Wellsite Valve Position Detection With Universal Sensor Mounting
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Solution Overview
Problem
Current methods for detecting and indicating the position of valves at wellsites are inefficient and costly, requiring physical modifications, are vendor-specific, and do not facilitate easy sharing of data across different service operators, posing safety risks due to manual checks and limitations in data accessibility.
Innovation Solution
A sensor-based apparatus and system that contactlessly detects the position of valve moving parts, generating output signals indicative of the operational position, which can be communicated and displayed remotely, allowing for universal compatibility across different valve types and IT infrastructures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mounting equipment on the frac tree to detect valve position, then valve position information can be obtained, but different valve types require different mounting hardware which is costly and inefficient
Solution Approach 1:
The patent applies universality by designing a standardized mounting interface that can accommodate different valve types from various vendors. The mounting hardware is made universal through the use of standard threaded patterns (NPT or API 6A) that can be adapted to any valve type without custom machining, allowing the same detection equipment to serve multiple valve configurations.
Solution Approach 2:
The patent implements nesting by placing the position detection assembly inside or adjacent to the valve actuator housing. The detection components (sensor, target, mounting bracket) are nested within the existing actuator structure, eliminating the need for external custom mounting hardware while maintaining detection functionality.
2Measurement precision
If using contact-based position detection design, then position information can be obtained, but the equipment becomes exceedingly long in physical dimensions
Solution Approach 1:
The patent replaces the mechanical contact-based detection system with a non-contact sensing system. Instead of using physical contacts that require long shafts to reach the valve stem, the invention uses magnetic or optical sensors that can detect valve position remotely through the actuator housing, dramatically reducing the equipment length.
Solution Approach 2:
The patent transitions from a one-dimensional contact approach (long shaft reaching the valve stem) to a three-dimensional non-contact approach. The sensor and target are positioned in adjacent spaces within the actuator housing, using magnetic or optical fields that can penetrate or bridge the gap between components without requiring physical contact, thus reducing the overall length.
3Measurement precision
If permanently installing valve-position equipment as integral part of specialized accumulator, then position information is available, but data cannot be readily shared by different service operators and equipment is costly
Solution Approach 1:
The patent segments the position detection system into separate, modular components that can be independently installed on different valves. Each valve can have its own detection assembly that communicates with a centralized data collection system, allowing multiple service operators to access the data without requiring a completely integrated specialized accumulator system.
Solution Approach 2:
The patent introduces an intermediary data communication layer between the valve position sensors and the service operators. This intermediary system (wireless transmitters, data loggers, or communication modules) enables different service operators to access valve position information through standard interfaces, facilitating data sharing without requiring direct integration into proprietary specialized equipment.
4Measurement precision
If manually checking valve position by sending individual to visually check, then position information is obtained, but safety risks arise from entering hazardous areas
Solution Approach 1:
The patent implements self-service by enabling the valve position detection system to automatically monitor and report its own status without requiring human intervention. The sensors continuously detect valve position and transmit this information to operators, eliminating the need for personnel to physically enter hazardous areas to visually check valve positions.
Solution Approach 2:
The patent replaces the mechanical human inspection process with an automated sensing and communication system. Instead of sending personnel to physically observe valve positions, the system uses sensors, transmitters, and display devices to automatically provide position information, thereby eliminating exposure to hazardous conditions.
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
Enables safe and efficient wellsite operations by providing accurate and shared valve position information, reducing the need for manual checks and enhancing data accessibility, thus preventing accidents and improving operational efficiency.
Implementation Method 1
The sensor is configured to be in communication with a target surface for contactless detecting of the operational position of the valve based upon the detected distance between the sensor and the target surface
Data Source
AI summary
Embodiments of the present disclosure relate to an apparatus, a system, and a method for detecting and indicating the operational position of a valve of wellsite equipment. The apparatus comprises a mount portion and a housing portion. The mount is operatively coupled to a non-moving part of the valve and the housing portion is configured to receive a sensor therewithin. The sensor is configured to detect the position of a moving part of the valve and to provide an output signal indicative of the position of the moving part of the valve. The position of the moving part of the valve is indicative of the operational position of the valve. The system comprises one or more such apparatus for detecting and indicating the operational position of one or more valves on a wellsite or well pad.