Valves and control systems for pressure equalization and de-energization
A pressure control system configured to automatically monitor and control pressure in fluid lines used in hydraulic fracturing or well stimulation activities is disclosed. The system generally includes at least two valve assemblies each having a valve and a valve actuation system, at least one pressure sensor, and an electro-mechanical control package. These components are configured such that the electro-mechanical controls automate the open and closed positions of the valve(s) via operation of the actuator(s) based on user inputs and information from the pressure sensor. This architecture allows the system to monitor and interpret pressures within the conduit and operate the valve position based on user defined signals and set-points. The valves may be positioned to redundantly monitor the same fluid conduit, or separate fluid conduits, and the system may be configured to enable independent valve positions based on independent user defined set-points or user inputted control signals.
1. A system for pressure control in a fluid conduit, the system comprising:
at least two valve assemblies, each valve assembly comprising:
a valve actuation system including a source of actuation fluid, and
a valve housing having a longitudinal bore therethrough, and including an upstream connection, a downstream connection, and a valve positioned therebetween,
wherein the valve housing is positionable on a bypass conduit downstream from a connection point with a main conduit, and
wherein at least one of the valve assemblies is configured to restrict flow of a fluid in the bypass conduit; and
a control system in electronic communication with the valve actuation system and configured to receive an electronic signal related to a fluid pressure in the main conduit,
wherein the control system is configured to open the valve of either or both valve assemblies,
wherein the restricted flow of the fluid in the bypass line is produced by a flow restrictor positioned in a portion of the bypass line downstream or upstream from the at least one valve assembly or positioned in the downstream or upstream connection, and
wherein the flow restrictor comprises two or more individually actuatable ports that open to provide fluid flow through the flow restrictor; and a hydraulic port that opens a main port to provide fluid flow that bypasses the individually actuatable ports.
2. The system of claim 1 , further comprising a pressure sensor configured to detect the fluid pressure in the main conduit, wherein the electronic signal related to the fluid pressure in the main conduit is received from the pressure sensor, from a pressure sensor on another system, from user input, or from a combination thereof.
3. The system of claim 2 , wherein the pressure sensor comprises:
at least one pressure transducer positioned in a main housing of the system, and
a pressure chamber having a deformable diaphragm contacting a pressure fluid within the pressure chamber,
wherein the pressure fluid is fluidly connected to the at least one pressure transducer to transfer an external fluid pressure on the deformable diaphragm to the at least one pressure transducers, and
wherein the pressure chamber is configured to be positioned on the main conduit line such that the fluid pressure in the main conduit line comprises the external fluid pressure on the diaphragm.
4. The system of claim 2 , wherein the pressure sensor comprises:
a sensor body comprising an inlet end, an outlet end, and central bore therebetween;
a pressure chamber having a deformable diaphragm contacting a pressure fluid within the pressure chamber; and
at least one pressure transducer fluidly connected to the pressure chamber,
wherein the sensor body is positioned in-line on a conduit such the deformable diaphragm of the pressure chamber registers a fluid pressure in the conduit and transfers that fluid pressure to the at least one pressure transducer via the pressure fluid.
5. The system of claim 4 , wherein the central bore of the sensor body comprises an inner wall between the inlet end and the outlet end, wherein the deformable diaphragm forms at least a portion of the inner wall.
6. The system of claim 4 , wherein the deformable diaphragm forms all or a portion of an inner wall of the central bore of the sensor body.
7. The system of claim 3 , wherein the pressure sensor comprises at least two pressure transducers.
8. The system of claim 7 , wherein the signal indicating the fluid pressure in the main conduit is from the pressure sensor and comprises individual signals from two or more pressure transducers, and wherein the individual signals are received at a rate of at least 50 signals/second.
9. The system of claim 3 , wherein the pressure sensor comprises three pressure transducers.
10. The system of claim 3 , wherein the pressure chamber is attachable on the main conduit such that the fluid pressure in the main conduit comprises the external fluid pressure on the diaphragm.
11. The system of claim 1 , wherein the control system opens the valve of at least one valve assembly upon receiving an initiation signal, wherein the initiation signal is sent by a user from a remote system, input on an input device of the control system, or based on the electronic signal related to the fluid pressure in the main conduit.
12. The system of claim 1 , wherein the control system opens the valve of at least one valve assembly when the fluid pressure in the main conduit exceeds a user-defined high-pressure limit.
13. The system of claim 12 , wherein the control system is configured to hold the valve of the at least one valve assembly open for a set time period, and if, after the set time period, the fluid pressure in the main conduit is at or below the user-defined low pressure limit, the control system is configured to close the valve.
14. The system of claim 1 , wherein the flow restrictor comprises perforations that allow the restricted flow of the fluid to pass at a reduced flow rate.
15. The system according to claim 14 , wherein the flow restrictor comprises an insert comprising the perforations.
16. The system of claim 1 , wherein the flow restrictor comprises two or more individually actuatable ports that open to provide fluid flow through the flow restrictor.
17. The system of claim 1 , wherein the valve comprises a ball valve having:
a ball having a throughbore, wherein an open position of the ball provides flow-through alignment of the throughbore with the upstream and downstream connections of the valve housing, and a closed position of the ball provides an out of flow-through alignment of the throughbore with the upstream and downstream connections of the valve housing,
an upstream seat comprising an outward facing surface positioned perpendicular to the longitudinal bore of the valve housing, wherein a fluid pressure on the outward facing surface forces the upstream seat against a sealing face of the ball, and
a downstream seat.
18. The system of claim 1 , wherein the valve comprises a rotary valve.
19. A system for pressure control in a fluid conduit, the system comprising:
at least two valve assemblies, each valve assembly comprising:
a valve actuation system including a source of actuation fluid, and
a valve housing having a longitudinal bore therethrough, and including an upstream connection, a downstream connection, and a valve positioned therebetween,
wherein the valve housing is positionable on a bypass conduit downstream from a connection point with a main conduit, and
wherein at least one of the valve assemblies is configured to restrict flow of a fluid in the bypass conduit; and
a control system in electronic communication with the valve actuation system and configured to receive an electronic signal related to a fluid pressure in the main conduit,
wherein the control system is configured to open the valve of either or both valve assemblies,
wherein the restricted flow of the fluid in the bypass line is produced by a flow restrictor positioned in a portion of the bypass line downstream or upstream from the at least one valve assembly or positioned in the downstream or upstream connection, and
wherein the flow restrictor allows fluid flow in either direction, wherein the fluid flow in a first direction is restricted by perforations that allow fluid to pass at a reduced flow rate, and the fluid flow in a second opposite direction is restricted by a valve plug and a spring such that fluid pressure on the valve plug forces compression of the spring and opening of the valve plug to allow fluid to flow in the second direction.
20. The system of claim 19 , wherein the valve comprises a rotary valve.
21. The system of claim 19 , further comprising a pressure sensor configured to detect the fluid pressure in the main conduit, wherein the electronic signal related to the fluid pressure in the main conduit is received from the pressure sensor, from a pressure sensor on another system, from user input, or from a combination thereof.
22. The system of claim 21 , wherein the pressure sensor comprises:
at least one pressure transducer positioned in a main housing of the system, and
a pressure chamber having a deformable diaphragm contacting a pressure fluid within the pressure chamber,
wherein the pressure fluid is fluidly connected to the at least one pressure transducer to transfer an external fluid pressure on the deformable diaphragm to the at least two pressure transducers, and
wherein the pressure chamber is configured to be positioned on the main conduit line such that the fluid pressure in the main conduit line comprises the external fluid pressure on the diaphragm.
23. The system of claim 21 , wherein the pressure sensor comprises:
a sensor body comprising an inlet end, an outlet out, and central bore therebetween;
a pressure chamber having a deformable diaphragm contacting a pressure fluid within the pressure chamber; and
at least one pressure transducer fluidly connected to the pressure chamber,
wherein the sensor body is positioned in-line on a conduit such the deformable diaphragm of the pressure chamber registers a fluid pressure in the conduit and transfers that fluid pressure to the at least one pressure transducer via the pressure fluid.
24. The system of claim 23 , wherein the central bore of the sensor body comprises an inner wall between the inlet end and the outlet end, wherein the deformable diaphragm forms at least a portion of the inner wall.
25. The system of claim 23 , wherein the deformable diaphragm forms all or a portion of an inner wall of the central bore of the sensor body.