Sensor-Controlled Lubrication Pumping With Debris-Tolerant Check Valves
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Solution Overview
Problem
Existing lubrication systems for high-pressure pumps in oil and gas operations fail due to debris clogging and metal-to-metal sealing failures, and lack the ability to selectively activate and deactivate lubrication based on sensed outputs, leading to excessive lubricant pressures and waste.
Innovation Solution
A lubrication system with larger elastomeric check valves and a sensor-controlled pump drive system that activates and deactivates based on measured parameters, using non-metallic inserts to prevent failure from debris and optimize lubricant flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal-to-metal sealing is used in check valves, then sealing capability is improved, but reliability deteriorates due to debris clogging and sealing failures
Solution Approach 1:
The patent changes the material parameter of the check valve sealing surface from metal to elastomeric material. This parameter change allows the sealing surface to deform and conform to the mating surface, maintaining sealing capability while resisting debris-induced failures that plague metal-to-metal seals.
Solution Approach 2:
The patent employs composite construction by combining elastomeric material with the check valve body. The elastomeric insert provides the sealing function while being inherently resistant to debris clogging, creating a hybrid solution that leverages the advantages of different material properties.
2Reliability
If continuous lubrication is provided, then lubrication reliability is improved, but energy consumption and lubricant waste increase
Solution Approach 1:
The patent implements periodic lubrication delivery by controlling the pump to operate in cycles rather than continuously. The pump activates to deliver a bolus of lubricant, then shuts off, allowing the system to maintain adequate lubrication with intermittent dosing rather than continuous flow, thereby reducing energy consumption and lubricant waste.
Solution Approach 2:
The patent incorporates sensors that monitor lubrication system parameters and provide feedback to the pump control system. This feedback mechanism allows the pump to adjust its operation based on actual system needs, activating only when lubrication is required and shutting off when adequate lubrication is present, optimizing both reliability and energy efficiency.
3Reliability
If pump operates continuously, then lubrication coverage is improved, but lubricant pressure excess and waste occur
Solution Approach 1:
The pump operates in periodic cycles rather than continuously, delivering lubricant in controlled bursts. This periodic operation ensures adequate lubrication coverage during active cycles while preventing pressure buildup and excessive lubricant consumption that occur with continuous operation.
Solution Approach 2:
The system applies partial action by delivering just enough lubricant during each pump cycle to maintain adequate coverage, rather than continuously supplying excess lubricant. The sensor-controlled pump delivers minimal necessary quantities, preventing both under-lubrication and over-lubrication waste.
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 prevents failure from environmental debris, reduces excessive lubricant pressures, and minimizes waste by selectively controlling lubricant delivery, ensuring efficient operation even in contaminated environments.
Implementation Method 1
The deformation of the elastomeric material allows the check valve to remain open and continue to deliver lubricant even when debris is present
Implementation Method 2
a sensor configured to measure a physical characteristic and provide an output
Implementation Method 3
The pump is configured to pressurize the lubricating medium and comprises at least one reciprocating plunger
Data Source
AI summary
A lubricating system configured to provide a lubricating oil from a lubricant reservoir to a fluid end by use of a pump. The lubricating system has a plurality of check valves that each have an elastomeric insert. The lubricating system also has at least one pressure relief valve that is configured to re-rout lubricant to the lubricant reservoir when needed to stabilize pressure within the system. The lubricating system uses a pump drive controller and at least one sensor to selectively turn the pump on and off.