Full-Bore Overpressure Venting for Fracking Flowline Protection
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Solution Overview
Problem
Current overpressure protection systems in well stimulation operations face challenges such as premature failure due to frequent testing, inadequate venting capabilities, and damage from high-pressure fluids, along with imprecise set-points and choking effects from smaller valve bores, posing safety and operational hazards.
Innovation Solution
An overpressure protection apparatus comprising a skid-mounted collection tank with baffles, a fail-open gate valve, and a hydraulic actuator system controlled by a PLC, which includes a full-bore flowline design and redundant valves to manage high-pressure fracking fluids efficiently, venting pressure quickly and safely while minimizing equipment damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fail-open valves are tested frequently to ensure reliability, then the overpressure protection system remains reliable, but the valves fail prematurely due to abrasive stimulation fluids
Solution Approach 1:
The patent employs a disposable rupture disk that is replaced after each use rather than repaired or reused. This single-use component is designed to fail safely during testing and overpressure events, eliminating the need for frequent maintenance of the entire valve assembly while maintaining system reliability.
Solution Approach 2:
The overpressure protection system is divided into separate functional components: a reusable fail-open valve assembly and a disposable rupture disk. This segmentation allows the expensive valve to be protected from abrasive fluid damage during testing, while the inexpensive disk absorbs the wear from frequent testing operations.
2Volume of moving object
If smaller bore valves are used in overpressure protection systems, then the valve size is reduced, but a choking effect occurs that lengthens pressure venting time and damages the valves
Solution Approach 1:
The patent extracts the flow restriction element (rupture disk) from the valve body, placing it in a separate rupture disk holder upstream of the fail-open valve. This allows the valve to maintain a large full-bore opening for rapid pressure relief while the rupture disk serves as a separate, replaceable flow control element that can be optimized independently.
Solution Approach 2:
The system transitions from a static restricted bore valve to a dynamic configuration where the rupture disk can be rapidly replaced and the fail-open valve maintains a full-bore opening when activated. This dynamic approach allows optimal flow capacity during overpressure events while enabling frequent testing without valve damage.
3Object-generated harmful factors
If traditional fail-open valve designs are used for venting overpressure, then pressure can be vented, but the set-points are not precise and resetting them after an over-pressure event is challenging
Solution Approach 1:
The patent changes the critical parameter from valve geometry (traditional spring-loaded valves with adjustable set-screws) to a replaceable rupture disk with precisely controlled burst pressure. The set-point is determined by the disk's manufacturing parameters rather than field-adjustable mechanics, providing superior precision and eliminating the need for complex resetting procedures.
4Reliability
If high-pressure fluids are vented violently to protect against overpressure, then overpressure protection is achieved, but the system jumps off the ground damaging flowlines and creating additional hazards
Solution Approach 1:
The patent introduces a rupture disk holder and associated piping as an intermediary between the pressure source and the vent outlet. This intermediary structure provides a controlled path for pressure relief that directs the force of venting fluids away from the skid-mounted equipment, preventing the system from jumping off the ground while maintaining effective overpressure protection.
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 apparatus effectively controls and vents high-pressure fluids, reducing the risk of equipment damage and operator safety hazards, extends the operational life of the system, and allows for precise pressure management and rapid return to safe operating conditions.
Implementation Method 1
a hydraulic actuator system controlled by a PLC
Implementation Method 2
a skid-mounted collection tank with baffles
Data Source
AI summary
An overpressure control apparatus is used to control jets of high-pressure fracking fluid or other stimulation fluid released from a treatment flowline in cases of overpressure. The apparatus includes a collection tank and one or more valves, which can all be mounted on or integrated to a skid. The sizes and weights of the collection tank and the skid may help to keep the apparatus on the ground during an overpressure event. The apparatus can be provided with an offline testing system that allows an operator to close off the communication between the apparatus and the treatment flowline, and instead, pump a clean fluid such as water at high-pressure to test the proper functioning of the valve.