This invention relates in general to producing hydrocarbons from subterranean wells using hydraulic fracturing, and in particular to remote operation and monitoring of well systems during hydraulic fracturing related activities.
Certain hydrocarbon production related activities, such as well stimulation and hydraulic fracturing, require the pumping of pressurized fluid down hole. During hydraulic fracturing, as an example, a fluid is pumped into a subterranean geologic formation through the wellbore. The fluid is provided at a sufficient pressure to fracture the geologic formation, thus facilitating the recovery of hydrocarbons from the formation. Fluid is pressurized by one or more pumps, which is then pumped down high pressure flow lines to the well bore.
There is a pressure zone identified around the well assemblies, which is a limited access area for safety purposes, due the high pressure options. This makes the regions in the vicinity of the well assemblies inaccessible to most individuals during frac operations. Because of such limited access to the pressure zone during hydraulic fracturing operations, operators face a significant amount of un-planned downtime due to the maintenance requirements and operational demands of hydraulic fracturing trees and manifolds. This results in delayed production and an increase in overall costs.
Embodiments of the current disclosure provide systems and methods for well mounted equipment to be remotely controlled and operated while hydraulic fracturing operations continue at nearby wells within the pressure zone.
In an embodiment of this disclosure a method for remotely controlling services to a well during hydraulic fracturing operations is disclosed. The method includes the steps of: (a) 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; (b) 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 service being remotely controlled; and (c) controlling the performance of the service from a remote operations hub. Step (a) and step (b) are performed simultaneously and step (c) is performed from the remote operations hub located outside of the pressure zone.
In an alternate embodiment of this disclosure, a method for remotely controlling services to a well during hydraulic fracturing operations is disclosed. The method includes performing a hydraulic fracturing operation at a first well. The hydraulic fracturing operation includes providing high pressure pumps at a well site. The well site includes the first well, a second well, and a pressure zone that circumscribes both the first well and the second well. The hydraulic fracturing operation also includes using the high pressure pumps to generate a high pressure fluid and to pump the high pressure fluid into a subterranean geologic formation through a wellbore of the first well to fracture the subterranean geologic formation. A remote operations hub is provided outside of the pressure zone. Simultaneously with pumping the high pressure fluid into the subterranean geologic formation through the wellbore of the first well, a service is performed on the second well from the remote operations hub.
In an another alternate embodiment of this disclosure, a system for remotely controlling services to a well during hydraulic fracturing operations is disclosed. A first well is in fluid communication with a high pressure pumping system that is operable to pump high pressure fluid into a subterranean geologic formation through a wellbore of the first well at a sufficient pressure to fracture the subterranean geologic formation. A second well is located within a pressure zone defined around the first well and the second well. A remote operations hub is in communication with the second well and operable to remotely control the performance of a service at the second well during operation of the high pressure pumping system at the first well. The remote operations hub is located outside of the pressure zone.
So that the manner in which the features, advantages and objects of the invention, as well as others which will become apparent, are attained and can be understood in more detail, more particular description of the invention briefly summarized above may be had by reference to the embodiment thereof which is illustrated in the appended drawings, which drawings form a part of this specification. It is to be noted, however, that the drawings illustrate only a preferred embodiment of the invention and is therefore not to be considered limiting of its scope as the invention may admit to other equally effective embodiments.
The methods and systems of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The methods and systems of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout.
It is to be further understood that the scope of the present disclosure is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation.
Looking at
High pressure pumping area 14 includes a series of pump trucks 26 that receive fluids from hazardous chemical area 12. Frac manifold 28 is also located within high pressure pumping area 14. Frac manifold 28 receives the high pressure fluids generated by pump trucks 26 and directs such fluids towards a well 30. Frac manifold 28 can have a fluid communication line with each well 30 and can be operated to select which well 30 is to receive the high pressure fluids. During hydraulic fracturing operations, pump trucks 26 generate a high pressure fluid and pump the high pressure fluid into a subterranean geologic formation through a wellbore of one of the wells 30, by way of frac manifold 28. The high pressure fluid is provided at a sufficient pressure to fracture the subterranean geologic formation.
Well area 16 can include a number of wells. In the example configuration of
Outside of hazardous chemical area 12, high pressure pumping area 14 and well area 16, there can be various additional storage tanks 34 and hydraulic fracturing monitoring and control units 36. Remote operations hub 38 can also be a part of hydraulic fracturing operation system 10 and located outside of pressure zone 32 as well as being outside of hazardous chemical area 12 and high pressure pumping area 14. Remote operations hub 38 can contain features required to remotely monitor or control an operation or service that is performed at one of the wells 30 within pressure zone 32. Remote operations hub 38 can remotely control services to one of the wells 30 while hydraulic fracturing operations are being undertaken at another of the wells 30 within pressure zone 32.
Remote operations hub 38 can be in the form of wheeled mobile operation center 40 (
Remote operations hub 38 can be protected by a blast-proof or fire resistant shield to further protect and secure the operators, the system components located on remote operations hub 38, and the data assets. Various system components 46 used to operate and monitor well mounted equipment 48 and characteristic of the well itself during and after fracturing operations can be mounted on remote operations hub 38. Such system components 46 can include: accumulators; hydraulic, electric, and pneumatic actuators; torque wrenches; grease pumps, hydraulic pressure pumps to test equipment during installation and service; pressure, flow, and temperature sensors; odometers; and visual indicators.
System components 46 are used to perform the services at one of the wells 30. The service performed at one of the wells 30 can be, for example, a monitoring operation, a prognostic operation, a diagnostic operation, or the control of well mounted equipment 48 (
System components 46 can be used to perform the services at one of the wells 30 during and after hydraulic fracturing operations. As an example, after a well 30 is fractured, and as wireline operations are being completed on such well 30, remote maintenance or other service on another well 30 can be undertaken at the same time. This prevents any additional maintenance or service downtime since the operator doesn't have to wait for the wireline operations to complete in order to access the well 30 that is being maintained or serviced.
Well mounted equipment 48 is equipment that is associated with a well 30 and can be located above the surface, such as on a wellhead assembly, or within the wellbore of well 30. Well mounted equipment 48 can include a tree, a manifold, a choke, a valve, an actuator, a separation unit, a flare stack, a pump, a sensor and a compression unit. As an example, a pressure sensor on remote operations hub 38 can be used to sense a pressure within a compression unit mounted on well 30.
In alternate embodiments, instead of monitoring or controlling well mounted equipment 48, a system component 46 can be used to operate and monitor other of the system components 46. As an example, a pressure sensor on remote operations hub 38 can be used to sense a pressure at a hydraulic pressure pump located on remote operations hub 38.
Communication lines 50 (
System components 46 that instead perform their function using an electric or other form of data transmission signal can be in communication with well mounted equipment 48 as well as the computer system with wires or by a wireless telemetry method, such as by radio, microwave, ultrasonic, or infrared systems, as applicable. For example, information relating to the health of well mounted equipment 48 and certain well characteristics, such as pressure, temperature and flow rates can be transmitted to remote operations hub 38 by wires that run between well 30 and the remote operations hub 38, or they can be transmitted to remote operations hub 38 by wireless communication means. Information can also be transferred between various system components 46 using the internet or cloud services, allowing such information to be viewed and utilized at multiple offsite locations, and for commands to be sent from multiple offsite locations. In embodiments where remote operations hub 38 is placed within line of sight from the wells 30, backup confirmation of the service being performed at wells 30 can be observed visually from active or passive optical devices, such as light emitting diodes, using sensors mounted directly on the well mounted equipment 48. If remote operations hub 38 is placed out of line of sight, back up confirmation of the service being performed at wells 30 can be transmitted through wires or wirelessly to remote operations hub 38. In alternate embodiments where the system has telemetry capabilities, there is no restriction how far remote operations hub 38 can be placed from wells 30.
System components 46 can additionally include a computer system that can have a personal computer component with a processing unit and a server component. The server component can include an application server, web server, database server, file server, home server, or standalone server. The hardware of the computer system can access a database to deposit, store, and retrieve data. A memory or computer readable medium can contain software programs with instructions for directing the system components to perform their respective functions. The computer system can be compatible with a common operating system, such as a Microsoft operating system, an Apple operating system, or can utilize a customized operating system.
Data obtained by the system components can be indicated on analog or digital visualization platforms or on a graphic user interface of the computer system. Looking at
Control panels 52 can also use controllers that interface with system components 46 for monitoring and directing the system components 46. The controllers can be mechanical, pneumatic, hydraulic, or electrical or can be part of the computer system. As an example of use, real-time display units can communicate information from a flowback section to study production data.
Additional display units can be in communication with the computer system with wires or by a wireless method such as wireless internet service or telemetry method, such as by radio, microwave, ultrasonic, or infrared systems, as applicable. Such additional display units can be for example, a tablet, iPad, cellular phone, or personal computer. Information relating to the position of the valves and the health of well mounted equipment 48 and certain well characteristics, such as pressure, temperature and flow rates can be transmitted to the additional display unit by wires, or they can be transmitted to the additional display unit by wireless communication means. Information can also be transferred between various system components using the internet or cloud services, allowing such information to be viewed and utilized at multiple offsite locations.
Turning to
In an example of greasing operations, after communication lines 50 have been put in place and remote operations hub 38 is operational, the pressure of a pressure media is built up so that a ball valve can be opened to supply grease through a grease supply line 58 to a manifold block. A pump selector can be switched to a desired grease pump, however the grease pump will not run until a valve selector is switched to select the valve to be greased. One valve can be selected at a time to grease valves individually, counting strokes of the grease pump to measure grease flow. A gauge can be monitored to ensure that the valve being greased is not over pressured. After greasing each of the valves of a stack of a wellhead assembly, a needle valve at end of the grease hose can be closed. Caution will be used while disconnecting grease fittings to make sure such fittings do not leak under pressure and pressure will be bled out of the grease system after each greasing operation is complete. Each of these steps can take place by an operator 60 at the grease skid 42, which is located remotely from the well 30 outside of the pressure zone 32, and through use of the control panel 52 on the grease skid 42.
Looking at
A first manifold block 64a is associated with a first well 30a and a third well 30c. A second manifold block 64b is associated with first well 30a and second well 30b. Grease supply line 58 extends from grease unit 62 to the first manifold block 64a. Another grease supply line, grease crossover line 66, extends from first manifold block 64a to second manifold block 64b. Additional grease supplies lines 68 extend from first manifold block 64a to first well 30a and to third well 30c, and extend from second manifold block 64b to first well 30a and to second well 30b. In such a configuration, grease can be supplied between manifold blocks 64 through a grease outlet to daisy chain grease supply. In the example schematic of
Each of the additional grease supply lines 68 can extend to a different valve at one of the wells 30. In the example of
Separate umbilicals or electrical lines 70 extend between grease unit 62 and each of the manifold blocks 64 for communicating signals and information between grease unit 62 and each of the manifold blocks 64. A separate remote controller 72, such as a pendant controller, can be used to communicate with grease unit 62. Wire mesh style strain relief systems can be used on both ends of a cable between separate remote controller 72 and grease unit 62 and on electrical lines 70. A visual identification system, such as colors, numbers, or other markings, can be used on grease supply line 58, grease crossover line 66, additional grease supplies lines 68, on the cable between separate remote controller 72 and grease unit 62, and on electrical lines 70 to help to visually distinguish between such lines in an efficient manner.
In an example of operation of grease unit 62, while hydraulic fracturing operations are being undertaken at first well 30a, a valve at each of the second and third wells 30b, 30c can be selected for greasing. Signals can be provided to first and second manifold blocks 64a, 64b by way of electrical lines 70 to select such valves. Grease can then be supplied through grease supply line 58 to first manifold block 64a and to second manifold block 64b through crossover line 66. First and second manifold blocks 64a, 64b can then simultaneously provide grease to the selected valves through the applicable grease supply lines 68.
Systems and methods described herein provide a range of functionality. Embodiments of the current disclosure provide systems and methods for valves and other well mounted equipment 48 to be remotely controlled and operated from control panels inside the trailer. Production characteristics, such as pressure, oil and gas ratio, water content, and chemical tracers, which provide information regarding the reservoir and efficiency of fracturing, can be observed in real-time allowing fracturing operators to modify the fracturing program in real-time. In addition, the drag characteristics and health of the valves can be monitored, and a programmed or manual re-grease protocol to improve equipment performance can be initiated. Data gathered by system components 46 can be used for preventative maintenance or pre-emptive actions, such as for the replacement of parts. Equipment diagnostics can be used to predict repair and failure life span. Bolt torque can be monitored by the system components for a stretch in bolts to identify re-torque requirements. Flexible controls at the mobile platform allow individual or group controls of well mounted equipment, such as trees, chokes, valves, on one or on a plurality of wells. With one push of a button, one can kill all pressure lines and isolate sections of the well or equipment as desired.
Embodiments of this disclosure can monitor, prognose, and diagnose operations at the well assembly and can therefore reduce the number of grease interference in hydraulic fracturing operations. In addition, the well assemblies can be greased remotely, allowing for continued fracking in a second well while a current first well assembly is being greased. Data gathered by the system components can be used for preventative maintenance or pre-emptive actions, such as for the replacement of parts. The diagnostics and prognostics operations can be used to predict repair and failure life span.
In some current hydraulic fracturing operations, human operators are required to be around pressurized equipment where there have been instances of physical harm. Remote operation removes the operator from the vicinity of high pressure equipment and improves safety. In addition, the mobile operation and diagnostic center can be equipped with multiple redundancies of operators, controls, and actuators which can be used as fail-safe measures in case of equipment failure or unforeseen behavior from the well or attached equipment.
The diagnoses of system conditions by system components of embodiments of this disclosure can reduce the number of grease interference in hydraulic fracturing operations. In addition, the trees can be greased remotely, allowing for continued fracking in a second well while a current first well is being greased.
The terms “vertical”, “horizontal”, “upward”, “downward”, “above”, and “below” and similar spatial relation terminology are used herein only for convenience because elements of the current disclosure may be installed in various relative positions.
The system and method described herein, therefore, are well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the system and method has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the system and method disclosed herein and the scope of the appended claims.
This application is a continuation of U.S. patent application Ser. No. 14/725,341 filed May 29, 2015, titled “REMOTE MOBILE OPERATION AND DIAGNOSTIC CENTER FOR FRAC SERVICES,” now U.S. Pat. No. 10,260,327, issued Apr. 16, 2019, and claims priority to and the benefit of U.S. Provisional Application No. 62/005,720 filed May 30, 2014, titled “Mobile Operation and Diagnostic Center for Frac Services,” and U.S. Provisional Application No. 62/006,681 filed Jun. 2, 2014, titled “Mobile Operation and Diagnostic Center for Frac Services,” and U.S. Provisional Application No. 62/092,543 filed Dec. 16, 2014, titled “Remote Frac Operations Hub,” the full disclosure of each which is hereby incorporated herein by reference in its entirety for all purposes.
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Number | Date | Country | |
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Parent | 14725341 | May 2015 | US |
Child | 16384149 | US |