US20200309319A1 - Method and Apparatus for Monitoring and On-demand Lubricating of Industrial Valves - Google Patents

Method and Apparatus for Monitoring and On-demand Lubricating of Industrial Valves Download PDF

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Publication number
US20200309319A1
US20200309319A1 US16/792,449 US202016792449A US2020309319A1 US 20200309319 A1 US20200309319 A1 US 20200309319A1 US 202016792449 A US202016792449 A US 202016792449A US 2020309319 A1 US2020309319 A1 US 2020309319A1
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Prior art keywords
valve
lubricant
lubrication
pressure
gate
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US16/792,449
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Jason Pitcher
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Batfer Investment SA
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Individual
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Priority to US16/792,449 priority Critical patent/US20200309319A1/en
Publication of US20200309319A1 publication Critical patent/US20200309319A1/en
Priority to CA3106193A priority patent/CA3106193A1/en
Priority to ARP210100178A priority patent/AR121132A1/es
Priority to US17/198,202 priority patent/US20210199243A1/en
Assigned to Batfer Investment S.A. reassignment Batfer Investment S.A. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: PITCHER, JASON
Abandoned legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16N—LUBRICATING
    • F16N29/00—Special means in lubricating arrangements or systems providing for the indication or detection of undesired conditions; Use of devices responsive to conditions in lubricating arrangements or systems
    • F16N29/02—Special means in lubricating arrangements or systems providing for the indication or detection of undesired conditions; Use of devices responsive to conditions in lubricating arrangements or systems for influencing the supply of lubricant
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16N—LUBRICATING
    • F16N7/00—Arrangements for supplying oil or unspecified lubricant from a stationary reservoir or the equivalent in or on the machine or member to be lubricated
    • F16N7/38—Arrangements for supplying oil or unspecified lubricant from a stationary reservoir or the equivalent in or on the machine or member to be lubricated with a separate pump; Central lubrication systems
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16N—LUBRICATING
    • F16N2210/00—Applications
    • F16N2210/26—Spinning spindles
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16N—LUBRICATING
    • F16N2230/00—Signal processing
    • F16N2230/22—Signal processing using counters
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16N—LUBRICATING
    • F16N2250/00—Measuring
    • F16N2250/04—Pressure
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16N—LUBRICATING
    • F16N2270/00—Controlling
    • F16N2270/20—Amount of lubricant
    • F16N2270/30—Amount of lubricant intermittent

Definitions

  • the invention relates generally to maintenance of valves for control of fluid flow. More particularly, the invention relates to automatic preventative maintenance greasing, or lubricating, of industrial valves in-service through coordination with regular operational valve operations.
  • Valves are commonly used to control passage through pipes and hoses as well as in/out of equipment, vessels, etc. Valves regulate the flow of gasses, liquids, slurries, or loose materials (hereinafter collectively referenced as fluids) through an aperture or conduit such as a hose, tube, or pipe (hereinafter collectively referenced as pipe or line), by opening, closing, or otherwise interrupting the path of flow.
  • Valves are manufactured by assembling multiple mechanical parts, primarily comprising: the body (an outer shell), trim (a combination of replaceable wetted parts), stem, bonnet (body end cap), and an actioning mechanism for applying a motive force (usually to a gate via the stem). Valves may be bifurcated into small bore sizes, generally 2 inches or less; and commercial/industrial valves, above 2 inches in diameter (generally designated as ‘Large Bore’).
  • Valves may be operated, or actioned, via rotating a stem with levers, and/or wheels (collectively called the valve ‘operator’). These are referred to as ‘manual valves.’ Valves may also be actioned via electromechanical devices (‘actuators’) that may be electric, pneumatic, hydraulic, gas over oil, etc. and are collectively designated as ‘actuated valves,’ which may optionally include a secondary manual operator for safety.
  • actuators electromechanical devices
  • a valve controls fluid flow and pressure by: stopping and starting fluid flow; varying fluid flow quantities, commonly referenced as ‘throttling’; directing fluid flow directions, ‘switching’; regulating downstream pressure; and/or relieving excessive pressures or ‘venting’.
  • Actuation of a valve may be through manual, hydraulic, pneumatic, or electric application of motive forces. Examples of common types include the ball valve, butterfly valve, globe valve, gate valve, plug valve, diaphragm valve, reducing valve, needle valve, check valve, and safety/relief valve.
  • the force applied may require a quarter rotation of a valve stem as in a ball valve, or require multiple complete revolutions, as in a globe valve.
  • valve type was designed for specific needs. Some valves are capable of throttling, while others can only start and stop flow. Some valve designs work well in corrosive systems, offer fine-control capabilities, and other valves are designed specifically for handling high pressure, caustics, abrasives, or combinations thereof. Each valve type, design, and final embodiment has certain inherent advantages and disadvantages.
  • references herein will be to API specifications for fluids in the O & G (Oil and Gas industry). Examples presented will focus on exploration and production processes, particularly emphasizing the inhospitable environment (as far as valves are concerned) of high-pressure fracturing operations.
  • API ‘6A specification’ is the international standard for valves specific to wellhead and Christmas tree equipment, used in the petroleum and natural gas industries. API 6A valves are designed for the demanding environments of onshore and offshore drilling; production, pressure, and temperature extremes; and heavy oil, sour, and subsea applications, including hydraulic fracturing operations incorporating pressure ratings in excess of 20,000 PSI (pounds per square inch).
  • a gate valve is the type commonly preferred in industrial piping.
  • LBGV hydraulically actuated large bore gate valve
  • gate valves The most significant feature of gate valves is their low obstruction to the fluid flow. Turbulence, like that caused by globe valves, causes a drop in the fluid's line pressure. When fluid is moving through long lengths of pipe, or when energy is being expended to increase pressure above a threshold level for a particular task, it is important that valve selection does not decrease that pressure. When a gate valve is wide open, the gate, (or wedge) is positioned entirely out of the flow path providing a straight passage through the valve body.
  • a gate valve is the preferred option over all other designs to avoid pressure drop in the lines.
  • gate valves should only be used in the fully open or closed positions; never for throttling purposes. Gates in intermediate, partially open, positions allow seals and seats to quickly erode as well as creating noisy chatter that propagates along the line.
  • partially open gates may allow production fluid exposure to lubricating grease in the valve cavity. Force, heat, and/or chemicals can break down lubricant and washout the valve's body cavity leaving the stem, gate, and seats unlubricated and open to wear. This is especially true in applications like high pressure frac operations where chemicals and proppants are intentionally introduced into the fluid.
  • Each valve manufacturer provides grease fittings at key locations on the valve body and provides instructions on valve maintenance. These manufacturer-specified procedures and intervals are based on factors, such as but not limited to: design, construction, materials, life expectancy, and cycling frequency.
  • a theoretical valve has a grease fitting protected by a grease fitting cap located on the bonnet flange for body cavity lubrication, and another grease fitting on the bearing cap for thrust bearing lubrication.
  • the manufacturer recommends body cavity lubrication every ten operating cycles, or monthly, whichever comes first.
  • Lubrication reduces friction between moving parts by substituting fluid friction for solid fiction. Reducing friction reduces the amount of energy that is dissipated as heat and the amount of energy required to perform mechanical actions. Lubrication is a matter of vital importance throughout industry. Automated lubrication systems exist to reduce the need for someone to constantly run around the equipment with an oil can or grease gun in hand.
  • Automated lubrication systems supply a continuous flow of lubricant to bearings, shafts, pulleys, gears, etc. using different methods ranging from gravity fed wicks dripping oil, or spinning gears splashing oil around a gear chamber, to pumps forcing lubricant under pressure into mechanical parts in measured quantities.
  • Centralized lubrication systems dispense lubricant from a supply reservoir by pumping it to divider valves or metering injectors.
  • Metering injectors are sized to fill with fluid, and when triggered, inject the quantity of fluid into its connected lubrication point.
  • Divider valves disperse lubricant received at frequent intervals directly to each covered point, dividing the total quantity according to set ratios. Sizing of the injectors, or configuration of the divider ratios can be adjusted along with the frequency of the intervals ensuring proper lubrication of continuously operating equipment.
  • Typical frac operations use as much as 40,000 barrels of water, stored in holding tanks/trucks or a pond.
  • the water is pumped by a Hydration Unit to a Blender truck and is mixed with chemicals supplied by a LAS truck (Liquid Additive System).
  • LAS truck Liquid Additive System
  • Sand Kings trucks or storage units for holding proppant feed the grit into the Blender for incorporation with the slime to produce frac fluid.
  • Frac fluid is fed through a manifold sled's, called the ‘Missile’, low pressure lines to 8-15 High-Pressure Pump trucks.
  • the trucks pressurize the frac fluid and return it to the Missile to be directed down the wellbore.
  • a Back-Pressure truck feeds back pressure to the well annular countering the forces, to ease equipment strain, and containing frac fluid within the well.
  • LBGVs Large bore gate valves
  • O & G production and used extensively in hydraulic fracturing operations such as those described above.
  • the required maintenance is dangerous to perform around the high-pressure lines but shutting down operations and relieving line pressure to allow lubrication is a costly option.
  • Downtime must be minimized to meet schedules which typically allow 2-3 days for a job before moving to the next scheduled well.
  • lubricant is pumped into a first lubricant port, an injecting port, filling the body cavity and flushing spent lubricant, fluids, and/or contaminants out of a second lubricant port.
  • the lower port may have a back-pressure tool so the new lubricant can approach operating pressure.
  • the second port may be closed first so pressure can be applied through the injecting port.
  • a hand operated grease pump may be sufficient to accomplish this job.
  • lubricant quantity for the body cavity is dependent on the valve's bore size and pressure rating, often requiring over 20 lbs. of grease, more than many hand pumps can deliver.
  • a typical frac-job utilizing only a single missile and the accompanying entourage of: sand kings, storage tanks, hydration units, blender trucks, pump trucks, etc. will require a conservative estimate of 50-70 LBGVs to interconnect. These LBGVs will cycle a minimum of once during every frac-op and require maintenance every 4-7 cycles under most company procedures.
  • FIG. 1 illustrates a typical layout of O & G equipment to contain, mix, pressurize, and inject hydraulic fracturing fluids into a wellbore for hydraulic fracturing operations.
  • FIG. 2A illustrates a manually operated large bore gate valve for use in typical O&G operations.
  • FIG. 2B illustrates an option for monitoring physical operation of a valve, here through sensing movement of a valve's balancing stem.
  • FIG. 2C illustrates an actuated large bore gate valve with secondary manual operation and balancing stem for use in typical O & G operation.
  • FIG. 2D illustrates an option for monitoring operation of a manual valve.
  • FIG. 2E illustrates an option for monitoring physical operation of an actuated valve with a secondary manual operator.
  • FIG. 3A shows a centralized sequential lubrication system for intermittent lubrication of continuous operation devices.
  • FIG. 3B shows a centralized parallel lubrication system for intermittent lubrication of continuous operation devices.
  • FIG. 4 shows a centralized on-demand lubrication system in accordance with an exemplary embodiment of the innovation.
  • FIG. 5 shows a centralized on-demand lubrication system, optionally cooperating with a control system, in accordance with an exemplary embodiment of the innovation.
  • FIG. 6 shows a centralized on-demand lubrication system integrated with a valve control system, in accordance with an exemplary embodiment of the innovation.
  • FIG. 7 shows a method of on-demand lubrication by a flow control system, in accordance with an exemplary embodiment of the innovation.
  • the innovation described herein automates valve maintenance by monitoring valve operation and delivering lubricant on-demand according to actual usage and coordinating the lubrication of the valve with in-service valve operations. This avoids downtime caused by taking a valve out-of-service for maintenance or more extensive repairs due to improper maintenance.
  • the coordination with in-service valve operations also eliminates effects of unnecessary (i.e. ‘maintenance only’) valve operations, and ensure maintenance is performed in accordance with company procedure. Additionally, alleviating maintenance personnel from this routine task lowers their exposure to hazards and increases their availability for other tasks.
  • Valve operations are monitored by a programmable logic controller that also controls delivery from a lubricant source to the valve.
  • the logic controller delivers lubricant to the valve when operations require, and the valve is in a condition to accept the lubricant.
  • the requirements for accepting, and proper condition to accept, lubricant is dictated by the specific valve and application environment.
  • the valve may be a plug valve which may be lubricated in a full open or full close position but must be pressure monitored to avoid over pressurization and possible damage.
  • the valve may need to be in either a full open or full close position but requires venting during lubricant injection.
  • Such valves often have upper and lower lubrication ports (grease fittings).
  • grease fittings may be replaced by control valves on lubrication ports to automate the regulation of lubricant or grease flow.
  • control valves connected to lubrication ports, have three states allowing the port to be: closed, connected to a lubricant supply, or vented.
  • a control valve may be throttled to control lubricant delivery.
  • throttling may be accomplished by control of the pump regulating delivery pressure of the lubricant supply.
  • secondary controls may be positioned near the valve and communicate to the controller through the sensor wired communication medium employed by the controller to monitor valve actuation.
  • the sensor communications and optional secondary controls may utilize a wireless communication medium.
  • An expansion of the preferred embodiment concerns cleaners and sealants for various valve types.
  • the fluid control equipment and controller may also provide delivery from a secondary reservoir of other fluids such as cleaner.
  • the controller being configured to optionally inject cleaner into a valve, such as a floating ball valve, prior to introducing lubricant/sealant during maintenance to flush debris into the fluid flow. Further specifics should be obvious to one skilled in the arts and is beyond the scope of this application.
  • a valve that traps pressure within the body cavity may experience pressure locking when line pressure decreases. In a pressure locked state, the valve is inoperable until body cavity pressure is relieved. Due to the high pressures involved, the equalizing procedures are considered dangerous, and is usually entrusted to skilled personnel exercising the utmost care.
  • a controller may include a sensor monitoring temperature of the valve body.
  • the controller being cognizant of possible binding can be configured to “bump” (provide a short burst of motive power) the valve's actuator to disengage the current limit switch prior to attempting to fully actuate the valve, possibly causing damage to the valve and/or actuator.
  • the controller may alert to the situation so personnel can heat the valve body to relieve the thermal binding without damage.
  • gate valves may require lubricating to prevent seal wear after every 2 nd or 3 rd cycling, i.e. moving from full-open to full-close, or vice versa.
  • High pressure in the lines makes it hazardous for personnel to be in the surrounding area.
  • the extensive number of valves complicates tracking maintenance, and any downtime can be very costly.
  • the preferred embodiment monitors valve operation and at prescribed intervals lubricates the valve according to set procedures.
  • the controller counts valve cycles for each valve and upon exceeding a limit, attempts to lubricate the valve in a manner that is minimally disruptive to service operations.
  • Minimally disruptive may be determined by configuration of the controller, which may be cognizant of operations and have sufficient artificial intelligence to: cycle an unused valve as required, delay a request for valve actuation for a limited period of time, or temporarily postpone a maintenance lubrication. Such controller configuration is beyond the current scope.
  • a lubrication port is opened venting spent fluids, the lubricant delivery source supplies lubricant, injecting a specific quantity through another lubrication port, into the valve body, forcing the venting of the spent fluids.
  • the venting lubrication port is closed, and the injecting lubrication port is pressurized as required, then closed, leaving the valve serviced and operational.
  • the lubricant delivery source is centralized and supplies lubricant at low pressure to a plurality of secondary pumps which pressurize the lubricant for injection into individual valves.
  • the low-pressure lubricant is delivered in large quantity and secondary pumps increase pressure and deliver high-pressure lubricant in a smaller quantity to supply an individual valve, the tended valve.
  • a secondary pump may have a local reservoir sized according to the tended valve's lubricant requirements.
  • spent fluids are collected during venting from the valve.
  • the collection may be centralized such that the venting valves are interconnected and extended for final discharge into a centralized reservoir.
  • control valves may be used to route one lubrication port to the lubricant supply and another lubrication port to the discharge collection allowing options for more efficient lubrication depending on, for instance, gate position.
  • a programmable logic controller monitors valve position and determines lubrication needs independent of manual operation or actuation by a second controller.
  • sensors provide information to the controller regarding valve operations.
  • sensors may be unique to the controller or provide a shared signal to one or more controllers associated with the valve.
  • the second controller may communicate with the first controller.
  • the first and second controllers may be a single controller to actuate the valve and control the lubrication.
  • FIG. 1 illustrates a typical layout of O & G equipment to contain, mix, pressurize, and inject hydraulic fracturing fluids into a wellbore for hydraulic fracturing operations.
  • the configuration of high-pressure hydraulic fracturing equipment ( 100 ) injects high-pressure fracturing fluids down a wellbore ( 110 ), to cause fracturing of rock formations thousands of feet under the surface.
  • a hydration unit 180
  • water lines 155
  • a chemical supply commonly referred to as a LAS truck
  • the slime has higher viscosity than water allowing suspension of sand/grit/abrasives known as proppant stored in several sand kings ( 174 ).
  • a blender truck ( 170 ) mixes the supplied slime ( 155 ) with the supply of proppant ( 157 ) to create fracturing fluid.
  • the fracturing fluid is supplied through low pressure lines ( 152 ) to a manifold sled, also known as a missile ( 160 ) for distribution to a fleet of high pressure fracturing pump trucks ( 165 ) which increase the fluid pressure as high as 20,000 PSI, and return the high pressure fluid through high pressure lines ( 125 ) to the missile ( 160 ) to collectively be injected ( 123 ) into the wellbore ( 110 ).
  • a manifold sled also known as a missile ( 160 ) for distribution to a fleet of high pressure fracturing pump trucks ( 165 ) which increase the fluid pressure as high as 20,000 PSI, and return the high pressure fluid through high pressure lines ( 125 ) to the missile ( 160 ) to collectively be injected ( 123 ) into the wellbore ( 110 ).
  • the high-pressure fluid is held in the wellbore ( 110 ) by balancing annular differential pressure by fluid back pressure ( 127 ) generated by a back-pressure truck ( 130 ).
  • Completing a frac-op involves closing off high-pressure lines to the wellbore ( 123 and 127 ) to allow spent fluid up the wellbore ( 110 ) to the return line ( 154 ) to the flowback tanks ( 140 ) or holding pond.
  • the entire operation is managed from a data monitoring van ( 190 ) which directs composition, pressure, flow, hold, and return of fluids through actuation of many valves ( 200 ), only a few of which are depicted here.
  • FIG. 2A illustrates a manually operated large bore gate valve for use in typical O&G operations.
  • the valve ( 200 ) has a valve body ( 210 ) encircling a flow path interruptible/controllable by a gate ( 230 ), illustrated here in a full-open position.
  • Other valves may interrupt the flow path in a more controllable manner through the positioning of a plate, disc, diaphragm, plug, or ball depending on the valve design.
  • the gate ( 230 ) connects to a stern ( 250 ), and an optional balancing stem ( 255 ) for actuation of the valve, here by a manual actuator ( 263 , a hand wheel).
  • the stems ( 250 and 255 ) typically pass through bonnets ( 240 ) which provide access to the stems ( 250 and 255 ) and gate ( 230 ) within the body cavity ( 212 ) for extensive rework and heavy maintenance.
  • the lubricant attempts to preserve gate seals, and seats, as well as the gate itself ( 230 ).
  • FIG. 2B illustrates an option. for monitoring physical operation of a valve, here through sensing movement of a valve's balancing stem.
  • the balancing stem ( 255 ) projects through the bottom of the valve body, or lower bonnet ( 240 ).
  • Actuation of the valve gate ( 230 , previous FIG.) moves the connected stems ( 255 here and 250 previous FIG.) changing the signals emitted through sensor wiring ( 282 ) by the sensors, shown here as an upper limit sensor ( 285 a ) and a lower limit sensor ( 285 b ).
  • FIG. 2C illustrates an actuated large bore gate valve with secondary manual operation and balancing stem for use in typical 0 & G operation.
  • the valve ( 200 ) has a body ( 210 , not indicated) which encircles a flow path interruptible by a gate ( 230 ), illustrated here in a full-closed position. Note the gate valve design is best suited for allowing or preventing fluid flow and can be damaged if employed for extensive periods of flow regulation.
  • the gate ( 230 ) connects to a stem ( 250 ) for actuation of the valve by an actuator ( 260 ), here a hydraulic actuator ( 260 ) with a control line ( 280 , not shown) connected to the hydraulic port ( 265 ), and with secondary manual actuation through a manual actuator ( 263 , a hand wheel).
  • the stem ( 250 ) is complimented by a balancing stem ( 255 ), and passes through an upper bonnet ( 240 ) which provide access to the stems ( 250 and 255 ) and gate ( 230 ) within the body cavity ( 212 , not designated) for extensive rework and heavy maintenance.
  • FIG. 2D illustrates an option for monitoring operation of a manual valve.
  • the valve body ( 210 not designated) has an upper lubrication port ( 220 ) and lower lubrication port ( 225 ) for lubricating the gate ( 230 ) connected to the stem ( 250 ).
  • the actuator's ( 260 ) motive power manual operation by rotating the hand wheel ( 263 ), moves the stern ( 250 ) to activate an upper limit switch ( 285 a ) or a lower limit switch ( 285 b ), sending a signal by wire ( 282 ) to a monitor.
  • Deactivating of one switch ( 285 a or 285 b ) without activating the other switch ( 285 b or 285 a ) indicates position along the travel ( 287 ), indicating the valve is partially engaged. This is an undesired position for a gate valve and may be detected by allowing a maximum time for valve transition, with an optional alarm being raised by the monitor.
  • FIG. 2E illustrates an option for monitoring physical operation of an actuated valve with a secondary manual operator.
  • the valve body ( 210 not designated) has an upper lubrication port ( 220 ) and lower lubrication port ( 225 ) for lubricating the gate ( 230 ) connected to the stem ( 250 ).
  • FIG. 3A shows a centralized sequential lubrication system for intermittent lubrication of continuous operation devices.
  • This continuous automatic lubrication system cascades rations of lubricant for sequential distribution among a plurality of devices periodically.
  • the intermittent sequential lubrication system ( 300 a ) has a pumping unit ( 310 ) with a lubricant reservoir ( 312 ), a pressure pump ( 315 ) and a pressure gauge ( 317 ).
  • a timer/controller ( 350 ) powers the pumping unit ( 310 ) delivering lubricant to the system for one or more cycles as designated by an end-of-cycle indicator ( 360 ).
  • the pumping unit ( 310 ) injects lubricant through supply lines ( 330 ) to a metering device ( 340 ), here a divider valve or divider ( 340 a ).
  • the divider ( 340 a ) sequentially delivers metered quantities of lubricant to each of its ports, cascading lubricant of unused ports to increase the quantity delivered to the next sequential port.
  • the ports of the divider ( 340 a ) may distribute fluid to supply lines ( 330 ) leading to additional dividers ( 340 a ) or to delivery lines ( 335 ) connected to fittings or bearings/joints/gears ( 305 ) serviced by the system.
  • FIG. 3B shows a centralized parallel lubrication system for intermittent lubrication of continuous operation devices.
  • This lubrication system meters out measured quantities of lubricant to be simultaneously injected in a plurality of device intermittently.
  • the intermittent parallel lubrication system ( 300 b ) has a pumping unit ( 310 ) with a lubricant reservoir ( 312 ), a pressure pump ( 315 ) and a pressure gauge ( 317 , not designated).
  • a timer/controller ( 350 ) powers the pumping unit ( 310 ) delivering lubricant to the system for one or more cycles as designated by an end-of-cycle indicator ( 360 ), which in this case is a pressure sensor ( 360 a ) and pressure relief trigger ( 360 b ).
  • the pumping unit ( 310 ) injects lubricant through supply lines ( 330 ) to feed metering devices ( 340 ), here metering injectors or injectors ( 340 b ).
  • the injectors ( 340 b ) independently collect and hold specific quantities of lubricant until pressure builds in the supply line ( 330 ) triggering the end-of-cycle indicator ( 360 ) to release the pressure.
  • the relief of pressure causes all injectors ( 340 b ) to each deliver their collected quantity of lubricant through delivery lines ( 335 ) connected by fittings ( 370 ) to the individual bearings/joints/gears ( 305 ) serviced by the system.
  • FIG. 4 shows a centralized on-demand lubrication system in accordance with an exemplary embodiment of the innovation.
  • the on-demand lubrication system ( 300 c ) has a programmable logic control unit, a controller ( 400 ) monitoring actuation of a valve ( 200 ), here by a manually powered actuator ( 260 ) for positioning of the gate ( 230 ) through manipulation of the stem ( 250 ).
  • the gate's ( 230 ) travel ( 287 ) is indicated by signal lines ( 282 ) from the upper limit switch ( 285 a ) and/or lower limit switch ( 285 b ) positioned on the stem ( 250 ) to the controller ( 400 ).
  • the valve's ( 200 ) gate ( 230 ) is in the fully open position as indicated by the upper limit sensor ( 285 a ), or the fully close position as indicated by the lower limit sensor ( 285 b ), lubrication maintenance may occur if needed.
  • a solenoid control valve specifically a solenoid operated directional spool-type control valve, one skilled in the art will appreciate other control options.
  • a pressure pump ( 315 ) in a centralized lubricant pump unit ( 310 , not indicated) distributes lubricant through a supply line ( 330 ) where an optional secondary pump ( 430 ) increases lubricant pressure along a delivery line ( 335 ).
  • the delivery line ( 335 ) may be routed by another solenoid control valve ( 410 ) to another lubrication port ( 225 or 220 ), the ‘injecting port,’ to deliver a measured quantity of lubricant in accordance with the valve's ( 200 ) specifications.
  • This inflow of pressurized lubricant through the injecting lubrication port simultaneously forces the venting of spent fluids out through the venting lubrication port to the centralized collection ( 312 ′) through the return line ( 337 ).
  • valve designs may allow for injecting lubricant simultaneous in more than one lubrication port, or that venting may occur through the flow pathway making venting unnecessary.
  • a measured quantity of lubricant may not be a specific quantity, but an undetermined amount required to achieve a desired pressure change at the lubrication port, which may be detected by monitor of the supply line or delivery lines.
  • FIG. 5 shows a centralized on-demand lubrication system, optionally cooperating with a control system, in accordance with an exemplary embodiment of the innovation.
  • This embodiment of an on-demand lubrication system ( 300 c ′) has a programmable logic control unit, a controller ( 400 ) monitoring actuation of the valve ( 200 ), controlled by a remote valve controller ( 460 ) through motive power ( 265 ) to an actuator, here a hydraulic actuator ( 260 ) with secondary manual actuation through a hand wheel ( 263 ).
  • the remote valve controller ( 460 ) may optionally communicate ( 440 ) with the controller ( 400 ), and/or may also monitor actuation of the valve ( 200 ) through shared ( 282 ′) signal lines ( 282 ) from the limit switches ( 285 a and 285 b ). Once the valve ( 200 ) is in the fully open position as indicated by movement of the stem ( 250 ) to engage the upper limit sensor ( 285 a ), or the fully close position as indicated by engagement of the lower limit sensor ( 285 b ), lubrication maintenance may occur as needed.
  • a pressure pump ( 315 ) in a centralized lubricant pump unit ( 310 , not indicated) distributes lubricant from the lubricant reservoir ( 312 ) through a supply line ( 330 ) where an optional secondary pump ( 430 ) may be used to increase lubricant pressure along a delivery line ( 335 ).
  • the secondary pump ( 430 ) may also incorporate a local reservoir to prevent starvation of lubricant by other valves in a multi-valve system employing the centralize lubricant supply reservoir ( 312 ).
  • the delivery line ( 335 ) may be routed by another solenoid control valve ( 410 ) to another lubrication port ( 225 or 220 , not indicated), the ‘injecting port,’ to deliver a measured quantity of lubricant in accordance with the valve's ( 200 ) specifications.
  • This inflow of pressurized lubricant through the injecting lubrication port simultaneously forces the venting of spent fluids out through the venting lubrication port to the centralized collection ( 312 ′) through the return line ( 337 ), as discussed above.
  • the communication ( 440 ) between controllers ( 400 and 460 ) may allow predictive use of the centralized pressure pump ( 315 ) ensuring sufficient pressure for feed lines ( 330 ), eliminating the need for separate delivery lines ( 335 ) and secondary pumps ( 430 ) by ensuring multiple valves ( 200 ) will not simultaneously lubricate, over taxing a shared pump unit ( 310 , not designated).
  • communication between multiple lubrication controllers ( 400 ) through a central controller ( 460 ) may allow problems of simultaneous demands to be mitigated by adjusting logic control accordingly.
  • FIG. 6 shows a centralized on-demand lubrication system integrated with a valve control system, in accordance with an exemplary embodiment of the innovation.
  • This embodiment of an on-demand lubrication system ( 300 c ′′) has a single programmable logic control unit, a controller ( 400 ) actuating the valve ( 200 ) and monitoring actuation in case of manual actuation.
  • the controller ( 400 ) monitors signal lines ( 282 ) from the limit switches ( 285 a and 285 b ) to determine lubrication needs, for instance by monitoring the time necessary for an actuator ( 260 ) to physically move a valve. Increased time from deactivation of one limit switch ( 285 a or 285 b ) to activation of the other limit switch ( 285 b or 285 a ) may indicate a need for maintenance.
  • the controller ( 400 ) also controls ( 415 ) solenoid control valves ( 410 ), a pump unit's ( 310 , not indicated) pressure pump ( 315 ), and optional secondary pump ( 430 ) for distribution ( 330 ) and delivery ( 335 ) of from a lubricant reservoir ( 312 ), and collection ( 337 ) to a centralize collection reservoir ( 312 ′) of spent fluids.
  • FIG. 7 shows a method of on-demand lubrication by a flow control system, in accordance with an exemplary embodiment of the innovation.
  • the on-demand automatic lubrication system provides monitoring and analysis for timely high-pressure delivery of lubrication coordinated with in-service valve operations to eliminate downtime or the effect of extraneous valve operations.
  • the flow control system ( 700 ) has a programmable logic control unit, a controller ( 400 ), monitoring actuation of a plurality of valves ( 200 a - c ), and providing motive power ( 265 ) to actuators ( 260 ) to independently actuate the valves ( 200 a - c ).
  • Monitoring actuation of the valves ( 200 ) through signal lines ( 282 ) from the limit switches ( 285 a and 285 b ) provide information on individual valve usage, and position for purposes of maintenance lubrication.
  • the controller ( 400 ) may consider an individual valve's performance, past usage, maintenance history, anticipated usage, etc. to prioritize maintenance lubrications.
  • the controller ( 400 ) controls ( 437 ) a pressure pump ( 315 ) of the centralized lubrication pump unit ( 310 ) delivering lubricant at low pressure from a lubricant reservoir ( 312 ) in large quantities through a supply line ( 330 ) to secondary pump ( 430 ) controlled ( 435 ) by the same controller.
  • the secondary pump ( 430 ) increases lubricant pressure for delivery ( 335 ) to a lubricant port ( 220 ), the injecting port.
  • a second lubricant port ( 225 ) is opened to vent fluids, a venting port, allowing the injection of lubricant to force venting of spent fluids/lubricant through the return line ( 337 ) to the collection reservoir ( 312 ′). Pressure of spent fluids exiting the venting port will gravitate to the unpressurized collection reservoir ( 312 ′) but may also be aided by additional pumps to assist flow.
  • the secondary pump ( 430 ) increases pressure by reducing the volume of the delivered lubricant.
  • the “large quantities” of the supply line are dictated by the consumption of a maximum number of secondary pumps ( 430 ) to be concurrently supported.
  • the secondary pumps ( 430 ) have local reservoirs for collecting sufficient lubricant required to lubricate a valve ( 200 ).
  • the secondary pump's ( 430 ) local reservoir may buffer the lubricant from the supply line.
  • throttling lubricant flow to one or more valves extends the service time in exchange for an increase in concurrent operations.

Landscapes

  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Valve Housings (AREA)
  • Mechanically-Actuated Valves (AREA)
  • Pipeline Systems (AREA)
  • Indication Of The Valve Opening Or Closing Status (AREA)
  • General Factory Administration (AREA)
  • General Details Of Gearings (AREA)
US16/792,449 2019-03-28 2020-02-17 Method and Apparatus for Monitoring and On-demand Lubricating of Industrial Valves Abandoned US20200309319A1 (en)

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US16/792,449 US20200309319A1 (en) 2019-03-28 2020-02-17 Method and Apparatus for Monitoring and On-demand Lubricating of Industrial Valves
CA3106193A CA3106193A1 (en) 2019-03-28 2021-01-20 Method and apparatus for monitoring and on-demand lubricating of industrial valves
ARP210100178A AR121132A1 (es) 2019-03-28 2021-01-24 Método y aparato para monitoreo y lubricación según demanda de válvulas industriales
US17/198,202 US20210199243A1 (en) 2019-03-28 2021-03-10 Rotary Manifold and Method of Use

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US201962825342P 2019-03-28 2019-03-28
US16/792,449 US20200309319A1 (en) 2019-03-28 2020-02-17 Method and Apparatus for Monitoring and On-demand Lubricating of Industrial Valves

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US17/198,202 Pending US20210199243A1 (en) 2019-03-28 2021-03-10 Rotary Manifold and Method of Use

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US20210199243A1 (en) 2021-07-01
AR121132A1 (es) 2022-04-20
CA3106193A1 (en) 2021-08-17
AR123952A1 (es) 2023-01-25
CA3135421A1 (en) 2022-09-10

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