Hydraulic Fracturing Manifold Swapping for Multi-Well Pressure Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current hydraulic fracturing systems face inefficiencies in managing the hydraulic fracturing process across multiple oil and gas wells, particularly in terms of fluid distribution, pressure equalization, and swapping between wells, which affects the overall productivity and operational efficiency.
Innovation Solution
A hydraulic fracturing system that includes a blender for mixing fracturing fluid with sand, a suction manifold, swap stations, and a zipper manifold to distribute pressurized fluid to frac legs, along with a grease system and controller to manage valve operations and fluid pressure, enabling efficient fracturing and swapping between wells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional hydraulic fracturing system is used to manage multiple wells, then the system structure is simpler, but the productivity and operational efficiency deteriorate due to inefficiencies in fluid distribution, pressure equalization, and swapping between wells
Solution Approach 1:
The hydraulic fracturing system is divided into multiple swap stations (first swap station, second swap station, etc.) that can independently manage different wells. Each swap station includes dedicated valves (first valve, second valve, third valve, fourth valve) and flow meters that can be controlled independently, allowing simultaneous or sequential fracturing operations on multiple wells without interference, thereby improving productivity while maintaining manageable complexity through modular design
Solution Approach 2:
The swap stations are designed with multi-functional capability to handle multiple wells through a unified system architecture. The same basic components (valves, flow meters, manifolds) are replicated and configured to serve different wells, allowing the system to universally manage fluid distribution, pressure control, and swapping operations across multiple wells, improving operational efficiency without requiring entirely separate systems for each well
2Productivity
If rapid swapping between wells is implemented, then the productivity improves, but the device complexity increases due to the need for multiple valves and control mechanisms
Solution Approach 1:
The system performs preliminary actions by pre-positioning valves in specific states before swapping operations. The first and second valves are configured to control fluid flow to different wells, while the third and fourth valves are pre-set to manage pressure equalization. This preliminary configuration allows rapid swapping between wells because the control sequence is already established, reducing the time and complexity of actual swapping operations
Solution Approach 2:
The system introduces intermediary components such as the third valve and fourth valve that act as mediators during the swapping process. These valves facilitate pressure equalization between wells and serve as intermediaries in the fluid transfer process, enabling rapid and controlled swapping without requiring direct, complex control between all system components, thereby improving swapping speed while managing device complexity
3Manufacturing precision
If proper fluid distribution and pressure management are ensured across multiple wells, then the manufacturing precision of fracturing operations improves, but the device complexity increases due to the need for multiple flow meters and pressure control mechanisms
Solution Approach 1:
The system implements local quality by placing dedicated flow meters at specific locations for each well stream. The first flow meter is positioned to measure fluid flow to the first well, while the second flow meter measures flow to the second well. This localized measurement approach ensures precise monitoring and control of fluid distribution for each well individually, improving fracturing precision without requiring a single complex centralized measurement system
Solution Approach 2:
The system incorporates feedback mechanisms through flow meters that continuously monitor fluid flow rates to different wells. This real-time feedback allows the control system to adjust valve positions and pump operations to maintain precise fluid distribution and pressure management. The feedback loop ensures that each well receives the correct amount of fluid at the correct pressure, improving fracturing precision while using relatively simple, standardized measurement and control components
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables efficient hydraulic fracturing across multiple wells by ensuring proper fluid distribution and pressure management, allowing for rapid swapping between wells, thereby enhancing productivity and reducing operational inefficiencies.
Implementation Method 1
a blender for mixing fracturing fluid with sand
Implementation Method 2
a grease system and controller to manage valve operations
Data Source
AI summary
A hydraulic fracturing plan executable by a hydraulic fracturing system to hydraulically fracture a plurality of oil and gas wells. In one or more embodiments, the execution of the hydraulic fracturing plan implements the following steps: communicating fluid to a first well via a manifold and a first valve, the first valve being associated with both the manifold and the first well; and, in response to determining that the fluid communicated via the manifold has satisfied one or more conditions: opening a second valve; communicating fluid to a second well via the second valve; and closing the first valve after opening the second valve.