Automated valve control for hydraulic fracturing

Abstract

A system for controlling flow of fluid for hydraulic fracturing includes a pump configured to pump fluid down a wellbore penetrating a subterranean formation; a valve disposed between the pump and the wellbore; a sensor configured to monitor a measurand of the hydraulic fracturing; and a controller configured to receive real time data of the measurand from the sensor, and control a degree of openness of the valve in real time based on the data and a valve sequencing algorithm.

Description

BACKGROUND

[0001] Manual control of valves in hydraulic fracturing can present significant challenges regarding flow rate control and managing dynamic operation conditions. Achieving the precision required for hydraulic fracturing can be difficult because flow rates must be adjusted to match changes in pressure and system demands. Human operators can be slow to react or make errors when relying on gauges or feedback systems. Dynamic operation conditions can amplify these challenges. For example, changes in flow rate, pressure, and fluid properties can lead to unpredictable changes. Operators may have trouble compensating for rapidly changing conditions, which can lead to system destabilization and unexpected down time. The system and method of the present disclosure may address one or more of these issues.BRIEF DESCRIPTION OF THE DRAWINGS

[0002] For a more complete understanding of the present disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.

[0003] FIG. 1 is a schematic diagram of mixing equipment and a frac spread, according to an embodiment of the present disclosure;

[0004] FIG. 2 is a schematic diagram of a well system, according to an embodiment;

[0005] FIG. 3A is a schematic diagram of a control system for real time valve control, according to an embodiment;

[0006] FIG. 3B is a schematic diagram of a control system for real time valve control, according to another embodiment;

[0007] FIG. 4A is a schematic diagram of a control system for adaptive valve control, according to an embodiment;

[0008] FIG. 4B is a schematic diagram of a control system for adaptive valve control, according to another embodiment;

[0009] FIG. 5A is a schematic diagram of a control system for machine learning-implemented valve control, according to an embodiment;

[0010] FIG. 5B is a schematic diagram of a control system for machine learning-implemented valve control, according to another embodiment;

[0011] FIG. 6A is a schematic diagram of a control system for integrative valve control, according to an embodiment;

[0012] FIG. 6B is a schematic diagram of a control system for integrative valve control, according to another embodiment;

[0013] FIG. 7 is a flow diagram of an exemplary method for controlling flow of fluid for hydraulic fracturing, according to an embodiment; and

[0014] FIG. 8 is a flow diagram of an exemplary method for controlling flow of fluid for hydraulic fracturing, according to another embodiment.DETAILED DESCRIPTION

[0015] It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or not yet in existence. The description that follows includes example systems, methods, techniques, and program flows that embody aspects of the disclosure. However, it is understood that this disclosure may be practiced without these specific details. For brevity, well-known steps, protocols, structures, and techniques have not been shown in detail in order not to obfuscate the description. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents.

[0016] As used herein the terms “uphole”, “upwell”, “above”, “top”, and the like refer directionally in a wellbore towards the surface, while the terms “downhole”, “downwell”, “below”, “bottom”, and the like refer directionally in a wellbore towards the toe of the wellbore (e.g. the end of the wellbore distally away from the surface), as persons of skill will understand. Orientation terms “upstream” and “downstream” are defined relative to the direction of flow of fluid, for example relative to flow of well fluid in the well. As used herein, orientation terms “upstream,”“downstream,”“up,” and “down” are defined relative to the direction of flow of well fluid in the well casing. “Upstream” is directed counter to the direction of flow of well fluid, towards the source of well fluid (e.g., towards perforations in well casing through which hydrocarbons flow out of a subterranean formation and into the casing). “Downstream” is directed in the direction of flow of well fluid, away from the source of well fluid. “Down” is directed counter to the direction of flow of well fluid, towards the source of well fluid. “Up” is directed in the direction of flow of well fluid, away from the source of well fluid.

[0017] Referring to FIG. 1, a well system 105, also referred to as a fracturing spread or frac spread, is shown comprising exemplary mixing equipment 140 and a frac pumping manifold 150. The mixing equipment 140 is in fluid communication with pumps 100 via feed / suction lines of a manifold 102, which is in further fluid communication with wellhead 104 via a high pressure flow line 113 (e.g., frac iron). In the frac pumping manifold 150, low pressure suction lines feeding pumps 100 and high pressure discharge lines from pumps 100 may be connected to the manifold 102. The pumps 100 may pump fracturing fluid, which may include proppant and / or other abrasive material. The proppant may be sand, for example. The manifold 102 may be a trailer system that transfers high-pressure fracturing fluid from the pumps 100 to a wellhead 104 and downhole to a perforated zone for fracturing. The mixing equipment may include a water source 108, a chemical storage 136, a proppant supply 112, and a blender 106. The manifold 102 may transfer low pressure fracturing fluid from the blender 106 via feed / suction lines to the pumps 100. The blender 106 may combine gelling agents and / or chemical additives (e.g., FR additives) from the chemical storage 136 and / or proppant from the proppant supply 112. At the blender 106, proppant may meter from proppant supply 112 into the mixture to become fracturing fluid that feeds into the pumps 100.

[0018] There may be valves 200 between the pumps 100 and the manifold 102. However, this is only one example of locations of the valves 200. The valves 200 may be located at any suitable position for regulating flow from the pumps into the wellhead 104. The pumps 100 may act as course flow control while the valves 200 act as fine flow control. For example, for a relatively large increase or decrease in flow rate, the pumps 100 (which may be diesel or electric) may adjust their output and the valves 200 may remain unchanged. For a relatively small increase or decrease in flow rate, the pumps may maintain their output and the valves 200 may change their degree of openness. In some embodiments, both the pumps 100 and the valves 200 are adjusted to achieve a desired flow rate. For example, the pumps 100 may be adjusted to roughly approximate a desired flow rate, and then the openness of one or more valves 200 may be adjusted to better approximate the desired flow rate. For example, if an increase in flow rate is desired, the pumps 100 may be controlled to increase their flow rate. However, if the pumps 100 overshoot the desired flow rate, the valves 200 may be partially closed to achieve the desired flow or come closer to achieving the desired flow rate. This can be especially helpful for diesel pumps, where gear changes can make it difficult to achieve certain flow rates. The valves 200 may be, for example, gate valves, ball, valves, choke valves, or any other suitable type of valve at any suitable location.

[0019] There may be sensors 400 between the pumps 100 and the valves 200 and / or at the wellhead 104 and / or downhole (e.g., in the wellbore) and / or in the manifold 102. However, these are only examples of possible locations of the sensors 400. The sensors 400 can be placed at any suitable position. The sensors may be pressure sensors and / or flow rate sensors and / or any other type of suitable sensor. A controller may control the pumps 100 and the valves 200 based on the sensor data to achieve a desired flow rate into the wellhead 104 and / or to regulate individual contributions to the overall flow rate by each pump 100.

[0020] Referring to FIG. 2, an exemplary well system 105 that may be used to introduce fracturing fluid (e.g., with proppant 116) into fractures 101 is shown. The well system 105 of FIG. 2 can be used in combination the frac spread embodiment shown in FIG. 1. The well system 105 may include the mixing equipment 140, the frac pumping manifold 150, and / or high pressure flow line 113. The frac pumping manifold 150 may be fluidly coupled with the high pressure flow line 113 to wellhead 104 to communicate the fracturing fluid into the wellbore 114.

[0021] The well system 105 may pump the fracturing fluid 117 into the subterranean formation 120 surrounding the wellbore 114. The wellbore 114 may include horizontal, vertical, slanted, curved, and / or other types of wellbore geometries and orientations, and the proppant may generally be applied to subterranean formation 120 surrounding any portion of wellbore 114, including the fractures 101. The wellbore 114 may include the casing 103 that may be cemented (or otherwise secured) to the wall of the wellbore 114 by cement sheath 122. Perforations 123 may allow communication between the wellbore 114 and the subterranean formation 120. The perforations 123 may penetrate the casing 103 and the cement sheath 122, allowing communication between the interior of the casing 103 and the fractures 101. A plug 124 may be disposed in wellbore 114 below the perforations 123.

[0022] A perforated interval of interest (e.g., an interval of the wellbore 114 including the perforations 123) may be isolated with the plug 124. A pad or pre-pad fluid (e.g., a clean fluid such as slick water) may be pumped into the subterranean formation 120 at a pumping rate and pressure at or above the fracture gradient to create and maintain at least one fracture 101 in subterranean formation 120. Then, proppant 116 may be mixed with an aqueous based fluid via mixing equipment 140, thereby forming a fracturing fluid (e.g., a dirty fluid). The fracturing fluid may be pumped via the frac pumping manifold 150 and high-pressure flow line 113 to the wellhead 104 and down the interior of the casing 103 and into subterranean formation 120 at or above a fracture gradient of the subterranean formation 120. Pumping the fracturing fluid at or above the fracture gradient of the subterranean formation 120 may create (or enhance) at least one fracture (e.g., fractures 101) extending from the perforations 123 into the subterranean formation 120, wherein the proppant is placed into the fractures and remains therein to prop open the fractures upon reduction of pumping pressure upon completion of the fracturing stage / job.

[0023] Referring to FIGS. 1 and 3A, dynamic valve control of frac process may be performed in real time. The dynamic valve control may be performed by a closed-loop valve control system that manages the position and operation of frac process valves 200 dynamically based on immediate data inputs and conditions. In some embodiments, the controller 300 (e.g., a pump and valve control system) comprises a first control module 310 (e.g., a valve control system) and a second module 320 (e.g., a pump control system). The controller 300 may adjust output of the pumps 100 and / or degree of openness of the valves 200 to achieve a desired flow rate. The closed-loop control system for frac process valves may add another layer of control capability for the frac job that can continuously monitor pressure and adjust flow automatically to reach desired performance levels accurately.

[0024] The system may continuously receive data from sensors 400 and compare it against desired set points, and then adjust the valves 200 accordingly to minimize errors. For example, a valve 200 may be programmed to remain closed until certain safety conditions are met. Each sequence may specify which valves should be open or closed, in what order, and for how long. The system, which may rely on the continuous monitoring of the frac process, may take immediate real-time actions to help enhance the safety measures, reduce downtime, improve operational efficiency, and leverage quality of the frac job. Data from the wellhead 104 and the downhole sensors 400 can be integrated and analyzed in real time to facilitate immediate control actions and to guide the sequence of operations. The valves 200 may be controlled dynamically based on real time data. For example, if wellhead pressure transducers detect a pressure drop, the controller 300 can immediately adjust relevant valves to stabilize the pressure. For example, in response to the pressure drop, the controller 300 may increase a degree of openness of one or more of the valves 200.

[0025] Employing feedback loops can help continuously monitor the valve adjustments and maintain frac process stability and efficiency. When integrated with a frac automation platform, the real-time valve control can help make decisions faster and adjust valve positions without human intervention. Using real-time control systems with powerful processors can handle vast amounts of data from wellhead 104 and subsurface sensors 400 at high frequencies. This processing capability and ability to make rapid decisions / adjustments can significantly enhance the quality of the frac job and maintain the continuity and integrity of the process. Referring to FIG. 3A, in some embodiments, the controller 300 comprises a consolidated valve control system and the pump control system to provide a unified control strategy that can simultaneously control the pump and valves to maintain desired frac responses. This coupled control scheme allows for improved stability and simplicity while considering all interactions within the frac process.

[0026] Referring to FIGS. 1 and 4A, an adaptive control scheme may be performed in real time. The adaptive control scheme may include an addition of one or more adaptive control elements to the embodiment of FIG. 3. Algorithms of the adaptive control scheme can evolve and become better suited to the process conditions they regulate. This may involve a learning component e.g., adjusting parameters automatically to optimize performance over time. In some embodiments, the controller 300 (e.g., a pump and valve adaptive control system) comprises a first control module 310 (e.g., an adaptive valve control system) and a second control module 320 (e.g., pump control system). The adaptive valve control system can significantly leverage effectiveness of frac process where the conditions may change unpredictably or where the optimal control strategy varies significantly over time. It may use complex algorithms that can change their behavior or structure in response to the performance of the control system itself. The adaptive real-time valve control system can ensure immediate responses and long-term optimization and efficiency.

[0027] Valve sequence logic can be implemented that helps ensure that valves are operated in a safe and correct manner. For example, a valve may be programmed to remain closed until certain safety conditions are met. The controller 300 may open one or more of the valves 200 in response to determining that a safety condition is met. The valves 200 may be opened according to a sequence. Each sequence may specify which valves should be open or closed, in what order, and for how long. The system may rely on the continuous monitoring of the frac process with control algorithms being adapted depending on the operating condition and optimization criteria. It may enhance the safety measures, reduce downtime, and optimize operational efficiency and the quality of the frac job. Data from wellhead 104 and downhole sensors 400 can be integrated and analyzed in real-time to adapt the control algorithms to cope with the operating condition while optimizing desired cost functions. The cost functions may minimize required energy and power resources for frac, maximize frac growth within desired constraints, optimize proppant placement, minimize deviation from desired pressure profile, minimize water usage, chemical additives and emission, and / or minimize the total financial cost of the frac process. The real-time adaptive control scheme can then help facilitate immediate control actions and guide the sequence of valve operations. Valves 200 may be controlled dynamically based on real-time data. For example, if wellhead pressure or condition changes, the controller 300 can immediately adapt itself and issues valve control commands to adjust relevant valves 200 to stabilize the pressure or maintain a desired response. The adaptation may happen when the pressure does not respond as expected to the valve controls. For example, if the deviation from the desired pressure does not respond adequately to the valve control input, adaptation can help capture the pressure response behavior enabling the valve control to more effectively follow the desired pressure profile.

[0028] The system may be integrated with an automation platform so that the real-time adaptive valve control system can help make optimum decisions quickly and adjust valve positions, e.g., without human intervention. Powerful processors can be used to handle vast amounts of operating conditions using data from wellhead and / or subsurface sensors 400. This processing capability and ability to make optimum and rapid decisions / adjustments can significantly enhance the quality of the frac job and maintain the continuity and integrity of the process. Referring to FIG. 4B, in some embodiments, the controller 300 comprises a consolidated valve control system and the pump control system to provide a unified adaptive control strategy that can simultaneously and adaptively control the pumps and valves to maintain desired frac responses at different operating conditions. This coupled adaptive control scheme allows for optimum performance, improved stability and simplicity while considering all interactions within the frac process.

[0029] Referring to FIGS. 1-2 and 4, a system for controlling flow of fluid for hydraulic fracturing may include a pump 100 configured to pump fluid down a wellbore 114 penetrating a subterranean formation 120; a valve 200 disposed between the pump 100 and the wellbore 114 (e.g., downstream from the pump 100); a sensor 400 configured to monitor a measurand (e.g., a parameter such as flow rate, temperature, or pressure) of the hydraulic fracturing (e.g., while the pump 100 is pumping fluid down the wellbore 114); and a controller 300 configured to receive real time data (e.g., data streamed in real time) of the measurand from the sensor 400, and control a degree of openness of the valve 200 (e.g., percentage indicating opened valve, closed valve, or intermediate positions between opened and closed) in real time based on the data and an adaptive parameter. The controller 300 may be further configured to control flow rate of the pump 100 in real time based on the data and the adaptive parameter.

[0030] The pump 100 may be one of a plurality of pumps 100 in fluid communication with the wellbore 114 and configured to be controlled simultaneously by the controller 300 (e.g., the controller 300 may control each of the pumps 100 such that they operate at the same speed or different speeds). The valve 200 may be one of a plurality of valves 200 respectively associated with the plurality of pumps 100 and configured to be controlled simultaneously by the controller 300 (e.g., the controller 300 may control each of the valves 200 independently). The sensor 400 may include a pressure sensor and the measurand may include pressure and / or the sensor 400 may include a flow rate sensor and the measurand may include flow rate. The adaptive parameter may be based on historical data. For example, the adaptive parameter may be set based on responses (pressure, flow rate, etc.) from other wellbores to valve and / or pump operations. The adaptive parameter may be based on a location of the wellbore, a geometry of the wellbore, a composition of the subterranean formation, and / or a state of the subterranean formation. For example, historical data may exist on location of wellbore(s), geometry of wellbore(s), composition of the subterranean formation(s), and / or a state of subterranean formation(s), and the adaptive parameter may be set based on one or more of those. The adaptive parameter may be updated based on new data from the sensors 400.

[0031] The controller 300 may include a first control module 310 configured to control the pump 100, and a second control module 320 configured to control the valve 200. For example, the first control module 310 may control the pump 100 based on data from the sensors 400, the second control module 320 may control the pump 100 based on the data from the sensors 400. The first control module 310 may be in communication with the second control module 320. For example, the first control module 310 and the second control module 320 may coordinate to achieve a desired setpoint based on the data from the sensors 400 using the adaptive parameter. The controller 300 may be further configured to control the valve 200 by an integrative control algorithm that is modified by the adaptive parameter.

[0032] Referring to FIG. 7, a method 700 for controlling flow of fluid for hydraulic fracturing may include the step 710 of monitoring, by a sensor, a measurand of the hydraulic fracturing; the step 720 of receiving, by a controller, real time data of the measurand from the sensor; and the step 730 of controlling, by the controller, a degree of openness of the valve in real time based on the data and an adaptive parameter. The valve may be disposed between a pump and a wellbore penetrating a subterranean formation, and the pump may be configured to pump fluid down the wellbore. The method 700 may further include controlling, by the controller, a flow rate of the pump in real time based on the data and the adaptive parameter. The pump may be one of a plurality of pumps in fluid communication with the wellbore and configured to be controlled simultaneously by the controller. The valve may be one of a plurality of valves respectively associated with the plurality of pumps and configured to be controlled simultaneously by the controller. The sensor may include a pressure sensor and the measurand may include pressure, and / or the sensor may include a flow rate sensor and the measurand may include flow rate. The adaptive parameter may be based on historical data. The adaptive parameter may be based on a location of the wellbore, a geometry of the wellbore, a composition of the subterranean formation, and / or a state of the subterranean formation. The controller may include a first control module configured to control the pump, and a second control module configured to control the valve. The first control module may be in communication with the second control module. The controller may be further configured to control the valve by an integrative control algorithm that is modified by the adaptive parameter.

[0033] Referring to FIGS. 1 and 5A, an artificial intelligence (AI) / machine learning (ML)-based valve control system can use Al to optimize frac performance and operation through controlling valves operations in a dynamic and real-time basis. The AI / ML valve control system may modify one or more adaptive parameters of the embodiment of FIG. 4. In some embodiments, the controller 300 (e.g., an AI / ML-based pump and valve control system) comprises a first control module 310 (e.g., an AI / ML-based valve control system) and a second module 320 (e.g., a pump control system). The first control module 310 may control the pump and the second control module 320 may control the valve 200. The first control module 310 and the second control module 320 may communicate to achieve a desired flow rate using the AI / ML-based valve control system (e.g., that tunes an adaptive parameter of a real time control system). Data-driven algorithms may be utilized to learn from historical and real-time data, enabling the control system to predict, adapt, and make intelligent decisions about valve operations. AI / ML models can identify patterns and dependencies in frac process data that might be too complex for traditional valve sequencing systems. This allows for more finely tuned control strategies that optimize process efficiency and resource usage.

[0034] In addition to reacting to current conditions, the AI / ML-based valve controller 300 for hydraulic fracking can predict future states of the frac process. This predictive capability can enable proactive adjustments to avoid problems before they occur, such as predicting and preventing potential pressure spikes and / or screenout issues. Sequence logic can help ensure that valves are operated in a safe and correct manner. For example, a valve 200 may be programmed to remain closed until certain safety conditions are met. Each sequence may specify which valves should be open or closed, in what order, and for how long. Data-driven algorithms may be used to learn from historical and real-time data to enable the control system to predict, adapt, and make intelligent decisions about valve operations to help enhance the safety measures, reduce downtime, and optimize operational efficiency and the quality of the frac job. Surface and subsurface data from wellhead and downhole sensors 400 can be analyzed along with historic data to build models that capture wellbore response against valve dynamics. The models can then be used to control the valves 200 to optimize the frac performance and operation. In addition to reacting to current conditions, AI / ML-based valve control can predict future response of the wellbore 114 during the frac process, enabling preemptive adjustments to prevent problems such as well interference, pressure spikes, and / or screenout.

[0035] The system may be integrated with a frac automation platform so that the AI / ML based control system can help make optimum and intelligent decisions and adjust valve positions without human intervention. The use of real-time AI / ML-based control systems with powerful processors can handle vast amounts of operating conditions using current and historic data from wellhead and subsurface sensors 400. This processing capability and ability to make intelligent decisions / adjustments can significantly enhance the quality of the frac job and maintain the continuity and integrity of the process. Referring to FIG. 5B, in some embodiments, the controller 300 comprises a consolidated valve control system with the pump control system to provide a unified intelligent control system that can simultaneously control the pumps 100 and valves 200 to maintain desired frac responses at different operating conditions. This coupled intelligent control scheme allows for optimum performance, improved stability, and simplicity while considering all interactions within the frac process. The AI / ML model may be trained on historical data (e.g., the historical data discussed with respect to the adaptive embodiment). The AI / ML model may be updated based on new information (e.g., new historical information and / or new information from the sensors 400).

[0036] Referring to FIGS. 1 and 6A, a real-time integrated control system may perform closed-loop valve control that manages the position and operation of the frac process valves 200 dynamically based on immediate data inputs and conditions; real-time valve control and valve sequencing may be integrated to combine responsiveness of real-time control with the structured, planned operations of valve sequencing. The control systems of any of the embodiments of FIGS. 1-3 may be integrated with a valve sequencing algorithm. In some embodiments, the controller 300 (e.g., a pump control and integrated real-time valve control and valve sequencing system) comprises a first control module 310 (e.g., an integrated real-time valve control and valve sequencing system) and a second control module 320 (e.g., a pump control system 320). Realtime control components can ensure rapid response to sensor inputs, while sequencing components can manage orderly operation of valves according to pre-defined procedures. A real-time valve control scheme may be integrated with the valve sequencing to maintain responsiveness of the real-time control system with the structured, planned operations of the valve sequencing. This control structure may ensure rapid response to sensor inputs through real-time valve control and orderly operation of valves according to pre-defined procedures through the valve sequencing algorithm.

[0037] Valve sequence logic can help ensure that valves are operated in a safe and correct manner. A valve 200 may be programmed to remain closed until certain safety conditions are met. For example, the valve 200 may be opened, in response to a safety condition being met, in accordance with a valve sequencing algorithm. The sequence(s) of the valve sequencing algorithm may specify which valves 200 should be open or closed, in what order, and / or for how long. The valve sequencing may be integrated with real-time valve control to enable the controller 300 to respond in a real-time and in an orderly fashion to help enhance safety measures, reduce downtime, and optimize operational efficiency and quality of the frac job. Data from the wellhead 104 and downhole sensors 400 can be integrated and analyzed in real time to facilitate immediate control actions and to guide the sequence of operations. Valves 200 may be controlled dynamically based on real-time data. For example, in response to wellhead pressure transducers detecting a pressure drop, the controller 300 may immediately adjust relevant valves to stabilize the pressure. For example, in response to detecting the pressure drop, the controller 300 may increase speed of one or more of the pumps 100 and / or increase a degree of openness of one or more of the valves 200. This may be done also in accordance with a valve sequencing algorithm. For example, some of the valves may remain closed according to the valve sequencing algorithm while the valves that are open according to the valve sequencing algorithm may make the adjustment necessary to increase pressure, thus compensating for the pressure drop in order to boost pressure back to the desired value. Feedback loops may be employed to help continuously monitor the valve adjustments and maintain the frac process stability and efficiency.

[0038] The system may be integrated with a frac automation platform so that the integrated control system can help make decisions faster and adjust valve operation without human intervention. The use of closed-loop control systems with powerful processors can handle vast amounts of operating conditions using data from wellhead and subsurface sensors 400. This processing capability and ability to rapidly respond to sensor inputs through real time valve control and orderly operation of valves sequence can significantly enhance the quality of the frac job and maintain the continuity and integrity of the process. Referring to FIG. 6B, in some embodiments, the controller 300 comprises a consolidated valve control system and the pump control system to provide unified control, e.g., simultaneously controlling the pump 100 and valves 200 to maintain desired frac responses. This control scheme allows for improved stability and simplicity while considering all interactions within the frac process.

[0039] Referring to FIGS. 1-2 and 6, a system for controlling flow of fluid for hydraulic fracturing may include a pump 100 configured to pump fluid down a wellbore 114 penetrating a subterranean formation 120; a valve 200 disposed between the pump 100 and the wellbore 114; a sensor 400 configured to monitor a measurand of the hydraulic fracturing; and a controller 300 configured to receive real time data of the measurand from the sensor 400, and control a degree of openness of the valve 200 in real time based on the data and a valve sequencing algorithm. The controller 300 may be further configured to control flow rate of the pump 100 in real time, based on the data and the valve sequencing algorithm. Data from the sensors may be used by the real-time control to provide rapid response against system changes, while sequencing components may manage the orderly operation of valves according to predefined procedures. The pump 100 may be one of a plurality of pumps 100 in fluid communication with the wellbore 114 and configured to be controlled simultaneously by the controller 300. The valve 200 may be one of a plurality of valves 200 respectively associated with the plurality of pumps 100 and configured to be controlled simultaneously by the controller 300. That is, the controller 300 may control the pumps 100 and valves 200 based on the data from the sensors 400 and the valve sequencing algorithm. The sensor 400 may include a pressure sensor and the measurand includes pressure, and / or the sensor 400 may include a flow rate sensor and the measurand includes flow rate.

[0040] The controller 300 may be further configured to control the openness of the valve 200 in real time by using an integrative control algorithm that executes the valve sequencing algorithm with real-time adjustments to the degree of openness based on the data. For example, in response to detecting based on the data from the sensors 400 that flow rate has deviated from a desired flow rate, the controller 300 may control openness of the valves 200 and flow rate output from the pumps 100 to restore the desired flow rate while keeping at least some of the valves 200 closed according to the valve sequencing algorithm. The controller 300 may be further configured to stabilize a pressure disturbance while executing the valve sequencing algorithm, using the integrative control algorithm. For example, while executing the valve sequencing algorithm to open the valves 200 in sequence, the controller 300 may automatically open a next valve in the sequence and / or adjust openness of one or more of the open valves 200 to stabilize the pressure disturbance.

[0041] The controller 300 may be further configured to open the valve 200, in response to detecting that a safety condition is met, using the integrative control algorithm. Employing feedback loops may help continuously monitor the valve adjustments and maintain the frac process stability and efficiency. Valve sequence logic may help ensure that valves are operated in a safe and correct manner. For example, a valve may be programmed to remain closed until certain safety conditions are met.

[0042] For example, the controller 300 may open the next valve 200 in the sequence of the valve sequencing algorithm in response to detecting that the safety condition is met (e.g., while controlling openness of the open valves 200 in real time). The controller 300 may include a first control module 310 configured to control the pump 100 and a second control module 320 configured to control the valve 200. The first control module 310 may be in communication with the second control module 320. For example, the first control module 310 and the second control module 320 may communicate such that the control modules 310,320 work together to operate the pumps 100 and the valves 200 based on the data from the sensors 400 and the valve sequencing algorithm. The integrative control algorithm may be modified by an adaptive parameter of the real-time control algorithm. The adaptive parameter may be adapted based on an AI / ML model, which may be trained on historical data.

[0043] Referring to FIG. 8, a method 800 for controlling flow of fluid for hydraulic fracturing may include the step 810 of monitoring, by a sensor, a measurand of the hydraulic fracturing; the step 820 of receiving, by a controller, real time data of the measurand from the sensor; and the step 830 of controlling, by the controller, a degree of openness of the valve in real time based on the data and a valve sequencing algorithm. The valve may be disposed between a pump and a wellbore penetrating a subterranean formation. The pump may be configured to pump fluid down the wellbore.

[0044] The method 800 may further include controlling, by the controller, flow rate of the pump in real time, based on the data and the valve sequencing algorithm. The pump may be one of a plurality of pumps in fluid communication with the wellbore and configured to be controlled simultaneously by the controller. The valve may be one of a plurality of valves respectively associated with the plurality of pumps and configured to be controlled simultaneously by the controller. The sensor may include a pressure sensor and the measurand includes pressure, and / or the sensor may include a flow rate sensor and the measurand includes flow rate. The method 800 may further include controlling, by the controller, the openness of the valve in real time by using an integrative control algorithm that executes the valve sequencing algorithm with real-time adjustments to the degree of openness based on the data. The method 800 may further include stabilizing, by the controller, a pressure disturbance while executing the valve sequencing algorithm, using the integrative control algorithm. The method 800 may further include opening, by the controller, the valve, in response to detecting that a safety condition is met, using the integrative control algorithm. The controller may include a first control module configured to control the pump, a second control module configured to control the valve. The first control module may be in communication with the second control module. The integrative control algorithm may be modified by an adaptive parameter.Additional Disclosure

[0045] The following are non-limiting, specific embodiments in accordance with the present disclosure:

[0046] In a first embodiment, a system for controlling flow of fluid for hydraulic fracturing comprises a pump configured to pump fluid down a wellbore penetrating a subterranean formation; a valve disposed between the pump and the wellbore; a sensor configured to monitor a measurand of the hydraulic fracturing; and a controller configured to receive real time data of the measurand from the sensor, and control a degree of openness of the valve in real time based on the data and an adaptive parameter.

[0047] A second embodiment can include the system of the first embodiment, wherein the controller is further configured to control flow rate of the pump in real time based on the data and the adaptive parameter.

[0048] A third embodiment can include the system of the first or second embodiments, wherein the pump is one of a plurality of pumps in fluid communication with the wellbore and configured to be controlled simultaneously by the controller.

[0049] A fourth embodiment can include the system of any of the first through third embodiments, wherein the valve is one of a plurality of valves respectively associated with the plurality of pumps and configured to be controlled simultaneously by the controller.

[0050] A fifth embodiment can include the system of any of the first through fourth embodiments, wherein the sensor comprises a pressure sensor and the measurand comprises pressure, or the sensor comprises a flow rate sensor and the measurand comprises flow rate.

[0051] A sixth embodiment can include the system of any of the first through fifth embodiments, wherein the adaptive parameter is based on historical data.

[0052] A seventh embodiment can include the system of any of the first through sixth embodiments, wherein the adaptive parameter is based on a location of the wellbore, a geometry of the wellbore, a composition of the subterranean formation, or a state of the subterranean formation.

[0053] An eighth embodiment can include the system of any of the first through seventh embodiments, wherein the controller comprises a first control module configured to control the pump, and a second control module configured to control the valve.

[0054] A ninth embodiment can include the system of any of the first through eighth embodiments, wherein the first control module is in communication with the second control module.

[0055] A tenth embodiment can include the system of any of the first through ninth embodiments, wherein the controller is further configured to control the valve by an integrative control algorithm that is modified by the adaptive parameter.

[0056] In an eleventh embodiment, a method for controlling flow of fluid for hydraulic fracturing comprises monitoring, by a sensor, a measurand of the hydraulic fracturing; receiving, by a controller, real time data of the measurand from the sensor; and controlling, by the controller, a degree of openness of a valve in real time based on the data and an adaptive parameter, wherein the valve is disposed between a pump and a wellbore penetrating a subterranean formation, and wherein the pump is configured to pump fluid down the wellbore.

[0057] A twelfth embodiment can include the method of the eleventh embodiment, further comprising controlling, by the controller, a flow rate of the pump in real time based on the data and the adaptive parameter.

[0058] A thirteenth embodiment can include the method of the eleventh or twelfth embodiments, wherein the pump is one of a plurality of pumps in fluid communication with the wellbore and configured to be controlled simultaneously by the controller.

[0059] A fourteenth embodiment can include the method of any of the eleventh through thirteenth embodiments, wherein the valve is one of a plurality of valves respectively associated with the plurality of pumps and configured to be controlled simultaneously by the controller.

[0060] A fifteenth embodiment can include the method of any of the eleventh through fourteenth embodiments, wherein the sensor comprises a pressure sensor and the measurand comprises pressure, or the sensor comprises a flow rate sensor and the measurand comprises flow rate.

[0061] A sixteenth embodiment can include the method of any of the eleventh through fifteenth embodiments, wherein the adaptive parameter is based on historical data.

[0062] A seventeenth embodiment can include the method of any of the eleventh through sixteenth embodiments, wherein the adaptive parameter is based on a location of the wellbore, a geometry of the wellbore, a composition of the subterranean formation, or a state of the subterranean formation.

[0063] An eighteenth embodiment can include the method of any of the eleventh through seventeenth embodiments, wherein the controller comprises a first control module configured to control the pump, and a second control module configured to control the valve.

[0064] A nineteenth embodiment can include the method of any of the eleventh through eighteenth embodiments, wherein the first control module is in communication with the second control module.

[0065] A twentieth embodiment can include the method of any of the eleventh through nineteenth embodiments, wherein the controller is further configured to control the valve by an integrative control algorithm that is modified by the adaptive parameter.

[0066] In a twenty-first embodiment, a system for controlling flow of fluid for hydraulic fracturing comprises a pump configured to pump fluid down a wellbore penetrating a subterranean formation; a valve disposed between the pump and the wellbore; a sensor configured to monitor a measurand of the hydraulic fracturing; and a controller configured to receive real time data of the measurand from the sensor, and control a degree of openness of the valve in real time based on the data and a valve sequencing algorithm.

[0067] A twenty-second embodiment can include the system of the twenty-first embodiment, wherein the controller is further configured to control flow rate of the pump in real time, based on the data and the valve sequencing algorithm.

[0068] A twenty-third embodiment can include the system of the twenty-first or twenty-second embodiments, wherein the pump is one of a plurality of pumps in fluid communication with the wellbore and configured to be controlled simultaneously by the controller.

[0069] A twenty-fourth embodiment can include the system of any of the twenty-first through twenty-third embodiments, wherein the valve is one of a plurality of valves respectively associated with the plurality of pumps and configured to be controlled simultaneously by the controller.

[0070] A twenty-fifth embodiment can include the system of any of the twenty-first through twenty-fourth embodiments, wherein the sensor comprises a pressure sensor and the measurand comprises pressure, or the sensor comprises a flow rate sensor and the measurand comprises flow rate.

[0071] A twenty-sixth embodiment can include the system of any of the twenty-first through twenty-fourth embodiments, wherein the controller is further configured to control the openness of the valve in real time by using an integrative control algorithm that executes the valve sequencing algorithm with real-time adjustments to the degree of openness based on the data.

[0072] A twenty-seventh embodiment can include the system of any of the twenty-first through twenty-sixth embodiments, wherein the controller is further configured to stabilize a pressure disturbance while executing the valve sequencing algorithm, using the integrative control algorithm.

[0073] A twenty-eighth embodiment can include the system of any of the twenty-first through twenty-sixth embodiments, wherein the controller is further configured to open the valve, in response to detecting that a safety condition is met, using the integrative control algorithm.

[0074] A twenty-ninth embodiment can include the system of any of the twenty-first through twenty-eighth embodiments, wherein the controller comprises a first control module configured to control the pump and a second control module configured to control the valve, and the first control module is in communication with the second control module.

[0075] A thirtieth embodiment can include the system of any of the twenty-first through twenty-ninth embodiments, wherein the integrative control algorithm is modified by an adaptive parameter.

[0076] In a thirty-first embodiment, a method for controlling flow of fluid for hydraulic fracturing comprises monitoring, by a sensor, a measurand of the hydraulic fracturing; receiving, by a controller, real time data of the measurand from the sensor; and controlling, by the controller, a degree of openness of the valve in real time based on the data and a valve sequencing algorithm, wherein the valve is disposed between a pump and a wellbore penetrating a subterranean formation, and wherein the pump is configured to pump fluid down the wellbore.

[0077] A thirty-second embodiment can include the method of the thirty-first embodiment, further comprising controlling, by the controller, flow rate of the pump in real time, based on the data and the valve sequencing algorithm.

[0078] A thirty-third embodiment can include the method of the thirty-first or thirty-second embodiments, wherein the pump is one of a plurality of pumps in fluid communication with the wellbore and configured to be controlled simultaneously by the controller.

[0079] A thirty-fourth embodiment can include the method of any of the thirty-first through thirty-third embodiments, wherein the valve is one of a plurality of valves respectively associated with the plurality of pumps and configured to be controlled simultaneously by the controller.

[0080] A thirty-fifth embodiment can include the method of any of the thirty-first through thirty-fourth embodiments, wherein the sensor comprises a pressure sensor and the measurand comprises pressure, or the sensor comprises a flow rate sensor and the measurand comprises flow rate.

[0081] A thirty-sixth embodiment can include the method of any of the thirty-first through thirty-fifth embodiments, further comprising controlling, by the controller, the openness of the valve in real time by using an integrative control algorithm that executes the valve sequencing algorithm with real-time adjustments to the degree of openness based on the data.

[0082] A thirty-eighth embodiment can include the system of any of the thirty-first through thirty-seventh embodiments, further comprising stabilizing, by the controller, a pressure disturbance while executing the valve sequencing algorithm, using the integrative control algorithm.

[0083] A thirty-eighth embodiment can include the system of any of the thirty-first through thirty-eighth embodiments, further comprising opening, by the controller, the valve, in response to detecting that a safety condition is met, using the integrative control algorithm.

[0084] A thirty-ninth embodiment can include the system of any of the thirty-first through thirty-eighth embodiments, wherein the controller comprises a first control module configured to control the pump and a second control module configured to control the valve, and the first control module is in communication with the second control module.

[0085] A fortieth embodiment can include the system of any of the thirty-first through thirty-ninth embodiments, wherein the integrative control algorithm is modified by an adaptive parameter.

[0086] While embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of this disclosure. The embodiments described herein are exemplary only and are not intended to be limiting. Many variations and modifications of the embodiments disclosed herein are possible and are within the scope of this disclosure. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted or not implemented. Also, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other techniques, systems, subsystems, or methods without departing from the scope of this disclosure. Other items shown or discussed as directly coupled or connected or communicating with each other may be indirectly coupled, connected, or communicated with. Method or process steps set forth may be performed in a different order. The use of terms, such as “first,”“second,”“third” or “fourth” to describe various processes or structures is only used as a shorthand reference to such steps / structures and does not necessarily imply that such steps / structures are performed / formed in that ordered sequence (unless such requirement is clearly stated explicitly in the specification).

[0087] Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations. For example, whenever a numerical range with a lower limit, R1, and an upper limit, Ru, is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=R1+k*(Ru−Ri), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent . . . 50 percent, 51 percent, 52 percent . . . 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. Language of degree used herein, such as “approximately,”“about,”“generally,” and “substantially,” represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the language of degree may mean a range of values as understood by a person of skill or, otherwise, an amount that is + / −10%.

[0088] Disclosure of a singular element should be understood to provide support for a plurality of the element. It is contemplated that elements of the present disclosure may be duplicated in any suitable quantity.

[0089] Use of broader terms such as comprises, includes, having, etc. should be understood to provide support for narrower terms such as consisting of, consisting essentially of, comprised substantially of, etc. The use of terms such as “high-pressure” and “low-pressure” is intended to only be descriptive of the component and their position within the systems disclosed herein. That is, the use of such terms should not be understood to imply that there is a specific operating pressure or pressure rating for such components. For example, the term “high-pressure” describing a manifold should be understood to refer to a manifold that receives pressurized fluid that has been discharged from a pump irrespective of the actual pressure of the fluid as it leaves the pump or enters the manifold. Similarly, the term “low-pressure” describing a manifold should be understood to refer to a manifold that receives fluid and supplies that fluid to the suction side of the pump irrespective of the actual pressure of the fluid within the low-pressure manifold.

[0090] Accordingly, the scope of protection is not limited by the description set out above but is only limited by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated into the specification as embodiments of the present disclosure. Thus, the claims are a further description and are an addition to the embodiments of the present disclosure. Any discussion of a reference herein is not an admission that it is prior art. Any disclosures of all patents, patent applications, and / or publications cited herein are hereby incorporated by reference, to the extent that they provide exemplary, procedural, or other details supplementary to those set forth herein.

[0091] As used herein, terms such as parallel, perpendicular, vertical, horizontal, and coincident are not intended to necessarily mean exactly parallel, exactly perpendicular, exactly vertical, exactly horizontal, and exactly coincident. Rather, those terms are intended to mean what those of ordinary skill in the art would recognize as parallel, perpendicular, vertical, horizontal, and coincident. In other words, those and similar terms may cover a structural configuration even when there is some imperfection, variation, or deviation from an exact relationship.

[0092] As used herein, the term “or” does not require selection of only one element. Thus, the phrase “A or B” is satisfied by either one or both elements from the set {A, B} . A clause that recites “A or B” can be infringed with only one of the listed items, both of the listed items, multiples of the listed items, and one or both of the listed items and another item not listed. The phrase “A, B, or C” is satisfied by any one or any combination of any two or more from the set {A, B, C}. A clause that recites “A, B, or C” can be infringed with only one of the listed items, multiples of the listed items, and one or more of the items from the list and another item not listed.

[0093] As used herein, the article “a” means “one or more.” As used herein, the article “an” means “one or more.” As used herein, the article “the” when referring to a singular noun means “the one or more.” Thus, the phrase “an element” means “one or more elements;” and the phrase “the element” means “the one or more elements.”

[0094] As used herein, the term “and / or” includes any combination of the elements associated with the “and / or” term. Thus, the phrase “A, B, and / or C” includes any of A alone, B alone, C alone, A and B together, B and C together, A and C together, or A, B, and C together.

Claims

1. A system for controlling flow of fluid for hydraulic fracturing, comprising:a pump configured to pump fluid down a wellbore;valves disposed between the pump and the wellbore;a sensor configured to monitor a measurand of the hydraulic fracturing; anda controller configured to receive real time real-time data of the measurand from the sensor, andopen two or more of the valves in sequence according to a valve sequencing algorithm while dynamically adjusting a degree of intermediate openness of at least one of the valves between fully opened and fully closed to stabilize a pressure disturbance in real time based on the data.

2. The system of claim 1, wherein the controller is further configured to control a flow rate of the pump in real time, based on the data and the valve sequencing algorithm.

3. The system of claim 2, wherein the pump is one of a plurality of pumps in fluid communication with the wellbore, which penetrates a subterranean formation.

4. The system of claim 3, wherein the valves are respectively associated with the pumps.

5. The system of claim 1, wherein the sensor comprises a pressure sensor and the measurand comprises pressure, or the sensor comprises a flow rate sensor and the measurand comprises flow rate.

6. The system of claim 1, wherein the controller is further configured to control the valves in real time by using an integrative control algorithm that executes the valve sequencing algorithm with real-time adjustments to the degree of intermediate openness based on the data.

7. The system of claim 6, wherein the controller is further configured to stabilize a the pressure disturbance while executing the valve sequencing algorithm, using the integrative control algorithm.

8. The system of claim 6, wherein the controller is further configured to open the two or more of the valves, in response to detecting that a safety condition is met, using the integrative control algorithm.

9. The system of claim 1, wherein the controller comprises a first control module configured to control the pump and a second control module configured to control the valves, and the first control module is in communication with the second control module.

10. The system of claim 6, wherein the integrative control algorithm is modified by an adaptive parameter.

11. A method for controlling flow of fluid for hydraulic fracturing, comprising:monitoring, by a sensor, a measurand of the hydraulic fracturing, wherein valves are disposed between a pump and a wellbore, and wherein the pump is configured to pump fluid down the wellbore;receiving, by a controller, real-time data of the measurand from the sensor; andopening, by the controller, two or more of the valves in sequence according to a valve sequencing algorithm while dynamically adjusting a degree of intermediate openness of at least one of the valves between fully opened and fully closed to stabilize a pressure disturbance.

12. The method of claim 11, further comprising controlling, by the controller, a flow rate of the pump in real time, based on the data and the valve sequencing algorithm.

13. The method of claim 12, wherein the pump is one of a plurality of pumps in fluid communication with the wellbore, which penetrates a subterranean formation.

14. The method of claim 13, wherein the valves are respectively associated with the pumps.

15. The method of claim 11, wherein the sensor comprises a pressure sensor and the measurand comprises pressure, or the sensor comprises a flow rate sensor and the measurand comprises flow rate.

16. The method of claim 11, further comprising controlling, by the controller, the valves in real time by using an integrative control algorithm that executes the valve sequencing algorithm with real-time adjustments to the degree of intermediate openness based on the data.

17. The method of claim 11, further comprising stabilizing, by the controller, a pressure disturbance while executing the valve sequencing algorithm, using an integrative control algorithm.

18. The method of claim 11, further comprising opening, by the controller, the two or more of the valves, in response to detecting that a safety condition is met, using an integrative control algorithm.

19. The method of claim 11, wherein the controller comprises a first control module configured to control the pump and a second control module configured to control the valves, and the first control module is in communication with the second control module.

20. The method of claim 16, wherein the integrative control algorithm is modified by an adaptive parameter.

21. A system for controlling flow of fluid for hydraulic fracturing, comprising:a pump configured to pump fluid down a wellbore penetrating a subterranean formation, wherein the pump is one of a plurality of pumps in fluid communication with the wellbore;a valve disposed between the pump and the wellbore, wherein the valve is one of a plurality of valves respectively associated with the plurality of pumps;a sensor configured to monitor a measurand of the hydraulic fracturing; anda controller configured to receive real-time data of the measurand from the sensor, continuously control a degree of intermediate openness of the valve between fully opened and fully closed in real time based on the data and a valve sequencing algorithm, control flow rate of the pump in real time based on the data and the valve sequencing algorithm, and open one or more of the plurality of valves in sequence according to the valve sequencing algorithm while dynamically adjusting the degree of intermediate openness of the valve between fully opened and fully closed to stabilize a pressure disturbance.

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