As oilfield companies seek additional ways to carve out new efficiencies and cost savings, linear pressure control infrastructure is overtaking conventional configurations as a method for securing such gains.
TYLER RICE, SPM™ Oil & Gas
Pressure pumping operations have long focused on horsepower and pumping capacity as the primary drivers of completion efficiency. However, pressure control infrastructure—the flow iron, valves and manifold systems that manage high-pressure fluids across a frac site—is equally critical for operational performance, as well as site safety. Traditional frac site configurations feature manifold trailers, with flow iron routed in multiple directions, creating complex networks of connections and directional changes, as well as a significant number of individual iron components. Each threaded connection represents a potential leak path, while internal component wear accelerates with every turn, resulting in costly nonproductive time (NPT) when failures occur.
As completion strategies evolved from single-well operations to multi-well pad configurations in the mid-2010s, the limitations of conventional pressure control became more pronounced. Traditional 3-in. or 4-in. steel pipes encounter abrasive proppant, cyclic high-pressure fatigue, corrosion and chemically aggressive fracturing fluids that can lead to unplanned repairs that halt pumping operations. The maze of ground iron creates trip hazards for personnel working in these high-pressure environments. For oilfield companies with rental fleets, these challenges can be exacerbated by inconsistent maintenance histories, which can increase the downtime needed for inspection and repair.
Multi-well pads benefit from a different pressure control approach. Linear flow architecture and automation are transforming what was recently considered novel into baseline operational practice. A linear pressure control configuration streamlines a site’s infrastructure by consolidating complex manifold systems into simplified flow paths, while automation technologies further remove personnel from hazardous zones and improve operational productivity, Fig. 1.
IMPROVED OPERATIONAL EFFICIENCY
For oilfield companies seeking faster pad transitions, reduced maintenance requirements and greater site safety, a linear system, such as the SPM Simplified Iron System, fundamentally changes the layout of a frac site to create a streamlined architecture capable of supporting those goals. Pre-assembled modular skids enable frac crews to quickly position equipment, connect it and then begin pumping. By eliminating the need to connect dozens of various lengths of iron pipe, rig-up can occur within hours, rather than days. This not only promotes faster pad-move cycles but also decreases associated labor, equipment, fuel standby, and other costs.
As the system’s single large-bore design reduces the total number of connections by more than 80%, NPT can be decreased.1 Having fewer connections allows crews to minimize the amount of time traditionally spent tightening and testing those connections. The reduced number of connections also significantly decreases the number of potential leak paths.
Employing a linear pressure control methodology supports today’s near-continuous operating demands and empowers pressure pumpers to maintain uptime for consecutive days, to attain truly sustained operations. For companies seeking to maximize pumping time or leverage a simul-frac strategy, linear pressure control configurations help optimize the number of stages completed each day.
These efficiency gains have an impact on the bottom line. Decreasing well completion times from more than 30 days to 14 days by maintaining operations during maintenance activities, rather than requiring the complete shutdowns mandated by conventional pressure control approaches, can help promote a 50% improvement in completion time.2 This operational transformation demonstrates how linear pressure control methods support the continuous pumping strategies of top fleets.
MINIMIZED MAINTENANCE
A linear pressure control approach also provides maintenance and reliability benefits. Using oversized bore diameters, like SPM Simplified Frac Iron, allows fluids to be transported at lower velocities, when compared to traditional small-bore configurations. This shift lowers the amount of internal wear and erosion generated by abrasive proppants, which helps extend component service life. This increased component longevity not only helps reduce maintenance requirements, but it also reduces OpEx.
The advanced gate valve technologies integrated within these systems eliminate the typical greasing required during hydraulic fracturing operations, which reduces downtime, as well as the labor and grease costs per job. Additionally, using API flanges and clamp hub style connections offers a more robust and reliable seal that lowers not only failure risks but also the traditional maintenance associated with legacy flow iron.
ENHANCED SITE SAFETY
Linear systems reduce site hazards, promoting crew safety in high-pressure environments. As a result of the minimal connections required by a linear system, oilfield companies can create a smaller wellsite footprint. This significantly reduces the trip hazards encountered on conventional sites.
Decreasing the amount of ground iron streamlines a site and reduces the amount of times that crew members must enter the “red zone.” As safety is a paramount concern in the oil field, minimizing exposure to high-risk areas is a welcome advancement.
Complementing linear infrastructure, automated relief valve technologies like the SPM SafeEdge™ ARC address both safety imperatives and operational efficiency by enabling remote pressure control management. For simul-frac configurations, the ability to control multiple relief valves at different pressures through a single controller eliminates the need to deploy separate control systems for each valve. As a result, manual valve operation in high-pressure zones is unnecessary.
This technology proved advantageous for an oilfield services company operating a six-well pad in South Texas, where the simul-frac completions technique was used. Treating line-pressure triggers saw a five-millisecond response time, compared to the 40-millisecond response times of alternative methods.3 This rapid response capability can determine whether a pressure spike necessitates complete iron inspection, resulting in a minimum four-day shutdown, or allows continued pumping operations.
Pairing relief valve automation with a linear pressure control configuration provides added safeguards, which help oilfield companies optimize the safety and efficiency benefits of this approach. With this strategic combination of technologies, companies can increase operational uptime, reliability and job site safety while reducing NPT.
A STRAIGHT LINE TO GREATER GAINS IN THE FIELD
As oilfield companies seek to support near-continuous pumping activity in a cost-effective manner, the adoption of linear pressure control systems continues to expand globally. With fewer leak paths, fewer connections to replace, fewer flow issues, reduced wear, reduced hazards and more robust connections, the linear methodology demonstrates clear operational, maintenance and safety advantages.
Linear pressure control infrastructure is field-proven to maximize frac spread utilization through faster pad transitions, enabling increased pumping hours. Additionally, the modular design of a linear iron method supports the complex logistics needed to successfully execute a simul-frac strategy. For companies determined to maximize frac pad efficiencies amid evolving operational demands, linear methodologies represent a reliable path to enhanced efficiency. Furthermore, advanced frac site automation technologies can add another layer of safety and solutions for the completions industry. WO
REFERENCES
SPM Oil & Gas, “One Straight Line, One Healthy Bottom Line.” https://s7d2.scene7.com/is/content/Caterpillar/CM20210609-cf8fe-885a5#:~:text=THE%20INNOVATION,iron%20and%20other%20tripping%20hazards.
SPM Oil & Gas, “SPM Pressure Control Solutions: Breaking from Tradition.” https://www.spmoilandgas.com/en_US/resources/blog/spm-pressure-control-solutions-breaking-from-tradition.html.
SPM Oil & Gas, “SPM® SafeEdge™ ARC System Reduces Costs and NPT in South Texas.” https://s7d2.scene7.com/is/content/Caterpillar/CM20210609-d0114-b13e9.
TYLER D. RICE has worked in the oil and gas industry for more than 20 years in several key basins. Throughout his career, he has held diverse roles across multiple functional areas, including operations, project management, sales and new product development. Mr. Rice resides in the Permian basin area, serving as the pressure control technologies champion at SPM Oil & Gas. In this role, he focuses on bringing deep knowledge, executing business development and product strategy, and driving market growth.