Valve Operator Conversion System for Fracturing Trees
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Solution Overview
Problem
In hydraulic fracturing operations, the high cost and non-productive time of actuated valves are significant issues due to their expensive nature and the fact that many are not in use during large portions of fracturing operations, leading to inefficient asset utilization.
Innovation Solution
A method and system for converting actuated valves to manually operated valves using a rotary to linear converter and bearing system, allowing for remote operation and quick switching between actuated and manual operation modes, reducing the need for actuated valves on non-active trees and optimizing asset utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If actuated valves are installed on multiple fracturing trees, then operational efficiency and remote control capability are improved, but cost and asset utilization efficiency deteriorate due to expensive equipment and idle periods
Solution Approach 1:
The valve operator is made dynamically configurable, allowing switching between manual and actuated operation modes. This enables the system to adapt its complexity level based on operational requirements, using actuated valves only when remote operation is needed and manual operation otherwise, thereby reducing overall cost while maintaining productivity when necessary.
Solution Approach 2:
The valve assembly is designed to accept both manual operators and actuated operators, making it universally compatible with either type of operator. This multi-functionality allows the same valve body to serve different operational needs, reducing the need for separate valve assemblies for manual and actuated applications and optimizing asset utilization.
2Ease of operation
If actuated valves are used on all fracturing trees, then remote operation capability is improved, but asset utilization deteriorates as expensive actuators remain idle during non-use periods
Solution Approach 1:
The operator configuration is made dynamic, allowing the system to switch between manual and actuated modes based on real-time operational requirements. This enables remote operation capability to be activated only when needed, improving asset utilization by avoiding continuous deployment of expensive actuators across all trees when their services are not required.
Solution Approach 2:
Actuated operators are deployed selectively to specific valves and trees based on local operational requirements rather than uniformly across all equipment. This localized application of actuation capability ensures that expensive actuators are utilized only where remote operation provides actual value, optimizing overall asset utilization while maintaining ease of operation where needed.
3Device complexity
If manual operators are used on all valves, then cost is reduced, but operational efficiency and remote control capability deteriorate
Solution Approach 1:
The system dynamically adjusts the level of automation based on operational demands, using manual operators for routine operations to reduce cost while enabling actuated operators to be deployed when operational efficiency and remote control are required, thereby optimizing the balance between cost and productivity.
Solution Approach 2:
The degree of automation is changed as a controllable parameter, allowing the system to operate in manual mode for cost-effective routine tasks and switch to actuated mode when productivity and remote control capabilities become critical, thus optimizing operational efficiency while managing costs.
4Productivity
If multiple actuated valves are deployed simultaneously, then operational capability is improved, but asset utilization and cost efficiency deteriorate due to simultaneous idle periods
Solution Approach 1:
The deployment of actuated valves is made dynamic and sequential rather than simultaneous. Actuated operators are deployed to different trees in sequence based on operational schedules, allowing each actuator to be actively used during its designated operational window and minimizing simultaneous idle periods, thereby improving asset utilization while maintaining operational capability.
Solution Approach 2:
The use of actuated valves follows a periodic pattern where different trees are activated in sequence rather than simultaneously. This periodic deployment ensures that actuated valves are actively utilized during their designated periods and properly stored or deactivated during non-use periods, optimizing asset utilization while maintaining the necessary operational capability across multiple trees.
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 approach reduces costs by minimizing the use of expensive actuated valves during non-active periods, increasing asset utilization, and maintaining operational efficiency by allowing actuated valves to be used only where needed, thereby decreasing overall operational expenses and downtime.
Implementation Method 1
converting actuated valves to manually operated valves using a rotary to linear converter and bearing system
Implementation Method 2
converting actuated valves to manually operated valves using a rotary to linear converter and bearing system
Data Source
AI summary
Embodiments of the present disclosure include a method of replacing valve operation methods during fracturing operations including installing a first operator on a first valve of a first fracturing tree. The method also includes installing a second operator on a second valve of a second fracturing tree, the second fracturing tree being adjacent the first fracturing tree. The method also includes removing the first operator from the first valve, the first valve maintaining a position on the first fracturing tree after the first operator is removed. The method further includes removing the second operator from the second valve, the second valve maintaining a position on the second fracturing tree after the second operator is removed. The method also includes installing the first operator on the second valve after the first operator is removed from the first valve and after the second operator is removed from the second valve.