Remote manifold valve and pump pairing technique for a multi-pump system
11668172 · 2023-06-06
Assignee
Inventors
Cpc classification
F17D5/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F17D5/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A technique for remote pairing of pumps and manifold valves at an oilfield. The technique takes advantage of a control unit having remote capability of opening and closing manifold valves. The control unit may also be in simultaneous communication with an individual sensor for each pump. Thus, unique protocols of valve opening and closing at the manifold in conjunction with monitoring of fluid-based detections by the unit may be used to establish pairing between specific pumps and manifold valves. Similarly, the system may also be inspected for leaks at particular locations through unique valve opening and closing sequences in conjunction with fluid monitoring.
Claims
1. A method of remotely pairing high pressure valves and low pressure valves at a manifold with pumps of a multi-pump system circulating a slurry at an oilfield, the method comprising: remotely opening all high pressure valves of the manifold; after opening all the high pressure valves, sequentially remotely opening low pressure valves at the manifold including: simultaneously opening a selected number of multiple low pressure valves at the manifold after closing all valves and before opening a given low pressure valve, the selected number of the multiple low pressure valves being fewer than a total of the low pressure valves at the manifold; confirming an absence of any responsive pressure increase in any pump of the multi-pump system; and upon confirming the absence of any responsive pressure increase in any pump of the multi-pump system, removing the selected number of the multiple low pressure valves from consideration as remaining low pressure valves for pairing, thereby reducing a time to remotely pair the valves of the multi-pump system; identifying a responsive fluid-based detection in a pump of the multi-pump system via at least one sensor located to monitor for a dedicated fluid flow to the pump upon opening the given low pressure valve, the dedicated fluid flow indicating fluid flowing directly from the given low pressure valve to the identified pump rather than to other pumps of the multi-pump system, thus establishing a pairing between the given low pressure valve and the identified pump; identifying responsive fluid-based detections at remaining pumps of the multi-pump system to identify individual pairings between the remaining low pressure valves and pumps; and recording the pairing between each of the identified pumps and the each of the given low pressure valves at a control unit at the oilfield, the pairing enabling each of the pumps to be individually and remotely connected to the multi-pump system by opening the paired valves and pumps, wherein the recorded pairing enables the control unit to close the appropriate paired valves when disconnecting a pump from the multi-pump system when the multi-pump system is operating, thereby maintaining operational integrity of the operating multi-pump system by enabling the multi-pump system to remain operational while the pump is being disconnected from the multi-pump system.
2. The method of claim 1 wherein maintaining comprises ensuring that a pump is not operating against an erroneously closed valve.
3. The method of claim 1 wherein the multiple low pressure valves are about half of the low pressure valves at the manifold.
4. The method of claim 3 wherein the manifold comprises stations each having a high pressure valve and two low pressure valves, the multiple low pressure valves comprising one of the two low pressure valves from each of the stations.
5. The method of claim 1 further comprising: closing all valves at the manifold; opening a selected one of the high pressure valves at the manifold; identifying a responsive fluid-based detection in a pump of the multi-pump system; and recording the identifying of the detection as a pairing between the pump and the selected opened high pressure valve at the control unit at the oilfield.
6. The method of claim 5 further comprising sequentially opening remaining high pressure valves at the manifold and identifying responsive fluid-based detections at remaining pumps of the multi-pump system to identify individual pairings between the remaining high pressure valves and pumps, the identified individual pairings between the high pressure valves and pumps recorded at the control unit.
7. The method of claim 6 further comprising performing an application in a well at the oilfield with the slurry.
8. The method of claim 7 wherein the application is one of a stimulation application and a fracturing application.
9. The method of claim 7 further comprising: employing the control unit to close identified high pressure and low pressure valves at the manifold; and taking a given pump of the multi-pump system off-line from the application, the given pump identified by the control unit as paired to the identified high pressure and low pressure valves.
10. The method of claim 7 further comprising: adding another pump to the multi-pump system for the application, the adding including hydraulically coupling the added pump to additional high pressure and low pressure valves at the manifold; and verifying pairing between the additional high pressure and low pressure valves at the manifold to the added pump, the verifying accounting for the identified individual pairings recorded at the control unit.
11. A multi-pump manifold system for circulating a slurry at an oilfield, the system comprising: a manifold for obtaining a slurry; a plurality of pumps hydraulically coupled to low pressure valves at the manifold for obtaining low pressure slurry therefrom, the pumps hydraulically coupled to high pressure valves at the manifold for returning high pressure slurry to the manifold; a control unit coupled to the manifold for directing opening and closing of the high and low pressure valves thereat, the control unit communicatively coupled to each of the plurality of pumps for obtaining fluid-based information therefrom; and a processor of the control unit for pairing each of the plurality of the pumps to individual high and low pressure valves at the manifold based on fluid-based information obtained from a plurality of sensors positioned to monitor whether fluid flow occurs during the opening and closing of the valves by the control unit, the pairing being determined upon receiving data from individual sensors of the plurality of sensors indicating a dedicated flow from a specific low pressure valve of the low pressure valves to a specific pump of the plurality of pumps rather than to other pumps of the plurality of pumps, thus establishing and recording a pairing between the specific low pressure valve and the specific pump, the pairing enabling each of the pumps to be remotely connected to the multi-pump manifold system by opening the appropriate recorded paired valves associated with the appropriate pumps, wherein the recorded pairing enables the control unit to close the appropriate paired valves when disconnecting a first pump from the multi-pump manifold system when the multi-pump manifold system is operating, thereby maintaining operational integrity of the operating multi-pump system by enabling the remaining pumps of multi-pump system to remain operational while the first pump is being disconnected from the multi-pump system; wherein monitoring whether fluid flow occurs during the opening and closing of the valves by the control unit comprises: simultaneously opening a selected number of multiple low pressure valves after closing all valves and before opening the specific low pressure valve, the selected number of the multiple low pressure valves being fewer than a total of the low pressure; confirming an absence of any responsive pressure increase in any pump of the multi-pump system; and upon confirming the absence of any responsive pressure increase in any pump of the multi-pump system, removing the selected number of the multiple low pressure valves from consideration as remaining low pressure valves for pairing, thereby reducing a time to remotely pair the valves of the multi-pump system.
12. The system of claim 11 wherein the processor is further configured to determine leak information based on fluid flow information obtained during the opening and closing of the valves by the control unit.
13. The system of claim 11 further comprising one of a flowmeter, a water transducer and a suction pressure sensor disposed within each pump of the plurality to provide the fluid-based information.
14. The system of claim 11 wherein the manifold is a first manifold, the system further comprising a second manifold hydraulically coupled to the first manifold for obtaining low pressure slurry therefrom and hydraulically coupled to pumps of the plurality for circulating slurry therebetween.
15. The system of claim 11 further comprising a mixer to provide the slurry to the low pressure slurry to the manifold from water and proppant sources.
16. The system of claim 11 wherein the low pressure slurry is at a pressure less than about 300 PSI and the high pressure slurry is at a pressure greater than about 3,000 PSI.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
(8) In the following description, numerous details are set forth to provide an understanding of the present disclosure. However, it will be understood by those skilled in the art that the embodiments described may be practiced without these particular details. Further, numerous variations or modifications may be employed which remain contemplated by the embodiments as specifically described.
(9) Embodiments are described with reference to certain embodiments of stimulation operations at an oilfield. Specifically, pumps, a manifold and other equipment are referenced for taking advantage of pairing techniques for performing stimulation applications. However, other types of operations may benefit from the embodiments of pairing techniques detailed herein. For example, such techniques may be employed for supporting fracturing or other related downhole operations supported by multiple high pressure pumps. Indeed, so long as pairing techniques are utilized which allow for both manually remote and substantially assured pairing between valve locations at the manifold and specific pumps, appreciable benefit may be realized.
(10) Referring now to
(11) As indicated, the embodiment of
(12) The mixer 122 is used to combine separate slurry components. Specifically, water from tanks 121 is combined with proppant from a proppant truck 125. The proppant may be sand of particular size and other specified characteristics for the application. Additionally, other material additives may be combined with the slurry such as gel materials from a gel tank 120. From an operators perspective, this mixing, as well as operation of the pumps 140-149, manifold 160 and other system equipment may be regulated from a control unit 110 having suitable processing and electronic control over such equipment. Indeed, as detailed further below, the control unit 110 may be outfitted with a capacity for remotely opening and closing the valves of the manifold 160 as needed, for example, when putting a pump 140-149 on or off-line.
(13) Continuing with reference to
(14) Continuing with reference to
(15) Pairing a given pump 140-149 with a particular high or low pressure manifold location may take less than about 5 minutes through the techniques detailed herein. As detailed further below, this is due to real-time pressure and/or flow information regarding each individual pump 140-149 being made available to the control unit 110 in combination with remote control over valves at the manifold 160. This allows for unique sequences of valve control to be exercised in combination with operating individual pumps 140-149 in order to remotely gamer pairing information. Indeed, as also detailed below, specific sequencing of valve control may also be utilized for sake of leak detection in advance of pairing determinations.
(16) Referring now to
(17) Apart from bleed-off devices 290-294 and other features, as alluded to above, each station 230-234 may include a few different valve locations 260-264, 270-274, 280-284 for hydraulic communication with the pumps 140-149 of
(18) By convention, the low pressure valve locations 270-274 at the bottom portion of the stations 230-234 are more likely to be utilized. However, this is not required. For example, upper low pressure valve locations 260-264 may be utilized when a bottom valve location 270-274 is defective, occupied by hydraulic linkup to another manifold, or for a variety of other reasons. Regardless the particulars, the presence of multiple low pressure valve locations 260-264, 270-274 at each station 230-234 adds to the sophisticated nature of the pairing between the pumps 140-149 and the manifold 160.
(19) In spite of the potential complexity of the myriad of potential hydraulic hookups between the pumps 140-149 and the manifold stations 230-234, in the embodiments of
(20) Referring now to
(21) Continuing with particular reference to
(22) With additional reference to
(23) Referring now to
(24) With specific reference to
(25) Referring specifically now to
(26) With all valves of the manifold 160 closed, the low pressure valves may be temporarily opened to trap fluid within each pump sufficient for subsequent detections (see 474). Specifically, the high pressure valve locations may now be opened sequentially, one-by-one as indicated at 475. Thus, each pump that displays a corresponding fluid-based detection from trapped fluid, in response to a high pressure valve opening may be recorded as paired thereto (see 480). Again, in this embodiment, the fluid-based detection may be one of fluid flow. However, other types of fluid detections are again possible. Regardless, all of the pairings between pumps 140-149 and the particular valve locations at the manifold 160 may now be complete.
(27) Once pairing is complete, there may still be a desire to add additional pumps to the overall system 100 (see
(28) Of course, added levels of sophistication may also be brought to bear on the techniques detailed above. For example, as described above, the stations of the manifold 160 may be equipped with multiple low pressure valve locations 260-264, 270-274 as depicted at
(29) The above described concept of dividing the low pressure valve locations 260-264, 270-274 into separate groupings for sake of time savings may be taken further, where more than one manifold 160 is utilized. For example, in many cases a manifold 160 as shown at
(30) Referring now to
(31) Embodiments described above take more complete advantage of the possibility of remotely turning manifold valves off or on. Specifically, in addition to merely removing personnel from the immediate vicinity of hazardously pressurized manifolds in order to tum valves off or on, operators are substantially assured of which particular valves are to be properly turned off or on. So, for example, where a pump is to be put on or taken off line, operators are assured as to which particular valves of the manifold are to be correspondingly opened or closed. In this manner, hazards such as leaving a high pressure pump operating against an erroneously closed manifold valve may be avoided. This is achieved through use of the remote pairing techniques detailed herein.
(32) The preceding description has been presented with reference to presently preferred embodiments. Persons skilled in the art and technology to which these embodiments pertain will appreciate that alterations and changes in the described structures and methods of operation may be practiced without meaningfully departing from the principle, and scope of these embodiments. For example, while a specifically located sensor is referenced herein for acquiring fluid flow readings, the sensor may be positioned in other locations or a different sensor type utilized. Specifically, a flow meter, water transducer, suction pressure sensor or different type of pressure sensor may be utilized. Furthermore, as a matter of practicality, while the pairing techniques detailed hereinabove may take place while pumps are in an idle state, this is not necessarily required. Along these lines, the foregoing description should not be read as pertaining only to the precise structures and techniques described and shown in the accompanying drawings, but rather should be read as consistent with and as support for the following claims, which are to have their fullest and fairest scope.