Automated Grease Manifold for Frac Valves
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Solution Overview
Problem
In frac operations, surface valves require frequent greasing, which is hazardous and inefficient due to the need for manual operation and deployment of long high-pressure hoses, posing risks and potential failures.
Innovation Solution
A frac valve greasing system incorporating a programmable logic controller, grease supply, grease pump, high flow manifold, and flow meter, allowing automated grease distribution with pressure-based and stage-based greasing profiles to ensure safe and efficient valve lubrication, reducing the need for manual intervention and minimizing hazards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual greasing operation is used, then personnel can directly service valves, but personnel are exposed to hazards and operation is time-consuming
Solution Approach 1:
The system enables self-service automated greasing where the PLC-controlled manifold automatically distributes grease to multiple valves without requiring personnel to manually intervene in the danger zone. The automated control system performs the greasing function independently based on programmed parameters.
Solution Approach 2:
The automated manifold system acts as an intermediary between the grease supply and the valves, eliminating the need for personnel to directly handle high-pressure hoses and equipment in the hazard zone. The system mediates the greasing process through automated control mechanisms.
2Adaptability or versatility
If multiple individual hoses are deployed to each valve, then each valve can be greased independently, but the number of hoses increases hazards and system complexity
Solution Approach 1:
The manifold merges multiple grease distribution lines into a single integrated system. Instead of requiring separate hoses for each valve, the manifold combines grease distribution for multiple valves through a unified controlled system, reducing the number of individual hoses while maintaining independent valve servicing capability.
Solution Approach 2:
The automated manifold system provides multi-functionality by serving multiple valves through a single system. The PLC-controlled manifold can distribute grease to any or all connected valves independently, making the system universal for greasing multiple different valve configurations without requiring additional individual hose assemblies.
3Reliability
If frequent greasing is performed manually, then valves are properly maintained, but personnel time and exposure increase
Solution Approach 1:
The automated system performs maintenance functions independently without requiring personnel time for each greasing operation. The PLC-controlled manifold executes greasing cycles automatically based on programmed parameters, maintaining valves reliably while eliminating the need for personnel to spend time on manual greasing tasks.
Solution Approach 2:
The system is pre-programmed with greasing schedules and parameters before operation begins. By establishing automated control routines in advance, the system prepares the maintenance schedule beforehand, eliminating the need for personnel to make repeated decisions and interventions during operation.
4Length of stationary object
If long high-pressure hoses are deployed, then grease can reach distant valves, but hose failures and safety hazards increase
Solution Approach 1:
The manifold merges multiple short connection points into a single centralized distribution system. Instead of deploying long individual hoses from a remote supply point to each valve, the manifold provides multiple accessible ports close to the valves, allowing short connections that reduce the risk of hose failures while maintaining the ability to reach all necessary valves.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables safe, efficient, and automated greasing of multiple valves, reducing personnel exposure to hazards and potential system failures by using a programmable logic controller to manage grease distribution, ensuring consistent pressure and volume delivery, and providing redundancy for reliable operation.
Implementation Method 1
the grease pump or pumps provide grease at, at least 15,000 psi in order to overcome pressure within the frak valve
Data Source
AI summary
A greasing system may use a programmable logic controller. The programmable logic controller, grease pumps, and power system control grease flow into two or more fracked valves on a well are maintained outside of the red zone of the well. The programmable logic controller includes a display that is adaptable to include information related to individual frak valves such as the associated well, the type of valve greasing utilized such as pressure based greasing or stage based greasing and also may include upper and lower limits on pressure and/or amount of grease utilized.