Wellhead Valve Control With Pressure Equalization Interlocks
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Solution Overview
Problem
Current fluid systems in oil and gas operations, particularly in hydraulic fracturing, face challenges in efficiently managing pressure differentials and automating valve operations, leading to potential safety hazards and inefficiencies.
Innovation Solution
A system comprising a manifold assembly, zipper modules, fracturing lines, and a controller that uses pressure sensors and equalization valves to intelligently manage pressure differentials and automate valve operations, ensuring safe and efficient hydraulic fracturing processes by remotely controlling valves and delivering and metering grease to process valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual valve operations are used in hydraulic fracturing systems, then personnel can directly control valve operations, but safety hazards increase due to personnel exposure in hazardous areas
Solution Approach 1:
The patent replaces manual mechanical valve operation with an automated control system that uses pressure sensors, controllers, and actuators to open and close valves automatically based on detected pressure differentials, eliminating the need for personnel to physically operate valves in hazardous areas
Solution Approach 2:
The system enables self-service operation where the fluid handling system automatically monitors its own pressure conditions through sensors and autonomously actuates valves through the controller without requiring external manual intervention, allowing the system to manage itself safely
2Productivity
If pressure differentials are not actively managed, then system operation is simpler, but operational efficiency decreases and safety hazards increase
Solution Approach 1:
The patent implements feedback control where pressure sensors continuously monitor pressure differentials across valves and feed this information to the controller, which automatically adjusts valve actuation to maintain safe and efficient pressure differentials during hydraulic fracturing operations
Solution Approach 2:
The system performs preliminary action by detecting pressure differentials before they reach hazardous levels and preemptively actuating valves to prevent unsafe conditions, ensuring pressure management occurs proactively rather than reactively
3Extent of automation
If valves are not automatically actuated, then system complexity is reduced, but the need for personnel in hazardous areas increases
Solution Approach 1:
The patent replaces manual valve actuation with automated actuators controlled by a controller that receives signals from pressure sensors, creating an automated mechanical system that eliminates personnel exposure while managing the necessary control complexity
Solution Approach 2:
The controller serves as an intermediary between the pressure sensors and the valve actuators, processing sensor data and translating it into appropriate actuator commands, thereby enabling automated valve operation without requiring direct personnel involvement in hazardous areas
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
The system enhances safety by reducing the need for personnel in hazardous areas, improves operational efficiency by automating valve control, and ensures precise pressure management, thereby optimizing hydraulic fracturing operations.
Implementation Method 1
A controller is operably coupled to the equalization valves and to pressure sensors
Implementation Method 2
A system includes a hydraulic power unit, a hydraulic manifold, and a plurality of valves
Implementation Method 3
delivering and metering grease to process valves
Data Source
AI summary
Methods and apparatus according to which a first valve is opened, or kept open, the first valve being part of a wellhead including a flow component above the first valve. The method may further include detecting a state of the first valve and, in response to detecting the state of the first valve, metering an amount of grease to the first valve. In addition, or instead, the method may further include opening, or keeping open, a second valve, the second valve being operably coupled to the wellhead and positioned above the flow component, and, after opening, or keeping open, each of the first and second valves, detecting whether the second valve is open or closed, in response to detecting that the second valve is open, preventing the first valve from being closed, and in response to detecting that the second valve is closed, allowing the first valve to be closed.