METHODS AND SYSTEMS ASSOCIATED WITH EXTENDED FLUID DISTRIBUTION WITH A LINE THAT BYPASSES PUMPING UNITS

Description

BACKGROUND INFORMATION

Field of the Disclosure

Examples of the present disclosure relate to methods and systems associated with extended fluid distribution on a manifold system. Specifically, embodiments are directed towards an additional line of low-pressure fluid that bypasses pumping units closest to a blender to supply dedicated fluid to pumping units further away from the blender while not interfering with the overall rate, volume, or slurry design.

Background

Frac manifold systemare large-bore pipes with multiple flanges that are used to consolidate high-pressure and flow rates from multiple hydraulic frac pumps to a singular flow. The singular flow is then pumped into one or more wellbores to stimulate a downhole formation. Frac manifold systemare formed of multiple elements, valves, and lines that supply fracturing fluid and/or media from a blender through a low-pressure system, which then gets discharged from the frac pump back to the missile’s high-pressure system, providing the means for the frac pumps to be fluidly connected to the wellheads during fracturing operations.

From a high-pressure side of the manifold system, fluid flows through a series of interconnected high-pressure piping, valving, and other high-pressure equipment to one or more wellheads that provide connectivity for fracturing.

Additionally, high-pressure pumps utilize a low-pressure intake system between a blender and the pump. High psi one-way check valves provide a connection and flow path to the high psi section of the manifold system that allows the fluid to flow from the pump to the high psi section. When no force is applied or present, the check valve closes, not allowing any high psi fluid to flow back to the pump trucks.

Conventionally, a blender is utilized to provide fluid to the low-pressure portion of the manifold system. Typically, the blender is a central location where all chemicals, proppants, and fluids come together to be mixed at a desired ratio to create the fracturing fluid. Blenders utilize several lines to provide the fracturing fluid to the low-pressure lines of the missile, where the fracturing fluid is distributed to the frac pumps tied into the low-pressure system, which then gets pressurized and reintroduced to the missile through the high-pressure side of the missile.

Currently, frac fleets are moving towards pumping units that can pump at much higher rates, measured in barrels per minute (bpm), than their predecessors. However, because of this additional throughput, there are supply issues within the low-pressure system with conventional designs. Namely, pumping units on trucks further away from the blender are at risk of being starved from the intake flow volume from the low-pressure media supplied by the blender, which creates risks of the pumps cavitating when the pumping unit is not intaking adequate fluid to maintain its intended pumping output rate. Cavitations cause violent shaking, vibrations, etc. that can damage valves, lines, etc.

Accordingly, needs exist for systems and methods for delivering dedicated fluid supply from the low-pressure system to the pumping units further away from the blender by utilizing an additional fluid line that bypasses pumping units that are positioned closer to the blender.

SUMMARY

Embodiments described herein disclose a manifold systemwith a blender supplying a plurality of low-pressure lines, a low-pressure bypass line, first pumping units fluidly coupled to the plurality of lines, and second pumping units fluidly coupled to the plurality of lines and the bypass line. In embodiments, the pumping units may be positioned physically closer to the blender than the second pumping units.

Embodiments are configured to evenly distribute the volume of fluids to the first pumping units and the second pumping units even though the second pumping units may be positioned further away from the blender. This may enable end users to utilize high-rate pumps more efficiently with the ability to supply fluid to the pumping units further away from the blender. This is unlike conventional systems where the fluid supplied at one end of the manifold systemmay only supply sufficient fluids to a first set of pumping units while not supplying enough fluids/media to a second set of pumping units further from the blender. In other words, embodiments are directed towards a low-pressure bypass line that delivers fluid to the front of the missile, away from the blender, and/or directly to the high-rate pumping units, because the fluid is being siphoned by the pumps upstream, or closer to the blender.

The blender manifold may be a machine that is configured to mix sand, water, and chemical additives to create fracturing fluid. The blender manifold may be configured to communicate the fracturing fluid to the plurality of lines and the bypass line on the low-pressure side of the manifold system.

The plurality of lines may be tubulars positioned in parallel that are configured to receive fracturing fluid from the blender manifold and supply fluid to the first pumping units and the second pumping units. One skilled in the art may appreciate that a plurality of lines may only be a single line from the blender manifold.

The bypass line may be in a tubular position in parallel to the plurality of lines, and may be configured to receive fracturing fluid from the blender manifold, bypass the first pumping units that are being fed from the common low-pressure system, and supply adequate fluid volume to the second pumping units. In embodiments, the bypass line may have an outlet that is tied into the plurality of lines at a position downstream from the first pumping units, such that the outlet of the bypass line is positioned communicatively closer to the second pumping units than the first pumping units. This may enable the bypass line to communicate dedicated fracturing fluids from the blender to pumping units that are further away from the blender manifold, which may not supply fracturing fluids to the first pumping units because this dedicated fluid may be supplied to the second pumping units.

The first pumping units may be fluidly coupled to the blender via the plurality of lines on the common low-pressure side. The first pumping units may be located physically closer along the plurality of lines than the second pumping units. Due to the location of the first pumping units along the plurality of lines, the first pumping units are not at risk for cavitation. However, the pumping units may decrease the volume supply of the frac fluid along the first plurality of lines. The first pumping units may be configured to increase the frac fluid pressure of fluid received from the plurality of lines and send the energized frac fluid to the high-pressure side of the manifold, where it enters the well through the wellhead. In specific embodiments, the first pumping units may be associated with diesel trucks.

The second pumping units may be fluidly coupled to the blender via the plurality of lines and the bypass line on the low-pressure side. The second pumping units may be located physically further away from the blender along the plurality of lines than the first pumping units. Due to the location of the second pumping units along the plurality of lines, the second pumping units may be at risk for cavitation. However, because the bypass line provided dedicated fluid to the second pumping units, that are not impacted by the first pumping units, the second pumping units may not cavitate. The second pumping unit may be configured to increase the frac fluid pressure, sending the energized frac fluid to the high-pressure side of the manifold, where it enters the well through the wellhead. In specific embodiments, the second pumping units may be associated with E-Trucks, which may have a higher throughput than the first pumping units.

These, and other, aspects of the invention will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. The following description, while indicating various embodiments of the invention and numerous specific details thereof, is given by way of illustration and not of limitation. Many substitutions, modifications, additions, or rearrangements may be made within the scope of the invention, and the invention includes all such substitutions, modifications, additions, or rearrangements.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting and non-exhaustive embodiments of the present invention are described concerning the following figures, wherein reference numerals refer to like parts throughout the various views unless otherwise specified.

FIG. 1A depicts a frac pad layout, according to an embodiment.

FIG. 1B depicts a manifold system, according to an embodiment

FIG. 2 depicts a side view of manifold system, according to an embodiment.

FIG. 3 depicts a view of a manifold system, according to an embodiment.

FIG. 4 depicts a method for a bypass line to deliver fluid to a second set of pumps that may be at risk for cavitation, according to an embodiment.

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

DETAILED DESCRIPTION

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

Embodiments are directed towards high-rate pumping operations where one or more trucks are used to provide a volume of fluid at a desired rate and pressure.

FIG. 1A depicts a frac pad layout 500, according to an embodiment. Frac pad layout 500 may include a blender 505, inputs 510 from a blender 505, manifold system 515, frac trucks 520 with pumping units 525, and wellhead 530.

The blender 505 may be a machine configured to mix sand, water, and chemical additives to create fracturing fluid. The blender 110 may be configured to communicate the mixed fracturing fluid to blender inputs 510.

Inputs 510 from blender 505 may be configured to supply the fracturing fluid from blender 505 to the manifold system 515. Manifold system 515 may be a manifold trailer designed to receive fluids from blender 505, and efficiently manage and distribute high-pressure fluids to a wellhead 530 by acting as a central hub that connects multiple flow lines and allows for controlled fluid delivery to the wellhead 530.

A plurality of frac trucks 520 with pumping units 525 may be coupled to the manifold system 515. Each frac truck 520 may be required to receive a desired volume of fluid, so the corresponding pumping unit 525 may pressurize the fluid before communicating high-pressure fluid to wellhead 530. However, based on the relative positioning of the frac trucks 520 along manifold system 515, each pumping unit 525 may not receive the desired volume of fluid from blender 505 without a bypass line.

The wellhead may be configured to receive high-pressure fluid from the pumping units 525 and control the pressure and flow of fluids during drilling and production.

FIG. 1B depicts a manifold system 100 including inputs 110 from a blender, a first line 115, second line 120, bypass line 130, first pumping units 140 on first line 115, first pumping units 142 on second line 120, and second pumping units 150 fluidly coupled to lines 115, 120 and the bypass line 130.

A blender may be a machine that is configured to mix sand, water, and chemical additives to create fracturing fluid. The blender may be configured to communicate the fracturing fluid to blender inputs 110 to supply fluid to the first line 115, the second line 120, and the bypass line 130 on the low-pressure side of the manifold system 100 before the fluid is energized.

First line 115 may be a tubular positioned in parallel to second line 120 and bypass line 130. First line 115 may be configured to receive fracturing fluid from the inputs 110 from the blender and to supply fluid to the first pumping units 140 and the second pumping units 150.

The second line 120 may be a tubular positioned in parallel to the first line 115 and bypass line 130. The second line 120 may be configured to receive fracturing fluid from the blender inputs 110 and to supply fluid to the first pumping units 142 and the second pumping units 150. One skilled in the art may appreciate that a manifold system 100 may only include first line 115 and bypass line 130.

The bypass line 130 may have a tubular position in parallel to the first line 115 and second line 120. Bypass line 130 may be configured to receive fracturing fluid from the blender inputs 110, bypass the first pumping units 140142 that are being fed from the common low-pressure system, and be tied into first line 115 and second line 120 at a location past first pumping units 140, 142, and supply dedicated fluid to the second pumping units 150. In embodiments, the bypass line 130 may have an outlet that is tied into lines 115, 120 at a position downstream from the first pumping units 140, 142, such that the outlet of the bypass line 130 is positioned communicatively closer to the second pumping units 150 than the first pumping units 140, 142. This may enable the bypass line 130 to communicate dedicated fracturing fluids from the blender inputs 110 to pumping units that are further away from the blender inputs 110, which may not supply fracturing fluids to the first pumping units 140, 142 because this dedicated fluid may be energized by the second pumping units 150. As such, bypass line 130 may supplement fluid to second pumping unit 150 which may require additional fluid, which may not be possible based on a location on a first line 115 having too many pumping units before the second pumping unit 150.

The first pumping units 140, 142 may be fluidly coupled to the blender inputs 110 via the plurality of lines 115, 120 on the low-pressure side. The first pumping units 140, 142 may be located physically closer along the plurality of lines 115, 120 to the blender inputs 110 than the second pumping units 110. Due to the location of the first pumping units 140, 142 along the plurality of lines 115, 120, the first pumping units 140, 142 are not at risk for cavitation. However, the pumping units 140, 142 may decrease the volume supply of the frac fluid along the plurality of lines 115, 120. The first pumping units 140, 142 may be configured to increase the frac fluid pressure of fluid received from the plurality of lines 115, 120, and send the energized frac fluid to the high-pressure side of the manifold, where it enters the well through the wellhead. In specific embodiments, the first pumping units 140, 142 may be associated with diesel trucks, and have an inlet that applies a suction force on lines 115, 120 to receive the fracturing fluid.

The second pumping units 150 may be fluidly coupled to the blender inputs 110 via first line 115 and/or second line 120 in combination with the bypass line 130 on the low-pressure side. This may enable the second pumping units 150 to receive the fracturing fluid from multiple sources, including a dedicated line that is not impacted by pressure drops caused by first pumping units 140, 142. The second pumping units 150 may be located physically further along the plurality of lines 115, 120 than the first pumping units 140, 142. Due to the location of the second pumping units 150 along the plurality of lines, the second pumping units 150 may be at risk for cavitation. However, because the bypass line 130 provided dedicated fluid to the second pumping units 150, which is not impacted by the first pumping units 140, 142, the second pumping units 150 may not cavitate. The second pumping units 150 may be configured to increase the frac fluid pressure, sending the energized frac fluid to the high-pressure side of the manifold, where it enters the well through the wellhead. In specific embodiments, the second pumping units 150 may be associated with E-Trucks, which may have a higher throughput than the first pumping units 140, 142.

FIG. 2 depicts a side view of manifold system 100, according to an embodiment.

As depicted in FIG. 2, bypass line 130 may run in parallel to first line 115, and bypass line 130 may not be tied into first line 115 until a location downstream from first pumping units 140.

FIG. 3 depicts a view of manifold system 100, according to an embodiment.

As depicted in FIG. 3, a joint 310 may tie bypass line 130 into first line 115 and/or second line 120 at a location downstream from first pumping units 140, wherein joint 310 may be positioned closer to second pumping units 150 than first pumping units 140.

In embodiments, joint 310 may be located along any point on first line 115 or second line 120 that is past at least one first pumping unit 140. In further embodiments, bypass line 130 may include a plurality of joints that tie in the dedicated fluid to first-line 115 or second lines 120 at various points that bypass first pumping units 140, 142.

FIG. 4 depicts a method 400 for a bypass line to deliver fluid to a second set of pumps that may be at risk for cavitation, according to an embodiment. The operations of method 400 presented below are intended to be illustrative. In some embodiments, method 400 may be accomplished with one or more additional operations not described, and/or without one or more of the operations discussed. Additionally, the order in which the operations of method 400 are illustrated in FIG. 4 and described below is not intended to be limiting.

At operation 410, a blender may mix sand, fluid, and chemical additives to create fracturing fluid. The blender may supply the fracturing fluid to a plurality of inputs from the blender.

At operation 420, the fracturing fluid may be communicated to a first line, a second line, and a bypass line via the inputs from the blender.

At operation 430, the first pumping units on the first line and the second line may pull fluid from the inputs from the blender, energizing the low-pressure fluid to create high-pressure fluid.

At operation 440, the pressure and volume of fluid on the first line and second line may decrease based on the first pumping units monopolizing the fluid on the first and second lines.

At operation 450, the bypass line may communicate the fracturing fluid to the first line and the second line at a location closer to the second pumping units than the first pumping units to provide dedicated fluid to the second pumping units.

At operation 460, the second pumping units on the first line and the second line may pull fluid from the first line, second line, and bypass line, energizing the low-pressure fluid to create high-pressure fluid.

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

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