Wellhead Valve Interlocks for Pressure Equalization in Fracturing
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Solution Overview
Problem
Current fluid systems in oil and gas operations, particularly in hydraulic fracturing, face challenges in efficiently managing pressure differentials and automating valve operations, leading to potential safety hazards and inefficiencies.
Innovation Solution
A system comprising interconnected zipper modules, fracturing lines, and wellheads with integrated pressure sensors and equalization valves, controlled by a hydraulic manifold and a controller, which enables intelligent pressure management and remote operation of valves to ensure safe and efficient hydraulic fracturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual intervention is used for valve operations in hydraulic fracturing systems, then operational flexibility is maintained, but safety hazards increase due to exposure in hazardous areas
Solution Approach 1:
The patent replaces manual mechanical valve operations with an automated control system that uses electronic signals to actuate valves. The controller receives pressure sensor data and automatically sends control signals to valve actuators, eliminating the need for personnel to physically operate valves in hazardous high-pressure zones. This substitution of manual mechanical operation with automated electronic control resolves the contradiction by improving safety while maintaining operational capability.
Solution Approach 2:
The system enables self-service operation where the control system automatically monitors pressure differentials through sensors and autonomously actuates equalization valves and other components without human intervention. The system serves itself by detecting pressure conditions and automatically responding with appropriate valve operations, thereby eliminating exposure to hazardous areas while maintaining system functionality.
2Productivity
If traditional pressure management systems are used in hydraulic fracturing, then system simplicity is maintained, but efficiency decreases due to inability to effectively manage pressure differentials
Solution Approach 1:
The patent implements a feedback control system where pressure sensors continuously monitor pressure differentials across valves and pipelines, transmit this data to the controller, and enable automatic adjustments to valve positions. This closed-loop feedback mechanism allows the system to dynamically respond to changing pressure conditions, significantly improving pressure management efficiency. The added complexity of sensors and control electronics is justified by the substantial gains in operational efficiency and safety.
Solution Approach 2:
The pressure management system is segmented into independent functional modules: pressure sensors positioned at specific locations, separate equalization valves for different sections, and a centralized controller that processes data from multiple sensors. This modular segmentation allows each component to perform its specific function efficiently while the overall system achieves superior pressure differential management through coordinated operation of discrete elements.
3Object-affected harmful factors
If equalization valves are not used, then device complexity is reduced, but harmful effects increase due to unmanaged pressure differentials
Solution Approach 1:
The patent introduces equalization valves as intermediary components that mediate between high-pressure and low-pressure zones. These valves provide a controlled pathway for pressure equalization, preventing dangerous pressure differentials from developing. The equalization valves act as intermediaries that safely transfer or balance pressure between system sections, eliminating hazardous pressure imbalances while adding necessary valving components to the system.
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 effectively equalizes wellbore pressure with pumped hydraulic fracturing fluid, reduces the need for manual intervention in hazardous areas, and enhances operational safety and efficiency by automating valve operations based on real-time pressure readings.
Implementation Method 1
A system comprising interconnected zipper modules, fracturing lines, and wellheads with integrated pressure sensors
Implementation Method 2
The system effectively equalizes wellbore pressure with pumped hydraulic fracturing fluid
Data Source
AI summary
Methods and apparatus according to which a first valve is opened, or kept open, the first valve being part of a wellhead including a flow component above the first valve. The method may further include detecting a state of the first valve and, in response to detecting the state of the first valve, metering an amount of grease to the first valve. In addition, or instead, the method may further include opening, or keeping open, a second valve, the second valve being operably coupled to the wellhead and positioned above the flow component, and, after opening, or keeping open, each of the first and second valves, detecting whether the second valve is open or closed, in response to detecting that the second valve is open, preventing the first valve from being closed, and in response to detecting that the second valve is closed, allowing the first valve to be closed.