FRACTURING MANIFOLD ALIGNMENT SYSTEMS

A manifold alignment system includes a first modular skid with a first frame, the first frame having a first end with at least one first sloped surface, a second modular skid with a second frame, the second frame having a second end with at least one second sloped surface, wherein the at least one first sloped surface mates with the at least one second sloped surface, and a removably mounted hydraulic mechanism attached to the first end of the first skid and the second end of the second skid.

BACKGROUND

Hydraulic fracturing is a stimulation treatment routinely performed on oil and gas wells in low-permeability reservoirs. Specially engineered fluids are pumped at high pressure and rate into the reservoir interval to be treated, causing a vertical fracture to open. The wings of the fracture extend away from the wellbore in opposing directions according to the natural stresses within the formation. Proppant, such as grains of sand of a particular size, is mixed with the treatment fluid to keep the fracture open when the treatment is complete. Hydraulic fracturing creates high-conductivity communication with a large area of formation and bypasses any damage that may exist in the near-wellbore area. Furthermore, hydraulic fracturing is used to increase the rate at which fluids, such as petroleum, water, or natural gas can be recovered from subterranean natural reservoirs. Reservoirs are typically porous sandstones, limestones or dolomite rocks, but also include “unconventional reservoirs” such as shale rock or coal beds. Hydraulic fracturing enables the extraction of natural gas and oil from rock formations deep below the earth's surface (e.g., generally 2,000-6,000 m (5,000-20,000 ft)), which is greatly below typical groundwater reservoir levels. At such depth, there may be insufficient permeability or reservoir pressure to allow natural gas and oil to flow from the rock into the wellbore at high economic return. Thus, creating conductive fractures in the rock is instrumental in extraction from naturally impermeable shale reservoirs.

A wide variety of hydraulic fracturing equipment is used in oil and natural gas fields such as a slurry blender, one or more high-pressure, high-volume fracturing pumps and a monitoring unit. Additionally, associated equipment includes fracturing tanks, one or more units for storage and handling of proppant, high-pressure treating iron, a chemical additive unit (used to accurately monitor chemical addition), low-pressure flexible hoses, and many gauges and meters for flow rate, fluid density, and treating pressure. Fracturing equipment operates over a range of pressures and injection rates, and can reach up to 100 megapascals (15,000 psi) and 265 litres per second (9.4 cu ft/s) (100 barrels per minute).

Conventional methods to connect the equipment currently use big bore manifolds (e.g., having 7 inch bores) deployed in pipe segments that must be flanged together on site. Given the size and weight of the pipe segments, properly aligning the spools rotationally (to line up the bolt holes) and axially (so that are near enough for the bolted connection and are not tilted with respect to one another) can prove to be very challenging on site. The aforementioned difficulties increase the time it takes to establish the proper connections required. Furthermore, recent trends have shifted frac manifolds toward bigger bore monoline manifolds. However, bigger bore monoline manifolds, are likewise deployed in pipe segments that are flanged together on site. Thus, the bigger bore monoline manifolds also require a significant amount of work on the part of field workers, who must manipulate the segments to rotationally align the bolt holes and establish a coaxial alignment of the pipe segments to allow the bolts to be inserted and torqued.

FIG. 1illustrates an example of an existing fracturing pad system100(often referred to as a “frac pad” system in the industry). The fracturing pad system100includes at least one pump truck102connected to a missile manifold104via fluid connections106. Additionally, a blending system108may be connected to the pump trucks102through one or more hoses110to supply proppant and other particulates to the pump trucks102to pump into the well (not shown) as part of the fracturing process. The missile trailer104may be connected to an isolation valve structure112that, for instance, can include a safety valve that may open to relieve pressure in the system under certain conditions. The valve structure112may be connected to at least one manifold114through a pipe spool116that is a plurality of pipes flanged together, for instance. As can be seen fromFIG. 1, the fracturing pad system100includes many, non-uniform connections that must be made up and pressure tested, including the conduits to/from the pump trucks102, missile trailer104, and blending system108. Furthermore, the connections between the missile manifold104and valve structure112, and the pipe spool116between the valve structure112and the manifolds114are also non-uniform connections that must be made up and pressure tested. These connections take valuable time and resources on site. Additionally, the fracturing pad system100is generally not flexible regarding the number of pumps that can be used.

SUMMARY

In one aspect, embodiments of the present disclosure relate to a manifold alignment system that includes a first modular skid with a first frame, the first frame having a first end with at least one first sloped surface, a second modular skid with a second frame, the second frame having a second end with at least one second sloped surface, wherein the at least one first sloped surface mates with the at least one second sloped surface, and a removably mounted hydraulic mechanism attached to the first end of the first skid and the second end of the second skid.

In another aspect, embodiments of the present disclosure relate to a method of aligning a plurality of skids that includes pulling a first modular skid towards a second modular skid with a removably mounted hydraulic mechanism or a crane, wherein the first modular skid has a first frame and the second skid has a second frame, axially aligning a first manifold connection on the first modular skid with a second manifold connection on the second modular skid, and closing a rotationally independent connector around axially aligned ends of the first manifold connection and the second manifold connection to fluidly connect the first manifold connection to the second manifold connection.

DETAILED DESCRIPTION

In one aspect, embodiments disclosed herein relate to a modular fracturing pad system. The modular fracturing pad system may also be interchangeably referred to as a modular skid system in the present disclosure. As used herein, the term “coupled” or “coupled to” or “connected” or “connected to” may indicate establishing either a direct or indirect connection, and is not limited to either unless expressly referenced as such. Wherever possible, like or identical reference numerals are used in the figures to identify common or the same elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale for purposes of clarification.

A modular skid system, according to embodiments herein, is a system in which the elements of a hydraulic fracturing system are modularized and deployed on connectable skids that can be secured together to form an integrated fracturing structure capable of spanning from the outlet of a hydraulic fracturing pump to the wellhead. The hydraulic fracturing system elements are modularized in a way such that the primary manifolds/flow functionality is made up when the skids are connected. Further, the modularized hydraulic fracturing system elements may be held on units having standardized uniform connections, such that different types of hydraulic fracturing system element units may be connected together using the same connection type. The reduction of using non-uniform connections that must be made up and pressure tested may significantly reduce the complexity, design, time, and weight of the system.

Modular skid systems of the present disclosure may include, for example, systems for use in hydraulic fracturing (e.g., where a fracturing modular skid system may be used to direct fluid from one or more pumps to be injected into one or more wellheads in a fracturing operation), in post-drilling operations (e.g., where the modular skid system may include one or more modularized skids holding flowback equipment, such as junk catchers, desanders, choke manifolds, etc.), and/or in other wellbore operations, where modular skids may be used to direct fluid produced from and/or injected into a well. As used herein, fluids may refer to proppant, liquids, gases, and/or mixtures thereof. Other instruments and devices, including without limitation, sensors and various valves may be incorporated within a modular skid system.

Conventional wellbore operation systems (e.g., hydraulic fracturing pad systems) in the oil and gas industry typically consume a large amount of space and resources of a rig area. Conventional wellbore operation systems may use elements that are individually designed and sized with pipes, flow lines, and other conduits being used to interconnect the elements of the system. Furthermore, pipes, flow lines, and other conduits being used to interconnect the conventional wellbore operation systems are not uniform and take valuable time to make up and pressure test. Additionally, the sheer number of pipes, hoses, and other fluid connections represent safety hazards for on-site workers. This additional need of more components needed to interconnect the conventional wellbore operation systems adds to the weight, installation costs, and overall cost of the system. However, using modular skid systems according to one or more embodiments of the present disclosure may overcome such challenges, as well as, provide additional advantages over conventional fracturing systems.

In one or more embodiments, a modular skid system may include purpose built, same-sized modular skids that are connected together to form a multi-functional super structure for use in wellbore operations. As used herein, purpose built modular skids may include modular skids having known and/or new equipment that serves a certain purpose or performs a certain job. For example, a modular skid according to embodiments of the present disclosure may have a known type of isolation valve mounted thereto or may have a new type of isolation manifold mounted thereto, where at least one purpose of the purpose built modular skid is to selectively isolate flow or fluid through the modular skid. Other equipment types currently known and/or unknown in the art (e.g., as shown in some of the examples provided herein) may be utilized in modular skids according to embodiments of the present disclosure.

Modular skids according to embodiments of the present disclosure may have standardized uniform mounting footprints, whether same-type or different-type equipment is mounted to the modular skids. In other words, a modular skid system according to embodiments of the present disclosure may include modular skids having same and/or different equipment configurations held on each modular skid, where each modular skid in the modular skid system may have the same mounting footprint. As used herein, a mounting footprint may refer to the size (width and length) of a base of a modular skid. Thus, in one or more embodiments, modular skids having different equipment units may have the same mounting footprint whether or not the different equipment units have different heights and/or elements of the different equipment units have different dimensions that swing or extend outward of the modular skid mounting footprint. For example, a modular skid system according to embodiments of the present disclosure may have a first modular skid with one or more elements of the equipment (e.g., a valve actuator or a valve connection flange) at a height above the first modular skid base and extending a distance outside of the first modular skid base width/length dimensions, and a second modular skid with an equipment unit configuration different from the first modular skid equipment, where both the first and second modular skids may have the same mounting footprint (e.g., a base with substantially the same width/length dimensions).

As described above, each modular skid in a modular skid system according to some embodiments of the present disclosure may have the same mounting footprint. However, in some embodiments, such as described in more detail below, a modular skid system may include one or more modular skids having a mounting footprint with one or more irregularities compared with the mounting footprints of the remaining modular skids, such that the modular skids in the modular skid system have substantially the same mounting footprints (i.e., have the same general base dimensions not including the one or more irregularities). For example, in some embodiments, a modular skid system having modular skids with bases of the same general width and length and with connection points at axial ends of the base length may include a Tee-configuration modular skid having base with an additional connection point extending past the width of the majority of the base, while the remaining modular skids in the modular skid system may have bases without such irregularities in the base width formed by an additional connection point. In such embodiments, the Tee-configuration modular skid may be said to have the same mounting footprint as the remaining modular skids in the modular skid system.

The size of modular skids (including the size of modular skid mounting footprints, modular skid heights, equipment configurations arranged on the modular skids, etc.) may be selected based, for instance, on the size limitations of common transportation means, Department of Transportation (DOT) requirements (e.g., to meet weight and size limits of loads being transported on roads by trailers), the type of function each modular skid is to perform, and/or to provide reduced cost and reduced time to manufacture. For instance, the size of the mounting footprint of modular skids may be selected so that three modular skids may fit end to end on a flatbed trailer. In some embodiments, the overall size of modular skids (including the mounting footprints and the size of the equipment held on the modular skids) may be selected such that one or more modular skids may be mounted to a flatbed trailer and also meet DOT regulations for transporting the loaded flatbed trailer.

For example, according to embodiments of the present disclosure, a modular skid may have a mounting footprint having a length ranging from, e.g., a lower limit selected from 7 ft, 10 ft or 14 ft to an upper limit selected from 14 ft or 28 ft, and a width ranging from, e.g., a lower limit selected from 4 ft, 6 ft or 8 ft to an upper limit selected from 6 ft, 8 ft, 10 ft, or 12 ft, where any lower limit may be used in combination with any upper limit. For example, in some embodiments, a modular skid may have a mounting footprint of about 8.5 ft wide and about 11.5 ft long. However, the dimensions of the mounting footprint of a modular skid may vary within the above-mentioned ranges or may be outside of the above-mentioned ranges, depending, for example, on the job the modular skid is designed to perform, DOT regulations, and/or other factors. For example, in some embodiments, the length of the mounting footprint for a modular skid may be designed to correspond with pump spacing when the modular skid is to be used in a pumping operation.

Further, in some embodiments, a modular skid may have a height ranging from, e.g., a lower limit selected from 2 ft, 4 ft or 6 ft to an upper limit selected from 10 ft, 14 ft, or 18 ft, where any lower limit may be used in combination with any upper limit. However, the height of a modular skid may be outside the above-mentioned ranges, depending, for example, on the job the modular skid is designed to perform, DOT regulations, and/or other factors. For example, in some embodiments, modular skids may be designed to have the same or different heights (depending on the types of equipment units being held on each modular skid), where the height of each of the modular skids may be about 10.6 ft or less. In instances where modular skids are being transported on a trailer (and DOT height regulations apply), the height of modular skids may be designed to be no greater than the regulation height minus the height of the trailer on which the modular skids are mounted to.

When modular skids according to embodiments of the present disclosure are connected together to form a modular skid system, equipment units held in different modular skid types may also be connected together to form a primary manifold having a continuous flow path formed therethrough with limited connection. Thus, modular skids according to embodiments of the present disclosure may include substantially uniform mounting footprints in addition to equipment configured to align and/or connect with equipment in adjacently mounted modular skids.

FIG. 2illustrates a modular skid system200according to embodiments of the present disclosure made of a plurality of connected-together modular skids. The modular skid system200may be connected at one end to one or more pumps, and may be connected at another end to at least one wellhead201. The modular skid system200couples with the at least one wellhead201by using at least one time and efficiency (TE) manifold skid or zipper manifold modular skid202. A zipper manifold modular skid202refers to a modular skid that is purpose built for connection to a wellhead, which may include an outlet head (which may be referred to as a fracturing head or goat head in fracturing operations) for connection to the wellhead and one or more gate valves. The zipper manifold equipment may be arranged to fit on a modular skid having a selected mounting footprint, where the base of the zipper manifold skid202may have a mounting footprint with a selected width and length.

Typically, spacing of the wellheads201may range from 6 feet to 10 feet, and thus, the at least one zipper manifold modular skid202may be designed to align with known spacing of the wellheads201. For example, the zipper manifold modular skids202may be designed to have a mounting footprint with a selected length that corresponds with an interval between wellheads201, and/or spacer modular skids207may be provided between the zipper manifold modular skids202to provide closer alignment of the spacing between the zipper manifold modular skids202with the spacing between the wellheads201. As used herein, spacer modular skids refer to modular skids that are purpose built to provide spacing between adjacent modular skids, which may include equipment to connect between the equipment in the adjacent modular skids. One skilled in the art will appreciate how piping may be used to couple the wellheads201to the at least one zipper manifold modular skid202(e.g., if the spacing between the outlet heads on the zipper manifold modular skids do not align with the wellhead spacing and/or if there is irregular wellhead spacing). One skilled in the art will appreciate how the modular skid system200is not limited to a set number of wellheads201. For example, additional zipper manifold skids202may be added to the modular skid system200to connect to additional wellheads201.

In one or more embodiments, the modular skid system200may include at least one pump modular skid203. The pump modular skid203may be used in the oil and gas production industry to perform servicing operations on a well by connecting a system manifold to a pump. For example, in a well fracturing operation the pump modular skid203may be used to inject a slurry into the wellbore in order to fracture the hydrocarbon bearing formation and thereby produce channels through which the oil or gas may flow by providing a fluid connection between the pump discharge of a pump and a primary manifold system. In this operation, the pump modular skid203may connect a number of high pressure pumping units (not shown) to the wellheads201. A pump modular skid may include pump connection equipment, such as an articulating fracturing arm (AFA) equipment unit. The pump connection equipment (e.g., AFA manifold equipment) may be arranged to fit on a modular skid having a selected mounting footprint, where the base of the pump modular skid203may have a mounting footprint with a selected width and length.

In some embodiments, a modular skid system may be formed without a pump modular skid. For example, in some embodiments, a modular skid system may be connected to one or more pumps using standard manifold rig-up, for example, using conventional piping (e.g., 3-inch iron piping) extending from a modular skid in the modular skid system to a pump.

In one or more embodiments, the modular skid system200may include at least one auxiliary modular skid204. The auxiliary modular skid204may provide a universal power and control unit, including a power unit and a primary controller, of the modular skid system200. Furthermore, the universal power and control unit within the auxiliary modular skid204may contain programmable logic controllers (PLC), sensors, and solar panel controllers. In one or more embodiments, a programmable logic controller monitors at least one sensor and makes decisions based upon a program to control the state of at least one controllable element. Additionally, the auxiliary modular skid204may include one or more electronically controlled pressure relief valves (ePRV) which may be electrically powered and require no gas bottles or hoses. For example, an auxiliary modular skid may include a universal power and control unit and two ePRVs. The ePRV may pop open in the event power is lost, unless a battery backup is employed. The power manifold equipment may be arranged to fit on a modular skid frame having a selected mounting footprint, such that the base of the auxiliary modular skid204may have a mounting footprint with a selected width and length.

In one or more embodiments, the modular skid system200may include at least one pop-off/bleed-off tank modular skid205. The pop-off/bleed-off tank modular skid205may be used in the oil and gas production industry to perform servicing operations on a well. For example, in a well fracturing operation the pop-off/bleed-off tank modular skid205may allow discharge pressure from bleed off/pop off operations to be immediately relieved and controlled. At the conclusion of high-pressure tests or treatments, the pressure within the associated systems must be bled off safely to enable subsequent phases of the operation to continue. The bleed off process must be conducted with a high degree of control to avoid the effect of sudden depressurization, which may create shock forces and fluid-disposal hazards. Thus, the pop-off/bleed-off tank modular skid205may equalize or relieve pressure from a vessel or system by collecting fluid bled-off from the system. The pop-off/bleed-off tank equipment may be arranged to fit on a modular skid frame having a selected mounting footprint, where the base of the pop-off/bleed-off tank modular skid205may have a mounting footprint with a selected width and length substantially equal to the dimensions of the mounting footprints of the remaining modular skids in the modular skid system.

In one or more embodiments, the modular skid system200may include at least one isolation modular skid206. The isolation modular skid206may be used in the oil and gas production industry to perform servicing operations on a well. For example, in a well fracturing operation an isolation modular skid may be used to allow pump-side equipment and well-side equipment to be isolated from each other. Additionally, the isolation modular skid206may be capable of being simultaneously attached to multiple external holding vessels (e.g., pop-off/bleed-off tanks) and directing wellbore fluid bled-off from the well-side equipment or from the pump-side equipment to any of the external holding vessels. In some embodiments, the isolation modular skid206may be connected to only one external holding vessel and may be capable of directing fluid from either the well-side equipment or from the pump-side equipment to the same external holding vessel. Thus, the well isolation unit may provide more options for bleeding off well-side and pump-side equipment than traditional well isolation equipment. In the embodiment shown, the isolation modular skid206may include a bleed-off manifold fluidly connected to the pop-off/bleed-off tanks held in the pop-off/bleed-off tank modular skid205, such that fluid bled off from the isolation equipment may be collected in the pop-off/bleed-off tanks.

Further, the isolation modular skid206may allow piping components with larger inner diameters than the piping components used in traditional wellbore operation systems to be used to perform wellbore operations by configuring the isolation equipment to have a primary manifold connection (e.g., one or more primary flow paths extending between a single primary manifold inlet and a single primary manifold outlet) with multiple isolation valves disposed along the primary manifold connection. The well isolation unit disclosed herein may include automated valves. Further, the isolation equipment may be arranged to fit on a modular skid frame having a selected mounting footprint, such that the base of the isolation modular skid206may have a mounting footprint with a selected width and length substantially equal to the dimensions of the mounting footprints of the remaining modular skids in the modular skid system. The modular skids202,203,204,205,206,207may align together to form an interconnected super structure. One skilled in the art will appreciate how the modular skid system200is not limited to a set number of modular skids but may have any number modular skids needed to perform a required job parameter.

In one or more embodiments, the modular skids202,203,204,205,206,207include primary manifold connections210that extend a length of the each of the modular skids202,203,204,205,206,207, such that when the primary manifold connections are connected together, a continuous primary flow path may be formed through the connected-together modular skids202,203,204,205,206,207.

The term primary may be used herein to describe lines, manifold connections, and other flow paths that, when connected together, are used to transport fluid between a pump and a well. For example, as used herein, a primary manifold connection refers to a piping or body having one or more primary flow paths formed therethrough which may carry fluid between a pump and a well. In addition to a primary manifold connection, modular skids of the present disclosure may also include one or more secondary lines, manifold connections, and/or other flow paths for use in secondary functions of the system (i.e., functions other than transporting fluid between a pump and a well). For example, modular skids of the present disclosure may include one or more secondary subsystems, such as a priming subsystem, a bleed-off subsystem, chemical injection, and/or others, where a secondary subsystem may be formed of one or more connected-together secondary flow paths.

As an example, the modular skid system200shown inFIG. 2may include connected-together primary manifold connections210extending through the entire modular skid system200, where when the modular skid system200is connected to the pumps and wellheads201, the connected-together manifold connections210provide a continuous primary flow path from the pumps to the wellheads201. The modular skid system200may further include at least one secondary subsystem, including a bleed-off manifold, which may be provided, for example, on the isolation modular skid206. The bleed-off manifold may be formed of one or more secondary flow paths having one or more valves disposed thereon and one or more secondary outlets. The secondary outlets to the bleed-off manifold may be connected to secondary inlets on the pop-off/bleed-off tanks held in the pop-off/bleed-off tank modular skid205, such that the bleed-off manifold in the isolation modular skid206may be fluidly connected to the pop-off/bleed-off tanks in the pop-off/bleed-off tank modular skid205.

According to embodiments of the present disclosure, primary manifold connections may have a single primary inlet and a single primary outlet with one or more primary flow paths extending therebetween. For example, a modular skid may have a primary manifold connection with single primary inlet at a first axial end of the primary manifold connection and a single primary outlet at an opposite axial end of the primary manifold connection, where a single primary flow path may extend therebetween (e.g., where the primary inlet, primary outlet and primary flow path may have substantially the same inner diameter), or where multiple primary flow paths may extend between the primary inlet and primary outlet (e.g., in parallel). In some embodiments, a primary manifold connection may have more than one primary inlet and/or more than one primary outlet. For example, a primary manifold connection may have a T-configuration including two primary outlets provided at opposite axial ends of the primary manifold connection, a primary flow path extending between the two primary outlets, and a primary inlet provided in a tie-in valve disposed along the primary flow path.

A primary manifold connection having a T-configuration may be provided on a modular skid in a modular skid system to provide the modular skid system with one or more perpendicular bends in the modular skid system configuration. For example,FIG. 2shows the modular skids202,203,204,205,206,207of the modular skid system200in a T-configuration (having two perpendicular turns). In some embodiments, a modular skid system may have a linear configuration, where modular skids of the modular skid system may each include primary manifold connections having primary inlets and primary outlets at opposite ends of the primary manifold connections, such that the primary manifold connections are connected together in a straight/linear configuration. One skilled in the art will appreciate how a modular skid system is not limited to a set configuration and may be adapted to any configuration based on the job requirements.

Primary manifold connections210may be mounted on an A-frame208of the modular skids. The A-frame208has a base with frame beams extending upward from the base. Additionally, the frame beams are angled inward and are connected with a top beam to create an A shape. The top beam extends from one side of the A-frame208to another end of the A-frame208. It is further envisioned that a frame (support structure) of a modular skid may be any shape suitable to encompass the required equipment and is not limited to being the A-frame shape as shown inFIG. 2. In some embodiments, a modular skid system may include modular skids having differently shaped and/or sized frames, while still maintaining substantially the same mounting footprint. For example, a first modular skid in a modular skid system may include a frame with a selected mounting footprint and a first height, and a second modular skid in the modular system may include a frame with the same selected mounting footprint as the first modular skid but with a second height different from the first height. Furthermore, one skilled in the art will appreciate how the frames of a modular skid may be formed from a base material such as metal, composite, plastic, or any material know in the art to be a suitable frame. Additionally, the frame of a modular skid may be coated with any material know the art to protect the base material.

The primary manifold connection210and same-sized mounting footprints of the modular skid frame208may allow for the number and order of the modular skids202,203,204,205,206,207to be easily changed depending on hydraulic fracturing pad design considerations or well conditions. Additionally, the primary manifold connection210simplifies the number of connections needed system wide, as the primary manifold connection210allows the modular skids202,203,204,205,206,207to be in fluid communication with a limited number of connections.

Further seen byFIG. 2, the modular skids202,203,204,205,206,207of the modular skid system200are mounted onto at least one trailer chassis209prior to deployment to the field. The modular skids202,203,204,205,206,207may use ISO connection blocks and twist locks (not shown) to mount the modular skids to the at least one trailer chassis209. In other embodiments, different connection types may be used to connect a modular skid to a chassis or other platform. In some embodiments, the weight of the modular skid and connections to adjacent modular skids (e.g., manifold connections and/or frame connections) may be used to hold the modular skid on a trailer.

Multiples trailer chassis209may be used depending on the number of modular skids being used. When using multiple trailer chassis209, the trailer chassis209may be aligned and joined using similar technology to removable gooseneck trailers. In mounting the modular skids202,203,204,205,206,207to the at least one trailer chassis209, a field rig-up time may be significantly reduced. As stated above, the at least one trailer chassis209may allow for different configurations per job requirements. Additionally, in using the same-sized A-frame208, the modular skids202,203,204,205,206,207may have identical mounting footprints, regardless of function. However, it is further envisioned that the modular skids202,203,204,205,206,207may be transported to the field and placed on a ground or other platform structure instead of using the at least one trailer chassis209.

Now referring toFIG. 3, in one or more embodiments,FIG. 3illustrates a closer look at an example of a plurality of same-size, purpose built modular skids301that are connected together to form a unitary skid structure or super structure300. In the super structure300, the modular skids301are pulled together and aligned. When the modular skids301are aligned, elements on the modular skids301may also be aligned, including ends of a primary manifold connection302. In other words, connecting elements on adjacent modular skids may be positioned in the modular skids, such that the connecting elements (e.g., the primary manifold connection302ends) may be aligned and connected upon alignment and connection of the adjacent modular skids on which the connecting elements are disposed, thereby making the axial alignment of the connecting elements easier. By simplifying alignment and connection of connecting elements such as the ends of the primary manifold connections302on adjacent modular skids301, the formation of super structure300may also be simplified. Further, a primary, high-pressure manifold through the modular skid system may be made up of big bore pipe segments by connecting primary manifold connections302having a reduced number of connections (e.g., a single primary inlet and a single primary outlet).

Rotationally independent connectors303may be used in conjunction with a manifold alignment system so that a rotational alignment of the primary manifold connection302may be ignored. For example, once ends of primary manifold connections302are aligned and pulled toward each other (e.g., either until the ends contact each other or to a distance apart to allow positioning of a rotationally independent connector therebetween), a rotationally independent connector303may be positioned to connect ends of the primary manifold connections302together to create a high-pressure seal. For example, in some embodiments, ends of primary manifold connections302in adjacent modular skids301may be axially aligned and pulled together until they contact each other. A rotationally independent connector303may then be positioned around the contacting primary manifold connection ends and tightened around the contacting ends to connect the ends together. In another example, ends of primary manifold connections302in adjacent modular skids301may be axially aligned and pulled to a distance apart to allow positioning of a rotationally independent connector303therebetween. The ends of the primary manifold connections302may then be moved to an interior of the connector303, and the connector303may be tightened around the ends to connect the primary manifold connections302.

In one or more embodiments, one or more alignment systems may be used to facilitate an automated alignment process, or at least a simplified alignment process in which one or more of the axial alignments may be more easily performed.

Modular skids may be aligned and connected together to form a super structure using a manifold alignment system according to embodiments of the present disclosure. For example, referring toFIGS. 4A-4B, a manifold alignment system400may be used to properly align modular skids401,402together. As can be seen byFIGS. 4A-4B, a first modular skid401and a second modular skid402each have a primary manifold connection403,404. Furthermore, the first modular skid401and the second modular skid402each have a support structure or frame405,406which surrounds the primary manifold connection403,404. The manifold alignment system400may include elements disposed on the frame405,406to align the first modular skid401and the second modular skid402. The elements of the manifold alignment system400may include a plurality of male cones407on a frame beam415of the frame405on the first modular skid401, a plurality of female cones408on a frame beam416of the frame406on the second modular skid402, and a removably mounted hydraulics409on an end of the frames405,406. The male cones407act as a guide to properly align the first modular skid401with the second modular skid402, and as such, the male cones407insert into to the female cones408in a direction of arrow410. As seen byFIG. 4C,FIG. 4Cshows a cross-section of the male cone407when inserted in the female cone408. Additionally, a fastener417, such as a bolt, is threaded into an end of the male cone407and further secures and pulls the male cone407flush with the female cones408. Referring back toFIGS. 4A-4B, the temporarily mounted hydraulics409is configured to draw the frames405,406together. One skilled in the art will appreciate how the removably mounted hydraulics409may be added to the frames405,406at any time to aid in pulling the first modular skid401and the second modular skid402together or apart. Once drawn together, the ends of the primary manifold connections403,404will contact one another in axial alignment such that they can be secured together and pressure tested. The manifold alignment system400may increase a speed at which the modular skids can be deployed and pressure tested in the field.

FIGS. 4A-Cshow an example of an alignment system according to embodiments of the present disclosure. However, other alignment systems may be used to align and/or connect modular skids according to embodiments of the present disclosure. For example, alignment systems according to embodiments to the present disclosure may include more or less elements than the example alignment system shown inFIGS. 4A-C(e.g., more or less pairs of mating cones, or no hydraulics are mounted to the modular skids). In some embodiments, different elements may be used to align modular skids, such as one or more pairs of mating sloped surfaces formed in or attached to the frames of the modular skids. In some embodiments, rather than using removable mounted hydraulics to pull modular skids together or apart, hydraulic mechanisms may be used to push modular skids together or modular skids may be manually pushed together and/or manually pulled apart.

In one or more embodiments, one or more rotationally independent connectors411, e.g., clamps, greyloc hubs, KL4 connectors, may be used to avoid the need to rotationally align a flanged connection between the primary manifold connections403,404, where rather than rotationally aligning connection points on primary manifold connections to connect them together, the primary manifold connections403,404may be axially aligned and held together by positioning the rotationally independent connector411around the ends of the axially aligned primary manifold connections403,404. In some embodiments, the rotationally independent connectors411may be attached to the end of one of the pipe segments to reduce the amount of work necessary to make up the connection.

Referring now toFIGS. 5A-5B, in one or more embodiments,FIGS. 5A-5Billustrates the rotationally independent connector411that facilitates an alignment of primary manifold connections (e.g.,403,404inFIGS. 4A-4B) alone or in conjunction with a plurality of male cones (e.g.,407inFIGS. 4A-4B), a plurality of female cones (e.g.,408FIGS. 4A-4B), and temporarily mounted hydraulics (e.g.,409inFIGS. 4A-4B).FIG. 5Ashows the rotationally independent connector411in an open position to allow primary manifold connections to be inserted. As seen byFIG. 5B, the rotationally independent connector411is in a closed position to align and connect the primary manifold connection. Additionally, in the closed position, rotationally independent connector411may aid in providing a proper seal between the primary manifold connections.

According to some embodiments, the rotationally independent connector411may be connected to a modular skid frame by a mounting bracket414on a side of the rotationally independent connector411. For example, the rotationally independent connector411may be mounted on the frame406of the second modular skid402or may be mounted on the frame405of the first modular skid401shown inFIGS. 4A-B. It is further envisioned, that one of the ends of the rotationally independent connector411may be tapered, and the opposite end may have an inner surface that accepts the taper so that the ends may more easily align. In some embodiments, the rotationally independent connector411may be torqued closed or opened by a single bolt413. For example, the rotationally independent connector411, such as a KL4 connector, advantageously only has one point of actuation and thus may use a single bolt (e.g., bolt413) for connection. As such, the rig up time may be significantly reduced by having one point of actuation rather than making multiple flange bolting connections, or even 4 bolts on the grayloc clamp. Additionally, the rotationally independent connector411may include a locking feature (not shown) on the single bolt413. The locking feature ensures the single bolt413will not back out or open the rotationally independent connector411.

Other types and configurations of rotationally independent connectors may be used to clamp together axially aligned manifold connections. For example, rotationally independent connectors may include different configurations of hinged arms shaped to fit around (partially or entirely) ends of manifold connections. One or more attachment mechanisms may be used to attach the hinged arms of a rotationally independent connector together around the ends of manifold connections. In some embodiments, rotationally independent connectors may include two independent arms, which may be attached together around ends of manifold connections at opposite ends of the arms. Arms (hinged or unhinged) of a rotationally independent connector may be shaped to correspond with an outer profile of ends of manifold connections. For example, arms of a rotationally independent connector may have a curved interior profile that may correspond with a curved outer profile of a manifold connection.

Further, rotationally independent connectors may be used to connect ends of primary manifold connections and/or secondary manifold connections during alignment and/or attachment of skids.

In one more embodiments, other alignment elements may be used that are known in the art. For instance, height adjustable or leveling mechanisms can be incorporated into the structure of a modular skid (e.g., on the frames405,406shown inFIGS. 4A-B) or provided under a modular skid. In some embodiments, a plurality of swivel mechanisms may be incorporated into primary manifold connections (e.g., connections403,404) to facilitate the makeup of flanged connections. In some embodiments, alignment and pulling elements may be incorporated into the ends of primary manifold connections.

One example element of incorporated alignment and pulling elements is a “soft landing/hard landing” assembly, which may be used for landing assemblies in subsea applications. In a soft landing/hard landing assembly, a shoulder and a latching mechanism may be positioned on the ends of connections. The shoulder on an end of a first connection may act as a contact surface for the end of a second connection. When the shoulder contacts the end of the second connection, a latching mechanism may catch with the end of the first connection, pull the first and second connections together, and complete the connection.

As described above, the soft landing/hard landing feature has been previously designed for subsea applications to prevent damage to the sealing surfaces/seals during installation. For example, when stabbing a subsea tree onto a wellhead, due to the waves/swells at sea, the subsea tree may damage or slam down onto the wellhead during installation. In such the case, seals may be damaged if the subsea tree is landed on the wellhead too hard and the stabbing process may have to be repeated. However, the hard landing/soft landing feature is designed with a surface/stop that allows the subsea tree to be slammed down onto the wellhead. The surface/stop ensures the subsea tree being slammed will not contact and/or damage the seals/sealing surfaces of either the subsea tree or the wellhead. Once the subsea tree is resting on the wellhead (e.g., from an initial hard landing or soft landing), the soft landing/hard landing feature is engaged and gently pulls the connections of the subsea tree and the wellhead together (typically either mechanically or hydraulically). Additionally, the soft landing/hard landing feature may simultaneously engage the seals safely and without damaging anything.

Trailer chassis according to embodiments of the present disclosure may utilize a soft landing/hard landing assembly between connections on the ends of the trailer chassis. For example, as described inFIGS. 6A-6C, trailer chassis according to embodiments of the present disclosure may have a soft landing/hard landing assembly formed at the connection ends of the trailer chassis. The trailer chassis be transported to a rig by being driven. As such, big rig drivers may be contracted to transport the trailer chassis. However, the level of skill of the big rig drivers may be inconsistent, and thus, relying on the big rig drivers to gently back a first trailer chassis into a second trailer chassis may be problematic. If big rig drivers back up too fast and slam the trailer chassis together, damages may occur to the seals and/or sealing surfaces on connection ends of the trailer chassis and/or the modular skids. Therefore, a soft landing/hard landing may be adapted on connection ends of either the trailer chassis and/or the modular skids, which may allow the big rig driver to slam into a mating trailer (on purpose or accident), without actually making initial contact with the seals and/or sealing surfaces. Once landed, a latching feature/hydraulic pull system may gently pull the trailer chassis and/or the modular skids together safely and gently engage the main seals.

In some embodiments, the latching feature/hydraulic pull system may have a plurality of hydraulic rams sticking out of a connection end (e.g., back) of the trailer chassis. The big rig driver may then back a trailer chassis into the plurality of hydraulic rams. Once the trailer chassis makes contact, the plurality of hydraulic rams may automatically lock into the mating trailer, and then hydraulically pull the trailer chassis into position to engage the seals and secure the connection.

As seen byFIGS. 6A-6C, in one more embodiments, perspective views of a trailer chassis600is shown. The trailer chassis600has a top surface601adapted to be a carrier for modular skids, such as described herein. Furthermore, the top surface601may be configured to lock the modular skids in place with a plurality of ISO retractable twist locks602or any known locking device known in the art.FIG. 6Aillustrates the trailer chassis600utilizing a removable gooseneck603as known in the art. The removable gooseneck603may allow the trailer chassis600to be easily coupled to a motor vehicle (not shown) and removed if the trailer chassis600needs to be connected to a second trailer chassis604(shown inFIGS. 6B-6C).

Further, seen byFIGS. 6B-6C, a plurality of male connections606on the trailer chassis600may be inserted into a plurality of female connections605on the second trailer chassis604to aid in proper alignment of the two trailers600,604. Furthermore, a plurality of trailer twist locks607on the trailer chassis600may engage and lock a plurality of ISO connection blocks608on the second trailer chassis604, thereby, locking the two trailers600,604together. It is further envisioned that the two trailers600,604may be coupled together by a means of any mechanical fastener and not limited to the plurality of trailer twist locks607and the plurality of ISO connection blocks608shown inFIGS. 6A-6C. Additionally, hydraulics may be used in conjunction or alone of the mechanical fastener. Furthermore, connection technologies such as a soft/hard landing assembly may be used to couple the two trailers600,604. In some embodiments, the two trailers600,604may be welded together or use adhesives.

According to embodiments of the present disclosure, the modular skid system may include a plurality of trailer chassis (such as describedFIGS. 6A-6C) adapted to be a carrier for modular skids. Furthermore, the primary flow line of the modular skid system may be connected-together by physically attaching the plurality of trailer chassis together in the field. For example, a first modular skid may be mounted on a first trailer and a second modular skid may be mounted on a second trailer. The first modular skid may be connected to the second modular skid without removing the first modular skid from the first trailer or the second modular skid from the second trailer. Additionally, the connecting of the first modular skid to the second modular skid may include connecting the first trailer to the second trailer. For example, the first modular skid may be positioned at a first connection end of the first trailer and the second modular skid may be positioned at a second connection end of the second trailer, such that when the first and second connection ends of the first and second trailers contact, the connection ends of the first and second modular skids also contact. It is further envisioned that the first modular skid from the first trailer may be connected to the second modular skid from the second trailer by using piping (i.e., ground iron) and with or without connecting the first trailer to second trailer.