Compartmentalized Hydraulic Fracturing for Selective Zone Maintenance
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Solution Overview
Problem
Hydraulic fracturing operations face significant downtime due to the need for halting the entire process for maintenance or repairs in high-pressure zones, leading to financial losses and safety risks.
Innovation Solution
A compartmentalized frac system that divides frac pumps into multiple zones, allowing selective deactivation of one zone for maintenance while others continue operating, using partition walls and remote control to manage pressure and fluid flow, enabling safe service without disrupting the entire operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire frac system is halted for maintenance or repairs in high-pressure zones, then safety risks are reduced and proper service can be performed, but downtime increases significantly and financial losses occur
Solution Approach 1:
The frac system is divided into multiple independently controllable zones separated by partition walls. Each zone can be deactivated and serviced independently while other zones continue operating, eliminating the need to halt the entire system for maintenance.
Solution Approach 2:
By maintaining operational zones while servicing deactivated zones, the system ensures continuous production and minimizes downtime. The useful action of fluid pumping continues uninterrupted through other zones during maintenance operations.
2Ease of repair
If the entire frac system is halted for maintenance, then proper service can be performed on equipment, but productivity decreases due to stopped operations
Solution Approach 1:
The system is segmented into independent zones that can be serviced separately. This allows maintenance personnel to access and service equipment in deactivated zones without affecting operations in active zones, maintaining productivity during repair activities.
Solution Approach 2:
Productivity is maintained by ensuring that while one zone is being serviced, other zones continue to pump fluid and perform their useful function, preventing complete operational shutdown.
3Object-affected harmful factors
If all zones are deactivated for safety during maintenance, then personnel can work safely in high-pressure zones, but the entire operation stops causing financial losses
Solution Approach 1:
Partition walls physically separate zones, allowing safety personnel to work in deactivated zones while other zones remain operational. This segmentation enables localized safety management without requiring complete system shutdown.
Solution Approach 2:
The system maintains continuous operation by keeping non-service zones active while deactivating only the specific zone requiring maintenance, thus preventing financial losses associated with complete operational stoppage.
4Adaptability or versatility
If the system is divided into multiple zones with partition walls and control systems, then selective deactivation for maintenance is enabled, but device complexity increases
Solution Approach 1:
The system is divided into zones with partition walls and individual control systems, enabling selective deactivation of specific zones for maintenance while others continue operating. This segmentation provides adaptability and flexibility in system management.
Solution Approach 2:
The control system is designed to manage multiple zones universally, with each zone having similar components (pumps, valves, partition walls) that can be controlled independently. This modular approach enables versatile zone-specific control while using standardized components.
Data Source
AI summary
A compartmentalized hydraulic fracturing (frac) system may include a mono line configured to carry frac fluid into a well. The system may include a plurality of zones, each zone comprising: a set of one or more frac pumps each configured to pump frac fluid into the mono line, an isolation valve configured to control the flow of frac fluid between the set of frac pumps and the mono line; and a bleed valve configured to release pressurized frac fluid from the set of frac pumps when in an open position. The system may include partition walls between the plurality of zones. The system may include a control system configured to deactivate or reactivate a zone of the plurality of zones by controlling the set of frac pumps, the isolation valve, and the bleed valve of the zone.