Remote High-Pressure Pump Disconnection via Isolation Valves
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Solution Overview
Problem
Current fracking operations face challenges in maintaining or repairing pump systems under operational pressure, leading to inefficiencies and increased costs due to the inability to remove and replace pump trucks without shutting down the system, as safety concerns prohibit work in the high-pressure zone.
Innovation Solution
A system and method for remotely disconnecting and reconnecting high-pressure fracking pump trucks from the fracturing system, utilizing selectively actuated valves and a bleed valve to vent pressure and allow for hot swapping of pump trucks while the system remains under pressure, enabling continuous operation and reducing maintenance downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pump trucks are repaired or maintained during operational pressure, then productivity and operational efficiency improve, but safety risks increase due to high-pressure hazards
Solution Approach 1:
The system segments the pump truck connection into multiple controllable sections using isolation valves. The pump truck can be disconnected from the high-pressure system in a controlled manner, allowing maintenance personnel to work on isolated components without exposure to system pressure, thereby maintaining productivity while ensuring safety.
Solution Approach 2:
The patent introduces an intermediary bleeding system with controlled venting capabilities between the pump truck and the high-pressure fracturing system. This intermediary mechanism allows pressure to be safely released and controlled during the disconnection process, enabling maintenance work without direct exposure to hazardous high-pressure conditions.
2Ease of repair
If pump trucks are taken offline for repair, then maintenance quality improves, but loss of time increases due to shutdown requirements
Solution Approach 1:
The system performs preliminary actions by pre-positioning isolation valves and bleeding controls before maintenance is needed. When a pump truck requires repair, the isolation valves are already in place and can be quickly activated to isolate the pump truck, and the bleeding system is pre-configured to safely vent pressure, enabling rapid maintenance without lengthy shutdown procedures.
Solution Approach 2:
The patent implements dynamic pressure control during the disconnection and maintenance process. The bleeding system allows controlled, dynamic pressure reduction rather than abrupt pressure release, enabling safe and quick pump truck replacement while minimizing downtime. The system can rapidly transition between operational and maintenance states.
3Reliability
If multiple pump trucks are maintained simultaneously, then reliability improves through redundancy, but device complexity increases due to additional equipment
Solution Approach 1:
The isolation valve assembly and bleeding system are designed as universal, multi-functional units that can be applied to any pump truck in the fleet. Each pump truck is equipped with the same standardized isolation and bleeding infrastructure, allowing multiple trucks to be maintained simultaneously using identical procedures and equipment, thereby improving reliability through redundancy without proportionally increasing overall system complexity.
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 solution allows for continuous pumping and increased operational efficiency by enabling pump truck maintenance and replacement without shutting down the fracking system, reducing transition times and costs, and minimizing the need for personnel to enter the high-pressure zone.
Implementation Method 1
a bleed valve in communication with a fluid passage interconnecting the missile side valve and the pump side valve
Data Source
AI summary
A system and method for remotely disconnecting a high-pressure pump from an active fracturing operation that includes a missile side valve in fluid communication with a missile or manifold of a fracturing system, a pump side valve in fluid communication with a moveable high-pressure pump and the missile side valve, and a bleed valve in communication with a fluid passage interconnecting the missile side valve and the pump side valve, wherein the operation of missile side valve, the pump side valve, and the bleed valve are controlled remotely.