Wellbore Pump Maintenance With Ballistic Barriers and Remote Isolation
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Solution Overview
Problem
Conventional pumping units require time-consuming and inefficient maintenance procedures, leading to job downtime due to the need to move the pump out of the 'red zone' of pressurized wellbore services equipment, which negatively impacts pumping efficiency.
Innovation Solution
The use of shielding, remote isolation, and de-pressurization techniques allows maintenance to be performed safely on the pump within the red zone by interposing a ballistic barrier between the pumping unit and the pressurized wellbore services manifold, enabling remote valve operation and fluid bleed-off to create a safe working environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the pump is removed from the red zone for maintenance, then worker safety is improved, but job downtime increases and pumping efficiency decreases
Solution Approach 1:
The system segments the maintenance operation from the pressurized system by introducing a remote isolation mechanism. The pump can be isolated from the pressurized manifold using remote valves and lockingout devices, creating a separate safe maintenance zone while the rest of the system remains pressurized and operational. This allows maintenance to proceed without moving the pump from the red zone.
Solution Approach 2:
A remote isolation system acts as an intermediary between the pressurized manifold and the pump. This intermediary mechanism includes remote-controlled valves, lockingout devices, and communication systems that enable safe disconnection and maintenance of the pump while it remains physically connected to the pressurized system, eliminating the need to move the pump out of the red zone.
2Object-affected harmful factors
If the pump is moved out of the red zone for maintenance, then safety is improved, but operational efficiency and productivity deteriorate
Solution Approach 1:
The system enables continuous operation of the wellbore services manifold while the pump undergoes maintenance. Other pumps on the manifold can continue operating, and the isolated pump can be maintained without halting the entire system. This maintains productivity and pumping efficiency while ensuring safety through remote isolation.
Solution Approach 2:
The maintenance operation is segmented from the operational system through remote isolation. The pump can be individually isolated and maintained while the rest of the manifold system continues to operate at full capacity, preventing any impact on overall pumping efficiency and productivity.
3Loss of time
If remote isolation and de-pressurization techniques are used, then maintenance can be performed in the red zone reducing downtime, but device complexity increases
Solution Approach 1:
A remote isolation system with automated valves and lockingout devices serves as an intermediary that enables safe in-situ maintenance. The complexity is managed through automated control systems and standardized procedures, allowing the pump to be isolated and maintained without manual intervention in the red zone, significantly reducing maintenance downtime.
Solution Approach 2:
Manual mechanical isolation procedures are replaced with remote-controlled automated systems. The lockingout device and remote valves can be operated from a safe location, eliminating the need for workers to physically manipulate valves and connections in the hazardous red zone, thereby reducing maintenance downtime while managing complexity through automation.
4Object-affected harmful factors
If shielding is introduced to enable in-situ maintenance, then worker safety is maintained while reducing downtime, but device complexity increases
Solution Approach 1:
Ballistic shielding acts as a physical intermediary that creates a safe work zone within the red zone. The shielding barrier protects workers from potential hazards while they perform maintenance on the isolated pump, allowing safety to be maintained without requiring the pump to be moved, thereby reducing downtime while managing complexity through physical protection.
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 downtime by allowing maintenance on the pump without disconnecting it from the pressurized manifold, ensuring worker safety and maintaining operational efficiency.
Implementation Method 1
a ballistic barrier disposed between a pumping unit and a wellbore services manifold trailer and configured to effectively shield a worker performing maintenance on a pump of the pumping unit from the pressurized wellbore services manifold trailer
Implementation Method 2
an inlet flowline valve configured for remote activation between an open and a closed position
Implementation Method 3
remotely isolating the pump from the pressurized wellbore services manifold trailer... and performing maintenance on the pump in situ while the pump remains connected to the wellbore services manifold trailer
Data Source
AI summary
A secondary barrier is used adjacent a pump of a pumping unit that is in fluid communication with a wellbore services manifold system having a ballistic barrier. The secondary barrier includes a first portion configured to be disposed in proximity to a fluid end of the pump and configured to be disposed between the fluid end of the pump and a power end of an adjacent pumping unit pump, and a second portion configured to face the ballistic barrier and the wellbore services manifold system.