ASSEMBLIES, METHODS, CONTROLLER, AND KITS FOR HYDRAULIC FRACTURING MANIFOLDS TO PROVIDE OVERPRESSURE RELIEF AND BLEED USING CHOKE VALVES

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to, and the benefit of U.S. Provisional Application No. 63/687,916, filed Aug. 28, 2024, titled “ASSEMBLIES, METHODS, CONTROLLER, AND KITS FOR HYDRAULIC FRACTURING MANIFOLDS TO PROVIDE OVERPRESSURE RELIEF AND BLEED USING CHOKE VALVES,” the disclosure of which is incorporated herein by reference in its entirety.

BACKGROUND

During a hydraulic fracturing operation, a pressurized fracturing fluid is injected into a subterranean formation via a wellbore or multiple wellbores. The injected fracturing fluid is at a higher pressure than the fracture pressure of the subterranean formation such that the fluid creates fractures therein. The fractures increase a permeability of the subterranean formation so that formation fluids (such as oil, gas, water, etc.) may more easily escape the subterranean formation and flow to the surface via the wellbore(s). Proppant (such as sand or other solids) may be mixed with the fracturing fluid prior to injecting the fracturing fluid downhole. The proppant may flow into the fractures in the subterranean formation to hold the fractures open after the hydraulic fracturing operation has ended.

Various fluid conveyance devices and systems are positioned at the surface to route the fracturing fluids into and out of the wellbore(s) during the hydraulic fracturing operation. The fluid conveyance devices may include various combinations of pipes, valves, hoses, conduits, manifolds, tanks, pumps, etc. At least some of these devices transport the fracturing fluid after it has been pressurized into the wellbore(s). Moreover, these devices may be mechanically sensitive to overpressure exposure. Thus, while the fluid conveyance devices (or some of the fluid conveyance devices) are configured to withstand relatively high differential pressures during operations, overpressure events may exceed mechanical limitations and cause damage. Due to the severe and volatile pressure conditions of a hydraulic fracturing operation, industry leading overpressure relief devices have experienced a high rate of mechanical failure or exhibit a less than desirable pressure relief response time. Applicant has recognized that the implementation of overpressure protection using industry leading relief valves, bleed valves, and relief control systems, have not achieved a suitable overpressure protection and bleed system for a hydraulic fracturing operation resulting in costly repairs, possible injury, increased downtime, and lost revenue.

BRIEF SUMMARY

Applicant has recognized a need for more reliable overpressure and bleed protection of hydraulic fracturing manifold systems by implementing assemblies, methods, and kits, each including a controller, a choke relief valve, and a choke bleed valve for an increased overpressure response time and effective bleed, thereby reducing a risk of mechanical failures, such as erosional wear, plaguing the fracturing industry, which lead to reduced frequency of repairs, increased production times, decreased risk of personnel injury, and increased revenue. For ease of explanation, the below disclosure will focus on an embodiment of an assembly, system, controller, method, and kit used within a monobore fracturing system. However, the below disclosure may be equally applicable to fracturing systems that utilize a monomissile or conventional treating iron, or the like, as would be understood by one skilled in the art, for overpressure and bleed protection. Therefore, the disclosure of the assembly below is an embodiment that may be utilized in existing or new fracturing systems for overpressure and bleed protection. Embodiments of the disclosure, for example, include an monobore assembly to be positioned in a hydraulic fracturing manifold system to provide overpressure relief and bleed using choke valves. The monobore assembly includes a control module, a pressure relief choke valve, a pressure transducer, and a bleed choke valve. The control module has a controller configured to receive and monitor a pressure signal and upon determination the pressure is above a predetermined threshold, sends an output action to relieve the pressure in a throughbore of the monobore assembly. The pressure relief choke valve has a body configured to be mounted to a first monobore junction that includes a throughbore configured to flow a pressurized fluid therethrough when in operation. The body has an inlet configured to fluidly connect to the throughbore when installed, an outlet configured to be connected to an overpressure relief conduit, and a pressure sensing aperture extending from an inner surface to an outer surface of the body such that the pressure sensing aperture is configured to be exposed to the pressure within the throughbore of the first monobore junction when in operation. The pressure relief choke valve is configured to receive the output action from the control module to actuate the pressure relief choke valve from a closed position to a fully open position in less than 0.4 seconds, thereby to prevent damage from overpressure in the hydraulic fracturing manifold system when the monobore assembly is installed therein. The pressure transducer is mounted to the pressure relief choke valve body and configured to receive the pressure from the pressure sensing aperture and transmit the pressure signal to the control module during operation. The bleed choke valve has a body configured to be mounted to a second monobore junction different than the first monobore junction. The body has a choke bean positioned therein configured to reduce the pressure of the pressurized fluid, thereby to adjust a flowrate of the fluid during operation. The bleed choke valve is configured to receive the output action from the control module to actuate the bleed choke valve to controllably evacuate the pressure or the pressurized fluid within a throughbore of the second monobore junction.

The controller of the monobore assembly includes a dual controller such that the output action thrusts (a) a first hydraulic fluid to the pressure relief choke valve to actuate to the fully open position and (b) a second hydraulic fluid to the bleed choke valve to controllably evacuate the pressure or the pressurized fluid.

Furthermore, the pressure relief choke valve of the monobore assembly fully opens from the closed position in less than about 0.2 seconds of the determination the pressure is above the predetermined threshold.

In another embodiment of the disclosure, for example, includes an assembly to be positioned in a hydraulic fracturing manifold system to provide overpressure relief and bleed using a choke valve. The assembly includes a control module, a pressure relief choke valve, and a pressure transducer. The control module has a controller configured to receive and monitor a pressure signal and upon determination the pressure is above a predetermined threshold, sends an output action to relieve the pressure in a throughbore of the assembly. The pressure relief choke valve has a body configured to be mounted to a first junction that includes a throughbore configured to flow a pressurized fluid therethrough when in operation. The body has an inlet configured to fluidly connect to the throughbore when installed, an outlet configured to be connected to an overpressure relief conduit, and a pressure sensing aperture extending from an inner surface to an outer surface of the body such that the pressure sensing aperture is configured to be exposed to the pressure within the throughbore of the first monobore junction when in operation. The pressure relief choke valve is configured to receive the output action from the control module to actuate the pressure relief choke valve from a closed position to a fully open position in less than 0.2 seconds, thereby to prevent damage from overpressure in the hydraulic fracturing manifold system when the monobore assembly is installed therein. The pressure transducer is mounted to the pressure relief choke valve body and configured to receive the pressure from the pressure sensing aperture and transmit the pressure signal to the control module during operation.

In yet another embodiment of the disclosure, for example, includes a hydraulic fracturing system that has a monobore assembly to provide an overpressure relief and bleed of the hydraulic fracturing system, thereby to prevent damage to associated fracturing system equipment. The system includes a wellhead, one or more fracking pumps configured to provide pressurized fluids to the wellhead, a monobore missile having one or more monobore junctions, and a monobore assembly to provide an overpressure relief and a bleed of the pressurized fluid in the throughbore. The monobore missile and each of the one or more monobore junctions have a throughbore that provide a pathway for the pressurized fluid to flow to the wellhead. Each of the one or more monobore junctions are configured to receive the pressurized fluid from the one or more fracking pumps and direct the pressurized fluid to the pathway. The monobore assembly includes a control module, a pressure relief choke valve, a pressure transducer, and a bleed choke valve. The control module has a controller configured to receive and monitor a pressure signal and upon determination the pressure is above a predetermined threshold, sends an output action to relieve the pressure in the throughbore. The pressure relief choke valve has a body configured to be mounted to a first monobore junction when installed. The body has an inlet configured to fluidly connect to the throughbore when installed, an outlet configured to be connected to an overpressure relief conduit, and a pressure sensing aperture extending from an inner surface to an outer surface of the body such that the pressure sensing aperture is configured to be exposed to the pressure within the throughbore of the first monobore junction when in operation. The pressure relief choke valve is configured to receive the output action from the control module to actuate the pressure relief choke valve from a closed position to a fully open position in less than 0.4 seconds, thereby to prevent damage from overpressure in the hydraulic fracturing manifold system when the monobore assembly is installed therein. The pressure transducer is mounted to the pressure relief choke valve body and configured to receive the pressure from the pressure sensing aperture and transmit the pressure signal to the control module during operation. The bleed choke valve has a body configured to be mounted to a second monobore junction different than the first monobore junction. The body has a choke bean positioned therein configured to reduce the pressure of the pressurized fluid, thereby to adjust a flowrate of the fluid during operation. The bleed choke valve is configured to receive the output action from the control module to actuate the bleed choke valve to controllably evacuate the pressure or the pressurized fluid within the throughbore.

The controller of the system includes a dual controller such that the controller receives the pressure signal from the pressure transducer and initiates an action for the pressure relief choke valve and the bleed choke valve based on exceeding predetermined thresholds, lapsed time intervals, or a combination thereof.

Another embodiment disclosed herein is directed to a method to relieve and bleed a hydraulic fracturing system from overpressure using choke valves. The method includes sensing a pressure of a throughbore positioned in a monobore missile at an inlet port of a pressure relief choke valve in a closed position with a pressure transducer mounted to the pressure relief choke valve to produce a pressure signal. The monobore missile has one or more monobore junctions and the pressure relief choke valve is configured to mount to a first monobore junction. A bleed choke valve is configured to mount to a second monobore junction different than the first monobore junction and the pressure relief choke valve has an actuator configured to drive a gate to fully retract from a seat within a body of the pressure relief choke valve after a determination of an overpressure. The method further includes transmitting the pressure signal to a control module configured to receive and monitor the pressure signal and evaluating whether the pressure signal is above a predetermined threshold, thereby to indicate a pressure that causes damage to associated hydraulic fracturing system equipment to be relieved. If so, the method sends an output action to the pressure relief choke valve and the bleed choke valve, thereby to (a) actuate the pressure relief choke valve to fully open in less than 0.4 seconds, thereby to relieve the pressure in the throughbore to prevent overpressure damage and (b) adjust the bleed choke valve to partially open to controllably evacuate pressure or fluid from the throughbore.

The method defines the controlled evacuation of the pressure or the fluid by the bleed choke valve includes increasing an annulus size between a choke bean and a plug positioned on a distal end of a stem within the bleed choke valve. Further, the bleed choke valve is opened in about 0.1 percentage intervals of a total bleed choke valve stroke distance.

The method defines the adjusting of the pressure relief choke valve to fully open from the closed position is performed less than about 0.20 seconds of the evaluation the pressure is above a predetermined threshold.

In another embodiment of the disclosure, for example, includes a hydraulic fracturing system having an assembly to provide an overpressure relief of the hydraulic fracturing system, thereby to prevent damage to associated fracturing system equipment. The system includes a wellhead, one or more fracking pumps configured to provide pressurized fluids to the wellhead, a missile having one or more junctions, and an assembly to provide an overpressure relief of the pressurized fluid in the throughbore. The missile and each of the one or more junctions have a throughbore that provides a pathway for the pressurized fluid to flow to the wellhead. Each of the one or more junctions are configured to receive the pressurized fluid from the one or more fracking pumps and direct the pressurized fluid to the pathway. Further, the assembly includes a control module, a pressure relief choke valve, and a pressure transducer. The control module has a controller configured to receive and monitor a pressure signal and upon determination the pressure is above a predetermined threshold, send an output action to relieve the pressure in the throughbore. The pressure relief choke valve has a body configured to be mounted to a first junction when installed. The body has an inlet configured to fluidly connect to the throughbore when installed, an outlet configured to be connected to an overpressure relief conduit, and a pressure sensing aperture extending from an inner surface to an outer surface of the body such that the pressure sensing aperture is configured to be exposed to the pressure within the throughbore of the first junction when in operation. Further, the pressure relief choke valve is configured to receive the output action from the control module to actuate the pressure relief choke valve from a closed position to a fully open position in less than about 0.2 seconds, thereby to prevent damage from overpressure in the hydraulic fracturing manifold system when the assembly is installed therein. The pressure transducer is mounted to the pressure relief choke valve body and configured to receive the pressure from the pressure sensing aperture and transmit the pressure signal to the control module during operation.

In still another embodiment of the disclosure, for example, includes a kit to retrofit a hydraulic fracturing system using an assembly having choke valves to relieve overpressure and bleed the hydraulic fracturing system to prevent damage to associated fracturing system equipment. The kit includes a control module, a pressure relief choke valve, a pressure transducer, and a bleed choke valve. The control module has a controller configured to receive and monitor a pressure signal and upon determination the pressure is above a predetermined threshold, send an output action to relieve the pressure in a throughbore of the assembly. The pressure relief choke valve has a body configured to be mounted to a first junction that includes a throughbore configured to flow a pressurized fluid therethrough when in operation. The body has an inlet configured to fluidly connect to the throughbore when installed, an outlet configured to be connected to an overpressure relief conduit, and a pressure sensing aperture extending from an inner surface to an outer surface of the body such that the pressure sensing aperture is configured to be exposed to the pressure within the throughbore of the first junction when in operation. The pressure relief choke valve is configured to receive the output action from the control module to actuate the pressure relief choke valve from a closed position to a fully open position in less than 0.4 seconds, thereby to prevent damage from overpressure in the hydraulic fracturing manifold system when the assembly is installed therein. The pressure transducer is mounted to the pressure relief choke valve body and configured to receive the pressure from the pressure sensing aperture and transmit the pressure signal to the control module during operation. The bleed choke valve has a body configured to be mounted to a junction different than the first junction. The body has a choke bean positioned therein configured to reduce the pressure of the pressurized fluid, thereby to adjust a flowrate of the fluid during operation. The bleed choke valve is configured to receive the output action from the control module to actuate the bleed choke valve to controllably evacuate the pressure or the pressurized fluid within a throughbore of the second junction.

In some embodiments disclosed herein, the kit further includes a check valve, one or more: (a) pipe spools, (b) hydraulic hoses, (c) electrical cords, (d) maintenance tools, (e) spare parts, or a combination thereof.

Embodiments described herein comprise a combination of features and characteristics intended to address various shortcomings associated with certain devices, systems, and methods. The foregoing has outlined rather broadly the features and technical characteristics of some of the disclosed embodiments in order that the detailed description that follows may be better understood. The various characteristics and features described above, as well as others, will be readily apparent to those having ordinary skill in the art upon reading the following detailed description, and by referring to the accompanying drawings. It should be appreciated that this disclosure may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes as the disclosed embodiments. It should also be realized that such equivalent constructions do not depart from the spirit and scope of the principles disclosed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure, and together with the detailed description, serve to explain principles of the embodiments discussed herein. No attempt is made to show structural details of this disclosure in more detail than may be necessary for a fundamental understanding of the embodiments discussed herein and the various ways in which they may be practiced. According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to illustrate embodiments of the disclosure more clearly.

FIG. 1 illustrates a schematic diagram of a hydraulic fracturing system including a manifold having a monobore assembly to provide overpressure relief and bleed using choke valves, according to one embodiment of the present disclosure.

FIG. 2A is perspective view of an embodiment of a monobore assembly, according to one embodiment of the present disclosure.

FIG. 2B is a top view of an embodiment of a monobore assembly shown in FIG. 2A, according to one embodiment of the present disclosure.

FIG. 2C is a side view of an embodiment of a monobore assembly shown in FIG. 2A, according to one embodiment of the present disclosure.

FIG. 3 is sectional view of an embodiment of an upstream portion of the monobore assembly taken along the lines of FIG. 3 of the side view of an embodiment of the monobore assembly from FIG. 2C, according to one embodiment of the present disclosure.

FIG. 4 is sectional view of an embodiment of a downstream portion of the monobore assembly taken along the lines of FIG. 4 of the side view of an embodiment of the monobore assembly from FIG. 2C, according to one embodiment of the present disclosure.

FIG. 5A is a perspective view of an embodiment of the pressure relief choke valve, according to one embodiment of the present disclosure.

FIG. 5B is a side view of an embodiment of the pressure relief choke valve, according to one embodiment of the present disclosure.

FIG. 5C is a sectional view of an embodiment of the pressure relief choke valve taken along the FIG. 5C lines of the side view of an embodiment of the pressure relief choke valve of FIG. 5C, according to one embodiment of the present disclosure.

FIG. 5D is a sectional view of an embodiment of the pressure relief choke valve of FIG. 5C without a body, according to one embodiment of the present disclosure.

FIG. 6A is a side view of an embodiment of the bleed choke valve, according to one embodiment of the present disclosure.

FIG. 6B is an exploded representation of an embodiment of the bleed choke valve, according to one embodiment of the present disclosure.

FIG. 6C is a sectional view of an embodiment of the bleed choke valve taken along the FIG. 6C lines of the side view of an embodiment of the bleed choke valve of FIG. 6A, according to one embodiment of the present disclosure.

FIG. 6D is a sectional view of an embodiment of the bleed choke valve of FIG. 6C without a body, according to one embodiment of the present disclosure.

FIG. 7A is a front perspective view of an embodiment of the control module, according to one embodiment of the present disclosure.

FIG. 7B is a front perspective view with a cover open of an embodiment of the control module, according to one embodiment of the present disclosure.

FIG. 7C is a back view of an embodiment of the control module, according to one embodiment of the present disclosure.

FIG. 7D is a back view with back panels open of an embodiment of the control module, according to one embodiment of the present disclosure.

FIG. 8 is a schematic view of a monobore assembly kit, according to one embodiment of the present disclosure.

FIG. 9 is a schematic representation of a controller used in the monobore assembly, according to one embodiment of the present disclosure.

FIG. 10 is a method to relieve a hydraulic fracturing system from overpressure using a choke valve, according to one embodiment of the present disclosure.

FIG. 11 is a method to bleed a hydraulic fracturing system from overpressure using a choke valve, according to one embodiment of the present disclosure.

FIG. 12 is a method to relieve and bleed a hydraulic fracturing system from overpressure using choke valves, according to one embodiment of the present disclosure.

FIG. 13 is a chart illustrating the response time of a pressure relief choke valve, according to one embodiment of the present disclosure.

FIG. 14 is a chart illustrating a response time of a pressure relief choke valve compared to competitor response times, according to one embodiment of the present disclosure.

To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated into other embodiments without further recitation.

DETAILED DESCRIPTION

As previously described, severe and volatile pressure conditions of a hydraulic fracturing operation may cause overpressure events that may exceed mechanical limitation of various fluid conveyance devices and systems. For example, fracturing pumps may be damaged upon exposure to overpressure and may necessitate repairs thereafter. Conventional overpressure relief valves have experienced a high rate of mechanical failure due differential pressures experienced upon a pressure release. Furthermore, conventional overpressure relief valves exhibit a less than desirable pressure relief response time leading to similar repairs from overpressure exposure. Conventional overpressure relief valves include ball valves and gate valves. Improvements to conventional overpressure relief valves include metallurgy and internal design. However, leading industry relief valves still plague fracturing systems by slow response times and are frequently in need of repair which increase operational costs, increase risk for injury, increase downtimes which increase lost revenue. Applicant has addressed the short comings of conventional overpressure relief valves, or associated improvements, by implementing choke valves in overpressure relief and bleed systems for hydraulic fracturing operations. As a result, through use of the embodiments disclosed herein, a monobore assembly for positioning in a hydraulic fracturing manifold system provides overpressure relief and bleed using choke valves increases reliability and response time for overpressure protection.

The terms “removing,” “removed,” “reducing,” “reduced,” or any variation thereof, when used in the claims or the specification includes any measurable decrease of one or more components in a mixture to achieve a desired result. The use of the words “a” or “an” when used in conjunction with any of the terms “comprising,” “including,” “containing,” or “having,” in the claims or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one. ” The terms “wt. %,” “vol. %,” or “mol. %” refers to a weight, volume, or molar percentage of a component, respectively, based on the total weight, the total volume of material, or total moles, which includes the component. In a non-limiting example, 10 grams of a component in 100 grams of the material is 10 wt. % of the component.

FIG. 1 illustrates a schematic diagram of a hydraulic fracturing system 8 including a manifold 60 having a monobore assembly 100 to provide overpressure relief and bleed using choke valves, according to one embodiment of the present disclosure. During operations, system 8 may inject a high-pressure fracturing fluid into a wellhead 102 that is connected to a wellbore (not shown) extending into a subterranean formation 103 to fracture the subterranean formation 103 as previously described. In some embodiments, the hydraulic fracturing system 8 may inject the high-pressure fracturing fluid into a plurality of wellheads so as to access the subterranean formation 103 via a plurality of wellbores.

It should be appreciated that the hydraulic fracturing system 8 shown in FIG. 1 depicts some components and assemblies that may be used during a hydraulic fracturing operation. In some embodiments, additional or fewer components may be used within the hydraulic fracturing system 8. Thus, the particular combination or arrangement of components of the hydraulic fracturing system 8 depicted in FIG. 1 is not limiting to other potential embodiments of the hydraulic fracturing system 8. As discussed above, the below disclosure may be equally applicable to fracturing systems that utilize a monomissile or conventional treating iron, or the like, as would be understood by one skilled in the art, for overpressure and bleed protection. Therefore, the disclosure of the assembly below is an embodiment that may be utilized in existing or new fracturing systems for overpressure and bleed protection.

The hydraulic fracturing system 8 may include a plurality of storage vessels 12 that are configured to hold a volume of fracturing fluid therein. The fracturing fluid stored in the storage vessels 12 may include any liquid or semi-liquid (such as a gel) that is suitable for injection into and fracturing of the subterranean formation 103. In some embodiments, the fracturing fluid includes an aqueous solution including substantially pure water or water mixed with one or more additives (such as gels, gelling agents, chemicals, etc.). The storage vessels 12 may include any suitable container for holding a volume of fluids (such as liquids) therein. For instance, in some embodiments, storage vessels may include rigid tanks, flexible tanks (such as bladders), open pits, mobile tanks (that may be pulled by a tractor trailer or other vehicle), or a combination thereof.

As shown in FIG. 1, a blender 14 is positioned downstream of the storage vessels 12 that is configured to mix a proppant into the fracturing fluid. The proppant may include sand or other suitable solids. As previously described, the proppant is configured to flow into the fractures within the subterranean formation 103 so as to hold the fractures open after the hydraulic fracturing operation has ended. In some embodiments, additives (such as chemical additives) may be mixed into the fracturing fluid within the blender 14 either in addition or alternatively to the proppant. The blender 14 emits the fracturing fluid, now with proppant mixed therein, to a manifold assembly 20 that communicates the fracturing fluid to and from a plurality of pumping units 40.

Specifically, the manifold assembly 20 includes one or more low-pressure, inlet manifolds 22 and one or more high-pressure, outlet manifolds, such as manifold 60. In the particular embodiment depicted in FIG. 1, manifold assembly 20 includes two inlet manifolds 22 and a single outlet manifold 60. However, in other embodiments, different members, arrangements, and combinations of inlet manifolds 22 and outlet manifolds 60 may be utilized, such as, for instance, a single outlet manifold 60, a plurality of outlet manifolds 60, a single inlet manifold 22, or a plurality of inlet manifolds 22. A plurality of inlet conduits 24 connect the inlet manifolds 22 to the plurality of pumping units 40. In addition, a plurality of outlet conduits 26 connect the plurality of pumping units 40 to the outlet manifold 60.

Each pumping unit 40 includes a pump 44 driven by a driver 42. Pump 44 may include any suitable fluid pumping device or assembly for pressurizing the fracturing fluid (with or without proppant or other additives entrained therein) to the pressures associated with a hydraulic fracturing operation. For instance, in some embodiments, the pump 44 may be configured to pressurize the fracturing fluid to a pressure of about 15,000 pounds per square inch (psi) or higher. One skilled in the art may refer to pumps similar to pump 44 as a “hydraulic fracturing pump(s)”. In some embodiments, the hydraulic fracturing system 8 may include several pumping units, such as one to forty pumping unit 40 in operation, standby, or at site. Depending on pumping configuration desired, there may be more than forty pumping units. In some embodiments, pump 44 may include a positive displacement pump, centrifugal pump, or other suitable pump types capable of pressurizing the fracturing fluid for wellbore entry. Driver 42 may include any suitable motor or engine that is configured to drive or actuate the corresponding pump 44 during operations. For instance, in some embodiments, driver 42 may include a diesel engine, a turbine (such as a gas turbine, steam turbine, etc.), an electric motor, or some combination thereof. During operations, within each pumping unit 40, the driver 42 may actuate the pump 44 to draw fracturing fluid into the pump 44 via the corresponding inlet conduit 24 and to pressurize and output the fracturing fluid from the pump 44 via the corresponding outlet conduit 26.

The pump 44 may provide the fracturing fluid to the outlet manifold 60 via the outlet conduits 26. The outlet manifold 60 directs the pressurized fracturing fluid toward the wellhead 102 such that it may access the subterranean formation 103 for hydraulic fracturing operations. During the hydraulic fracturing operations, fracturing fluid may be emitted from the wellbore via the wellhead 102 and recycled back to the storage vessels 12 through one or more recycle conduits 16. In some embodiments, the wellhead 102 may possess multiple valves configurable to stop, or direct flow to, for example, the storage vessels 12, into the wellbore for fracturing operations, or sampling stations. In some embodiments, the fracturing fluid output from the wellhead 102 may be routed through one or more filtering or separation assemblies or devices (not shown) to remove additives, proppant, or other fluids or solids (such as rock chips, formation fluids, etc.) that may be entrained within the fracturing fluid, prior to recycling the fracturing fluid to the storage vessels 12. The valves of the wellhead 102 are represented in FIG. 1 as a single wellhead valve 190, however many valve may exist in this position for redundancy. The wellhead valve 190 may be open, partially closed, partially opened, or closed.

The monobore assembly 100 includes a pressure relief choke valve 102 and a bleed choke valve 104 positioned downstream of the outlet manifold 60 to relieve and bleed overpressure in the outlet manifold 60 during, and in response to, an overpressure event and to redirect the relieved or bled fracturing fluid to a relief location, as illustrated in FIG. 1. Moreover, in some embodiments, the monobore assembly 100 may be positioned between the outlet manifold 60 and the wellhead valve 190 of the wellhead 102. An overpressure event may occur, for example, as a result of an unstable reservoir release from a fracturing operation, or as a result of an intended, or inadvertent, closing of wellhead valve 190. For example, after desired fracturing operations, there may be a need to shut the wellbore while maintaining pressurized fracturing fluid therein. A sequence of shut down operations may necessitate the closure of the wellhead valve 190 to shut in the fluids downhole of the wellhead 102, thus maintaining the pressure and integrity of the wellbore. However, the closure of the wellhead valve 190 may occur while one or more pumps 44 are providing pressurized fluids to the outlet manifold 60. The closed wellhead valve 190 and the continued, or shutting down, operation of the one or more pumps 44 may create an overpressure event that may cause damage to equipment fluidly connected to the hydraulic fracturing system 8. Thus, the monobore assembly 100 is configured to provide pressure relief from an overpressure event, as discussed above, and bleed a volume of pressurized fluid trapped between the wellhead valve 190 and a backflow prevention device 108 in the monobore assembly 100. In some embodiments, a plurality of outlet manifold 60 may each utilize a monobore assembly. In those embodiments, a predetermined pressure threshold of a first monobore assembly may be the same, or different, than the predetermined pressure threshold of a second monobore assembly. In the embodiments where the predetermined pressure thresholds of the first and second monobore assemblies are different, the predetermined pressure thresholds may sequence so as to stagger the overpressure reliefs. Furthermore, it is contemplated that each of the plurality of outlet manifold 60 may flow a different pressurized fluid to the wellhead 102.

In some embodiments the monobore assembly 100 may further include a control module 106 in communication with a controller positioned within the control module 106. The control module 106 may be connected to the pressure relief choke valve 102 and the bleed choke valve 104 by one or more hydraulic lines 112 and one or more electrical connections, such as electrical connection 114. In some embodiments, the control module 106 may communicatively be connected to a human machine interface (HMI) 116, such as a laptop. In some embodiments, the HMI 116 may enable the operator to process, or change, data provided from the pressure relief choke valve 102, the bleed choke valve 104, or other components within the control module 106.

FIG. 2A is perspective view of an embodiment of a monobore assembly 200, according to one embodiment of the present disclosure. The illustration of FIG. 2A is an embodiment similar to the monobore assembly 100 of FIG. 1 with additional details. FIG. 2B is a top view of an embodiment of a monobore assembly 200 shown in FIG. 2A, according to one embodiment of the present disclosure. FIG. 2C is a side view of an embodiment of a monobore assembly 200 shown in FIG. 2A, according to one embodiment of the present disclosure.

The monobore assembly 200 comprises an elongate member 206 that includes inline piped components defined by wetted components in the pressurized fluid pathway direction 208 during normal operation, as indicated on the backflow prevention device 108. For purposes of facilitating understanding, “normal operation” may be defined as a fluid delivery system without open relief conduits, so to provide a fluid flow from a source to the destination, such as the pumps to the wellhead 102. Therefore, the elongate member 206 may include one or more piping sections 10, one or more monobore junctions 30, each having one or more junction connectors 50 configured to connect to a device, such as an outlet of a pump 44 to receive a fluid therethrough, and a backflow prevention device 108. The one or more piping sections 10, such as pipe spools, connect the monobore junctions 30 to other inline piped components, such as the backflow prevention device 108, for example. In the embodiments illustrated in FIGS. 2A, 2B, and 2C, the elongate member 206 is shown to connect a first piping section 10a to a first monobore junction 30a, the first monobore junction 30a to a second piping section 10b, the second piping section 10b to the backflow prevention device 108, the backflow prevention device 108 to a third piping section 10c, the third piping section 10c to a second monobore junction 30b, and the second monobore junction 30b to a fourth piping section 10d. The inlet 202 may be configured to be connected to the outlet manifold 60 of FIG. 1, when installed. During normal operation, the pressurized fluid flowing from the outlet manifold 60 may be received through the monobore assembly inlet 202 such that the fluid may flow through the backflow prevention device 108 and out the outlet 204 of the monobore assembly. The outlet 204 of the monobore assembly may be configured to connect to a segment of piping that directs flow to the wellhead 102. The elongate member 206 may be positioned on one or more supports 222 to elevate the elongate member 206 to a proper height to connect to the outlet manifold 60, for example. Each of the one or more supports 222 may include adjustable legs 224, such as a telescoping jack, that provides desired height for installation or stability of the supports 222 when installed. As illustrated, connection plugs 226 may be positioned on the one or more junction connectors 50 to prevent debris infiltration during shipping or storage. Similarly, connection plugs 226 may be positioned on the relieving valves discussed below.

The monobore assembly 200 further comprises a control module 106, a pressure relief choke valve 102, and bleed choke valve 104. The pressure relief choke valve 102 and bleed choke valve 104 are each fluidly connected to the control module 106 via hydraulic lines 112. The hydraulic lines 112, also referred to as “hydraulic hoses” by one skilled in the art, may provide a hydraulic fluid conduit to the pressure relief choke valve 102 and bleed choke valve 104 for hydraulic actuation of the respective valve. The pressure relief choke valve 102 may be configured to be mounted on the first monobore junction 30a such that particles fall towards a throughbore 316, thereby to reduce particle buildup in the pressure relieve choke valve 102. The throughbore 316 (shown in FIGS. 3 and 4) is positioned within the elongate member 206 and extends from the monobore assembly inlet 202 to the monobore assembly outlet 204 to provide the flow pathway in the direction of the pressurized fluid pathway 208, when in operation. The bleed choke valve 104 may be configured to be mounted on the second monobore junction 30b such that particles fall towards the throughbore 316, thereby to reduce particle buildup in the bleed choke valve 104. As discussed above, the fracturing fluid may contain sand and the positioning of the pressure relief choke valve 102 and bleed choke valve 104 in the embodiments of FIGS. 2A, 2B, and 2C, advantageously prevent sediment buildup in the relief inlets per the respective valves enabling a valve having a relief inlet without flow inhibiting sediment when overpressure relief is initiated.

The monobore assembly 200 further comprises one or more valve position transducers 118 and one pressure transducer 120 each connected and in electrical communication to the control module 106. For example, the electrical connection 114 may be configured to transmit a pressure signal from the pressure transducer 120 to the control module 106 for analysis by the controller positioned within the control module 106.

Referring to FIG. 2B, the elongate member 206 has an overall length equal to the sum of the inline components. For example, the length of each of the piping sections 10a, 10b, 10c, and 10d, illustrated as L_10a, L_10b, L_10c, and L_10d, may each be about 24 inches. In some embodiments, the length of each of the monobore junctions 30a and 30b, illustrated as L_30a and L_30b, may each be about 22 inches. In some embodiments, the backflow prevention device 108 may be about 20 to about 36 inches, such as about 32 inches in length. The pressure relief choke valve 102 and the bleed choke valve 104 are rotatable in a direction 232 such that each maintains a position above the associated monobore junction 30 but may direct the corresponding outlets in any direction 232. For example, the piping associated to the relief location of FIG. 1 for the pressure relief choke valve 102 may be connectable in a north facing direction while the piping associated to the relief location of FIG. 1 for the bleed choke valve 104 may be connectable in an east facing direction. In this example, both the pressure relief choke valve 102 and the bleed choke valve 104 are mounted to the associated monobore junction 30 such that particles fall towards the throughbore 316, as discussed above.

Referring to FIG. 2C, the elongate member 206 may divided into two portions, the upstream portion 230 and the downstream portion 232, by the backflow prevention device 108. Therefore, when installed, the upstream portion 230 contains, not only the first monobore junction 30a, the pressure relief choke valve 102, and the associated piping sections, 10a and 10b, but also contains the manifold assembly 20 and any connected pumping units 40. Therefore, as provided herein, a reference to the upstream portion 230 includes any fluidly connected equipment to the outlet manifold 60 upstream of the backflow prevention device 108. The downstream portion 232 includes the associated piping sections, 10c and 10d, the second monobore junction 30b, the bleed choke valve 104, and piping connected to the wellhead valve 190, as discussed in FIG. 1. Therefore, as provided herein, a reference to the downstream portion 232 includes any fluidly connected piping from the backflow prevention device 108 to the wellhead valve 190.

The backflow prevention device 108 may be a suitable backflow prevention device, such as a check valve of various types. Suitable check valve types include, for example, swing, wafer, ball, butterfly, tilting disc, dual disc, nozzle, and piston type check valves rated above pressures exposed during overpressure events or normal operation. In some embodiments the backflow prevention device 108 may be rated to 15,000 psi, or higher. Similarly, the piping and the monobore junctions in the elongate member 206 may be each rated to 15,000 psi, or higher. The backflow prevention device 108 may provide lifting loops 228 to lift the backflow prevention device 108 into position during installation. As would be understood by one skilled in the art, fluid flowing in the pressurized fluid pathway direction 208 through the backflow prevention device 108 keeps the backflow prevention device 108 from closing. When fluid flow has ceased, the backflow prevention device 108 shuts in a manner to prevent any downstream portion 232 flow from reverse flowing through the backflow prevention device 108 and gaining access to the upstream portion 230. Therefore, in the event of a stoppage of fluid flow, the backflow prevention device 108 isolates the pressurized fluid, from the upstream portion 230, within the downstream portion 232. Similarly, as would also be understood by one skilled in the art, pressure induces flow from a high pressure source to a low pressure area. Therefore, in the event the pumps 44 fail to provide fluids at a higher pressure to the upstream portion 230 than a pressure present in the downstream portion 232, the check valve will close to prevent reverse flow towards the upstream portion 230 from the downstream portion 232. As will be discussed in greater detail below, the downstream portion 232 may trap pressurized fluid between a closed wellhead valve 190 and the backflow prevention device 108 as a result of an overpressure relief event using an embodiment of the present disclosure.

FIG. 3 is sectional view of an embodiment of an upstream portion 230 of the monobore assembly 200 taken along the lines of FIG. 3 of the side view of an embodiment of the monobore assembly 200 from FIG. 2C, according to one embodiment of the present disclosure. The embodiment of an upstream portion 230 of the monobore assembly 200 will be referred to as the upstream monobore relief assembly portion 300. The upstream monobore relief assembly portion 300 includes the pressure relief choke valve 102 connected to an overpressure relief conduit 302 and also connected to the first monobore junction 30a. The pressure relief choke valve 102 has a relief valve inlet 304 and a relief valve outlet 306. The relief valve outlet 306 is in fluid communication with relief conduit 302, when installed. The relief valve inlet 304 is in fluid communication with the relief conduit 302 however a pressure relief gate 308 blocks flow between the relief valve inlet 304 and the relief conduit 302 until the pressure relief choke valve 102 is opened to allow flow between the relief valve inlet 304 and towards the relief conduit 302, such as to relieve overpressure in the throughbore 316. The opening of the pressure relief choke valve 102 moves the pressure relief gate 308 from a pressure relief seat 310 to create an open flow path, such as flow annulus 350, to relieve the pressure sensed at the relief valve inlet 304 from the throughbore 316.

One example of an overpressure event that opens the pressure relief choke valve 102 may be a closed wellhead valve 190. Intentional or inadvertent closing of the wellhead valve 190 may cause an increase in pressure in the hydraulic fracturing system 8 as the pumps 44 may continue to pump fluid into the manifold 60. While pumps 44 may be equipped with shut down features, such as high-pressure trips (causing the driver 42 to stop actuation of the pump 44), shutting down multiple high pressure pumps may be a delayed process. The delays may cause some of the pumps to continue to operate while others initiate a shutdown. In some embodiments, the drivers 42 may be variable speed and in the event of a high-pressure trip, may reduce the output pressure of the pump 44 rather than shutting down. The delayed shut down, or slowing, of the pumps 44 against a closed wellhead valve 190 may deadhead the pumps 44, as would be understood by one skilled in the art. The deadhead may cause damage as fracturing fluid may be incompressible. As such, a high pressure impulse in the manifold 60 may be observed at a rate equal to the speed of sound in the fracturing fluid and thus, pressure increases relatively instantly. The pressure relief choke valve 102 is configured to be fast acting and fully open upon a sensed pressure exceeding a predetermined pressure threshold and sized to relieve the pressure in the manifold 60 and further flow the remaining fluid flow of the reduced rate pumps, thereby to prevent damage to the costly fracturing equipment.

The pressure relief choke valve 102 includes an actuator 312 connected to a stem 314. The stem 314 may be directly connected to the pressure relief gate 308 such that the actuator 312 may move the stem 314 which also moves the pressure relief gate 308 a distance “D” to fully open the pressure relief choke valve 102. As will be discussed in greater detail in FIG. 5, an overpressure event may cause a controller to hydraulically actuate the actuator 312 to open the pressure relief choke valve 102. In all embodiments, the actuator 312 provides sufficient force to overcome the pressure at the relief valve inlet 304, and within valve body, to open the pressure relief choke valve 102, thereby to relieve overpressure. In some embodiments, the pressure relief choke valve 102 may be a fast acting relief valve capable of moving the pressure relief gate 308 in less than about 0.4 seconds, such as less than about 0.35 seconds, such as less than about 0.3 seconds, such as less than about 0.25 seconds, such as less than about 0.2 seconds, such as less than about 0.18 seconds, such as less than about 0.16 seconds, such as less than about 0.14 seconds, such as less than about 0.13 seconds, such as less than about 0.126 seconds, such as less than 0.117 seconds, such as about 0.117 seconds. Industry standards may dictate excess pressure above pressure relief setpoints should not exceed 10 percent over the pressure relief setpoint, thus the pressure relief choke valve 102 advantageously meets and exceeds the requirements of industry standards, as evidenced by not exceeding pressure increase by 10 percent after opening of the pressure relief choke valve 102. In some embodiments, the pressure relief choke valve 102 may be a fast closing relief valve capable of moving the pressure relief gate 308 to the closed position in less than about 0.4 seconds, such as less than about 0.35 seconds, such as less than about 0.3 seconds, such as less than about 0.25 seconds, such as less than about 0.24 seconds, such as about 0.235 seconds. In some embodiments, the pressure relief choke valve 102 may be controllably closed at a desired close rate by the operator, or the controller within the control module 106, to reduce frequency of open/close cycling or to reduce valve chatter, as would be understood by one skilled in the art. In some embodiments, the pressure relief choke valve 102 may be manufactured in compliance with American Petroleum Institute (API) Section 6A and National Association of Corrosion Engineers (NACE). The pressure in the throughbore 316 may experience up to 15,000 psi. However, an overpressure event may be triggered upon, for example, exceeding a 11,900 psi predetermined threshold set in the controller. In this example, the pressure transducer 120 may sense an elevated pressure and via a controller instruction, the pressure relief choke valve 102 may be opened to relieve the throughbore 316 of the overpressure within. Similarly, after relief, the pressure transducer 120 may sense a desired lower pressure and a via controller instruction, the pressure relief choke valve 102 may be closed to normally operate the system. In some examples, the pressure relief choke valve 102 may cycle through opening and closing several times in the event of continuous, or repeating, over pressure. Furthermore, while the above example may experience up to 15,000 psi, the pressure relief choke valve 102 may be rated for 20,000 psi, 25,000 psi, or greater depending on well and pump dynamics, as would be understood by one skilled in the art. Similarly, components of the system, including the assembly, such as the bleed choke valve 104 and the backflow prevention device 108, may be rated to withstand 20,000 psi, 25,000 psi, or greater pressures.

The pressure differential between the relief valve inlet 304 and the relief conduit 302 may be substantial in an overpressure event, such as about 11,900 psi when the relief conduit is at an atmospheric pressure. In some embodiments, the pressure differential between the relief valve inlet 304 and the relief conduit 302 may be about 15,000 psi or higher. The opening of the pressure relief choke valve 102 may induce cavitation, or micro-sized implosions, of the relieved fluid. As would be understood by one skilled in the art, cavitation occurs upon the pressure of a fluid reducing momentarily below the vapor pressure of the fluid and then increasing above the vapor pressure of the fluid. In those situations, the fluid creates miniature explosives, via the vapor particles produced, that cause damage to the wetted area nearby, which include the flow annulus 350, the pressure relief gate 308, or the pressure relief seat 310. In an effort to reduce frequency of replacing the internal components of the pressure relief choke valve 102, the valve may contain a dual sided, and reversible, pressure relief gate 308 configured to be installed in a flipped orientation to expose an unused side of the pressure relief gate 308 to the fluid. In some embodiments, the pressure relief gate 308 and the pressure relief seat 310 include tungsten carbide.

FIG. 4 is sectional view of an embodiment of a downstream portion 232 of the monobore assembly 200 taken along the lines of FIG. 4 of the side view of an embodiment of the monobore assembly 200 from FIG. 2C, according to one embodiment of the present disclosure. The embodiment of a downstream portion 232 of the monobore assembly 200 will be referred to as the downstream monobore relief assembly portion 400. The downstream monobore relief assembly portion 400 comprises the bleed choke valve 104 connected to the evacuation conduit 402 and also connected to the second monobore junction 30b. The bleed choke valve 104 has a bleed valve inlet 404 and a bleed valve outlet 406. The bleed valve outlet 406 is in fluid communication with the evacuation conduit 402. The bleed valve inlet 404 is in fluid communication with the evacuation conduit 402 however a bleed stem plug 408 blocks flow between the bleed valve inlet 404 and the evacuation conduit 402 until an instruction triggers an opening of the bleed choke valve 104 to allow flow between the bleed valve inlet 404 and towards the evacuation conduit 402, such as to controllably bleed trapped pressurized fluid in the downstream portion 232. The opening of the bleed choke valve 104 moves the bleed stem plug 408 from a bleed valve seat 410, commonly referred to as a “choke bean” by one skilled in the art, to create a flow path, such as flow annulus 450, to bleed the trapped pressurized fluid received by the bleed valve inlet 404 from the throughbore 416.

The bleed choke valve 104 includes an actuator 412 connected to a stem 414. The stem 414 may be directly connected to the bleed stem plug 408, at a distal end of the stem 414, such that the actuator 412 may move the stem 414, which also moves the bleed stem plug 408, to controllably open the bleed choke valve 104. As will be discussed in greater detail in FIG. 5, an instruction may cause a controller to hydraulically actuate the actuator 412 to controllably open the bleed choke valve 104. In all embodiments, the actuator 412 provides sufficient force to overcome the pressure at the bleed valve inlet 404, and within valve body, to open the bleed choke valve 104, thereby to open the valve. In some embodiments, the bleed choke valve 104 may be opened at about 0.1 percent intervals, or increments, of a total bleed choke valve stroke distance. In some embodiments, the bleed choke valve 104 may be controllably positioned at about 0.1 percent intervals, or increments, to about 99.9 percent intervals to control flow. In some embodiments, the bleed choke valve 104 may be controllably positioned at about 0.1 percent intervals after exceeding about 1.5 percent open of the total bleed valve stroke, also referred to as the “dead band” by one skilled in the art. In some embodiments, the bleed choke valve 104 may be a fast acting bleed valve capable of “burping” the valve (an action to open and close the valve) in less than about 10 seconds, such as about 0.1 second to about 9 seconds, such as about 0.1 second to about 8 seconds, such as about 0.1 second to about 7 seconds, such as about 0.1 second to about 6 seconds, such as about 0.1 second to about 5 seconds, such as about 0.1 second to about 4 seconds, such as about 0.1 second to about 3 seconds, such as about 0.1 second to about 2 seconds, such as about less than 9 seconds, such as about less than 7 seconds, such as about less than 5 seconds, such as about less than 4 seconds, such as about less than 3 seconds, such as about less than 2 seconds.

In some embodiments, the bleed choke valve 104 may be manufactured in compliance with API Section 6A and NACE. The pressure in the throughbore 316 may experience about 15,000 psi or higher. However, an overpressure event, such as a shut wellhead valve 190 with continued pumping operations, may trigger, by exceeding a predetermined pressure threshold set in the controller, the opening of the pressure relief choke valve 102, as discussed above. In this example, after the opening of the pressure relief choke valve 102, pressurized fluid may be trapped in the downstream portion 232 as result of the closing of the backflow prevention device 108 from a reduction, or lack of, forward fluid flow. The pressurized fluid in the downstream portion 232 may then be controllably released to a relief location via the evacuation conduit 402 via the bleed choke valve 104. Recalling that the pressure transducer 120 senses the relieved pressure in the upstream portion 230, the bleed choke valve 104 may continue to bleed the downstream portion 232, via operator or controller instruction, until the downstream pressure is at or below the pressure of the upstream portion 230. The bleed operation may be complete when the pressure transducer 120 measures a lower pressure in the upstream portion 230 as a result of the downstream portion 232 having a pressure equal or below the pressure of the upstream portion 230. Once the downstream pressure is at least equalized or below the upstream pressure, the backflow prevention device 108 may open to allow any higher upstream pressure to flow the fluid to towards downstream portion 232 and thus, reducing the pressure measured by pressure transducer 120 in the upstream portion 230 which may indicate a completed bleeding operation of the hydraulic fracturing system 8. In some examples, the bleed choke valve 104 may be repeatedly burped, or cycled through opening and closing several times, as desired by the operator to obtain desired pressure bleed.

Similar to the pressure relief choke valve 102, the pressure differential experienced by the bleed choke valve 104, may be substantial, such as, for example, about 15,000 psi, or higher, in an overpressure event shutdown leading to a bleeding of the downstream portion 232. Additionally, the bleed choke valve 104 may be configured to tolerate a low pressure differential, such as about 10 psi to about 400 psi above the desired closed in pressure of the downstream portion 232. Therefore, the bleed choke valve 104 may accommodate a large range of pressure differentials experienced by pressure relief choke valve 102 setpoints and the bleed. The opening of the bleed choke valve 104 may induce cavitation of the relieved fluid that may cause damage about the flow annulus 450, such as the bleed stem plug 408 and the bleed valve seat 410. In an effort to reduce the frequency of replacing internal components, the bleed valve seat 410 may be lined with tungsten carbide, such as seat liner 418. In some embodiments, the bleed stem plug 408 may include tungsten carbide material.

FIG. 5A is a perspective view of an embodiment of the pressure relief choke valve 102, according to one embodiment of the present disclosure. FIG. 5B is a side view of an embodiment of the pressure relief choke valve 102, according to one embodiment of the present disclosure. FIG. 5C is a sectional view of an embodiment of the pressure relief choke valve 102 taken along the FIG. 5C lines of the side view of an embodiment of the pressure relief choke valve 102 of FIG. 5C, according to one embodiment of the present disclosure. FIG. 5D is a sectional view of an embodiment of the pressure relief choke valve 102 of FIG. 5C without a body 502, according to one embodiment of the present disclosure.

The pressure relief choke valve 102 includes a body 502, a bonnet 530, an actuator 312, a position transducer 118, and a pressure transducer 120. The body 502 of the pressure relief choke valve 102 is illustrated as a cube shape. Multiple shapes are contemplated that are suitable to withstand pressures up to 15,000 psi or higher. In some embodiments the rating of the pressure relief choke valve 102, and internal components are rated to withstand 20,000 psi. The body 502 includes the relief valve inlet 304 and the relief valve outlet 306 positioned at an angle of about 90 degrees, such that fluid flowing through the relief valve inlet 304 may redirect to turn about 90 degrees to exit the relief valve outlet 306. Other flow paths are contemplated. The embodiment of FIGS. 5A, 5B, and 5C are referred to as “angle choke valves” by one skilled in the art. The body 502 has an interior that houses a guide 532, the pressure relief gate 308, and the pressure relief seat 310, among other components, such as packings and seals. The guide 532 may be a tubular component configured to position the pressure relief gate 308 into proper alignment for contact with the pressure relief seat 310. The guide 532 has a void space positioned away from the relief valve outlet 306 configured to provide space for the pressure relief gate 308 to retract from the pressure relief seat 310 when in operation. The guide 532 may be securely positioned in the body 502 such that a movement of the pressure relief gate 308 does not move the guide 532. The pressure relief gate 308 may be a cylindrical shape with channels extending from the pressure relief seat 310 to the void space of the guide 532. The channels may be utilized to allow fluid to enter the void space of the guide 532, such that the pressure relief gate 308 movement is not hindered by vacuum or compressibility of the fluid, thus using less force to move the pressure relief gate 308 when in operation. The pressure relief seat 310 may be configured to seal against the pressure relief gate 308 when the valve is in the closed position, thereby to prevent leaks to the relief valve outlet 306.

The body 502 has an exterior that supports the pressure transducer 120, one or more gantry mounting plates 508, one or more lifting loops 506, one or more studs 512, and one or more nuts 514, among other features. The pressure transducer 120 may be an analog, or serial, device that measures pressure in the throughbore 316 via an aperture 520 extending from the interior to the exterior of the body 502 as illustrated in FIG. 5C. The aperture 520 may allow the pressure transducer 120 to measure the pressure at the relief valve inlet 304. In some embodiments the pressure transducer 120 is rated for 20,000 psi, although a pressure rating equal to the pressure rating of the pressure relief choke valve 102 is contemplated. In some examples, a higher rated pressure transducer may provide for increased accuracy of pressure measurement, as compared to a lower pressure rated pressure transducer, as would be understood by one skilled in the art. In all embodiments, the pressure transducer 120 is rated to at least the pressure rating of the pressure relief choke valve 102. The pressure transducer 120 is configured to physically receive an electrical cable, such as the electrical connection 114, and to transmit the measured pressure to the control module 106 for analysis by the controller within. In some embodiments, the pressure transducer 120 is bolted on to the exterior of the body 502, although other method of fastening the pressure transducer 120 are contemplated. The one or more gantry mounting plates 508 are non-pressure retaining plates. The one or more gantry mounting plates 508 are configured to be replaced with a gantry 810, such a gantry illustrated in FIG. 8, for ease of maintenance of internal components of the pressure relief choke valve 102. For example, an installed gantry 810 may support the weight of the components found in FIG. 5D when servicing the pressure relief choke valve 102 to provide easier access to, for example, the pressure relief seat 310 or the pressure relief gate 308. The one or more lifting loops 506 may be positioned on a side of the body 502 to provide a lifting site for installation of the pressure relief choke valve 102. The one or more studs 512 and one or more nuts 514 are positioned on sides configured to connect to adjacent piping, such as one or more junction connectors 50 to mount atop the first monobore junction 30a, or the relief conduit 302, as illustrated in FIGS. 2A, 2B, 2C, and 3.

The bonnet 530 is configured to retain pressure in the body 502 and configured to guide the stem 314 to drive the pressure relief gate 308, when in operation. The bonnet 530 is connected, and fastened, to the body 502 with a bonnet nut 504. The bonnet 530 may be also connected to the actuator 312. The actuator 312 may be a linear actuator, although other types of actuators are contemplated. The actuator 312 may be a piston actuator, as illustrated in the embodiment of FIGS. 5C and 5D. In an embodiment, the piston 516 is directly connected to the stem 314 and is positioned between a first hydraulic chamber 522 and a second hydraulic chamber 524. The first hydraulic chamber 522 is in fluid communication to a hydraulic line, such as the one or more hydraulic lines 112 via one of the hydraulic connections 510, and may be configured to fill with a hydraulic fluid to drive the piston 516 away from the bonnet 530, thus moving the stem 314 and the pressure relief gate 308 away from the pressure relief seat 310 to open the pressure relief choke valve 102. The second hydraulic chamber 524 is in fluid communication to a hydraulic line, such as the one or more hydraulic lines 112 via one of the hydraulic connections 510, and may be configured to fill with a hydraulic fluid to drive the piston 516 toward the bonnet 530, thus moving the stem 314 and the pressure relief gate 308 toward the pressure relief seat 310 to close the pressure relief choke valve 102. In some embodiments, the pressure relief gate 308 is driven and compressed against the pressure relief seat 310 to create a seal, thereby to prevent leaks. In yet another embodiment, the pressure relief gate 308 is linearly driven and compressed against the pressure relief seat 310 when the actuator 312 is a linear-type actuator. The actuator 312 further includes a cover plate 534 configured to retain any hydraulic pressure exerted onto the piston 516 when in operation. The cover plate 534 may allow the position transducer 118 to measure the position of the piston 516, which is a direct measurement of the stem 314, thus providing positional information of the pressure relief choke valve 102. While not illustrated, the position transducer 118 may be electrically connected to the control module 106 to provide valve position information to the controller.

FIG. 6A is a side view of an embodiment of the bleed choke valve 104, according to one embodiment of the present disclosure. FIG. 6B is an exploded representation of an embodiment of the bleed choke valve 104, according to one embodiment of the present disclosure. FIG. 6C is a sectional view of an embodiment of the bleed choke valve 104 taken along the FIG. 6C lines of the side view of an embodiment of the bleed choke valve 104 of FIG. 6A, according to one embodiment of the present disclosure. FIG. 6D is a sectional view of an embodiment of the bleed choke valve 104 of FIG. 6C without a body, according to one embodiment of the present disclosure.

The bleed choke valve 104 includes a body 602, a bonnet, an adaptor 606, an actuator 412, a position transducer 118. The body 602 of the bleed choke valve 104 is configured to withstand pressures of about 15,000 psi and, in some embodiments, the rating of the bleed choke valve 104, and internal components, withstand about 15,000 psi. The body 602 includes the bleed valve inlet 404 and the bleed valve outlet 406 positioned at an angle of about 90 degrees, such that fluid flowing through the bleed valve inlet 404 may redirect to turn about 90 degrees to exit the bleed valve outlet 406. Other flow paths are contemplated. The body 602 has an interior that houses a guide 622, the bleed stem plug 408, the bleed valve seat 410, and a portion of a stem 414, among other components, such as packings and seals, when in operation. The guide 622 may be a tubular component configured to position the bleed stem plug 408 into proper alignment for contact with the bleed valve seat 410. The guide 622 may be securely positioned in the body 602 such that a movement of the bleed stem plug 408, via the stem 414, does not move the guide 622. The bleed stem plug 408 may be a truncated conical shape. The bleed valve seat 410 may be configured to seal against the bleed stem plug 408 when the valve is in the closed position, thereby to prevent leaks to the bleed valve outlet 406.

The body 602 has an exterior that is connected to an inlet flange 608 and an outlet flange 612. The inlet flange 608 may be configured to receive one or more studs and one or more nuts from the associated junction connectors 50, as shown in FIGS. 2A, 2C, and 4. The outlet flange 612 may be configured to receive one or more studs and one or more nuts from the associated evacuation conduit 402 flange, as shown in FIG. 4. In some embodiments, the size of the evacuation conduit 402 exceeds the size of the bleed choke valve 104. For example, a 3 inch bleed choke valve 104 would be connected to an evacuation conduit 402 larger than 3 inch, such as 4 or more inches. The larger evacuation conduit 402 size is advantageous to provide a larger volume for rapid depressurization of the evacuated fluid.

The bonnet is configured to retain any pressure in the body 602 and to guide the stem 414 to drive the bleed stem plug 408, when in operation. The bonnet is connected, and fastened, to the body 602 with a bonnet nut 604. The bonnet may be also connected to the actuator 412. In some embodiments, as illustrated in FIGS. 6A, 6B, 6C, and 6D, the actuator 412 may be connected to an adaptor 606 which is connected to the bonnet. The actuator 412 may be a linear actuator, although other types of actuators are contemplated. The actuator 412 may be a piston actuator, as illustrated in the embodiment of FIGS. 6C and 6D. In an embodiment, the piston 614 is directly connected to the stem 414 and is positioned between a first hydraulic chamber 616 and a second hydraulic chamber 618. The first hydraulic chamber 616 is in fluid communication to a hydraulic line, such as the one or more hydraulic lines 112 via one of the hydraulic connections 610, and may be configured to fill with a hydraulic fluid to drive the piston 614 away from the adaptor 606, thus moving the stem 414 and the bleed stem plug 408 away from the bleed valve seat 410 to open the bleed choke valve 104. The second hydraulic chamber 618 is in fluid communication to a hydraulic line, such as the one or more hydraulic lines 112 via one of the hydraulic connections 610, and may be configured to fill with a hydraulic fluid to drive the piston 614 toward the adaptor 606, thus moving the stem 414 and the bleed stem plug 408 toward the bleed valve seat 410 to close the bleed choke valve 104. In some embodiments, the bleed stem plug 408 is driven and compressed against the bleed valve seat 410 to create a seal, thereby to prevent leaks. In yet another embodiment, the bleed stem plug 408 is linearly driven and compressed against the bleed valve seat 410 when the actuator 412 is a linear-type actuator. The actuator 412 further includes a cover plate 620 configured to retain hydraulic pressure exerted onto the piston 614 when in operation. The cover plate 620 may allow the position transducer 118 to measure the position of the piston 614, which is a direct measurement of the stem 414, thus providing positional information of the bleed choke valve 104. While not illustrated, the position transducer 118 may be electrically connected to the control module 106 to provide valve position information to the controller.

FIG. 7A is a front perspective view of an embodiment of the control module, according to one embodiment of the present disclosure. FIG. 7B is a front perspective view with a cover open of an embodiment of the control module, according to one embodiment of the present disclosure. FIG. 7C is a back view of an embodiment of the control module, according to one embodiment of the present disclosure. FIG. 7D is a back view with back panels open of an embodiment of the control module, according to one embodiment of the present disclosure.

The control module 106 may contain various components to effectuate the output actions of the controller within. For example, the control module 106 may contain the controller, cabling to power and transmit signals to the controller, pressure gauges, push buttons or switches, a hydraulic reservoir configured to contain hydraulic fluids, a pressurization system configured to drive hydraulic fluids during operation, and various controls to operate the pressurization system, among other components.

The control module 106 may be an exterior rated unit including a cover 702, a body 704, front access doors 706, and back access doors 710 to protect against elements such as heat, debris, and rain. The cover 702 is configured to protect an interface 708 and one or more pressure gauges and is positionable with pneumatic supports, such as gas struts, to provide access to, for example, the interface 708. In some embodiments, the interface 708 has an interface screen 710 to display the windows programed on the controller. The controller will be discussed in greater detail below. The interface 708 further has one or more manual override controls, such as push buttons or switches. As illustrated in the embodiment of FIG. 7B, the manual override controls of the interface 708 have a power switch, a push button to trip the control module 106, and a reset push button to regain power to the control module in the event of a trip. One of the pressure gauges may monitor the control pressure, such as the setpoint the predetermined pressure threshold. In an embodiment, the second pressure gauge may monitor the system pressure, such as the pressure measured by the pressure transducer 120. The one or more pressure gauges may be fixed and positioned to face an operator for ease of visibility at both the control pressure and the system pressure.

As illustrated, the control module 106 is a cabinet, however, carts, in non-threatening environments may be used to house the components within or on the control module 106.

The back face of the control module 106, as shown in FIG. 7C, may include back access doors 710, with latches, and protective guards 712 configured to protect various connections to the control module 106. As would be understood by one skilled in the art, cables and hoses, for example, have a maximum bend radius that if exceeded, may compromise structural integrity the cables and hose. To prevent against bending the cables, or hoses, beyond the maximum bend radius, the protective guards 712 may project outward to prohibit objects, such as a wall, to bend the cables, or hoses, or to damage input couplings on the control module 106 configured to receive the cables or hoses.

As illustrated in FIG. 7D, the latchable back access doors 710 protect various components within in the control module 106. For example, the control module 106 may house a hydraulic driving system, such as gas bottle. The hydraulic driving system may be configured to receive a hydraulic fluid driver, such as nitrogen, and drive pressurized hydraulic fluid to the hydraulic connections, such as hydraulic connections 510, or 610, of the associated valve. The hydraulic fluid driver and the hydraulic fluid may be collectively referred to as hydraulic fluid sources. In an embodiment, the hydraulic fluid sources are rated up to, or about, 1500 psi. In another embodiment, the hydraulic driving system is a gas bottle with an expandible bladder within. The bladder may be filled with nitrogen, and the bottle, outside of the bladder, may contain hydraulic fluid. Upon an instruction to actuate a valve from the controller, the nitrogen may pressurize and expand the bladder to drive the hydraulic fluid out of the bottle and into the hydraulic filled hydraulic connections to actuate the intended valve. The controller may effectuate the actuation of the valves by signaling the hydraulic fluid driver, such as a pressurized gas source, to release into, for example, the gas bottle. In some embodiments, the hydraulic fluid driver may be nitrogen. In other embodiments, the hydraulic fluid driver may be air. In yet another embodiment, the hydraulic fluid driver may be nitrogen with back-up air, should nitrogen fail. The hydraulic driving system may have various components to condition the hydraulic fluid driver for delivery. For example, the hydraulic fluid driver may be compressed, by a compressor, within the control module 106. In some embodiments, the compressor may have pressure indication transmitted to controller to signal that the hydraulic driving system is ready. Furthermore, the hydraulic driving system may have gas valves, regulators, and or gauges, to condition and monitor the pressure of the hydraulic fluid driver. In some embodiments, the hydraulic driving system may contain a pressure relief valve to protect the hydraulic driving system from overpressure in the control module 106. Other components include one or more of each: vent and drain valves, pressure reducing valves, shuttle valves, check valves, needle valves, isolation valves, filters, and pressure transducers. The hydraulic driving system may also include the hydraulic reservoir positioned in the control module 106 and associated level controls or indications to provide a signal to the controller that the hydraulic driving system is ready.

FIG. 8 is a schematic view of a monobore assembly kit 800, according to one embodiment of the present disclosure. The monobore assembly kit 800 may include several components positioned within a container 802. Due to the size and weight of the components, the components of the monobore assembly kit 800 may be positioned for shipment, or transportation, in one or more containers. Moreover, the container 802 may include any suitable container or support (such as the platform) for transporting the selected components of kit 800 to and about the hydraulic fracturing system (such as hydraulic fracturing system 8 in FIG. 1). In some embodiments, container 802 may include a box, crate, or similar container. In some embodiments, container 802 may include a pallet, frame, flatbed, or other support that may be moved about the hydraulic fracturing system 8 (such as via crane, forklift, truck, etc.). In some embodiments, one or more of the components positioned within container 802 may be positioned within additional sub-containers that are further positioned within container 802. In yet another embodiment, the monobore assembly kit 800 may be fully, or partially, assembled to ship as a skid, or a modular unit for installation.

As illustrated, the container 802 may include the control module 106, the pressure relief choke valve 102, and the bleed choke valve 104. Other components may include electrical cables, such as the electrical connection 114 for transmission of the pressure signal, a second electrical connection 114 may be provided when a position transducer 118 is physically connected to the control module 106, a power cable 806 to supply power the control module 106, and at least four hydraulic lines 112. In some embodiments, the HMI 116 may be provided within the monobore assembly kit 800. The HMI 116 may be provided with a protective case 808. Therefore, the monobore assembly kit 800 may include a backflow prevention device 108, one or more: (a) pipe spools, such as piping sections 10, (b) hydraulic hoses, (c) electrical cords, (d) maintenance tools, (e) spare parts, or a combination thereof. In some embodiments, the maintenance tools may include a seat removal tool, a bonnet nut wrench, a gate removal tool, a stem removal tool, pliers, or a dead-blow hammer. Further, it is to be understood by one skilled in the art that the monobore assembly kit 800 may also include one or more: (a) instructional manuals, (b) video tutorials, (c) connection plugs 226, (d) o-rings or seals, (e) fluids, such as hydraulic oil, lubrication oil, anti-seize, dielectric grease, or oil-based grease, (f) snap rings, (g) nuts and bolts, or (h) personal protective equipment, such as protective eyewear, gloves, and helmets. The components, as illustrated within the monobore assembly kit 800 of FIG. 8, are not representative of the actual size, or quantity, but rather are exemplary to view an embodiment of a kit.

FIG. 9 is a schematic representation of a controller 902 used in the monobore assembly 200, according to one embodiment of the present disclosure. The control module 106 contains therewithin, a controller 902. The controller may contain a processor 904 and memory 906. In an embodiment, the controller 902 is a programmable logic controller (PLC) connected to the inputs of the control module 106 to monitor data related to, for example, pressure, positional, power, or level activity associated with the monobore assembly 200. In some embodiments, the controller 902 may be configured to send alerts, or alarms, to inform personnel that an activity will commence, or conclude, upon received instructions or deviations from predetermined threshold limits or ranges. The controller 902 may further have a variety of functions, as discussed above, to provide, receive, monitor, store, analyze, process information, and send an output action to components associated with the monobore assembly 200. In some embodiments, the controller 902 may be a dual controller configured to receive a single input and upon processing, transmit a plurality of output actions to various components, for example, to independently adjust the pressure relief choke valve 102 and the bleed choke valve 104.

In some embodiments the controller 902 may be in signal communication with various other controllers throughout or external to the monobore assembly 200, such as the emergency shutdown system of the hydraulic fracturing system 8. The controller 902 may include one or more processors, such as processor 904, as well as a memory or machine-readable storage medium, such as memory 906. As used herein, a “machine-readable storage medium” may be any electronic, magnetic, optical, or other physical storage apparatus to contain or store information such as executable instructions, data, and the like. For example, any machine-readable storage medium described herein may be any of random access memory (RAM), volatile memory, non-volatile memory, flash memory, a storage drive, a hard drive, a solid state drive, any type of storage disc, and the like, or a combination thereof. The memory 906 stores or includes instructions executable by the processor 904. As used herein, a “processor” includes, for example, one processor or multiple processors included in a single device or distributed across multiple computing devices. The processor 904 may be at least one of a central processing unit (CPU), a semiconductor-based microprocessor, a graphics processing unit (GPU), a field-programmable gate array (FPGA) to retrieve and execute instructions, a real time processor (RTP), other electronic circuitry suitable for the retrieval and execution instructions stored on a machine-readable storage medium, or a combination thereof. Also, as used herein, “signal communication” refers to electric communication such as hard wiring two components together or wireless communication, as understood by those skilled in the art. For example, hard wiring two components may be by modbus, profibus, industrial ethernet, foundation fieldbus, or the like, while wireless communication may be Wi-Fi®, Bluetooth®, ZigBee, or forms of near field communications. Therefore, the controller 902 includes instructions to commence or conclude the overpressure monitoring, relief, and bleed procedures according to the examples disclosed herein.

The memory 906 may include various computer programs 908, or stored information algorithms, each configured to communicate with the processor 904 to address deviations of desired setpoints in operation. The controller 902 may further transmit output actions to address the deviations. For example, computer programs 908 may include a pressure sensor detector module 910, a pressure relief choke valve adjustment module 912, a bleed choke valve adjustment module 914, a valve position sensor detector module 912, and a hydraulic fluid level detector module 918. Each of the exemplary modules may possess information, such as predetermined thresholds, for desired operation conditions.

In an embodiment, the controller 902 may be configured to receive information from an HMI 116, a pressure transducer 120, a pressure relief choke valve position sensor 118, a bleed choke valve position sensor 118, a hydraulic reservoir level indication 908, a power indication 910, and an emergency shutdown system 912. For example, the HMI 116 may send and receive data from the controller 902 to adjust setpoints, or threshold limits or ranges, and to receive historical operations data. In some embodiments, while not illustrated, the controller 902 may receive data from HMI 116 via an antenna, or wireless access point, positioned on, or within, the control module 106, thereby to provide a remote communications between the HMI 116 and the controller 902, such as wireless communication. In other embodiments, the HMI 116 may be directly connected via an information transfer cable, such as a cable with data transfer connections, for example, HDMI ends, as would be understood by one skilled in the art. In another example, as discussed above, the pressure transducer 120 provides pressure data to the controller 902. The controller 902 may process the pressure signal and upon processing, transmit a plurality of output actions to the hydraulic fluid sources to independently adjust the pressure relief choke valve 102 and the bleed choke valve 104 as illustrated in FIGS. 10, 11, and 12. Similarly, in another example, the controller 902 may receive positional information from either, or both, the position transducers 118 of the pressure relief choke valve 102 and the bleed choke valve 104. In some embodiments, the controller 902 may receive level information of hydraulic reservoirs within the control module 106 to alert personnel of sufficient hydraulic fluid levels, replacement of the hydraulic fluid, or fill of the hydraulic fluid reservoirs. In yet another embodiment, the controller 902 may receive power status information and may further send alerts to personnel of sufficient power supply status or battery conditions to increase reliability against power failures. The controller 902 may further receive status information from the emergency shutdown system, such that the monobore assembly 200 is configured to activate during emergency shutdown initiation of the hydraulic fracturing system 8.

FIG. 10 is a method 1000 to relieve a hydraulic fracturing system 8 from overpressure using a choke valve, according to one embodiment of the present disclosure. The method 1000 may begin at block 1002, where during normal operation, the pressure transducer 120 may sense the pressure in the throughbore 316 in the monobore assembly 200. The pressure signal may be received by the controller 902 and evaluated against a predetermined pressure threshold. At decision diamond 1004, the controller 902, through the processor 904 and memory 906, may determine if the pressure is within the predetermined threshold. The predetermined threshold may be limit or a range. Upon a determination that the pressure is within the predetermined threshold, the method 1000 may continue to block 1006.

At block 1006, the controller 902 may request or receive a position signal from the position transducer 118 of the valve. The controller 902 may determine if the valve is closed at decision diamond 1008. Upon a determination that the valve is closed, the method 1000 may cycle back to block 1002. Upon a determination that the valve is not closed, the controller 902 may send an output action to the hydraulic fluid sources to actuate the valve closed at block 1010 as a predetermined closing rate.

Referring back to decision diamond 1004, upon a determination that the pressure is not within the predetermined threshold, the method 1000 may continue to block 1012. At block 1012, the controller 902 may send an output action to the hydraulic fluid sources to open the valve. At block 1014, the controller 902 may request or receive a position signal from the position transducer 118 of the valve. The controller 902 may determine if the valve is fully open at decision diamond 1016. Upon a determination that the valve is not fully open, the controller 902 may send, or continue to send, an output action to the hydraulic fluid sources to actuate the valve fully open at block 1012. Upon a determination that the valve is fully open, the method 1000 may cycle back to block 1002 to sense the pressure in the throughbore 316.

In some embodiments, the controller 902 may be instructed by, for example, the HMI 116 to stroke the valve for maintenance or safety compliance. Block 1018 represents an instruction received by the controller 902 to stroke the valve. The method 1000 may continue as described above.

In another embodiment, the controller 902 may be connected to the emergency shutdown system of the hydraulic fracturing system 8. Block 1020 illustrates the controller 902 monitoring emergency shutdown system for a shutdown instruction. The controller 902 may evaluate, at decision diamond 1022 whether the emergency shutdown system has provided a shutdown instruction. Upon a determination that a shutdown instruction was received, the method 1000 may continue to block 1012 to open the valve. Upon a determination that a shutdown instruction was not received, the method 1000 may continue to block 1020 for continued monitoring for a shutdown instruction from the emergency shutdown system.

The valve referenced in FIG. 10 may be the pressure relief choke valve 102. In some embodiments the valve of FIG. 10 may be the bleed choke valve 104 upon a failure of the pressure relief choke valve 102. Therefore, the pressure relief choke valve 102 may have a fast acting opening and a predetermined or adjustable closing rate. Similarly, the bleed choke valve 104 may have the ability to relieve pressure by fully opening while having a predetermined or adjustable closing rate.

FIG. 11 is a method 1100 to bleed a hydraulic fracturing system 8 from overpressure using a choke valve, according to one embodiment of the present disclosure. The method 1100 may begin at block 1102, where during normal operation, the pressure transducer 120 may sense the pressure in the throughbore 316 in the monobore assembly 200. The pressure signal may be received by the controller 902 and evaluated against a predetermined pressure threshold. At decision diamond 1104, the controller 902, through the processor 904 and memory 906, may determine if the pressure is within the predetermined threshold. The predetermined threshold may be limit or a range. Upon a determination that the pressure is within the predetermined threshold, the method 1100 may continue to block 1106.

At block 1106, the controller 902 may request or receive a position signal from the position transducer 118 of the valve. The controller 902 may determine if the valve is closed at decision diamond 1108. Upon a determination that the valve is closed, the method 1100 may cycle back to block 1102. Upon a determination that the valve is not closed, the controller 902 may send an output action to the hydraulic fluid sources to actuate the valve closed at block 1110.

Referring back to decision diamond 1104, upon a determination that the pressure is not within the predetermined threshold, the method 1100 may continue to decision diamond 1112. At decision diamond 1112, the controller 902 may evaluate whether a manual override instruction has been received. The manual override instruction may include an operator instructing the controller 902 through the HMI 116, for example, to actuate the valve. Upon a determination that no manual override instruction was received, the method 1100 continues to block 1114.

At block 1114, the controller 902 may initiate a timer. In some embodiments, the controller may alternatively, or in conjunction with the starting of the time, send an alert to personnel that an overpressure event has occurred. In some embodiments, the timer may serve as a buffer for operator intervention. However, if no operator intervention occurs, the method 1100 may continue to decision diamond 1116, where the controller 902 evaluates whether the timer has lapsed. Upon the expiration of the time, the controller 902 may send an output action to hydraulically adjust the valve to the predetermined open setpoint to open the valve at block 1118.

At block 1120, the controller 902 may request or receive a position signal from the position transducer 118 of the valve. The controller 902 may determine if the valve is closed at decision diamond 1122. Upon a determination that the valve is not open, or not opened to the setpoint, the controller 902 may send, or continue to send, an output action to the hydraulic fluid sources to adjust the valve at block 1118. Upon a determination that the valve is within the setpoint, the method may evaluate whether the pressure has achieved desired downstream pressure at decision diamond 1130. As discussed above, pressure transducer 120 may sense pressure upstream of the backflow prevention device 108. Upon a bleed of the downstream portion 232, the upstream portion 230 may experience a reduction in pressure. The reduction in pressure may be sensed by the pressure transducer 120 and a thus, a desired downstream pressure is achieved, according to one embodiment of the present disclosure.

At decision diamond 1130, upon a determination that the desired pressure downstream has been achieved, the method 1100 may continue to block 1132. At block 1132, the valve may be adjusted to close to a closing setpoint. At block 1134, the controller 902 may request or receive a position signal from the position transducer 118 of the valve. The controller 902 may determine if the valve is closed at decision diamond 1136. Upon a determination that the valve position is not within the setpoint to close, the controller 902 may send, or continue to send, an output action to the hydraulic fluid sources to adjust the valve at block 1132 to close. Upon a determination that the valve position is within the setpoint, the method 1100 may cycle back to block 1102 to sense the pressure in the throughbore 316.

Referring back to decision diamond 1112, upon a determination that a manual override instruction was received, the method 1100 continues to block 1124. At block 1124, the controller 902 follows the manual override instruction to adjust the valve to the desired setpoint to open the valve. At block 1126, the controller 902 may request or receive a position signal from the position transducer 118 of the valve. The controller 902 may determine if the valve is closed at decision diamond 1128. Upon a determination that the valve position is not within the instructed setpoint, the controller 902 may send, or continue to send, an output action to the hydraulic fluid sources to adjust the valve to the instructed setpoint at block 1124. Upon a determination that the valve position is within the instructed setpoint, the method 1100 continues to decision diamond 1130 and continued as discussed above.

In an embodiment, the controller 902 may be connected to the emergency shutdown system of the hydraulic fracturing system 8. Block 1140 illustrates the controller 902 monitoring emergency shutdown system for a shutdown instruction. The controller 902 may evaluate, at decision diamond 1142 whether the emergency shutdown system has provided a shutdown instruction. Upon a determination that a shutdown instruction was received, the method 1100 may continue to block 1118. Upon a determination that a shutdown instruction was not received, the method 1100 may continue to block 1140 for continued monitoring for a shutdown instruction from the emergency shutdown system.

The valve referenced in FIG. 11 may be the bleed choke valve 104. In some embodiments the valve of FIG. 11 may be the pressure relief choke valve 102 upon a failure of the bleed choke valve 104. Therefore, the pressure relief choke valve 102 may have a controllable opening similar to the normal operation of the bleed choke valve 104.

FIG. 12 is a method 1200 to relieve and bleed a hydraulic fracturing system 8 from overpressure using choke valves, according to one embodiment of the present disclosure. The method 1200 may begin at block 1202, where during normal operation, the pressure transducer 120 may sense the pressure in the throughbore 316 in the monobore assembly 200. The pressure signal may be received by the controller 902 and evaluated against a predetermined pressure threshold. In this embodiment, the controller 902 is a dual controller configured to instruct a series of outputs, such as instruction signals or output actions, to independently operate a plurality of components based on one input. As would be understood by one skilled in the art, a dual controller is not limited to one input but may be configured to receive several inputs and instruct a plurality of outputs. At decision diamond 1204, the controller 902, through the processor 904 and memory 906, may determine if the pressure is within the predetermined threshold. The predetermined threshold may be limit or a range. Upon a determination that the pressure is within the predetermined threshold, the method 1200 may continue to block 1206 and block 1212, depending on the type of valve.

At block 1206, the controller 902 may request or receive a position signal from the position transducer 118 of the pressure relief choke valve 102 (PRV). The controller 902 may determine if the PRV is closed at decision diamond 1208. Upon a determination that the PRV is closed, the method 1200 may cycle back to block 1202. Upon a determination that the PRV is not closed, the controller 902 may send an output action to the hydraulic fluid sources to actuate the PRV closed at block 1210.

At block 1212, the controller 902 may request or receive a position signal from the position transducer 118 of the bleed choke valve 104 (BCV). The controller 902 may determine if the BCV is closed at decision diamond 1214. Upon a determination that the BCV is closed, the method 1200 may cycle back to block 1202. Upon a determination that the BCV is not closed, the controller 902 may send an output action to the hydraulic fluid sources to actuate the BCV closed at block 1216.

Referring back to decision diamond 1204, upon a determination that the pressure is not within the predetermined threshold, the method 1200 may continue to block 1218 and decision diamond 1226.

At block 1218, the controller 902 may send an output action to the hydraulic fluid sources to open the PRV. At block 1220, the controller 902 may request or receive a position signal from the position transducer 118 of the PRV. The controller 902 may determine if the PRV is fully open at decision diamond 1222. Upon a determination that the PRV is not fully open, the controller 902 may send, or continue to send, an output action to the hydraulic fluid sources to actuate the PRV fully open at block 1218. Upon a determination that the PRV is fully open, the method 1200 may cycle back to block 1202 to sense the pressure in the throughbore 316.

In some embodiments, the controller 902 may be instructed by, for example, the HMI 116 to stroke the PRV for maintenance or safety compliance. Block 1224 represents an instruction received by the controller 902 to stroke the PRV. The method 1200 may continue to block 1218, as described above.

Referring back to decision diamond 1204, if the valve is a BCV and upon a determination that the pressure is not within the predetermined threshold, the method 1200 may continue to decision diamond 1226. At decision diamond 1226, the controller 902 may evaluate whether a manual override instruction has been received. The manual override instruction may include an operator instructing the controller 902 through the HMI 116, for example, to actuate the BCV. Upon a determination that no manual override instruction was received, the method 1200 continues to block 1228.

At block 1214, the controller 902 may initiate a timer. In some embodiments, the controller may alternatively, or in conjunction with the starting of the time, send an alert to personnel that an overpressure event has occurred. In some embodiments, the timer may serve as a buffer for operator intervention and to provide time for the overpressure relief of the upstream portion 230 by actuation of the PRV. However, if no operator intervention occurs, the method 1200 may continue to decision diamond 1230, where the controller 902 evaluates whether the timer has lapsed. Upon the expiration of the time, the controller 902 may send an output action to hydraulically adjust the BCV to the predetermined open setpoint to open the BCV at block 1232.

At block 1234, the controller 902 may request or receive a position signal from the position transducer 118 of the BCV. The controller 902 may determine if the BCV is within the setpoint threshold at decision diamond 1234. Upon a determination that the BCV is not open, or not opened to within the setpoint, the controller 902 may send, or continue to send, an output action to the hydraulic fluid sources to adjust the BCV at block 1232. Upon a determination that the BCV is within the setpoint, the method may evaluate whether the pressure has achieved desired downstream pressure at decision diamond 1244. As discussed above, pressure transducer 120 may sense pressure upstream of the backflow prevention device 108. Upon a bleed of the downstream portion 232, the upstream portion 230 may experience a reduction in pressure. The reduction in pressure may be sensed by the pressure transducer 120 and a thus, a desired downstream pressure is achieved, according to one embodiment of the present disclosure.

At decision diamond 1244, upon a determination that the desired pressure downstream has been achieved, the method 1200 may continue to block 1246. At block 1246, the BCV may be adjusted to close to a closing setpoint, or at a specified rate. At block 1248, the controller 902 may request or receive a position signal from the position transducer 118 of the BCV. The controller 902 may determine if the BCV is closed, closing, or closed to a desired setpoint, at decision diamond 1250. Upon a determination that the BCV position is not within the setpoint to close, the controller 902 may send, or continue to send, an output action to the hydraulic fluid sources to adjust the BCV at block 1246 to close. Upon a determination that the BCV position is within the setpoint to close, the method 1200 may cycle back to block 1202 to sense the pressure in the throughbore 316.

Referring back to decision diamond 1226, upon a determination that a manual override instruction was received, the method 1200 continues to block 1238. At block 1238, the controller 902 follows the manual override instruction to adjust the BCV to the desired setpoint to open the BCV. At block 1240, the controller 902 may request or receive a position signal from the position transducer 118 of the BCV. The controller 902 may determine if the BCV is closed at decision diamond 1242. Upon a determination that the BCV position is not within the instructed setpoint, the controller 902 may send, or continue to send, an output action to the hydraulic fluid sources to adjust the BCV to the instructed setpoint at block 1238. Upon a determination that the BCV position is within the instructed setpoint, the method 1200 continues to decision diamond 1244 and continued as discussed above.

In an embodiment, the controller 902 may be connected to the emergency shutdown system of the hydraulic fracturing system 8. Block 1252 illustrates the controller 902 monitoring emergency shutdown system for a shutdown instruction. The controller 902 may evaluate, at decision diamond 1254 whether the emergency shutdown system has provided a shutdown instruction. Upon a determination that a shutdown instruction was received, or activated, the method 1200 may continue to block 1218 to open the PRV and to block 1232 to adjust the BCV, as discussed above. Upon a determination that a shutdown instruction was not received, the method 1200 may continue to block 1252 for continued monitoring for a shutdown instruction from the emergency shutdown system.

EXAMPLES

The following examples reveal the response times of the pressure relief choke valve 102 of the monobore assembly 200 to relieve overpressure, as discussed above. The pressure relief choke valve 102 was experimentally evaluated to exhibit fast opening at various flowrates and set overpressure thresholds. Below are the findings of relief scenarios tested for pressure relief choke valve 102 response time.

Example 1

FIG. 13 is a chart illustrating a response time of the pressure relief choke valve 102, according to one embodiment of the present disclosure. The chart illustrates the information collected from at least fourteen runs using a pressure relief choke valve 102 with a 3″ orifice, such as a CORTEC Model CRV pressure relief choke valve offered by Cortec Fluid Control. In a first example, a pressure relief choke valve 102 was mounted on a monobore junction as illustrated in FIG. 2A. The monobore junction was connected to a fracking missile for testing at an active fracturing site. The experiment was performed with a simulated fracking fluid loop wherein the monobore junction flowed fracturing fluid from operational fracturing pumps to a tank. The experiment tested overpressure relief of three operational pressure setpoints including about 6,000 psi, about 8,000 psi, and about 10,000 psi. At the aforementioned pressures, the fluid was flowing at about 6 barrels per minute (bpm), about 8 bpm, and about 10 bpm. The greatest flow rate achieved was about 12 bpm. Upon a closure of a simulated wellhead valve, an overpressure event was simulated causing the pressure relief choke valve 102 to open to relieve pressure and close after obtaining a desired reduced pressure. The experiment setpoint for closure of the valve was set at a pressure of about 3,500 psi. After fourteen experimental runs, the data obtained was graphed, as shown in FIG. 13, illustrating psi as the y-axis and time, in milliseconds, as the x-axis to reveal a pressure curve as time progressed during the experiment. FIG. 13 indicates the open response time for the pressure relief choke valve 102 averaged less than 0.117 seconds to fully open, sensed via a position transducer as discussed above. The data further indicates the closing response time for the pressure relief choke valve 102 averaged less than 0.235 seconds to close, sensed via the position transducer. The rate of depressurization was consistent with a tolerance rate of about +/−28 psi per millisecond across each of the experimental runs.

Example 2

FIG. 14 is a chart illustrating the response time of a pressure relief choke valve 102 compared to competitor response times, according to one embodiment of the present disclosure. The chart illustrates the information collected from at least fourteen experimental runs using a pressure relief choke valve 102 with a 3″ orifice, such as a CORTEC Model CRV pressure relief choke valve offered by Cortec Fluid Control compared to industry leading relief valve response times. FIG. 14 illustrates psi as the y-axis and time, in milliseconds, as the x-axis to reveal a pressure curve as time progressed during the experiment for comparison to advertised competitor response times. As already noted above, the experimental data for the pressure relief choke valve 102 indicates the open response time for the pressure relief choke valve 102 averaged less than 0.117 seconds to fully open. Industry leading relief valves were compared to the result of the pressure relief choke valve 102 of the present disclosure. The opening time of a first industry leading relief valve was about 0.4 seconds. The opening time of a second industry leading relief valve was about 0.5 seconds. Compared to industry leading relief valves, the pressure relief choke valve 102 opens at least 0.283 seconds faster than the fastest competitor opening time. The closing time of the first industry leading relief valve was about 4 seconds. The closing time of the second industry leading relief valve was about 2.8 seconds. Compared to industry leading relief valves, the pressure relief choke valve 102 closes at least 2.565 seconds faster than the fastest competitor closing time. Therefore, the pressure relief choke valve 102 opens and closes before the fastest industry leading relief valve can open, advantageously providing for fast acting overpressure relief in situations that may otherwise cause damage to costly equipment, increased risk of injury to personnel, increase downtime, and lost revenue.

The preceding discussion is directed to various embodiments. However, one of ordinary skill in the art will understand that the examples disclosed herein have broad application, and that the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment.

In the discussion herein and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . .” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection of the two devices, or through an indirect connection that is established via other devices, components, nodes, and connections.

This application claims priority to, and the benefit of U.S. Provisional Application No. 63/687,916, filed Aug. 28, 2024, titled “ASSEMBLIES, METHODS, CONTROLLER, AND KITS FOR HYDRAULIC FRACTURING MANIFOLDS TO PROVIDE OVERPRESSURE RELIEF AND BLEED USING CHOKE VALVES,” the disclosure of which is incorporated herein by reference in its entirety.

While some embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teachings herein. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the systems, apparatus, and processes described herein are possible and are within the scope of the disclosure. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. Unless expressly stated otherwise, the steps in a method claim may be performed in any order. The recitation of identifiers such as (a), (b), (c) or (1), (2), (3) before steps in a method claim are not intended to and do not specify a particular order to the steps, but rather are used to simplify subsequent reference to such steps.