Remote Grease Cartridge Manifold for High-Pressure Plug Valves
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Solution Overview
Problem
Current greasing systems for high-pressure plug valves in hydraulic fracturing operations are inefficient and unsafe, as they require manual operation close to high-pressure zones, leading to significant downtime and risk of contamination, and are not suitable for the high viscosity greases needed for effective sealing.
Innovation Solution
A remotely operable greasing system with multiple pre-loaded grease cartridges and longer, larger-bore hoses, using water instead of hydraulic oil, and incorporating remote-controlled distribution valves for efficient and safe lubrication of multiple plug valves, allowing for continuous operation and reduced personnel risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual greasing operation is performed close to high-pressure zones, then effective lubrication of plug valves is achieved, but personnel safety is compromised and significant downtime occurs
Solution Approach 1:
The greasing system is divided into separate functional components: a remotely located pump unit, intermediate distribution manifolds, and local grease injection points at each valve. This segmentation allows the hazardous high-pressure grease pumping to be performed remotely while delivering grease directly to valves through distributed injection points, eliminating the need for personnel to be close to high-pressure zones.
Solution Approach 2:
A water-based intermediate fluid is introduced to carry grease through the distribution system. The water acts as a carrier that can be pumped remotely and safely, then transfers the high-viscosity grease to the valves. This intermediary approach allows remote operation while maintaining effective grease delivery to the plug valves.
2Reliability
If high viscosity grease is used for effective sealing in plug valves, then sealing performance is improved, but pumping capability of commercially available pumps deteriorates
Solution Approach 1:
The system uses a hydraulic pump designed specifically for high-viscosity materials, located remotely, to pump the high-viscosity grease. The hydraulic system incorporates heating elements and pressure control mechanisms to maintain grease pumpability while preserving its high-viscosity sealing properties. Water-based intermediate fluid is used to transport the grease through distribution lines.
Solution Approach 2:
The grease parameters are modified by controlling temperature and viscosity through heating elements in the pump and distribution system. The grease is heated to reduce viscosity during pumping, then allowed to cool and regain high viscosity at the injection points for effective sealing. This parameter change approach maintains both pumpability and sealing performance.
3Reliability
If greasing is performed systematically between fracing stages, then valve sealing is maintained, but operational downtime increases
Solution Approach 1:
The remotely operable system allows grease to be pumped continuously through the distribution manifold to multiple valves simultaneously or in rapid sequence. The system can maintain grease pressure and flow continuously between stages, eliminating the need to stop and restart the greasing process for each valve, thereby reducing downtime while maintaining sealing.
Solution Approach 2:
The system pre-positions grease in the distribution manifold and maintains it under pressure ready for immediate delivery to any valve. This preliminary preparation allows rapid response to sealing needs without requiring time-consuming setup or manual intervention at each valve location, reducing operational downtime.
4Productivity
If multiple plug valves are serviced simultaneously, then productivity is improved, but system complexity increases
Solution Approach 1:
The system is segmented into a central pump unit and multiple independent distribution manifolds, each serving specific valves. This modular segmentation allows simultaneous servicing of multiple valves through parallel distribution paths while keeping each manifold relatively simple and manageable. The segmented architecture reduces overall system complexity compared to a single centralized manifold.
Solution Approach 2:
The distribution manifold is designed as a universal component that can serve multiple valves with the same grease delivery mechanism. This multi-functional design allows a single manifold configuration to service different valves simultaneously, improving productivity without proportionally increasing system complexity, as the same components are reused across multiple service points.
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
The system enables efficient and safe lubrication of multiple plug valves during fracturing operations, reducing downtime and contamination risks while maintaining personnel safety by allowing greasing to be performed from a distance, with features like grease volume monitoring and pressure measurement.
Implementation Method 1
A high-pressure water pump, located remote from the well, moves water through high-pressure hoses to a water piston
Implementation Method 2
The water piston compresses a grease piston, which in turn moves grease through high-pressure hoses or manifolds
Data Source
AI summary
A system for distributing high viscosity grease to at least one plug valve includes a replaceable cartridge with a body having a chamber and a piston disposed within the chamber. The piston defines a first space within the chamber for receiving solid grease and a second opposing space within the chamber for receiving fluid for driving the piston to compress the solid grease received within the first space. A manifold detachably couples to the replaceable cartridge and has a manifold chamber for receiving grease flowing under compression from an outlet of the cartridge and a plurality of valves in fluid communication with the manifold chamber for selectively distributing grease to corresponding grease ports of the at least one plug valve.