Ram-Based Frac Stack Flow Control Eliminates Proppant Interference
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Solution Overview
Problem
Conventional fracturing trees with valves are hindered by proppant interference during fracturing operations, affecting pressure control and fluid flow management.
Innovation Solution
The implementation of a fracturing system using rams within a frac stack body to control fluid flow, where rams can be opened and closed to manage fracturing fluid and pressure without the need for valves, utilizing a housing with a bore and actuators to control the rams' position and sealing within the frac stack body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional valves are used to control fluid flow in fracturing trees, then pressure control capability is provided, but proppant interference occurs affecting operation reliability
Solution Approach 1:
The patent removes the valve component from the fracturing tree system and replaces it with a ram-based flow control mechanism. The ram can be actuated to close off flow paths without requiring traditional valve seats and disclosures, thereby eliminating the harmful effect of proppant interference with valve operation while maintaining pressure control capability.
Solution Approach 2:
The patent substitutes the traditional mechanical valve system with a hydraulic ram system. Instead of using valve discs and seats that are susceptible to proppant interference, the system uses rams that can be actuated hydraulically to close flow paths, replacing the vulnerable mechanical valve mechanism with a more robust alternative.
2Ease of operation
If valves are used for flow control, then pressure management is achieved, but device complexity increases due to valve components
Solution Approach 1:
The patent extracts and removes the complex valve assembly from the fracturing tree, retaining only the essential flow control function. By eliminating the valve body, valve seats, and associated components, the system achieves simpler construction while maintaining the ability to control fluid flow and pressure through the ram mechanism.
Solution Approach 2:
The patent applies flow control functionality locally at specific points in the system where rams are positioned, rather than using distributed valve components throughout the tree. This localized approach using rams at critical junctions simplifies the overall device architecture while preserving necessary flow management capabilities.
3Productivity
If traditional fracturing trees with valves are used, then fluid flow control is provided, but maintenance difficulty increases due to proppant accumulation in valves
Solution Approach 1:
The patent removes the valve components that are difficult to maintain and access, replacing them with rams that have simpler maintenance requirements. The ram mechanism lacks the complex internal passages and sealing surfaces of valves where proppant accumulates, making the system easier to maintain and repair.
Solution Approach 2:
The patent employs rams that can be more easily replaced or serviced compared to traditional valves. The simplified ram construction allows for quicker maintenance interventions and reduces the time and cost associated with repairing flow control components during fracturing operations.
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 enhances the control and management of fracturing fluid flow and pressure, reducing interference from proppant and improving operational efficiency by eliminating the need for valves, thus ensuring effective fracturing operations.
Implementation Method 1
a single ram that opens and closes the bore and forms a seal with the housing around the bore without seats
Data Source
AI summary
Fracturing systems having rams for controlling flow through fracturing trees are provided. In one embodiment, a fracturing system includes a frac stack mounted on a wellhead. The frac stack can include a flow control device having a housing and a single ram for opening and closing a bore of the housing. The single ram can form a seal with the housing around the bore without seats. Additional systems, devices, and methods for fracturing are also disclosed.