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Eliminate 88% of potential leak paths on your frac site

Simplifying the Frac Site

With an innovative linear, large-bore design, a recent configuration of Weir’s Simplified Frac Iron System dramatically reduced iron, connections, hazards, and costs for an operator in Canada.

The System

While traditional frac sites feature numerous iron strings with angled flow paths, the pressure control components of the Weir Oil & Gas’ Simplified Frac Iron System feature a single, large-bore linear design. Components of this system include the Weir Vertical Zipper Manifold, the patent-pending Weir One Straight Line (OSL) Frac Connection, and the Weir Frac Stack.

In this configuration, the number of required pipe connections is reduced from 100 to 12, eliminating the potential for leak paths by 88% (rig site set-up will vary total reduction). Throughout the design, Weir uses standard API-6A connections, which minimize interchangeability issues, feature a reliable metal-seal gasket, and rarely require tightening in the field.

Collectively, this system is designed to improve safety and performance, minimize pressure-drop and erosion–thus extending equipment life–and reduce non-productive time, rig-up time, and material and labor costs.

The Challenge

Weir’s simplified system that included a configuration of the Weir Vertical Zipper Manifold, the patent-pending Weir One Straight Line (OSL) Frac Connection, and the Weir Frac Stack using gate valves was initially put to the test in Canada by an independent operator whose previous installation had failed after three days. The equipment, a competitor’s version of a single-line zipper tie-in, had completed only ten stages and had to be completely dismantled. A trial version of Weir’s system was subsequently installed on two wells, at 40 stages per well. Fracking commenced, averaging a flow rate of 12 m3/minute at 11,750 psi.

Prior to operation, a Computational Fluid Dynamics (CFD) analysis was conducted to predict equipment erosion. When compared to analyses of similar designs, Weir’s system estimated approximately 70% less wear and 900 psi less pressure drop. The reduction was attributed to the straight-path design, which helped to minimize fluid turbulence and friction.

The analysis showed that the estimated erosion of the 5” tie-in pipeline would only be 0.003” during the single-well frac. The 7” trunk line erosion would only be 0.004” throughout the entire five-well frac program, and the 7” cross in the trunk line was estimated to erode by a mere 0.039”–all acceptable rates in today’s conditions.

These findings also predicted a reduction in the horsepower required to drive the pumps, giving the Weir configuration an estimated power savings over leading competitors. The reduction in line losses would also help ensure that pump pressure measured at the surface would more accurately reflect what was delivered into the formation.

During maintenance shutdowns, an Ultrasonic Thickness Survey (UTS) was also conducted, indicating very little erosion on any of the components–approximately 12% of allowable limits.

The Result

After 14 days, this configuration of Weir’s system completed all 80 frac stages with minimal pipe wear. Overall, the system lasted more than three times longer than the previous installation. While delivering greater performance, it minimized risks, non-productive time, rig-up time, iron, connections, and costs—demonstrating a clear advantage over traditional iron configurations and current single-line alternatives.

Fit-for-purpose and ideal for demanding applications, Weir’s Simplified Frac Iron System can be used for any well and tailored to any condition. Equipment is available for rent, fully inspected and re-certified after every job.

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