Note: Descriptions are shown in the official language in which they were submitted.
ADJUSTABLE FRACTURING MANIFOLD MODULE, SYSTEM AND METHOD
FIELD OF THE INVENTION
This invention relates in general to hydrocarbon well stimulation equipment
and
methods for downhole hydraulic fracturing, and in particular, to equipment,
systems and
methods used in multi-pad drilling and fracturing operations in order to align
skid
mounted fracturing manifold modules of a fracturing manifold system for
adjustable
connection to a shared fracturing manifold trunk line.
BACKGROUND
Current methods for completing hydrocarbon wells often require initial high
pressure fracturing fluids to be introduced to hydraulically fracture the
formation,
increasing permeability and allowing the flow of hydrocarbons during
production. The
stimulation services provide the high pressure fracturing fluid, which is
transported
through the fracturing manifold system to fracturing trees rated for the high-
pressure
stimulation on the wellheads. On multi-pad well sites, the fracturing manifold
system
controls the flow of the fracturing fluid to the corresponding well being
stimulated and
isolates flow to the other wells.
This process of hydraulic fracturing ("fracing") creates hydraulic fractures
in
rocks, to increase the output of a well. The hydraulic fracture is formed by
pumping a
fracturing fluid into the wellbore at a rate sufficient to increase the
pressure downhole to
a value exceeding the fracture gradient of the formation rock. The fracture
fluid can be
any number of fluids, with chemical additives, ranging from water to gels,
foams,
nitrogen, carbon dioxide, acid or air in some cases. The pressure causes the
formation
to crack, allowing the fracturing fluid to enter and extend the crack further
into the
formation. To maintain the fractures open, propping agents are introduced into
the
fracturing fluid and pumped into the fractures to extend the breaks and pack
them with
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proppants, or small spheres generally composed of special round quartz sand
grains,
ceramic spheres, or aluminum oxide spheres. The propped hydraulic fracture
provides
a high permeability conduit through which the hydrocarbon formation fluids can
flow to
the well.
At the surface, hydraulic fracturing equipment for oil and natural gas fields
usually includes frac tanks holding fracturing fluids and proppants which are
coupled
through supply lines to a slurry blender, one or more high-pressure fracturing
pumps to
pump the fracturing fluid to the frac head of the well, and a monitoring unit.
Fracturing
equipment operates over a range of high pressures and injection rates. Many
frac
pumps are typically used at any given time to maintain the very high, required
flow rates
into the frac head and into the well.
The high pressure fracturing fluid flows to the inlet of shared fracturing
manifold
trunk lines (also known as zipper manifolds), through a single large diameter
high-
pressure line or multiple smaller diameter high-pressure lines. The inlet
block of the
shared fracturing manifold trunk line is fluidly connected to one of the
fracturing
manifold modules (also known as manifold leg or zipper module), or between two
fracturing manifold modules, and additional fracturing manifold modules are
connected
together with a single shared manifold trunk line. The shared fracturing
manifold trunk
line may include joints, which may or may not be adjustable. Each fracturing
manifold
module typically corresponds to a single well for stimulation. The flow
control unit
components of the fracturing manifold module typically include an inlet (for
example an
inlet tee, cross or block) to align and connect to the shared manifold trunk
line, one or
more control valves (typically two, for example gate valves or plug valves)
and an outlet
(for example an outlet tee, cross or block) to align to the well. The outlet
connects to
the fracturing tree on the wellhead through one or more high-pressure conduit
lines or
multiple high-pressure lines that may include connection blocks, pipe sections
and
possibly pivot or swivel joints.
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The fracturing manifold modules may be pre-assembled prior to transporting to
the well pad and may be skid mounted. The skid may include one or multiple
fracturing
manifold modules, wherein each module includes the flow control unit
components of
an inlet, one or more control valves and an outlet. Each of these manifold
modules is
attached together at the inlet with the shared manifold trunk line, commonly
with
flanged connections and metal sealing gaskets. When making up this flanged
connection, the flange faces must be aligned, that is parallel and coaxial
with the axis of
the shared manifold trunk line for integrity of the metal seal.
Due to the high-pressure rating required for the fracturing manifold
equipment,
each manifold module and skid commonly exceeds 20,000 lbs. A high capacity
crane
at the well pad is typically used to support and align each manifold module
and skid
when making up this connection to the shared fracturing manifold trunk line.
Supporting the skid by crane, while aligning the connection at the inlet, is
tedious, time
consuming, and costly. As well, the crane supported skid connection to the
shared
manifold trunk line creates additional risks for workers.
SUMMARY
In some embodiments, the subject invention reduces or eliminates the need for
a
high capacity crane in building the high pressure portions of a fracturing
manifold
system. A high capacity crane, if used at all, approximately locates each
fracturing
manifold module proximate to one of the plurality of wellheads or to the
shared manifold
trunk line, and then is not involved in aligning and making the connections of
each
fracturing manifold module to the shared fracturing manifold trunk line and to
the
plurality of wellheads.
In some embodiments, the fracturing manifold module of this invention is pre-
assembled prior to transport and landing, and provides for adjusting such that
one or
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both of the inlet and the outlet of the manifold module can be axially aligned
for
connection to the fracturing manifold system using rotation, and preferably
also
translational movement, between a flow control unit that includes the inlet
and the
outlet, and a transport skid with supports the flow control unit.
In some embodiments, the flow control unit and the transport skid are
connected
together with a plurality of independently controlled, actuated cylinders, to
provide for
rotation of the flow control unit relative to the transport skid in a
generally horizontal x-y
plane relative to the ground, the rotation being about a z-axis perpendicular
to the x-y
plane to provide for adjustable connection to the fracturing manifold system
at one or
both of the inlet and the outlet.
In some embodiments the transport skid and the flow control unit are also
connected together for translational movement of the flow control unit
relative to the
transport skid for movement in the x-y plane, for example in the direction of
both a y-
axis and an x-axis of the fracturing manifold module.
In some embodiments, the fracturing manifold module also provides for height
adjustment to level the flow control unit relative to the ground.
By providing both translational and rotational movement between the flow
control
unit and the transport skid, preferably also with height adjustment, the
fracturing
manifold module achieves adjustable connection in each of the x, y and z
directions to
connect the inlet in alignment with the axis of the shared manifold trunk
line, herein
termed the y-axis of the shared manifold trunk line. This allows the
connection at the
inlet to be made up in a safe and time effective manner. This also allows the
high
capacity crane, if needed at all, to quickly and approximately locate each
fracturing
manifold module, and then move on to assist in other stimulation services set-
up rather
than remaining for further connections in the fracturing manifold system.
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Broadly stated, the present disclosure provides a fracturing manifold module
of a
fracturing manifold system for controlling the flow of fracturing fluid from a
shared
manifold trunk line to a plurality of wellheads each adapted for fracturing a
well. The
fracturing manifold module includes a transport skid adapted to be ground
supported
and a flow control unit supported on the transport skid. The flow control unit
includes
an inlet adapted for connection along an axis of the shared manifold trunk
line, an outlet
adapted for connection to one of the plurality of wellheads via one or more
fluid
conduits, and one or more flow control valves between the inlet and the
outlet. The
transport skid and the flow control unit are connected together to provide for
rotation of
the flow control unit relative to the transport skid in a generally horizontal
x-y plane
relative to the ground, the rotation being about a z-axis perpendicular to the
x-y plane to
provide for adjustable connection to the fracturing manifold system at one or
both of the
inlet and the outlet.
In some embodiments of the fracturing manifold module, the transport skid and
the flow control unit are connected together to provide for translational
movement of the
flow control unit relative to the transport skid in the x-y plane, for example
in the
direction of a y-axis of the fracturing manifold module which is adapted to
extend
parallel to the y-axis of the shared manifold trunk line, and an x-axis of the
fracturing
manifold module extending perpendicularly to the y-axis of the fracturing
manifold
module in the x-y plane, to provide for adjustable connection to the
fracturing manifold
system at one or both of the inlet and the outlet.
In some embodiments of the fracturing manifold module, the rotation about the
z-axis and the translational movement of the flow control unit in the x-y
plane relative to
the transport skid are provided by a plurality of independently controlled,
actuated
cylinders, for example three or more cylinders, at least one cylinder being
oriented to
provide the translational movement in the direction of either the x-axis or
the y-axis, and
at least two cylinders oriented to provide the translational movement in the
direction of
the other of the x-axis or the y-axis, such that movement of both an x-axis
directional
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cylinder and a y-axis directional cylinder provides the rotation about the z-
axis.
In some embodiments of the fracturing manifold module, the transport skid and
the flow control unit are further adapted to provide for height adjustment
along the z-
axis to level the flow control unit relative to the ground and to provide for
adjustable
connection to the fracturing manifold trunk line at one or both of the inlet
and the outlet.
In some embodiments, the flow control unit is connected to a flow control
frame
for fixed movement therewith, while the transport skid remains ground
supported and
stationary. The flow control unit frame is supported on the transport skid and
is
connected to the transport skid through the plurality of cylinders to provide
the rotation
and the translational movement relative to the transport skid. The flow
control unit
components of the inlet, outlet and flow control valves may be pedestal
mounted to the
flow control frame and aligned along an x-axis of the flow control unit frame.
In other
embodiments, the flow control unit components may be aligned along a z-axis.
In another broad aspect, the present disclosure provides a fracturing system
for controlling the flow of fracturing fluid to a plurality of wellheads, each
adapted for
fracturing a well. The fracturing system includes a fracturing manifold system
connected
to the plurality of wellheads for delivering fracturing fluid to the plurality
of wellheads.
The fracturing manifold system includes a shared manifold trunk line and a
plurality of
fracturing manifold modules connected to the shared manifold trunk line for
controlling
the flow of the fracturing fluid from the shared manifold trunk line to one of
the plurality
of wellheads. Each of the fracturing manifold modules includes a transport
skid adapted
to be ground supported, and a flow control unit supported on the transport
skid and
including an inlet adapted for connection along an axis of the shared manifold
trunk
line, an outlet adapted for connection to one of the plurality of wellheads
via one or
more fluid conduits, and one or more flow control valves between the inlet and
the
outlet. The transport skid and the flow control unit are connected together
for rotation
of the flow control unit relative to the transport skid in a generally
horizontal x-y plane
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relative to the ground, said rotation being about a z-axis perpendicular to
the x-y plane
to provide for adjustable connection to the fracturing manifold system at one
or both of
the inlet and the outlet.
In yet another broad aspect, the present disclosure provides a method of
aligning
a fracturing manifold module for connection to a shared manifold trunk line of
a
fracturing manifold system. The method includes:
providing a flow control unit, the flow control unit including an inlet
adapted for
connection along an axis of the shared manifold trunk line, an outlet adapted
for
connection to one of a plurality of wellheads via one or more fluid conduits,
and one or
more flow control valves between the inlet and the outlet;
supporting the flow control unit on a transport skid adapted to be ground
supported, the flow control unit and the transport skid being connected
together to
provide for rotation of the flow control unit relative to the transport skid
in a generally
horizontal x-y plane relative to the ground, said rotation being about a z-
axis
perpendicular to the x-y plane;
landing the transport skid and flow control unit for proximity to the shared
manifold trunk line and to one of the plurality of wellheads; and
adjusting the position of the flow control unit by rotating the flow control
unit
relative to the transport skid in the x-y plane about the z-axis to align one
or both of the
inlet and the outlet for connection to the fracturing manifold system.
In some embodiments of the method, the transport skid and the flow control
unit
are connected together to provide for translational movement of the flow
control unit
relative to the transport skid in the x-y plane. In such embodiments, the
adjusting step
further includes translating the flow control unit relative to the transport
skid in the x-y
plane to align one or both of the inlet and the outlet for connection to the
fracturing
manifold system.
In some embodiments, the method includes landing the transport skid and the
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flow control unit such that the transport skid is ground supported, and
leveling the flow
control unit in the x-y plane relative to the ground by adjusting the height
of the flow
control unit.
DESCRIPTION ON THE DRAWINGS
Certain embodiments of the above features, aspects and advantages of the
invention are described in greater detail with reference to the accompanying
drawings
in which like characters represent like parts throughout the drawings, in
which:
FIG. 1 illustrates a portion of a fracturing system in accordance with one
embodiment of the present disclosure in which a plurality of fracturing
manifold
modules, here five, are axially aligned and connected via the inlets to a
shared
fracturing manifold trunk line. The shared manifold trunk line receives high
pressure
fracturing fluid at inlet block(s), as pumped from the stimulation services S.
The shared
manifold trunk line is connected through the flow control unit components of
each
fracturing manifold module and through one or more fluid conduits at the
outlet to one
of the plurality of wellheads W, the outlet connections and the wellheads
being shown
schematically in the Figure.
FIG. 2 is a perspective view of a fracturing manifold module of the fracturing
system of FIG. 1 showing additional details in accordance with one embodiment
of the
disclosure in which the flow control unit components of an inlet, an outlet
and two
valves, are pedestal mounted on a flow control unit frame, which is in turn
supported on
a lower transport skid. The flow control unit components are mounted for fixed
movement with the flow control unit frame. To provide for adjustable
connection along
the y-axis of the shared manifold trunk line at the inlet, the flow control
unit frame and
the transport skid are connected together to allow for rotation of the flow
control unit
relative to the transport skid in an x-y plane relative to the ground and
about a z-axis
perpendicular to the x-y plane (Rz), and for translational movement in each of
the x and
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y directions, as shown in the cartesian coordinates inset. The transport skid
is also
provided with height adjustable legs for leveling the flow control unit
relative to the
ground, thus providing for vertical adjustment in the z-direction. The
fracturing manifold
module is shown in the pre-assembled and locked position for transport and
landing.
FIG. 3 is a side perspective view of the fracturing manifold module of FIG. 2
with
the flow control unit frame partially cut away to show additional details of
the frame
system for each of the flow control unit frame and the transport skid, a
plurality of
independently controlled, actuating cylinders (three) pivotally connected
between the
flow control unit frame and the transport skid, and a friction reducing member
provided
at the points of contact between the flow control unit frame and the transport
skid.
FIG. 4 is a side perspective view of the fracturing manifold module of FIG. 2
showing height adjustable legs on the transport skid to level the flow control
unit, its
components, and its frame relative to the ground. Leg locking mechanisms on
each leg
lock the legs against further movement. A releasable locking device between
the flow
control unit frame and the transport skid locks against relative movement.
FIG. 5 is a perspective view of the fracturing manifold module of FIG. 2,
illustrating relative translational movement of the flow control unit and
frame relative to
the transport frame in both the x and y directions to adjust the position of
the inlet for
connection along the y-axis of the shared fracturing manifold trunk line.
FIG. 6 is a perspective view of the fracturing manifold module of FIG 2,
illustrating rotation of the flow control unit and frame relative to the
transport skid in the
x-y plane relative to the ground and about the z-axis for adjustable
connection along the
y-axis of the shared manifold trunk line.
FIG. 7 is a side perspective view of the fracturing manifold module in the
position
of FIG. 6, with the flow control unit frame partially cut away.
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FIG. 8 is a top view of the fracturing manifold module of FIG. 6, but with the
flow
control unit components and pedestal mounts removed and the flow control unit
frame
partially cut away.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
Fracturing System
One embodiment of a fracturing system is shown generally at 10 in FIG. 1. A
plurality of wellheads W1 - W5, each adapted for fracturing a well in a manner
known in
the industry, receives a high pressure fracturing fluid pumped from
stimulation services
S (as described above) through a fracturing manifold system 20 which includes
a
plurality of fracturing manifold modules 22. FIG. 1 shows five identical
fracturing
manifold modules 22a - 22e connected to a shared manifold trunk line 24,
although in
other embodiments, the fracturing manifold modules may vary one from another
both in
respect of the components included, and the connections to the fracturing
manifold
system 20. The shared manifold trunk line 24 of FIG. 1 is shown to include two
inlet
blocks 26 located between two adjacent fracturing manifold modules 22b, 22c,
receiving the high pressure fracturing fluid from the stimulation services S
via fluid
conduits 27, and a plurality of interconnected spacer spools 28 between other
of the
adjacent fracturing manifold modules 22a-22e. In FIG. 1, the shared manifold
trunk line
24 extends along an aligned, common center axis, which is herein referred to
as the y-
axis of the shared manifold trunk line 24. As noted above, the connections
along the
shared manifold trunk line 24 are commonly flanged connections with metal
sealing
gaskets, so the flange faces are sufficiently aligned, that is parallel and
coaxial with the
axis of the shared manifold trunk line 24, in order to preserve the integrity
of the metal
seal. It will be understood that FIG. 1 shows one exemplary embodiment of a
shared
manifold trunk line 24. In other embodiments, the inlet block 26 may be
connected at a
different points along the shared manifold trunk line, and may be configured
with more
or fewer outlets to the shared manifold trunk line 24. The shared manifold
trunk line 24
may include other components such as tee connections and valves. Similarly,
the
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manifold trunk line may include branch lines such as lines that are
perpendicular to or
parallel to other portions of the trunk line, and thus the fracturing manifold
modules
connected along these branch lines may be connected in a manner such that
components of adjacent fracturing modules are located perpendicularly,
parallel or
opposed to each other.
Each of the fracturing manifold modules 22a-22e may include similar
components or different components. In FIG. 1, the modules 22a-22e each
include a
flow control unit 30 providing an inlet 32, an outlet 34 and one or more
control valves
between the inlet 32 and the outlet 34, such as a remotely operated gate valve
36 and
a manually operated gate valve 38. The control valves might alternatively be
plug
valves or other industry standard control valves. In FIG. 1, the inlet 32,
outlet 34 and
control valves 36, 38 are interconnected and axially aligned along an x-axis
of the
fracturing manifold module extending perpendicularly to the y-axis of the
shared
manifold trunk line 24. However, in other embodiments, the components of the
flow
control unit 30 may be interconnected and axially aligned along a z-axis
(generally a
vertical axis). The connections between the flow control unit components are
shown as
flange connections, although other industry standard connections may also be
used.
The inlet 32 is shown as a 4-way cross, and the outlet 34 is shown as a 6-way
cross,
although other industry standard inlets and outlets may be used, with more or
fewer
connections at each of the inlets and outlets. The outlet 34 provides for
connection to
one of the wellheads W, via one or more fluid conduits 35. Both the wellheads
W and
conduits 35 are shown schematically in FIG. 1, and may be varied in accordance
with
industry standards to meet the needs of a particular fracturing operation.
As described more fully below, each of the fracturing manifold modules 22a-22e
(shown in greater detail as 22 in FIGS. 2-8) includes a transport skid 40
which supports
the flow control unit 30. In some embodiments, more than one flow control unit
may be
supported on a single transport skid 40. For example, two or more parallel
spaced flow
control units may be provided on a single transport skid, with the inlets
aligned along a
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common y-axis, or multiple flow control units may be provided on a single
transport skid
in which the inlet of the flow control units is shared, but the each flow
control unit
provides a separate outlet.
The transport skid 40 is adapted to be ground supported, and may include one
or more height adjustable legs 42 for leveling purposes. Alternatively, in
some
embodiments, the height adjustment may be provided by a support frame for the
flow
control unit 30. The transport skid 40 and the flow control unit 30 are
connected
together to provide for rotation of the flow control unit relative to the
transport skid in a
generally horizontal x-y plane relative to the ground. For ease of explanation
herein, the
x, y, z cartesian co-ordinates as applied to the fracturing manifold module 22
and the
shared manifold trunk line 24 are shown as an inset in FIG. 2. A y-axis (Y) of
the
fracturing manifold module 22 extends through the inlet 32 so as to be aligned
with the
y-axis of the shared manifold trunk line. An x-axis of the fracturing manifold
module 22
extends perpendicularly to the y-axis in an x-y plane. The x-y plane is a
plane which is
generally horizontal relative to the ground, and may be envisaged as a
generally
horizontal plane extending through the inlet 32 (for aligned connection at the
inlet 32), a
generally horizontal plane extending through the outlet 34 (for aligned
connection at the
outlet 34) or a generally horizontal plane extending through a support frame
for the flow
control unit such that the flow control unit components have fixed movement
with the
frame (such as flow control unit frame 44 in FIG. 2, for aligned connection at
the inlet 32
and/or the outlet 34). The z-axis is generally perpendicular to the x-y plane,
and
generally refers to a vertical direction (i.e., generally parallel to the z-
axis). The rotation
of the flow control unit 30 relative to the transport skid is shown as Rz in
FIG. 2, and is
about the z-axis perpendicular to the x-y plane. This rotation of the flow
control unit 30
in the x-y plane relative to the transport skid provides for adjustable
connection to the
shared manifold trunk line 24 once the module 22 is landed with the inlet 32
positioned
proximate to the connection to the shared manifold trunk line 24. In some
embodiments, this rotation may provide for adjustable connection at the outlet
34 to the
fracturing manifold system 10, for example via the fluid conduits 35 to one of
the
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plurality of wellheads W.
In the embodiments shown herein and described below, the transport skid 40
and the flow control unit 30 are also connected together to provide for
translational
movement of the flow control unit 30 relative to the transport skid 40 in the
x-y plane. In
FIG. 2, this relative translational movement is shown to be in the direction
of both the y-
axis and the x-axis of the fracturing manifold module 22 (i.e., separate
translational
movement in a direction generally parallel to the y-axis and in a direction
generally
parallel to the x-axis of the fracturing manifold module 22, with the y-axis
being set to be
parallel to the y-axis of the shared manifold trunk line 24). This relative
translational
movement provides for adjustable connection to the fracturing manifold system
20, for
example to the shared manifold trunk line 24 at the inlet 32 and/or at the
outlet 34 to the
wellhead W through the fluid conduits 35. In the description which follows,
this
adjustable connection is described at the inlet 32 and along an aligned y-axis
of the
shared manifold trunk line 24. However, it will be understood that the
adjustable
connection can be made at the inlet 32, along a different axis of the shared
manifold
trunk line 24 that is not co-axial through the inlet 32, such as along an axis
perpendicular to the y-axis with the inlet connections for the shared manifold
trunk line
24 being at right angles through the inlet 32. It will also be understood that
the
adjustable connection can be made at the outlet 34. As used herein and in the
claims
when describing a connection at the inlet along an axis of the shared manifold
trunk
line, the axis refers to the center axis of the particular inlet connection to
that portion of
the shared manifold trunk line.
Fracturing Manifold Module
One exemplary embodiment of a fracturing manifold module 22 is shown in
FIGS. 2-8. The flow control unit 30 is shown to be pedestal mounted on a flow
control
unit frame 44 for fixed movement with the frame 44, that is, as the frame 44
is moved in
an x-y plane extending horizontally though the frame 44, each of the
components of the
inlet 32, outlet 34 and control valves 36, 38 have fixed movement with the
frame 44.
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The flow control unit frame 44 is supported by the transport skid 40, which in
turn is
adapted to be ground supported. A pedestal frame 46 provides rigid vertical
and
horizontal supports 48, 50 secured to the flow control unit frame 44,
elevating the
components (32, 34, 36, 38) of the flow control unit 30 above the frame 44.
The inlet
32, and control valves 36, 38 may be secured by bolting or other fasteners to
the
horizontal plate supports 50 of the pedestal frame 46 (inlet fasteners 53 are
visible in
FIG. 2), with the flange connections between the components 32, 34, 36 and 38
being
axially aligned along an x-axis of the fracturing manifold module. The outlet
34 is shown
to be additionally retained with a clamp connection 52 to secure the outlet 34
to the
pedestal frame 46. The inlet 32 is shown as a 4-way cross, the outlet 34 is
shown as a
6-way cross, and the control valves are shown as a remotely operated gate
valve 36
and a manually operated gate valve 38. The components of the flow control unit
30
and their connections are industry standard and may be varied according with
industry
known standards. As noted above, in some embodiments, the flow control unit
components may be axially aligned along a z-axis, so as extend in a vertical
stack on
the frame 44. In such embodiments, the inlet is commonly positioned at the
bottom of
the stack while the outlet is located at the top of the stack.
In FIGS 2-3, the fracturing manifold module 22 is shown pre-assembled, in the
locked mode for transport and landing. In FIG. 2, an inset of x, y and z
coordinates of
the fracturing manifold module 22 is included, with the y-axis being set to be
parallel to
the center y-axis of the shared manifold trunk line 24. With reference to
these cartesian
co-ordinates, the flow control unit frame 44 is shown to include a plurality
of parallel
spaced frame members 54 such as I-beams, extending in the direction of the y-
axis of
the module 22, and a pair of parallel spaced side frame members 56 such as I-
beams,
extending in the direction of the x-axis of the module 22, which combined form
the rigid
rectangular frame 44. A top plate 58 is connected along the top edges of the
frame
members 54, 56, and the pedestal frame 46 is rigidly connected, for example by
welding and/or bolting, to the top plate 58 and frame members 54, 56.
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The transport skid 40 includes a pair of parallel spaced skid frame members 60
such as l-beams (also known as runners), extending in the direction of the x-
axis of the
module 22, and parallel spaced cross members 62, such as I-beams extending
transversely (i.e., in the direction of the y-axis of the module) between the
skid frame
members 60 to provide the generally rigid rectangular transport skid 40.
Parallel spaced
support plates 64 extend transversely between the upper edge portions of the
skid
frame members 60 above the transverse cross members 62. In FIG. 3, the cross
members 62 are not visible, but extend below the support plates 64. Transport
skid roll
ends 66 extend through the skid frame members 60 at the front and rear corners
of the
transport skid 40 (front being at the inlet end) and extend outwardly from the
skid frame
members 60. These roll ends 66 provide for attachment to a crane for transport
and
landing, and/or for dragging the module 22 into a desired position. Additional
structural
frame members for the transport skid 40 and/or the flow control unit frame 44
may be
included as appropriate to provide rigid frames to support the weight of the
flow control
unit 30, to withstand the relative movement between the frames, and to
withstand
vibration that may occur from the high pressure fracturing fluid.
Also shown are a plurality (such as three or four) height adjustable legs 42
connected at the four corners of the transport skid 40, connected to the skid
frame
members 60. The legs 42 may be manual jacks, but due to the weight of the
module,
the legs 42 are more preferably independently controlled, actuated cylinders,
such as
hydraulic cylinders. Each leg 42 is preferably provided with a leg locking
mechanism
68, such as a threaded ring lock, which can be threaded onto mating threads of
the legs
42 once each leg 42 is height adjusted in order to lock the leg in position.
FIG. 4 shows
three of the four adjustable legs 42, with the leg 42 at the outlet end of the
module 22
locked in position with the leg locking mechanism 68 against the cylinder
portion of the
adjustable leg 42, while the leg 42 at the inlet end of the module 22 is
height adjusted
with the leg locking mechanism 68 not yet in the locked position. Although not
shown in
the other Figures, once the module 22 is leveled and the legs 42 are locked,
these leg
locking mechanisms 68 remain in place on each leg 42. FIG. 4 also shows
releasable
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locking devices 69 comprising bolted connections between the side members 56
of the
flow control unit frame 44 and the skid frame members 60 of the transport
skid. These
releasable locking devices 69 are used to prevent relative movement during
transport
and landing of the fracturing manifold module 22. FIG. 4 also shows ladder
rungs 71 to
assist an operator in climbing to the top plate 58. Worker safety platform or
railings and
the like may be connected to the top plate 58 to operate and service the
control valves
36, 38. Mounting holes 59 for a worker safety platform are shown in FIG. 4.
During pre-assembly of the fracturing manifold module 22, the flow control
unit
frame 44 is supported on the transport skid 40, with the lower edges of the
parallel
spaced frame members 54 supported on the support plates 64 of the transport
skid 40.
To reduce friction between the frame members, a friction reducing member 70 is
provided at the one or more points of contact between the frame members 54,
64. In
FIGS. 3-4, the friction reducing member 70 is shown as a sheet of a low
friction material
extending between the lower edges of the parallel spaced frame members 54 of
the
flow control unit frame 44 and the support plates 64 of the transport skid 40.
Alternatively, this low friction material may be provided as shorter strips at
these points
of contact. Exemplary low friction materials include plastic and thermoplastic
materials
such as acetal, polycarbonate, PEEK, PTFE, UHMW, Nylon 6 Cast, Nylon 6/6 PVC
and
polypropylene. The friction reducing member 70 may alternatively be provided
as a
lubricant, or as a coating of a low friction material onto one or more of the
frame
members at the points of contact.
In some embodiments, to provide the above-described relative rotational
movement, and preferably also translational movement, between the transport
skid 40
and the components of the flow control unit 30, to align the inlet 32 for
connection to the
shared manifold trunk line 24, the flow control unit frame 44 and the
transport skid 40
are connected together by a plurality of independently controlled, actuated
cylinders,
such as pneumatic or hydraulic cylinders. In other embodiments, the plurality
of
cylinders might be replaced by manual actuators such as crank systems. As best
seen
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in the cut away figures, FIGS. 3, 7 and 8, this relative movement is shown to
provided
by three, independently controlled, hydraulic cylinders, with one cylinder 72
extending in
the direction of the x-axis of the manifold module 22, and two parallel spaced
cylinders
74 extending in the direction of the y-axis of the manifold module. The x-axis
directional
cylinder 72 has its ends 72a, 72c pivotally connected to an upwardly extending
mounting bracket 72b connected to the front end of the transport skid 40, and
to a
mounting bracket 72d connected to the front most frame member 54 of the flow
control
unit frame 44 (see FIG. 2). The x-axis directional cylinder 72 preferably
extends parallel
to a center axis of the manifold module 22, and generally horizontally in to
the x-y
plane. The y-axis directional cylinders 74 each have its ends 74a, 74c
pivotally
connected to a mounting bracket 74b attached to cylinder mounting beam 76 of
the
flow control unit frame 44 (see FIG. 8), and to a mounting bracket 74d
attached to a
cylinder mounting beam 78 of the transport skid (see FIGS. 3 and 8). The y-
axis
directional cylinders 74 are provided in spaces between the support plates 64
of the
transport skid 40 so as not to interfere with the relative rotational and/or
translational
movement. The support plates 64 are sized to provide a supporting platform for
the
frame members 54 of the flow control unit frame 44 throughout the full range
of the
rotational and translational movement, as best shown in FIGS. 5-7. The y-axis
directional cylinders 74 are preferably mounted to remain horizontal in the x-
y plane. In
other embodiments, the y-axis directional cylinders may be replaced with a
single
cylinder, and the x-axis directional cylinder may be replaced with a pair of
parallel
spaced cylinders. In other embodiments, additional cylinders might be
provided,
however, the provision of the three cylinders provides a simplicity of
operation and
hydraulic controls. The provision of the plurality of cylinders as described
above,
pivotally connected between the transport skid 40 and the flow control unit
frame 44,
allows for translational movement in the direction of either the x-axis or the
y-axis of the
flow control unit 30, and thus the inlet 32, by moving only the x-axis
directional cylinder
72 or the y-axis directional cylinders 74 respectively. However, movement of
both the
x-axis directional cylinder and one or both of the y-axis directional
cylinders 74 provides
the relative rotation in the x-y plane about the z-axis, to provide for
adjustable
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connection to the shared manifold trunk line 24 at the inlet 32.
A hydraulic control system 80 is shown schematically in FIG. 2 for operation
of
the adjustable legs 42 and cylinders 72, 74. The hydraulic control system 80
includes
appropriate control valves to extend and retract the hydraulic cylinders 72
and 74. The
control system provides hydraulic locking of the cylinders 72, 74 against
further relative
movement after aligning the inlet 32 for connection to the shared manifold
trunk line 24.
The hydraulic locking mechanism for the cylinders 72, 74 includes check valves
in the
hydraulic lines beyond the hydraulic control valves, to lock the cylinders 72,
74 in place.
Similar controls and locking are provided for each of the adjustable legs 42
to lock the
legs 42 after leveling.
In the event of settling of the transport skid 40, or if other minor
adjustments are
needed, one or more of the locking systems for the adjustable legs 42 and
cylinders 72,
74 can be unlocked (with unlocking of the leg locking mechanism 68), to allow
for
further adjustments to the position of the inlet 32 or outlet 34 with
cylinders 42, 72
and/or 74, and then the adjustable legs 42, leg locking mechanism 68, and
hydraulic
cylinders 72, 74 are re-locked.
Operation
Operation of the fracturing system 10 according to one or more embodiments
will
now be described. A plurality of fracturing manifold modules 22 are pre-
assembled as
needed for a particular configuration of a fracturing system 10, the pre-
assembly being
repeated for each manifold module 22. The flow control unit 30, is pre-
assembled prior
to connecting to the pedestal frame 46 of the flow control unit frame 44. As
above,
each flow control unit 30 generally includes an inlet 32, two flow control
valves 36, 38
and an outlet 34. The inlet 32 is commonly a 4-way cross. The flow control
valves 36,
38 are commonly gate valves, one remote operation, one manual operation. The
outlet
34 has connections for one or more fluid conduits 35, with the figures showing
a 6-way
cross. In general, a 6-way cross outlet 34 provides for a total of five fluid
conduit
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connections. Two 6-way cross outlets 34 provide for nine fluid conduit
connections. Still
alternatively, the outlet may provide for more or fewer fluid conduit
connections, such as
a single fluid conduit. This varies with the particular fracturing operation,
required
fracturing rates, and the inlet block 26 configuration to the shared manifold
trunk line
24. As above, the components of the flow control unit 30, the inlet block 26,
the
components of the shared manifold trunk line 24 and the connections throughout
the
fracturing manifold system 20 may be varied as appropriate for a particular
fracturing
operation and in view of the layout of a particular well pad fracturing
operation.
The shared manifold trunk line 24 typically has a uniform bore size, such as a
7-1/16" bore, although a different bore size may be specified, such as a 5-
1/8" bore.
This 7-1/16" bore is generally consistent through the shared manifold trunk
line 24, and
through each component (32, 34, 36, 38) of the flow control unit 30.
The outlet 34, as shown, with multiple fluid conduit connections 35, is
generally
prepared for common frac iron being 3" (2.75" or other bore size) or 4" (3,50,
3.75" or
other bore size). Alternatively, an outlet with a single fluid conduit
connection may
match the 7-1/16" bore in the flow control unit 30 or a reduced bore such as 5-
1/8".
Other inlet and outlet configurations and connections may be provided as
appropriate.
The shared manifold trunk line 24 has a single inlet block or multiple inlet
blocks
26 adapted to receive high pressure fracturing fluids through one or more
fluid conduits
27 from the high-pressure stimulation services S. FIG. 1 shows two inlet
blocks 26
providing a total of eight fluid conduit connections, with each inlet block 26
having four
fluid conduit connections. These fluid conduits 27 are generally prepared for
3" frac
iron (2.75" or other bore size) or 4" frac iron (3.50", 3.75" or other bore
size).
Alternatively, an inlet block 26 may be provided with a 4-way cross, similar
to the inlet
32 no the individual flow control units 30. The inlet block 26 with one fluid
conduit may
match the 7-1/16" bore of the shared manifold trunk line or a 5-1/8" bore, for
example.
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The flow control unit 30 is pedestal mounted in the pockets provided by the
horizontal pedestal support plates 50. The pockets provide recesses for the
control
valves 36, 38. The inlet 32 and control valves 36, 38 are bolted and/or welded
in place.
For retaining the flow control unit 30 to the pedestal frame 46, the clamp
connection 52
is fastened on the flange of the outlet 34, and inlet fasteners 53 secure the
inlet 32 to
the horizontal plate 50 of the pedestal frame 46.
The flow control unit 30 is mounted for fixed movement with the flow control
unit
frame 44, which in turn is supported on the transport skid 40, with the
friction reducing
members 70 in place, and the hydraulic cylinders 72 and 74 pivotally connected
between the flow control unit frame 44 and the transport skid 40 as described
above.
This pre-assembled fracturing manifold module 22 is then ready for road
transport to
the well pad.
In the transport (home) position of the fracturing manifold module 22 shown in
FIGS 1-3, the four height adjustable legs 42 (hydraulic cylinders) of the
transport skid
40 are fully retracted, such that the skid frame members 60 are on the ground.
The leg
locking mechanisms 68 are not yet in place on the four adjustable legs 42 in
this
transport position.
The flow control unit frame 44 is adjusted relative to the transport skid 40
with
the three hydraulic cylinders 72, 74 to place the flow control unit frame 44
in the
transport position. In this position the releasable locking devices 69 are
installed and
mechanically lock the flow control unit frame 44 to the transport skid 40. The
releasable locking mechanism of the hydraulic control system locks the
hydraulic
cylinders 72, 74 against relative movement, and also locks adjustable legs 42
against
movement. In the transport position, the hydraulic cylinders 72, 74 are
generally in the
midpoint position for the extension and retraction of the three hydraulic
cylinders, i.e.
there is equal translational movement in the x direction of the one cylinder,
and equal
translational movement in the y direction for the other cylinders, in the
transport
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position.
The four skid roll ends 66 are used for lifting the fracturing control module
22 by
a high capacity crane, or two of the skid roll ends 66 are used with a winch-
tractor or
bed-truck for transporting and/or initial landing placement of the fracturing
manifold
module 22, i.e, in the direction of the x-axis of the fracturing module 22.
On location, rough measurements are made for initial placement of the
fracturing
manifold module(s) 22. There is consideration to the grade for movement in the
z
direction for each fracturing manifold module 22.
The number of fracturing manifold modules 22 generally corresponds to the
number of wells being stimulated through fracturing wellheads W. The inlet
block(s) 26
of the shared manifold trunk line 24 receive the high pressure fracturing
fluid through
one or more fluid conduits 27 from the stimulation services S and distribute
to the
shared manifold trunk line 24 for all modules 22. Placement of the inlet
block(s) 26 can
be at either end of the outermost modules (ex. 22a, 22e), or between any two
modules
(ex. between 22b and 22c as in FIG. 1).
The shared manifold trunk line 24 includes spacer spools 28 of frac iron
between
inlets 32 of the fracturing manifold modules 22. Spacer spools 28 are standard
length,
in foot increment lengths, from approximately 2 feet to 12 feet. Spacer spools
28 may
be provided in non-standard lengths. Connections of the spacer spools 28 are
typically
industry standard flanges with pressure-energized metal seal ring gaskets.
These
connections are also standard for the components of the flow control units 30.
Spacer
spools 28, flow control unit inlets 32, and inlet blocks 26 may be provided
with other
industry standard connections, for example clamp-end hub connections with
pressure
energized metal seals.
Outrigger pads may be provided for the adjustable legs 42 on the transport
skid
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40, reducing the need for additional specifications to the end user to prepare
the grade
and surface on location. The allotted footprint on location and proximity to
wellheads
determines the placement of the fracturing manifold modules 22, the inlet
block 26 and
number of spacer spools 28 required between subsequent modules 22. Distances
are
known from one fracturing manifold module 22 to the next (i.e., adjacent
fracturing
manifold modules 22) depending on the length of spacer spools 28 on each
section of
the shared manifold trunk line 24. The location of the first fracturing
manifold module 22
is determined with consideration to the corresponding well and the allotted
footprint for
all modules 22. Due to the adjustability provided in each of the fracturing
manifold
modules 22, only minor consideration is needed for the x-y plane of the first
module 22.
The high capacity crane lifts and lands the fracturing module 22 by the four
roll ends 66
such that inlet is proximate to the location for connecting along the y-axis
of the shared
manifold trunk line 24. As above, this initial placement may be set for the
outlet
connections, but the inlet connections more commonly set the position for the
first
module 22. Alternatively, if space permits, the module 22 may be landed with a
bed
truck or winch tractor or other equipment, using two skid roll ends 66 on the
transport
skid 40 and moving the module 22 in the general x-direction (relative to the y-
axis of the
shared manifold trunk line 24), with the skid frame members 60 sliding on
location for
proximate placement.
From the known distances each remaining fracturing manifold module 22 is
placed with previous consideration to the y-axis of the shared manifold trunk
line 24 (or
the outlet position in some cases). The high capacity crane is not further
needed for
making up the connections at the inlet 32 along the shared manifold trunk line
24 or at
the outlet 34.
Once all fracturing manifold modules 22 are located, outrigger pads may be
placed under each adjustable leg 42 of the first module 22. The adjustable
legs 42 are
raised in the direction of the z-axis to level the flow control unit 30 (and
the flow control
unit frame 44 and inlet 32), such that the x-y plane of the inlet 32 of the
flow control unit
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30 (in general this is parallel to the x-y plane of the flow control unit
frame 44) is
generally horizontal and parallel to the ground. The hydraulic system locks
all
adjustable legs 42 during leveling and then the leg locking mechanisms 68 are
placed
on all four adjustable legs 42.
The releasable locking devices 69 are removed between the transport skid 40
and the flow control unit frame 44. As required, the three hydraulic cylinders
72, 74 are
operated to adjust the position of the inlet and the outlet in x-y plane of
the frame 44 by
rotating the flow control unit frame 44 relative to the stationary transport
skid 40. This
adjusts the position of the inlet 32 and the outlet 34 in the x-y plane about
the z-axis (Rz
in FIG. 2). This relative rotational movement is shown in FIGS. 6-8. The
hydraulic
cylinders 72 and/or 74 may also be adjusted in the direction of the x-axis and
the y-axis
with relative translational movement to align the inlet 32 for connection with
the y-axis of
the shared manifold trunk line 24 (see FIG. 5), although for the first module
22, this may
not be needed, depending on the initial placement. After alignment and
connection at
the inlet 32, hydraulic controls for the x and y-directional cylinders 72, 74
lock the
cylinders 72, 74 against further relative movement between the transport skid
40 and
the flow control unit frame 44.
On the second (next adjacent) fracturing manifold module 22, the outrigger
pads
are placed beneath the adjustable legs 42 and the releasable locking devices
69 are
removed between the transport skid 40 and the flow control unit frame 44. The
adjustable legs 42 are operated to level the frame 44 relative to the ground
and to
provide for proximity at the inlet 32 to the y-axis of shared manifold trunk
line. The
three cylinders 72, 74 are operated to establish the x-y plane rotated on the
z-axis to
have the inlet y-axis coaxial with the shared manifold trunk line 24 (as
above). The two
hydraulic cylinders in the y-direction 74 may be adjusted to assist making up
the spacer
spools 28. After spacer spools 28 connections are made-up, the four leg
locking
mechanisms 68 are placed on the adjustable legs 42, and the hydraulic controls
lock
the cylinders 72, 74 and adjustable legs 42 against further movement.
Alternatively, as
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CA 3014102 2018-08-13
noted above, this second fracturing manifold module 22 may be aligned for
connections
at the outlet 34.
This process is repeated for the remaining fracturing manifold modules.
During stimulation, the leg locking mechanisms 68 are inspected. If required,
for
example due to settling, the hydraulic locks for adjustable legs 42 and the
leg locking
mechanisms 68 are unlocked, the adjustable legs 42 are operated to level at
the inlet
32 and/or at the outlet 34, and the hydraulic controls and the leg locking
mechanisms
68 are reset. If needed, the hydraulic cylinders 72, 74 may be unlocked for
fine
adjustments at the inlet 32 and/or the outlet 34. After any adjustment, the
hydraulic
controls are re-locked and the leg locking mechanism 68 are reset.
As used herein and in the claims, the word "comprising" is used in its non-
limiting
sense to mean that items following the word in the sentence are included and
that items
not specifically mentioned are not excluded. The use of the indefinite article
"a" in the
claims before an element means that one of the elements is specified, but does
not
specifically exclude others of the elements being present, unless the context
clearly
requires that there be one and only one of the elements.
All references mentioned in this specification are indicative of the level of
skill in
the art of this invention. All references are herein incorporated by reference
in their
entirety to the same extent as if each reference was specifically and
individually
indicated to be incorporated by reference. However, if any inconsistency
arises
between a cited reference and the present disclosure, the present disclosure
takes
precedence. Some references provided herein are incorporated by reference
herein to
provide details concerning the state of the art prior to the filing of this
application, other
references may be cited to provide additional or alternative device elements,
additional
or alternative materials, additional or alternative methods of analysis or
application of
the invention.
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The terms and expressions used are, unless otherwise defined herein, used as
terms of description and not limitation. There is no intention, in using such
terms and
expressions, of excluding equivalents of the features illustrated and
described, it being
recognized that the scope of the invention is defined and limited only by the
claims
which follow. Although the description herein contains many specifics, these
should not
be construed as limiting the scope of the invention, but as merely providing
illustrations
of some of the embodiments of the invention.
One of ordinary skill in the art will appreciate that elements and materials
other
than those specifically exemplified can be employed in the practice of the
invention
without resort to undue experimentation. All art-known functional equivalents,
of any
such elements and materials are intended to be included in this invention. The
invention
illustratively described herein suitably may be practised in the absence of
any element
or elements, limitation or limitations which is not specifically disclosed
herein.
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