Hydraulic Valve Control Units for Multi-Valve Hose Reduction
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Solution Overview
Problem
The existing well fracturing operations require numerous hydraulic and lubricant hoses, which are costly, time-consuming to install, and pose trip hazards, while also being prone to interference from high-pressure fracking fluids that degrade lubricants, necessitating frequent manual replenishment.
Innovation Solution
A system with control units that connect multiple valves to a single hose set for hydraulic pressure and lubricant sources, using solenoid-operated valves and pumps to selectively operate valves and distribute lubricants, reducing the need for individual hoses and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If individual hydraulic hoses are used to connect each valve actuator to the HPU, then each valve can be operated independently, but the number of hoses increases significantly, increasing cost, installation time, and trip hazards
Solution Approach 1:
The patent combines multiple hydraulic hose connections into a single hydraulic hose that serves multiple valve actuators. The single hose includes multiple hydraulic fluid communication paths that can selectively connect to different valve actuators, eliminating the need for separate hoses for each actuator while maintaining independent operation capability.
Solution Approach 2:
The single hydraulic hose is designed to perform multiple functions by selectively connecting to different valve actuators. It serves as a universal connection that can supply hydraulic fluid to any number of valve actuators on the Christmas tree, replacing the need for dedicated hoses for each actuator.
2Reliability
If multiple individual hoses are used for hydraulic and lubricant connections, then each valve receives dedicated fluid supply, but the installation time and cost increase significantly
Solution Approach 1:
The patent merges multiple hydraulic and lubricant hose connections into integrated assemblies where a single hydraulic hose and a single lubricant hose replace multiple individual hoses. This consolidation maintains reliable fluid supply to each valve while dramatically reducing the number of connection points and installation steps.
3Reliability
If manual lubricant injection is performed using a grease pump, then lubricant can be replenished, but the operator is exposed to safety hazards and the process is time-consuming
Solution Approach 1:
The system enables automatic lubricant delivery where the lubricant hose and connected lubricant source automatically replenish lubricant to the valve actuators without requiring manual intervention. This eliminates operator exposure to hazardous areas and removes the need for manual grease pump operation.
4Extent of automation
If a centralized lubrication system with individual lubricant hoses is used, then automated lubricant delivery is achieved, but the number of hoses increases, increasing cost and trip hazards
Solution Approach 1:
The patent consolidates multiple individual lubricant hoses into a single lubricant hose that serves multiple valve actuators. The single hose includes multiple lubricant communication paths that can selectively deliver lubricant to different actuators, maintaining automated delivery capability while reducing hose quantity and associated hazards.
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 solution significantly reduces the number of hoses required, decreases setup time and costs, and minimizes hazards by centralizing the connection of hydraulic and lubricant sources, ensuring efficient operation and safety in well fracturing sites.
Implementation Method 1
using solenoid-operated valves and pumps to selectively operate valves and distribute lubricants
Implementation Method 2
Each valve comprises a hydraulic actuator which is operated by hydraulic pressure from a hydraulic pressure source
Implementation Method 3
The lubricant not only forms a barrier to prevent the ingress of fracking fluid into the cavity, but also cleans and coats the sealing surfaces of the valves
Data Source
AI summary
A system for operating and/or lubricating a plurality of valves. The system includes at least first and second control units, each of which is associated with a respective valve. Each control unit includes a hydraulic pressure inlet, a hydraulic pressure outlet, a hydraulic pressure line connected between the hydraulic pressure inlet and the hydraulic pressure outlet, and a hydraulic port which is connectable to the valve. The hydraulic pressure inlet of the first control unit is connectable to a hydraulic pressure source and the hydraulic pressure outlet of the first control unit is connectable to the hydraulic pressure inlet of the second control unit. In operation, the control unit is operable to selectively communicate hydraulic pressure from the hydraulic pressure line to the hydraulic port.