Service Module for Pumping Unit Sensor Bypass
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Solution Overview
Problem
In the oil and gas industry, troubleshooting pumping units often requires disconnecting safety shut-down sensors, leading to the risk of forgetting to reconnect them, which can result in pipeline rupture and environmental hazards.
Innovation Solution
A service module that operates in both normal and troubleshooting modes, allowing the high pressure shutoff sensor to remain connected to the motor, with a controller automatically switching back to normal mode after a predetermined time interval, eliminating the need for manual reconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the high pressure shutoff sensor is disconnected from the motor during troubleshooting, then the motor can be serviced without shutdown interference, but the safety protection is lost and pipeline rupture risk increases
Solution Approach 1:
The system is segmented into two operational modes: normal mode where the shutoff sensor is fully connected and active, and troubleshooting mode where the sensor remains physically connected but its shutdown function is temporarily disabled through the service module. This segmentation allows the motor to be serviced without disconnection while maintaining safety protocols when not in troubleshooting mode.
Solution Approach 2:
The service module acts as an intermediary component between the high pressure shutoff sensor and the motor. It receives the shutdown signal from the sensor but can selectively block or pass the signal to the motor, thereby mediating between safety protection requirements and troubleshooting needs without requiring physical disconnection of the sensor.
2Reliability
If the service technician manually reconnects the shutoff sensor after troubleshooting, then safety protection is restored, but human error may cause forgetting to reconnect, leading to pipeline damage
Solution Approach 1:
The service module provides self-service functionality by automatically restoring the shutoff sensor connection to active status after a predetermined time interval following troubleshooting mode activation. This eliminates the need for manual reconnection by the technician, thereby removing the human error component that could lead to forgotten reconnection and subsequent pipeline damage.
Solution Approach 2:
The system performs preliminary action by pre-programming the automatic reconnection timing within the service module. Before any potential harm can occur from forgotten reconnection, the module automatically restores the safety shutdown functionality after the troubleshooting period expires, ensuring safety is restored without relying on technician memory or action.
3Reliability
If the shutoff sensor remains connected during troubleshooting, then safety protection is maintained, but the motor cannot be restarted for diagnostic purposes
Solution Approach 1:
The service module introduces dynamic switching capability that allows the system to transition between normal operation and troubleshooting modes. In troubleshooting mode, the module dynamically blocks the shutdown signal from reaching the motor while keeping the sensor connected, enabling motor restart for diagnostics. The module can then dynamically revert to normal mode after the troubleshooting period, restoring full safety functionality.
Data Source
AI summary
A service module for troubleshooting a pumping unit, particularly that used in the oil/gas industry, is operatively coupled between a motor of the pumping unit and a high pressure shutoff sensor which acts to kill the motor of the pumping unit in the event a pressure of the pipeline exceeds a prescribed threshold. The service module is operable in a first normal operating mode in which the shutoff sensor acts as it normally would to shut off the motor when the prescribed threshold is exceeded, and in a second troubleshooting mode where the normal operation of the shutoff sensor is bypassed for a predetermined period of time. After the predetermined period of time of the second troubleshooting mode has elapsed, the service module automatically returns to the normal operating mode. The shutoff sensor thus remains operatively coupled to the motor during troubleshooting of the motor.