Frac Pump Isolation Safety System

Abstract

The improved system allows an operator overseeing a well stimulation hydraulic fracturing operation to bring frac pumps online and offline as necessary. A control panel allows the operator to remain at a safe distance from high-pressure equipment, including the frac pumps and respective remotely actuated isolation valves, yet allows monitoring and operation of same. The operating condition of the frac pumps and the isolation valves is monitored by an automated processing device, which prevents operation of same during certain pump and valve conditions. A wireless operator interface is also provided.

We claim: 
     
         1 . A high-pressure fluid delivery system having a plurality of fluid pumps in fluid communication with a manifold to provide high fluid pressures and high fluid volumes, the system comprising:
 an isolation valve in a fluid circuit between a fluid discharge of each of a plurality of fluid pumps and a fluid manifold, the isolation valve capable of substantially isolating the fluid pump discharge from the manifold, the isolation valve adapted to allow for remote actuation; and   a remote operator control panel, the control panel in signal communication with each isolation valve and its respective pump, the control panel adapted to monitor at least one valve condition and at least one respective pump condition, the isolation valve operable in response to a signal from the operator control panel.   
     
     
         2 . The system of  claim 1 , the control panel further comprising:
 a graphical operator interface adapted to allow an operator to remotely monitor the at least one valve condition or the at least one pump condition during operations.   
     
     
         3 . The system of  claim 1 , the control panel further comprising:
 a graphical operator interface adapted to allow an operator to remotely monitor the at least one valve condition or the at least one pump condition during operations, and to effect actuation of each isolation valve and/or operation of each pump.   
     
     
         4 . The system of  claim 1  further comprising:
 a graphical operator interface in wireless communication with the control panel, the interface adapted to allow an operator to remotely monitor the at least one valve condition and/or the at least respective one pump condition during operations. 
 
     
     
         5 . The system of  claim 1  further comprising:
 a graphical operator interface in wireless communication with the control panel, the interface adapted to allow an operator to remotely monitor the at least one valve condition and/or the at least one respective pump condition during operations, and to effect actuation of each isolation valve and/or operation of each hydraulic fracturing pump. 
 
     
     
         6 . The system of  claim 1  further comprising:
 a hydraulic or pneumatic valve actuation system, the actuation system in fluid communication with the isolation valves for isolation valve actuation, the actuation system in further signal communication with the control panel to effect the isolation valve actuation. 
 
     
     
         7 . The system of  claim 1  further comprising:
 an electromechanical valve actuation system, the actuation system in mechanical communication with the isolation valves for isolation valve actuation, the actuation system in further signal communication with the control panel to effect the isolation valve actuation. 
 
     
     
         8 . The system of  claim 1 , wherein the at least one pump condition is an indication of the operational status of the pump, the system further comprising:
 an automated processing and control device adapted to perform the program steps for:
 accepting a request by operator to close the isolation valve; 
 if the respective pump is not operating, closing the isolation valve; and 
 if the respective pump is operating, maintaining the valve open. 
   
     
     
         9 . The system of  claim 1 , wherein the at least one valve condition is an indication of the open or closed state of the valve, the system further comprising:
 an automated processing and control device adapted to perform the program steps for:
 accepting a request by operator to engage the transmission on a hydraulic fracturing pump; 
 if the respective isolation valve is open, starting the pump; and 
 if the respective isolation valve is not open, warning the operator of the valve condition. 
   
     
     
         10 . The system of  claim 1 , wherein the at least one valve condition is an indication of the open or closed state of the valve, the system further comprising:
 an automated processing and control device adapted to perform the program steps for:
 accepting a request by operator to engage the transmission on a hydraulic fracturing pump; 
 if the respective isolation valve is open, starting the pump; and 
 if the respective isolation valve is not open, automatically opening the isolation valve before starting the pump. 
   
     
     
         11 . The system of  claim 1 , wherein the at least one valve condition is an indication of the open or closed state of the valve and the at least one pump condition is an indication of the physical integrity of the pump, the system further comprising:
 an automated processing and control device adapted to perform the program steps for:
 monitoring the physical integrity of the pump to determine an adverse change in the pump operational characteristics necessitating isolation; 
 if the pump transmission is not disengaged, disengaging the pump transmission; and 
 closing the isolation valve. 
   
     
     
         12 . A hydraulic fracturing pump isolation safety system, the system comprising:
 a plurality of remotely actuated isolation valves, each isolation valve in fluid communication with the fluid head of a hydraulic fracturing pump, the plurality of isolation valves in further fluid communication with a manifold through which fracturing fluid is provided to a well head; and   a control panel located remotely from the plurality of isolation valves and the hydraulic fracturing pumps, the control panel in signal communication with the plurality of plug valves and the hydraulic fracturing pumps, the control panel comprising an operator interface for monitoring by an operator of at least one valve condition and at least one respective pump condition,   wherein the control panel is adapted to allow the operator to remotely monitor and control each valve and/or pump in response to the monitored conditions.   
     
     
         13 . The system of  claim 12 , the system further comprising:
 an automated processing device adapted to automatically monitor the pump condition and to prevent the ability to change the operating condition of the respective isolation valve in response to this monitored pump condition.   
     
     
         14 . The system of  claim 12 , the system further comprising:
 an automated processing device adapted to automatically monitor the isolation valve condition and to prevent the ability to change the operating condition of the respective hydraulic fracturing pump in response to this monitored valve condition.   
     
     
         15 . The system of  claim 12 , the system further comprising:
 an automated processing device adapted to automatically monitor the first condition of a pump and to automatically operate the respective isolation valve in response to this monitored pump condition.   
     
     
         16 . The system of  claim 12 , the control panel further comprising:
 a graphical operator interface adapted to allow an operator to remotely monitor the at least one valve condition and/or the at least one pump condition during well stimulation operations.   
     
     
         17 . The system of  claim 12 , the control panel further comprising:
 a graphical operator interface adapted to allow an operator to remotely monitor the at least one valve condition and/or the at least one pump condition during well stimulation operations, and to effect operation of each isolation valve and/or operation of each hydraulic fracturing pump.   
     
     
         18 . The system of  claim 12 , the system further comprising:
 a graphical operator interface in wireless communication with the control panel, the interface adapted to allow an operator to remotely monitor the at least one valve condition and/or the at least one pump condition during well stimulation operations.   
     
     
         19 . The system of  claim 12 , the system further comprising:
 a graphical operator interface in wireless communication with the control panel, the interface adapted to allow an operator to remotely monitor the at least one valve condition and/or the at least one pump condition during well stimulation operations, and to effect operation of each isolation valve and/or operation of each hydraulic fracturing pump.