Frac Stack Rams with Protective Sleeves for Seal Wear Reduction
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Solution Overview
Problem
Conventional fracturing systems face challenges in controlling fluid flow and reducing erosive wear on seals during fracturing operations, leading to inefficiencies and equipment degradation.
Innovation Solution
The use of rams with protective sleeves and actuators in a frac stack body to control fluid flow, along with features like wire mesh seals and wiper seals to mitigate erosive wear, provides a more efficient and durable fracturing system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional valves are used to control fluid flow through the fracturing tree, then flow control is achieved, but erosive wear on seals occurs due to high-velocity fracturing fluid
Solution Approach 1:
A protective sleeve is introduced as an intermediary component between the fracturing fluid and the ram seals. The sleeve is positioned within the bore of the frac stack body to shield the seals from direct exposure to high-velocity erosive fluid, while still permitting controlled fluid flow when the ram is in the open position.
Solution Approach 2:
The protective sleeve is installed beforehand to prevent erosive wear before it can damage the seals. This pre-protective measure ensures that the seals are cushioned from the harmful effects of erosive fluid flow during fracturing operations, extending their service life without requiring design changes to the flow control mechanism.
2Ease of operation
If rams are used to control fluid flow instead of conventional valves, then flow control capability is improved, but the system complexity increases
Solution Approach 1:
The frac stack body is designed to perform multiple functions: it serves as the structural housing for the ram mechanism, contains the protective sleeve, and provides the bore for fluid flow control. By integrating these functions into a single component, the overall system complexity is reduced despite the advanced flow control capabilities provided by the ram.
3Reliability
If protective sleeves are added to cover ram cavities during fracturing, then seal wear is reduced, but device complexity increases
Solution Approach 1:
The protective sleeve is merged with the frac stack body structure, where the sleeve is positioned and secured within the existing bore of the frac stack body. This integration approach minimizes the number of separate components and assembly steps, reducing the increase in device complexity while still providing effective seal protection during fracturing operations.
Data Source
AI summary
A fracturing system having rams for controlling flow through a fracturing tree is provided. In one embodiment, a well intervention method includes injecting fracturing fluid into a well through a bore of a frac stack coupled to a wellhead. The frac stack includes rams that can be moved between open and closed positions to control flow through the bore. The well intervention method also includes coupling a lubricator to the frac stack without a blowout preventer between the lubricator and the frac stack and lowering an intervention tool from the lubricator through the bore of the frac stack and into the well. Additional systems, devices, and methods for fracturing and intervention are also disclosed.