Remote Hydraulic Valve Control System for Wellhead Safety
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Solution Overview
Problem
During well completions or workover operations, the hazardous conditions around frac trees, including high pressures and potentially flammable atmospheres, make it unsafe for personnel to manually operate valves, necessitating a remote control solution for hydraulic systems.
Innovation Solution
A remote hydraulic system comprising a remote hydraulic skid with a hydraulic reservoir, pump, accumulator, and manifold, along with a control skid and power supply skid, where the control skid and power supply are positioned outside a hazardous zone to safely operate valves at the wellhead or frac manifold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If valves are operated manually at the frac tree, then direct control is achieved, but personnel safety is compromised due to high pressures and flammable atmospheres in the hazardous zone
Solution Approach 1:
The patent introduces a remote hydraulic control system as an intermediary between the operator and the valve. The control system includes a remote control unit positioned outside the hazardous zone that transmits hydraulic signals through hoses to actuate the valve at the frac tree, allowing indirect operation without direct personnel exposure to dangerous conditions
Solution Approach 2:
The patent replaces manual mechanical valve operation with a hydraulic actuation system. The valve is equipped with a hydraulic actuator that receives hydraulic fluid through remotely connected hoses, substituting the need for direct mechanical handling by personnel with an automated hydraulic mechanism controlled from a safe distance
2Device complexity
If the remote hydraulic skid is positioned within the hazardous zone close to the wellhead, then hydraulic line complexity is reduced, but personnel must operate in dangerous conditions
Solution Approach 1:
The patent divides the hydraulic control system into separate functional modules: the remote hydraulic skid containing the pump and control valves is positioned outside the hazardous zone, while only the essential valve actuation components remain at the wellhead. This segmentation allows the majority of the system to be located in a safe area while maintaining functional proximity to the wellhead through extended hydraulic connections
3Reliability
If the control system is positioned outside the hazardous zone, then personnel safety is improved, but hydraulic line length and system complexity increase
Solution Approach 1:
The patent utilizes hydraulic fluid transmission to bridge the distance between the control system positioned outside the hazardous zone and the valve at the wellhead. High-pressure hydraulic lines convey actuation signals over extended distances, enabling safe remote operation while maintaining sufficient control force through hydraulic pressure amplification
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 remote operation of wellhead or frac manifold valves, reducing the risk of accidents by keeping personnel outside hazardous zones and improving operational efficiency by minimizing pressure drops and reducing the complexity of hydraulic line installations.
Implementation Method 1
The remote hydraulic skid may include a hydraulic reservoir, a hydraulic pump, and an accumulator
Implementation Method 2
The remote hydraulic skid may include a hydraulic reservoir, a hydraulic pump, and an accumulator
Implementation Method 3
The remote hydraulic skid may include a hydraulic manifold operatively coupled to the accumulator
Data Source
AI summary
A remote hydraulic system for controlling a valve of a wellhead or frac manifold includes a remote hydraulic skid, control skid, and power supply skid. The remote hydraulic skid includes a hydraulic reservoir, a hydraulic pump, an accumulator, a hydraulic manifold operatively coupled to the accumulator, and a hydraulic valve operatively coupled to the hydraulic manifold. The hydraulic valve is operatively coupled to the valve of the wellhead or frac manifold by a hydraulic line. The control skid includes an interface and is operatively coupled to the remote hydraulic skid. The power supply skid is coupled to the remote hydraulic skid to provide the power necessary to drive the hydraulic pump on the remote hydraulic skid. The remote hydraulic skid is positioned within a hazardous zone around the wellhead, while the control skid and power supply skid are positioned outside of the hazardous zone.