Remote Pressure Bleed-Off Valve Control for Frac Line Safety
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Solution Overview
Problem
Existing pressure relief systems in hydraulic fracturing operations require manual operation in high-pressure zones, posing safety risks and inefficiencies, especially when controlling pressure bleed-off valves.
Innovation Solution
An electronically controlled pressure bleed-off system that includes low and high pressure lines with fluid bypasses, transducers for pressure monitoring, and electrically activated plug valves, allowing for remote operation and sequential valve control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operation of pressure bleed-off valves is used, then the system structure is simple, but safety risk increases due to manual intervention in high-pressure zones
Solution Approach 1:
The patent introduces an intermediary control system that includes a controller, transducers for pressure sensing, and electric actuators that mediate between the operator and the high-pressure bleed-off valves. This intermediary layer eliminates direct manual intervention in high-pressure zones while maintaining system control, thereby improving safety without excessive complexity
Solution Approach 2:
The patent replaces manual mechanical operation of bleed-off valves with an electronically controlled system. Electric actuators driven by the controller substitute for manual mechanical manipulation, eliminating the need for operators to physically handle valves in high-pressure environments while achieving precise pressure control
2Reliability
If remote electronic control is implemented, then safety improves by eliminating manual intervention, but device complexity increases
Solution Approach 1:
The control system incorporates self-service features through automatic pressure monitoring and control. Transducers continuously sense pressure conditions and automatically trigger actuators when preset thresholds are reached, enabling the system to regulate itself without constant operator intervention. This automation improves safety while keeping the control logic relatively simple
Solution Approach 2:
The patent implements feedback control where transducers monitor pressure conditions and provide information to the controller, which then adjusts actuator operation accordingly. This closed-loop feedback mechanism ensures safe automatic response to pressure changes while maintaining straightforward control system architecture
3Manufacturing precision
If sequential valve control is used, then pressure management precision improves, but control complexity increases
Solution Approach 1:
The controller is programmed with preliminary action sequences that automatically execute the correct sequence of valve operations based on detected pressure conditions. When pressure thresholds are reached, the controller pre-determines and executes the appropriate sequence of actuator activations, ensuring precise pressure management without requiring complex real-time decision-making
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
Enables safe and efficient remote control of pressure bleed-off operations, reducing the risk of manual intervention in high-pressure zones and improving the overall management of hydraulic fracturing processes.
Implementation Method 1
a transducer disposed along the fluid bypass line and in fluid communication with the fluid line at the fluid inlet
Implementation Method 2
an electric actuator residing on the first plug valve and configured to rotate the first plug valve between open and closed positions in response to an actuation signal
Data Source
AI summary
A pressure bleed-off system. The system includes a fluid bypass line having an inlet and an opposing outlet, wherein the inlet is in fluid communication with a high pressure frac line for a hydraulic fracturing operation. The system also includes a high-pressure transducer located proximate the fluid inlet, a first plug valve residing along the fluid bypass line, and a first electric actuator residing on the first plug valve. The actuator is configured to rotate the first plug valve between close and open positions in response to command signals from a controller. The controller, in turn, sends the command signals in response to control signals delivered by an operator, remotely. Preferably, the command signals are wireless signals sent from outside of the red zone. The system may also include a second plug valve along the bypass line.