Zipper Manifold Valve Swapping for Multi-Well Fracturing
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Solution Overview
Problem
Current hydraulic fracturing systems face inefficiencies in managing the hydraulic fracturing process across multiple oil and gas wells, particularly in terms of fluid pressure equalization, valve operation, and swapping between wells, which affects the overall efficiency and speed of the fracturing process.
Innovation Solution
A hydraulic fracturing system that includes a blender for mixing fracturing fluid, a suction manifold, swap stations, and a zipper manifold, along with a grease system and a controller to manage the fracturing process, allowing for efficient fluid distribution and pressure equalization across multiple wells, and enabling rapid swapping between fracturing stages using zipper valves and a frac queue/wireline queue for coordinated operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional hydraulic fracturing systems are used to manage multiple wells, then the system structure is simpler, but the efficiency and speed of fracturing process decreases due to inefficiencies in fluid pressure equalization, valve operation, and swapping between wells
Solution Approach 1:
The system is divided into multiple swap stations (first swap station, second swap station, etc.) that can independently manage different wells. Each swap station includes dedicated zipper valves and control mechanisms, allowing parallel operations on multiple wells without interfering with each other, thus improving overall productivity while maintaining manageable complexity through modular design
Solution Approach 2:
The swap stations are designed with universal functionality to handle multiple wells through standardized interfaces. The same swap station structure and control logic can be applied to different wells, enabling efficient swapping between stages and wells using a consistent system architecture rather than custom solutions for each well
2Loss of time
If rapid swapping between wells is implemented, then the time between fracturing stages is reduced, but the valve operation complexity and pressure management difficulty increases
Solution Approach 1:
The zipper valves are pre-positioned and pre-configured in each swap station before fracturing operations begin. The system prepares the fluid pathways and valve states in advance, allowing rapid switching between wells without complex real-time decision-making during the actual swapping process, thus reducing transition time while keeping control complexity manageable
Solution Approach 2:
The swap station acts as an intermediary device between the fluid source and multiple wells. It mediates the complex pressure equalization and valve coordination tasks, isolating the complexity from the main control system and enabling rapid swapping through a dedicated intermediate component that handles pressure management and valve 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
The system enhances the efficiency and speed of hydraulic fracturing by ensuring precise fluid pressure management and rapid swapping between wells, reducing the time between fracturing stages and improving overall operational efficiency.
Implementation Method 1
a grease system and a controller to manage the fracturing process
Implementation Method 2
A hydraulic fracturing system that includes a blender for mixing fracturing fluid, a suction manifold, swap stations, and a zipper manifold
Data Source
AI summary
A hydraulic fracturing plan executable by a hydraulic fracturing system to hydraulically fracture at least first and second wells. In one or more embodiments, executing the hydraulic fracturing plan includes opening a first valve while hydraulic fracturing fluid is communicated to the second well via a second valve and a manifold, the first valve being associated with both the first well and the manifold, and the second valve being associated with both the second well and the manifold. In one or more embodiments, executing the hydraulic fracturing plan further includes closing the second valve, wherein the second valve is closed after opening the first valve, and while hydraulic fracturing fluid is communicated to the first well via the first valve and the manifold.