Centralized Valve Lubrication Control to Cut Fracturing Hoses
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Solution Overview
Problem
The existing well fracturing operations require a large number of hydraulic and lubricant hoses, which are costly, time-consuming to install, and pose trip hazards, while also being inefficient due to the need for frequent lubricant replenishment and manual operation, which exposes personnel to hazardous conditions.
Innovation Solution
A system with control units that connect multiple valves to a single hose set for hydraulic pressure and lubricant sources, using solenoid-operated valves and pumps to selectively operate and lubricate valves, reducing the need for individual hoses and enabling remote monitoring and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If individual hydraulic hoses and lubricant hoses are used to connect each valve actuator to the HPU and lubrication system, then each valve can be independently controlled and lubricated, but the number of hoses increases significantly, increasing cost, installation time, and trip hazards
Solution Approach 1:
The patent combines multiple hydraulic hoses and lubricant hoses into a single integrated hose assembly. This hose assembly includes a hydraulic line with branches to multiple actuators and a lubricant line with fittings that can service multiple valves, reducing the total number of separate hoses while maintaining independent control capability.
Solution Approach 2:
The single hose assembly is designed to serve multiple functions: it provides hydraulic pressure to multiple valve actuators through branched lines and delivers lubricant to multiple valve cavities through integrated fittings. This multi-functional design eliminates the need for separate dedicated hoses for each function.
2Reliability
If manual lubricant injection using a grease pump is used, then lubricant can be delivered to valve cavities, but the process is time-consuming and exposes operators to hazardous conditions
Solution Approach 1:
The system incorporates automatic lubrication features where lubricant is delivered to valve cavities through the integrated hose assembly without requiring manual intervention. The design allows lubricant to be pumped through the system and distributed to multiple valves automatically, reducing operator exposure and maintenance time.
3Adaptability or versatility
If multiple separate hoses are used for hydraulic and lubricant delivery, then connection flexibility is maintained, but installation time and costs increase significantly
Solution Approach 1:
Multiple hydraulic lines and lubricant lines are merged into a single integrated hose assembly that can be installed as one unit. This assembly includes pre-attached fittings and branches that maintain the flexibility to connect to multiple valves while reducing installation time compared to installing individual hoses separately.
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 significantly reduces the number of hoses required, decreases setup time and costs, and minimizes hazards by centralizing the connection of hydraulic and lubricant sources, improving operational efficiency and safety.
Implementation Method 1
The activation means may comprise an electrically, hydraulically or pneumatically operated valve, such as a solenoid operated valve
Implementation Method 2
Each valve comprises a hydraulic actuator which is operated by hydraulic pressure from a hydraulic pressure source
Implementation Method 3
The lubricant not only forms a barrier to prevent the ingress of fracking fluid into the cavity, but also cleans and coats the sealing surfaces of the valves
Data Source
AI summary
A system for operating and/or lubricating a plurality of valves mounted on a number of christmas trees, each valve including a hydraulic actuator operated by hydraulic pressure from a hydraulic pressure source and a lubricant inlet connected to an interior portion of the valve. The system includes a plurality of control units, each of which is associated with a respective valve and each of which has at least one of a hydraulic pressure line which is connectable to the hydraulic pressure source and a lubricant line which is connectable to the lubricant source. Each control unit is operable to selectively connect the hydraulic pressure source to the hydraulic actuator to thereby operate the valve and/or to selectively connect the lubricant source to the lubricant inlet to thereby communicate lubricant into the interior portion of the valve.