U.S. patent application number 13/830619 was filed with the patent office on 2013-09-26 for modular manifold of a wellsite fluid system and method of using same.
This patent application is currently assigned to Schlumberger Technology Corporation. The applicant listed for this patent is SCHLUMBERGER TECHNOLOGY CORPORATION. Invention is credited to Jonathan Wun Shiung Chong, Muhammad Fuad Bin Mohamed Zain.
Application Number | 20130248182 13/830619 |
Document ID | / |
Family ID | 49210706 |
Filed Date | 2013-09-26 |
United States Patent
Application |
20130248182 |
Kind Code |
A1 |
Chong; Jonathan Wun Shiung ;
et al. |
September 26, 2013 |
MODULAR MANIFOLD OF A WELLSITE FLUID SYSTEM AND METHOD OF USING
SAME
Abstract
A mobile manifold assembly of a fluid system for providing fluid
to a wellsite during well construction. The fluid system includes
auxiliary components including at least one fluid source, mixer and
high pressure pump. The manifold assembly includes a modular
manifold and a mobile frame. The modular manifold includes manifold
pumps, valves and pipes integrated together for transport.
Connector portions of the pipes extend from the modular manifold in
an arrangement corresponding to an arrangement of the auxiliary
components to define a plug-in configuration therebetween such that
the connector portions of the pipes are positionable in alignment
with the auxiliary components for direct and removable connection
therewith. The manifold pumps and valves are positioned about the
pipes to selectively pump the fluid. The modular manifold is
securable to a base of the mobile frame whereby the modular
manifold is transportable to the auxiliary components for operable
connection therewith.
Inventors: |
Chong; Jonathan Wun Shiung;
(Kuching, MY) ; Zain; Muhammad Fuad Bin Mohamed;
(Singapore, SG) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SCHLUMBERGER TECHNOLOGY CORPORATION |
Sugar Land |
TX |
US |
|
|
Assignee: |
Schlumberger Technology
Corporation
Sugar Land
TX
|
Family ID: |
49210706 |
Appl. No.: |
13/830619 |
Filed: |
March 14, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61613635 |
Mar 21, 2012 |
|
|
|
Current U.S.
Class: |
166/285 ;
166/379; 166/90.1 |
Current CPC
Class: |
E21B 21/062 20130101;
B01F 13/0032 20130101; E21B 33/13 20130101; B28C 9/004 20130101;
E21B 33/14 20130101; E21B 41/00 20130101 |
Class at
Publication: |
166/285 ;
166/90.1; 166/379 |
International
Class: |
E21B 41/00 20060101
E21B041/00; E21B 33/13 20060101 E21B033/13 |
Claims
1. A mobile manifold assembly of a fluid system for providing fluid
to a wellsite during well construction, the wellsite having a rig
positionable about a wellbore, the fluid system comprising
auxiliary components comprising at least one fluid source, at least
one mixer and at least one high pressure pump, the mobile manifold
assembly comprising: a modular manifold comprising a plurality of
manifold pumps, a plurality of valves and a plurality of pipes
integrated together for transport, connector portions of the
plurality of pipes extending from the modular manifold in an
arrangement corresponding to an arrangement of the auxiliary
components to define a plug-in configuration therebetween such that
the connector portions of the plurality of pipes are positionable
in alignment with the auxiliary components for direct and removable
connection therewith, the plurality of manifold pumps and valves
positioned about the plurality of pipes to selectively pump the
fluid about the modular manifold and at least one of the auxiliary
components; and a mobile frame comprising a base portion and a
carrier portion, the modular manifold securable to the base portion
and the carrier portion of the mobile frame, the modular manifold
liftable via the mobile frame whereby the modular manifold is
transportable to the auxiliary components for operable connection
therewith.
2. The mobile manifold assembly of claim 1, further comprising at
least one knock off cap.
3. The mobile manifold assembly of claim 1, further comprising at
least one inlet.
4. The mobile manifold assembly of claim 1, further comprising at
least one drain.
5. The mobile manifold assembly of claim 1, wherein at least one of
the plurality of valves comprises a butterfly valve.
6. The mobile manifold assembly of claim 5, wherein the butterfly
valve is one of automatically and manually activated.
7. The mobile manifold assembly of claim 5, wherein the plurality
of manifold pumps selectively adjust fluid flow through the
plurality of pipes.
8. The mobile manifold assembly of claim 1, wherein the plurality
of pipes define a plurality of horizontal pipe portions and a
plurality of vertical pipe portion, the plurality of vertical pipe
portions extending between the plurality of horizontal pipe
portions.
9. The mobile manifold assembly of claim 8, wherein the plurality
of valves are positionable about the plurality of pipes and provide
selective fluid communication between the plurality of pipes and
the auxiliary components.
10. The mobile manifold assembly of claim 8, wherein the plurality
of manifold pumps are positionable about the plurality of
horizontal pipe portions.
11. The mobile manifold assembly of claim 8, wherein the plurality
of manifold pumps are positionable about the plurality of vertical
pipe portions.
12. The mobile manifold assembly of claim 8, further comprising
knock off caps positioned at opposite ends of one of the horizontal
portions.
13. The mobile manifold assembly of claim 8, further comprising
inlets positioned between opposite ends of one of the horizontal
portions.
14. The mobile manifold assembly of claim 8, wherein one of the
plurality of horizontal portions extends between a pair of the
plurality of manifold pumps.
15. The mobile manifold assembly of claim 14, wherein two of the
plurality of vertical portions extends between the one of the
plurality of horizontal portion with the plurality of manifold
pumps and another of the plurality of horizontal portions.
16. The mobile manifold assembly of claim 15, wherein another of
the plurality of vertical portions extends between the another of
the plurality of horizontal portions and yet another of the
plurality of horizontal portions.
17. The mobile manifold assembly of claim 8, wherein the connector
portions extend from one of the plurality of horizontal portions of
the modular manifold.
18. The mobile manifold assembly of claim 1, wherein a portion of
the connector portions extend horizontally from the modular
manifold and a portion of the connector portions extend vertically
from the modular manifold.
19. The mobile manifold assembly of claim 1, wherein the connector
portions of the plurality of pipe are connectable to at least one
fluid source, at least one mixer, and at least one high pressure
pump.
20. The mobile manifold of claim 1, wherein the carrier portion
extends vertically above the base portion.
21. The mobile manifold of claim 1, wherein the carrier portion has
one of a handle and a grip for lifting the frame.
22. A well construction fluid system for providing fluid to a
wellsite during well construction, the wellsite having a rig
positionable about a wellbore, the fluid system comprising:
auxiliary components comprising at least one fluid source, at least
one mixer and at least one high pressure pump; and a mobile
manifold assembly, comprising: a modular manifold comprising a
plurality of manifold pumps, a plurality of valves and a plurality
of pipes integrated together for transport, connector portions of
the plurality of pipes extending from the modular manifold in an
arrangement corresponding to an arrangement of the auxiliary
components to define a plug-in configuration therebetween such that
the connector portions of the plurality of pipes are positionable
in alignment with the auxiliary components for direct and removable
connection therewith, the plurality of manifold pumps and valves
positioned about the plurality of pipes to selectively pump the
fluid about the modular manifold and at least one of the auxiliary
components; and a mobile frame comprising a base portion and a
carrier portion, the modular manifold securable to the base portion
and the carrier portion of the mobile frame, the modular manifold
liftable via the mobile frame whereby the modular manifold is
transportable to the auxiliary components for operable connection
therewith.
23. The fluid system of claim 22, wherein the auxiliary components
comprise a mixing portion, and a delivery portion.
24. The fluid system of claim 23, wherein the delivery portion
comprises the at least one high pressure pump, a motor, at least
one drive shaft, and at least one slurry tank.
25. The fluid system of claim 23, wherein the mixing portion
comprises the at least one mixer, at least one mixing tank and at
least one fluid source.
26. The fluid system of claim 22, wherein the at least one fluid
source comprises an averaging tank, a water/chemical supply, and a
mixing water supply.
27. The fluid system of claim 22, wherein the auxiliary components
further comprise a supply portion, a pumping portion, a transfer
portion, and a batch mixer portion.
28. The fluid system of claim 27, wherein the batch mixer portion
comprises a batch mixer tank.
29. The fluid system of claim 22, wherein the auxiliary components
comprise a mixing portion and wherein the mobile manifold assembly
is integrated with the mixing portion.
30. The fluid system of claim 29, wherein the mobile manifold
assembly and the mixing portion are positionable on a skid and
transportable thereon.
31. The fluid system of claim 22, wherein the at least one mixer
comprises one of a single mixer and a dual mixer.
32. A method for providing fluid to a wellsite during well
construction, the wellsite having a rig positionable about a
wellbore, the method comprising: providing a fluid system about a
wellsite, the fluid system comprising: auxiliary components
comprising at least one fluid source, at least one mixer and at
least one high pressure pump; and a mobile manifold assembly,
comprising: a modular manifold comprising a plurality of manifold
pumps, a plurality of valves and a plurality of pipes integrated
together for transport, connector portions of the plurality of
pipes extending from the modular manifold in an arrangement
corresponding to an arrangement of the auxiliary components to
define a plug-in configuration therebetween such that the connector
portions of the plurality of pipes are positionable in alignment
with the auxiliary components for direct and removable connection
therewith, the plurality of manifold pumps and valves positioned
about the plurality of pipes to selectively pump the fluid about
the modular manifold and at least one of the auxiliary components;
and a mobile frame comprising a base portion and a carrier portion,
the modular manifold securable to the base portion and the carrier
portion of the mobile frame; transporting the modular manifold to
the auxiliary components using the mobile frame; operatively
connecting the modular manifold to the auxiliary components; and
pumping fluid to the wellbore using the modular manifold.
33. The method of claim 33, further comprising mixing the fluid
with the at least one mixer.
34. The method of claim 32, further comprising recirculating fluid
between the auxiliary components and the modular manifold.
35. The method of claim 32, further comprising selectively
diverting fluid from the modular manifold to one of a mixing
portion, a batch portion and a delivery portion of the fluid
system.
36. The method of claim 32, further comprising cementing the
wellbore using the fluid pumped to the wellbore.
37. The method of claim 32, wherein the pumping further comprises
pumping the fluid to the wellbore using the auxiliary
components.
38. The method of claim 23, further comprising transporting the
auxiliary components and the mobile manifold assembly on a skid.
Description
BACKGROUND
[0001] The present disclosure relates to the field of well
construction equipment. More particularly, the present disclosure
relates particularly, but not by way of limitation, to flow control
systems and components that may be used for well construction
services techniques. The statements in this section merely provides
information related to the present disclosure and may not
constitute prior art, and may describe some embodiments
illustrating the invention.
[0002] Oilfield operations may be performed to locate and gather
valuable downhole fluids, such as hydrocarbons. Wellbores may be
drilled to reach subsurface reservoirs and draw hydrocarbons to the
surface. During drilling, various fluids may be deployed downhole
to facilitate drilling, production, stimulation, completion and/or
other operations.
[0003] In some cases, devices may be used for storing fluids,
mixing fluids, and distributing fluids to the wellbore. Fluids may
be passed into the wellbore by surface fluid equipment. Some fluid
equipment may have devices, such as valves, pumps, etc., to
facilitate flow of fluids. Examples of fluid equipment or
techniques are provided in US Patent/Application Nos. 5232279,
20020001255, and 20030161212.
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] The techniques disclosed herein relate to a mobile manifold
assembly of a fluid system for providing fluid to a wellsite during
well construction. The wellsite has a rig positionable about a
wellbore. The fluid system includes auxiliary components including
at least one fluid source, at least one mixer and at least one high
pressure pump. The mobile manifold assembly includes a modular
manifold and a mobile frame. The modular manifold includes a
plurality of manifold pumps, valves and pipes integrated together
for transport. Connector portions of the pipes extend from the
modular manifold in an arrangement corresponding to an arrangement
of the auxiliary components to define a plug-in configuration
therebetween such that the connector portions of the pipes are
positionable in alignment with the auxiliary components for direct
and removable connection therewith. The manifold pumps and valves
are positioned about the pipes to selectively pump the fluid about
the modular manifold and at least one of the auxiliary components.
The mobile frame includes a base portion and a carrier portion. The
modular manifold is securable to the base portion and the carrier
portion of the mobile frame. The modular manifold is liftable via
the mobile frame whereby the modular manifold is transportable to
the auxiliary components for operable connection therewith.
[0006] The mobile manifold assembly may also include at least one
knock off cap, at least one inlet, and/or at least one drain. At
least one of the valves includes a butterfly valve. The butterfly
valve may be automatically and manually activated. The manifold
pumps selectively adjust fluid flow through the pipes. The pipes
define a plurality of horizontal pipe portions and a plurality of
vertical pipe portion, with the plurality of vertical pipe portions
extending between the horizontal pipe portions.
[0007] The valves may be positionable about the pipes and provide
selective fluid communication between the pipes and the auxiliary
components. The manifold pumps may be positionable about the
horizontal or vertical pipe portions. The mobile manifold assembly
may also include knock off caps positioned at opposite ends of one
of the horizontal portions, and/or inlets positioned between
opposite ends of one of the horizontal portions. One of the
horizontal portions may extend between a pair of the manifold
pumps. Two of the vertical portions may extend between the one
horizontal portion with the manifold pumps and another of the
horizontal portions. The another of the vertical portions may
extend between the another of the horizontal portions and yet
another of the horizontal portions.
[0008] The connector portions may extend from one of the horizontal
portions of the modular manifold. A portion of the connector
portions may extend horizontally from the modular manifold and a
portion of the connector portions may extend vertically from the
modular manifold. The connector portions of the pipes may be
connectable to the fluid source, mixer, and high pressure pump. The
carrier portion may extend vertically above the base portion. The
carrier portion may have a handle or a grip for lifting the
frame.
[0009] In another aspect, the disclosure relates to a well
construction fluid system for providing fluid to a wellsite during
well construction. The wellsite has a rig positionable about a
wellbore. The fluid system includes the auxiliary components and
the mobile manifold assembly.
[0010] The auxiliary components may include a mixing portion, and a
delivery portion. The delivery portion may include the high
pressure pump, a motor, at least one drive shaft, and at least one
slurry tank. The mixing portion may include the mixer, at least one
mixing tank and at least one fluid source. The fluid source may
include an averaging tank, a water/chemical supply, and a mixing
water supply. The auxiliary components may include a supply
portion, a pumping portion, a transfer portion, and a batch mixer
portion. The batch mixer portion may include a batch mixer
tank.
[0011] The auxiliary components may include a mixing portion, and
the mobile manifold assembly may be integrated with the mixing
portion. The mobile manifold assembly and the mixing portion may be
positionable on a skid and transportable thereon. The mixer may
include a single or a dual mixer.
[0012] Finally, in another aspect, the disclosure relates to a
method for providing fluid to a wellsite during well construction.
The wellsite has a rig positionable about a wellbore. The method
involves providing a fluid system about a wellsite. The fluid
system includes the auxiliary components and the mobile manifold
assembly. The method also involves transporting the modular
manifold to the auxiliary components using the mobile frame,
operatively connecting the modular manifold to the auxiliary
components, and pumping fluid to the wellbore using the modular
manifold.
[0013] The method may also involve mixing the fluid with the at
least one mixer, recirculating fluid between the auxiliary
components and the modular manifold, and/or transporting the
auxiliary components and the modular manifold assembly on a skid.
The method may also involve selectively diverting fluid from the
modular manifold to a mixing portion, a batch portion and/or a
delivery portion of the fluid system. The method may also involve
cementing the wellbore using the fluid pumped to the wellbore. The
pumping may also involve pumping the fluid to the wellbore using
the auxiliary components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Embodiments of the method and system for performing well
construction are described with reference to the following figures.
Like reference numerals are intended to refer to similar elements
for consistency. For purposes of clarity, not every component may
be labeled in every drawing.
[0015] FIG. 1 is a schematic diagram illustrating a wellsite having
a fluid system with a modular manifold in accordance with an
embodiment of the present disclosure.
[0016] FIG. 2.1 is a block diagram illustrating a mixing process
for a fluid system in accordance with an embodiment of the present
disclosure. FIGS. 2.2, and 2.2.1-2.2.4 depict a table of various
scenarios illustrating operation of the mixing process of FIG. 2.1
in accordance with an embodiment of the present disclosure.
[0017] FIG. 3 is a block diagram illustrating an overall mixing
process for a fluid system with a modular manifold in accordance
with an embodiment of the present disclosure.
[0018] FIG. 4.1 is a schematic diagram illustrating a modular
manifold in accordance with an embodiment of the present
disclosure. FIGS. 4.2 and 4.2.1-4.2.4 depict a table of various
scenarios illustrating operation of the modular manifold of FIG.
4.1 in accordance with an embodiment of the present disclosure.
[0019] FIGS. 5.1-5.4 are schematic views illustrating a modular
manifold in accordance with an embodiment of the present
disclosure.
[0020] FIGS. 6.1-6.4 are schematic views illustrating another
modular manifold in accordance with an embodiment of the present
disclosure.
[0021] FIGS. 7.1 and 7.2 are schematic diagrams illustrating
modular single mixer configurations of a fluid system with modular
manifold in accordance with an embodiment of the present
disclosure.
[0022] FIGS. 8.1 and 8.2 are schematic diagrams illustrating
modular dual mixer configurations of a fluid system with modular
manifold in accordance with an embodiment of the present
disclosure.
[0023] FIGS. 9.1-9.3 are schematic diagrams illustrating various
views of portions of a modular fluid system with modular manifold
in accordance with an embodiment of the present disclosure.
[0024] FIGS. 10.1 and 10.2 are schematic diagrams illustrating
integrated configurations of a fluid system with modular manifold
in accordance with an embodiment of the present disclosure.
[0025] FIGS. 11.1-11.3 are schematic diagrams illustrating various
views of portions of an integrated fluid system with modular
manifold in accordance with an embodiment of the present
disclosure.
[0026] FIGS. 12.1 and 12.2 are schematic diagrams illustrating
modular configurations of a mobile manifold assembly with modular
manifold in accordance with an embodiment of the present
disclosure.
[0027] FIGS. 13.1 and 13.2 are schematic diagrams illustrating
integrated configurations of a modular manifold in accordance with
an embodiment of the present disclosure.
[0028] FIG. 14 is a flow chart illustrating a fluid method in
accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION
[0029] Specific embodiments of the present disclosure will be
described in detail with reference to the accompanying drawings.
Further, in the description of embodiments of the present
disclosure, numerous specific details are set forth in order to
provide a more thorough understanding of the invention. However, it
will be apparent to one of ordinary skill in the art that the
embodiments disclosed herein may be practiced without these
specific details. In other instances, well-known features have not
been described in detail to avoid unnecessarily complicating the
description.
[0030] The present disclosure relates to devices and methods for
providing fluid at a wellsite. Fluid systems may be provided for
facilitating the mixing, pumping and delivery of the fluid. Part or
all of the fluid systems may be portable, removable and/or modular.
The fluid system may include local equipment, such as a mobile and
removable manifold (and associated equipment), and auxiliary
equipment, such as mixers, tanks, supplies and/or pumps (and
associated equipment). As used herein, "local" may refer to
components or operations of the fluid/slurry mixing manifold, and
"auxiliary" may refer to components or operations of the remainder
of the fluid system. The fluid system may be used for delivering
fluid to the wellbore for performing well construction. As used
herein `well construction` includes operations, such as cementing
used in completing the wellbore.
[0031] At least one embodiment of the present disclosure relates to
a modular manifold that consolidates piping and flow control
components, such as valves, into a compact, portable, modular and
stand-alone product that can connect to various related components
used for mixing and pumping slurries for well construction
services, such as mixers, pumps, mixing and averaging tubs,
displacement tanks and batch tanks. The modular manifold may also
incorporate logic for mixing and pumping slurries for well
construction services, such as recirculation, fluid transfer,
gravity feed, and redundancies and backups for pump failures. At
least one embodiment of the present disclosure may allow for
scalability of multiple mixing systems through the use of one or
multiple modular manifolds.
[0032] According to one or more aspects of the present disclosure,
a portable and optimized fluid/slurry mixing manifold is provided,
enabling flexibility in installations due to, at least,
independence and modularity; and enabling a compact bounding volume
optimized for transport and installation. According to at least one
or more additional aspects of the present disclosure, a method for
maintainability is provided for allowing: ease in maintenance and
troubleshooting due to, at least, clear overall visual of the
modular manifold; minimal volume of flushing/washing fluids due to,
at least, compactness of the system; and ease in replacement of
piping, if desired. According to at least one or more additional
aspects of the present disclosure, a method and system for
scalability of multiple mixing systems is provided.
[0033] In accordance with at least one embodiment of the present
disclosure, the fluid system and modular manifold may be a modular
fluid/slurry mixing (or fluid) system with modular manifold. The
fluid system and/or modular manifold may be portable. The modular
manifold may be connectable to pumping and mixing components of the
fluid system using hoses or hard piping if desired. The modular
manifold bounding volume allows the modular manifold to be
transportable on trailers, both on land and offshore on shipping
racks.
[0034] The bounding volume of the modular manifold may comprise
overall dimensions that may be no more than 8 ft (or 2438.4 mm), or
any dimension which corresponds with the ISO container width
specification--ISO 668: "Series 1 freight
containers--Classification, dimensions and ratings," which is
subject to change. It should be noted that various industry
standards may exist which may dictate certain design requirements
and objectives; therefore, the piping and components described
herein may be designed and manufactured in accordance with those
standards, for example, ASME B31.3.
[0035] The modular manifold may be adapted and re-sized to meet
connection (or nozzle) points that may require exceeding the 8 ft
(2.44 m) desired dimension. As opposed to having piping run across
the skid or tight confined areas, the modular manifold may be
easily accessible and visible for maintenance and troubleshooting.
This level of modularity can enable the modular manifold to be
deployed for various oilfield pumping equipment, and may allow a
higher level of standardizing of piping design, for example, piping
designed for mixing fluid/slurry. Moreover, the modular manifold,
apparatus, systems and methods presented herein may be configured
to reduce the learning curve for operators.
[0036] These together with other aspects, features, and advantages
of the present disclosure, along with the various features of
novelty, which characterize the invention, are pointed out with
particularity in the claims annexed to and forming a part of this
disclosure. The above aspects and advantages are neither exhaustive
nor individually or jointly critical to the spirit or practice of
the disclosure. Other aspects, features, and advantages of the
present disclosure will become readily apparent to those skilled in
the art from the following detailed description in combination with
the accompanying drawings. Accordingly, the drawings and
description are to be regarded as illustrative in nature, and not
restrictive.
[0037] Referring to the drawings, illustrations, pictures and
attachments and in particular FIG. 1, a wellsite 100 that is an
example environment in which the present disclosure may be
implemented is depicted. The wellsite 100 is depicted at an
offshore location, but may be land-based or in other
configurations. The wellsite 100 includes a platform 102 with a rig
104 and a fluid system 106. The platform 102 has a riser 108
extending to a wellbore 110 in the sea floor 112.
[0038] The fluid system 106 includes pumping equipment 114, mixing
manifold(s) 118, and mixers 120. The fluid system 106 may be a
modular system positionable about the wellsite 100. The fluid
system 106 may be fluidly coupled to the riser 108 via surface
equipment for providing fluid thereto. The fluid system 106 may be
used to mix and pump fluids to the wellbore 110, for example, for
drilling, cementing, or other purposes. In an example, the fluid
system 106 may be cementing equipment that is used to mix and pump
slurries down the well for well construction (e.g., zonal
isolation, cementing, etc.).
[0039] FIGS. 2.1 and 2.2 are block flow diagrams depicting an
example fluid system 206 for performing modular fluid/slurry mixing
and pumping. The fluid system 206 may be used to provide fluids to
a wellbore as shown, for example, in FIG. 1.
[0040] The system 206 includes a primary mixing portion 230, a
supply portion 232, a pump portion 234, a secondary mixing portion
236, a batch mixing portion 238, and a delivery portion 240. The
primary mixing portion 230 includes a mixing water supply 242, a
water/chemical supply 244, and an averaging tank 245. The mixing
water supply 242, water/chemical supply 244, and the averaging tank
245 may store fluids therein and/or be linked to storage facilities
for receiving fluids. The mixing water supply 242 may include water
or other fluids defining the mixing water supply 242 fluids. The
water/chemical supply 244 may include seawater or other fluids
defining the water/chemical supply fluids. The averaging tank 245
may include cement slurries or other fluids defining the averaging
tank 245 fluids.
[0041] The mixing water supply 242 is fluidly coupled to mixers
246.1 and 246.2, and mixing tanks 248.1 and 248.2, and delivers the
mixing water supply 242 fluids thereto. The mixing water supply 242
fluids may be selectively provided to one or more of the mixers
246.1, 246.2 and/or mixing tanks 248.1, 248.2. The mixers 246.1,
246.2 deliver fluid to the mixing tanks 248.1, 248.2.
[0042] The mixing tanks 248.1, 248.2, water/chemical supply 244,
and averaging tank 245 pass fluid to the pumping portion 234 via
supply portion 232. The pumping portion 234 includes manifold pumps
250.1, 250.2. The supply portion 232 includes pipes (or flowlines)
S1-S4 extending from mixing tank 248.2, averaging tank 245,
water/chemical supply 244 and mixing tank 248.1, respectively, to
pump 250.2. The supply portion 232 also includes pipes S5-S7
extending from averaging tank 245, water/chemical supply 244 and
mixing tank 248.1, respectively, to pump 250.1. The pumps 250.1,
250.2 may be fluid pumps capable of driving fluid from the initial
mixing portion 230 and through the remainder of the fluid system
206 and to the platform 102 for use (see, e.g., FIG. 1).
[0043] Referring still to FIG. 2.1, the pump 250.2 is fluidly
coupled back to mixer 246.1, 246.2 and mixing water supply 242,
respectively, via mixing pipes M1, M2 and M3, respectively, until
mixed as desired. The pump 250.1 is fluidly coupled back to the
mixer 246.1 via mixing pipe M4 until mixed as desired. Fluid is
also pumped from pump 250.2 to the batch mixing portion 238 via
pipe B3 and from pump 250.1 to the batch mixing portion 238 via
pipe B4.
[0044] The batch mixing portion 238 includes batch mixer tank(s)
252. Fluid from pumps 250.1, 250.2 may be passed to the batch mixer
tanks 252 via pipes B3 and B4, respectively. Fluid may also be
passed from pumps 250.1 and 250.2 to the batch mixing portion 238
and fluidly coupled to the batch mixer tanks 252 via valve B5.
Fluid may also be diverted from the batch mixing tanks 252 back to
pumps 250.1, 250.2 via pipes B2 and B1, respectively.
[0045] Fluid may then be passed from the pumps 250.1, 250.2 via
pipes D1 and D2 and from batch mixer tank(s) 252 via pipe B5 to
intersection I1. From intersection I1, fluid may then flow to the
delivery portion 240 via pipes D3 and D4. The delivery portion 240
includes a high pressure pump 254. Fluid may be passed from valve
B5 to the high pressure pump 254 via pipe D3. Fluid may also be
delivered back to the averaging tank 245 or batch mixer 252, if
desired, via pipe D4.
[0046] The pumps 250.1, 250.2 and related equipment, such as pipes
(or pipes) S1-S7, M1-M4, B1-B5, D1-D4, may be considered "local"
components. Fluid flow relating to these local components may be
referred to as "local process flow." The remainder of the
components may be considered "auxiliary components." Fluid flow
relating to these auxiliary components may be considered "auxiliary
process flow."
[0047] While the system 206 depicts certain pipes, tanks, pumps,
mixers and other components, the system 206 may include various
numbers of the various supplies, pumps, mixers, tanks, etc. Also,
various fluid control devices, such as valves, pipes, etc. may be
provided to facilitate the flow of fluid through the system 206 as
desired. More examples of various fluid systems and manifolds are
provided herein.
[0048] Referring to FIGS. 2.1 and 2.2, the fluid system (and
modular fluid/slurry mixing manifold) 206 may be used in various
scenarios. FIGS. 2.2 and 2.2.1-2.2.4 include a table 251 including
various process flow combinations. The table 251 provides examples
of various scenarios which may be performed by at least one
embodiment of the fluid system disclosed herein. By way of example,
scenario D4 is an example process flow that may be used. Scenario
D4 involves re-circulating to the averaging tank 245 or batch mixer
tank(s) 252.
[0049] As shown in Table 251, scenarios A1-35, B 1-3 and C1-7 are
provided along the left side of the Table 251. These scenarios
refer to A) scenarios for pumpers where there may be additional
pumps and with complete backup or redundancy, B) scenarios with no
additional pumps and no backup or redundancy, and C) other
scenarios. Along the top of Table 251, pipes S1-S7, M1-M4, B1-B5
and D1-D4 (FIG. 2.1) are provided indicating flow for the various
scenarios. Below is a summary of the various scenarios, which are
neither exhaustive or limiting: [0050] A. Scenarios A1-A35: For
pumpers where there may be additional pump(s) to supply mixing
water to the mixer(s), the role of the manifold is to facilitate
and control the fluid/slurry mixing logic, with complete backup or
redundancy. Scenarios 1-8 are depicted as examples for pumpers with
a single mixer and mixing tank i.e., mixer 246.1 and mixing tank
248.1; whereas, scenarios 9-35 are depicted as examples for pumpers
with dual mixers 246.1, 246.2 and mixing tanks i.e., an additional
mixer 246.2 and mixing tank 248.2, and a common averaging tank 245.
Dual mixing can also be achieved with two totally independent
mixing manifolds. In this case, the mixing logic and redundancies
for each system may remain the same as scenarios A1-8. Such dual
mixing can also be extended to as many mixing systems as needed.
The following example scenarios may be implemented in accordance
with at least one embodiment of the present disclosure: [0051] 1.
Pump 250.1 may be used to re-circulate fluid/slurry between mixing
tank 248.1 and mixer 246.1. After the desired density/property is
achieved and the fluid/slurry flows to the averaging tank 245, pump
250.2 may be used to transfer fluid/slurry from the averaging tank
245 to the high pressure pump(s) 254. [0052] 2. If pump 250.1 is
down, pump 250.2 may be used to re-circulate fluid/slurry between
mixing tank 248.1 and Mixer 246.1. After the desired
density/property is achieved, pump 250.2 may also be used to
concurrently transfer fluid/slurry from mixing tank 248.1 to the
High pressure pump(s) 254, while maintaining re-circulation. [0053]
3. If pump 250.2 is down, pump 250.1 may be used to re-circulate
fluid/slurry between mixing tank 248.1 and mixer 246.1. After the
desired density/property is achieved, pump 250.1 may also be used
to concurrently transfer fluid/slurry from mixing tank 248.1 to the
high pressure pump(s) 254, while maintaining re-circulation. [0054]
4. Same process objectives as scenario (1), but fluid/slurry is
delivered from the averaging tank 245 to the batch mixer tank(s)
252. Pumps from the batch mixer tank(s) 252 may then deliver
fluid/slurry to the high pressure pump(s) 254. [0055] 5. Same
process objectives as scenario (2) but fluid/slurry is delivered
from mixing tank 248.1 to the batch mixer tank(s) 252. Pumps from
the batch mixer tank(s) 252 may then deliver fluid/slurry to the
high pressure pump(s) 254. [0056] 6. Same process objectives as
scenario (3) but fluid/slurry is delivered from mixing tank 248.1
to the batch mixer tank(s) 252. Pumps from the batch mixer tank(s)
252 may then deliver fluid/slurry to the high pressure pump(s) 254.
[0057] 7. Same process objectives as scenario (1) but fluid/slurry
is delivered from the averaging tank 245 to the batch mixer tank(s)
252, and when batch mixer tank(s) 252 pumps are not available. Pump
250.2 may be used to transfer a fixed desired volume of
fluid/slurry to the batch mixer tank(s) 252, subsequently pump
250.2 may also be used to transfer fluid/slurry from the batch
mixer tank(s) 252 to the high pressure pump(s) 254. [0058] 8. Same
process objectives as scenario (1), but fluid/slurry is delivered
from the averaging tank 245 to the batch mixer tank(s) 252, and
when batch mixer tank(s) 252 pumps are not available. Pump 250.2
may be used to concurrently transfer fluid/slurry from the
averaging tank 245 to the batch mixer tank(s) 252, and from the
batch mixer tank(s) 252 to the high pressure pump(s) 254. [0059] 9.
For the dual mixers option, there may be two additional external
pumps used to re-circulate fluid/slurry between mixer 246.1 and
mixing tank 248.1, and mixer 246.2 and mixing tank 248.2
respectively. Also, both pump 250.1 and pump 250.2 can be
available. When the desired density/property for both mixing tanks
is reached and fluid/slurry flows to the averaging tank 245, pump
250.1 or pump 250.2 may be used to transfer fluid/slurry from the
averaging tank 245 to the high pressure pump(s) 254. [0060] 10.
Same process objectives as scenario (9), except that if pump 250.2
is down, pump 250.1 may be used to transfer fluid/slurry from the
averaging tank 245 to the high pressure pump(s) 254. [0061] 11.
Same process objectives as scenario (9), except that if pump 250.1
is down, pump 250.2 may be used to transfer fluid/slurry from the
averaging tank 245 to the high pressure pump(s) 254.
[0062] 12. Same process objectives as scenario (9), except when
higher fluid/slurry delivery rates are desired, pump 250.1 and pump
250.2 may both be used to transfer fluid/slurry from the averaging
tank 245 to the high pressure pump(s) 254. [0063] 13. Same process
objectives as scenario (9), if mixer 246.1-mixing tank 248.1
external re-circulation pump is down, pump 250.1 can take over the
role of that pump (while mixer 246.2-mixing tank 2 external
re-circulation pump can still operate). When the desired
density/property for both mixing tanks is reached and fluid/slurry
flows to the averaging tank 245, pump 250.2 may be used to transfer
fluid/slurry from the averaging tank 245 to the high pressure
pump(s) 254. [0064] 14. Same process objectives as scenario (9), if
mixer 246.2-mixing tank 248.2 external re-circulation pump is down,
pump 250.2 can take over the role of that pump (while mixer
246.1-mixing tank 248.1 external re-circulation pump can still
operate). When the desired density/property for both mixing tanks
is reached and fluid/slurry flows to the averaging tank 245, pump
250.1 may be used to transfer fluid/slurry from the averaging tank
245 to the high pressure pump(s) 254. [0065] 15. For the dual
mixers option, if a common averaging tank 245 is not available
(e.g., due to space constraints) or both external re-circulation
pumps are down, pump 250.1 and pump 250.2 may be used to
re-circulate fluid/slurry between mixer 246.1 and mixing tank
248.1, and mixer 246.2 and mixing tank 2 respectively. When the
desired density/property for both mixing tanks is reached, pump
250.1 and pump 250.2 can transfer fluid/slurry from mixing tank
248.1 and mixing tank 248.2 respectively, to the high pressure
pump(s) 254. [0066] 16. Same process objectives as scenario (9) but
fluid/slurry is delivered from the averaging tank 245 to the batch
mixer tank(s) 252. Pumps from the batch mixer tank(s) 252 can then
deliver fluid/slurry to the high pressure pump(s) 254. [0067] 17.
Same process objectives as scenario (10) but fluid/slurry is
delivered from the averaging tank 245 to the batch mixer tank(s)
252. Pumps from the batch mixer tank(s) 252 can then deliver
fluid/slurry to the high pressure pump(s) 254. [0068] 18. Same
process objectives as scenario (11) but fluid/slurry is delivered
from the averaging tank 245 to the batch mixer tank(s) 252. Pumps
from the batch mixer tank(s) 252 can then deliver fluid/slurry to
the high pressure pump(s) 254. [0069] 19. Same process objectives
as scenario (12) but fluid/slurry is delivered from the averaging
tank 245 to the batch mixer tank(s) 252. Pumps from the batch mixer
tank(s) 252 can then deliver fluid/slurry to the high pressure
pump(s) 254. [0070] 20. Same process objectives as scenario (13)
but fluid/slurry is delivered from the averaging tank 245 to the
batch mixer tank(s) 252. Pumps from the batch mixer tank(s) 252 can
then deliver fluid/slurry to the high pressure pump(s) 254. [0071]
21. Same process objectives as scenario (14) but fluid/slurry is
delivered from the averaging tank 245 to the batch mixer tank(s)
252. Pumps from the batch mixer tank(s) 252 can then deliver
fluid/slurry to the high pressure pump(s) 254. [0072] 22. Same
process objectives as scenario (15) but fluid/slurry is delivered
from mixing tank 248.1 and mixing tank 248.2 to the batch mixer
tank(s) 252. Pumps from the batch mixer tank(s) 252 can then
deliver fluid/slurry to the high pressure pump(s) 254. [0073] 23.
Same process objectives as scenario (9) but fluid/slurry is
delivered from the averaging tank 245 to the batch mixer tank(s)
252, and when batch mixer tank(s) 252 pumps are not available. Pump
250.1 may be used to transfer fluid/slurry from the averaging tank
245 to the batch mixer tank(s) 252. Pump 250.2 may then be used to
transfer fluid/slurry from the batch mixer tank(s) 252 to the high
pressure pump(s) 254. [0074] 24. Same process objectives as
scenario (9) but fluid/slurry is delivered from the averaging tank
245 to the batch mixer tank(s) 252, and when batch mixer tank(s)
252 pumps are not available. Pump 250.1 or pump 250.2 may be used
to transfer a fixed desired volume of fluid/slurry to the batch
mixer tank(s) 252, subsequently pump 250.1 or pump 250.2 may also
be used to transfer fluid/slurry from the batch mixer tank(s) 252
to the high pressure pump(s) 254. [0075] 25. Same process
objectives as scenario (9) but fluid/slurry is delivered from the
averaging tank 245 to the batch mixer tank(s) 252, and when batch
mixer tank(s) 252 pumps are not available. Pump 250.1 or pump 250.2
may be used to concurrently transfer fluid/slurry from the
averaging tank 245 to the batch mixer tank(s) 252, and from the
batch mixer tank(s) 252 to the high pressure pump(s) 254. [0076]
26. Same process objectives as scenario (10) but fluid/slurry is
delivered from the averaging tank 245 to the batch mixer tank(s)
252, and when batch mixer tank(s) 252 pumps are not available. Pump
250.1 may be used to transfer a fixed desired volume of
fluid/slurry to the batch mixer tank(s) 252, subsequently pump
250.1 may also be used to transfer fluid/slurry from the batch
mixer tank(s) 252 to the high pressure pump(s) 254. [0077] 27. Same
process objectives as scenario (10) but fluid/slurry is delivered
from the averaging tank 245 to the batch mixer tank(s) 252, and
when batch mixer tank(s) 252 pumps are not available. Pump 250.1
may be used to concurrently transfer fluid/slurry from the
averaging tank 245 to the batch mixer tank(s) 252, and from the
batch mixer tank(s) 252 to the high pressure pump(s) 254. [0078]
28. Same process objectives as scenario (11) but fluid/slurry is
delivered from the averaging tank 245 to the batch mixer tank(s)
252, and when batch mixer tank(s) 252 pumps are not available. Pump
250.2 may be used to transfer a fixed desired volume of
fluid/slurry to the batch mixer tank(s) 252, subsequently pump
250.2 may also be used to transfer fluid/slurry from the batch
mixer tank(s) 252 to the high pressure pump(s) 254. [0079] 29. Same
process objectives as scenario (11) but fluid/slurry is delivered
from the averaging tank 245 to the batch mixer tank(s) 252, and
when batch mixer tank(s) 252 pumps are not available. Pump 250.2
may be used to concurrently transfer fluid/slurry from the
averaging tank 245 to the batch mixer tank(s) 252, and from the
batch mixer tank(s) 252 to the high pressure pump(s) 254. [0080]
30. Same process objectives as scenario (12) but fluid/slurry is
delivered from the averaging tank 245 to the batch mixer tank(s)
252, and when batch mixer tank(s) 252 pumps are not available. Pump
250.1 and pump 250.2 may be used to transfer a fixed desired volume
of fluid/slurry to the batch mixer tank(s) 252, subsequently pump
250.1 and pump 250.2 may also be used to transfer fluid/slurry from
the batch mixer tank(s) 252 to the high pressure pump(s) 254.
[0081] 31. Same process objectives as scenario (12) but
fluid/slurry is delivered from the averaging tank 245 to the batch
mixer tank(s) 252, and when batch mixer tank(s) 252 pumps are not
available. Pump 250.1 and pump 250.2 may be used to concurrently
transfer fluid/slurry from the averaging tank 245 to the batch
mixer tank(s) 252, and from the batch mixer tank(s) 252 to the high
pressure pump(s) 254. [0082] 32. Same process objectives as
scenario (13) but fluid/slurry is delivered from the averaging tank
245 to the batch mixer tank(s) 252, and when batch mixer tank(s)
252 pumps are not available. Pump 250.2 may be used to transfer a
fixed desired volume of fluid/slurry to the batch mixer tank(s)
252, subsequently pump 250.2 may also be used to transfer
fluid/slurry from the batch mixer tank(s) 252 to the high pressure
pump(s) 254. [0083] 33. Same process objectives as scenario (13)
but fluid/slurry is delivered from the averaging tank 245 to the
batch mixer tank(s) 252, and when batch mixer tank(s) 252 pumps are
not available. Pump 250.2 may be used to concurrently transfer
fluid/slurry from the averaging tank 245 to the batch mixer tank(s)
252, and from the batch mixer tank(s) 252 to the high pressure
pump(s) 254. [0084] 34. Same process objectives as scenario (14)
but fluid/slurry is delivered from the averaging tank 245 to the
batch mixer tank(s) 252, and when batch mixer tank(s) 252 pumps are
not available. Pump 250.1 may be used to transfer a fixed desired
volume of fluid/slurry to the batch mixer tank(s) 252, subsequently
pump 250.1 may also be used to transfer fluid/slurry from the batch
mixer tank(s) 252 to the high pressure pump(s) 254. [0085] 35. Same
process objectives as scenario (14) but fluid/slurry is delivered
from the averaging tank 245 to the batch mixer tank(s) 252, and
when batch mixer tank(s) 252 pumps are not available. Pump 250.1
may be used to concurrently transfer fluid/slurry from the
averaging tank 245 to the batch mixer tank(s) 252, and from the
batch mixer tank(s) 252 to the high pressure pump(s) 254. [0086] B.
Scenarios B1-B3: For pumpers where there may be no additional pump
to supply mixing water, and/or where there is no backup or
redundancy. The following possible scenarios may be implemented in
accordance with at least one embodiment of the present disclosure:
[0087] 1. Unlike pumper variation A, pump 250.2 may be used to
supply mixing water to mixer 246.246.1 and mixing tank 248.1. Pump
250.1 may be used to re-circulate fluid/slurry between mixing tank
248.1 and mixer 246.1. After the desired density/property is
achieved, pump 250.1 may also be used to concurrently transfer
fluid/slurry from mixing tank 248.1 to the high pressure pump(s)
254, while maintaining re-circulation. [0088] 2. Same process
objectives as scenario (B)(1) but fluid/slurry is delivered from
mixing tank 248.1 to the batch mixer tank(s) 252. Pumps from the
batch mixer tank(s) 252 can then deliver fluid/slurry to the high
pressure pump(s) 254. [0089] 3. Same process objectives as scenario
(B)(1) but fluid/slurry is delivered from mixing tank 248.1 to the
batch mixer tank(s) 252 and when batch mixer tank(s) 252 pumps are
not available. Pump 250.1 may be used to transfer a fixed desired
volume of fluid/slurry to the batch mixer tank(s) 252, subsequently
pump 250.1 may also be used to transfer fluid/slurry from the batch
mixer tank(s) 252 to the high pressure pump(s) 254. [0090] C.
Scenarios C1-7: Other possible scenarios related to general
fluid/slurry delivery may be implemented in accordance with at
least one embodiment of the present disclosure: [0091] 1. When
higher delivery rates are desired, pumps 250.1, 250.2 may be used
to transfer fluids from the water/chemical supply 244 to the high
pressure pump(s) 254. [0092] 2. If pump 250.2 is down, pump 250.1
may be used to transfer fluids from the water/chemical supply 244
to the high pressure pump(s) 254. [0093] 3. If pump 250.1 is down,
pump 250.2 may be used to transfer fluids from the water/chemical
supply 244 to the high pressure pump(s) 254. [0094] 4. When higher
delivery rates are desired, pump 250.1 and pump 250.2 may be used
to transfer fluids from the water/chemical supply 244 to the high
pressure pump(s) 254. [0095] 5. Same process objectives as scenario
(1) but fluid from the water/chemical supply 244 may be delivered
to the batch mixer tank(s) 252 (or any other destination). [0096]
6. Same process objectives as scenario (2) but fluid from the
water/chemical supply 244 may be delivered to the batch mixer
tank(s) 252 (or any other destination). [0097] 7. Same process
objectives as scenario (3) but fluid from the water/chemical supply
244 may be delivered to the batch mixer tank(s) 252 (or any other
destination).
[0098] FIG. 3 is a simplified flow diagram of a fluid system 206
which depicts a mixing modular manifold 336 as an interface between
the mixer 330 and high pressure pump(s) 354 that are used to
deliver the mixed fluids to the wellsite.
[0099] The mixer 330 includes mixers 246, mixing tanks 248,
averaging tanks 245, mixing fluid supply 242 and batch mixer tank
252. The mixer 330 passes fluid to the mixing modular manifold 336.
Fluid is recirculated to the mixer via mixing recirculation lines
337 as indicated by the arrows. The fluid may then be passed from
the mixing modular manifold 336 to the high pressure pump 354, and
on to the wellhead at the wellbore.
[0100] Although the example scenarios have been described in FIGS.
1-3 are with reference to specific implementations, the present
disclosure is not to be limited by or to such implementations
and/or embodiments. For example, scenarios may exist where either
one or both pumps 250.1, 250.2 are replaced by external pumps to
perform substantially similar functions. Moreover, equivalent
functional scenarios may be encompassed within the scope of the
present disclosure, such as the multiple usages of nozzle points,
or the use of pits rather than batch mixer tank(s) 252.
Furthermore, subsets of scenarios described above may exist, for
example, in scenario (26), a single pump may be utilized to
transfer fluid from the batch mixer tank(s) 252 to the high
pressure pump(s) 254. In addition, combinations of scenarios or
combinations of subsets of scenarios are encompassed in all such
modifications, variations and enhancements of at least one
embodiment of the present disclosure. Various combinations of the
fluid systems (e.g., 106, 206 and/or 306) may be combined as
desired to achieve desired configurations.
[0101] Referring now to FIGS. 4.1 and 4.2, an example design of a
modular fluid/slurry mixing modular manifold 436 is depicted in
accordance with at least one embodiment of the present disclosure.
The modular manifold may include flow control systems and
components that may be used for well construction services. The
modular manifold 436 as shown in FIG. 4.1 includes pumps 250.1,
250.2, pipes 254.1-254.13, valves V1-V22, and intersections
257.1-257.10. The pipes 254.1-254.13 may have connection points
1-13 (e.g., nozzles, or inlets or other devices), respectively, to
manipulate flow into and out of the modular manifold 436 through
pipes 254.1-254.13. Connectors (not shown) may be provided for
connection to the remainder of the fluid system for fluid
communication therewith.
[0102] At connection point 1, pipe 254.1 fluidly couples averaging
tank 245 to intersection 257.1 via valve V1. At connection point 2,
pipe 254.2 fluidly couples mixing tank 248.1 to intersection 257.2
via valve V9. At connection point 3, pipe 254.3 fluidly couples
displacement tank or auxiliary water/chemical supply 244 to
intersection 257.1 via valve V14. At connection point 4, pipe 254.4
fluidly couples auxiliary mixer 246.1 to intersection 257.3 via
valve V12. At connection point 5, pipe 254.5 fluidly couples
averaging tank 245 and batch mixer tank(s) 252 to intersection
257.7 via valve V7 if desired. At connection point 6, pipe 254.6
fluidly couples suction of high pressure pump(s) 254 to
intersection 257.7 via valve V8.
[0103] At connection point 7, pipe 254.7 optionally fluidly couples
batch mixer tank(s) 252 to intersection 257.4 via valve V16. At
connection point 8, pipe 254.8 optionally fluidly couples batch
mixer tank(s) 252 and high pressure pump(s) 254 to intersection
257.5 via valve V17. At connection point 9, pipe 254.9 optionally
fluidly couples additional mixing tank 248.2 for a dual mixers 446
to intersection 257.9 via valve V18. At connection point 10, pipe
254.10 fluidly couples auxiliary mixer 246.1 for pumper variation B
or additional auxiliary mixer 246.2 for dual mixers to intersection
257.8 via valve V19. At connection point 11, pipe 254.11 fluidly
couples batch mixer tank(s) 252 to intersection 257.9. At
connection point 12, pipe 254.12 fluidly couples batch mixer
tank(s) 252 to intersection 257.2. At connection point 13, pipe
254.13 fluidly couples drain 456 to intersection 257.10 via valve
V21.
[0104] Pump 250.2 is fluidly coupled to intersection 257.9 via
valve V3, and to intersection 257.8 via valve V4. Pump 250.1 is
fluidly connected to intersection 257.2 via valve V10, and to
intersection 257.3 via valve V11. Valve V15 fluidly couples
intersections 257.10 and 257.2. Valve V2 fluidly couples
intersections 257.1 and 257.9. Valve V5 fluidly couples
intersections 257.8 and 257.9. Valve V6 fluidly couples
intersections 257.6 and 257.5. Valve V20 fluidly couples
intersections 257.3 and 257.4.
[0105] The modular manifold 436 may also be provided with other
fluid control or other devices, such as knock-off caps for cleaning
and inspection at strategic points as will be described further
herein. Valves V16 and V17 may be optional depending on whether
batch mixer tank(s) 252 are used. Valve V18 may be optional
depending on whether dual mixers 246.1, 246.2 are used. Valve V19
may be optional depending on whether dual mixers 246.1, 246.2
and/or mixing water supply 242 are used.
[0106] In an example, valve V7 may be adjustable to compensate for
increased re-circulation flow to the averaging tank 245 or batch
mixer tank(s) 252, and may ensure against insufficient suction
pressure at the high pressure pump(s) 254. For conditions where
either one of pumps 250.1, 250.2 is down, valve V16 may be
adjustable to ensure that maximum supply rate to the batch mixer
tank(s) 252 does not come at the expense of insufficient
re-circulation rate and pressure for mixing. Valve V6 may be
adjustable to optimize re-circulation rate and pressure when it is
desired to mix and pressurize high pressure pump(s) 254
simultaneously.
[0107] Referring to FIGS. 4.2 and 4.2.1-4.2.4, a table 437 is
provided depicting possible valve combinations and connection
points listed as examples to correspond with at least one of the
various scenarios discussed herein. An example logic table is
indicated therein by numerical sequence, which may be referenced
for logic explanation and not particularly for physical operating
sequence. For the valve combinations referenced in table 437, one
may assume that the valves are closed by default.
[0108] As shown in table 437, various scenarios are provided for
valve combinations involving valves V1-V22 being actuated in the
order sequence of 1, 2, 3 and so forth. The scenarios include
A1-35, B1-3 and C1-7 as previously described.
[0109] Referring now to FIGS. 5.1-6.4, example modular fluid/slurry
mixing modular manifolds are presented therein in accordance with
certain embodiments of the present disclosure. Each modular
fluid/slurry mixing manifold presented in FIGS. 4.1-5.4 includes a
centrifugal pump, for example an RA5X6 (inlet 6 in (15.24) and
outlet 5 in (12.70)). Moreover, each modular fluid/slurry mixing
manifold presented may be designed to facilitate fluid/slurry
mixing logic, and may be modular and compact so as to fit within a
specified bounding volume.
[0110] The fluid/slurry mixing manifold constructed in accordance
with the present disclosure may be designed and manufactured in
accordance to ASME B31.3, having flanges and buttweld fittings
designed to meet ASME B16.5 and ASME B16.9 respectively, and welds
designed for Non-Destructive Testing (NDT). The nozzles (e.g., N7
and N8) may be arranged such that the batch mixer tank(s) 252 can
be installed from either side of the manifold, thereby enhancing
flexibility in installations.
[0111] FIGS. 5.1-5.4 depict front, perspective, rear and side
views, respectively, of modular manifold 536 and FIGS. 6.1-6.4
depict front, perspective, rear and side views, respectively, of
modular manifold 636 in a physical configuration removable
connectable to a fluid system, such as those described herein. In
the examples of modular fluid/slurry mixing manifolds, FIGS.
5.1-5.4 depict the modular manifold 536 and centrifugal pumps
250.1, 250.2 installed vertically, and FIGS. 6.1-6.4 depict the
modular manifold 636 and centrifugal pumps 250.1, 250.2 installed
horizontally in accordance with at least one embodiment of the
present disclosure. The modular manifolds 536 and 636 are
constructed as unitary component that is transportable and
modularly connectable between a mixer 330 and high pressure pumps
354 of a fluid system for passing fluid therebetween as shown, for
example, in FIG. 3.
[0112] The modular manifolds 536, 636 each include pumps 250.1,
250.2, pipes 254.1-254.13, valves V1-V22, intersections
257.1-257.10, and nozzles N1-13 operable as schematically depicted
in FIG. 4.1. Inlets 562.1, 562.2 depict options for receiving
fluid/slurry from batch mixer tank(s) 252. The modular fluid/slurry
mixing manifold is also shown to include knock-off caps 560, which
may be placed at strategic locations for cleaning and
inspection.
[0113] In the vertical configuration of FIGS. 5.1-5.4, the modular
manifold 536 includes horizontal portions 564.1-564.3 and vertical
portions 566.1-566.4. Horizontal portion 564.1 extends from inlet
562.1 to 562.2. Horizontal portion 564.2 extends from knockoff cap
560.1 to knockoff cap 560.2. Horizontal portion 564.3 extends from
V4 to V11. Vertical portion 566.1 extends between horizontal
portions 564.1, 564.2. Vertical portions 566.2, 566.3 extend
between opposite ends of horizontal portions 564.2, 564.3.
Centrifugal pumps 250.1, 250.2 are positioned about the vertical
portions 566.2, 566.3.
[0114] In the horizontal configuration of FIGS. 6.1-6.4, the
modular manifold 636 includes horizontal portions 664.1-664.3 and
vertical portions 666.1-666.4. Horizontal portion 664.1 extends
from knockoff cap 660.1 to knockoff cap 660.2. Horizontal portion
664.2 extends from valve V19 to knockoff cap 660.3. Horizontal
portion 664.3 extends from valve V18 to knockoff cap 660.34.
Vertical portions 666.2, 666.3 extend between opposite ends of
horizontal portions 664.1, 664.2. Vertical portion 666.1 extends
between horizontal portions 664.2, 664.3. Centrifugal pumps 250.1,
250.2 extend from opposite ends of horizontal portion 664.3.
[0115] The modular manifold 536, 636 may also be provided with
connectors 253 for operative connection with portions of the fluid
system. The connectors 253 may releasably connect the modular
manifold to the fluid system when positioned adjacent thereto.
Various connectors may be provided for linking portions of the
modular manifold 536, 636 to the various components of the fluid
system, such as at connection points 1-13.
[0116] The modular manifolds herein may be used as part of fluid
systems, such as those of FIGS. 1 and 2.1. The fluids system may be
configured to receive the modular manifold. FIGS. 7.1-9.2 depict
various configurations of a fluid system 706.1, 706.2, 806.1,
806.2, 906.1, 906.2 with a modular manifold. Each of these fluid
systems includes a mixer portion, a modular manifold and a delivery
portion.
[0117] FIGS. 7.1 and 7.2 depict a single mixer configuration. These
figures include a horizontal single mixer fluid system 706.1 and a
vertical single mixer fluid system 706.2, respectively. As
demonstrated by these figures, the fluid system may be in a variety
of configurations such that fluid is mixed, pumped and delivered to
the wellbore as shown in FIGS. 1 and 2.1-2.3.
[0118] The fluid system 706.1 includes a mixing portion 730, a
modular manifold 736, and a delivery portion 740. The mixing
portion 730 includes a mixer 746, an averaging tank 745 and a
mixing tank 748. The mixing portion 730 receives and mixes fluids.
The mixed fluids are passed from mixer 746 to the averaging tank
745 and the mixing tank 748.
[0119] The modular manifold 736 is removably fluidly coupled to the
mixing tank 748 and the averaging tank 745 for receiving fluids
therefrom. The modular manifold 736 may recirculate fluid to the
mixing portion 730, and then passes the fluid as mixed slurry 753
on to the delivery portion 740. The delivery portion includes high
pressure pumps 754 and a motor (e.g., a prime mover engine/motor)
755. Drive shafts 757 may be provided between the motor 755 and the
high pressure pumps 754 for driving the pumps 754.
[0120] FIGS. 8.1 and 8.2 depict a dual mixer configuration. These
figures include a horizontal dual mixer fluid system 806.1 and a
vertical dual mixer fluid system 806.2, respectively. As
demonstrated by these figures, the fluid system may be in a variety
of configurations such that fluid is mixed, pumped and delivered to
the wellbore as shown in FIGS. 1 and 2.1-2.3.
[0121] The fluid system 806.1 includes a mixing portion 830, a
modular manifold 836, and a delivery portion 840. The mixing
portion 830 includes mixers 846, an averaging tank 845 and mixing
tanks 848. The mixing portion 830 receives and mixes fluids. The
mixed fluids are passed from mixers 846 to the averaging tank 845
and the mixing tank 848.
[0122] The modular manifold 836 is removably fluidly coupled to the
mixing tank 848 and the averaging tanks 845 for receiving fluids
therefrom. The modular manifold 836 may recirculate fluid to the
mixing portion 830, and then passes the fluid as mixed slurry 853
on to the delivery portion 840. The delivery portion includes high
pressure pumps 854 and a motor (e.g., a prime mover engine/motor)
855. Drive shafts 857 may be provided between the motor 855 and the
high pressure pumps 854 for driving the pumps 854.
[0123] FIGS. 9.1-9.3 depict an example configuration of the fluid
systems 706.1, 706.2, 806.1, and/or 806.2. FIG. 9.3 is a plan view
of the fluid assembly 706.1, 806.1. FIG. 9.1 is a perspective view
of the mixing portion 730, 830 removed from the fluid system 706.1,
806.2. FIG. 9.2 depicts the modular manifold 736, 836 removed from
the fluid system 706.1, 806.1.
[0124] FIGS. 10.1 and 10.2 depict an integrated manifold
configuration. These figures include a horizontal integrated fluid
system 1006.1 and a vertical integrated fluid system 1006.2,
respectively. As demonstrated by these figures, the fluid system
may be in a variety of configurations such that fluid is mixed,
pumped and delivered to the wellbore as shown in FIGS. 1 and
2.1-2.3.
[0125] The fluid system 1006.1 includes an integrated mixing and
manifold portion 1031, and a delivery portion 1040. The integrated
portion 1031 includes a mixing portion 1030 and modular manifold
1036. The mixing portion 1030 and the modular manifold 1036 may be
integrated into a unitary structure for transport. The integrated
portion 1031 may be positioned on a skid 1074 movably positionable
about the wellsite and/or the delivery portion 1040.
[0126] The mixing portion 1030 includes mixers 1046, an averaging
tank 1045 and mixing tanks 1048. The integrated portion 1031
receives and mixes fluids. The mixed fluids are passed from mixers
1046 to the averaging tank 1045 and the mixing tank 1048. The
modular manifold 1036 is removably fluidly coupled to the mixing
tank 1048 and the averaging tank 1045 for receiving fluids
therefrom.
[0127] The modular manifold 1036 may recirculate fluid to the
mixing portion 1030, and then passes the fluid on to the delivery
portion 1040. The delivery portion includes high pressure pumps
1054 and a motor (e.g., a prime mover engine/motor) 1055. Drive
shafts 1057 may be provided between the motor 1055 and the high
pressure pumps 1054 for driving the pumps 1054.
[0128] FIGS. 11.1-11.3 depict an example configuration of the fluid
systems 1006.1 and/or 906.2. FIG. 11.3 is a plan view of the fluid
assembly 1006.1 depicting the pumping equipment. FIG. 11.1 is a
perspective view of the mixing portion 1030 removed from the fluid
system 1006.1. FIG. 11.3 depicts the mixing manifold 1036 removed
from the fluid system 1006.1.
[0129] FIGS. 12.1-13.2 depict various configurations of a modular
manifold usable with the various fluid systems herein. These
figures may use aspects of the manifold configurations described
herein, such as the pipe, valves and pumps as previously described.
FIGS. 12.1 and 12.2 show a modular manifold 1236 mounted on a frame
1270 to form a mobile manifold assembly. FIGS. 13.1 and 13.2 show a
modular manifold without a frame.
[0130] FIGS. 12.1 and 12.2 depict front and rear perspective views,
respectively, of the modular manifold 1236. This modular manifold
1236 may be used, for example, with the configurations of FIGS.
7.1-9.3 and incorporate the valves V1-21, inlets 1-13, pipes
254.1-254.13, and pumps 250.1, 250.2 (only some of which are shown
in these figures). In the configuration shown, the modular manifold
1236 includes two pumps 1250.1, 1250.2 fluidly coupled via pipes
and valves to auxiliary equipment of the fluid system. A flow
control valve 1272 (e.g., butterfly valve with manual lever) is
also provided for fluidly coupling to the remainder of the fluid
system.
[0131] As shown in FIGS. 12.1 and 12.2, the modular manifold 1236
fluidly couples to averaging tank 245 at connection point 1, mixing
tank 248 at connection point 2, displacement tank or auxiliary
water/chemical supply 244 at connection point 3 (not shown), to
auxiliary mixer 246.2 at connection point 4 (not shown),
re-circulation to averaging tank 245 or batch mixer tank(s) 252 if
required at connection point 5, to densitometer flow meter and
suction of high pressure pump(s) 254 at connection point 6, to
batch mixer tank(s) 252 (optional) at connection point 7, from
batch mixer tank(s) 252 to high pressure pump(s) 254 (optional) at
connection point 7, from additional mixing tank 248.2 for dual
mixers option (optional) at connection point 9, to auxiliary mixer
246.2 for pumper variation B or to additional auxiliary mixer 246.2
for dual mixers at connection point 10, from batch mixer tank(s)
252 to pump 250.2 at connection point 11, from batch mixer tank(s)
252 to pump 1 at connection point 12, and to drain 456 at
connection point 13. Knock-off caps may also be provided for
cleaning and inspection at strategic.
[0132] This modular manifold 1236 and the frame 1270 form a mobile
manifold assembly for lifting, transporting and supporting the
modular manifold 1236. The frame 1270 may be configured for
connection to the fluid system. As shown, the frame 1270 includes a
base portion 1271, vertical support 1273 and brackets 1275 made up
of a plurality of bars forming a grid for supporting the modular
manifold 1236. The base portion 1271 may be a frame, skid or other
platform for supporting the modular manifold 1236 on the ground or
other surface. The carrier portion 1273 is operatively connected to
the base portion 1271 and extends a distance above. The carrier
portion 1273 may be used to provide support to portions of the
modular manifold 1236. The carrier portion 1273 may also be
provided with a handle, grips or other devices for lifting the
modular manifold 1236. The brackets 1275 are provided to support
the pumps 250.1, 250.2. Additional supports, such as brackets 1275
may also be provided for supporting various portions of the modular
manifold 1236 on the frame 1270. The modular manifold 1236 may be
securable to the base portion 1271 and the carrier portion 1273 of
the mobile frame 1270. The modular manifold is liftable via the
mobile frame 1270 whereby the modular manifold is transportable to
the auxiliary components for operable connection therewith.
[0133] Portions of the modular manifold 1236 may be positioned
about the frame 1270 to facilitate transport, delivery, connection
and operation of the modular manifold 1236. As shown, the
horizontal portions of the pipes extend along linear bars forming
the frame. Portions of the modular manifold 1236 extend through the
frame 1270 such that a portion of the modular manifold 1236 is on
each side of the vertical support 1273. The connector portions of
the modular manifold 1236 are positioned on one side of the
vertical support 1273 and has connectors extending therefrom for
connection with the fluid system. Connector portions of the pipes,
such as the portions of the pipes at the connection points, extend
from the modular manifold in an arrangement corresponding to an
arrangement of the auxiliary components to define a plug-in
configuration therebetween such that the connector portions of the
pipes are positionable in alignment with the auxiliary components
for direct and removable connection therewith. A pump portion of
the modular manifold 1236 is positioned on the other side of
vertical support 1273. In this configuration, the modular manifold
1236 may be `plugged in` to the remainder of the fluid system for
operation therewith.
[0134] FIGS. 13.1 and 13.2 depict front and rear perspective views,
respectively, of a modular manifold 1336. This modular manifold
1336 may be used, for example, with the configurations of FIGS.
10.1-11.3. In the configuration shown, the modular manifold
includes two pumps 250.1, 250.2 fluidly coupled via pipes 1345 and
valves to auxiliary equipment of the fluid system. A flow control
valve 1372 (e.g., butterfly valve with pneumatic actuator) is also
provided for fluidly coupling to the remainder of the fluid
system.
[0135] As shown in FIGS. 13.1 and 13.2, the modular manifold 1336
fluidly couples to averaging tank 250 at position 1, mixing tank
248 at position 2, displacement tank or auxiliary water/chemical
supply 244 at position 3, to auxiliary mixer 246.2 at position 4,
re-circulation to averaging tank 245 or batch mixer tank(s) 252 if
required at position 5, to suction of high pressure pump(s) 254 at
position 6, to batch mixer tank(s) 252 (optional) at position 7,
from batch mixer tank(s) 252 to high pressure pump(s) 254
(optional) at position 8, from additional mixing tank 248.2 for
dual mixers option (optional) at position 9, to auxiliary mixer
246.1 for pumper variation B or to additional auxiliary mixer 246.2
for dual mixers at position 10, from batch mixer tank(s) 252 to
manifold/mixing pump 250.2 at position 11, from batch mixer tank(s)
252 to maniflold/mixing pump 250.1 at position 12, and to drain 456
at position 13. Knock-off caps may also be provided for cleaning
and inspection as needed.
[0136] The manifolds herein are provided with various connectors
253 for operative connection to the remainder of the fluid systems,
and fluid control devices, such as pumps for driving fluid, valves
for selectively diverting fluid, drains for releasing fluid, and/or
other such devices. The manifolds may be pre-assembled in the
appropriate configuration for operation with the fluid system and
for transport and delivery. The manifolds may be operatively
connected to a frame, skid and/or other transport device to
facilitate installation, lifting, and/or transport of the
manifold.
[0137] FIG. 14 is a method 1400 of providing fluid to a wellsite
during well construction. The method 1400 involves (1480) providing
a fluid system about a wellsite, the fluid system including
auxiliary components (at least one fluid source, at least one mixer
and at least one high pressure pump), and a mobile manifold
assembly and/or a modular manifold. The fluid system and mobile
manifold assembly may be those described herein. The method
continues with (1482) transporting the modular manifold to the
auxiliary components using the mobile frame, (1484) operatively
connecting the connector portions of the modular manifold to the
auxiliary components, and (1486) pumping fluid to the wellbore
using the modular manifold.
[0138] The method may also involve mixing the fluid with the mixer,
recirculating fluid between the auxiliary components and the
modular manifold, selectively diverting fluid from the modular
manifold to a mixing portion, a batch portion and/or a delivery
portion of the fluid system, and/or cementing the wellbore using
the fluid pumped to the wellbore. The method may be performed in
any order and repeated as desired.
[0139] It should be noted that the valves described and depicted
herein may be actuated in a variety of methods, or derivatives
thereof. For example: actuation may be in-situ and manually with
handles or wheels, remotely via direct pneumatics, remotely and
indirectly using electrical solenoids and spools to
regulate/control pneumatics (such feature may also enable process
control via automated routines written for at least one of the
operating scenarios described herein). Moreover, it should also be
noted that the pumps may be run in accordance with a variety of
methods, or derivatives thereof. For example, running the pumps may
comprise drive shafts, electric motors or hydraulic motors. One
skilled in the art will recognize that alternative methods can be
employed in practicing the present disclosure.
[0140] Although the present disclosure has been described with
reference to exemplary embodiments and implementations thereof, the
present disclosure is not to be limited by or to such exemplary
embodiments and/or implementations. Rather, the systems and methods
of the present disclosure are susceptible to various modifications,
variations and/or enhancements without departing from the spirit or
scope of the present disclosure. Accordingly, the present
disclosure expressly encompasses all such modifications, variations
and enhancements within its scope.
[0141] The terminology and phraseology used herein is solely used
for descriptive purposes and should not be construed as limiting in
scope. Language such as "including," "comprising," "having,"
"containing," or "involving," and variations thereof, is intended
to be broad and encompass the subject matter listed thereafter,
equivalents, and additional subject matter not recited.
[0142] Moreover, in this description the terms "up" and "down";
"upward" and downward"; "upstream" and "downstream"; and other like
terms indicating relative positions above or below a given point or
element are used in this description to more clearly described some
embodiments of the invention.
[0143] It should be noted that in the development of any such
actual embodiment, numerous implementations and specific decisions
may be made to achieve the developer's specific goals, such as
compliance with system related and business related constraints,
which may vary from one implementation to another. Moreover, it
will be appreciated that such a development effort may be complex
and time consuming, but may nevertheless be a routine undertaking
for those of ordinary skill in the art having the benefit of this
disclosure. In addition, the composition used/disclosed herein can
also comprise some components other than those cited.
[0144] Each numerical value herein should be read once as modified
by the term "about" (unless already expressly so modified), and
then read again as not so modified unless otherwise indicated in
context. Also, in the disclosure, it should be understood that a
concentration range listed or described as being useful, suitable,
or the like, is intended that any and every concentration within
the range, including the end points, is to be considered as having
been stated. For example, "a range of from 1 to 10" is to be read
as indicating each and every possible number along the continuum
between about 1 and about 10. Thus, even if specific data points
within the range, or even no data points within the range, are
explicitly identified or refer to only a few specific, it is to be
understood that inventors appreciate and understand that any and
all data points within the range are to be considered to have been
specified, and that inventors possessed knowledge of the entire
range and all points within the range.
[0145] Although only a few example embodiments have been described
in detail above, those skilled in the art will readily appreciate
that many modifications are possible in the example embodiments
without materially departing from this invention. Accordingly, all
such modifications are intended to be included within the scope of
this disclosure as defined in the following claims. In the claims,
means-plus-function clauses are intended to cover the structures
described herein as performing the recited function and not only
structural equivalents, but also equivalent structures. Thus,
although a nail and a screw may not be structural equivalents in
that a nail employs a cylindrical surface to secure wooden parts
together, whereas a screw employs a helical surface, in the
environment of fastening wooden parts, a nail and a screw may be
equivalent structures. It is the express intention of the applicant
not to invoke 35 U.S.C. .sctn.112, paragraph 6 for any limitations
of any of the claims herein, except for those in which the claim
expressly uses the words `means for` together with an associated
function.
[0146] In a given example, the modular manifold may have valves and
flowlines/pipes positioned on a frame in various configurations and
provided with various connectors to facilitate connection to a
mixing portion of a fluid system.
* * * * *