Fracturing Stack Valve Assembly Pressure Isolation
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Solution Overview
Problem
In fracking and well workover operations, maintaining pressure within the fracturing stack during multi-stage fracturing is challenging, leading to prolonged downtime and increased costs due to the need for frequent depressurization and re-pressure testing.
Innovation Solution
A valve assembly with multiple operating volumes and pressure management systems allows for isolation and pressurization of different components, enabling the introduction and removal of tools and well drops without depressurizing the system, thereby maintaining pressure and reducing the need for repeated pressure testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the fracturing stack is depressurized to introduce or remove tools and well drops, then tools can be introduced or removed, but the system loses pressure and requires re-pressure testing, leading to prolonged downtime
Solution Approach 1:
The fracturing stack is divided into multiple isolated chambers or zones using valve assemblies. Each chamber can be independently pressurized or depressurized, allowing tools to be introduced or removed from specific zones without affecting the pressure status of the entire system. This segmentation enables continuous operation in other zones while maintenance or tool changes occur in isolated zones.
Solution Approach 2:
Valve assemblies act as intermediary components that control pressure isolation between different sections of the fracturing stack. These valves serve as mediators that allow the system to maintain pressure in operational zones while permitting tool introduction or removal in non-operational zones, thereby eliminating the need for complete system depressurization.
2Ease of operation
If the entire fracturing stack is depressurized for tool changes, then tools can be accessed, but all fracturing operations must pause, reducing productivity
Solution Approach 1:
The system is segmented into isolated pressure zones using valve assemblies, allowing specific sections to be depressurized for tool access while other sections maintain pressure and continue fracturing operations. This enables parallel operation of different system components, maintaining overall productivity.
Solution Approach 2:
The valve assembly system enables continuous fracturing operations by allowing tool changes and maintenance in isolated zones without interrupting pressure maintenance or fracturing activities in other zones. The useful action of fracturing continues uninterrupted while tool maintenance occurs simultaneously in separate isolated sections.
3Reliability
If frequent pressure testing is performed to maintain system integrity, then safety and reliability are improved, but operational time is reduced and costs increase
Solution Approach 1:
The fracturing stack is divided into multiple isolated chambers using valve assemblies, allowing pressure testing to be performed on individual zones rather than the entire system. This segmentation reduces the scope and frequency of required pressure tests, as each isolated chamber can be tested independently and maintains pressure integrity without affecting other zones.
Solution Approach 2:
The valve assembly system allows for preliminary isolation of specific zones before pressure testing or tool introduction. By pre-establishing pressure barriers through valve closure, the system can maintain overall pressure integrity without requiring frequent comprehensive pressure tests, as the isolated zones are inherently protected from pressure loss.
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
This solution reduces downtime and costs by allowing continuous operation between fracturing stages without depressurizing the fracturing stack, minimizing equipment wear, and decreasing non-productive operator time.
Implementation Method 1
A valve assembly with multiple operating volumes and pressure management systems allows for isolation and pressurization of different components
Implementation Method 2
A first equalizing conduit in fluid communication with the first and second operating volumes allows the second operating volume to be pressurized to within a specified maximum pressure differential of the first operating volume
Data Source
AI summary
While a fracturing stack on a well is at fracturing pressure, receiving a perforating string in a section of the center bore of the fracturing stack. The section is a section above a fracturing head of the fracturing stack. While the fracturing stack is at fracturing pressure, sealing the section of the center bore to maintain a fracturing pressure in and below the fracturing head. Equalizing pressure in the section to atmospheric pressure. Receiving, at atmospheric pressure, a well drop in the section. Equalizing pressure in the section to pressure in the fracturing stack below the section. Releasing the well drop into the center bore of the fracturing head and to the well.