Assemblies, methods, controller, and kits for hydraulic fracturing manifolds to provide overpressure relief and bleed using choke valves

Abstract

The present disclosure provides embodiments of a monobore assembly to be positioned in a hydraulic fracturing manifold system to provide overpressure relief and bleed using choke valves. The monobore assembly includes a control module, a pressure relief choke valve, a pressure transducer, and a bleed choke valve. The control module has a controller configured to receive a pressure signal, from the pressure transducer, and upon determination the pressure is above a predetermined threshold, send an output action to relieve the pressure in a throughbore of the monobore assembly. The pressure relief choke valve is configured to receive the output action and open in less than 0.4 seconds, thereby to prevent damage from overpressure within a throughbore of a first monobore junction. The bleed choke valve is also configured to receive the output action to controllably evacuate pressure, or pressurized fluid, within a throughbore of a second monobore junction.

What is claimed is: 
     
         1 . A monobore assembly to be positioned in a hydraulic fracturing manifold system to provide overpressure relief and bleed using choke valves, the monobore assembly comprising:
 a control module having a controller configured to receive and monitor a pressure signal and upon determination the pressure is above a predetermined threshold, send an output action to relieve the pressure in a throughbore of the monobore assembly;   a pressure relief choke valve having a body configured to be mounted to a first monobore junction that includes a throughbore configured to flow a pressurized fluid therethrough when in operation, the body having an inlet configured to fluidly connect to the throughbore when installed, an outlet configured to be connected to an overpressure relief conduit, and a pressure sensing aperture extending from an inner surface to an outer surface of the body such that the pressure sensing aperture is configured to be exposed to the pressure within the throughbore of the first monobore junction when in operation, the pressure relief choke valve configured to receive the output action from the control module to actuate the pressure relief choke valve from a closed position to a fully open position in less than 0.4 seconds, thereby to prevent damage from overpressure in the hydraulic fracturing manifold system when the monobore assembly is installed therein;   a pressure transducer mounted to the pressure relief choke valve body and configured to receive the pressure from the pressure sensing aperture and transmit the pressure signal to the control module during operation; and   a bleed choke valve having a body configured to be mounted to a second monobore junction different than the first monobore junction, the body having a choke bean positioned therein configured to reduce the pressure of the pressurized fluid, thereby to adjust a flowrate of the fluid during operation, the bleed choke valve configured to receive the output action from the control module to actuate the bleed choke valve to controllably evacuate the pressure or the pressurized fluid within a throughbore of the second monobore junction.   
     
     
         2 . The monobore assembly of  claim 1 , wherein the controller of the control module comprises a dual controller such that the output action thrusts (a) a first hydraulic fluid to the pressure relief choke valve to actuate to the fully open position and (b) a second hydraulic fluid to the bleed choke valve to controllably evacuate the pressure or the pressurized fluid. 
     
     
         3 . The monobore assembly of  claim 2 , wherein the control module has one or more hydraulic fluid sources within the control module configured to be fluidly connected to the pressure relief choke valve and the bleed choke valve via hydraulic connections. 
     
     
         4 . The monobore assembly of  claim 3 , wherein the one or more hydraulic fluid sources of the control module includes hydraulic oil driven by nitrogen or air, and wherein the pressure relief choke valve relieves overpressure at a depressurization rate of about 28 psi per millisecond. 
     
     
         5 . The monobore assembly of  claim 3 , wherein the pressure relief choke valve has a piston actuator configured to actuate by a force exerted thereon by a hydraulic fluid supplied through the hydraulic connections. 
     
     
         6 . The monobore assembly of  claim 3 , wherein the bleed choke valve has a piston actuator configured to actuate by a force exerted thereon by a hydraulic fluid through the hydraulic connections. 
     
     
         7 . The monobore assembly of  claim 3 , wherein each of the one or more hydraulic fluid sources comprises a rating of about 1500 pounds per square inch. 
     
     
         8 . The monobore assembly of  claim 1 , wherein the pressure relief choke valve is configured to be mounted on the first monobore junction such that particles fall towards the throughbore, thereby to reduce particle buildup in the pressure relieve choke valve. 
     
     
         9 . The monobore assembly of  claim 8 , wherein the bleed choke valve is configured mounted on the second monobore junction such that particles fall towards the throughbore, thereby to reduce particle buildup in the bleed choke valve. 
     
     
         10 . The monobore assembly of  claim 1 , further comprising a check valve configured to be positioned between the first monobore junction and the second monobore junction such that the pressurized fluid flows from the first monobore junction, through the check valve, and to the second monobore junction during operation. 
     
     
         11 . The monobore assembly of  claim 10 , wherein the bleed choke valve is configured to be connected to an evacuation conduit, the evacuation conduit configured to receive evacuated fluid from downstream of the check valve. 
     
     
         12 . The monobore assembly of  claim 10 , further comprising one or more pipe spools configured to be positioned between (a) the first monobore junction and the check valve and (b) between the check valve and the second monobore junction. 
     
     
         13 . The monobore assembly of  claim 1 , wherein the pressure relief choke valve comprises a connection to a linear actuator configured to linearly actuate the pressure relief choke valve. 
     
     
         14 . The monobore assembly of  claim 1 , wherein the pressure relief choke valve fully opens from the closed position in less than about 0.2 seconds of the determination the pressure is above the predetermined threshold. 
     
     
         15 . The monobore assembly of  claim 1 , wherein the pressure relief choke valve further comprises a position transducer configured to sense a valve position of the pressure relief choke valve and transmit a position signal to the control module. 
     
     
         16 . The monobore assembly of  claim 1 , wherein the bleed choke valve further comprises a position transducer configured to sense a valve position of the bleed choke valve and transmit a position signal to the control module. 
     
     
         17 . The monobore assembly of  claim 1 , wherein the body of the pressure relief choke valve further includes a gantry mounting plate configured to mount a gantry, thereby to service internals of the pressure relief choke valve on site. 
     
     
         18 . The monobore assembly of  claim 1 , wherein the body of the pressure relief choke valve houses a stem, a gate, and a seat, the stem being configured (a) to linearly compress the gate into the seat when the pressure relief choke valve is closed and (b) to linearly retract the gate from the seat when the pressure relief choke valve is opening. 
     
     
         19 . The monobore assembly of  claim 1 , wherein the pressure relief choke valve comprises a connection to a piston actuator configured to linearly actuate the pressure relief choke valve. 
     
     
         20 . An assembly to be positioned in a hydraulic fracturing manifold system to provide overpressure relief using a choke valve, the assembly comprising:
 a control module having a controller configured to receive and monitor a pressure signal and upon determination the pressure is above a predetermined threshold, send an output action to relieve the pressure in a throughbore of the assembly;   a pressure relief choke valve having a body configured to be mounted to a first junction that includes a throughbore configured to flow a pressurized fluid therethrough when in operation, the body having an inlet configured to fluidly connect to the throughbore when installed, an outlet configured to be connected to an overpressure relief conduit, and a pressure sensing aperture extending from an inner surface to an outer surface of the body such that the pressure sensing aperture is configured to be exposed to the pressure within the throughbore of the first junction when in operation, the pressure relief choke valve configured to receive the output action from the control module to actuate the pressure relief choke valve from a closed position to a fully open position in less than about 0.2 seconds, thereby to prevent damage from overpressure in the hydraulic fracturing manifold system when the assembly is installed therein; and   a pressure transducer mounted to the pressure relief choke valve body and configured to receive the pressure from the pressure sensing aperture and transmit the pressure signal to the control module during operation.   
     
     
         21 . A hydraulic fracturing system having a monobore assembly to provide an overpressure relief and bleed of the hydraulic fracturing system, thereby to prevent damage to associated fracturing system equipment, the system comprising:
 a wellhead;   one or more fracking pumps configured to provide pressurized fluids to the wellhead;   a monobore missile having one or more monobore junctions, the monobore missile and each of the one or more monobore junctions having a throughbore that provide a pathway for the pressurized fluid to flow to the wellhead, each of the one or more monobore junctions configured to receive the pressurized fluid from the one or more fracking pumps and direct the pressurized fluid to the pathway; and   a monobore assembly to provide an overpressure relief and a bleed of the pressurized fluid in the throughbore, the monobore assembly including:
 a control module having a controller configured to receive and monitor a pressure signal and upon determination the pressure is above a predetermined threshold, send an output action to relieve the pressure in the throughbore; 
 a pressure relief choke valve having a body configured to be mounted to a first monobore junction when installed, the body having an inlet configured to fluidly connect to the throughbore when installed, an outlet configured to be connected to an overpressure relief conduit, and a pressure sensing aperture extending from an inner surface to an outer surface of the body such that the pressure sensing aperture is configured to be exposed to the pressure within the throughbore of the first monobore junction when in operation, the pressure relief choke valve configured to receive the output action from the control module to actuate the pressure relief choke valve from a closed position to a fully open position in less than 0.4 seconds, thereby to prevent damage from overpressure in the hydraulic fracturing manifold system when the monobore assembly is installed therein; 
 a pressure transducer mounted to the pressure relief choke valve body and configured to receive the pressure from the pressure sensing aperture and transmit the pressure signal to the control module during operation; and 
 a bleed choke valve having a body configured to be mounted to a second monobore junction different than the first monobore junction, the body having a choke bean positioned therein configured to reduce the pressure of the pressurized fluid, thereby to adjust a flowrate of the fluid during operation, the bleed choke valve configured to receive the output action from the control module to actuate the bleed choke valve to controllably evacuate the pressure or the pressurized fluid within the throughbore. 
   
     
     
         22 . The system of  claim 21 , further comprising a second monobore assembly connected to the hydraulic fracturing system, and wherein a predetermined threshold of the second monobore assembly is different than the predetermined threshold of the first monobore assembly. 
     
     
         23 . The system of  claim 21 , further comprising a second monobore missile and a second monobore assembly connected to the second monobore missile, the second monobore missile containing a second pressurized fluid to the wellhead, the second monobore assembly configured to relieve a pressure of the second monobore missile independent of the pressure in the first monobore missile. 
     
     
         24 . The system of  claim 21 , wherein the output signal received by the bleed choke valve comprises a delay by a predetermined time interval after the pressure relief choke valve actuates. 
     
     
         25 . The system of  claim 21 , wherein the controller of the control module comprises a dual controller such that the controller receives the pressure signal from the pressure transducer and initiates an action for the pressure relief choke valve and the bleed choke valve based on exceeding predetermined thresholds, lapsed time intervals, or a combination thereof. 
     
     
         26 . A hydraulic fracturing system having an assembly to provide an overpressure relief of the hydraulic fracturing system, thereby to prevent damage to associated fracturing system equipment, the system comprising:
 a wellhead;   one or more fracking pumps configured to provide pressurized fluids to the wellhead;   a missile having one or more junctions, the missile and each of the one or more junctions having a throughbore that provide a pathway for the pressurized fluid to flow to the wellhead, each of the one or more junctions configured to receive the pressurized fluid from the one or more fracking pumps and direct the pressurized fluid to the pathway; and   an assembly to provide an overpressure relief of the pressurized fluid in the throughbore, the assembly including:
 a control module having a controller configured to receive and monitor a pressure signal and upon determination the pressure is above a predetermined threshold, send an output action to relieve the pressure in the throughbore; 
 a pressure relief choke valve having a body configured to be mounted to a first junction when installed, the body having an inlet configured to fluidly connect to the throughbore when installed, an outlet configured to be connected to an overpressure relief conduit, and a pressure sensing aperture extending from an inner surface to an outer surface of the body such that the pressure sensing aperture is configured to be exposed to the pressure within the throughbore of the first junction when in operation, the pressure relief choke valve configured to receive the output action from the control module to actuate the pressure relief choke valve from a closed position to a fully open position in less than about 0.2 seconds, thereby to prevent damage from overpressure in the hydraulic fracturing manifold system when the assembly is installed therein; and 
 a pressure transducer mounted to the pressure relief choke valve body and configured to receive the pressure from the pressure sensing aperture and transmit the pressure signal to the control module during operation. 
   
     
     
         27 . A method to relieve and bleed a hydraulic fracturing system from overpressure using choke valves, the method comprising:
 sensing a pressure of a throughbore positioned in a monobore missile at an inlet port of a pressure relief choke valve in a closed position with a pressure transducer mounted to the pressure relief choke valve to produce a pressure signal, the monobore missile having one or more monobore junctions, the pressure relief choke valve configured to mount to a first monobore junction, a bleed choke valve configured to mount to a second monobore junction different than the first monobore junction, the pressure relief choke valve having an actuator configured to drive a gate to fully retract from a seat within a body of the pressure relief choke valve after a determination of an overpressure;   transmitting the pressure signal to a control module configured to receive and monitor the pressure signal; and   evaluating whether the pressure signal is above a predetermined threshold, thereby to indicate a pressure that causes damage to associated hydraulic fracturing system equipment to be relieved, if so:
 sending an output action to the pressure relief choke valve and the bleed choke valve, thereby:
 (a) actuating the pressure relief choke valve to fully open in less than 0.4 seconds, thereby to relieve the pressure in the throughbore to prevent overpressure damage; and 
 (b) adjusting the bleed choke valve to partially open to controllably evacuate pressure or fluid from the throughbore. 
 
   
     
     
         28 . The method of  claim 27 , wherein a predetermined time interval lapses prior to adjusting a position of the bleed choke valve. 
     
     
         29 . The method of  claim 27 , wherein the controlled evacuation of the pressure or the fluid by the bleed choke valve comprises increasing an annulus size between a choke bean and a plug positioned on a distal end of a stem within the bleed choke valve, and wherein the bleed choke valve is opened in about 0.1 percentage intervals of a total bleed choke valve stroke distance. 
     
     
         30 . The method of  claim 27 , wherein the output action thrusts a hydraulic fluid to the associated choke valve fluidly connected to one or more hydraulic fluid sources positioned within the control module, and wherein the pressure relief choke valve and the bleed choke valve each have a linear piston actuator.