1111111111111111 IIIIII IIIII 1111111111 11111 lllll lllll lllll 111111111111111 1111111111 11111111
`US 20200149389Al
`
`c19) United States
`c12) Patent Application Publication
`Al-Salmani et al.
`
`c10) Pub. No.: US 2020/0149389 Al
`May 14, 2020
`(43) Pub. Date:
`
`(54) SURFACE COMPLETION SYSTEM FOR
`OPERATIONS AND MONITORING
`
`(71) Applicant: GE Oil & Gas Pressure Control LP,
`Houston, TX (US)
`
`(72)
`
`Inventors: Zeyad Al-Salmani, Calgary (CA);
`Jason Williams, Calgary (CA);
`Saurabh Kajaria, Houston, TX (US)
`
`(73) Assignee: GE Oil & Gas Pressure Control LP,
`Houston, TX (US)
`
`(21) Appl. No.: 16/681,314
`
`(22) Filed:
`
`Nov. 12, 2019
`
`Related U.S. Application Data
`
`(60) Provisional application No. 62/760,719, filed on Nov.
`13, 2018.
`
`Publication Classification
`
`(51)
`
`(52)
`
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`
`Int. Cl.
`E21B 47109
`E21B 34102
`E21B 47106
`E21B 41100
`U.S. Cl.
`CPC .......... E21B 47109 (2013.01); E21B 4110092
`(2013.01); E21B 47106 (2013.01); E21B 34102
`(2013.01)
`
`ABSTRACT
`(57)
`A wellhead monitoring system includes a conversion assem(cid:173)
`bly, the conversion assembly including an actuator element
`for modifying an operating mode of a valve from manual to
`remote. The system also includes one or more sensors,
`associated at least one of a fracturing tree or the conversion
`assembly, the one or more sensors obtaining wellhead oper(cid:173)
`ating conditions. The system further includes a control unit,
`adapted to receive information from the one or more sensors,
`the control unit presenting the information, on a display, and
`transmitting the information to a remote system for analysis.
`
`108
`
`----:-102
`
`202
`
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`Patent Application Publication May 14, 2020 Sheet 1 of 10
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`US 2020/0149389 Al
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`/100
`
`1 0 2~ - - - - -
`
`/ i
`
`104
`
`106
`
`106
`
`110
`
`FIG. 1
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`Patent Application Publication May 14, 2020 Sheet 2 of 10
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`US 2020/0149389 Al
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`112
`
`106
`
`108
`
`110
`
`-----:-102
`
`202
`
`-----.;.._ 200
`
`FIG. 2
`
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`Patent Application Publication May 14, 2020 Sheet 3 of 10
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`Patent Application Publication May 14, 2020 Sheet 4 of 10
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`Patent Application Publication May 14, 2020 Sheet 5 of 10
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`US 2020/0149389 Al
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`Patent Application Publication May 14, 2020 Sheet 6 of 10
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`L--------------
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`
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`

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`Position 1 Open
`Position 1 Close YES
`WellHead 4 Valve Data
`Sensor 5
`0.31 MPa
`Sensor 4
`0.47 MPa
`Sensor 3
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`
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`
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`Position 1 Close I YES I
`WellHead 3 Valve Data
`Sensor 5
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`IWS EXHIBIT 1020
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`

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`
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`

`Patent Application Publication May 14, 2020 Sheet 9 of 10
`
`US 2020/0149389 Al
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`IWS EXHIBIT 1020
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`

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`
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`
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`
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`

`US 2020/0149389 Al
`
`May 14, 2020
`
`1
`
`SURFACE COMPLETION SYSTEM FOR
`OPERATIONS AND MONITORING
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`[0001] This application claims priority to and the benefit
`of co-pending U.S. Provisional Application Ser. No. 62/760,
`719 filed Nov. 13, 2018 titled "OPTIMIZING AND MONI(cid:173)
`TORING SURFACE FRAC EQUIPMENT," the full disclo(cid:173)
`sure of which is hereby incorporated herein by reference in
`their entirety for all purposes.
`
`BACKGROUND
`
`1. Field of Invention
`[0002] This disclosure relates in general to oil and gas
`tools, and in particular, to systems and methods for moni(cid:173)
`toring and controlling surface completion operations.
`
`2. Description of the Prior Art
`
`[0003] Certain oil and gas operations, such as fracturing
`operations, may utilize a variety of surface valves and
`components in order to control various downhole opera(cid:173)
`tions. For example, surface valves may be cycled to enable
`different equipment to pass into well bores ( e.g., frac balls,
`wireline, etc.). There may be many operations ongoing at
`one time at the well site, and even a particular pad, and as
`a result monitoring and recording each operation may be
`challenging. Moreover, manually operated valves may be
`positioned within high pressure areas, thereby preventing
`undesirable working conditions. Because oil and gas opera(cid:173)
`tions often utilize rented equipment, it is important that
`operations are conducted efficiently and that wells are not
`subject to large amounts of "non-productive time" (NPT)
`where the well sits idle. The undesirable conditions, as well
`as multiple operations continuing at the same time, may
`increase NPT at well sites, thereby reducing profitability.
`
`SUMMARY
`[0004] Applicant recognized the problems noted above
`herein and conceived and developed embodiments of sys(cid:173)
`tems and methods, according to the present disclosure, for
`operating electric powered fracturing pumps.
`[0005]
`In an embodiment, a wellhead monitoring system
`includes a conversion assembly, the conversion assembly
`including an actuator element for modifying an operating
`mode of a valve from manual to remote. The system also
`includes one or more sensors, associated at least one of a
`fracturing tree or the conversion assembly, the one or more
`sensors obtaining wellhead operating conditions. The sys(cid:173)
`tem further includes a control unit, adapted to receive
`information from the one or more sensors, the control unit
`presenting the information, on a display, and transmitting the
`information to a remote system for analysis.
`[0006]
`In an embodiment, a wellhead monitoring system
`includes a pressure sensor arranged at a fracturing tree, the
`pressure sensor being communicatively coupled to a control
`unit. The system also includes a valve position sensor
`arranged at a valve of the fracturing tree, the valve position
`sensor being communicatively coupled to the control unit.
`The system also includes an actuator unit, coupled to the
`valve, the actuator unit controlling operation of the valve to
`transition the valve between an open position and a closed
`
`position. The control unit is arranged at a location remote
`from the fracturing tree and outside of a pressure zone, the
`control unit collecting information from the pressure sensor
`and the valve sensor, the control unit further operable to
`drive movement of the valve via the actuator unit.
`[0007]
`In an embodiment, a method for monitoring opera(cid:173)
`tions at a well sit includes receiving, from a pressure sensor,
`pressure information for a fracturing tree, the pressure
`information indicative of an operational stage. The method
`also includes receiving, from a valve position sensor, valve
`position information for a valve of a fracturing tree, the
`valve being moveable between an open position and a closed
`position, the valve information being indicative of the opera(cid:173)
`tional stage. The method further includes determining, based
`at least in part on the pressure information and the valve
`position information, a current status of a wellhead. The
`method also includes determining, based at least in part on
`the current status of the wellhead, time information of the
`wellhead, the time information identifying different opera(cid:173)
`tional stages of the wellhead over a period of time.
`[0008]
`In embodiments, a wellhead monitoring system
`includes at least one of a pressure sensor or a valve position
`sensor, communicatively coupled to a control system, the at
`least one of the pressure sensor or the valve position sensor
`transmitting information indicative of a wellbore operation
`to the control unit. Additionally, the system includes the
`control system, executing, via a processor, an algorithm
`stored on non-transitory memory. The control system
`includes receiving, from the at least one of the pressure
`sensor or the valve position sensor, first information indica(cid:173)
`tive of the wellbore operation. Additionally, the control
`system includes determining, based at least in part on the
`first information, a first status of the wellhead. The control
`system also includes determining, based at least in part on
`the first information, a first time of the first status. The
`control system further includes receiving, from the at least
`one of the pressure sensor or the valve position sensor,
`second information indicative of the wellbore operation. The
`control system also includes determining, based at least in
`part on the second information, a second time of the second
`status. The control system includes determining, based at
`least in part on a difference between the first status and the
`second status, a working time for the wellbore operation.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`[0009] The present technology will be better understood
`on reading the following detailed description of non-limiting
`embodiments thereof, and on examining the accompanying
`drawings, in which:
`[0010] FIG. 1 is a perspective view of an embodiment of
`a frac tree with a conversion assembly, in accordance with
`embodiments of the present disclosure;
`[0011] FIG. 2 is a perspective view of an embodiment of
`a frac tree with a conversion assembly, in accordance with
`embodiments of the present disclosure;
`[0012] FIG. 3 is a perspective view of an embodiment of
`a frac tree with a conversion assembly, in accordance with
`embodiments of the present disclosure;
`[0013] FIG. 4 is a perspective view of an embodiment of
`a control panel, in accordance with embodiments of the
`present disclosure;
`[0014] FIG. 5 is a perspective view of an embodiment of
`a control unit, in accordance with embodiments of the
`present disclosure;
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`2
`
`[0015] FIG. 6 is a perspective view of an embodiment of
`a control unit, in accordance with embodiments of the
`present disclosure;
`[0016] FIG. 7 is a perspective view of an embodiment of
`an interface, in accordance with embodiments of the present
`disclosure;
`[0017] FIG. 8 is a schematic view of an embodiment of a
`well system, in accordance with embodiments of the present
`disclosure;
`[0018] FIG. 9 is a schematic view of an embodiment of an
`interface, in accordance with embodiments of the present
`disclosure; and
`[0019] FIG. 10 is a schematic view of an embodiment of
`an interface, in accordance with embodiments of the present
`disclosure.
`
`DETAILED DESCRIPTION OF THE
`INVENTION
`
`[0020] The foregoing aspects, features and advantages of
`the present technology will be further appreciated when
`considered with reference to the following description of
`preferred embodiments and accompanying drawings,
`wherein like reference numerals represent like elements. In
`describing the preferred embodiments of the technology
`illustrated in the appended drawings, specific terminology
`will be used for the sake of clarity. The present technology,
`however, is not intended to be limited to the specific terms
`used, and it is to be understood that each specific term
`includes equivalents that operate in a similar manner to
`accomplish a similar purpose.
`[0021] When introducing elements of various embodi(cid:173)
`ments of the present invention, the articles "a," "an," "the,"
`and "said" are intended to mean that there are one or more
`of the elements. The terms "comprising," "including," and
`"having" are intended to be inclusive and mean that there
`may be additional elements other than the listed elements.
`Any examples of operating parameters and/or environmen(cid:173)
`tal conditions are not exclusive of other parameters/condi(cid:173)
`tions of the disclosed embodiments. Additionally, it should
`be understood that references to "one embodiment", "an
`embodiment", "certain embodiments," or "other embodi(cid:173)
`ments" of the present invention are not intended to be
`interpreted as excluding the existence of additional embodi(cid:173)
`ments that also incorporate the recited features. Further(cid:173)
`more, reference to terms such as "above," "below," "upper",
`"lower", "side", "front," "back," or other terms regarding
`orientation are made with reference to the illustrated
`embodiments and are not intended to be limiting or exclude
`other orientations.
`[0022] Embodiments of the present disclosure are directed
`toward, among other things, improving efficiency of frac(cid:173)
`turing operations. For example, fracturing operations may be
`approximately 60 percent efficient, thereby costing operators
`significant amounts of money in order to complete opera(cid:173)
`tions. One problem stems from having multiple vendors on
`site performing a variety of different tasks, and as a result,
`non-productive time (NPT) may be difficult to track for all
`of the vendors. This is a significant problem, as an hour of
`NPT may cost operators approximately $10,000. Accord(cid:173)
`ingly, it is important for operators to be able to identify and
`track NPT to develop solutions. Furthermore, safety is
`important at the well site. Fracturing operations may be
`conducted in harsh environments under high pressures, and
`as a result, continuous monitoring of valve positions and
`
`wellbore pressure may enable safer operations. Often, pres(cid:173)
`sure is not monitored at a frac tree, as customers may be
`resistant to having their pressure readings located there,
`since visual verification would lead to an employee getting
`close to the frac tree, which may be under pressure. Systems
`and methods of the present disclosure address these prob(cid:173)
`lems by tracking NPT, along with providing continuous
`monitoring of pressure and valve positions. The pressure and
`valve position monitoring may be conducted at a remote
`location, thereby improving safety at the well site. In certain
`embodiments, the information collected may be provided on
`a visual interface to the operators.
`[0023] Embodiments of the present disclosure include
`conversion assemblies that may convert a manually operated
`valve into a remotely operated valve. In embodiments,
`remote operation is enabled by providing an actuator that
`couples to a manually operated valve without taking the
`valve out of service. For example, the conversion assembly
`may include a frame for securing the actuator to the valve
`body and an interface for engaging one or more components
`of the valve, such as a gate or valve stem. In various
`embodiments, the actuator may be driven by a pneumatic
`source, an electrical source, a hydraulic source, or any other
`reasonable source. Often, these sources are already present
`at the well site, and as a result, integration of the conversion
`assembly into the well site may be simple, thereby lowering
`a barrier of entry to use. In various embodiments, the
`conversion assembly includes a position sensor, which may
`be indicative of a position of the valve. For example, the
`position assembly may determine whether the valve is in a
`closed position, an open position, or an intermediate posi(cid:173)
`tion. The conversion assemblies may be remotely operated,
`for example from a remotely positioned control panel, such
`that operators will not be arranged within a pressure zone of
`the frac tree (e.g., an area surrounding the frac tree that may
`be susceptible to damage or health hazards). As a result,
`operators may continue to remotely operate the valves while
`keeping personnel away from the frac tree.
`[0024]
`In various embodiments of the present disclosure,
`one or more pressure sensors may be incorporated into the
`frac tree in order to facilitate remote monitoring and control
`of the fracturing site. By way of example, the pressure
`sensors may be communicatively coupled to the control
`panel, which may include a display to relay information
`from the pressure sensors to the operator. As a result, the
`operator may be able to evaluate a particular mode or stage
`within the fracturing operation, which may drive additional
`operations. For example, an indication oflow pressure or no
`pressure within a portion of the well may illustrate a well
`that is blocked in.
`[0025] Embodiments of the present disclosure may further
`provide systems and methods for monitoring and tracking
`operations at the well site in order to improve efficiencies by
`determining operational stages at the well site. For example,
`systems and methods may track non-productive time (NPT)
`at the well site to determine when operators are at the site,
`but not performing certain duties due to one or more other
`situations at the well site. As an example, if a first operator
`is a pressure pumper, that operator may not be able to
`perform pumping operations until a second operation, which
`may be a sand supplier, provides sand to form the slurry that
`is injected during a fracturing operation. As a result, it may
`not be economical for the well site operator to have the first
`operator at the site until the sand has been delivered.
`
`IWS EXHIBIT 1020
`
`EX_1020_013
`
`

`

`US 2020/0149389 Al
`
`May 14, 2020
`
`3
`
`Additionally, certain operators may not be able to perform
`their duties during pumping operations, and as a result,
`having them on site during pumping may cost the well site
`operator unnecessary money. Accordingly, embodiments of
`the present disclosure may track operations at the site in
`order to identify various stages, which may be useful in
`recognizing efficiencies at the well site and/or for deploying
`different crews to the well site. For example, if the well site
`operator can determine that the well site will be ready for
`pressure pumping in 2 days, the well site operator may plan
`for the pressure pumper to arrive at that time, rather than
`having the pressure pumper arrive earlier and/or later.
`[0026] Various embodiments describe a user interface and
`display module for presenting information, for example at
`the control panel, for operators to track and monitor well site
`operations. In various embodiments, systems and methods
`may include a software application, which may be locally
`hosted or part of a distributing computing offered ( e.g.,
`Software as a Service) to monitor and optimize operations
`by minimizing operational uncertainty, capturing NPT,
`reducing unplanned outages, and improving safety. The
`system may include real time monitoring and recording of
`events, secure and efficient management of operations data,
`and a visualization interface to stream live operations data.
`As a result, owner and operators can determine leaks and
`pressures spikes to improve operational efficiency, ensure
`reliable and optimized operation through real time opera(cid:173)
`tional data analytics, including information on NPT, enhance
`operational safety and minimize operational uncertainty by
`adjacent well monitoring and erosion monitoring, and pre(cid:173)
`pare detailed pad report summaries. In various embodi(cid:173)
`ments, machine learning systems may also be incorporated
`in order to provide predictive analytics. By way of example
`only, machine learning systems may identify certain char(cid:173)
`acteristics of a fracturing operation, such as formation
`properties, and correlate those to pumping information in
`order to predict potential breakthroughs and the like. The
`system may utilize this information to provide notifications
`of upcoming events, thereby enabling operators to plan
`ahead in a proactive, rather than reactive, manner.
`[0027] FIGS. 1-10 describe various embodiments of sys(cid:173)
`tems and methods for controlling and monitoring well
`operations, for example during completion operations at a
`fracturing site. In various embodiments, systems may
`include one or more assemblies to convert manually actu(cid:173)
`ated valves into remotely controllable valves, for example,
`via hydraulic, pneumatic, electric, or other actuation
`devices. The assemblies may include a valve frame ( e.g.,
`actuation frame, actuator frame) that couples to a stem of an
`existing valve, for example as part of a frac stack or frac tree
`(e.g., a collection of valves and piping at a surface location
`of a fracturing operation). The frame may be mounted to the
`exiting valve, for example in the field, and may also be field
`removable. The actuator on the frame may be remotely
`controllable, for example via a control system or control
`panel, and therefore operators may not enter the pressure
`zone around the fracturing operation. In various embodi(cid:173)
`ments, the valve frame may also couple to actuated valves.
`[0028] Various embodiments of the present disclosure
`include one or more sensors associated with the assembly
`and/or the valve frames. For example, the sensor may be a
`position indicator that determines whether the valve is in an
`open position or a closed position. In various embodiments,
`the sensor may evaluate a position of the valve stem to
`
`determine whether the valve is in an open position or a
`closed position. Additionally, in other embodiments, the
`sensor may evaluate a pressure ( e.g., a hydraulic pressure, a
`pneumatic pressure) within a chamber of the actuator to
`determine whether the valve is in the closed position or the
`open position. It should be appreciated that various sensor
`arrangements may be incorporated into the assembly and/or
`valve frame in order to monitor a position of the valve.
`[0029]
`In various embodiments, additional sensors may
`further be incorporated into the assembly to evaluate one or
`more properties of the frac tree and/or ongoing wellbore
`operations. For example, the additional sensors may be
`pressure transducers that determine a wellbore pressure at
`various times. The wellbore pressure may be indicative of an
`ongoing operation within the wellbore. For example, a
`pressure pumping operation would result in high pressure,
`due to the pressure of the fluid injected into the well to
`enable hydraulic fracturing. However, a low pressure may be
`indicative of a shut in well or other wellbore operation.
`[0030] Embodiments of the pressure disclosure may also
`include a software system to monitor information from the
`wellbore, the assembly, user input information, or the like to
`determine or more properties associated with the wellbore.
`For example, the output from the position sensor may be
`indicative of what stage of operation the wellbore is in
`because multiple cycles of the valve may be indicative of
`certain operations. Additionally, in embodiments, the pres(cid:173)
`sure may also be indicative of the operation. Furthermore,
`the software system may enable user inputs to provide
`information, such as the vendor currently in operation, start
`times, and the like. Accordingly, the system may identify
`certain event types and also maintain a count of the events.
`Combination of information may be utilized to compute
`non-productive time (NPT). NPT may refer to a state where
`no operations are being conductive. As described above,
`NPT may be undesirable at least because operators continue
`to pay for equipment that sits idle at the well site. In various
`embodiments, an identification of down time may enable the
`system to transmit a notification, for example to one or more
`shareholders, to alert them of down time at the well. In
`certain embodiments, information may be collected and
`aggregated from multiple pads of well sites, to bench mark
`and compare operation performance. In various embodi(cid:173)
`ments, the software system is operational through a distrib(cid:173)
`uted computing environment (e.g., cloud computing envi(cid:173)
`ronment) to enable remote access from a variety of different
`locations.
`[0031] FIGS. 1-3 illustrate embodiments of a fracturing
`tree (e.g., frac tree) including a conversion assembly that
`convert manually operated valves into remotely controllable
`actuated valves. The illustrated frac tree includes valves and
`piping components, as described above. It should be appre(cid:173)
`ciated that the frac tree may include more components than
`those illustrated herein, and that the illustration frac tree is
`for example purposes only and is not intended to be limiting
`as to the only components that may be utilized with the frac
`tree.
`[0032] As illustrated, the conversion assembly includes
`valve frames that couple directly to the valves of the frac
`tree. The valve frames in the illustrated embodiment are
`coupled to the fasteners of the valve bonnet, however it
`should be appreciated that the valve frames may be other(cid:173)
`wise coupled to the valves. The valve frames include an
`actuation element that couples to the stem for driving
`
`IWS EXHIBIT 1020
`
`EX_1020_014
`
`

`

`US 2020/0149389 Al
`
`May 14, 2020
`
`4
`
`movement of the valves between an open position and a
`closed position. In the embodiment illustrated in FIG. 2, the
`valve frame engages hand wheels of the valves. The actua(cid:173)
`tion element may be hydraulically driven, for example via
`hydraulic fluid pumped via hoses, as illustrated. Addition(cid:173)
`ally, in various embodiments, the actuation element may be
`pneumatic, electric, or the like.
`[0033] The valve frame further includes a sensor to evalu(cid:173)
`ate a position of the valve. The position may be related to
`whether the valve is open, whether the valve is closed, or
`some condition in between ( e.g., how much flow is enabled
`through the valve). The valve frame further includes a
`pressure transducer, which may determine a pressure within
`the wellbore or some other location of the well and/or frac
`tree. As noted above, the pressure may be indicative of an
`operation conducted via the frac tree.
`[0034] FIG. 1 is an isometric view of an embodiment of a
`fracturing tree 100, which may be arranged at a well site
`during a fracturing operation. While not illustrated in FIG.
`1 for simplicity, the fracturing tree 100 maybe coupled to a
`wellbore formed in an underground formation. Furthermore,
`the well site may include additional equipment, which is not
`pictured, such as various piping arrangement, fracturing
`pumps, sand loaders, and the like. During hydraulic frac(cid:173)
`turing operations, high pressure fluids, which may be slurry
`mixtures of components such as liquids and abrasives, may
`be injected into the wellbore, through the fracturing tree 100,
`at high pressures. The high pressures crack the formation,
`thereby forming fissures extending into potentially hydro(cid:173)
`carbon producing zones. The abrasives may remain in the
`fissures after the fluid is removed from the well bore, thereby
`propping open the fissures to facilitate hydrocarbon flow.
`[0035]
`In various embodiments, the fracturing tree 100
`may include valves 102, among other components, that
`regulate flow of fluid into and out of the wellbore. For
`example, certain valves may be moved between closed
`positions and open positions in order to direct fluids through
`the wellbore. In various embodiments, the valves may be
`operational via manual controls, such as hand wheels. These
`control systems, however, may be undesirable when the
`fracturing tree 100 is exposed to high pressures because of
`potential safety concerns with having operators within a
`zone of pressure formed around the fracturing tree 100.
`Additionally, including various meters and sensors at the
`fracturing tree 100 faces similar problems because operators
`may have difficulty reading the sensors without getting
`close, which as noted above, is undesirable in high pressure
`applications.
`[0036] Embodiments of the present disclosure included
`conversion assemblies 104 that may be utilized to convert
`manually operated valves 102 into remotely operated valves.
`Additionally,
`in various embodiments,
`the conversion
`assemblies 104 may further be utilized to convert actuated
`valves into valves actuated by a different mechanism ( e.g.,
`convert a pneumatic actuator into a hydraulic actuator). In
`certain embodiments, the conversion assemblies 104 include
`a valve frame 106 for coupling to the valves 102. For
`example, the valve frame 106 may be coupled to a body of
`the valve 102, thereby securing the conversion assembly 104
`to the valve 102. The illustrated conversion assemblies 104
`further include an actuator element 108, which may be a
`remotely-actuatable element, such as a hydraulic actuator, a
`pneumatic actuator, an electrical actuator, or the like. The
`actuator element 108 may couple to a valve stem or a manual
`
`operator, which may then drive movement of the valve stem
`between an open position and a closed position. In this
`manner, the conversion assembly may be used in order to
`adjust operation of the valves 102.
`[0037]
`In various embodiments, one or more flow lines
`110 are utilized to provide motive power to the illustrated
`actuator elements 108. For example, the flow line 110 may
`enable hydraulic fluid to enter and exit a chamber of the
`actuator element 108, thereby driving movement of the
`valve stem to adjust a position of the valve. It should be
`appreciated that the