US20230392478A1 - Partitioning High Pressure Pumps At A Well Site - Google Patents
Partitioning High Pressure Pumps At A Well Site Download PDFInfo
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- US20230392478A1 US20230392478A1 US18/327,600 US202318327600A US2023392478A1 US 20230392478 A1 US20230392478 A1 US 20230392478A1 US 202318327600 A US202318327600 A US 202318327600A US 2023392478 A1 US2023392478 A1 US 2023392478A1
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- slurry
- pumps
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- brine
- barrier
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- 238000000638 solvent extraction Methods 0.000 title description 3
- 239000002002 slurry Substances 0.000 claims abstract description 244
- 239000012267 brine Substances 0.000 claims abstract description 112
- HPALAKNZSZLMCH-UHFFFAOYSA-M sodium;chloride;hydrate Chemical compound O.[Na+].[Cl-] HPALAKNZSZLMCH-UHFFFAOYSA-M 0.000 claims abstract description 112
- 230000004888 barrier function Effects 0.000 claims abstract description 95
- 238000012423 maintenance Methods 0.000 claims abstract description 50
- 238000011064 split stream procedure Methods 0.000 claims abstract description 28
- 238000000034 method Methods 0.000 claims description 36
- 239000000956 alloy Substances 0.000 claims description 3
- 229910045601 alloy Inorganic materials 0.000 claims description 3
- 239000002131 composite material Substances 0.000 claims description 3
- 239000002184 metal Substances 0.000 claims description 3
- 229910052751 metal Inorganic materials 0.000 claims description 3
- 150000002739 metals Chemical class 0.000 claims description 3
- 229920000642 polymer Polymers 0.000 claims description 3
- 230000037452 priming Effects 0.000 claims description 3
- 238000005086 pumping Methods 0.000 claims description 3
- 239000012530 fluid Substances 0.000 description 25
- 238000013459 approach Methods 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- 239000004576 sand Substances 0.000 description 3
- 239000000243 solution Substances 0.000 description 3
- 229930195733 hydrocarbon Natural products 0.000 description 2
- 150000002430 hydrocarbons Chemical class 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 208000010392 Bone Fractures Diseases 0.000 description 1
- 206010017076 Fracture Diseases 0.000 description 1
- 229920000271 Kevlar® Polymers 0.000 description 1
- 208000002565 Open Fractures Diseases 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000004761 kevlar Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B41/00—Equipment or details not covered by groups E21B15/00 - E21B40/00
- E21B41/0021—Safety devices, e.g. for preventing small objects from falling into the borehole
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/25—Methods for stimulating production
- E21B43/26—Methods for stimulating production by forming crevices or fractures
- E21B43/2607—Surface equipment specially adapted for fracturing operations
Definitions
- Embodiments of the technology relate generally to partitioning high pressure pumps at a well site.
- High pressure pumps are commonly used at a well site in connection with the production of hydrocarbons.
- the high pressure pumps are used to inject a variety of fluids into an oil or gas well during certain well operations.
- One such operation is hydraulic fracturing, which is a process that involves injecting fluids into a well at high pressure to fracture a formation.
- the injected fluids include a slurry containing particles that prop open fractures in the formation to improve the flow of hydrocarbons from the formation into the well.
- Hydraulic fracturing typically uses high pressure pumps to obtain the required high pressures for injecting the fluids into the well.
- a well site often includes a well pad with multiple wellheads. Numerous high pressure pumps at the well site are used to inject the high pressure fluids into the wells.
- the high pressure pumps are typically connected to a fracturing manifold that directs the high pressure fracturing fluids to a zipper manifold which in turn directs the fluids to the wellheads at the well pad.
- a significant limitation to improving the operational performance of a well site employing hydraulic fracturing is the need for regular maintenance on the high pressure pumps.
- the area around the high pressure pumps is referred to as the red zone because the high pressures generated by the pumps create risks of leaks and equipment failures that can be dangerous to workers.
- maintenance typically requires that the high pressure pumps are turned off and depressurized before the workers can enter the red zone to perform maintenance.
- turning off and depressurizing the high pressure pumps requires shutting down the equipment at the well site for significant periods of time, resulting in substantial disruption of the operations of the well site as well as added costs.
- the present disclosure is generally directed to a system at a well site.
- the system can comprise a plurality of brine pumps and a plurality of slurry pumps.
- the brine pumps can be configured to pump brine into at least one wellhead at the well site.
- the plurality of slurry pumps can be configured to pump slurry into the at least one wellhead at the well site.
- a split stream barrier can separate the plurality of brine pumps from the plurality of slurry pumps. At least one slurry barrier can separate a first slurry pump and a second slurry pump of the plurality of slurry pumps.
- the present disclosure is generally directed to a method for operating a well site.
- the method can comprise: 1) positioning a plurality of brine pumps at the well site, wherein the plurality of brine pumps are configured to pump brine into at least one wellhead at the well site; 2) positioning a plurality of slurry pumps at the well site, wherein the plurality of slurry pumps are configured to pump slurry into the at least one wellhead at the well site; 3) separating the plurality of brine pumps from the plurality of slurry pumps by installing a split stream barrier between the plurality of brine pumps and the plurality of slurry pumps; 4) separating each slurry pump of the plurality of slurry pumps by placing a slurry barrier between each adjacent slurry pump of the plurality of slurry pumps; 5) identifying a selected slurry pump for maintenance, wherein a remainder of the slurry pumps are not selected for maintenance; 6) remotely turning off and depressurizing the selected slurry pump with a remotely operated actuator;
- the present disclosure is generally directed to a system at a well site, the system comprising a brine pump area comprising a plurality of brine pumps and a slurry pump area comprising a plurality of slurry pumps.
- the plurality of brine pumps are configured to pump brine into at least one wellhead at the well site, while the plurality of slurry pumps are configured to pump slurry into the at least one wellhead at the well site.
- a split stream barrier separates the brine pump area from the slurry pump area.
- At least one slurry barrier separates a first slurry pump of the plurality of slurry pumps from a second slurry pump of the plurality of slurry pumps.
- the present disclosure is generally directed to a method for operating a well site.
- the method can comprise: 1) positioning a plurality of brine pumps in a brine pump area at the well site, wherein the plurality of brine pumps are configured to pump brine into at least one wellhead at the well site; 2) positioning a plurality of slurry pumps in a slurry pump area at the well site, wherein the plurality of slurry pumps are configured to pump slurry into the at least one wellhead at the well site; 3) separating the brine pump area from the slurry pump area by installing a split stream barrier between the brine pump area and the slurry pump area; 4) separating a first slurry pump of the plurality of slurry pumps from a second slurry pump of the plurality of slurry pumps by installing a slurry barrier between the first slurry pump and the second slurry pump; 5) identifying the first slurry pump for maintenance; 6) remotely turning off and depressurizing the first slurry pump
- FIG. 1 illustrates a well site with a plurality of high pressure pumps as known in the prior art.
- FIG. 2 illustrates a barrier placed between two wellheads as known in the prior art.
- FIG. 3 illustrates a wellsite with a barrier system in accordance with the example embodiments of the present disclosure.
- FIG. 4 illustrates a method for operating a well site in accordance with the example embodiments of the present disclosure.
- FIGS. 5 - 10 illustrate various configurations for brine pumps and slurry pumps in accordance with the example embodiments of the present disclosure.
- the example embodiments discussed herein are directed to apparatus and methods for partitioning high pressure pumps at a well site to improve operations of the well site. Because slurry pumps typically require frequent maintenance while brine pumps do not, a brine pump area and a slurry pump area can be separated by a split stream barrier. Additionally, the slurry pump area can sub-divided with slurry barriers to separate one or more slurry pumps from other slurry pumps. The system of barriers allows one or more slurry pumps to be deactivated for maintenance while other slurry pumps and the brine pumps continue to operate. Isolating the high pressure slurry pumps for maintenance improves the safety of the well site for workers performing maintenance on the slurry pumps. Additionally, the system of barriers permits operations of the well site to continue while maintenance is performed on a selected slurry pump. Accordingly, the well site can operate more efficiently.
- FIGS. 1 and 2 illustrate prior art approaches to operating a well site.
- FIG. 1 illustrates a typical well site 100 as known in the prior art.
- Well sites can often include multiple wells as illustrated by well 1 , well 2 , well 3 , and well 4 located on well pad 105 .
- Well site 100 includes tanks 150 , 152 , and 154 containing fracturing fluid that is injected at the wellhead of each well.
- the fracturing fluid can include brine as well as other fluids that assist with the hydraulic fracturing operation.
- a blender 140 can be used to mix sand or other proppant into one or more streams of the fracturing fluid.
- Flow lines connect the tanks 150 , 152 , and 154 and the blender 140 to a fracturing manifold 115 .
- the fracturing manifold 115 feeds the various fracturing fluid streams to the high pressure pumps 120 , 122 , 124 , 126 , 128 , and 130 where the pressure of the fluid streams is increased before they are injected into the wells.
- the fracturing manifold 115 directs the high pressure fracturing fluids to a zipper manifold 110 that is coupled to the wellheads of each of wells 1 , 2 , 3 , and 4 .
- a hydraulic fracturing operation performed on a single well often requires multiple high pressure fluid streams from multiple high pressure pumps.
- the high pressures generated by the pumps increase the probability of equipment leaking or failing, thereby increasing the risks for workers in the areas around the high pressure pumps 120 , 122 , 124 , 126 , 128 , and 130 . Accordingly, it is common to refer to the areas around the high pressure pumps as red zones. Given the increased risks in the red zones, if maintenance is needed on a single pump, it is common to shut down and depressurize all nearby pumps so that the maintenance can be performed. However, shutting down all nearby pumps disrupts the operation of the well site 100 .
- FIG. 2 illustrates an example of a prior art wellhead barrier that can be installed at a well pad of a well site 200 .
- wellhead barrier 215 is installed between wellhead 205 and wellhead 210 .
- the wellhead barrier 215 provides protection to workers performing work on one of the wells so that the other well can remain pressurized and operating.
- Well site 300 in accordance with the embodiments of this disclosure is illustrated.
- Well site 300 includes a well pad 305 with wells 1 , 2 , 3 , 4 , 5 , 6 , and 7 .
- Well site 300 is arranged for hydraulic fracturing operations.
- the well site includes a boost pump 342 that pumps hydraulic fracturing fluid from tanks 350 for use in the wells at the well pad 305 .
- a blender 340 can mix sand (and/or another proppant) from sand storage area 355 into certain of the streams of hydraulic fracturing fluid.
- Well site 300 includes two strategies for improving the operation of the well site.
- the high pressure pumps are organized into a split stream arrangement where they are separated into a brine pump area 370 and a slurry pump area 380 .
- the brine pumps will pump brine solution that does not include a proppant.
- the slurry pumps will pump a slurry solution that includes a proppant.
- the existence of a proppant in the fluid stream often causes fouling of valves and other components of the pumps, resulting in the need for more frequent maintenance of the pumps.
- the advantage of the split stream arrangement is that the pumps handling the fluid streams with proppant, which will require more frequent maintenance, are separated into a slurry pump area.
- the pumps handling a brine solution that does not include a proppant, and therefore require less frequent maintenance are organized into a brine pump area.
- FIG. 3 illustrates a barrier system 360 that separates a brine pump area 370 from two slurry pump areas 380 and 381 . While the barrier system 360 is illustrated in general form in FIG. 3 , examples of specific implements of the barrier system are shown in greater detail in FIGS. 5 - 10 .
- the barrier system can include a split stream barrier that separates the brine pump area from the slurry pump area(s).
- the barrier system can also include slurry barriers located between individual slurry pumps or groups of slurry pumps. Given the more frequent maintenance of the slurry pumps, the slurry barriers are beneficial for isolating individual slurry pumps or groups of slurry pumps.
- the barrier system allows individual slurry pumps or groups of slurry pumps to be turned off and depressurized for performing maintenance while the remaining slurry pumps and the brine pumps can continue to operate.
- the barrier system will protect workers in the red zone area around the pump(s) receiving maintenance from the high pressure conditions of surrounding slurry pumps and brine pumps that are continuing to operate.
- a fracturing manifold 315 receives slurry fluid streams containing proppant from the blender 340 and supplies those slurry fluid streams to the slurry pumps in slurry pump areas 380 and 381 .
- the fracturing manifold 315 receives brine fluid streams (without a proppant) from the boost pump 342 and supplies those brine fluid streams to the brine pumps in the brine pump area 370 .
- the fracturing manifold 315 then receives the pressurized slurry fluid streams and brine fluid streams from the respective pumps and supplies those pressurized streams to the zipper manifold 310 for delivery to the wellhead of each well
- method 400 is illustrated for operating a well site in accordance with the example embodiments of the present disclosure. It should be understood that method 400 is intended to be a representative example and that in alternate embodiments certain operations of method 400 can be combined, performed in parallel, or omitted. Additionally, other operations can be added to method 400 .
- brine pumps are positioned at the well site in the brine pump area and slurry pumps are positioned at the well site in the slurry pump area.
- the brine pumps and slurry pumps are typically located on trailers that are transported to and positioned at the well site.
- one or more split stream barriers are installed between the brine pump area and the slurry pump area.
- one or more slurry barriers are installed between the slurry pumps. In some cases, slurry barriers can be installed between each slurry pump. In other cases, slurry barriers can be installed between subgroups of slurry pumps.
- slurry pumps can be identified for maintenance when needed.
- a slurry pump is selected for maintenance.
- a subgroup of slurry pumps can be selected for maintenance.
- the slurry pump selected for maintenance is turned off and depressurized.
- Each slurry pump can be equipped with an actuator that is remotely controlled and that can control powering off/on and depressurizing/ pressurizing the slurry pump.
- the actuator can be remotely controlled by radio signals or a length of cable that allows a worker to control the pump without being in proximity to the pump.
- method 400 can return to operation 420 where the hydraulic fracturing operations can proceed at the well site until maintenance is required on another slurry pump.
- method 400 of FIG. 4 describes operations for performing maintenance on a slurry pump
- the method can be adapted for performing maintenance on a group of slurry pumps.
- method 400 also can be adapted for performing maintenance on a brine pump or a group of brine pumps.
- slurry pumps and brine pumps are not required to be in the off state for priming such that in some embodiments the slurry and brine pumps can be remotely primed while they are pumping.
- the barriers can take a variety of shape and form.
- the barrier walls can be walls or flexible curtains of high strength material such as composites, metals, alloys, or polymers such as Kevlar.
- the dimensions of the barrier walls should be sufficient to protect workers from the high pressures of adjacent pumps.
- the thickness of the barrier walls should be relatively thin, such as within the range of 0.25 inches to 6 inches, so that they can easily fit between slurry pumps at a well site.
- the height of the barrier walls should be at least 6 feet and preferably in the range of 8 feet to 20 feet.
- the barrier walls typically will have one or more openings, flaps, or ports that allow flow lines to pass through the barrier wall, such as the lines that pass between the pumps and the fracturing manifold.
- FIG. 5 an example well site 500 is illustrated.
- Well site 500 has been divided into a brine pump area 570 , containing brine pumps, and a slurry pump area 580 , containing slurry pumps.
- a split stream barrier 561 separates the brine pump area 570 from the slurry pump area 580 .
- the slurry pump area 580 is subdivided into areas B, C, D, and E.
- One or more slurry pumps can be located in each of areas B, C, D, and E.
- Slurry barriers 563 are placed between each of areas B, C, D, and E. Accordingly, area C, for example, is separated from adjacent areas B and D by slurry barriers and is separated from the adjacent brine pump area 570 by split stream barrier 561 . As such, the barrier system provides protection to workers performing maintenance on a slurry pump in area C while the brine pumps in the brine pump area 570 and the slurry pumps in slurry pump areas B, D, and E continue to operate at high pressures.
- FIG. 6 illustrates another example of a barrier system arranged at well site 600 .
- a split stream barrier 661 is positioned between a brine pump area 670 and a slurry pump area 680 .
- the slurry pump area is subdivided into areas B, C, D, and E, each of which can contain one or more slurry pumps.
- Slurry barriers 663 are placed between each of subdivided areas B, C, D, and E.
- Area B for example, is separated from adjacent slurry pumps in areas C, D, and E by slurry barriers 663 and is separated from the adjacent brine pump area 670 by split stream barrier 661 . Accordingly, workers can perform maintenance on a slurry pump in area B while being protected by the barrier system from pumps in slurry pump areas C, D, and E and pumps in brine pump area 670 that continue to operate at high pressures.
- FIG. 7 illustrates another configuration of a well site 700 .
- brine pump area 770 is separated from the slurry pump area 780 by a split stream barrier 761 .
- the slurry pumps in the slurry pump area are separated into areas C and D by a slurry barrier 763 .
- the brine pump area 770 is subdivided into areas A and B by a brine barrier 765 .
- the brine barrier 765 can be similar to the other types of barriers previously described and can be used to isolate individual brine pumps or subgroups of brine pumps for purposes of performing maintenance on the brine pumps.
- the brine barrier 765 can allow maintenance to be performed on one or more brine pumps in area A while the brine pumps in area B continue to operate.
- FIG. 8 illustrates yet another configuration of a well site 800 .
- the configuration of well site 800 is similar to that of well site 700 in that brine pump area 870 is separated from the slurry pump area 880 by a split stream barrier 861 .
- the slurry pumps in the slurry pump area are separated into areas C, D, E and F by slurry barriers 863 .
- the brine pump area 770 is subdivided into areas A and B by a brine barrier 865 , which is similar to the brine barrier 765 of FIG. 7 .
- the brine barrier 865 can be used to isolate individual brine pumps or subgroups of brine pumps for purposes of performing maintenance on the brine pumps.
- FIG. 9 illustrates yet another configuration of a well site 900 .
- brine pump area 970 is separated from slurry pump areas 980 and 981 by split stream barriers 961 .
- the slurry pumps in the slurry pump areas are separated into areas B, C, D and E by a slurry barriers 963 and 964 .
- FIG. 10 illustrates yet another configuration of a well site 1000 .
- brine pump area 1070 is separated from slurry pump areas 1080 by split stream barriers 1061 .
- the slurry pumps in the slurry pump areas are separated into areas B, C, D and E by a slurry barriers 1063 .
- one or more of the components may be omitted, added, repeated, and/or substituted. Additionally, it should be understood that in certain cases components of the example systems can be combined or can be separated into subcomponents. Accordingly, embodiments shown in a particular figure should not be considered limited to the specific arrangements of components shown in such figure. Further, if a component of a figure is described but not expressly shown or labeled in that figure, the label used for a corresponding component in another figure can be inferred to that component. Conversely, if a component in a figure is labeled but not described, the description for such component can be substantially the same as the description for the corresponding component in another figure.
- Values, ranges, or features may be expressed herein as “about”, from “about” one particular value, and/or to “about” another particular value. When such values, or ranges are expressed, other embodiments disclosed include the specific value recited, from the one particular value, and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It will be further understood that there are a number of values disclosed therein, and that each value is also herein disclosed as “about” that particular value in addition to the value itself.
- use of the term “about” means ⁇ 20% of the stated value, ⁇ 15% of the stated value, ⁇ 10% of the stated value, ⁇ 5% of the stated value, ⁇ 3% of the stated value, or ⁇ 1% of the stated value.
Abstract
Hydraulic fracturing pumps at a well pad comprising multiple wells can be separated into brine pumps and slurry pumps. A split stream barrier separates the brine pumps from the slurry pumps. At least one slurry barrier separates a first slurry pump and a second slurry pump. The split stream barrier and the slurry barrier allow maintenance to be performed on the first slurry pump while the second slurry pump and the brine pumps continue to operate.
Description
- The present application claims priority to U.S. Provisional Patent Application No. 63/347,856, filed Jun. 1, 2022, the entire content of which is incorporated herein by reference.
- Embodiments of the technology relate generally to partitioning high pressure pumps at a well site.
- High pressure pumps are commonly used at a well site in connection with the production of hydrocarbons. The high pressure pumps are used to inject a variety of fluids into an oil or gas well during certain well operations. One such operation is hydraulic fracturing, which is a process that involves injecting fluids into a well at high pressure to fracture a formation. The injected fluids include a slurry containing particles that prop open fractures in the formation to improve the flow of hydrocarbons from the formation into the well. Hydraulic fracturing typically uses high pressure pumps to obtain the required high pressures for injecting the fluids into the well. A well site often includes a well pad with multiple wellheads. Numerous high pressure pumps at the well site are used to inject the high pressure fluids into the wells. The high pressure pumps are typically connected to a fracturing manifold that directs the high pressure fracturing fluids to a zipper manifold which in turn directs the fluids to the wellheads at the well pad.
- A significant limitation to improving the operational performance of a well site employing hydraulic fracturing is the need for regular maintenance on the high pressure pumps. The area around the high pressure pumps is referred to as the red zone because the high pressures generated by the pumps create risks of leaks and equipment failures that can be dangerous to workers. For the safety of workers, maintenance typically requires that the high pressure pumps are turned off and depressurized before the workers can enter the red zone to perform maintenance. However, turning off and depressurizing the high pressure pumps requires shutting down the equipment at the well site for significant periods of time, resulting in substantial disruption of the operations of the well site as well as added costs.
- Accordingly, improved approaches to performing maintenance on the high pressure pumps use in hydraulic fracturing would improve the operations of the well site and reduce costs.
- In one example embodiment, the present disclosure is generally directed to a system at a well site. The system can comprise a plurality of brine pumps and a plurality of slurry pumps. The brine pumps can be configured to pump brine into at least one wellhead at the well site. The plurality of slurry pumps can be configured to pump slurry into the at least one wellhead at the well site. A split stream barrier can separate the plurality of brine pumps from the plurality of slurry pumps. At least one slurry barrier can separate a first slurry pump and a second slurry pump of the plurality of slurry pumps.
- In another example embodiment, the present disclosure is generally directed to a method for operating a well site. The method can comprise: 1) positioning a plurality of brine pumps at the well site, wherein the plurality of brine pumps are configured to pump brine into at least one wellhead at the well site; 2) positioning a plurality of slurry pumps at the well site, wherein the plurality of slurry pumps are configured to pump slurry into the at least one wellhead at the well site; 3) separating the plurality of brine pumps from the plurality of slurry pumps by installing a split stream barrier between the plurality of brine pumps and the plurality of slurry pumps; 4) separating each slurry pump of the plurality of slurry pumps by placing a slurry barrier between each adjacent slurry pump of the plurality of slurry pumps; 5) identifying a selected slurry pump for maintenance, wherein a remainder of the slurry pumps are not selected for maintenance; 6) remotely turning off and depressurizing the selected slurry pump with a remotely operated actuator; and 7) performing the maintenance on the selected slurry pump while continuing operation of the plurality of brine pumps.
- In yet another example embodiment, the present disclosure is generally directed to a system at a well site, the system comprising a brine pump area comprising a plurality of brine pumps and a slurry pump area comprising a plurality of slurry pumps. The plurality of brine pumps are configured to pump brine into at least one wellhead at the well site, while the plurality of slurry pumps are configured to pump slurry into the at least one wellhead at the well site. A split stream barrier separates the brine pump area from the slurry pump area. At least one slurry barrier separates a first slurry pump of the plurality of slurry pumps from a second slurry pump of the plurality of slurry pumps.
- In yet another example embodiment, the present disclosure is generally directed to a method for operating a well site. The method can comprise: 1) positioning a plurality of brine pumps in a brine pump area at the well site, wherein the plurality of brine pumps are configured to pump brine into at least one wellhead at the well site; 2) positioning a plurality of slurry pumps in a slurry pump area at the well site, wherein the plurality of slurry pumps are configured to pump slurry into the at least one wellhead at the well site; 3) separating the brine pump area from the slurry pump area by installing a split stream barrier between the brine pump area and the slurry pump area; 4) separating a first slurry pump of the plurality of slurry pumps from a second slurry pump of the plurality of slurry pumps by installing a slurry barrier between the first slurry pump and the second slurry pump; 5) identifying the first slurry pump for maintenance; 6) remotely turning off and depressurizing the first slurry pump with a remotely operated actuator; and 7) performing the maintenance on the first slurry pump while continuing operation of the second slurry pump and the plurality of brine pumps.
- The foregoing embodiments are non-limiting examples and other aspects and embodiments will be described herein. The foregoing summary is provided to introduce various concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify required or essential features of the claimed subject matter nor is the summary intended to limit the scope of the claimed subject matter.
- The accompanying drawings illustrate only example embodiments of a system and method for a well site comprising multiple wells and therefore are not to be considered limiting of the scope of this disclosure. The principles illustrated in the example embodiments of the drawings can be applied to alternate methods and apparatus. Additionally, the elements and features shown in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the example embodiments. Certain dimensions or positions may be exaggerated to help visually convey such principles. In the drawings, the same reference numerals used in different embodiments designate like or corresponding, but not necessarily identical, elements.
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FIG. 1 illustrates a well site with a plurality of high pressure pumps as known in the prior art. -
FIG. 2 illustrates a barrier placed between two wellheads as known in the prior art. -
FIG. 3 illustrates a wellsite with a barrier system in accordance with the example embodiments of the present disclosure. -
FIG. 4 illustrates a method for operating a well site in accordance with the example embodiments of the present disclosure. -
FIGS. 5-10 illustrate various configurations for brine pumps and slurry pumps in accordance with the example embodiments of the present disclosure. - The example embodiments discussed herein are directed to apparatus and methods for partitioning high pressure pumps at a well site to improve operations of the well site. Because slurry pumps typically require frequent maintenance while brine pumps do not, a brine pump area and a slurry pump area can be separated by a split stream barrier. Additionally, the slurry pump area can sub-divided with slurry barriers to separate one or more slurry pumps from other slurry pumps. The system of barriers allows one or more slurry pumps to be deactivated for maintenance while other slurry pumps and the brine pumps continue to operate. Isolating the high pressure slurry pumps for maintenance improves the safety of the well site for workers performing maintenance on the slurry pumps. Additionally, the system of barriers permits operations of the well site to continue while maintenance is performed on a selected slurry pump. Accordingly, the well site can operate more efficiently.
- In the following paragraphs, particular embodiments will be described in further detail by way of example with reference to the drawings. In the description, well-known components, methods, and/or processing techniques are omitted or briefly described. Furthermore, reference to various feature(s) of the embodiments is not to suggest that all embodiments must include the referenced feature(s).
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FIGS. 1 and 2 illustrate prior art approaches to operating a well site.FIG. 1 illustrates atypical well site 100 as known in the prior art. Well sites can often include multiple wells as illustrated by well 1, well 2, well 3, and well 4 located onwell pad 105.Well site 100 includestanks blender 140 can be used to mix sand or other proppant into one or more streams of the fracturing fluid. Flow lines connect thetanks blender 140 to a fracturingmanifold 115. The fracturingmanifold 115 feeds the various fracturing fluid streams to the high pressure pumps 120, 122, 124, 126, 128, and 130 where the pressure of the fluid streams is increased before they are injected into the wells. The fracturingmanifold 115 directs the high pressure fracturing fluids to azipper manifold 110 that is coupled to the wellheads of each ofwells - As referenced previously, the high pressures generated by the pumps increase the probability of equipment leaking or failing, thereby increasing the risks for workers in the areas around the high pressure pumps 120, 122, 124, 126, 128, and 130. Accordingly, it is common to refer to the areas around the high pressure pumps as red zones. Given the increased risks in the red zones, if maintenance is needed on a single pump, it is common to shut down and depressurize all nearby pumps so that the maintenance can be performed. However, shutting down all nearby pumps disrupts the operation of the
well site 100. - Separately,
FIG. 2 illustrates an example of a prior art wellhead barrier that can be installed at a well pad of awell site 200. As shown inFIG. 2 ,wellhead barrier 215 is installed betweenwellhead 205 andwellhead 210. Thewellhead barrier 215 provides protection to workers performing work on one of the wells so that the other well can remain pressurized and operating. - Referring now to
FIGS. 3-10 , example embodiments for improved barrier systems for well sites will be described in accordance with the example embodiments of this disclosure. Referring toFIG. 3 , awell site 300 in accordance with the embodiments of this disclosure is illustrated. Wellsite 300 includes awell pad 305 withwells site 300 is arranged for hydraulic fracturing operations. The well site includes aboost pump 342 that pumps hydraulic fracturing fluid fromtanks 350 for use in the wells at thewell pad 305. Ablender 340 can mix sand (and/or another proppant) fromsand storage area 355 into certain of the streams of hydraulic fracturing fluid. - Well
site 300 includes two strategies for improving the operation of the well site. First, the high pressure pumps are organized into a split stream arrangement where they are separated into abrine pump area 370 and aslurry pump area 380. The brine pumps will pump brine solution that does not include a proppant. In contrast, the slurry pumps will pump a slurry solution that includes a proppant. The existence of a proppant in the fluid stream often causes fouling of valves and other components of the pumps, resulting in the need for more frequent maintenance of the pumps. The advantage of the split stream arrangement is that the pumps handling the fluid streams with proppant, which will require more frequent maintenance, are separated into a slurry pump area. In contrast, the pumps handling a brine solution that does not include a proppant, and therefore require less frequent maintenance, are organized into a brine pump area. -
FIG. 3 illustrates abarrier system 360 that separates abrine pump area 370 from twoslurry pump areas barrier system 360 is illustrated in general form inFIG. 3 , examples of specific implements of the barrier system are shown in greater detail inFIGS. 5-10 . Specifically, the barrier system can include a split stream barrier that separates the brine pump area from the slurry pump area(s). The barrier system can also include slurry barriers located between individual slurry pumps or groups of slurry pumps. Given the more frequent maintenance of the slurry pumps, the slurry barriers are beneficial for isolating individual slurry pumps or groups of slurry pumps. In contrast, there is not the same level of need for individual barriers between brine pumps in the brine pump area because the brine pumps require relatively infrequent maintenance. The barrier system allows individual slurry pumps or groups of slurry pumps to be turned off and depressurized for performing maintenance while the remaining slurry pumps and the brine pumps can continue to operate. The barrier system will protect workers in the red zone area around the pump(s) receiving maintenance from the high pressure conditions of surrounding slurry pumps and brine pumps that are continuing to operate. - As illustrated in
FIG. 3 , a fracturingmanifold 315 receives slurry fluid streams containing proppant from theblender 340 and supplies those slurry fluid streams to the slurry pumps inslurry pump areas manifold 315 receives brine fluid streams (without a proppant) from theboost pump 342 and supplies those brine fluid streams to the brine pumps in thebrine pump area 370. The fracturingmanifold 315 then receives the pressurized slurry fluid streams and brine fluid streams from the respective pumps and supplies those pressurized streams to thezipper manifold 310 for delivery to the wellhead of each well - Referring now to
FIG. 4 , andexample method 400 is illustrated for operating a well site in accordance with the example embodiments of the present disclosure. It should be understood thatmethod 400 is intended to be a representative example and that in alternate embodiments certain operations ofmethod 400 can be combined, performed in parallel, or omitted. Additionally, other operations can be added tomethod 400. - In
operation 405, brine pumps are positioned at the well site in the brine pump area and slurry pumps are positioned at the well site in the slurry pump area. The brine pumps and slurry pumps are typically located on trailers that are transported to and positioned at the well site. Inoperation 410, one or more split stream barriers are installed between the brine pump area and the slurry pump area. Inoperation 415, one or more slurry barriers are installed between the slurry pumps. In some cases, slurry barriers can be installed between each slurry pump. In other cases, slurry barriers can be installed between subgroups of slurry pumps. Once the barrier system is installed, the hydraulic fracturing operations can proceed with a split stream approach on the wells inoperation 420. - Given the negative affects of proppant on the slurry pumps, slurry pumps can be identified for maintenance when needed. In
operation 425, a slurry pump is selected for maintenance. Alternatively, a subgroup of slurry pumps can be selected for maintenance. Inoperation 430, the slurry pump selected for maintenance is turned off and depressurized. Each slurry pump can be equipped with an actuator that is remotely controlled and that can control powering off/on and depressurizing/ pressurizing the slurry pump. The actuator can be remotely controlled by radio signals or a length of cable that allows a worker to control the pump without being in proximity to the pump. With the selected slurry pump turned off and depressurized, it is now safe for workers to be in the red zone surrounding the slurry pump in order to perform maintenance as indicated inoperation 435. The protection provided by the barrier system allows adjacent slurry pumps and brine pumps to continue operating at high pressures while the workers perform maintenance on the selected slurry pump. - After the maintenance is complete, the workers can move away from the selected slurry pump and can use the remotely controlled actuator to prime and restart the selected slurry pump in
operation 440. As indicated inoperation 445,method 400 can return tooperation 420 where the hydraulic fracturing operations can proceed at the well site until maintenance is required on another slurry pump. - While
method 400 ofFIG. 4 describes operations for performing maintenance on a slurry pump, it should be understood that the method can be adapted for performing maintenance on a group of slurry pumps. Additionally,method 400 also can be adapted for performing maintenance on a brine pump or a group of brine pumps. As another modification ofmethod 400, it should be understood that slurry pumps and brine pumps are not required to be in the off state for priming such that in some embodiments the slurry and brine pumps can be remotely primed while they are pumping. - Turning to
FIGS. 5-10 , example implementations of barrier systems are illustrated. It should be appreciated that other variations on the configurations of the barrier systems ofFIGS. 5-10 are encompassed by this disclosure. Additionally, the barriers can take a variety of shape and form. In certain examples, the barrier walls can be walls or flexible curtains of high strength material such as composites, metals, alloys, or polymers such as Kevlar. The dimensions of the barrier walls should be sufficient to protect workers from the high pressures of adjacent pumps. The thickness of the barrier walls should be relatively thin, such as within the range of 0.25 inches to 6 inches, so that they can easily fit between slurry pumps at a well site. The height of the barrier walls should be at least 6 feet and preferably in the range of 8 feet to 20 feet. The barrier walls typically will have one or more openings, flaps, or ports that allow flow lines to pass through the barrier wall, such as the lines that pass between the pumps and the fracturing manifold. Referring toFIG. 5 , anexample well site 500 is illustrated. Wellsite 500 has been divided into abrine pump area 570, containing brine pumps, and aslurry pump area 580, containing slurry pumps. Asplit stream barrier 561 separates thebrine pump area 570 from theslurry pump area 580. Theslurry pump area 580 is subdivided into areas B, C, D, and E. One or more slurry pumps can be located in each of areas B, C, D, andE. Slurry barriers 563 are placed between each of areas B, C, D, and E. Accordingly, area C, for example, is separated from adjacent areas B and D by slurry barriers and is separated from the adjacentbrine pump area 570 bysplit stream barrier 561. As such, the barrier system provides protection to workers performing maintenance on a slurry pump in area C while the brine pumps in thebrine pump area 570 and the slurry pumps in slurry pump areas B, D, and E continue to operate at high pressures. -
FIG. 6 illustrates another example of a barrier system arranged atwell site 600. Atwell site 600, asplit stream barrier 661 is positioned between a brine pump area 670 and a slurry pump area 680. Additionally, the slurry pump area is subdivided into areas B, C, D, and E, each of which can contain one or more slurry pumps.Slurry barriers 663 are placed between each of subdivided areas B, C, D, and E. Area B, for example, is separated from adjacent slurry pumps in areas C, D, and E byslurry barriers 663 and is separated from the adjacent brine pump area 670 bysplit stream barrier 661. Accordingly, workers can perform maintenance on a slurry pump in area B while being protected by the barrier system from pumps in slurry pump areas C, D, and E and pumps in brine pump area 670 that continue to operate at high pressures. -
FIG. 7 illustrates another configuration of awell site 700. Inwell site 700,brine pump area 770 is separated from theslurry pump area 780 by asplit stream barrier 761. The slurry pumps in the slurry pump area are separated into areas C and D by aslurry barrier 763. Additionally, thebrine pump area 770 is subdivided into areas A and B by abrine barrier 765. Thebrine barrier 765 can be similar to the other types of barriers previously described and can be used to isolate individual brine pumps or subgroups of brine pumps for purposes of performing maintenance on the brine pumps. Thebrine barrier 765 can allow maintenance to be performed on one or more brine pumps in area A while the brine pumps in area B continue to operate. -
FIG. 8 illustrates yet another configuration of awell site 800. The configuration ofwell site 800 is similar to that ofwell site 700 in thatbrine pump area 870 is separated from theslurry pump area 880 by asplit stream barrier 861. The slurry pumps in the slurry pump area are separated into areas C, D, E and F byslurry barriers 863. Additionally, thebrine pump area 770 is subdivided into areas A and B by abrine barrier 865, which is similar to thebrine barrier 765 ofFIG. 7 . Similar to the brine barrier ofFIG. 7 , thebrine barrier 865 can be used to isolate individual brine pumps or subgroups of brine pumps for purposes of performing maintenance on the brine pumps. -
FIG. 9 illustrates yet another configuration of awell site 900. Inwell site 900,brine pump area 970 is separated fromslurry pump areas split stream barriers 961. The slurry pumps in the slurry pump areas are separated into areas B, C, D and E by aslurry barriers -
FIG. 10 illustrates yet another configuration of awell site 1000. Inwell site 1000,brine pump area 1070 is separated fromslurry pump areas 1080 bysplit stream barriers 1061. The slurry pumps in the slurry pump areas are separated into areas B, C, D and E by aslurry barriers 1063. - For any figure shown and described herein, one or more of the components may be omitted, added, repeated, and/or substituted. Additionally, it should be understood that in certain cases components of the example systems can be combined or can be separated into subcomponents. Accordingly, embodiments shown in a particular figure should not be considered limited to the specific arrangements of components shown in such figure. Further, if a component of a figure is described but not expressly shown or labeled in that figure, the label used for a corresponding component in another figure can be inferred to that component. Conversely, if a component in a figure is labeled but not described, the description for such component can be substantially the same as the description for the corresponding component in another figure.
- With respect to the example methods described herein, it should be understood that in alternate embodiments, certain operations of the methods may be performed in a different order, may be performed in parallel, or may be omitted. Moreover, in alternate embodiments additional operations may be added to the example methods described herein. Accordingly, the example methods provided herein should be viewed as illustrative and not limiting of the disclosure.
- Terms such as “first”, “second”, “top”, “bottom”, “side”, “distal”, “proximal”, and “within” are used merely to distinguish one component (or part of a component or state of a component) from another. Such terms are not meant to denote a preference or a particular orientation, and are not meant to limit the embodiments described herein. In the example embodiments described herein, numerous specific details are set forth in order to provide a more thorough understanding of the invention. However, it will be apparent to one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.
- The terms “a,” “an,” and “the” are intended to include plural alternatives, e.g., at least one. The terms “including”, “with”, and “having”, as used herein, are defined as comprising (i.e., open language), unless specified otherwise.
- Various numerical ranges are disclosed herein. When Applicant discloses or claims a range of any type, Applicant's intent is to disclose or claim individually each possible number that such a range could reasonably encompass, including end points of the range as well as any sub-ranges and combinations of sub-ranges encompassed therein, unless otherwise specified. Numerical end points of ranges disclosed herein are approximate, unless excluded by proviso.
- Values, ranges, or features may be expressed herein as “about”, from “about” one particular value, and/or to “about” another particular value. When such values, or ranges are expressed, other embodiments disclosed include the specific value recited, from the one particular value, and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It will be further understood that there are a number of values disclosed therein, and that each value is also herein disclosed as “about” that particular value in addition to the value itself. In another aspect, use of the term “about” means ±20% of the stated value, ±15% of the stated value, ±10% of the stated value, ±5% of the stated value, ±3% of the stated value, or ±1% of the stated value.
- Although embodiments described herein are made with reference to example embodiments, it should be appreciated by those skilled in the art that various modifications are well within the scope of this disclosure. Those skilled in the art will appreciate that the example embodiments described herein are not limited to any specifically discussed application and that the embodiments described herein are illustrative and not restrictive. From the description of the example embodiments, equivalents of the elements shown therein will suggest themselves to those skilled in the art, and ways of constructing other embodiments using the present disclosure will suggest themselves to practitioners of the art. Therefore, the scope of the example embodiments is not limited herein.
Claims (19)
1. A system for operating a well site, the system comprising:
a plurality of brine pumps configured to pump brine into at least one wellhead at the well site;
a plurality of slurry pumps configured to pump slurry into at least one wellhead at the well site;
a split stream barrier separating the plurality of brine pumps from the plurality of slurry pumps; and
at least one slurry barrier, wherein the at least one slurry barrier separates a first slurry pump from a second slurry pump of the plurality of slurry pumps.
2. The system of claim 1 , wherein each slurry pump of the plurality of slurry pumps is separated from other slurry pumps of the plurality of slurry pumps by a slurry barrier.
3. The system of claim 1 , wherein the split stream barrier and the at least one slurry barrier comprise one or more of composites, metals, alloys, or polymers.
4. The system of claim 1 , wherein each slurry pump of the plurality of slurry pumps comprises a remotely operated actuator for controlling operation of each slurry pump.
5. The system of claim 1 , wherein the split stream barrier and the at least one slurry barrier allow maintenance on a selected slurry pump or a selected brine pump while other slurry pumps and other brine pumps continue to operate.
6. A method of operating a well site, the method comprising:
positioning a plurality of brine pumps at the well site, wherein the plurality of brine pumps are configured to pump brine into at least one wellhead at the well site;
positioning a plurality of slurry pumps at the well site, wherein the plurality of slurry pumps are configured to pump slurry into the at least one wellhead at the well site;
separating the plurality of brine pumps from the plurality of slurry pumps by installing a split stream barrier between the plurality of brine pumps and the plurality of slurry pumps;
separating each slurry pump of the plurality of slurry pumps by placing a slurry barrier between each adjacent slurry pump of the plurality of slurry pumps;
identifying a selected slurry pump for maintenance, wherein a remainder of the slurry pumps are not selected for maintenance;
remotely turning off and depressurizing the selected slurry pump with a remotely operated actuator; and
performing the maintenance on the selected slurry pump while continuing operation of the plurality of brine pumps.
7. The method of claim 6 , further comprising continuing operation of the remainder of the slurry pumps while performing the maintenance on the selected slurry pump.
8. The method of claim 6 , wherein each slurry pump of the plurality of slurry pumps comprises a remotely operated actuator for controlling operation of each slurry pump.
9. The method of claim 6 , further comprising:
after completion of the maintenance on the selected slurry pump, remotely turning on and pressurizing the selected slurry pump with the remotely operated actuator.
10. The method of claim 6 , further comprising: priming one or more of the plurality of slurry pumps and the plurality of brine pumps while pumping.
11. A system for operating a well site, the system comprising:
a brine pump area comprising a plurality of brine pumps configured to pump brine into at least one wellhead at the well site;
a slurry pump area comprising a plurality of slurry pumps configured to pump slurry into the at least one wellhead at the well site;
a split stream barrier separating the brine pump area from the slurry pump area; and
at least one slurry barrier separating a first slurry pump of the plurality of slurry pumps from a second slurry pump of the plurality of slurry pumps.
12. The system of claim 11 , wherein each slurry pump of the plurality of slurry pumps is separated from other slurry pumps of the plurality of slurry pumps by a slurry barrier.
13. The system of claim 11 , the split stream barrier and the at least one slurry barrier comprise one or more of composites, metals, alloys, or polymers.
14. The system of claim 11 , wherein each slurry pump of the plurality of slurry pumps comprises a remotely operated actuator for controlling operation of each slurry pump. The system of claim 11 , wherein the split stream barrier and the at least one slurry barrier allow maintenance on a selected slurry pump or a selected brine pump while other slurry pumps and other brine pumps continue to operate.
16. A method of operating a well site, the method comprising:
positioning a plurality of brine pumps in a brine pump area at the well site, wherein the plurality of brine pumps are configured to pump brine into at least one wellhead at the well site;
positioning a plurality of slurry pumps in a slurry pump area at the well site, wherein the plurality of slurry pumps are configured to pump slurry into the at least one wellhead at the well site;
separating the brine pump area from the slurry pump area by installing a split stream barrier between the brine pump area and the slurry pump area;
separating a first slurry pump of the plurality of slurry pumps from a second slurry pump of the plurality of slurry pumps by installing a slurry barrier between the first slurry pump and the second slurry pump;
identifying the first slurry pump for maintenance;
remotely turning off and depressurizing the first slurry pump with a remotely operated actuator; and
performing the maintenance on the first slurry pump while continuing operation of the second slurry pump and the plurality of brine pumps.
17. The method of claim 16 , further comprising installing a slurry barrier between each slurry pump of the plurality of slurry pumps.
18. The method of claim 16 , wherein each slurry pump of the plurality of slurry pumps comprises a remotely operated actuator for controlling operation of each slurry pump.
19. The method of claim 16 , further comprising:
after completion of the maintenance on the first slurry pump, remotely turning on and pressurizing the first slurry pump with the remotely operated actuator.
20. The method of claim 16 , further comprising: priming one or more of the plurality of slurry pumps and the plurality of brine pumps while pumping.
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