Remote Valve Greasing Skids for Hazardous Wellhead Lubrication
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Solution Overview
Problem
The challenge in oilfield operations is the need for regular lubrication of wellhead and frac manifold valves, which requires halting operations due to safety hazards from high pressures and flammable atmospheres, making it unsafe for personnel to perform lubrication tasks manually.
Innovation Solution
A remote greasing system comprising a grease supply skid, a remote greasing skid, and a control skid, where the grease supply skid and remote greasing skid are positioned near the wellhead within a hazardous zone, and the control skid is operated from a safe distance, allowing for lubrication of valves without personnel entering the hazardous area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual lubrication is performed by wellsite personnel, then valve lubrication can be accomplished directly, but personnel safety is compromised due to high pressures and flammable atmospheres in the hazardous zone
Solution Approach 1:
The lubrication system is divided into multiple components: a grease supply unit positioned outside the hazardous zone, grease lines that traverse through the hazardous zone, and grease manifolds positioned near the wellhead. This segmentation allows the control system to remain in a safe location while still delivering lubrication to valves in the hazardous area.
Solution Approach 2:
Grease lines act as intermediaries, transmitting lubrication material from the safe zone to the hazardous zone where valves are located. This intermediary mechanism enables personnel to perform lubrication tasks remotely without direct exposure to high pressures and flammable atmospheres.
2Object-affected harmful factors
If well operations are halted for valve lubrication, then personnel can safely perform lubrication tasks, but operational productivity decreases
Solution Approach 1:
The remote lubrication system enables continuous well operations by allowing valve lubrication to be performed without halting production activities. The system maintains continuous grease supply to valves through automated mechanisms, eliminating the need to stop operations for maintenance tasks.
Solution Approach 2:
The lubrication system incorporates automated grease delivery mechanisms that can operate without continuous human intervention. Once configured, the system self-regulates grease flow to valves, reducing the need for personnel to enter hazardous zones and minimizing operational disruptions.
3Ease of operation
If control equipment is positioned within the hazardous zone, then lubrication control can be performed directly at the wellhead, but personnel exposure to high pressures and flammable atmospheres increases
Solution Approach 1:
The control system is relocated from the traditional wellhead location to a remote position outside the hazardous zone, utilizing spatial separation. Control signals are transmitted through the grease line infrastructure, allowing operators to monitor and control lubrication functions from a safe distance while maintaining operational effectiveness.
Data Source
AI summary
A remote greasing system for lubricating a valve of a wellhead or frac manifold includes a grease supply skid, remote greasing skid, and a control skid. The grease supply skid includes a grease reservoir and a grease pump. The remote greasing skid includes a grease manifold and a grease supply valve. The grease manifold is operatively coupled to the grease pump of the grease supply skid by a grease trunk line. The grease supply valve is operatively coupled to the grease manifold. The grease supply valve includes an output port operatively coupled to a lubrication port of the valve of the wellhead or frac manifold by a grease supply line. The control skid is operatively coupled to the remote greasing skid by a control line. The grease supply skid and remote greasing skid are positioned within a hazardous zone, and the control skid is positioned outside of the hazardous zone.