by the pressure sensor 179. The piston rod 181 of the pressure intensifier 170 may then stop. The relief valve 173 may be closed but configured to open at a limit pressure (e.g., 500 psi). The controller 184 may indicate whether the pressure test was successful or not. If successful, the controller 184 may proceed to step 1008.

[0057] In step 1008, the controller 184 may equalize the pressure of the pumping unit 104 to the high-pressure (HP) side. Step 1008 may be performed based on an inputted request from the operator for the valve assembly 112 to be equalized. From the configuration of the valve assembly 112 in step 1006, the controller 184 may open the relief valve 173 to induce flow past the sensor of the check valve 176. The operator may also input an equalization pressure, and / or the controller 184 may be configured to receive a frac side pressure input from a sensor in the system 100. The controller 184 may stroke out the pressure intensifier 170 by fully extending the piston rod 181 until the desired pressure is met. The piston rod 181 may then stop.

[0058] In step 1010, the controller 184 may operate the pumping unit 104. The controller 184 may configure valves 172-175 and intensifier 170 for a pumping operation, ensuring that there is no flow from the high-pressure side to the low-pressure side. From the configuration of the valve assembly in step 1008, the relief valve 173 may close the relief valve 173. The controller 184 may determine that there is no flow past the flow sensor of the check valve 176, from the high-pressure side to the low-pressure side. The pressure intensifier 170 may stroke out to max, and the intensifier valve 172 may close. The pressure intensifier 170 may be fully extended when not in use, such that the pressure intensifier may be primed with fluid when it is needed and to mitigate sand intrusion into the fluid pressuring envelope. Once the conditions are met, the high-pressure valve 174 may open, and the pumping unit 104 may be operated for fracing. In step 1012, the controller 184 may shut the pumping unit 104 down.

[0059] In step 1014, the controller 184 may isolate the pumping unit 104. The controller 184 may close the high-pressure valve 174 and the low-pressure valve 175, and open the intensifier valve 172 and the relief valve 173. The controller 184 may bleed the pumping unit 104 into the low-pressure side. The controller 184 may retract the pressure intensifier 170 to reduce the pressure. Once the pressure in the pumping unit 104 is brought down to atmospheric or close to atmospheric conditions, the controller 184 may indicate that the pumping unit 104 is depressurized for transportation. The pumping unit 104 may then determine that the pumping unit 104 may be transported for swapping and / or maintenance.

[0060] In step 1016, the controller 184 may release the brake of the carrier 106. The controller 184 may open the fluid path of the valve 196 between the pressurized fluid source 194 and close the fluid path with the atmosphere 199 to release the brake 192.

[0061] In step 1018, the carrier 106 may transport the pumping unit 104 out of the red zone 10. A visual and / or audible indicator may indicate to the operator of the carrier 106 to pull the trailer 114 forward to bring the pumping unit 104 out of the red zone. In some embodiments, as illustrated in FIGS. 3A-B and 6, the trailer 114 may pull the conduit 122 that translates the guide member 150 along the platform 120. The conduit 122 may extend out of the channel 126 as the pumping unit 104 is pulled out of the red zone 10, and in some embodiments, the rotary member 124 may swivel. In some embodiments, as illustrated in FIG. 6, the guide member 60 may bend and the articulating segments 162 may deflect relative to each other as the pumping unit 104 is pulled out of the red zone 10. In some embodiments, as illustrated in FIGS. 7A-B, the reel 164 may rotate as the conduit 122 unwinds and the pumping unit 104 is pulled out of the red zone 10. If the controller 184 may monitor the travel of the pumping unit 104 and / or carrier 106, and determine that the pumping unit is pulled past a predetermined distance from the valve assembly 112. The controller 184 may then engage the carrier brake 192 to prevent damage, for example due to excessive tension to the conduit 122. With the pumping unit 104 outside of the red zone 10, an operator may disconnect the conduit 122 from the pumping unit 104 at the coupling 105, taking the pumping unit 104 offline for swapping and / or maintenance.

[0062] While systems and methods have been described in connection with the various embodiments of the various figures, it will be appreciated by those skilled in the art that changes could be made to the embodiments without departing from the broad inventive concept thereof. It is understood, therefore, that this disclosure is not limited to the particular embodiments disclosed, and it is intended to cover modifications within the spirit and scope of the present disclosure as defined by the claims.

Examples

Embodiment Construction

[0026]The present disclosure is directed to methods and systems for continuous hydraulic fracturing operations with standard pumping equipment, while limiting or eliminating operator exposure to the high-pressure environment.

[0027]In some embodiments, the system may be for swapping pumping units outside of an immediate vicinity of operating by moving the necessary fracturing connections to a safe area. Thus, the pump may be connected or disconnected out of the redzone. For example, the methods and systems may be configured to remove the essential pumping unit connections outside of the redzone for safe make up and disconnection processes such that standard fracturing connections and processes can be utilized. The system may include integrated safety mechanisms so the pumping unit cannot be moved passed the safe mobilization range before the disconnection process is complete. The system may also include remote pressure testing capability that does not utilize the pumping unit to perf...

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional Application No. 63 / 673,988, filed Jul. 22, 2024, the entirety of which is incorporated herein by reference.TECHNICAL FIELD

[0002] This disclosure relates generally to methods and systems for maintaining and / or swapping equipment, and more specifically, the present disclosure is directed to maintaining and / or swapping pumping equipment in a frac system during active operations.BACKGROUND

[0003] Frac pumps must be swapped out for maintenance often resulting in down time for operations. However, it is industry standard to have a safe working zone that is a specified distance from active pressurized fracturing (fracing) operations.SUMMARY

[0004] The present inventors recognize a need for methods and systems for safe continuous hydraulic fracturing operations while avoiding operator exposure to the high-pressure environment. A limiting feature on the operations is the fact that the pumps must be swapped for maintenance. No personnel working should be in the red zone according to the industry standard. The present inventors also recognize that the pumping units need to be isolated and bleed off. The present inventors contemplate solutions using standard and non-standard pumping equipment.

[0005] The foregoing needs are met by the various embodiments as disclosed herein.

[0006] A first aspect of the present disclosure is directed to a system comprising: a platform having a channel, wherein the platform is configured to receive a carrier mounted with a pumping unit; and a conduit configured to transfer fluid to or from a manifold system, the conduit having a first end configured to be connected to the pumping unit, wherein the channel is configured to receive the conduit when the carrier is at least partially received on the platform.

[0007] In some embodiments, the system of the first aspect may include one or more of the following features. The platform may have a frame defining the channel. The channel may be underneath an upper surface of the platform, wherein the upper surface is configured to support the carrier. The system may include a pivoting member underneath an upper surface of the platform and connected to a second end of the conduit; and a second conduit having a first end connected to the pivoting member and a second end connected to a valve assembly. The system may include a guide member configured to guide the conduit into the channel. The guide member may be configured to travel relative to the platform. The guide member may include a rounded portion and an abutment surface, wherein the conduit is configured to extend at last partially around the rounded portion, and the carrier is configured to engage the abutment surface. The guide member may be deflectable and configured to support the conduit. The guide member may include a plurality of articulating segments configured to deflect relative to each other to allow the guide member to bend or curl. The system may further include a valve assembly configured to isolate the pumping unit from the manifold system. The valve assembly may include a pressure intensifier configured to control pressure in the system. The pressure intensifier may be configured to perform a pressure test of the system. The system may include an intensifier valve configured to isolate the pressure intensifier.

[0008] A second aspect of the present disclosure is directed to a system comprising: a conduit configured to transfer fluid to a manifold system, the conduit having a first end configured to be connected to a pumping unit on a carrier; and a reel configured to rotate in a first direction to wind the conduit around an axis to store the first conduit when the pumping unit travels toward a manifold system and to rotate in a second direction to unwind the first conduit as the carrier travels away from the manifold system.

[0009] In some embodiments, the system of the second aspect may include one or more of the following features. The system may include a valve assembly configured to isolate the pumping unit from the manifold system. The valve assembly may include a pressure intensifier configured to control pressure in the system. The pressure intensifier may be configured to perform a pressure test of the system. The system may include an intensifier valve configured to isolate the pressure intensifier.

[0010] A third aspect of the present disclosure is directed to a system comprising: a valve assembly comprising one or more valves configured to fluidly connect a pumping unit to a manifold system; a braking assembly configured to be connected to a carrier that transports the pumping unit, wherein the braking assembly includes a valve actuator configured to control a valve between a brake and a source of pressurized fluid; and a controller configured to control the valve actuator to engage the brake and prevent movement of the carrier when the pumping unit is actuated.

[0011] In some embodiments, the system of the third aspect may include one or more of the following features. The controller may prevent manual release of the brake by an operator when the brake are engaged by the controller.

[0012] A fourth aspect of the present disclosure is directed to a method comprising: engaging, with a controller, a brake of a carrier of a pumping unit based on the pumping unit being actuated; operating, with the controller, the pumping unit to perform a fracing operation by actuating one or more valves of a valve assembly; isolating, with the controller, the pumping unit from the manifold system by actuating the one or more valves of the valve assembly; and releasing, with the controller, the brake of the carrier based on the valve assembly isolating the pumping unit from the manifold system.

[0013] In some embodiments, the method of the fourth aspect may include one or more of the following features. Releasing the brake may be by controlling a valve between the brake and a source of pressurized fluid. The method may further include preventing, with the controller, manual release of the brake by an operator when the brake are engaged by the controller. The method may further include priming, with the controller, the pumping unit based on the brake being engaged. The method may further include pressure testing, with the controller, the pumping unit based on the brake being engaged. Pressuring testing may be by actuating a pressure intensifier in the valve assembly. The method may further include moving the carrier out of the area with respect to the manifold system after the releasing the brake.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The present application is further understood when read in conjunction with the appended drawings. For the purpose of illustrating the subject matter, there are shown in the drawings exemplary embodiments of the subject matter; however, the presently disclosed subject matter is not limited to the specific methods, devices, and systems disclosed. In the drawings:

[0015] FIG. 1 illustrates a system for hydraulic fracturing and injection well.

[0016] FIG. 2 illustrates a schematic of a system for swapping pumping units according to the present disclosure.

[0017] FIGS. 3A-B illustrate a first embodiment of the system of FIG. 2.

[0018] FIGS. 4A-B illustrate an exemplary embodiment of a pivoting member according to the first embodiment of FIG. 3A-B.

[0019] FIG. 5 illustrates a second embodiment of the system of FIG. 2.

[0020] FIG. 6 illustrates a third embodiment of the system of FIG. 2.

[0021] FIGS. 7A-B illustrate a fourth embodiment of the system of FIG. 2.

[0022] FIG. 8 illustrates a valve assembly of the system of FIGS. 1-7B.

[0023] FIG. 9 illustrates a braking assembly of the system of FIGS. 1-8.

[0024] FIG. 10 illustrates a method of swapping a pumping unit with the system of FIGS. 1-9.

[0025] Aspects of the disclosure will now be described in detail with reference to the drawings, wherein like reference numbers refer to like elements throughout, unless specified otherwise.DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0026] The present disclosure is directed to methods and systems for continuous hydraulic fracturing operations with standard pumping equipment, while limiting or eliminating operator exposure to the high-pressure environment.

[0027] In some embodiments, the system may be for swapping pumping units outside of an immediate vicinity of operating by moving the necessary fracturing connections to a safe area. Thus, the pump may be connected or disconnected out of the redzone. For example, the methods and systems may be configured to remove the essential pumping unit connections outside of the redzone for safe make up and disconnection processes such that standard fracturing connections and processes can be utilized. The system may include integrated safety mechanisms so the pumping unit cannot be moved passed the safe mobilization range before the disconnection process is complete. The system may also include remote pressure testing capability that does not utilize the pumping unit to perform a pressure test or to prime the pumping unit. The system may further include an electronic safeguard for ensuring that pumping unit cannot be started or pumped without active pressure relief or an open valve.

[0028] FIG. 1 illustrates a system 100 for hydraulic fracturing. The system 100 may include a manifold system 102 and one or more pumping units 104. The one or more pumping units 104 may include a positive displacement pump, a centrifugal pump, a progressive cavity pump, and / or a hydraulic piston pump. In some embodiments, the one or more pumping units 104 may each include one or more drive rods to drive a plunger or piston to generate the pressure. The one or more pumping units 104 may have three or more separate drive rods. For example, the one or more pumping units 104 may be a triplex pump or a quintuplex pump. Each of the pumping units 104 may be attached to a carrier 106 for transportation. The carrier 106 may be configured to support the one or more pumping units 104 for transportation relative to the manifold system 102.

[0029] The system 100 may further include a blender 108 configured to mix one or more components to generate a frac fluid. The frac fluid may be one or more liquids, slurries, water, or brine. The frac fluid may include one or more additives, such as chemicals, proppants, diverter material, sand, and other additives.

[0030] The frac fluid may be pumped at a low-pressure from the blender 108 to the manifold system 102. The manifold system 102 may have various flow path segments for fluid distribution and include a low-pressure manifold 130 and a high-pressure manifold 132, as schematically illustrated in FIG. 8. The low-pressure manifold 130 may be configured to receive the low-pressure fluid from the blender 108 and distribute the low-pressure fluid to the one or more pumping units 104 through a low-pressure line. Each pumping unit 104 may be configured to receive the fluid at a low-pressure and discharge it through a high-pressure line to the high-pressure manifold 132 at a high-pressure. The high-pressure manifold 132 may be fluidly connected to a wellbore extending into the ground. The frac fluid may be used to cause fractures in a subterranean formation to enable the collection of hydrocarbons from the wellbore.

[0031] Due to the pressure of the frac fluid being generated by the one or more pumping units 104 through the manifold system 102, an area or red zone 10 exists around the manifold system 102 where entry by personnel is limited during operation of the system 100. The red zone 10 presents challenges for fracking operations. In the past, the systems often time have to be shut down in order to disconnect one of the pumping units 104 for repair and / or maintenance. Thus, in case of a failure of one or more of the pumping units 104, the operator may have to choose between continuing to run the system 100 at less power due to the inoperable pump unit(s) or depressurizing the system 100 to allow personnel to enter the red zone 10 to disconnect the inoperable pumping unit 104 for maintenance. Either operation would undesirably increase downtime reducing output of the system 100.

[0032] As illustrated in FIG. 2, each of the pumping units 104 may be connected to the manifold system 102 with a connection assembly 110 and / or a valve assembly 112. The connection assembly 110 may include one or more conduits configured to transport the fluid between the manifold system 102 and the pumping unit 104 during operation of the system 100. Each of the connection assemblies 110 may include a low-pressure conduit configured to transport the fluid at low-pressure from the manifold system 102 to the pumping unit 104 and a high-pressure conduit configured to transport the fluid at high-pressure from the pumping unit 104 to the manifold system 102. The valve assembly 112 may include one or more valves to isolate the pumping unit 104 from the manifold system 102 for decoupling. In some embodiments, the carrier 106 may be at least partially received on a platform 120 when in the red zone 10.

[0033] FIGS. 3A-B illustrate a first embodiment of a connection assembly 110. The connection assembly 110 may include the platform 120, a first conduit 122 configured to connect to the pumping unit 104, a second conduit (not shown) positioned in or on the platform 120, and a rotary member 124 coupling the first conduit 122 and the second conduit. Thus, each of the low-pressure line and high-pressure line for the pumping unit 104 may separately have a first conduit 122 configured to connect to the pumping unit 104 at the coupling 105, a second conduit (not shown) positioned in the platform 120, and a rotary member 124 coupling the first conduit 122 and the second conduit (although both high-pressure and low-pressure sides not shown in FIGS. 3A-B). As further illustrated, the pumping unit 104 may be received on a trailer 114 of the carrier 106 for transportation relative to the manifold system 102.

[0034] The connection assembly 110 may have a first configuration (as illustrated in FIG. 3A) where at least a portion of the trailer 114 is in a first position to place at least the rear end of the pumping unit 104 in the red zone 10. At least a portion of the trailer 114 may be received on the platform 120 when in the first position (FIG. 3A). The connection assembly 110 may have a second configuration (as illustrated in FIG. 3B) where at least a portion of the pumping unit 104 is in a second position outside of the red zone 10 for the conduit 122 to be disconnected from the pumping unit 104. For example, the connection assembly 110 may be configured to position the coupling 105 out of the red zone 10 in the second configuration (FIG. 3B). Thus, the pumping unit 104 may be closer to the manifold system 102 when the connection assembly 110 is in the first configuration (FIG. 3A) than when the connection assembly 110 is in the second configuration (FIG. 3B).

[0035] The coupling 105 may be configured to connect and / or disconnect the pumping unit 104 from the manifold system 102 by an operator when the pumping unit 104 is outside of the redzone (FIG. 3B). In some embodiments, the coupling 105 may be a standard connection, enabling the connection assembly 110 to be used on any type of pumping equipment using standard procedures and equipment. For example, the coupling 105 may include a threaded connection, a clamping connection, a quick-connect connection, a sleeve connection, and / or a bolted connection (e.g., with an API flange and Bolt Pattern). However, in some embodiments, the coupling 105 may not be a standard connection.

[0036] The platform 120 may include a channel 126. The channel 126 may be immovably fixed to the platform 120. The channel 126 may be defined by an interior of a frame 127 integrated or fixed in or on the platform 120. In some embodiments, the channel 126 may be underneath an upper surface 128 of the platform 120 and running in the direction to and from the manifold system 102, where the upper surface 128 is configured to support the carrier 106. In some embodiments, the frame 127 may be secured between and / or join two distinct parts of the platform 120 (as illustrated in FIGS. 5 and 6). In some embodiments, the frame 127 may be positioned over or on the upper surface 128 and beside and / or in between the pumping unit(s) 104. The channel 126 may receive at least a portion of the first conduit 122 in the first configuration (FIG. 3A). The rotary member 124 may be in or on the platform 120 and be configured to rotate relative to a lateral axis of the platform 120 to extend and retract the conduit 122. For example, the rotary member 124 may be in the channel 126 of the frame 127 and / or underneath the upper surface 128. The rotary member 124 may guide the first conduit 122 out of the channel 126 when the pumping unit 104 pulls the first conduit 122 in traveling away from the manifold system 102 out of the red zone 10 (traveling from FIG. 3A to FIG. 3B). Similarly, the rotary member 124 may guide the first conduit 122 into the channel 126 when the pumping unit 104 pushes the first conduit 122 in traveling toward from the manifold system 102 into the red zone 10 (traveling from FIG. 3B to FIG. 3A). Each of the first conduits 122 of the low-pressure line and the high-pressure line may be received in the same channel 126 or different channels 126. The channel(s) 126 may enable storage of the first conduit 122 in the first configuration while preventing the first conduit 122 from being damaged by the trailer 114 or cluttering walkway space. The rotary member 124 may be positioned away from the manifold system 102 and / or valve assembly 112, for example at least about 1 feet away from the valve assembly 112 to provide sufficient space in the channel 126 for the conduit 122 in the first configuration (FIG. 3A) and travel of the trailer 114 to the second configuration (FIG. 3B). However, in some embodiments, the rotary member 124 may be integrated into the valve assembly 112.

[0037] As illustrated in FIGS. 4A-4B, the rotary member 124 may be configured to pivot or swivel as the first conduit 122 is pulled by the pumping unit 104. A pair of rotary members 124 are illustrated in each of FIGS. 4A-B, one for each of the low-pressure line and the high-pressure line. As further illustrated, the rotary members 124 of the low-pressure line and high-pressure line may pivot together during the travel of the pumping unit 104 as illustrated in FIGS. 3A-B. Each of the rotary members 124 may have a first tubular connection 140 configured to fluidly connect to the first conduit 122 and a second tubular connection 142 configured to fluidly connect to the second conduit. The rotary member 124 may have a U-shaped configuration. The first tubular connection 140 and the second tubular connection 142 may be substantially parallel in a first configuration (FIG. 4A), such that the first conduit 122 and the second conduit are directed substantially toward the manifold system 102 and at least a portion of the pumping unit 104 may be disposed in the red zone 10, as illustrated in FIG. 3A. The first tubular connection 140 and the second tubular connection 142 of each rotary member 124 may be rotationally offset in a second configuration (FIG. 4B), such that the first conduit 122 may be directed away from the manifold system 102 and the pumping unit 104 may be disposed out of the red zone 10, as illustrated in FIG. 3B. The rotary member 124 may include a rotary coupling 144 configured to rotationally and fluidly connect the first tubular connection 140 and the second tubular connection 142. The rotary coupling 144 may be configured to allow the first tubular connection 140 to swivel relative to the second tubular connection 142 between the first configuration (FIG. 4A) and the second configuration (FIG. 4B). The rotary coupling 144 may include a fitting fixed to the second tubular connection 142 and receiving a lateral portion of the first fluid connection 140 with ball bearings or the like to reduce friction during the swiveling. The rotary coupling 144 may not impart a substantial torque, such that rotation is provided by the travel of the carrier 106. The first conduit 122 may be coupled to the first tubular connection 140 in any reasonable manner for fluid communication. Similarly, the second conduit may be coupled to the second tubular connection 142 in any reasonable manner for fluid communication.

[0038] The first conduit 122 may be flexible and be configured to deflect during the travel of the pumping unit 104, as illustrated in FIGS. 3A-B. The first conduit 122 for each of the low-pressure line and the high-pressure line have a minimum bend radius of about 30 inches (e.g., about 0.75 meters). The first conduit 122 may be made of a rubber, an elastomeric, braided, woven, and / or reinforced composite material. The connection assembly 110 may further include a guide member 150 configured to guide the deflection and prevent overbending of the first conduit 122 as the trailer 114 travels. The guide member 150 may include a rounded portion 152 having a radius configured to ensure that the first conduit 122 is not bent past a minimum radius (e.g., about 30 inches). As illustrated in FIG. 3A, the first conduit 122 may be configured to extend at least partially around the rounded portion 152 in the first configuration to prevent overbending. The guide member 150 may further include an abutment surface 154 configured to engage the trailer 114, for example at a bumper of the trailer 114. The guide member 150 may be engaged to the platform 120 for the guide member 150 (e.g., by being received in the channel 126 or other tracks) to travel in a single degree of freedom between the first configuration (FIG. 3A) and the second configuration (FIG. 3B). The guide member 150 may be a dolly. For example, the guide member 150 may have wheels engaging the platform 120 (e.g., the frame 127 and / or the upper surface 128) and be configured to reduce friction during the travel along the platform 120. Thus, the first conduit 122 may extend around the rounded portion 152 to pull the guide member 150 from the first configuration (FIG. 3A) to the second configuration (FIG. 3B) when the trailer 114 travels from the first position to the second position. The trailer 114 may abut the abutment surface 154 to push the guide member 150 from the second configuration (FIG. 3B) to the first configuration (FIG. 3A) when the trailer 114 travels from the second position to the first position. The rounded portion 152 may guide the first conduit 122 back into the channel 126 as the trailer 114 travels to the first position. The second conduit may extend between the rotary member 124 and the valve assembly 112 in or on the platform 120. The second conduit may be rigid. The guide member 150 may simultaneously guide the first conduit 122 for both of the high-pressure line and the low-pressure line with the rounded portion 152 into and out of the same channel 126.

[0039] FIG. 5 illustrates a second embodiment of the connection assembly 110′. The connection assembly 110′ may be similar to the connection assembly 110 of the first embodiment, the entire disclosure of which is incorporated herein, except when otherwise indicated. As illustrated, the connection assembly 110′ may include a guide member 150′ configured to guide the deflection and prevent overbending of the first conduit 122 as the trailer 114 travels. The guide member 150′ may include a rounded portion 152′ having a radius configured to ensure that the first conduit 122 is not bent past a minimum radius (e.g., 30 inches). The first conduit 122 may be configured to extend at least partially around the rounded portion 152′ in the first configuration to prevent overbending. As illustrated, the rounded portion 152′ may have an arc shape configured to guide bending of the first conduit 122. The rounded portion 152′ may include rollers 153′ configured to rotate and reduce friction on the first conduit 122 as the first conduit 122 travels along the rounded portion 152′. The guide member 150′ may further include an abutment surface 154′ configured to engage the trailer 114, for example at a bumper of the trailer 114. The guide member 150′ may be engaged to the platform 120 for the guide member 150 (e.g., by being received in the channel 126 or other tracks) to travel in a single degree of freedom between the first configuration (FIG. 3A) and the second configuration (FIG. 3B). The guide member 150 may be a dolly. For example, the guide member 150′ may have wheels engaging the platform 120 (e.g., the upper surface 128) and be configured to reduce friction during the travel along the platform 120. Thus, the first conduit 122 may extend around the rounded portion 152′ to pull the guide member 150′ from the first configuration (FIG. 3A) to the second configuration (FIG. 3B) when the trailer 114 travels from the first position to the second position. The trailer 114 may abut the abutment surface 154′ to push the guide member 150′ from the second configuration (FIG. 3B) to the first configuration (FIG. 3A) when the trailer 114 travels from the second position to the first position. The rounded portion 152′ may guide the first conduit 122 back into the channel 126 as the trailer 114 travels to the first position. The guide member 150′ may simultaneously guide the first conduit 122 for both of the high-pressure line and the low-pressure line with the rounded portion 152′ into and out of the same channel 126.

[0040] FIG. 6 illustrates a third embodiment of the connection assembly 110″. The connection assembly 110″ may be similar to at least one of the connection assembly 110 of the first embodiment and the connection assembly 110′ of the second embodiment, the entire disclosure of which is incorporated herein, except when otherwise indicated. The connection assembly 110″ may include a guide member 160 to extend and retract the conduit 122. The guide member 160 may be in the form of a sleeve or rail configured to receive the first conduit 122 (not shown). The guide member 160 may be deflectable and configured to support the conduit 122. For example, as illustrated, the guide member 160 may be formed by a plurality of articulating segments 162 configured to deflect relative to each other to allow the guide member 160 to bend or curl. The articulating segments 162 may be rigid and / or discrete segments connected to each other. The articulating segments 162 may be connected through a male / female connection, a pin connection, and / or a ball / socket connection to allow the articulating segments 162 to deflect relative to each other. The articulating segments 162 may limit the bending of the first conduit 122 by abutting each other when the articulating segments 162 deflect at a predetermined bend radius. The guide member 160 may be received in the channel 126 with the first conduit 122 when the trailer 114 is in the first position (as illustrated in FIG. 3A). The guide member 160 may have a length that substantially matches a length of the conduit 122. As illustrated in FIG. 5, the length of the guide member 160 may be longer than a length of the channel 126, such that the guide member 160 is bent or curled in the first configuration and the second configuration to provide a proper angle of the conduit 122 for the coupling 105 to connect to the pumping unit 104. The guide member 160 may be connected to the platform 120 away from the manifold system 102 and / or valve assembly 112, for example at least about 1 feet away from the valve assembly to provide sufficient space in the channel 126 for the conduit 122 in the first configuration (FIG. 3A) and travel of the trailer 114 to the second configuration (FIG. 3B).

[0041] FIGS. 7A-B illustrate a fourth embodiment of a connection assembly 110′″ of the system of the present disclosure. The connection assembly 110′″ may be similar to at least one of the connection assembly 110 of the first embodiment, the connection assembly 110′ of the second embodiment, and the connection assembly 110″ of the third embodiment, the entire disclosure of which is incorporated herein, except when otherwise indicated. As illustrated, the connection assembly 110′″ may include a guide member 164 configured to extend and retract the conduit 122. The guide member 164 may include a reel configured to rotate in a first direction to wind the first conduit 122 around an axis to store the first conduit 122 in a first configuration (FIG. 7A) when the pumping unit 104 is in the red zone 10. The reel 164 may configured to rotate in a second direction to unwind the first conduit 122 as the trailer 114 travels out of the redzone to a second configuration (FIG. 7B). The reel 164 may include a motor or biasing force configured to rotate the reel 164 to automatically retract the first conduit 122 in a controlled manner when the trailer 114 travels into the red zone 10. The motor may be a tension driven servo configured to reel and unreel the reel 164. In some embodiments, the motor may provide sufficient torque to the reel 164 to pull the trailer 114 and / or carrier 106 into the red zone 10 autonomously via the first conduit 122. The second conduit 123 is illustrated extending from the reel 164 to the valve assembly 112. It should be noted that in any of the embodiments, the second conduit 123 may be integrally and continuously formed with the first conduit 122 or be a separate hose or tube from the first conduit 122 and joined at a coupling.

[0042] As illustrated in FIG. 8, the valve assembly 112 may include a pressure intensifier 170, an intensifier valve 172, a relief valve 173, a high-pressure valve 174, and a low-pressure valve 175. The valve assembly 112 may further include a check valve 176 downstream of the relief valve 173 and a check valve 177 downstream of the high-pressure valve 174. The various components of the valve assembly 112 may be situated on the same or different housings, skids, and / or vehicles.

[0043] The valve assembly 112 may provide a primary flow path through a low-pressure side from the low-pressure manifold 130 past the low-pressure valve 175, through the connection assembly 110, through the pumping unit 104, back through the connection assembly 110, through the high-pressure valve 174 on a high-pressure side, and to the high-pressure manifold 132. A first pressure sensor 178 may be fluidly connected between the pressure intensifier 170 and the intensifier valve 172. A second pressure sensor 179 may be in the primary flow path downstream of the pumping unit 104 and upstream of the high-pressure manifold 132.

[0044] The pressure intensifier 170 may be configured to pressurize and depressurize the system according to methods as disclosed herein. For example, the pressure intensifier 170 may be configured to perform a pressure test of the connection assembly 110 and / or the valve assembly 112 without using the pumping unit 104. The intensifier valve 172 may be configured to isolate the pressure intensifier 170 from the primary flow path. When the intensifier valve 172 is open, the pressure intensifier 170 may be configured to pressurize and depressurize the primary flow path. The pressure intensifier 170 may be a variable volume mechanism including a piston cylinder 180 having a longitudinal bore with a first end that is closed and a second end that is open. A piston rod 181 may be positioned within the longitudinal bore of the piston cylinder 180 and be moveable along a longitudinal axis of the longitudinal bore. The piston cylinder 180 may define a hydraulic or pneumatic chamber 182 between the closed end of the longitudinal bore and the piston rod 181. Pneumatic or hydraulic fluid may be pumped into or out of the chamber 182 to move the piston rod 181 longitudinally within the piston cylinder 180 to pressurize or depressurize the valve assembly 112. In other embodiments, the piston rod 181 may be moved within the piston cylinder 180 by an electro-magnetic system, such as via electro-magnets or a coil positioned along the longitudinal bore proximate to the closed first end of the piston cylinder 180 and extending toward the open second end. Electrical impulses sent to the coil or magnetic fields generated may cause the piston rod 181 to move within the longitudinal bore.

[0045] Increasing the volume of the chamber 182, such as by pumping pneumatic or hydraulic fluid volume into the chamber 182, pushes the piston rod 181 down to increase the pressure in the primary flow path. Likewise, decreasing the volume of the chamber 182, such as by pumping pneumatic or hydraulic fluid volume out of the chamber 182, pulls the piston rod 181 up to reduce the pressure in the primary flow path. Alternatively, an electromagnetic system as described hereinabove may move the piston rod 181 through the piston cylinder 180 to affect the pressure in the primary flow path.

[0046] The relief valve 173 may be configured to prevent overpressure in the primary flow path and / or redirect fluid flow from the high-pressure side back to the low-pressure side upstream or downstream of the low-pressure valve 175, for example when the high-pressure valve 174 is closed. In some embodiments, the relief valve 173 may be a bleed valve. The relief valve 173 may be embodied by the valves for pressure relief as disclosed in U.S. Pat. No. 10,627,003 and U.S. Patent Pub. Nos. 2022 / 0300014 and 2024 / 0125401, the entire disclosures of which are expressly incorporated herein by reference. The check valve 177 may include a limit switch and / or be fluidly connected to a flow sensor configured to measure the fluid flow from the high-pressure side to the low-pressure side.

[0047] Each of the valves 172-175 may be connected to any type of actuator configured to operate the valve 172-175 from a closed position to an open position, and then back to the closed position during each of a plurality of operation cycles, or from the open position to the closed position and back. In some embodiments, each valve actuator may be a solenoid actuator, a hydraulic actuator, an electromagnetic actuator, an electric motor, pneumatic actuator, and / or other similar or different types of actuators, as desired. According to some embodiments, each valve actuator may be a pneumatic or hydraulic actuator driven by an actuator fluid. Such an embodiment may provide improved safety on extreme worksites, such as those of a standard hydraulic fracturing or wellbore completion operation (e.g., exposure to extremes temperatures and weather).

[0048] As further illustrated, a controller 184 may be configured to perform the methods as disclosed herein. The controller 184 may be configured to modulate the extension of the pressure intensifier 170 and / or the opening and closing of the valves 172-175 via the valve actuators. For example, the controller 184 may be in communication with one or more hydraulic supplies configured to actuate the various components of the valve assembly 112. The controller 184 may be configured to pump hydraulic or pneumatic fluid into and out of the chamber 182 to actuate the piston rod 181. The controller 184 may also be configured to pump hydraulic or pneumatic fluid into and out of the valve actuators for each of the valve 172-175.

[0049] The controller 184 may monitor, interpret, control, and provide user interface and / or information feedback. The controller 184 may monitor or interpret process conditions and manage the components based on user desired function or interpreting control algorithms and signals. For example, the controller 184 may automatically actuate the valve assembly 112 to prime, pressure test, operate, and / or isolate the pumping unit 104 while the system 100 is operating.

[0050] The controller 184 may include a processing unit that executes logic to control the various components. Inputs from various sensors may be relayed to the controller 184 via direct electrical connection, such as from the various sensors and actuators. The controller 184 may include a computer programmed to respond to specific sensor input to control the positions of the various valves and the piston rod. The controller 184 may further include memory, non-volatile storage, and / or a display. The display be configured to display system information or status and / or receive user input and direct the user input to the VVM control module. The controller 184 may further include a network interface that provides connection to external components via a network, such as to a client device. The connection may be used to provide instructions to the controller 184 from the client device and / or relay information from the controller to the client device, such as via a wireless connection, Bluetooth, intranet, and / or internet communication. The network interface may also provide connection to any of the sensors and / or actuators, as discussed herein.

[0051] FIG. 9 illustrates a braking assembly 190 on the carrier 106 and / or trailer 114. As illustrated, the braking assembly 190 may include a brake 192, a compressed fluid source 194, a valve 196 between the tailer brake 192 and the compressed air source 194, and a valve actuator 198 configured to control fluid paths in the valve 196. The brake 192 may require air pressure from the compressed fluid source 194 to release. The compressed fluid source 194 may include an engine driven air compressor and a reservoir that holds compressed air. The valve 196 when actuated may provide a fluid path for the compressed air from the source 194 to one or more secondary chambers to compress a power spring (not shown) to release the brake 192. The compressed air may remain in the secondary chamber to compress the power spring the entire time that the brake 192 is disengaged. The valve 196 may also release the compressed air from the secondary chambers by providing a fluid path into the atmosphere 199 to reengage the brake 192. The carrier 106 may include brakes 192 for multiple wheels.

[0052] The controller 184 may automatically control the brake 192 with the valve actuator 198. The valve actuator 198 may include a source of hydraulic fluid configured to open and close the valve 196. The valve actuator 198 may selectively open and close the fluid paths for each of the compressed fluid source 194 and the atmosphere 199. For example, the valve actuator 198 may be configured to close the fluid path of the valve 196 to the compressed fluid source 194 and open the fluid path of the valve 196 to the atmosphere 199 to bleed the secondary chamber(s) ensuring that the tailer brake 192 is engaged and set preventing the pumping unit 104 from being moved when the pumping unit 104 and / or the valve assembly 112 is pressurized. Thus, the controller 184 may monitor and automatically control the brake 192 to prevent the carrier 106 from traveling out of the red zone 10 until after the pumping unit 104 and / or the valve assembly 112 is depressurized. In some embodiments, the controller 184 may automatically engage the brake 192, additionally or alternatively, based on geolocation, for example to prevent over tension of the first conduit 122. Likewise, if any of the criteria is not met as discussed, the controller 184 may blead off the braking assembly 190 to immediately engage the trailer brake 192 to ensure fracturing conduits are not damaged. The valve actuator 198 may further prevent the operator from manually releasing the brake 192 when the brake 192 is engaged by the controller 184.

[0053] FIG. 10 illustrates a method 1000 of swapping a pumping unit 104 with the system of FIGS. 1-9. The method 1000 may begin with the pumping unit 104 outside of the red zone 10. The conduit(s) 122 may be extended, and the coupling 105 of the conduit(s) 122 may be secured to the pumping unit 104 outside of the red zone 10, for example as illustrated in FIG. 3B. The valve assembly 112 may be depressurized, such that the carrier brake 192 may be released. With the coupling 105 secured to the conduit 122, the trailer 114 may be backed into the red zone 10 and stopped at a pumping position, for example as illustrated in FIG. 1A.

[0054] In step 1002, the controller 184 may automatically engage the brake 192 to prevent movement of the trailer 114 based on the priming of step 1004 being initiated and / or once the pumping unit 104 has reached its stationary spot inside of the redzone. The controller 184 may lock out the braking assembly 190 to prevent the trailer 114 from being moved forward based on the priming of step 1004 being initiated. The valve actuator 198 may open the fluid path of the valve 196 with the atmosphere 199 and close the fluid path of the valve 196 with the source 194 to engage the brake 192. The valve actuator 198 may further prevent the operator from manually releasing the brake 192 when engaged by the controller 184. Pressurization and testing may then be performed.

[0055] In step 1004, the controller 184 may prime the pumping unit 104 when the trailer 114 is in the red zone 10. The priming of the pumping unit 104 may be according to a request by an operator. During step 1004, the intensifier valve 172 and the high-pressure valve 174 may be closed to isolate the pressure intensifier 170 and the high-pressure manifold 132. The relief valve 173 and the low-pressure valve 175 may be opened to allow fluid flow from the low-pressure manifold 130. The fluid flow may flow through the valve assembly 112 and the pumping unit 104, and through the relief valve 173. The check valve sensor may indicate flow which may be recirculated back to the low-pressure side of the valve assembly 112. With the pumping unit 104 primed, the operator may engage the pumping unit 104 as needed to prime the fluid end of the pumping unit 104.

[0056] In step 1006, the controller 184 may perform a pressure test on the valve assembly 112 and / or the pumping unit 104. The operator may input a request for the pressure testing operation and in some embodiments input a test pressure. From the configuration of the valve assembly 112 in step 1004, the controller 184 may close the relief valve 173 and open the intensifier valve 172. The controller 184 may first retract the piston rod 181 within the piston cylinder 180 to prime at the blender pressure. The controller 184 may then start to extend the piston rod 181 through the piston cylinder 180 until the inputted pressure is met as indicated by the pressure sensor 179. The piston rod 181 of the pressure intensifier 170 may then stop. The relief valve 173 may be closed but configured to open at a limit pressure (e.g., 500 psi). The controller 184 may indicate whether the pressure test was successful or not. If successful, the controller 184 may proceed to step 1008.

[0057] In step 1008, the controller 184 may equalize the pressure of the pumping unit 104 to the high-pressure (HP) side. Step 1008 may be performed based on an inputted request from the operator for the valve assembly 112 to be equalized. From the configuration of the valve assembly 112 in step 1006, the controller 184 may open the relief valve 173 to induce flow past the sensor of the check valve 176. The operator may also input an equalization pressure, and / or the controller 184 may be configured to receive a frac side pressure input from a sensor in the system 100. The controller 184 may stroke out the pressure intensifier 170 by fully extending the piston rod 181 until the desired pressure is met. The piston rod 181 may then stop.

[0058] In step 1010, the controller 184 may operate the pumping unit 104. The controller 184 may configure valves 172-175 and intensifier 170 for a pumping operation, ensuring that there is no flow from the high-pressure side to the low-pressure side. From the configuration of the valve assembly in step 1008, the relief valve 173 may close the relief valve 173. The controller 184 may determine that there is no flow past the flow sensor of the check valve 176, from the high-pressure side to the low-pressure side. The pressure intensifier 170 may stroke out to max, and the intensifier valve 172 may close. The pressure intensifier 170 may be fully extended when not in use, such that the pressure intensifier may be primed with fluid when it is needed and to mitigate sand intrusion into the fluid pressuring envelope. Once the conditions are met, the high-pressure valve 174 may open, and the pumping unit 104 may be operated for fracing. In step 1012, the controller 184 may shut the pumping unit 104 down.

[0059] In step 1014, the controller 184 may isolate the pumping unit 104. The controller 184 may close the high-pressure valve 174 and the low-pressure valve 175, and open the intensifier valve 172 and the relief valve 173. The controller 184 may bleed the pumping unit 104 into the low-pressure side. The controller 184 may retract the pressure intensifier 170 to reduce the pressure. Once the pressure in the pumping unit 104 is brought down to atmospheric or close to atmospheric conditions, the controller 184 may indicate that the pumping unit 104 is depressurized for transportation. The pumping unit 104 may then determine that the pumping unit 104 may be transported for swapping and / or maintenance.

[0060] In step 1016, the controller 184 may release the brake of the carrier 106. The controller 184 may open the fluid path of the valve 196 between the pressurized fluid source 194 and close the fluid path with the atmosphere 199 to release the brake 192.

[0061] In step 1018, the carrier 106 may transport the pumping unit 104 out of the red zone 10. A visual and / or audible indicator may indicate to the operator of the carrier 106 to pull the trailer 114 forward to bring the pumping unit 104 out of the red zone. In some embodiments, as illustrated in FIGS. 3A-B and 6, the trailer 114 may pull the conduit 122 that translates the guide member 150 along the platform 120. The conduit 122 may extend out of the channel 126 as the pumping unit 104 is pulled out of the red zone 10, and in some embodiments, the rotary member 124 may swivel. In some embodiments, as illustrated in FIG. 6, the guide member 60 may bend and the articulating segments 162 may deflect relative to each other as the pumping unit 104 is pulled out of the red zone 10. In some embodiments, as illustrated in FIGS. 7A-B, the reel 164 may rotate as the conduit 122 unwinds and the pumping unit 104 is pulled out of the red zone 10. If the controller 184 may monitor the travel of the pumping unit 104 and / or carrier 106, and determine that the pumping unit is pulled past a predetermined distance from the valve assembly 112. The controller 184 may then engage the carrier brake 192 to prevent damage, for example due to excessive tension to the conduit 122. With the pumping unit 104 outside of the red zone 10, an operator may disconnect the conduit 122 from the pumping unit 104 at the coupling 105, taking the pumping unit 104 offline for swapping and / or maintenance.

[0062] While systems and methods have been described in connection with the various embodiments of the various figures, it will be appreciated by those skilled in the art that changes could be made to the embodiments without departing from the broad inventive concept thereof. It is understood, therefore, that this disclosure is not limited to the particular embodiments disclosed, and it is intended to cover modifications within the spirit and scope of the present disclosure as defined by the claims.

Examples

Embodiment Construction

[0026]The present disclosure is directed to methods and systems for continuous hydraulic fracturing operations with standard pumping equipment, while limiting or eliminating operator exposure to the high-pressure environment.

[0027]In some embodiments, the system may be for swapping pumping units outside of an immediate vicinity of operating by moving the necessary fracturing connections to a safe area. Thus, the pump may be connected or disconnected out of the redzone. For example, the methods and systems may be configured to remove the essential pumping unit connections outside of the redzone for safe make up and disconnection processes such that standard fracturing connections and processes can be utilized. The system may include integrated safety mechanisms so the pumping unit cannot be moved passed the safe mobilization range before the disconnection process is complete. The system may also include remote pressure testing capability that does not utilize the pumping unit to perf...

Claims

1. A system comprising:a platform having a channel, wherein the platform is configured to receive a carrier mounted with a pumping unit; anda conduit configured to transfer fluid to or from a manifold system, the conduit having a first end configured to be connected to the pumping unit,wherein the channel is configured to receive the conduit when the carrier is at least partially received on the platform.

2. The system of claim 1, wherein the platform has a frame defining the channel.

3. The system of claim 1, wherein the channel is underneath an upper surface of the platform, wherein the upper surface is configured to support the carrier.

4. The system of claim 1, further comprising:a pivoting member underneath an upper surface of the platform and connected to a second end of the conduit; anda second conduit having a first end connected to the pivoting member and a second end connected to a valve assembly.

5. The system of claim 1, further comprising a guide member configured to guide the conduit into the channel.

6. The system of claim 5, wherein the guide member is configured to travel relative to the platform.

7. The system of claim 5, wherein the guide member includes a rounded portion and an abutment surface, wherein the conduit is configured to extend at last partially around the rounded portion, and the carrier is configured to engage the abutment surface.

8. The system of claim 5, wherein the guide member is flexible and configured to support the conduit.

9. The system of claim 8, wherein the guide member includes a plurality of articulating segments configured to deflect relative to each other to allow the guide member to bend or curl.

10. The system of claim 1, further comprising a valve assembly configured to isolate the pumping unit from the manifold system.

11. The system of claim 10, wherein the valve assembly includes a pressure intensifier configured to control pressure in the system.

12. The system of claim 11, wherein the pressure intensifier is configured to perform a pressure test of the system.

13. The system of claim 11, further comprising an intensifier valve configured to isolate the pressure intensifier.

14. A system comprising:a conduit configured to transfer fluid to a manifold system, the conduit having a first end configured to be connected to a pumping unit on a carrier; anda reel configured to rotate in a first direction to wind the conduit around an axis to store the first conduit when the pumping unit travels toward a manifold system and to rotate in a second direction to unwind the first conduit as the carrier travels away from the manifold system.

15. The system ofclaim 14, further comprising a valve assembly configured to isolate the pumping unit from the manifold system.

16. The system of claim 15, wherein the valve assembly includes a pressure intensifier configured to control pressure in the system.

17. The system of claim 16, wherein the pressure intensifier is configured to perform a pressure test of the system.

18. The system of claim 16, further comprising an intensifier valve configured to isolate the pressure intensifier.

19. A system comprising:a valve assembly comprising one or more valves configured to fluidly connect a pumping unit to a manifold system;a braking assembly configured to be connected to a carrier that transports the pumping unit, wherein the braking assembly includes a valve actuator configured to control a valve between a brake and a source of pressurized fluid; anda controller configured to control the valve actuator to engage the brake and prevent movement of the carrier when the pumping unit is actuated.

20. The system of claim 19, wherein the controller prevents manual release of the brake by an operator when the brake are engaged by the controller.

21. A method comprising:engaging, with a controller, a brake of a carrier of a pumping unit based on the pumping unit being actuated;operating, with the controller, the pumping unit to perform a fracing operation by actuating one or more valves of a valve assembly;isolating, with the controller, the pumping unit from the manifold system by actuating the one or more valves of the valve assembly; andreleasing, with the controller, the brake of the carrier based on the valve assembly isolating the pumping unit from the manifold system.

22. The method of claim 21, wherein the releasing the brake is by controlling a valve between the brake and a source of pressurized fluid.

23. The method of claim 21, further comprising preventing, with the controller, manual release of the brake by an operator when the brake are engaged by the controller.

24. The method of claim 21, further comprising priming, with the controller, the pumping unit based on the brake being engaged.

25. The method of claim 21, further comprising pressure testing, with the controller, the pumping unit based on the brake being engaged.

26. The method of claim 25, wherein the pressuring testing is by actuating a pressure intensifier in the valve assembly.

27. The method of claim 21, further comprising moving the carrier out of the area with respect to the manifold system after the releasing the brake.

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