TECHNICAL FIELD

[0001] This disclosure is generally directed to oil and gas field technologies. More specifically, this disclosure is directed to a system and method for improved grease handling.

RELATED APPLICATIONS / PRIORITY

[0002] This application claims priority to U.S. Provisional Application No. 63/325,992 (filed on March 31, 2022). The Application incorporates these applications by reference herein for all purposes.

BACKGROUND

[0003] Massive plunger pumps are frequently utilized in the oil and gas business in order to pump fracturing fluid, sometimes known as "frac," down a well. To pump the frac fluid down the well, a single pumping unit (which can weigh as much as 15 tons) can have many plunger pumps — for example, four to six — loaded onto it. This allows for greater efficiency. Grease that can withstand high temperatures and is designed for industrial use is typically used to lubricate plunger pumps of this type so that they can function properly. The viscosity of this frac grease decreases as it is used up, and when it does, it is collected in grease traps that are located beneath plunger pumps.

[0004] These grease traps have been the source of a great deal of trouble. Conventionally, cleaning out such traps is a multi-hour process that needs the dismounting of the plunger pumps, the removal of the trap, and the shoveling out of the grease. This method is not only labor-intensive but also time-consuming. In many cases, a welding operation is required in order to remove the trap. This is true for both the removal and the reinsertion of the trap. Many people choose not to clear out the traps because of the amount of labor that is required, which results in the traps either becoming nearly full or reaching a point where they are nearly full. The contents of the traps, which have either been overfilled or are extremely close to reaching their capacity, flow out all over the place, including on the ground, the tires for the units, and other machinery within the pumping units. These spills result in fines being issued by the Department of Transportation as well as conflicts between a frac fluid unit operator and a drilling operator over allegations of polluting a site with contaminated frac fluid. They also present a safety risk since grease can get onto the brakes of a frac truck and make it more difficult for the truck to come to a stop.

[0005] Additionally, in addition to reducing the power of the brakes, grease that was applied to the brakes has also ignited fires.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] For a more complete understanding of this disclosure and its features, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which: [0007] Figure 1 show contextual information for typical grease traps;

[0008] Figures 2A and 2B show features a grease trap, according to an embodiment of the disclosure;

[0009] Figures 3, 4, and 5 show views of a container, according to an embodiment of the disclosure; [0010] Figure 6 shows how a container my hang from other equipment, according to an embodiment of the disclosure;

[0011] Figures 7A and 7B show an example of monitoring the load of the container, according to an embodiment of the disclosure; and

[0012] Figure 8 shows a method of servicing containers, according to an embodiment of the disclosure.

SUMMARY OF THE DISCLOSURE

[0013] A container for capturing spent grease has been disclosed. The container hasa flexible body and straps to connect the flexible body to industrial equipment. The strap having one or more connectors. The container also has a module having a processor, one more sensor, memory, a location feature, and a communication feature, the module connected to the straps, the one or more connectors, or the flexible body.

[0014] Before undertaking the DETAILED DESCRIPTION below, it may be advantageous to set forth definitions of certain words and phrases used throughout this patent document: the terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation; the term “or,” is inclusive, meaning and/or; the phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like.. The phrase “at least one of,” when used with a list of items, means that different combinations of one or more of the listed items may be used, and only one item in the list may be needed. For example, “at least one of: A, B, and C” includes any of the following combinations: A; B; C; A and B; A and C; B and C; and A and B and C. Definitions for certain words and phrases are provided throughout this patent document, those of ordinary skill in the art should understand that in many if not most instances, such definitions apply to prior, as well as future uses of such defined words and phrases. DETAILED DESCRIPTION

[0015] The FIGURES described below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure invention may be implemented in any type of suitably arranged device or system. Additionally, the drawings are not necessarily draw n to scale.

[0016] It will be understood that well known processes and components have not been described in detail and have been omitted for brevity. Although specific steps, structures and materials may have been described, the present disclosure may not be limited to these specifics, and others may be substituted as it is well understood by those skilled in the art, and various steps may not necessarily be performed in the sequences shown.

[0017] Additionally, although described in the context of oil and gas applications, other industrial processes can avail from the teachings of this disclosure.

[0018] In the oil and gas industry, massive plunger pumps are often used to pump fracturing or “frac” fluid down a well. Multiple plunger pumps (e.g., four to six) can be loaded onto a single pumping unit (which can be upwards of 15 tons) to pump the frac fluid down the well. To allow such plunger pumps to operate effectively, the plunger pumps are lubed with an industrial, high heat resistant grease. As this grease is spent, viscosity' is degraded and the spent frac grease is caught in grease traps under the plunger pumps.

[0019] These grease traps have caused a lot of problems. The conventional method of cleaning out such traps involves a multi-hour process that requires a dismounting of the plunger pumps, a removal of the trap, and shoveling out of the grease. The removal of the trap, itself often involves welding operation - for both removal and reinsertion of the trap. Because of the effort involved, many avoid cleaning out the traps - allowing them to overfill or remain at a state of near full. The traps (overfilled or closed to being full) spill out everywhere - on the ground, on the tires for the units, and on other equipment in the pumping units. These spills lead to fines by the department of transportation and conflicts between a frac fluid unit operator and a drilling operator amongst allegations of contaminating a site. They also are a safety hazard as the grease can get on breaks and inhibit ability of a frac truck to stop.

[0020] Given these concerns, certain embodiments of the disclosure provide a system and method for improved grease handling.

[0021] The background information for typical grease traps is presented in Figure 1. The grease trap can be any particular size and design, and it can be created out of any material that is suitable. This includes traditional metal material, which requires welding, or plastic.

[0022] A lip located at the top of the grease trap can be used in certain configurations to detachably position the trap on, for instance, a vehicle. This lip is located at the trap's top. In addition, the grease trap can be used in certain configurations to replace pre-existing grease traps, for instance as a retrofit. The grease traps, on their own, are sometimes able to be switched out for one another, depending on the particular design.

[0023] While a particular shape and size is shown, others may be utilized in other configurations. Additionally, while an oil and gas application are described, the grease traps described herein may be utilized in other settings. In particular, although spent frac grease has been described, one of at least ordinary skill in the art having read this disclosure will recognize that other applications may avail from the teachings disclosed herein.

[0024] Figures 2A and 2B show views of a container, according to an embodiment of the disclosure. In certain arrangements, the container might be used as a liner for a grease trap that already exists. Alternatively, it might hold the grease itself. Or, as another possibility, the container might entirely subsume the function of a grease trap that was previously in place in certain configurations. In some configurations, the container may be one that is thrown away after use.

[0025] With regard to disposability, in certain configurations, the container avoids the need for cleaning. When the container approaches capacity or, alternatively, when a user reaches a convenient disposal location, the container can be thrown away and replaced with a new container.

[0026] The container may be made of any suitable materials, including but not limited to, polyesters coated with polyurethane, polyethylene, vinyl, and other plasticbased materials. Additionally, in other configuraitons, yet other types of materials may be utilized including, but not limited to, natural fabrics, recycled polyester, bio-based polymers, TPU-coated fabrics, silicone-coated fabri, and wax-coated fabrics.

[0027] Natural fabrics include fabrics made from natural fibers like cotton, hemp, linen, and wool. These materials are sustainable, biodegradable, and can be produced without harmful chemicals.

[0028] Recycled polyester include polyesters made from post-consumer plastic bottles and can be used as a sustainable alternative to virgin polyester. Such materials have similar performance properties to polyester with a lower environmental impact. [0029] Bio-based polymers incudes materials like polylactic acid (PLA) and polyhydroxyalkanoates (PHA) that are derived from renewable resources like com starch and sugarcane.

[0030] Thermoplastic polyurethane (TPU) is a flexible, abrasion-resistant material that can be used. Silicone-coated fabrics are a durable, waterproof alternative to polyester coated with vinyl. They are often used in outdoor gear and medical applications. Wax-coated fabrics include waxed cotton and canvas. They are water- resistant.

[0031] When fabrics and other materials are used, perceivable gaps may be seen. However, the viscosity of the dispensed materials will prevent traveling through such perceivable gaps.

[0032] While certain materials are referenced in particular configurations, yet other materials may be used in other configurations. Such material has a function of preventing the travel of materials through the container. In particular configurations, the container has a flexible shape. The flexible shape may allow easy placement in existing grease traps. Also, when not in use, in some configurations, the container may be folded.

[0033] In particular configurations, the material and construction of the container are specifically chosen to sufficiently hold the weight of the materials placed therein, for example, grease. In particular configurations, a composite of materials may be used. And, to create a shape for the container (e g., when filled), certain configurations may meld or stitch different parts of the container together. While stitching is mentioned as one example, other couplings techniques may be used as well.

[0034] As shown, the container may also include straps that allow placement and removal of the container. While a particular configuration for such straps is shown, others may be used.

[0035] Also, in particular configurations in which the container is flexible, stiffening elements maybe inserted to help the container hold its shape while in use. When the container approaches its useful life (e.g., it is full or when a user has a convenient dumpiong location), the stiffeners can be removed and the container can be disposed. In particular configurations, the stiffening elements may assist with disposal.

[0036] Figures 3, 4, and 5 show views of a container, according to an embodiment of the disclosure. The container of Figures 3, 4, and 5 functionally works in a similar manner and has similar features to the container of Figures 2A and 2B. However, additional details are shown with respect to the straps. The straps show the ability to quickly loop around a support for the container using, for example, a buckle. The buckle is chosen to support the weight of the materials in the container. While a particular type of buckle is shown (e.g., a push-button buck), other types of bucks and/or connection mechanisms may be used.

[0037] Figure 6 shows how a container my hang from other equipment, according to an embodiment of the disclosure. In Figure 6, the container 600 is shown haning by straps 610, 620 from pieces 650A, 650B of equipment. Any of variety connection pieces can be used to facilite such a connection including, but no limited to hooks and bars. A connection mechanisms 612, 622 may allow for a quick disconnectin. A person having ordinary skill in the art will recognize that a variety of other mechnaims may be also be utilized.

[0038] Figures 7A and 7B show an example of monitoring the load of the container, according to an embodiment of the disclosure. The container 600 may generally have the same features shown in FIGURE except that an extra modules 618,

628, are included. The modules 618, 628 may be part of the connection mechanism or separate.

[0039] An example of one of the extra module 618, 628 are shown. Here, therey are shown with a processor, one or more sensor, memory, a location module, and a communication moduesl. In one configuration, the sensors can sense weight. Each may independently sense, store, and communicate the weight. In alternative configurations, yet other sensor may be used in additional or lieu of a weight sensor to determine the load (or weight). Examples include reflective sensors such as radar, ultrasonic, infrared, LiDAR, passive infrared, and the like.

[0040] To appropropraitely communicate the information concerning the load, either the sensor or a device in communciton with the sensor may communicate load information via the communaiton module. Non-limiting examples of communication include, but are not limited to Bluetooth, cellular (GSM, CDMA, an the like), Wi-Fi, NFC, RFID, Zigbee, Z-wave, LoRa (Long Range).

[0041] In some configurations, either the senses or communication modules, or another module may have a location detection module that is used to detect the location of the container to which it is attached. Such location detection module may re-use technologies for communciotioin. Non-limiting examples of location technologies include, global position system (GPS), Bluetooth lower energy' (signal strength or triangulation), Wi-Fi positioning systems, Near Field Communication (NFC), Inertial Measurement Unit (IMU), and RFID. In select configurations the placement of a container and associated sensors may use an external device like a mobile phone for location presence. The mobile phone in turn can communicate a unique identifier associated with the extra modules (and container) for location placement in a remote system.

[0042] Figure 8 shows a method of servicing containers, according to an embodiment of the disclosure. For a variety of reasons, ajob site may wish for a service to come out and remove, for example, the spent grease. As one example, the job site my not have the necessary facilities to dispose of, for example, the spent grease. As another example, the job site may not have the expertise or time to handl the spent grease. A service model also allows those experienced with servicing containers to handle them.

[0043] In servicing, the method 800 in partiualr confiugations may use cloud computers that analyze efficient servicing based on, for example, other containers int the area and their relative fill, the rate at which containers are filling, and the like.

[0044] The method 800 starts with a trigger 810 for service. In some confiugrations, the trigger may be a normal schedule for visual observations to see if containers may need to be serviced. In other configurations, the trigger may be feedback from extra modules (including sensors) that inform a system that one or more containers needs to be serviced at a paraticualr location. In some configurations, thresholds may be used for the triggers. For example, if a percentage of container are above a certain weight in a certain area, the trigger may be service the area. In determining whether or not a trigger has occurred, certain configurations may consider the past information for the different containres. For example, to optimize time in servicing an area, a remote cloud system may determine when a particular container is expected to be full relative to how fast other containers in similar area are filling. In yet other configuaratoins, a trigger may be an on-demand request from a customer. In such a configuration, the system may determine others in the area that may also need to be serviced since a given location is being serviced.

[0045] Once a trigger to visit a job site is determined, a service vehicle can be sent to the job site at step 820 and service the container at step 830. The container may be disposed of and replaced or simply replaced. The spent grease in particular configuratsion may be placed in a service vehicle. In other congifurations, the spent grease may be disposed of on-site.

[0046] Following service at a job site, a determination may be made at step 840 as to whether there are other job sites that also need servicing. If so, the method may revert to the next j ob site. If not, the method may end (and restart waiting for a trigger).

[0047] The location feature of certain congifrations allows a container to be moved. The location of containers can be usd to determine an effective service model.

[0048] While the figures herein show certain sizes, others may be utilized in other configurations. Additionally, while an oil and gas application are described, the grease traps described herein may be utilized in other settings. In particular, although spent frac grease has been described with reference to the figures herein, one of at least ordinary skill in the art having read this disclosure will recognize that other applications may avail from the teachings disclosed herein.

[0049] While this disclosure has described certain embodiments and generally associated methods, alterations, and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure, as defined by the following claims. As a non-limiting example, while a particular application has been described, the described process may be used with other oilfield applications and industrial applications.