Redundant Multi-Valve Control for Pump Downtime Reduction
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Solution Overview
Problem
High-pressure fluid pumping systems used in oil and gas operations face mechanical wear issues due to the high-pressured and high-stressed nature of the pumping environment, leading to frequent part replacements and increased operational costs.
Innovation Solution
The implementation of a multi-valve control system with redundant suction and discharge valves, monitored by a control system that can switch between operational and redundant valves in case of failure, to minimize downtime and extend the lifespan of pump components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If frequent part replacement is performed to address mechanical wear, then component reliability is maintained, but operational downtime and loss of time increase
Solution Approach 1:
The system pre-positions redundant valves (first and second valves) in standby configuration before any failure occurs. When a valve fails, the system has already prepared alternative components that can be immediately activated, eliminating the need for time-consuming replacement operations during active pumping.
Solution Approach 2:
The invention applies redundancy specifically to the valve components that are most prone to failure in the high-pressure pumping environment. By having multiple valves with identical functionality positioned at critical locations, the system ensures that localized failures do not compromise overall system operation.
2Productivity
If redundant valves are added to the pump system, then operational continuity is improved, but device complexity increases
Solution Approach 1:
The first and second redundant valves are integrated into a single valve assembly structure, sharing common mounting fixtures, actuation mechanisms, and control circuitry. This merging approach allows the system to achieve redundancy while minimizing the increase in overall complexity through shared components.
Solution Approach 2:
The redundant valves are designed with universal interfaces and control mechanisms that allow them to perform identical functions to the primary valve. The control system uses the same actuation signals and monitoring protocols for all valves, simplifying the operational complexity despite having multiple components.
Data Source
AI summary
A pump comprising a fluid end comprising a bellows housing having an interior volume, a power end, a reciprocating element, a bellows disposed at least partially within the bellows housing and dividing the interior volume of the bellows housing into a first volume interior to the bellows and a second volume exterior to the bellows, suction valve(s) fluidly coupled to the second volume of the bellows housing. and discharge valve(s) fluidly coupled to the second volume of the bellows housing. The suction valve(s), the discharge valve(s), or both the suction valve(s) and the discharge valve(s) comprise a redundant valve including at least two of said valves, such that, during normal operation, one of the at least two said valves of the redundant valve is open/online while another of the at least two said valves of the redundant valve is closed/offline.