PCE Grease Injection & Hydraulic Control System

Description

PCE Grease Injection & Hydraulic Control System

Technical Description

The Grease Injection & Hydraulic Control System is a multi-functional power unit designed to operate the various hydraulic components of a high-pressure PCE stack. It combines high-pressure grease pumps (for the liquid seal) with hydraulic control manifolds (for the BOP, Tool Trap, and Tool Catcher), providing the operator with a single, synchronized interface to manage wellbore pressure.

Key Technical Specifications and Operation

• Integrated Grease Circuit: Utilizes high-ratio, air-driven pumps to deliver sealant grease to the stuffing box. It features an accumulator system to maintain a constant “buffer” of pressure, preventing seal failure if air supply fluctuates.

• Multi-Valve Hydraulic Manifold: Provides dedicated control circuits for:

  • BOP Actuation: Opening and closing the RAMs.

  • Tool Trap/Catcher: Engaging or releasing the safety flappers.

  • Stuffing Box: Adjusting the “squeeze” on the packing rubbers.

• Differential Pressure Management: The system is equipped with highly accurate sensing lines that monitor wellhead pressure and automatically (or via manual adjustment) maintain the grease injection pressure at 1000 PSI above wellbore pressure.

• Safety Interlocks: Many systems include “fail-safe” logic, ensuring that critical valves (like the BOP) can be closed even in the event of a primary power loss, often using nitrogen-charged accumulators.

• Grease Return & Filtration: Features a dedicated circuit to catch “spent” grease returning from the stuffing box, filtering out debris before recycling or disposal to ensure the pump internals remain protected.

Customization and Materials

• Enclosure Options: Available in open-frame skids for easy maintenance or fully enclosed, sound-attenuated stainless steel cabins for harsh offshore environments.

• Hose Reel Assemblies: Can be customized with multi-bore “umbilical” reels (often 100ft to 200ft) that consolidate grease lines, hydraulic lines, and return lines into a single, organized bundle.

• Instrumentation: Options for analog “deadweight” gauges or digital pressure transducers with remote data-logging capabilities for pressure test certification.

Critical Parameters