Remote Pressure Relief Valve Skid for Sand-Resistant Fracturing
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Solution Overview
Problem
Traditional relief and bleed valve systems in hydraulic fracturing operations suffer from reduced effectiveness due to sand and dirt buildup, requiring costly and time-consuming maintenance, and are difficult to access during emergencies, posing safety risks.
Innovation Solution
An intelligent valve system with pressure relief and bleed down valve configurations, utilizing redundant gate valves and transducers, controlled by a software module to manage pressure levels and vent residual pressure, preventing debris accumulation and enhancing operational safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional relief and bleed valve systems are used, then pressure management is achieved, but sand and dirt buildup reduces valve effectiveness and increases maintenance requirements
Solution Approach 1:
The valve system is extracted from the main fluid line and mounted on a remote skid, physically separating it from the sand and dirt environment. This allows the valves to operate in a cleaner environment while still managing pressure in the fracturing system, preventing debris accumulation that would otherwise reduce valve effectiveness
Solution Approach 2:
A remote skid acts as an intermediary platform that houses the valve system. The skid provides a stable, accessible mounting location away from the main fluid line, allowing pressure management functionality while isolating the valves from harmful factors like sand and dirt
2Reliability
If traditional valve systems are used, then pressure relief is achieved, but maintenance downtime is costly and time-consuming
Solution Approach 1:
The valve system is extracted from the main fluid line and mounted on a remote skid, making it easily accessible for maintenance without requiring shutdown of the entire fracturing system. This reduces maintenance downtime while maintaining pressure management reliability
Solution Approach 2:
The valve system is segmented into a separate, modular skid-mounted unit. This allows the valves to be maintained independently from the main fluid line system, enabling quick replacement or servicing without affecting overall system operation
3Ease of operation
If traditional relief valves are used, then pressure relief is achieved, but accessibility during emergencies is difficult
Solution Approach 1:
The valve system is extracted from the confined main fluid line and mounted on a remote skid with easy access. This improves emergency accessibility while the modular skid design keeps the system configuration manageable and well-organized
4Reliability
If redundant pressure relief valves are used, then pressure management reliability is improved, but system complexity increases
Solution Approach 1:
Multiple pressure relief valves are merged into a single integrated skid-mounted system. This consolidates the redundant valves and associated piping into one organized unit, improving reliability through redundancy while keeping the overall system configuration manageable through modular design
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 effectively manages pressure levels, reduces maintenance needs, and ensures rapid response to emergencies by preventing debris accumulation and automating valve operations, thereby enhancing safety and reducing downtime.
Implementation Method 1
a pressure relief valve system for releasing pressure from the main fluid line
Implementation Method 2
a pressure relief transducer configured to measure pressure levels within the pressure relief block
Data Source
AI summary
An intelligent valve system and methods are disclosed for releasing pressure from a main fluid line that defines a primary fluid flow path. In one aspect, the intelligent valve system includes a pressure relief valve system having a pressure relief block connected to the main fluid line, a first pressure relief valve coupled to the pressure relief block, and a second pressure relief valve coupled to the first pressure relief valve, where the pressure relief valves define an alternative fluid flow path that extends approximately perpendicular to the primary fluid flow path. The intelligent valve system may also include a bleed down valve system having a bleed down block, a first bleed down valve coupled to the bleed down block, and a second bleed down valve coupled thereon. The bleed down valves define a flow path that extends approximately perpendicular to the primary fluid flow path.