Oilfield surface equipment cooling system
Systems and methods for cooling process equipment are provided. The system includes a process fluid source, and a heat exchanger fluidly coupled with the process equipment and the process fluid source. The heat exchanger is configured to receive a process fluid from the process fluid source and transfer heat from the process equipment to the process fluid. The system also includes a control system fluidly coupled with the heat exchanger. The control system is configured to vary a temperature of the process fluid heated in the heat exchanger. Further, at least a portion of the process fluid heated in the heat exchanger is delivered into a wellbore at a temperature below a boiling point of the process fluid.
1. A method for cooling process equipment, comprising:
receiving a process fluid from a process fluid source;
transferring heat from a process equipment to the process fluid, such that a heated process fluid is generated;
receiving at least a portion of the heated process fluid in a mixing assembly;
mixing one or more additives with the heated process fluid using the mixing assembly;
controlling a temperature of the heated process fluid, such that the heated process fluid is maintained in a range of temperatures, wherein a maximum of the range of temperatures is below a boiling point of the process fluid, wherein controlling the temperature of the heated process fluid comprises:
combining the at least a portion of the heated process fluid with additional process fluid having a lower temperature in response to determining that a temperature of the at least a portion of the heated process fluid upstream from the mixing assembly is above temperature threshold, such that a combined process fluid is produced having a temperature that is less than the temperature of the heated process fluid;
determining that the temperature of the combined process fluid is higher than the temperature threshold; and
increasing a flowrate of the process fluid having the lower temperature, or reducing a flowrate of the at least a portion of the heated process fluid, or both, so as to reduce the temperature of the combined process fluid upstream of the mixing assembly; and
delivering at least a portion of the heated process fluid into a wellbore.
2. The method of claim 1 , wherein controlling the temperature of the heated process fluid comprises:
combining, upstream from the mixing assembly, the at least a portion of the heated process fluid with additional process fluid from the process fluid source, such that a combined process fluid is produced having a temperature that is lower than a temperature of the at least a portion of the heated process fluid prior to the combining.
3. The method of claim 1 , wherein transferring heat from the process equipment to the process fluid comprises:
receiving a first portion of the process fluid in a first heat exchanger that is fluidly coupled with the mixing assembly, so as to transfer heat form the mixing assembly to the first portion of the process fluid;
receiving a second portion of the process fluid in a second heat exchanger that is fluidly coupled with a pump, so as to transfer heat from the pump to the second portion of the process fluid;
mixing at least some of the second portion of the process fluid with a gelling agent, using a mixing assembly positioned downstream from the second heat exchanger, such that a gelled process fluid is produced;
combining the gelled process fluid with at least some of the first portion of the process fluid, such that a diluted, gelled process fluid is produced; and
receiving the diluted, gelled process fluid into a tank.
4. The method of claim 3 , wherein controlling the temperature of the heated process fluid further comprises:
flowing back to the process fluid source at least some of the second portion of the process fluid downstream from the second heat exchanger and upstream of the mixing assembly; and
flowing back to the process fluid source some of the first portion of the process fluid downstream from the first heat exchanger and upstream of a point where the at least some of the first portion of the process fluid is combined with the gelled process fluid.
5. The method of claim 3 , further comprising transferring heat from the mixing assembly to the diluted, gelled process fluid in the tank.
6. The method of claim 1 , further comprising:
receiving the process fluid in a displacement tank; and
recirculating at least a portion of the heated process fluid to the displacement tank; and
mixing at least a portion of the heated process fluid with a cement, wherein delivering at least a portion of the heated process fluid into the wellbore comprises performing a cementing operation using the at least a portion of the heated process fluid.
7. The method of claim 1 , wherein delivering at least a portion of the heated process fluid into the wellbore comprises:
combining the heated process fluid with a gelling agent, a proppant, or both; and
performing a hydraulic fracturing operation using the heated process fluid.
8. A method for cooling process equipment, comprising:
receiving a process fluid from a process fluid source in a displacement tank;
transferring heat from a process equipment to the process fluid, such that a heated process fluid is generated;
mixing at least a portion of the heated process fluid with a cement;
recirculating at least a portion of the heated process fluid to the displacement tank;
controlling a temperature of the heated process fluid, such that the heated process fluid is maintained in a range of temperatures, wherein a maximum of the range of temperatures is below a boiling point of the process fluid; and
delivering at least a portion of the heated process fluid into a wellbore, wherein delivering at least a portion of the heated process fluid into the wellbore comprises performing a cementing operation using the at least a portion of the heated process fluid.
9. The method of claim 8 , further comprising:
receiving at least a portion of the heated process fluid in a mixing assembly; and
mixing one or more additives with the heated process fluid using the mixing assembly and wherein a maximum of the range of temperatures is below a boiling point of the process fluid.
10. The method of claim 9 , wherein controlling the temperature of the heated process fluid comprises:
combining, upstream from the mixing assembly, the at least a portion of the heated process fluid with additional process fluid from the process fluid source, such that a combined process fluid is produced having a temperature that is lower than a temperature of the at least a portion of the heated process fluid prior to the combining.
11. The method of claim 9 , wherein controlling the temperature of the heated process fluid comprises:
determining that a temperature of the at least a portion of the heated process fluid upstream from the mixing assembly is above temperature threshold; and
in response, combining the at least a portion of the heated process fluid with additional process fluid having a lower temperature, such that a combined process fluid is produced having a temperature that is less than the temperature of the heated process fluid.
12. The method of claim 11 , wherein controlling the temperature of the heated process fluid further comprises:
determining that the temperature of the combined process fluid is higher than the temperature threshold; and
increasing a flowrate of the process fluid having the lower temperature, or reducing a flowrate of the at least a portion of the heated process fluid, or both, so as to reduce the temperature of the combined process fluid upstream of the mixing assembly.
13. The method of claim 8 , wherein transferring heat from the process equipment to the process fluid comprises:
receiving a first portion of the process fluid in a first heat exchanger that is fluidly coupled with a mixing assembly, so as to transfer heat form the mixing assembly to the first portion of the process fluid;
receiving a second portion of the process fluid in a second heat exchanger that is fluidly coupled with a pump, so as to transfer heat from the pump to the second portion of the process fluid;
mixing at least some of the second portion of the process fluid with a gelling agent, using the mixing assembly positioned downstream from the second heat exchanger, such that a gelled process fluid is produced;
combining the gelled process fluid with at least some of the first portion of the process fluid, such that a diluted, gelled process fluid is produced; and
receiving the diluted, gelled process fluid into a tank.
14. The method of claim 13 , wherein controlling the temperature of the heated process fluid further comprises:
flowing back to the process fluid source at least some of the second portion of the process fluid downstream from the second heat exchanger and upstream of the mixing assembly; and
flowing back to the process fluid source some of the first portion of the process fluid downstream from the first heat exchanger and upstream of a point where the at least some of the first portion of the process fluid is combined with the gelled process fluid.
15. The method of claim 13 , further comprising transferring heat from the mixing assembly to the diluted, gelled process fluid in the tank.
16. The method of claim 8 , wherein delivering at least a portion of the heated process fluid into the wellbore comprises:
combining the heated process fluid with a gelling agent, a proppant, or both; and
performing a hydraulic fracturing operation using the heated process fluid.