Note: Descriptions are shown in the official language in which they were submitted.
1
MODULAR FRACTURING PAD STRUCTURE
BACKGROUND
[0001] Hydraulic fracturing is a stimulation treatment routinely
performed on oil and
gas wells in low-permeability reservoirs. Specially engineered fluids are
pumped at
high pressure and rate into the reservoir interval to be treated, causing a
vertical fracture
to open. The wings of the fracture extend away from the wellbore in opposing
directions
according to the natural stresses within the formation. Proppant, such as
grains of sand
of a particular size, is mixed with the treatment fluid to keep the fracture
open when the
treatment is complete. Hydraulic fracturing creates high-conductivity
communication
with a large area of formation and bypasses any damage that may exist in the
near-
wellbore area. Furthermore, hydraulic fracturing is used to increase the rate
at which
fluids, such as petroleum, water, or natural gas can be recovered from
subterranean
natural reservoirs. Reservoirs are typically porous sandstones, limestones or
dolomite
rocks, but also include "unconventional reservoirs" such as shale rock or coal
beds.
Hydraulic fracturing enables the extraction of natural gas and oil from rock
formations
deep below the earth's surface (e.g., generally 2,000-6,000 m (5,000-20,000
ft)), which
is greatly below typical groundwater reservoir levels. At such depth, there
may be
insufficient permeability or reservoir pressure to allow natural gas and oil
to flow from
the rock into the wellbore at high economic return. Thus, creating conductive
fractures
in the rock is instrumental in extraction from naturally impermeable shale
reservoirs.
[0002] A wide variety of hydraulic fracturing equipment is used in oil
and natural gas
fields such as a slurry blender, one or more high-pressure, high-volume
fracturing
pumps and a monitoring unit. Additionally, associated equipment includes
fracturing
tanks, one or more units for storage and handling of proppant, high-pressure
treating
iron, a chemical additive unit (used to accurately monitor chemical addition),
low-
pressure flexible hoses, and many gauges and meters for flow rate, fluid
density, and
treating pressure. Fracturing equipment operates over a range of pressures and
injection
rates, and can reach up to 100 megapascals (15,000 psi) and 265 litres per
second (9.4
cu ft/s) (100 barrels per minute).
[0003] As seen by the prior art in Figure 1, Figure 1 illustrates an
example of an existing
hydraulic fracturing pad system 100 (often referred to as a "frac pad" in the
industry).
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The fracturing pad system 100 includes at least one pump truck 102 connected
to a
missile manifold 104 via fluid connections 106. Additionally, a blending
system 108
may be connected to the pump trucks 102 through one or more hoses 110 to
supply
proppant and other particulates to the pump trucks 102 to pump into the well
(not
shown) as part of the fracturing process. The missile trailer 104 may be
connected to a
valve structure 112 that, for instance, can include a safety valve that may
open to relieve
pressure in the system under certain conditions. The valve structure 112 may
be
connected to at least one manifold 114 through a pipe spool 116 that is a
plurality of
pipes flanged together, for instance. As can be seen from Figure 1, the
fracturing pad
system 100 includes many, non-uniform connections that must be made up and
pressure
tested, including the conduits to/from the pump trucks 102, missile trailer
104, and
blending system 108. Furthermore, the connections between the missile manifold
104
and valve structure 112, and the pipe spool 116 between the valve structure
112 and the
manifolds 114 are also non-uniform connections that must be made up and
pressure
tested. These connections take valuable time and resources on site.
Additionally, the
fracturing pad system 100 is generally not flexible regarding the number of
pumps that
can be used.
SUMMARY
[0004] This summary is provided to introduce a selection of concepts
that are further
described below in the detailed description. This summary is not intended to
identify
key or essential features of the claimed subject matter, nor is it intended to
be used as
an aid in limiting the scope of the claimed subject matter.
[0005] In one aspect, the embodiments disclosed herein relate to a
modular pad system
that includes a plurality of connected-together modular skids, wherein each of
the
modular skids has a frame and a primary manifold connection with a primary
inlet, a
primary outlet and one or more primary flow paths extending therebetween,
wherein
the frame of each modular skid has a mounting footprint having substantially
the same
size, and wherein the primary manifold connection of each modular skid are
connected
together to fluidly connect the modular skids together.
[0006] In another aspect, the embodiments disclosed herein relate to a
method of
forming a modular pad system that includes connecting a first modular skid to
a second
modular skid, wherein each of the first and second modular skids a primary
manifold
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connection with a primary inlet, a primary outlet and one or more primary flow
paths
extending therebetween, and a frame, wherein the frames of the first and
second
modular skids have a substantially same mounting footprint, and connecting the
primary manifold connection of the first and second modular skids together to
fluidly
connect the first and second modular skids together.
[0007] Other aspects and advantages will be apparent from the following
description
and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
[0008] Figure 1 is a block diagram of an example of a conventional
hydraulic fracturing
pad system.
[0009] Figures 2A-2B are perspective views of a modular hydraulic
fracturing pad
system in accordance with one or more embodiments of the present disclosure.
[0010] Figures 3A-3C are perspective views of a trailer chassis in
accordance with one
or more embodiments of the present disclosure.
[0011] Figures 4A-4B are perspective views of an articulating fracturing
arm (AFA)
modular skid in accordance with one or more embodiments of the present
disclosure.
[0012] Figures 5A-5B are perspective views of a power system modular
skid in
accordance with one or more embodiments of the present disclosure.
[0013] Figures 6A-6C are perspective views of a pop-off/bleed-off tank
modular skid
in accordance with one or more embodiments of the present disclosure.
[0014] Figure 7 is a perspective view of a well isolation modular skid
in accordance
with one or more embodiments of the present disclosure.
[0015] Figures 8A-8B are perspective views of a zipper manifold modular
skid in
accordance with one or more embodiments of the present disclosure.
[0016] Figures 9A-9C are perspective views of equipment modular skids in
accordance
with one or more embodiments of the present disclosure.
[0017] Figures 10A-10B are perspective views of equipment modular skids
in
accordance with one or more embodiments of the present disclosure.
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DETAILED DESCRIPTION
[0018] In one aspect, embodiments disclosed herein relate to a modular
fracturing pad
system. The modular fracturing pad system may also be interchangeably referred
to
as a modular skid system in the present disclosure. As used herein, the term
"coupled"
or "coupled to" or "connected" or "connected to" may indicate establishing
either a
direct or indirect connection, and is not limited to either unless expressly
referenced
as such. Wherever possible, like or identical reference numerals are used in
the figures
to identify common or the same elements. The figures are not necessarily to
scale and
certain features and certain views of the figures may be shown exaggerated in
scale
for purposes of clarification.
[0019] A modular skid system, according to embodiments herein, is a
system in which
the elements of a hydraulic fracturing system are modularized and deployed on
connectable modular skids that can be secured together to form an integrated
fracturing
structure capable of spanning from the outlet of a hydraulic fracturing pump
to the
wellhead. The hydraulic fracturing system elements are modularized in a way
such that
the primary manifolds/flow functionality is made up when the modular skids are
connected. Further, the modularized hydraulic fracturing system elements may
be held
on units having standardized uniform connections, such that different types of
hydraulic
fracturing system element units may be connected together using the same
connection
type. The reduction of using non-uniform connections that must be made up and
pressure tested may significantly reduce the complexity, design, time, and
weight of
the system. Additionally, a modular skid system may be used to direct fluid
produced
from or injected into a well. Furthermore, the modular skid system may be
adapted for
any operations in or around the well. For example, the modular skid system may
be
used for flow back operations, drill-out operations, well-logging operations,
or any
other post-drilling operations know in the art.
[0020] In some embodiments, multiple modular skids may be loaded onto
and
connected-together on a single chassis. In such embodiments, a chassis holding
multiple rigged-up modular skids may be transported to a wellsite such that
the
equipment on the modular skids (e.g., junk catchers, desanders, choke
manifolds, etc.)
may all be pre-rigged and dropped on location in rigged-up condition. By using
modular
skid systems according to embodiments of the present disclosure to rig-up a
wellbore
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operations system, equipment may be pre-rigged and dropped on location in
rigged-up
condition, thereby reducing rig-up time in the field. As used herein, fluids
may refer to
proppant, liquids, gases, and/or mixtures thereof. Other instruments and
devices,
including without limitation, sensors and various valves may be incorporated
within a
modular hydraulic fracturing pad system.
[0021] Conventional hydraulic fracturing pad systems in the oil and gas
industry
typically consume a large amount of space and resources of a rig area.
Conventional
hydraulic fracturing pad systems may use elements that are individually
designed and
sized with pipes, flow lines, and other conduits being used to interconnect
the
conventional hydraulic fracturing pad systems. Furthermore, pipes, flow lines,
and
other conduits being used to interconnect the conventional hydraulic
fracturing pad
systems are not uniform and take valuable time to make up and pressure test.
Additionally, the sheer number of pipes, hoses, and other fluid connections
represent
safety hazards for on-site workers. This additional need of more components
needed to
interconnect the conventional hydraulic fracturing pad systems adds to the
weight,
installation costs, and overall cost of the conventional hydraulic fracturing
pad systems.
However, using modular skid systems according to one or more embodiments of
the
present disclosure may overcome such challenges, as well as, provide
additional
advantages over conventional fracturing systems.
[0022] In one or more embodiments, a modular skid system may include
purpose built,
same-sized modular skids that are connected together to form a multi-
functional super
structure for use in fracturing operations. As used herein, purpose built
modular skids
may include modular skids having known and/or new equipment that serves a
certain
purpose or performs a certain job. For example, a modular skid according to
embodiments of the present disclosure may have a known type of isolation valve
mounted thereto or may have a new type of isolation valve mounted thereto,
where at
least one purpose of the purpose built modular skid is to selectively isolate
flow or fluid
through the modular skid. Other equipment types currently known and/or unknown
in
the art (e.g., as shown in some of the examples provided herein) may be
utilized in
modular skids according to embodiments of the present disclosure.
[0023] Modular skids according to embodiments of the present disclosure
may have
standardized uniform mounting footprints, whether same-type or different-type
equipment is mounted to the modular skids. In other words, a modular skid
system
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according to embodiments of the present disclosure may include modular skids
having
same and/or different equipment configurations held on each modular skid,
where each
modular skid in the modular skid system may have the same mounting footprint.
As
used herein, a mounting footprint may refer to the size (width and length) of
a base of
a modular skid. Thus, in one or more embodiments, modular skids having
different
equipment units may have the same mounting footprint whether or not the
different
equipment units have different heights and/or elements of the different
equipment units
have different dimensions that swing or extend outward of the modular skid.
For
example, a modular skid system according to embodiments of the present
disclosure
may have a first modular skid with one or more elements of the equipment
(e.g., a valve
actuator or a valve connection flange) at a height above the first modular
skid base and
extending a distance outside of the first modular skid base width/length
dimensions,
and a second modular skid with an equipment unit configuration different from
the first
modular skid equipment, where both the first and second modular skids may have
the
same base width/length dimensions).
[0024] As described above, each modular skid in a modular skid system
according to
some embodiments of the present disclosure may have the same mounting
footprint.
However, in some embodiments, such as described in more detail below, a
modular
skid system may include one or more modular skids having a mounting footprint
with
one or more irregularities compared with the mounting footprints of the
remaining
modular skids, such that the modular skids in the modular skid system have
substantially the same mounting footprints (i.e., have the same general widths
and
lengths not including the one or more irregularities). For example, in some
embodiments, a modular skid system haying modular skids with bases of the same
general width and length and with connection points at axial ends of the base
length
may include a modular skid having base with an additional connection point
extending
past the width of the majority of the base, while the remaining modular skids
in the
modular skid system may have bases without such irregularities in the base
width
formed by an additional connection point.
[0025] The size of modular skids (including the size of modular skid
mounting
footprints, modular skid heights, equipment configurations arranged on the
modular
skids, etc.) may be selected based, for instance, on the size limitations of
common
transportation means, Department of Transportation (DOT) requirements (e.g.,
to meet
CA 2999306 2018-03-23
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weight and size limits of loads being transported on roads by trailers), the
type of
function each modular skid is to perform, and/or to provide reduced cost and
reduced
time to manufacture. For instance, the size of the mounting footprint of
modular skids
may be selected so that three modular skids may fit end to end on a flatbed
trailer. In
some embodiments, the overall size of modular skids (including the mounting
footprints and the size of the equipment held on the modular skids) may be
selected
such that one or more modular skids may be mounted to a flatbed trailer and
also meet
DOT regulations for transporting the loaded flatbed trailer.
[0026] For example, according to embodiments of the present disclosure,
a modular
skid may have a mounting footprint having a length ranging from, e.g., a lower
limit
selected from 7 ft, 10 ft or 14 ft to an upper limit selected from 14 ft or 28
ft, and a
width ranging from, e.g., a lower limit selected from 4 ft, 6 ft or 8 ft to an
upper limit
selected from 6 ft, 8 ft, 10 ft, or 12 ft, where any lower limit may be used
in combination
with any upper limit. For example, in some embodiments, a modular skid may
have a
mounting footprint of about 8.5 ft wide and about 11.5 ft long. However, the
dimensions of the mounting footprint of a modular skid may vary within the
above-
mentioned ranges or may be outside of the above-mentioned ranges, depending,
for
example, on the job the modular skid is designed to perform, DOT regulations,
and/or
other factors. For example, in some embodiments, the length of the mounting
footprint
for a modular skid may be designed to correspond with pump spacing when the
modular
skid is to be used in a pumping operation.
[0027] Further, in some embodiments, a modular skid may have a height
ranging from,
e.g., a lower limit selected from 2 ft, 4 ft or 6 ft to an upper limit
selected from 10 ft,
14 ft, or 18 ft, where any lower limit may be used in combination with any
upper limit.
However, the height of a modular skid may be outside the above-mentioned
ranges,
depending, for example, on the job the modular skid is designed to perform,
DOT
regulations, and/or other factors. For example, in some embodiments, modular
skids
may be designed to have the same or different heights (depending on the types
of
equipment units being held on each modular skid), where the height of each of
the
modular skids may be about 10.6 ft or less. In instances where modular skids
are being
transported on a trailer (and DOT height regulations apply), the height of
modular skids
may be designed to be no greater than the regulation height minus the height
of the
trailer on which the modular skids are mounted to.
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[0028] When modular skids according to embodiments of the present
disclosure are
connected together to form a modular skid system, different type equipment
units held
in different modular skids may also be connected together to form a manifold
having a
continuous flow path formed therethrough with limited connection. Thus,
modular
skids according to embodiments of the present disclosure may include
substantially
uniform mounting footprints in addition to equipment configured to align
and/or
connect with equipment in adjacently mounted modular skids.
[0029] Using modular skid systems according to embodiments of the
present disclosure
may reduce or eliminate the need for extensive non-uniform connections since
the
modular skid pad system is modularized and may be deployed on connectable
skids to
reduce the number of connections to other equipment. Further, modular skid
systems
according to embodiments of the present disclosure may be tailored to meet the
specific
job requirements needed (Rate, number of pumps, etc.), for example, by adding
or
subtracting a number of a certain purpose-type modular skid and/or by
rearranging the
connection pattern of modular skids. Overall, a modular skid system according
to
embodiments of the present disclosure may minimize product engineering, risk
associated with non-uniform connections, reduction of assembly time, hardware
cost
reduction, and weight and envelope reduction.
[0030] Referring to Figures 2A-2B, Figures 2A-2B illustrates an example
of a modular
skid system 200 which connects to at least one wellhead 201. The modular skid
system
200 couples with the at least one wellhead 201 by using at least one time and
efficiency
(TE) manifold modular skid or zipper manifold skid 202. A zipper manifold skid
202
refers to a modular skid that is purpose built for connection to a wellhead,
which may
include an outlet head (which may be referred to as a fracturing head or goat
head in
fracturing operations) for connection to the wellhead and one or more gate
valves. The
zipper manifold equipment may be arranged to fit on a modular skid frame
having a
selected mounting footprint, such that the base of the zipper manifold skid
202 may
have a mounting footprint with a selected width and length.
[0031] Typically, spacing of the wellheads 201 is from 6 feet to 10
feet, and thus, the
at least one zipper manifold skid 202 may be designed to align with known
spacing of
the wellheads 201. For example, the zipper manifold skids 202 may be designed
to
have a mounting footprint with a selected length that corresponds with an
interval
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between wellheads 201. Spacer skids 207 (modular skids that are purpose built
to
provide spacing between adjacent modular skids, which may include equipment to
connect between the equipment in the adjacent modular skids) may be provided
between the zipper manifold skids 202 to provide closer alignment of the
spacing
between the zipper manifold skids 202 with the spacing between the wellheads
201. If
the wellheads 201 are spaced irregularly, one skilled in the art will
appreciate how
piping may be used to couple the wellheads 201 to the at least one zipper
manifold skid
202. One skilled in the art will appreciate how the modular skid system 200 is
not
limited to a set number of wellheads 201. For example, additional zipper
manifold
skids 202 may be added to the modular skid system 200 to connect to additional
wellheads 201.
[0032] In one or more embodiments, the modular skid system 200 may
include at least
one pump modular skid 203 such as, but not limited to, an articulating
fracturing arm
(AFA) modular skid. The pump modular skids 203 may be used in the oil and gas
production industry to perform servicing operations on a well by connecting a
system
manifold to a pump. For example, in a well fracturing operation the pump
modular skid
203 may be used to inject a slurry into the wellbore in order to fracture the
hydrocarbon
bearing formation, and thereby produce channels through which the oil or gas
may flow,
by providing a fluid connection between pump discharge and the modular skid
system
200. In some embodiments, the pump modular skid 203 may use standard 3"
connections with a plurality of piping (i.e., ground iron) running on the
ground from a
pump to the pump modular skid 203. In this operation, the pump skids 203 may
connect a number of high pressure pumping units to the wellheads 201. The AFA
manifold equipment may be arranged to fit on a modular skid haying a selected
mounting footprint, such that the base of the AFA skid 203 may have a mounting
footprint with a selected width and length.
[0033] In one or more embodiments, the modular skid system 200 may
include at least
one auxiliary modular skid 204. The auxiliary skid 204 may provide a universal
power
and control unit, including a power unit and a primary controller of the
modular skid
system 200. Furthermore, the universal power and control unit within the
auxiliary skid
204 may contain programmable logic controllers (PLC), sensors, and solar panel
controllers. In one or more embodiments, a programmable logic controller
monitors at
least one sensor and makes decisions based upon a program to control the state
of at
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least one controllable element. Additionally, the auxiliary skid 204 may
include one or
more electronically controlled pressure relief valves (ePRV) which may be
electrically
powered and require no gas bottles or hoses. For example, an auxiliary modular
skid
may include a universal power and control unit and two ePRVs. The ePRV may pop
open in the event power is lost, unless a battery backup is employed. The
power
manifold equipment may be arranged to fit on a modular skid frame having a
selected
mounting footprint, such that the base of the auxiliary skid 204 may have a
mounting
footprint with a selected width and length.
[0034] In one or more embodiments, the modular skid system 200 may
include at least
one pop-off/bleed-off tank modular skid 205. The pop-off/bleed-off tank
modular skid
205 may be used in the oil and gas production industry to perform servicing
operations
on a well. For example, in a well fracturing operation the pop-off/bleed-off
tank skid
205 may allow discharge pressure from bleed off/pop off operations to be
immediately
relieved and controlled. At the conclusion of high-pressure tests or
treatments, the
pressure within the associated systems must be bled off safely to enable
subsequent
phases of the operation to continue. The bleed off process must be conducted
with a
high degree of control to avoid the effect of sudden depressurization, which
may create
shock forces and fluid-disposal hazards. Thus, the pop-off/bleed-off tank skid
205 may
equalize or relieve pressure from a vessel or system by collecting fluid bled-
off from
the system. The pop-off/bleed-off tank equipment may be arranged to fit on a
modular
skid frame having a selected mounting footprint, such that the base of the pop-
off/bleed-
off tank skid 205 may have a mounting footprint with a selected width and
length.
[0035] In one or more embodiments, the modular skid system 200 may
include at least
one isolation modular skid 206. The isolation skid 206 may be used in the oil
and gas
production industry to perform servicing operations on a well. For example, in
a well
fracturing operation an isolation modular skid may be used to allow pump-side
equipment and well-side equipment to be isolated from each other.
Additionally, the
isolation skid 206 may be capable of being simultaneously attached to multiple
external
holding vessels (e.g., pop-off/bleed-off tanks) and directing wellbore fluid
bled-off
from the well-side equipment or from the pump-side equipment to any of the
external
holding vessels. Furthermore, the isolation skid 206 may be connected to only
one
external holding vessel and may be capable of directing fluid from either the
well-side
equipment or from the pump-side equipment to the same external holding vessel.
Thus,
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the well isolation unit may provide more options for bleeding off well-side
and pump-
side equipment than traditional well isolation equipment. In the embodiment
shown,
the isolation skid 206 may include a bleed-off manifold fluidly connected to
the pop-
off/bleed-off tanks held in the pop-off/bleed-off tank skid 205, such that
fluid bled off
from the isolation equipment may be collected in the pop-off/bleed-off tanks.
[0036] Further, the isolation skid 206 may allow piping components with
larger inner
diameters than the piping components used in traditional wellbore operation
systems to
be used to perform wellbore operations. The well isolation unit disclosed
herein may
include automated valves. The isolation equipment may be arranged to fit on a
modular
skid frame having a selected mounting footprint, such that the base of the
isolation skid
206 may have a mounting footprint with a selected width and length. The
modular skids
202, 203, 204, 205, 206, 207 may align together to form a super structure. One
skilled
in the art will appreciate how the modular skid system 200 is not limited to a
set number
of modular skids but may have any number modular skids needed to perform a
required
job parameter.
[0037] In one or more embodiments, the modular skids 202, 203, 204, 205,
206, 207
may each include a primary manifold connection 210 with a single primary inlet
and a
single primary outlet and one or more primary flow paths extending
therebetween
mounted on same-sized A-frames 208 of the modular skids. Further, the primary
manifold connections 210 extend a length of the modular skids 202, 203, 204,
205, 206,
207. The same-sized A-frames 208 have a base with frame beams extending upward
from the base. Additionally, the frame beams are angled inward and are
connected with
a top beam to create an A shape. The top beam extends from one side of the
same-sized
A-frame 208 to another end of the same-sized A-frame 208. It is further
envisioned the
same-sized A-frame 208 may be any shape suitable to encompass the required
equipment and is not limited to being the same-sized shape shown in Figures 2A
and
2B. Furthermore, one skilled in the art will appreciate how the same-sized A-
frames
208 may be formed from a base material such as metal, composite, plastic, or
any
material know in the art to be a suitable frame. Additionally, the A-frame 208
may be
coated with any material know the art to protect the base material. The
primary
manifold connections 210 and same-sized A-frame 208 allow for the number and
order
of the modular skids 202, 203, 204, 205, 206, 207 to be easily changed
depending on
hydraulic fracturing pad design considerations or well conditions.
Additionally, the
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primary manifold connections 210 may simplify the number of connections needed
system wide, as the primary manifold connections 210 allows the modular skids
202,
203, 204, 205, 206, 207 to be in fluid communication via the primary manifold
connections 210. Furthermore, Figure 2A shows the modular skids 202, 203, 204,
205,
206, 207 of the modular skid system 200 in a Tee configuration (i.e., forming
a T-
shape). In one or more embodiments, as shown in Figure 2B, the modular skids
202,
203, 204, 205, 206, 207 of the modular skid system 200 may be in a straight or
linear
configuration. One skilled in the art will appreciate how the modular skid
system 200
is not limited to a set configuration and may be adapted to any configurations
based on
the job requirements.
[0038] According to embodiments of the present disclosure, a primary
manifold
connection may include piping or a body having one or more flow paths formed
therethrough with a single inlet and a single outlet to the one or more flow
paths. For
example, when a primary manifold connection includes multiple flow paths
(e.g., two
or more flow paths run in parallel), secondary flow paths may branch off from
a junction
with a single inlet and/or may branch off from a junction with a primary flow
path
extending from the single inlet, and secondary flow paths may join at one or
more
junctions to a single outlet and/or primary flow path. In some embodiments, a
primary
manifold connection may include more than one primary inlet and/or more than
one
primary outlet with one or more primary flow paths extending therebetween.
[0039] As used herein, a flow path between a primary manifold connection
may be
referred to as a primary flow path. When multiple primary manifold connections
(from
multiple modular skids) are connected together to make up the primary flow
functionality of a modular skid system, the connected-together primary
manifold
connections may form a primary flow path extending from one end of the modular
skid
system to another end of the modular skid system. For example, in the modular
skid
system shown in Figure 2A, the connected-together primary manifold connections
210
may provide a primary flow path extending from one or more pumps (at the pump
skids
203) to the wellheads (at the zipper manifold modular skids 202).
[0040] As mentioned above, a primary flow path may include one or more
secondary
flow paths branching from and/or joining with the primary flow path extending
between
a single primary inlet and single primary outlet manifold connection. In some
embodiments, one or more secondary flow paths may be used in different
subsystems
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of a modular skid system. For example, secondary flow paths may be formed
through
a bleed-off manifold in an isolation modular skid, and flow path(s) formed
between a
primary manifold connection of the isolation modular skid may form the primary
flow
path(s), where the primary flow path(s) may be used for transporting fluid
from the
pump side to the well side of the isolation modular skid, and where the
secondary flow
paths may carry fluid from the primary flow path(s) to be bled off (e.g., to a
connected
bleed-off tank or other external holding vessel). Accordingly, in some
embodiments,
secondary flow paths may have different outlets (referred to herein as
secondary
outlets) from the single primary outlet of a primary manifold connection.
Further, in
some embodiments, one or more secondary flow paths may have a different inlet
(referred to herein as a secondary inlet) from the single primary inlet of the
primary
manifold connection. In some embodiments, such as described above, a secondary
flow
path may branch off and join a primary flow path within the distance between a
single
primary inlet and a single primary outlet of a primary manifold connection,
such that
the secondary flow path does not have a secondary inlet or secondary outlet.
[0041] According to embodiments of the present disclosure, one or more
modular skids
may have one or more secondary inlets and/or secondary outlets in addition to
a primary
manifold connection. In some embodiments, a secondary inlet of a modular skid
may
connect with a secondary outlet of an adjacent modular skid. In some
embodiments, a
secondary inlet and/or a secondary outlet of a modular skid may connect with
an
external vessel, which may or may not be modularized into a modular skid.
[0042] As described above, the term "primary" may be used for
lines/manifold
connections that are connected together to transport fluid from the pump to
the well,
while the term "secondary" can be used for lines/manifold that flow into or
out of the
primary lines/manifold connections, such as bleed offs, prime up lines, and /
or
chemical injections (Acid). In one or more embodiments of the present
disclosure, when
the primary manifold connections 210 of each modular skids are made up in the
modular skid system 200, the connected-together primary manifold connections
210
provide a primary flow path extending from pump(s) (not shown) to wellheads
201,
whereas the secondary lines/manifold do not. For example, the secondary
lines/manifold may be used for priming. In priming, prime pumps may be used to
circulate fluid through prime-up lines in a pump side system, but does not go
all the
way to the well. Additionally, secondary lines/manifold, such as chemical
injection
CA 2999306 2018-03-23
14
lines, may be used to inject different chemicals into the primary
lines/manifold. As
such, the primary lines/manifold will typically be bigger than secondary
lines/manifold.
[0043] According to embodiments of the present disclosure, the modular
skid system
200 may be configured to a pressure rating of any job requirement.
Specifically, a main
pressure rating limitation of the modular skid system 200 may correspond with
the
wellheads 201, as known in the art. Furthermore, the modular skid system 200
may be
rated up to 15,000 psi but is not limited to 15,000 psi (in some cases the
pressure rating
may go up to 20,000 psi or more). One skilled in the art will appreciate how
the various
equipment of the modular skid system 200 may have different pressure ratings.
For
example, a pump side (i.e., the isolation modular skid 206, pop-off/bleed-off
tank
modular skid 205, pump skid 203, and auxiliary modular skid 204) may have a
pressure
rating of 15,000 psi while the wellheads 201 and the zipper manifold skid 202
may have
a pressure rating of 10,000 psi. In some embodiments, the pump side of the
modular
skid system 200 may be pressure rated higher than the wellheads 201 and the
zipper
manifold skid 202, which may have pressures ratings from 5,000 psi up to 15000
psi,
for example, and can change from job to job.
[0044] According to embodiments of the present disclosure, a primary
manifold
connection may have an inner diameter ranging from, for example, 4 inches to 8
inches,
such as about 7 inches. One skilled in the art will appreciate how the primary
manifold
connection is not limited to the range of 4 inches to 8 inches and may be any
desired
inner diameter based on the job requirements. As such, the primary manifold
connection may be as small as 1/4 inches (i.e., a 1" flow line) or as large as
30" (API 6A
has regulations up to a 30" ID, 3000 PSI capacity). In some embodiments, the
single
primary inlet and the single primary outlet of a primary manifold connection
may have
inner bore diameters greater than the inner diameter of the one or more
primary flow
paths extending between the inlet and outlet. In such a case, the ends of the
primary
manifold connection may have an upset section to transition from a larger
inner
diameter at the ends to a smaller inner diameter. As stated above, the primary
flow path
will more than likely be larger than any of the secondary flow path lines.
Typically, the
primary flow path will be a 7-1/16" bore while the secondary lines may be 2"
flow line
iron (actual inner diameter 1.75").
[0045] Referring again to Figures 2A-2B, the modular skids 202, 203,
204, 205, 206,
207 of the modular skid system 200 may be mounted onto at least one trailer
chassis
CA 2999306 2018-03-23
15
209 prior to deployment to the field. The modular skids 202, 203, 204, 205,
206, 207
may use ISO blocks and twist locks (not shown) to mount the modular skids to
the at
least one trailer chassis 209. In other embodiments, different connection
types (such as
mechanical fasteners) may be used to connect a modular skid to a chassis or
other
platform. Additionally, the modular skids may use an adhesive or be welded to
the at
least one trailer chassis 209. In some embodiments, the weight of the modular
skid and
connections to adjacent modular skids (e.g., manifold connections and/or frame
connections) may be used to hold the modular skid on a trailer. Furthermore,
the at least
one trailer chassis 209 may be formed to have a surface with a plurality of
grooves so
that the same-sized A-frame 208 of the modular skids are designed to fit
within the
grooves.
[0046] Multiples trailer chassis 209 may be used depending on the number
of modular
skids being used. When using multiple trailer chassis 209, the trailer chassis
209 may
be aligned and joined using similar technology to removable gooseneck
trailers. In
mounting the modular skids 202, 203, 204, 205, 206, 207 to the at least one
trailer
chassis 209, a field rig-up time may be significantly reduced. As stated
above, the at
least one trailer chassis 209 may allow for different configurations per job
requirements.
Additionally, in using the same-sized A-frame 208, the modular skids 202, 203,
204,
205, 206, 207 may have identical mounting footprints, regardless of function.
However,
it is further envisioned that the modular skids 202, 203, 204, 205, 206, 207
may be
transported to the field and placed on a ground or other platform structure
instead of
using the at least one trailer chassis 209.
[0047] As seen by Figures 3A-3C, in one more embodiments, perspective
views of a
trailer chassis 300 is shown. The trailer chassis 300 has a top surface 301
adapted to be
a carrier for the modular skids described in Figures 2A-2B. Furthermore, the
top surface
301 may be configured to lock the modular skids in place with a plurality of
ISO
retractable twist locks 302 or any known locking device known in the art.
Figure 3A
illustrates the trailer chassis 300 utilizing a removable gooseneck 303 as
known in the
art. The removable gooseneck 303 may allow the trailer chassis 300 to be
easily coupled
to a motor vehicle (not shown) and removed if the trailer chassis 300 needs to
be
connected to a second trailer chassis 304 (shown in Figures 3B-3C).
[0048] Further, seen by Figures 3B-3C, a plurality of male connections
306 on the
trailer chassis 300 may be inserted into a plurality of female connections 305
on the
CA 2999306 2018-03-23
16
second trailer chassis 304 to aid in proper alignment of the two trailers 300,
304.
Furthermore, a plurality of trailer twist locks 307 on the trailer chassis 300
may engage
and lock a plurality of ISO connection blocks 308 on the second trailer
chassis 304,
thereby, locking the two trailers 300, 304 together. It is further envisioned
that the two
trailers 300, 304 may be coupled together by a means of any mechanical
fastener and
not limited to the plurality of trailer twist locks 307 and the plurality of
ISO connection
blocks 308. Additionally, hydraulics may be used in conjunction or alone of
the
mechanical fastener. Furthermore, subsea connection technologies such as
soft/hard
landing may be used to couple the two trailers 300, 304. In some embodiments,
the two
trailers 300, 304 may be welded together or use adhesives.
[0049] According to embodiments of the present disclosure, a modular
skid system
may include a plurality of trailer chassis (e.g., as described Figures 3A-3C)
adapted to
be a carrier for modular skids according to embodiments of the present
disclosure.
Furthermore, the primary flow line of the modular skid system may be connected-
together by physically attaching the plurality of trailer chassis together in
the field. For
example, a first modular skid may be mounted on a first trailer and a second
modular
skid may be mounted on a second trailer. The first modular skid may be
connected to
the second modular skid without removing the first modular skid from the first
trailer
or the second modular skid from the second trailer. Additionally, the
connecting of the
first modular skid to the second modular skid may include connecting the first
trailer to
the second trailer. It is further envisioned that the first modular skid on
the first trailer
may be connected to the second modular skid on the second trailer by using
piping (i.e.,
ground iron) and with or without connecting the first trailer to second
trailer.
[0050] As seen by Figures 4A-4B, in one more embodiments, a perspective
view of
pump skid or an articulating fracturing arm (AFA) modular skid 400 from two
different
sides is shown. While Figures 4A-4B illustrates articulating fracturing arm
(AFA)
modular skid 400, one skilled in the art would understand the AFA skid 400 may
be
configured to be a pump modular skid carrying other pump connecting equipment.
For
example, using a different pump modular skid, the plurality of AFA arms 403
may be
replaced with a standard 3" connection. The AFA skid 400 may include a primary
manifold connection 401 (e.g., primary manifold connection with a single
primary inlet
and a single primary outlet and one or more primary flow paths extending
therebetween,
such as described above) and a dual segment low pressure line 402 (which may
have
CA 2999306 2018-03-23
17
secondary flow paths formed therethrough). The primary manifold connection 401
may
be connected to a pump (not shown) on either side via the AFA arms 403 and may
receive pressurized output from the pumps. Additionally, the dual segments low
pressure line 402 may form two portions of a single low pressure manifold that
receive
particulates from a blending system (not shown) and provide particulates to
fluid from
the pumps through outlets. Furthermore, blenders (not shown) may operate
anywhere
from 0-150 psi, and a max of 120 BPM, and thus, the low pressure equipment may
be
rated higher than 150 psi for a safety factor. One skilled in the art would
understand
how the further away the pump is from the blender, the lower the pressure head
can be
at the pump. For example, if all the pumps are stroking, the first few pumps
closest to
the blender may have the greatest suction head and the ones further away may
have
less. Thus, the pumps may be run at different rates to compensate and prevent
cavitation
on the pumps with low suction head.
[0051] The dual segments low pressure line 402 has one end that is a low
pressure hose
404 and an opposite end that is a low pressure header 405. One skilled in the
art will
appreciate how the low pressure hose 404 may allow flexibility in connecting
the skids
during rig-up operation. It is further envisioned that the dual segments low
pressure line
402 may self-connect and not be limited having the low pressure hose 404 and
the low
pressure header 405. Furthermore, the low pressure header 405 may include vane
(air)
actuated butterfly valves 409. Further seen by Figures 4A-4B, the AFA skid 400
contains its own independent local hydraulic accumulator 406 for shock
absorption.
Additionally, a local power station 407 may be powered by a solar panel 408,
which
may provide power to work area flood lights (not shown). In some embodiments,
the
local power station 407 may include at least one programmable logic
controllers (PLC),
at least one sensor, and other electronics to aid in communicating directly
with the
automation of the AFA skid 400. Additionally, a hydraulically actuated 3" ULT
Valve
410 may be connected to the AFA arms 403 and the primary manifold connection
401.
Also seen by Figures 4A-4B are a plurality of ISO connection blocks 411 which
may
engage with the plurality of ISO retractable twist locks 301 (see Figure 3A)
to lock the
AFA skid 400 to the trailer chassis 300 (see Figure 3A).
[0052] According to embodiments of the present disclosure, Figure 4A
illustrates a
height 412, a width 413, and a length 414 of the AFA skid 400. For example,
the width
413 may be 8 1/4 feet and the length 414 may be 11 V2 feet. However, width 413
and the
CA 2999306 2018-03-23
18
length 414 is not limited to 8 1/2 feet and 11 1/2 feet respectively and may
be any width
or length to properly align the AFA skid 400 with the pumps or any other job
requirements. Furthermore, the height 412 of the AFA skid 400 may be limited
by a
Department of Transportation (DOT) requirement. For example, in Texas the
height
limit is 14 feet of a total height of equipment mounted on a trailer chassis.
As such, the
height 412 of the AFA skid 400 may correspond with a height of a trailer that
the AFA
skid 400 sits on. For example, if the trailer sits 40 inches off the ground,
the height 412
of the AFA skid 400 may not exceed 10.6 feet to comply with some DOT
requirements
(if the height 412 exceeds 10.6 feet, special permits are needed).
Furthermore, the
aforementioned dimensions of the AFA skid 400 may be used on any modular skids
mentioned in the present application but are only shown in Figure 4A for
simplicity
purposes.
[0053] Now
referring to Figures 5A-5B, in one or more embodiments, Figures 5A-5B
illustrates an electronically controlled pressure relief valves
(ePRV)/auxiliary modular
skid 500 with a primary manifold connection 501 (e.g., a primary manifold
connection
with a single primary inlet and a single primary outlet and one or more
primary flow
paths extending therebetween, such as described above) that can be connected
directly
to another modular skid in any particular order. The auxiliary modular skid
500 may
include a low pressure header 502 configured to couple to dual segment low
pressure
line 402 of the AFA skid 400 shown in Figures 4A-4B. The auxiliary skid 500
may
have dual ePRVs 503 for redundancy. Furthermore, the auxiliary skid 500 may
include
an ePRV discharge iron 504 to discharge directly into a pop-off tank (not
shown) or
other external holding vessel. Additionally, hydraulically actuated isolation
valves 505
may be used to connect the dual ePRVs 503 with the primary manifold connection
501.
The auxiliary skid 500 may have a local power station 506, which may be
powered by
a solar panel 507. Further, hydraulic / air storage tanks 508 may be used on
the auxiliary
skid 500. Also seen by Figures 5A-5B are a plurality of ISO connection blocks
509
which may engage with ISO retractable twist locks (e.g., locks 301 in Figure
3A) to
lock the power skid 500 to a trailer chassis (e.g., trailer chassis 300 in
Figure 3A) or
other mounting structure. One skilled in the art will appreciate how the power
skid 500
may have an onboard power unit 510, such as an EnPac unit, to provide
hydraulic/air/electricity for the entire modular hydraulic fracturing pad
system. The
local power station 506 may run off of battery/solar system primarily, but may
use the
CA 2999306 2018-03-23
19
onboard power unit 510 if the battery/solar system supply isn't sufficient. In
some
embodiments, the local power station 506 may include at least one programmable
logic
controllers (PLC), at least one sensor, and other electronics to aid in
communicating
directly with the automation of the auxiliary modular skid 500.
[0054] Now referring to Figures 6A-6C, in one or more embodiments,
Figures 6A-6C
illustrates a pop-off/bleed-off tank modular skid 600 with a primary manifold
connection 601 (e.g., a primary manifold connection with one or more primary
inlets,
one or more primary outlets and one or more primary flow paths extending
therebetween) that can be connected directly to another modular skid in any
particular
order. The pop-off/bleed-off tank skid 600 may collect all discharge energy
from bleed
off/pop off operations (via a bleed off inlet 606 or a pop off inlet 604 in
tank 603) to
provide immediate relief and control. It is further envisioned a smart fluid
level
technology (not shown) may be used in a tank 603 to detect need for draining,
leak
detection from ePRV or bleed off systems, etc. Further, a drain valve may be
disposed
near a bottom of the tank 603. Additionally, the pop-off/bleed-off tank skid
600 may
have a built-in baffle system 602 (See Figure 6C) to distribute pressure and
force into
the tank 603. The pop-off/bleed-off tank skid 600 has the ability to be daisy
chained in
the modular hydraulic fracturing pad system for increased capacity.
Additionally, more
than one pop-off/bleed-off tank skid 600 may be provided in a modular
hydraulic
fracturing pad system. One skilled in the art will appreciate how the pop-
off/bleed-off
tank skid 600 provides the capability to remove iron (piping connections) from
the
ground (where without the pop-off/bleed-off tank modular skid, iron must be
ran to an
open top/tank on location). Furthermore, the pop off inlet 604 may couple to
the ePRV
discharge iron 504 of the auxiliary modular skid 500 (not shown).
Additionally, the
bleed off inlet 606 may couple to an isolation modular skid (not shown). Also
seen by
Figures 6A-6C are a plurality of ISO connection blocks 607 which may engage
with
the plurality of ISO retractable twist locks to lock the pop-off/bleed-off
tank skid 600
to a trailer chassis or other mounting platform.
[0055] Referring now to Figure 7, in one or more embodiments, Figure 7
illustrates an
isolation modular skid 700 with a primary manifold connection 701 that can be
connected directly to another modular skid. The isolation skid 700 may include
an
integrated automated bleed-off manifold having one or more valved bleed-off
outlets
702 (e.g., two bleed-off outlets 702 shown in Figure 7) configured to couple
to the bleed
CA 2999306 2018-03-23
20
off inlet of an external holding vessel (e.g., the bleed off inlet 606 of the
pop-off/bleed-
off tank skid 600 shown in Figures 6A-6C). Additionally, the integrated
automated
bleed-off manifold may have one or more connections 703 for connecting the
bleed-off
manifold to other bleed-off pathways in the modular skid system. Furthermore,
the
isolation skid 700 may have at least one hydraulically actuated 4" ULT valve
704 and
at least one 4" check valve 705. Advantageously, the isolation skid 700 may
remove all
treating lines from the modular hydraulic fracturing pad system, integrates
with the
pop-off/bleed-off tank pod 600 (see Figures 6A-6C), bleeds well side or pump
side
independently to one or more bleed-off outlets, and optionally to a connected
bleed-off
tank (e.g., tank 603 in Figures 6A-6C). Also seen by Figure 7 is a plurality
of ISO
connection blocks 706 which may engage with a plurality of ISO retractable
twist locks
to lock the isolation skid 700 to a trailer chassis or other mounting
platform.
[0056]
Now referring to Figures 8A-8B, in one or more embodiments, Figures 8A-8B
illustrates a time and efficiency (TE) manifold modular skid, also referred to
as a zipper
manifold modular skid 800 with a primary manifold connection 801 that can be
connected directly to another modular skid. A gate valve 802 may be provided
on the
primary manifold connection 801 to divert flow into the TE manifold skid 800
(which
may prevent "Sand-Offs" of unused mainline). Furthermore, the zipper manifold
skid
800 may save space by using a dual valve block 803 (e.g., which may include
one
manual valve 804 and one hydraulic valve 805) to open/close flow to a specific
well
(not shown). Additionally, a goat head 806 (also referred to as a frac head in
the
industry) may hang off a side of the zipper manifold skid 800 for easy ground
access
for rigging up to the well. One skilled in the art will appreciate how the
modular
hydraulic fracturing pad system may have multiple zipper manifold skids 800,
as
needed per job requirements. Also seen by Figures 8A-8B are a plurality of ISO
connection blocks 807 which may engage with a plurality of ISO retractable
twist locks
to lock the zipper manifold modular skid 800 to a trailer chassis or other
mounting
platform.
[0057] Now
referring to Figures 9A-9C, in one or more embodiments, Figures 9A-9C
illustrates different equipment modular skids with a primary manifold
connection 901
that can be connected directly to another modular skid in any particular
order. In Figure
9A, a spacer modular skid 900 is shown that is configured to allow proper
equipment
spacing when needed in the modular skid system. Further, Figures 913 and 9C
illustrate
CA 2999306 2018-03-23
21
a Tee configuration modular skid 902 which includes a tie-in valve 903
connected to a
Tee manifold connection 906 to allow the modular skid system to be
reconfigured for
different pad layouts/requirements. The manifold connection of the Tee
configuration
modular skid 902 may be referred to as a Tee manifold connection, as the
primary flow
path extending between an inlet and an outlet has a third access point (via
the tie-in
valve. The inlet, the outlet and/or the tie-in valve of the Tee manifold
connection may
be connected to an adjacent primary manifold connection to provide the primary
flow
functionality of a modular skid system. Additionally, Figure 9C shows a
trailer tie-in
904 to allow the Tee configuration modular skid 902 to secure to a trailer
chassis. Also
seen by Figures 9A-9C are a plurality of ISO connection blocks 905 which may
engage
with a plurality of ISO retractable twist locks to lock the spacer modular
skid 900 or
the Tee configuration skid 902 to a trailer chassis or other mounting
platform.
[0058] Further seen by Figures 10A-10B, in one or more embodiments,
Figures 10A-
10B illustrates an example of a post-drilling operation modular skid 1000 with
a
plurality of equipment 1001 mounted on a trailer 1002. The post-drilling
operation skid
1000 may connect to the at least one wellhead, for example, using piping. One
skilled
in the art will appreciate how the plurality of equipment 1001 of the post-
drilling
operation skid 1000 may include equipment required for flow back operations,
drill-out
operations, well-logging operations, or any other post-drilling operations
know in the
art.
[0059] According to embodiments of the present disclosure, an axial end
of a primary
manifold connection on a modular skid may be connected to a tie-in valve of a
Tee
manifold connection on an adjacent Tee configuration modular skid to provide a
perpendicular turn in the configuration of a modular skid system. In some
embodiments, more than one Tee configuration modular skid may be used in a
modular
skid system to provide multiple perpendicular turns in the configuration of a
modular
skid system. In some embodiments, a Tee manifold connection may not be used,
where
a modular skid system may be made up of connected-together modular skids
having a
linear configuration.
[0060] In one or more embodiments, a modular skid system can be deployed
in at least
two ways. In a first way, modular skids may be loaded onto a truck and
unloaded on
site via a crane, for instance. Once unloaded, the modular skids can be placed
in
proximity to one another and secured together, such as by bolts and/or
hydraulics, to
CA 2999306 2018-03-23
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form a unitary structure. The end portions (the primary inlet(s) and the
primary
outlet(s)) of primary manifold connections on the modular skids may be
connected
together by any known mechanisms, including flanges, clamps, grayloc hubs, KL4
connectors. In some embodiments, modular skids may be mounted and deployed on
flatbeds. Primary manifold connections between multiple modular skids on a
truck can
be made up before the trucks are driven to the site. In the case that enough
modular
skids are required such that multiple trucks are needed, the primary manifold
connection between the end modules of the trucks may be made up in the field.
[0061] While
the present disclosure has been described with respect to a limited
number of embodiments, those skilled in the art, having benefit of this
disclosure, will
appreciate that other embodiments may be devised which do not depart from the
scope
of the disclosure as described herein. Accordingly, the scope of the
disclosure should
be limited only by the attached claims.
CA 2999306 2018-03-23
