Remote Operations Hub for Hydraulic Fracturing Well Control
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Solution Overview
Problem
Hydraulic fracturing operations face significant unplanned downtime and increased costs due to limited access to high-pressure zones around well assemblies, necessitating improved remote operation and monitoring solutions.
Innovation Solution
The implementation of a remote operations hub located outside the pressure zone, which allows for simultaneous control and monitoring of well-mounted equipment and services at nearby wells, using a system that includes high-pressure pumps, communication lines, and control panels to perform services such as greasing and diagnostics without direct human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If operators perform maintenance and services on well assemblies during hydraulic fracturing operations, then operational demands are met, but unplanned downtime increases due to limited access to the pressure zone
Solution Approach 1:
A remote operations hub is introduced as an intermediary system that enables operators to control and monitor well assemblies from a safe location outside the pressure zone. The hub includes control panels, communication systems, and diagnostic equipment that interface with well-mounted equipment, allowing remote operation without physical presence in the hazardous area.
Solution Approach 2:
Physical mechanical access to well assemblies is replaced with electronic and telecommunication systems. The remote operations hub uses electrical signals, digital communication, and automated control mechanisms to perform functions that previously required direct physical interaction with the well equipment, eliminating the need for operators to enter the pressure zone.
2Ease of operation
If operators are positioned within the pressure zone to service wells, then direct control is possible, but safety risks increase due to high pressure hazards
Solution Approach 1:
The remote operations hub serves as a protective intermediary between the operator and the high-pressure environment. All control signals and diagnostic data are transmitted electronically through the hub, which is positioned outside the pressure zone, thereby eliminating direct exposure to safety hazards while maintaining full operational control.
Solution Approach 2:
The operator is extracted from the hazardous pressure zone and repositioned in a safe location. The critical function of direct control is preserved through the extraction of the control capability itself, which is now remotely accessible via the hub's communication and control systems without requiring physical presence in the dangerous area.
3Productivity
If manual intervention is used for well maintenance during frac operations, then services can be performed, but operational efficiency decreases due to access limitations
Solution Approach 1:
The system enables self-service operation where the well assembly can be monitored, diagnosed, and controlled automatically through the remote hub without requiring manual intervention. Well-mounted equipment such as grease pumps and valves can operate autonomously based on commands from the remote operations hub, significantly improving operational efficiency while maintaining ease of access.
Solution Approach 2:
Manual mechanical operations are replaced with automated electronic control systems. The remote operations hub uses electrical actuators, digital sensors, and automated diagnostic tools to perform maintenance functions that previously required manual physical intervention, thereby increasing productivity while eliminating access constraints.
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, enhances safety by removing operators from high-risk areas, and enables continuous operation of hydraulic fracturing by allowing remote maintenance and monitoring of well equipment, thereby improving operational efficiency and reducing costs.
Implementation Method 1
generating a high pressure fluid and pumping the high pressure fluid into a subterranean geologic formation through a wellbore of a first well, the high pressure fluid being provided at a sufficient pressure to fracture the subterranean geologic formation
Data Source
AI summary
A method for remotely controlling services to a well during hydraulic fracturing operations includes generating a high pressure fluid and pumping the high pressure fluid into a subterranean geologic formation through a wellbore of a first well, the high pressure fluid being provided at a sufficient pressure to fracture the subterranean geologic formation. The method also includes performing a service on a second well, the second well being located within a pressure zone defined around the first well and the second well. The method further includes controlling the performance of the service from a remote operations hub.