Patent ID: 12203354

Corresponding reference characters indicate corresponding components throughout the several views of the drawings. Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of various embodiments of the present disclosure. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present disclosure.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one having ordinary skill in the art that the specific detail need not be employed to practice the present invention. In other instances, well-known materials or methods have not been described in detail in order to avoid obscuring the present invention.

FIG.1depicts an automated zipper manifold100, according to an embodiment. Automated zipper manifold100may include modules, wherein each module includes a mixing chamber110and a plurality of lines120.

The modules may be arranged with mixing chamber110positioned in series to form an elongated buffer chamber extending from a first end112of mixing chambers110to a second end114of mixing chambers110. First end112and/or second end114may be configured to receive a fluid flow from a frac missile. Mixing chambers110may have a plurality of outlets116positioned on a first sidewall of mixing chambers110. The second sidewall of mixing chambers110may be a continuous sidewall extending from first end112to second end114, wherein the second sidewall may not include outlets. Each of the outlets116may be coupled to an independent line120.

Line120may be configured to control the flow of fluid from mixing chambers110to a well. A proximal end122of line120may be fluidly coupled to mixing chamber110, and a distal end124of line120may be fluidly coupled to a well. In embodiments, each different line120may be coupled to a different well. In between proximal end122and distal end124of each line may be a first valve130and a second valve132positioned in series.

FIG.2depicts automated zipper manifold100, according to an embodiment. Elements depicted inFIG.2may be described above, and for the sake of brevity a further description of these elements may be omitted.

Line120may include a first valve210, second valve220, first pressure transducer230, and second pressure transducer240.

First valve210and second valve220may be devices for controlling the passage of fluid through line120. First valve210and second valve220may be configured to open and close a barrier to control the fluid flowing through line120. First valve210and second valve220may be positioned in series, wherein first valve210is positioned closer to an outlet116of mixing chamber110, and second valve220is positioned more proximate to well200than first valve210. In embodiments, fluid may flow through second valve220only when first valve210is opened, and fluid may flow from mixing chamber110to well200only when both first valve210and second valve220are open.

First valve210may be configured to be locally opened and closed by an operator performing actions of first valve210to open and close the valve. For example, the operator may turn a wheel or pull a lever in a first direction to open first valve210, and the operator may turn the wheel or push the lever in a second direction to close the valve. First valve210may also be opened and closed remotely. First valve210may include a first indicator212. First indicator212may be configured to determine if first valve210is opened or closed. In embodiments, first indicator212may indicate if first valve210is open or closed or in an intermittent position between open and closed.

Second valve220may be configured to be remotely opened and closed by an operator performing actions on a graphical user interface of an operator computing device to open and close the valve. In embodiments, second valve220may include a localized power unit positioned on second valve220, wherein the local power unit is configured to control a hydraulic actuator to open and close the valve. By positioning a localized power unit on each second valve220within a system100, each second valve may have its own power source, which may limit the need to run hydraulic hoses to and from an external hydraulic power unit located away from system100. In further embodiments, both the first valve210and second valve220may have their own localized power source, which may further limit the need to run hydraulic hoses to and from an external hydraulic power unit, while also allowing both valves to be remotely opened and closed. Although first valve210and second valve220may utilize a localized power unit to remotely open and close the valves, a hydraulic power unit or other external power source may be used to open and close the valves. Second valve220may include a second indicator222. Second indicator222may be configured to determine if second valve220is opened or closed. In embodiments, second indicator222may indicate if second valve220is open or closed or in an intermittent position between open and closed.

Accordingly, first valve210and second valve220may be operated independently through different mechanisms, and from different locations. In further embodiments, both first valve210and second valve220may be remotely opened and closed by a user performing actions on the graphical user interface. In further implementations, the opening and/or closing of first valve210and second valve220may be dependent on the opening and/or closing of first valve210and second valve220. For example, if first valve210is closed, then second valve220may simultaneously close as well. In further implementations, the opening of second valve220may not be dependent on the opening of first valve210, yet the closing of second valve220may still be dependent on the closing of first valve210.

First pressure transducer230may be positioned between first valve210and second valve220after a barrier associated with first valve210. First pressure transducer230may be directly embedded within the flow path and configured to determine a fluid flow data between first valve210and second valve230. This fluid flow data may assist in determining if first valve210and/or second valve220are opened. Specifically, based on the data received from first pressure transducer230it may be determined if first valve210is opened. In certain applications, it may be desired to determine the magnitude of fluid pressure between valves in a zipper manifold. First pressure transducer230may provide indication on the health of the first valve210and second valve220, such as the amount of fluid that may flow through the valves. In embodiments, first pressure transducer230may be configured to communicate data to an operator computing device, which may display data received from the first pressure transducer on a graphical user interface.

Second pressure transducer240may be configured to be positioned in a flow path after a barrier associated with second valve220. Second pressure transducer240may be configured to determine a pressure of the fluid flow downstream of second valve220. By determining the pressure on the downstream side between second valve220and well200, it can be determined if the valve is open, closed, or closed and leaking. Second pressure transducer240may be directly embedded within the flow path after second valve220, and be configured to communicate data to the operator computing device over a wired or wireless connection. In certain applications, it may be desired to determine the magnitude of fluid pressure between a second valve220and a well to compare the pressure differentials on pressure transducer240to pressure transducer230. Furthermore, pressure transducer240may determine if wireline is being pumped down on well200while at least second valve220is closed. In embodiments, the operator computing device may display data received from second pressure transducer240on a graphical user interface.

In implementations, valves may utilize a minimum amount of seating pressure, SPSI, to move a barrier associated with the valve from a neutral floating position over to the barriers sealing position. Fracturing pressure, FPSI, may also be higher than the seating pressure. When wireline operations commence on a well, the second valve may register pump-down pressure, PDPSI, which may be substantially higher than SPSI, but lower than FPSI.

FIG.3depicts one system topology for communicating data, according to an embodiment. Topology300may include a first module310, second module320, and operator computing device330. The elements depicted in topology300may be communicatively coupled to each other over network305.

Network305may be a wired or wireless network such as the Internet, an intranet, a LAN, a WAN, Bluetooth, infrared, a cellular network, or another type of network configured to communicate data. It will be understood that network305may be a combination of multiple different kinds of wired or wireless networks, which may operate according to different protocols.

First module310may be a hardware processing device that is configured to process instructions and connect to network305to transmit data associated with a first module, wherein the first module may include a mixing chamber and a plurality of lines. In embodiments, each of the plurality of lines associated with the first mixing chamber may include a first pressure transducer, a second pressure transducer, a first valve indicator, a second valve indicator, a first valve actuator, and a second valve actuator. The first pressure transducer may be configured to transmit data over network305associated with fluid flowing between a first valve on the line and a second valve on the line. The second pressure transducer may be configured to transmit data over network305associated with fluid flowing after a barrier of second valve to a well. The first valve indicator may be configured to transmit a data over network305indicating if the first valve is open or closed. The second valve indicator may be configured to transmit data over network305indicating if the second valve is open or closed. The first valve actuator may be configured to receive instructions over network305to open or close the first valve. The second valve actuator may be configured to receive instructions over network305to open of close the second valve.

Second module320may be a hardware processing device that is configured to process instructions and connect to network305to transmit data associated with a second module, wherein the second module may include a mixing chamber and a plurality of lines. In embodiments, each of the plurality of lines associated with the first mixing chamber may include a first pressure transducer, a second pressure transducer, a first valve indicator, a second valve indicator, a first valve actuator, and a second valve actuator. The first pressure transducer may be configured to transmit data over network305associated with fluid flowing between a first valve on the line and a second valve on the line. The second pressure transducer may be configured to transmit data over network305associated with fluid flowing after a barrier of second valve to a well. The first valve indicator may be configured to transmit data over network305indicating if the first valve is open or closed. The second valve indicator may be configured to transmit data over network305indicating if the second valve is open or closed. The first valve actuator may be configured to receive instructions over network305to open or close the first valve. The second valve actuator may be configured to receive instructions over network305to open of close the second valve.

Operator computing device330may be a laptop computer, desktop computer, smart phone, tablet computer, personal data assistant, or any other type of device with a hardware processor that is configured to receive data from first module310, second module320, process instructions and connect to network305, and transmit commands to first module310and second module320over network305. In embodiments, operator computing device330may be configured to remotely, automatically, and simultaneously control a plurality of valves positioned on lines on a plurality of modules. Responsive to receiving data from first module310and/or second module320, an operator may be able to quickly and efficiently determine what valves in a zipper manifold are open and/closed and pressure ratings and fluid flow rates across the valve. This central interface may enable risks to be reduced by limiting unexpected high pressure areas being formed due to inadvertently opened or closed valves, determine if valves are leaking, while also allowing valves to be remotely opened and closed. This may enable grease to be injected through desired valves in effort to temporarily enhanced sealing capability of leaking valves, and also perform maintenance of the valves. While in other instances other valves may be open to reduce the overall pressure within the zipper manifold or the system may be automatically shut down if conditions warrant. In some instances, it is useful to an operator to know the number of pressure cycles as well as the number of open and close cycles, time each valve was in an open or closed position that a valve or tubular has been subjected to.

Grease module340may also include a first grease line with a first grease pressure transducer, and a second grease line with a second grease pressure transducer. The first grease pressure transducer may be configured to determine pressure data on a first grease line, and transmit this data to operator computing device330, wherein the first grease line is configured to supply grease to the first valve. The second grease pressure transducer may be configured to determine pressure data on a second grease line, and transmit this data to the operator computing device330, wherein the second grease line is configured to supply grease to second valve.

FIG.4depicts an operator computing device330, according an embodiment. Elements depicted inFIG.4may be described above, and for the sake of brevity a further description of these elements is omitted. Operator computing device330may include a processing device405, communication device410, memory device415, graphical user interface420, first valve actuator module425, second valve actuator module430, first pressure transducer module435, and second pressure transducer module440.

Processing device405may include memory, e.g., read only memory (ROM) and random access memory (RAM), storing processor-executable instructions and one or more processors that execute the processor-executable instructions. In embodiments where processing device405includes two or more processors, the processors may operate in a parallel or distributed manner. Processing device405may execute an operating system of operator computing device330or software associated with other elements of operator computing device330.

Communication device410may be a device that allows operator computing device330to communicate with another device over network305. Communication device410may include one or more wireless transceivers for performing wireless communication and/or one or more communication ports for performing wired communication over the internet, WLAN, LAN, Bluetooth, PSTN, etc. Communication device410may be configured to communicate data over a plurality of different standard and/or protocols.

Memory device415may be a device that stores data generated or received by operator computing device330. Memory device415may include, but is not limited to a hard disc drive, an optical disc drive, cloud storage and/or a flash memory drive. In embodiments, memory device415may be configured to store information received from a first module310and/or second module320. The information stored within memory device415may be accessed by elements of operator computing device330. For example, memory device415may be configured to store data associated with manifold pressure cycles to provide stage counts for each well, store data associated with fluid flowing through wells since a last grease cycle, time frac'd on each stage, pumpdown time on each wireline, volume and frequency of grease, nonproductive time etc.

Graphical user interface420may be a hardware presentation device and user interface that is configured to present data to an operator and receive commands from the operator. The term “graphical user interface” may include, but is not limited to being, a touch screen, a physical keyboard, a mouse, a camera, a video camera, a microphone, and/or a speaker. Utilizing the graphical user interface420, the operator may perform commands to open and close a plurality of valves individually and/or simultaneously based on data presented.

First valve actuator module425may be a hardware processing device configured to receive commands from an operator to close or open first valves associated with at least one module. Responsive to an operator performing actions on the graphical user interface420to open or close a first valve, first valve actuator module425may transmit instructions to an actuator positioned at a first valve to open or close the valve. This may enable the operator to individually and simultaneously open and close a plurality of first valves on a plurality of different lines on a plurality of different modules receiving fluid from the same or different frac missiles. Further, first valve actuator module425may be configured to receive data associated with a valve position indicator determining if a first valve is open or closed.

Second valve actuator module430may be a hardware processing device configured to receive commands from an operator to close or open second valves associated with at least one module. Responsive to an operator performing actions on the graphical user interface420to open or close a second valve, second valve actuator module430may transmit instructions to an actuator positioned at a second valve to open or close the second valve. This may enable the operator to individually and simultaneously open and close a plurality of second valves on a plurality of different lines on a plurality of different modules receiving fluid from the same or different frac missiles. Further, second valve actuator module430may be configured to receive data associated with a valve position indicator determining if a second valve is open or closed.

First pressure transducer module435may be a hardware processing device configured to receive data from a first transducer positioned between a first valve and a second valve on a first line. For example, first pressure transducer module435may be configured to receive pressure per square inch data from the first transducer.

Second pressure transducer440may be a hardware processing device configured to receive data from a second transducer positioned after a second valve on the first line. For example, second pressure transducer module440may be configured to receive pressure per square inch data from the second transducer.

In implementations, operating computing device330may be configured to present on graphical user interface420or transmit notifications to external computing devices about statistics of a well or job, and the estimated time to completion. These statistics may be related with, number of stages per well, estimated pump time per stage, estimated wireline run time, estimated FPSI and estimated pump-down pressure, PDPSI, for wireline runs. Operating computing device330may be configured to record and present pressure increases on the various wells or the manifold pressure cycles to provide the stage count for each well. Operating computing device330may be configured to present the statistics on graphical user interface420, wherein the statistics include the stage count and where each well is in the fracking program providing a completion percentage for each well based on what stage out of the total number of stages per well a particular well is on.

Based on the operating data determined by operating computing device330, combined with the job inputs, operating computing device330may determine the estimated completion time of the total job under normal circumstances. The completion date is then updated based on improvements and/or delays in operations in real time. Operating computing device330may also be configured to provide a post-job analysis to allow an understanding of the efficiencies of the job or diagnose areas for improvement. Operating computing device330may also be configured to present total pump times and wireline run times for each well, as well as irregularities identified throughout the job. Such post job analysis provides insights by mapping non-productive time vs non-pumping time. Based upon the operating inputs provided by the operator operating computing device330is able to determine that a portion of the non-pumping time is non-productive time. For example, at a particular point the pumps are pre-programmed to shut off for 2 hours however the pumps are in fact off for 3.3 hours. Operating computing device330would indicate 3.3 hours of non-pumping time at the particular point in the pumping routine but would also indicate 1.3 hours of non-productive time, which is the time overage between 2 hours of planned maintenance and 3.3 hours of actual down time. Non-pumping time may be the measure of when no pumping or wireline operations are ongoing. Non-pumping time can be the result of normal downtime for equipment maintenance, well swap operations, or other activities such as safety meetings, crew changes, weather, etc. Operating computing device330is able to identify and flag abnormal non-pumping times to be correlated with other data recorded on site, usually as non-productive time.

FIG.5depicts a system500configured to automatically control a zipper manifold, according to an embodiment. Elements depicted inFIG.5may be described above, and for the sake of brevity these elements have been omitted.

As depicted inFIG.5, an operator computing device330may be configured to present a graphical user interface420. The graphical user interface420may be configured to present data to the operator associated with a first line510associated with a first well, and a second line520associated with a second well.

More specifically, graphical user interface420may be configured to present an indicator530indicated that a first valve210on a first line is open, an indicator540indicating that a second valve200on a first line is open, an indicator550indicating that a first valve on a second line is closed, and an indicator indicating560indicating that a second valve on the second line is not fully closed or opened. As such, graphical user interface420may be configured to depict real time data associated with a zipper manifold to an operator.

Furthermore, the operator may be configured to perform actions on graphical user interface420to remotely open and close the valves at the zipper manifold.

FIG.6depicts a system500configured to automatically control a zipper manifold, according to an embodiment. Elements depicted inFIG.6may be described above, and for the sake of brevity these elements have been omitted.

As depicted inFIG.6, graphical user interface may also be configured to display data610received from a first pressure transducer on a first line, data620received from a second pressure transducer on a second line, data630received from a first pressure transducer on a second line, and data640received from a second pressure transducer on a second line.

Based on the data received from the pressure transducer and indicators associated with valves, an operator may determine if a valve is leaking. For example, data630may indicate that over one thousand PSI is present between an indicator550for a closed first valve210and an indicator560for closed second valve220on a second line. Because both of these valves are closed, the pressure data associated with the line indicates that there is either FPSI or PDPSI getting passed the first valve and/or second valve, alluding to leaking valves and/or predictive indication there is a valve failure. This situation may provide the operator a notification that maintenance is required on the line. In certain situations, SPSI may fluctuate during pump operations, thus an acceptable psi fluctuation, SPSIΔ, is preferably set to cue an alarm or notification that a valve is potentially failing or needs maintenance. For example if SPSIΔ is set at 1,000 psi and the SPSI becomes equal to or greater than SPSIΔ the central interface will alert the user of the situation via the control screen.

On the other hand, data610and620may indicate that the FPSI flowing through the first line with valves opened with FPSI, which indicates the adjoining well is receiving a frack stage.

FIG.7depicts a system700configured to automatically control a zipper manifold, according to an embodiment. Elements depicted inFIG.7may be described above, and for the sake of brevity these elements have been omitted. Grease operations may be a maintenance task or remedy to prevent valve failures after sand, water and other elements have been pumped through the valves. In an embodiment, an operator will generally choose to apply grease to a valve or a plurality of valves at a predetermined frequency and/or other predetermined condition. Generally, the grease is supplied from a central pump moving through a line that branches to each valve. A solenoid or other actuator may be used in the line, preferably near the valve to open and close the grease line leading into a particular valve so that when grease is not being delivered to the valve, the grease lines and valve may be isolated from one another. This allows for a plurality of valves to be maintained with grease, or isolating the flow of grease to be delivered and injected to a single valve or set of valves.

As depicted inFIG.7, a line may include a first grease line710with a first grease pressure transducer, and a second grease line720with a second grease pressure transducer. The first grease pressure transducer may be configured to determine pressure data on a first grease line710, and transmit this data to an operator computing device, wherein the first grease line710is configured to supply grease to first valve210. Second grease pressure transducer may be configured to determine pressure data on a second grease line720, and transmit this data to the operator computing device, wherein the second grease line720is configured to supply grease to second valve220. The grease pressure transducers on grease lines710and720may provide verification that grease is being delivered to the injection points on first valve210and second valve220.

In implementations, the valves210,220may have a recommended grease pressure, GPSI, is set as a threshold in the operator computing system. For normal maintenance operations, the operator transmit instructions from an operator computing device to pump grease to predetermined valves at predetermined times. The operator computing device sends instructions to the grease pump to pump grease through grease line710and/or grease line720until the grease pressure transducers transmit a data to the operator computing device that the grease pressure transducers have surpassed GPSI. The operator computing device may then transmits instructions to the grease pump to stop pumping grease to first valve210and/or second valve220. Solenoid valves and/or other actuated devices may be used on grease lines710and720to stop flow of grease to first valve210and/or second valve220once GPSI is surpassed.

In embodiments, responsive to an operator reviewing a graphical user interface and determining that a first valve or second valve on a line is leaking, the operator may be configured to perform actions on the remote graphical user interface transmit instructions to a grease pump to supply grease to the leaking valve via first grease line710and second grease line720. The grease supplied to the valve may be configured to assist in removing debris from the valve, allowing the valve to seal and perform more reliably. In embodiments, the grease lines710,720may be configured to supply grease to the valves210,220. Grease lines710,720may supply grease when the valve open or valve close indicators indicate a corresponding valve210,220is open or closed, respectively, and the pressure transducer230,240indicates that the pressure is above a first threshold associated with first valve210or a second threshold associated with second valve220. The supplied grease may clear debris from a valve automatically based on the valve open or valve close indicators and the pressure measurements at different locations within the line, wherein the first threshold may be greater than, less than, or equal to the second threshold. The operator computing device may be set to automatically deliver grease to valves when certain criteria is met. For example, every time is opened, the grease pump is instructed to deliver grease. Furthermore, grease can automatically pump grease to valves after a frack stage is completed and before the valve is closed by using the valve position indicators and valve pressure transducers that communicate the valve in the open position and frack pressure, FPSI, bled down to a marginal pressure that can be settable thresholds to trigger greasing actions.

In embodiments, the grease lines may be coupled to a levelling sensor in a reservoir that stores the grease. The leveling sensor may be utilized to determine an amount of grease within the reservoir, and to determine that the grease is actually being pumped into a valve when desired.

FIG.8depicts a method800for automatically and remotely controlling a zipper manifold, according to an embodiment. The operations of method800presented below are intended to be illustrative. In some embodiments, method800may be accomplished with one or more additional operations not described, and/or without one or more of the operations discussed. Additionally, the order in which the operations of method800are illustrated inFIG.8and described below is not intended to be limiting. Furthermore, the operations of method800may be repeated for multiple modules and lines for a zipper manifold.

At operation810, an operator computing device may receive data from a first transducer and/or a second transducer. The data may indicate a PSI within a line after a barrier for a valve. This may enable the operator to determine operating characteristics of multiple lines at various place in real-time.

At operation820, an operator may close a first valve in a line based on the data received. The operator may close the first valve by turning a handwheel, moving a mechanical lever located at the zipper manifold, or operated remotely.

At operation830, the operator may perform actions on the operator computing device to transmit commands to a hydraulic actuator positioned at the second valve to remotely close the valve.

At operation840, the operator computing device may receive data from a first transducer and/or a second transducer. The data may indicate a PSI within a line after a barrier for a valve.

At operation850, the operator may review a graphical user interface to determine if the pressure data associated with the first transducer and/or second transducer align with what is expected from a line with one or both closed valves. If the pressure data indicates that the first valve or the second valve is leaking, grease may be injected into the first valve and/or the second valve to perform maintenance tasks on the valve. A leaking valve may be determined by comparing the valve's indication that it is closed with a pressure indicator giving an unexpectedly high reading on the side of the valve where the high-pressure reading was not expected. To remedy this issue and to try to seal a leaking valve, grease may be pumped into the valve. Additionally, grease may be pumped automatically into a valve upon a valve's pressure transducer reaching certain threshold indicating a valve beginning to fail or leak. For example, with a valve in the closed position, the valve's pressure transducer may indicate a pressure greater than the pre-set seating pressure SPSIΔ. The grease pump may then be triggered to pump grease into the leaking valve to mitigate or eliminate that potential failure or leak. The user may also manually trigger the grease pump when notified of the potential valve failure. For example, if a valve is experiencing a potential failure, which is identified by its associated pressure transducer registering a pressure greater than the pre-set SPSIΔ, then a pressure associated with grease GPSI may be greater than the PSI registered on the respective valve's pressure transducer. Similarly, the GPSI may be greater than SPSI, FPSI, and PDPSIwhen the grease pump is activated to grease a valve or series of valves while pumping operations and/or wireline operations are in process.

Reference throughout this specification to “one embodiment”, “an embodiment”, “one example” or “an example” means that a particular feature, structure or characteristic described in connection with the embodiment or example is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment”, “in an embodiment”, “one example” or “an example” in various places throughout this specification are not necessarily all referring to the same embodiment or example. Furthermore, the particular features, structures or characteristics may be combined in any suitable combinations and/or sub-combinations in one or more embodiments or examples. In addition, it is appreciated that the figures provided herewith are for explanation purposes to persons ordinarily skilled in the art and that the drawings are not necessarily drawn to scale.

Although the present technology has been described in detail for the purpose of illustration based on what is currently considered to be the most practical and preferred implementations, it is to be understood that such detail is solely for that purpose and that the technology is not limited to the disclosed implementations, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present technology contemplates that, to the extent possible, one or more features of any implementation can be combined with one or more features of any other implementation.