Integrated HPU Skid for Shared Hydraulic and Grease Pumping
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Solution Overview
Problem
The petroleum industry faces inefficiencies and space constraints on frac pads due to separate infrastructures for hydraulic and greasing systems, leading to idle equipment and increased space requirements.
Innovation Solution
An integrated high-pressure unit (HPU) skid combining hydraulic and grease pumping systems, featuring electric and diesel-driven pumps, accumulators, and a portable frame, which allows for simultaneous operation of hydraulic and grease pumps, reducing the need for multiple lines and equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate infrastructures are used for hydraulic and greasing systems, then each system can operate independently, but equipment space and line count increase
Solution Approach 1:
The patent combines separate hydraulic and greasing systems into a single integrated HPU skid. The hydraulic pump serves dual purposes: powering hydraulic valves and driving the grease pump. The grease pump is integrated onto the same skid as hydraulic components, sharing common infrastructure while maintaining functional independence through controlled fluid distribution pathways.
Solution Approach 2:
The hydraulic pump is designed with multi-functionality, serving both the hydraulic system (powering valves) and the greasing system (driving the grease pump). This universal component reduces the need for separate power sources and minimizes overall equipment footprint while maintaining independent operational capabilities.
2Adaptability or versatility
If multiple separate systems are used, then functional independence is maintained, but the number of lines and equipment increases
Solution Approach 1:
The patent merges hydraulic and greasing lines into a unified fluid distribution network on the integrated skid. The system uses a single hydraulic pump to generate pressure for both hydraulic valve operation and grease pump activation, reducing the number of separate lines and connections required while preserving functional independence through controlled fluid routing.
3Ease of operation
If separate air compressor-powered grease pump is used, then grease pumping capability is provided, but equipment space and power requirements increase
Solution Approach 1:
The patent extracts the air compressor from the system entirely, replacing it with a grease pump integrated onto the hydraulic skid that is directly powered by the hydraulic pump. This eliminates the need for a separate air compressor and its associated power requirements, reducing equipment quantity while maintaining grease pumping capability through hydraulic power transmission.
4Reliability
If idle equipment is present, then system redundancy is provided, but space and maintenance requirements increase
Solution Approach 1:
The integrated system ensures continuous useful action by having the hydraulic pump continuously available to power both hydraulic valves and the grease pump as needed. The accumulator provides continuous stored energy for valve operation, eliminating idle time between hydraulic and greasing operations. This integration maximizes equipment utilization by ensuring all components are actively used when required.
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 integrated system enhances efficiency by allowing shared use of hydraulic pumps, reduces equipment and line count, and creates a cleaner, safer working environment by consolidating operations and eliminating the need for an air compressor-powered grease pump.
Implementation Method 1
a hydraulic pump in fluid communication with a hydraulic reservoir to draw hydraulic fluid from the hydraulic reservoir and pump the hydraulic fluid to a hydraulic line
Implementation Method 2
opening the actuator valve places the accumulator in fluid communication with the hydraulic pump using the hydraulic line
Implementation Method 3
The grease pump delivers grease to the valves using a conveyance mechanism such as grease lines
Data Source
AI summary
A high-pressure unit (HPU) skid includes one or more hydraulic pumps, a grease pump, a hydraulic reservoir, and two or more accumulators all mounted on a portable frame. The HPU skid also includes fluidic connections to connect one or more valves to an output of the grease pump and fluidic connections to connect one or more valves to an output of at least one of the two or more accumulators. The accumulators are configured to close at least one of the one or more valves using a charged pressure. The HPU skid further includes fluidic connections to connect one or more valves to at least one of the one or more hydraulic pumps. The hydraulic pumps are configured to withdraw hydraulic fluid from the hydraulic reservoir for charging the accumulators, operating the grease pump, charging the accumulators and operating the grease pump at a same time, or operating one or more valves.