Methods and systems associated with an automated zipper manifold
An automated zipper manifold system for remotely monitoring and controlling valves between a mixing chamber and one or more wells. Each line includes a pair of valves, each with an actuator, position indicator, and pressure transducer. A computing device communicates with the valve modules to receive position and pressure data, determine valve states, and issue commands to open, close, or inject grease through dedicated lines. The system can automatically detect leaks, verify seals, and balance pressure within the manifold. A graphical user interface displays real-time valve and pressure data, allowing remote and simultaneous control of multiple valves. Automated routines may be executed to maintain valve performance, reduce non-productive time, and improve operational safety during fracturing or wireline operations.
1 . A zipper manifold comprising:
a mixing chamber;
a line extending from a block to a wellbore with hydrocarbons;
a first valve positioned on the line, the first valve including a first pressure transducer;
a first pressure transducer configured to determine a first pressure across the first valve, the first pressure transducer being positioned between the first valve on the line and the second valve on the line;
a second valve positioned on the line, the first valve and the second valve being positioned in series, the second valve including a second pressure transducer;
a second pressure transducer configured to determine a second pressure across the second valve, the second pressure transducer being positioned between the second valve on the line and the wellbore;
an indicator associated with the first valve configured to indicate that the first valve is in a closed position
a first grease line configured to supply grease to the first valve during the fracturing operation when it is determined that the first valve is leaking and not forming a full seal across the first valve based on the first pressure, wherein the supplied grease is utilized to form the full seal across the first valve during the fracturing operation.
2 . The zipper manifold of claim 1 , wherein the first grease line is configured to supply the grease to the first valve when the first valve is closed and the first pressure is above a first threshold.
3 . The zipper manifold of claim 2 , further comprising:
a first grease pressure transducer positioned between a grease reservoir and the first valve.
4 . The zipper manifold of claim 3 , wherein the first grease pressure transducer is configured to determine pressure data on the first grease line to verify that grease is being delivered on the first grease line.
5 . The zipper manifold of claim 4 , further comprising:
a first grease pump configured to communicate grease from the grease reservoir over the first line until the first grease pressure transducer indicates a grease pressure threshold is met.
6 . The zipper manifold of claim 3 , further comprising:
a second grease line configured to supply grease to the second valve, wherein the second grease line is configured to supply the grease to the second valve when the second valve is closed and the second pressure is above a second threshold.
7 . The zipper manifold of claim 6 , wherein the first threshold and the second threshold are different amounts.
8 . The zipper manifold of claim 6 , wherein the second grease line is configured to supply the grease to the second valve independently from the first grease line supplying the grease to the first valve.
9 . The zipper manifold of claim 6 , further comprising:
a second grease pressure transducer positioned between a grease reservoir and the second valve.
10 . A method of utilizing a zipper manifold, the method comprising:
performing a fracturing operation through a line utilizing a mixing chamber, the line extending from a block to a wellbore with hydrocarbons;
determining a first pressure across a first valve positioned on the line via a first pressure transducer during the fracturing operation, the first pressure transducer being positioned between the first valve on the line and the second valve on the line;
determining a second pressure across a second valve positioned on the line via a second pressure transducer during the fracturing operation, the first valve and the second valve being positioned in series, the second pressure transducer being positioned between the second valve on the line and the wellbore;
determining that an indicator associated with the first valve indicates that the first valve is in a closed position;
determining that the first valve is leaking and not forming a full seal based on the first pressure during the frac operation;
supplying grease to the first valve via a first grease line after determining that the first valve is in the closed position and leaking during the fracturing operation;
utilizing the supplied grease for the first valve to form the full seal during the fracturing operation.