Valves for Hydraulic Fracturing and Deep-Sea Drilling

Offshore and subsea projects drive valve industry growth with the constant demand of high-performance systems to ensure safety, efficiency, and environmental compliance.

By Robert McIlvaine – CEO – McIlvaine Company

There is substantial — and growing — valve markets in hydraulic fracturing and deep-sea oil drilling. Hydraulic fracturing (or fracking) and deep-sea oil and gas extraction are critical processes in the energy industry.

Both enable access to hydrocarbon resources that are otherwise difficult to obtain. However, they require stringent technical, environmental, and regulatory considerations to maximize efficiency, and minimal environmental impact.

Hydraulic Fracturing Processes

Hydraulic fracturing involves injecting high-pressure fluid into underground rock formations to create fractures, allowing oil or gas to flow more freely. This process requires several technical and regulatory components including:

• Water and Chemical Management: Fracking fluid typically consists of water, sand, and chemical Securing a reliable water source is essential as the process requires millions of gallons of water per well. Companies must also disclose the chemical composition of their fluid in many jurisdictions to meet compliance with environmental standards.
• Wastewater Treatment: Fracking generates significant volumes of wastewater, which may contain heavy metals, radioactive materials, and residual chemicals. Proper treatment and disposal are essential to prevent environmental harm.
• Air Quality Controls: Fracking can also release volatile organic compounds (VOCs) into the atmosphere. Vapor recovery units and low-emission valves are often deployed to limit air pollution.

Deep-Sea Oil and Gas Extraction

These processes involve drilling wells in offshore environments, often at depths exceeding 1,000 meters. It comes with unique challenges and requirements.

Valve Requirements for Hydraulic Fracturing and Deep-Sea Drilling

Valves play an essential role in hydraulic fracturing and deep-sea drilling, ensuring safe, efficient control of fluid flow during these processes. These components are critical for managing high pressures, preventing leaks, and maintaining operational safety.

The requirements for valves used in these applications are rigorous, given the demanding conditions. Below is an explanation of the valve requirements for both processes.

Hydraulic Fracturing

Valves are integral to controlling the flow, pressure, and direction of the fracturing fluid. Key requirements include:

• High-Pressure Tolerance: Operations use pressures that can exceed 10,000 psi. Valves must be designed to withstand extreme pressures. Materials such as forged steel or high-strength alloys are often used for their durability.
• Corrosion Resistance: The contents of fracturing fluid may be highly corrosive, meaning that valves must be resistant to corrosion and chemical degradation. As a result, stainless steel, or special coatings, such as nickel or epoxy, are used for durability.
• Abrasion Resistance: Sand and other proppants in the fluid can cause wear, so the valves must be equipped with abrasion-resistant linings or constructed from durable, reliable materials.
• Leak Prevention: Hydraulic fracturing requires precise control to prevent leaks that could contaminate surrounding groundwater or the environment. Valves with advanced sealing mechanisms ensure a tight seal under high-pressure circumstances.

Deep-Sea Drilling

Valves are critical for managing drilling fluids and maintaining safety. Specific requirements include:

• High-Pressure and High-Temperature (HPHT) Capabilities: Deep-sea drilling often occurs in environments with pressures exceeding 15,000 psi and temperatures above 350°F (177°C). Valves must be specially engineered to operate reliably under these conditions.
• Corrosion and Seawater Resistance: Exposure to saltwater and other corrosive elements requires valves to be made from corrosion-resistant materials and/or specialized coatings.
• Explosion and Blowout Prevention: Valves play a key role in preventing blowouts, which are uncontrolled releases of oil or gas. Blowout preventers (BOPs) are specialized valve systems designed to seal the wellbore in emergencies.
• Subsea Operability: Valves are often located on the seafloor and are operated remotely via hydraulic or electric actuation. They need to be engineered for reliability to manage extreme underwater conditions.
• Preventing Environmental Risks: Given the potential for devastating oil spills, valves must incorporate fail-safe mechanisms to shut off flow in the event of system failure. Double-block-and-bleed designs are commonly used to ensure redundancy and safety.

Advantages of Smart Valve Technology for Deep-Sea Drilling

These advanced valves incorporate sensors, automation, and real-time monitoring systems, making them indispensable in the challenging conditions of offshore oil and gas extraction. Below are the key advantages of smart valve technology in deep-sea drilling:

• Enhanced Safety: By providing instant alerts, they help prevent catastrophic events like blowouts. Automated shutoff mechanisms can also seal off wellbores during emergencies, minimizing accidents.
• Improved Operational Efficiency: Automation and remote-control capabilities allow smart valves to adjust flow rates, pressure, and other parameters with precision. This reduces the need for manual intervention, streamlining operations and increasing efficiency. Additionally, predictive maintenance features help identify potential issues before they escalate, reducing downtime and maintenance costs.
• Environmental Protection: In deep-sea drilling, even minor leaks can have devastating consequences. Smart valves help mitigate these risks by providing continuous monitoring and immediate response to leaks. Their ability to provide precise control of drilling fluids and hydrocarbons minimizes waste and reduces the likelihood of spills.

Summary

Deep-sea drilling and hydraulic fracturing are high-growth markets for the valve industry. The rigorous requirements highlight their critical role in ensuring safe and efficient operations while addressing environmental and helping shape the future of these industries.