US20230091302A1

US20230091302A1 - System and method for plug milling / flow-back / live descaling integrated improved workflow operations

Info

Publication number: US20230091302A1
Application number: US17/933,611
Authority: US
Inventors: Diogo Cesar Piasseski
Original assignee: Worldwide Oilfield Machine Inc
Current assignee: Worldwide Oilfield Machine Inc
Priority date: 2021-09-23
Filing date: 2022-09-20
Publication date: 2023-03-23

Abstract

A system for plug milling/flowback/descaling operations utilizes a data management component to receive and analyze data. A fluid management physical interconnection component has a debris separation device, a pressure control device and at least one mechanism connected for gas management and flow measurements of solids and liquids. The analysis by the data management component is used to provide control signals for use in or for the pressure control device. A vacuum/flush solid management system utilizes a combination of flush and vacuum pumps to convey solids in a slurry to a low pressure tank for disposal. The system directs frac sands through the debris separation device, through the pressure control device, and through the at least one mechanism for gas management and flow measurements to the low pressure tank.

Description

BACKGROUND

The present invention relates generally to valve and equipment assemblies and, more particularly, to an improved system and method for Plug Milling/Flow-back integrated improved workflow operations. Additionally, the same system and method can be used for live descaling operations, since the presence the solids and hydrocarbons can be managed safely with the same.
The prior art plug milling/flowback systems are manually operated. Automatic and/or coordinated operation of the system components such as automatic control of choke size and/or pump rates is not available. The prior art for plug milling/flow-back operations requires considerable human intervention such as manual extraction of plug material, which is more hazardous. The prior art utilizes high pressure separation of the frac sand early in the process that requires heavy equipment. The same limitations are applicable to live descaling operations. These and other disadvantages of the prior art are discussed in more detail hereinafter in conjunction with the drawings.

SUMMARY OF THE INVENTION

An object of the present invention is an improved plug milling flowback system which can also be applied for live descaling well operations.
An advantage of the present invention is the option to automatically control functions of the system such as automatic selection of choke sizes and/or pump rate of the coiled tubing unit whereby the components of the system work advantageously together rather than being worked without regard to each other.
Another advantage of the present invention is avoidance of the need for manual removal of the plug debris or larger solids from descaling to enhance safety of operation by means of flush and vacuum pumps interconnected between a debris separation module and a unique low pressure liquid/solids tank where gas, solids and liquids may be separated.
Yet another advantage of the present invention is the elimination of high pressure equipment to remove frac sands/solid scales whereby instead frac sands and scales are connected to pass through multiple sections of the fluid management system into the low pressure liquid/solids tank.
These and many other objects and advantages will become apparent from a review of the present specification.
One general aspect includes a system for plug milling/flowback/live descaling operations. The system includes a coiled tubing unit; a data management component may include a data aggregation portion, an analysis module and a control system; and a fluid management physical interconnection component may include a debris separation device, a pressure control device may include a choke, and at least one mechanism connected for gas management and for flow measurements of solids and liquids; where said data management component receives coiled tubing data, choke measurement data, and flow measurements of said solids and said liquids. Other embodiments of this aspect include corresponding computer systems, apparatus, and computer programs recorded on one or more computer storage devices, each configured to perform the actions of the methods.
Implementations may include one or more of the following features. The system where said data management component is operable to provide control information for operation of said fluid management physical interconnection component. Said data management component is operable to automate operation of said fluid management physical interconnection component based on an analysis of flow measurements of said solids and said liquids. A fluid management physical interconnection component may further include a tank for liquid and solids, a water treatment module, and a flush and vacuum system for solids management. The fluid management physical interconnection component is configured to separate plug debris or larger solid particles from frac sands or smaller solids, gas, and pumped fluid, and to utilize said flush and vacuum system to convey said plug debris or larger solid particles to said tank for liquids and solids. The system is operable to monitor pressures, temperatures, gas flow rates, and solid and liquid flow rates, analyze this data and use it for control purposes. Said tank for liquid and solids may include a plurality of weir plates and a sparging system. Said pressure control device may include a plurality of valves and at least four chokes and said data management component is operable to automatically choose which choke size or choke branch of said at least four chokes to utilize for operation of said pressure control device. Said data management component and said fluid management physical interconnection component are substantially entirely installed in interconnectable trailers. Said at least one mechanism connected for gas management and for flow measurements of solids and liquids may include a liquid gas separator that is configured to operate near atmospheric pressure. Said control system controls a choke size for said pressure control device. Choke measurement data and said flow measurements of said solids and said liquids may be used for selection of a pump rate for said coiled tubing unit. Implementations of the described techniques may include hardware, a method or process, or computer software on a computer-accessible medium.
One general aspect includes a system for plug milling/flowback/live descaling operations. The system includes a coiled tubing unit; a low pressure tank for disposal; a data management component; and a fluid management physical interconnection component that may include a debris separation device, a pressure control device may include at least one choke, and at least one mechanism connected for gas management and flow measurements of solids and liquids, a solid management system may include a combination of flush and vacuum pumps, said solid management system being connected to convey solids in a slurry to said low pressure tank for disposal. Other embodiments of this aspect include corresponding computer systems, apparatus, and computer programs recorded on one or more computer storage devices, each configured to perform the actions of the methods.
Implementations may include one or more of the following features. The system may include a water treatment system connected to said low pressure tank to produce recycled water. Said data management component receives coiled tubing data, choke measurement data, and flow measurements of said solids and said liquids and produces control signals for said pressure control device. Said control signals are utilized to select a choke size for said pressure control device. The system where said solid management system is configured so that operator contact for removal of plug debris is eliminated. Implementations of the described techniques may include hardware, a method or process, or computer software on a computer-accessible medium.
One general aspect includes a system for plug milling/flowback/live descaling operations. The system also includes a coiled tubing unit; a data management component; a fluid management physical interconnection component may include a debris (larger solid particles) separation device, a pressure control device may include at least one choke, and at least one mechanism connected for gas management and for flow measurements of solids and liquids, and a tank for liquid and solids; and where said fluid management physical interconnection component is configured so that frac sands or smaller solids are directed to flow through said debris separation device, through said pressure control device, through said at least one mechanism connected for gas management and flow measurements of solids and liquids, and into said tank for liquid and solids. Other embodiments of this aspect include corresponding computer systems, apparatus, and computer programs recorded on one or more computer storage devices, each configured to perform the actions of the methods.
Implementations may include one or more of the following features. The system where said data management component is configured to receive coiled tubing data, choke measurement data, and flow measurements of said solids and liquids and produces control signals for said pressure control device. The system may include a solid management system may include a combination of flush and vacuum pumps, said solid management system being connected to convey solids in a slurry from said debris separation device to said tank for liquid and solids. Implementations of the described techniques may include hardware, a method or process, or computer software on a computer-accessible medium.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description and claims are merely illustrative of the generic invention. Additional modes, advantages, and particulars of this invention will be readily suggested to those skilled in the art without departing from the spirit and scope of the invention. A more complete understanding of the invention and many of the attendant advantages thereto will be readily appreciated by reference to the following detailed description when considered in conjunction with the accompanying drawings, wherein like reference numerals refer to like parts and wherein:

FIG. 1A is a high-level operation description diagram prior to well plugs being drilled out.

FIG. 1B is a high-level operation description diagram showing a location of scaling in a well bore.

FIG. 2 is a diagram of a prior art Plug Milling/Flow-back system.

FIG. 3 is a diagram of a Plug Milling and/or Flow-back and/or Descaling system and method in accord with one embodiment of the present invention.

DETAILED DESCRIPTION

For decades, unconventional oil and gas reserves were not accessible due to the tight oil and gas reservoir characteristics. Reservoir Fracturing was a key element to enable the production from such reservoirs. The reservoir fracturing process requires the installation of multiple plugs in the wellbore to provide isolation to the different zones being fractured. Those plugs are drilled after the fracking operation is concluded to allow the connection of the reservoir to the well bore. This allows the production of the reservoir. The Frac Plug Drill Out (FPDO) operations are normally done by Coiled Tubing (CT) equipment and Flow Back Well Test equipment (FBWT) after the fracturing equipment is demobilized from the site. The operations of CT and FBWT are essential to ensure the wellbore and the reservoir connect and allow the hydrocarbons to be produced. Following the milling of plugs, a flow period is normally conducted, where further frac fluids, solids and hydrocarbons are recovered to the surface temporary facilities. This initial recovery of frac fluids is essential to guarantee that the full extent of fractures are connected to the well bore and will later contribute to the production. Also, the reservoir drawdown and overbalance are important variables in this process, as they can lead to fracture closure or non-connection, leading to future production losses. Control of parameters, process stabilization and reservoir understanding combined can improve the final production of the wells.
Another situation that occurs on the hydrocarbon well lifecycle is the accumulation of scales, which are product of downhole chemical reactions and eventually lead to the choking of the production tubing, limiting the outcome of hydrocarbons of this well. Those scales are in form of hard solids that are removed mechanically, chemically or combined both methods for removal. It requires coil tubing equipment to allow the proper chemicals placement and mechanical removal. Planning for this operation is supported by well surveys using different access methods such as wireline or slick line or even coil tubing special tools. There is a special interest for live descaling since the avoidance of reservoir infiltration with “killing fluids” will allow faster production recovery and avoidance of additional costs to eventually treat for formation damage or long flowbacks for fluid recovery. Live descaling operations have additional execution challenges, when compared with overbalance descaling, especially when toxic gases like H2S and Naturally occurring radioactive material (NORM) maybe present. In those scenarios, a wide and random solid distribution, potentially radioactive, in presence of toxic gases, flammable hydrocarbons, high pressure streams, need to be managed safely, with minimum direct human intervention or contact with the return medias.
Looking at FIG. 1A, a basic description of the well operation setup 10 can be seen. Coiled tubing units are well known. The coiled tubing unit 12 comprises coiled tubing that runs through the Christmas Tree and the Pressure control equipment (PCE), 14 that provides the safety barriers for pressure integrity. The bottom hole assembly (BHA) 16 contains a milling tool to allow for the frac isolation plugs 18 to be removed from the wellbore. Removal of the plugs provides connection of reservoir 20 and fractures 22 to the wellbore 24. While milling, the pressure stabilization is a complex task. The residual fracture pressure, the natural reservoir pressure and the accommodation of the frac sands in the fractures 20 create an operational challenge to stabilize pressure, flowrate, solid returns (removed from the well bore). Lack of control can easily lead to shocks in the reservoir formation and risks of fracture closure and expelling of solids to the well bore. The flow that circulates out of the BHA 16 depending on the pressures, viscosity and rate will carry the plug milling debris, proppant frac, residual gas and liquid hydrocarbon. Those returns are carried to the surface in the annulus between the wellbore 24 and the CT pipe, which is conducted through surface piping 26 to the Flowback well test equipment 28. When it comes to descaling a similar coil tubing equipment is deployed, but the downhole scenario changes. Other than milling plugs and cleaning the residual proppant frac, now the coil tubing will apply various mechanical and chemical techniques that will lead to the removal of the scales 17, shown in FIG. 1B, that are mostly in solid form back to the surface The composition of prior art systems varies but can be described in general terms by the FIG. 2 .
Looking to FIG. 2 , a diagram of a generalized prior art FPDO, FBWT and live descaling system 200 is shown. The coiled tubing has a pump rate 202 and depth 204, which comprise the CT (coiled tubing) data 206. A CT unit oversees a series of parameters. A few parameters have a bigger impact on the final fracture connection and protection than others, the same applies for live descaling. The fluid input 210 is produced by controlling the pump rate 202 and pressure feedback 236. The milling/jetting operations are controlled with the drill motor and mill 16, depth of CT 204, weight on string, and other factors by a first team of operators. On the fluid returns side, a second team of operators, the Flowback team, controls the choke size at the pressure control device 226 to stabilize the overall system pressure to the required pressure and receive the returns. The returns are composed of residual reservoir gas 218 (occasional for FPDO and constant for live descaling), residual reservoir liquid hydrocarbon (occasional for FPDO and constant for live descaling), pumped-in fluid 210 returns (predominant media for FPDO), plug debris/bigger solids 214 and fracturing sands/finer solids 216 that remained or were expelled in the well bore and near well bore areas, or generated by the scale disaggregation. Generally, large pieces of plug debris/bigger solids are removed from the stream 222 followed by sand removal/finer solids 224, a pressure control element (via a choke valve or expendable choke system, (ECS) 226 and fluids have either a separation stage or go to waste pits or tanks 228.
Due to the high pressure, flowrates, the abrasive and potentially sour/radioactive environment, and due to possible presence of toxic gases and NORM, the tools available for flow rate measurements are very limited, being not widely used due to accuracy and poor results. Furthermore, the sand and solids produced and associated to high pressure also often cause “wash-out” or erosion of pipes and equipment, which leads to loss of process control and integrity of the system. Several accidents are recorded in the Oil and Gas industry related to those scenarios. Often plug debris/bigger solids are manually removed 234 where a strainer vessel has to be isolated, depressurized and accessed to allow an operator to collect the pieces into a container. This operation has a high operator exposure as often only a single barrier is present and also the small instrumentation liners used for depressurization are exposed to extremely abrasive fluids, leading to complete wash-outs. On the sand/finer solids separation 224, the practice is to remove the solids “as upstream as possible” to reduce the exposure of other regular FBWT/live descaling equipment. This solid separation concept leads to high pressure separation systems, which are heavy, expensive and limited in adapting to the operating windows. Different methods are used, between sand traps, filters and cyclonic or combination of the above. Flush equipment 230 is used with the sand/solid separator isolated (off-line) or in-stream (live), using external fluids to push the accumulated solids out to a solid box 232. In some cases, the pressure from the system is used to push the accumulated solids out as option. Handling high concentration of solids with high pressure creates a high risk of erosion for valves, instrumentation lines and pipe.
The CT and FBWT/live descaling systems are normally operated with a low degree of integration as shown in FIG. 2 , with data distributed only in the CT and FBWT modules. Decisions are motivated by execution time, risk of getting CT stuck, and pipe or equipment erosion as the main concerns, as they can lead to loss of pressure containment and exposure of personnel in the surroundings. Currently the activity is clustered, and no data/action interlink happens between the blocks. This limits the actions to the clusters themselves, where operators may individually take decisions that are not favorable to efficiency, such as, if the CT do a single “bite” to bring more solids in one trip. This may be more efficient usage of the coiled tubing, which makes less runs, but may lead to excess sand at surface causing multiple problems that can lead to downtime. Additional problems with the prior art include, but are not limited to: Erosion and the inherent integrity related issues, Lack of flow measurements and leading to potential lack of process control, Limited or inexistent sampling due to valve erosion risks, Plugging issues leading to process upsets and downtime, Limited Process metering and process instrumentation due to harsh conditions, Distributed data in different locations and work units, Solids handling with people exposure to the effluents and pressure, Generalized lack of process knowledge due to limited data acquisition, caused by the challenges of adding instruments in harsh environment, and Multiple heavy assets and complex rig-up.
Turning now to FIG. 3 , a diagram shows the present system and method for integrated plug milling and flow-back operations (live descaling). The present invention provides an innovative workflow for FPDO and FBWT, which allows better process controls leading to process safety, pressure integrity, operational efficiency and production improvements. The system is composed of two main components, a data management component 350 and a fluid management physical interconnection component 360. The system architecture and the individual features are applied to achieve solid separation and measurements of liquid and solids for all coiled tubing related well intervention operations. This system architecture, through safely managing the effluent and the harsh operating environment, allows for a higher degree of instrumentation, leading to valuable process insights that were not possible in the prior art. The proposed solids management and its strategy of safely moving the solids to downstream, with minimized erosion and plugging risks allows for application of standard instruments in points of the process where it wasn't possible in the prior art. Any process optimization is highly dependent on the degree of available information and what you choose to do with it. Following this logic, the present system aims to benefit by a new level of access to samples and measurements to allow better decisions, both human or machine based, that will lead to operational efficiency and process safety.
The data needs to flow to allow information to be converted into actionable insights with specific objectives. The main listed objectives are to allow the proper assessment of the traditional concerns, as described hereinbefore in reference to FIG. 2 , and to integrate all the process parameters in a single unit to allow more efficient data processing. The data processing includes, but is not limited to, proper selection of pump rates, circulation rates, choke sizes to regulate system pressure, protection of fractures downhole via data analysis (not the direct intention of this invention, although it will provide the support to achieve it), data storage to allow future learning by workers or artificial intelligence and provide a base output for fully autonomous system. The process works as a simple interactive cycle, where process changes lead to new input parameters seeking for live optimizations for the new current conditions. Coiled tubing data 306 obtains the pump rate 302 and the depth 304 of the coiled tubing milling assembly. The pump rate 302, which is normally given by the coiled tubing data system 306 as a measurement from a positive displacement pump (piston type normally) needs to be synchronized with the Pressure control device 326, which may have a complete automatic control option, so that the user can set a pressure target and the device compensates for the process variations, or the device is set fixed and the process will vary accordingly. The choke measurement data and feedback 342 is composed of multiple variables, such as pressures, temperatures, opening and other control parameters, which allows for a better, human or machine, selection of pump rate 302.
The commands, or control information, for the choke are given by the Flowback control system 330. This system allows for multiple operation mode layers, from manual to fully automatic with the required overrides to allow for back-up manual operations in case of extreme process degradation or equipment failure. The system also removes the need of the operators to be in direct contact with the equipment. In the simplest operations mode (manual), the system utilizes remote electric commands, which eliminate the need of direct contact or proximity by the operator with the equipment. The data flow from CT system 306, from Choke measurements 342, from Flow measurements 332 into Well test/flowback centralized data aggregation portion or platform 308 to be further processed in the Flowback data analysis module 328 to provide the actionable insight to the Flowback control system 330. The Flowback data analysis 328 is based on the interpretation and answering of the following questions: How much pressure? How much temperature? Are Hydrocarbons present? How much solids production? How much Gas production? How much liquid production? What is the choke opening? What type of liquids? All of those questions can also be placed in the transient domain by asking: how has this parameter changed? The system trends can be analyzed, and the combinations of those main process answers will provide the human or machine, the capabilities to take better decisions and differentiate the potential events or underbalance conditions, fluid losses, fracture unfavorable flow conditions, excess solids production, and the like.
The Fluid management component 360 is the physical interconnection of the different equipment blocks and how each participates in the process. In one embodiment of the present invention, these equipment components may include, but are not limited to: A debris separator 322 in the high-pressure section, to allow the collection of the bigger pieces of solids from milling of plugs and minimized operator exposure. Pressure control device 326 provides pressure reduction (stabilization and/or automation) of the stream that includes all the fine solids. Effluent separation (gas/liquid/solid) split is provided in gas management/flow measurement 334. Liquid solid separation occurs in tank 336. Solid mass balance trough measurements and the calibration methods 346 are developed to improve accuracy. Pumped in fluid filtration and treatment allow fluid re-use from water treatment system 338 as recycled water. Solid handling trough vacuum/flush system 340 provides multiple alternatives of flushing points and solids collection.
The fluid management physical interconnection component 360 is configured to separate plug debris from frac sands, gas, and pumped fluid, and to utilize the flush and vacuum system 340 to convey plug debris to the tank 336 for liquids and solids.
Another difference is that unlike the prior art, the frac sands/finer solids are not separated at high pressure. Instead, as shown in FIG. 3 , frac sands/finer solids are directed to flow through the debris separation device 322, through said pressure control device 326, through the at least one mechanism connected for gas management and flow measurements of solids and liquids 324 and into the tank 336 for liquid and solids.
Safe access to sampling points as the system manages the effluent stream safely to low pressure. With a simplified and innovative workflow, where critical data like liquid and solid flowrate are available, in combination with automation of pressure control tasks, the solid handling capabilities of the system without precedents, new limits can be achieved. The proposed system architecture has a much safer concept of solids handling, which also allows for more solids handling capability and overall efficiency. The debris separation step 322 is intended to filter the bigger solid particles that can create issues to the next device in the stream. This equipment is composed of pots similar to the Plug & trash catchers, with millimeter scale strainer/filter (typical 5 mm holes strainer), with the difference of being vertical, with higher volume and allowing to be emptied without the need to be opened. Also, the filter device can be of different shapes, being short and allowing solids collection on the whole pot body, or being long, with the collection happening in the filter ID. The collection can only be achieved by the application of Vacuum and flush 340 from different access points in the solid retainer vessel. The flush pump can push solids from the vessel directly, trough access points in the sides and top, or using the fitted venturi in the bottom of the pot, which allow the flush line to create some negative pressure to disaggregate the solids and carry them. As a last resource, the vacuum can be used in batches to move the solids out. All the solids are accumulated in the vacuum vessel and pumped as slurry to disposal pits or a tank. Or if flushed, the solids can be directly sent for disposal.
The pressure control device 326, normally called the Choke manifold, is a combination of hydraulic and manually operated gate valves, instrumentation flanges, and choke valves, both fixed type and adjustable type. This manifold has to operate in the presence the high concentration of solids and high-pressure flow, which is an extremely abrasive condition. The stream nature (liquid dominant, no compressible fluid or gas present, compressible fluid) will lead to different erosion mechanisms, and both have to be treated with different operational strategies and a common mechanical arrangement that addresses both is needed. The first feature is the use of two choke valves to reduce the pressure in steps. The first, being a “drilling” choke valve, with a quick opening profile, using a plug/seat type of mechanical construction, fitted with an actuator and feedback, that will allow remote and automatic operations, and eventually degraded operations with the override system. To compensate for the exit jet effects (incompressible stream) and velocity increase due to expansion (compressible stream), a spacer joint with bigger diameter or an angular arrangement may be used to allow for a blast blind flange on a block that can be easily replaced. Both configurations can be used depending on the specific flow parameters for the system being deployed. Different units may use one or the other system according to the more specific flowrate and space requirements. Downstream this joint or block arrangement there will be the second choke valve. This choke valve is fitted with the fixed orifice type. The pressure breakdown strategy in two steps enhances the life of the choke valves and surrounding equipment considerably in both operating stream types. The combination of fixed beam plus automatic adjustable choke allows for pressure stabilization independently of the process variations. The 1^stvalve will automatically modulate to a certain position to compensate for variations and achieve a given pressure set point, which is normally desired in FPDO operations. Alternatively, the valves can be set to a position and the process variations will lead to pressures and flowrate variations, which may normally be desired in FBWT, when the well is flowing.
The arrangement will allow for reduced velocities in the equipment and therefore enhance the life in high concentration of solids. The Gas management/flow measurement 334 plus the calibration of measurement 346 can happen in the same module, if desired. The presence of gas isn't desired in the FPDO operations, as it is predominantly an overbalance operation. But, in some occasions gas comes while drilling the plug, or potentially a more serious loss of over balance. In order to help identifying quickly that presence of Hydrocarbon gas, a meter and detection system is installed in the gas line outlet of the device, to allow the operation team to spot and act quickly in that event and also record the event for further investigations and procedures improvement. In the case of live descaling the hydrocarbons will be always present and that won't present a risk or a problem, since the equipment can handle it. Given the need to reduce restrictions in that line and the detection criteria, an ultrasonic full-bore type of meter is applied. In a preferred embodiment, the vessel used for this purpose has a set of inlet devices to improve the gas separation from stream, as the gas migrating to liquid can create other problems on the downstream liquid outlet, such as measurement errors, higher velocity and degassing in the downstream tank. The meter used for this application is a mass meter fitted with diagnosis tools based on multi-frequency technology, being this diagnosis is essential to indicate the meter is operating within the right conditions to validate the measurements of the liquid and solids mass. The meter provides a mass output, that can be further processed to extract the split between liquid and solids. This measurement will then be validated by a large quantitative sample extracted from the process in the calibration system 346. The flow is deviated for a short time to a separated enclosed tank, which is supported by load cells. The initial load values can be offset from the measurements. The tank is filled, with the stream content, after settling an overall mass is recorded, the tank has a filtered suction line and a set of internals that reduce the movement of solids to that point, after draining, solids will be “as dry as possible” and measured its mass. These values can all be compared to the periods before and after the “calibration run” and correction factor can be introduced. The calibration tank also has a gas vent and can be flushed or vacuumed to ensure it is clean for the next run. In summary, gas efficiency separation is enhanced, gas is metered and presence of hydrocarbon indicated, liquid and solids leg will not contain gas, and if they do the meter can get indication of that, which is used as a measurement quality control, mass is measured, post processing allows for the mass split of solids and liquid and a correction factor based on the calibration factor found is applied to adjust the measurement accuracy.
Accordingly, a system for improved workflow in plug milling/flowback/descaling operations is provided that may comprise a data management component further comprising a centralized data aggregation platform, an analysis module and a control system.
Additionally a fluid management physical interconnection component further comprises a debris separation device, a pressure control device, a gas management and flow measurements device, a tank for liquid/solids, a water treatment module and a flush/vacuum system for solids management.
The data management component analyzes a plurality of fluid and solid characteristics of a return fluid to automate operation of said fluid management physical interconnection based on a predefined set of variables for said fluid and solid characteristics.
The fluid management component separates the plug debris/bigger solids in the high-pressure section and safely conveys all the remaining solids to the downstream part of the process.
In one embodiment, the system is operable to monitor remotely from human contact attributes such as pressures, temperatures, gas flow rate, solid and liquid mass flow rate and trough calculations. The system may deduct the split of the mass, with the support of calibration procedure that uses actual flow conditions data and samples, measuring the solids and liquid content. An alternative method allows the application of a liquid/solid split correction coefficient.
A solid management system is provided that is based on combined flush and vacuum pumps. The flush can be direct or with venturi to create suction effect on bottom of vessels. Vacuum can be provided with a dedicated tank and with batch operation. This system is connected in strategic process locations to allow sparging, dynamic vacuum and flush with the intention to convey solids in the slurry to low pressure tanks for disposal, eliminating the operator contact with it. Thus, the system reduces people's exposure.
A rugged solid resistant design of pressure control device is provided, with automatic\manual pressure or position control, with at least two actuated gate valves with double barrier, making a total of eight isolation valves, four chokes, fixed and actuated, split in two flow branches with spacer flow joint or angular block with cushion blind flanges to enhance the resistance to operate in the presence of solids.
A modular system is designed to reduce mobilization and demobilization mechanical lifting and complexity, having equipment substantially entirely installed in interconnectable trailers and having the mechanical arrangements to allow for the minimum use of external equipment. The modules also allow for the adaptation of extra tanks and flow equipment according to the specific operations requirements.
A unique liquid/solid tank design allows handling of liquids and solids in large quantities, containing multiple engineered weir plates, sparging/circulation systems and with some capacity to handle gas, this tank provides enhanced oil/water separation prior to the next fluid processing step.
A high efficiency liquid gas separator is designed to work as close as possible to atmospheric pressure improves separation. The separator has a gas meter installed that has no obstructions, and a customized carry under preventer valve to enhance process safety.
A debris separation device with accumulation vessels is designed to separate the bigger debris pieces from the main stream using trough gravity and filtration, with engineered flush and vacuum ports to allow the solids removal without operator contact
A modular trailer mounted system is provided with optimized connections and for improved mobilization time.
The water treatment system considers and allows the connection of different water treatment methods.
A pressure control device allows for setting a fixed pressure target so that the choke valve can be automatically modulated to compensate for the process variations and achieve the desired pressure set point.
A method is provided to reliably extract liquid and solid mass split from a mass meter and applies correction factors and quality control to validate the measurement.
The use of a full-bore metering device may be used in the separator gas line to ensure the detection of hydrocarbon and the quantification of it.
A meter site calibration method with dedicated equipment is based on a large volume sample, and mass measurements and drainage system.
The foregoing description of the preferred embodiments of the invention has been presented for purposes of illustration and description only. It is not intended to be exhaustive or to limit the invention to the precise form disclosed; and many modifications and variations are possible in light of the above teaching. Such modifications and variations that may be apparent to a person skilled in the art are intended to be included within the scope of this invention as defined by the accompanying claims.

Claims

1. A system for well operations, comprising:

a coiled tubing unit;

a data management component comprising a data aggregation portion, an analysis module and a control system; and

a fluid management physical interconnection component comprising a debris separation device, a pressure control device comprising a choke, and at least one mechanism connected for gas management and for flow measurements of solids and liquids;

whereby said data management component receives coiled tubing data, choke measurement data, and flow measurements of said solids and said liquids.

2. The system of claim 1 wherein said system is configured to operate for at least one of coil plug milling, flowback, or descaling.

3. The system of claim 2, wherein said data management component is operable to provide control information for operation of said fluid management physical interconnection component.

4. The system of claim 3, wherein said data management component is operable to automate operation of said fluid management physical interconnection component based at least in part on an analysis of said flow measurements of said solids and said liquids.

5. The system of claim 3 wherein said a fluid management physical interconnection component further comprises a tank for liquid and solids, a water treatment module, and a flush and vacuum system for solids management.

6. The system of claim 5 whereby said fluid management physical interconnection component is configured to separate plug debris from frac sands, gas, and pumped fluid, and to utilize said flush and vacuum system to convey said plug debris to said tank for liquids and solids.

7. The system of claim 6, said system is operable to monitor pressures, temperatures, gas flow rate, and solid and liquid flow rates.

8. The system of claim 2 wherein said pressure control device comprises a plurality of valves and at least four chokes and said data management component is operable to automatically choose which of said at least four chokes to utilize for operation of said pressure control device.

9. The system of claim 2, wherein said data management component and said fluid management physical interconnection component are substantially entirely installed in interconnectable trailers.

10. The system of claim 5, wherein said tank for liquid and solids comprises a plurality of weir plates and a sparging system.

11. The system of claim 2 wherein said at least one mechanism connected for gas management and for flow measurements of solids and liquids comprises a liquid gas separator that is configured to operate near atmospheric pressure.

12. The system of claim 2 wherein said control system controls a choke size for said pressure control device.

13. The system of claim 2, wherein choke measurement data and said flow measurements of said solids and said liquids are used for selection of a pump rate.

14. A system for well operations, comprising:

a coiled tubing unit;

a low pressure tank for disposal;

a data management component; and

a fluid management physical interconnection component comprising a debris separation device, a pressure control device comprising at least one choke, and at least one mechanism connected for gas management and flow measurements of solids and liquids,

a solid management system comprising a combination of flush and vacuum pumps, said solid management system being connected to convey solids in a slurry to said low pressure tank for disposal.

15. The system of claim 14 wherein said system is configured to operate for at least one of coil plug milling, flowback, or descaling.

16. The system of claim 15, further comprising a water treatment system connected to said low pressure tank to produce recycled water.

17. The system of claim 15, wherein said data management component receives coiled tubing data, choke measurement data, and flow measurements of said solids and said liquids and produces control signals for said pressure control device.

18. The system of claim 17, wherein said control signals are utilized to select a choke size for said pressure control device.

19. The system of claim 17 whereby said solids comprise plug debris, said solid management system is configured so that operator physical contact with said plug debris for removal of said plug debris is eliminated.

20. A system for well operations, comprising:

a coiled tubing unit;

a data management component;

a fluid management physical interconnection component comprising a debris separation device, a pressure control device comprising at least one choke, and at least one mechanism connected for gas management and for flow measurements of solids and liquids, and a tank for liquid and solids; and wherein

said fluid management physical interconnection component is configured so that frac sands are directed to flow through said debris separation device, through said pressure control device, through said at least one mechanism connected for gas management and flow measurements of solids and liquids, and into said tank for liquid and solids.

21. The system of claim 20 wherein said system is configured to operate for at least one of coil plug milling, flowback, or descaling.

22. The system of claim 21, wherein said data management component is configured to receive coiled tubing data, choke measurement data, and flow measurements of said solids and liquids and produces control signals for said pressure control device.

23. The system of claim 21, further comprising a solid management system comprising a combination of flush and vacuum pumps, said solid management system being connected to convey solids in a slurry from said debris separation device to said tank for liquid and solids.