Grease Accumulator Pressure Delivery for Remote Wellhead Greasing
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Solution Overview
Problem
The high-pressure and abrasive nature of fracking fluids in oil and gas operations leads to frequent maintenance needs for gate valves, increasing operational costs and safety risks due to the requirement for frequent greasing, which is hindered by limited access and safety zones around high-pressure equipment.
Innovation Solution
A grease delivery system utilizing a pressurized fluid source and grease accumulator, allowing for remote operation and efficient distribution of grease to wellhead components, including a system with a first compartment for pressurized fluid, a second compartment for grease, and a discharge conduit to apply accumulated pressure for effective greasing, while minimizing pressure loss and risk through proximity and remote bulk reservoir placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If frequent greasing is performed to maintain valve functionality under high-pressure and abrasive conditions, then valve reliability is improved, but operational time is lost due to frequent maintenance interruptions
Solution Approach 1:
The grease accumulator is pre-filled with grease before fracking operations begin. This preliminary preparation eliminates the need for frequent grease refilling during operations, allowing maintenance personnel to perform quick top-ups without interrupting the fracking process for extended periods.
Solution Approach 2:
The system uses a hydraulic accumulator to store pressurized grease and deliver it to the valve through a controlled system. This hydraulic mechanism enables rapid grease delivery during maintenance windows, reducing the time valves remain out of service while ensuring adequate lubrication under high-pressure conditions.
2Reliability
If manual greasing is performed frequently to combat debris accumulation and abrasion, then valve sealing capability is maintained, but safety risks increase due to personnel presence in high-pressure safety zones
Solution Approach 1:
The grease accumulator system is designed to be remotely operable, allowing the accumulator itself to serve as the primary grease delivery mechanism. Maintenance personnel can refill the accumulator from outside the safety zone, and the system automatically delivers grease to valves during operations, minimizing human exposure to high-pressure hazards while maintaining valve sealing capability.
Solution Approach 2:
The hydraulic accumulator acts as an intermediary between the grease supply and the valves. It receives grease refills remotely and autonomously delivers pressurized grease to the valves through controlled discharge, eliminating the need for personnel to manually grease valves within the dangerous safety zone while ensuring continuous lubrication.
3Device complexity
If grease is delivered without accumulated pressure to wellhead components, then system complexity is reduced, but grease delivery effectiveness is insufficient under high-pressure fracking conditions
Solution Approach 1:
The system incorporates a hydraulic accumulator that uses fluid pressure to store and deliver grease to the valves. This hydraulic mechanism provides the necessary pressure to overcome the high-pressure fracking environment and ensure effective grease delivery to valve components, while remaining a relatively simple add-on to existing wellhead infrastructure.
Solution Approach 2:
The grease delivery system is designed to dynamically respond to system pressure conditions. The accumulator charges during low-pressure periods and automatically discharges during high-pressure fracking operations, adapting its operation to match the varying pressure conditions without requiring complex control systems.
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
This system reduces operational costs and enhances safety by enabling efficient and remote greasing of wellhead components, maintaining valve functionality and reducing the need for frequent maintenance within safety zones, thus optimizing fracking operations.
Implementation Method 1
a hydraulic accumulator in communication with the grease accumulator to pressurize the grease
Data Source
AI summary
A grease delivery with accumulated pressure system includes a grease accumulator comprising a first compartment containing a pressurized fluid and a second compartment containing a grease, a pressurized fluid source in communication with the first compartment, a grease reservoir connected to the second compartment through a supply conduit, and a discharge conduit extending from the second compartment to a receiving component.