Remote operator interface and control unit for fluid connections

A remote operator interface and control unit configured to monitor status of, and control over, fluid connections at wellheads. Independent and concurrent status monitoring and control communication with fluid connections is provided at each of a plurality of wells. The operator interface and control unit allows a remote operator to lock and unlock fluid connection assemblies on wellheads, while at the same time viewing wellhead conditions accompanying such actions.

FIELD OF THE DISCLOSURE

This disclosure relates generally to remote status monitoring and control over fluid delivery from surface-deployed equipment to wells drilled through subsurface formations. More particularly, in some embodiments, this disclosure relates to a remote operator interface and control unit providing independent and concurrent communication with fluid connections at each of a plurality of wells.

BACKGROUND

Co-pending and commonly-owned U.S. patent application Ser. No. 16/221,279 (the “'279 Application”) is entitled “Remotely Operated Fluid Connection and Seal” and describes a fluid connection assembly in which embodiments may be remotely actuated. See, for example, Paragraphs 0016 and 0058. Paragraph 0016 states that a technical advantage of the fluid connection assembly is that it may be remotely operable. According to illustrated embodiments, a locking ring may be brought onto locking elements in order to lock a fluid connection adapter inside a fluid connection housing assembly and provide a pressure seal. The locking may be brought onto the locking elements via remotely-actuated retraction of the locking ring.

From time to time, this disclosure will refer more conveniently to fluid control housing assembly300in the '279 Application and in the instant application by its acronym, FCHA. FCHA and fluid connection housing assembly are synonymous in this disclosure.

Paragraph 0058 of the '279 Application describes embodiments of the disclosed fluid connection assembly in which at least one actuator assembly energizes retraction of the locking ring. In some embodiments, the actuator assemblies are hydraulically-actuated piston assemblies in which pistons extend and retract the locking ring away from and towards the locking elements. Hydraulic actuation of the piston assemblies may be remote.

Co-pending and commonly-owned U.S. patent application Ser. No. 16/426,990 (the “'990 Application”) is entitled “Pressure Retaining Seals Useful on Wellheads” and describes a pressure control assembly in which cam-locking embodiments may be actuated. Paragraph 0005 states that the disclosed embodiments are hydraulically-actuated and -deactuated systems that may lock pressure control equipment to the wellhead via a remote control station. Referring now to Paragraph 0045 and FIG. 1, a cam lock sealing mechanism may be remotely engaged. First, remote hydraulic actuation causes cam lock pistons to extend, which causes rotation of the cam locks. Rotation of the cam locks moves them into an engaged position to lock an adapter into an internal receptacle and provide a pressure seal. Then, again by remote hydraulic actuation, retraction of locking ring pistons causes a locking ring to move into position over the cam locks and retain them in the engaged position.

Co-pending and commonly-owned U.S. patent application Ser. No. 16/188,795 (the “'795 Application”) discloses sensor embodiments useful for remote monitoring the connection status of fluid connection assemblies such as, for example, pressure control assemblies described in the '990 Application. FIGS. 1 through 9 of the '795 Application depict pressure control assembly embodiments also described in the '990 Application. Paragraph 0059 and FIG. 10 of the '795 Application states that a disk shaped head (hereafter “cam rod puck”) may be disposed on the bottom of selected cam lock pistons deployed on a pressure control assembly embodiment from the '990 Application, such that the proximity of the cam rod puck may be detected by a sensor when the cam lock piston is fully extended and the cam lock is in a fully engaged position (see FIG. 9 of the '795 Application). The sensor may be, for example, a limit switch that closes or opens when the cam rod puck contacts the sensor. Paragraph 0061 of the '795 Application further describes a “ring rod puck” and sensor disposed on the bottom of selected locking ring pistons on the pressure control assembly. The ring rod pucks and sensors are advantageously in a similar configuration to the cam rod pucks and sensors. In the case of ring rod pucks and sensors, however, the proximity of a ring rod puck may be detected by a sensor when the locking ring piston is fully extended and the locking ring is fully disengaged from the cam locks (see FIGS. 7 and 8 of the '795 Application).

A remote operator interface and control unit is needed to provide remote actuation of fluid connection devices, including those described in the '279 Application and the '990 Application. Advantageously the operator interface and control unit will further allow a remote operator also to monitor associated conditions of the fluid connection devices, such as the actuation/deactuation status of the fluid connections during remote control operations. In some embodiments, puck and sensor arrangements such as described in the '795 Application will advantageously assist the operator interface and control unit in monitoring some conditions of the fluid connections.

SUMMARY AND TECHNICAL ADVANTAGES

This application describes a remote operator interface and control unit configured to monitor status of, and control over, fluid connections at wellheads. Disclosed embodiments describe independent and concurrent status monitoring and control communication with fluid connections at each of a plurality of wells. In some exemplary embodiments, the operator interface and control unit described in the instant application allows a remote operator to retract and extend the locking ring on fluid connection assemblies such as are described in the '279 Application. The control unit enables such remote locking ring retraction/extension via remote hydraulic actuation of the piston assemblies in the actuation assemblies on the fluid connection assembly.

The control unit further allows a remote operator to monitor a retraction/extension status of the locking ring. According to embodiments described in the instant application, the fluid connection assembly provides sensors on guide rods on the actuation assemblies where the sensed position of the guide rods corresponds to a retraction/extension of the locking ring. The sensors are in electrical communication with the control unit.

Some embodiments of the control unit further allow a remote operator to pressurize and depressurize a quick test connection provided on the fluid connection assembly.

Further exemplary embodiments of the operator interface and control unit described in the instant application allow a remote operator to extend the cam lock pistons on cam-locking pressure control assemblies such as are described in the '990 Application. Extension of the cam lock pistons causes rotation of the cam locks into an engaged position, which engagement locks a fluid delivery adapter into the pressure control assembly. Embodiments of the operator interface and control unit then, again by remote hydraulic actuation, allow a remote operator to move a locking ring into position over the cam locks in an engaged position, wherein the locking ring retains the cam locks in their engaged position.

The control unit further allows a remote operator to monitor a positional status of the cam locks and the locking ring to determine when the locking ring is in position to retain the cam locks in an engaged position. According to embodiments described in the instant application, the pressure control assembly provides sensors on a crown attached to the locking ring where a sensed proximity of cam activator surfaces corresponds to a positional status in which the locking ring is retaining the cam locks in an engaged position. The sensors are in electrical communication with the control unit.

Some embodiments of the control unit further allow a remote operator to pressurize and depressurize a quick test connection provided on the pressure control assembly.

Further embodiments of the operator interface and control unit described in the instant application allow, for example, a remote operator to monitor conditions or status of fluid connections via puck and sensor arrangements such as are described in the '795 Application. For example, in control unit embodiments in communication with pressure control assemblies described in the '990 Application, puck and sensor arrangements may be deployed on pressure control assemblies such that the sensors may detect the proximity of corresponding cam rod pucks connected to cam lock pistons. Such detected proximity signifies that a cam lock piston is fully extended and the corresponding cam lock is in the engaged position. In such embodiments, the sensor is in electrical communication with the control unit.

In other pressure control assembly embodiments according to the '990 Patent, ring rod pucks may be provided on locking ring pistons. In such embodiments, sensors may detect the proximity of ring rod pucks connected to locking ring pistons. Such detected proximity signifies that a locking ring piston is fully extended and the locking ring is in a disengaged position over the cam locks. In such embodiments, the sensor is in electrical communication with the control unit.

It is therefore a technical advantage of the disclosed operator interface and control unit to enable a remote operator to monitor status of, and control over, multiple fluid connections at a plurality of wellheads, each independently and concurrently. Illustrated embodiments described in this disclosure allow a remote operator to monitor status and exercise control over four (4) fluid connections independently and concurrently. The scope of this disclosure is not limited in this regard, however. The disclosed technology is scalable in this regard.

A further technical advantage of the disclosed operator interface and control unit technology is to promote operator safety. First, as previously noted, the technology allows an operator to control fluid connections remotely. The safety risks presented to personnel working nearby wellheads are well understood, especially during high pressure/high volume fluid transfers into or out of the wellhead. The remote hydraulic and electrical communication technology disclosed in the instant application allows the operator to actuate fluid connections and monitor related sensors from a safe distance.

Second, the operator interface and control unit technology promotes operator safety by including alerts and fail-safe measures. The fail-safe measures reduce (if not eliminate the chance of operator error allowing unintentional pressurization of a fluid connection that is not ready to be pressurized. In currently preferred embodiments, positional sensors on the fluid connection advantageously detect and alert the remote operator when the fluid connection is in a mechanical condition to be pressurized internally (e.g. connection closed and locked). In other embodiments, pressure sensors on the fluid connection may detect and alert the remote operator of the presence of internal pressure. Unintentional unlocking or opening of the connection will be prevented in such pressure conditions.

A further technical advantage of the disclosed operator interface and control unit technology is its user-friendliness. Such user-friendliness is at least partially attributable to the technology's user-intuitive design. A goal of simplicity in design facilitates operator training and discourages operator error. In particular, the user-intuitive fail-safe measures described in the previous paragraph includes easily-recognizable alerts and warning conditions on the operator interface.

A further technical advantage of the disclosed operator interface and control unit technology is to allow management oversight at locations yet further remote from the control unit's current location. In currently preferred embodiments, the control unit may broadcast information regarding its current status to, e.g., an offsite computer via a cellular network connection. The cellular network connection enables, for example, an offsite operations center to monitor multiple concurrent well operations and well status potentially far away from the control unit. Alternatively, the operations center may accumulate control unit status data for later analysis. In other embodiments, a GPS location module and satellite antenna on the control unit may also concurrently broadcast the control unit's location to the offsite operations center. In other embodiments, a satellite antenna may broadcast information regarding the control unit's status to, for example, an offsite computer or operations center when cellular network coverage is poor (or non-existent), or when cellular transmission is prohibited.

In accordance with a first aspect, therefore, this disclosure describes embodiments of a control unit, comprising: a first hydraulic hose, the first hydraulic hose disposed to be connected to a fluid connection housing assembly (FCHA) such that pressurization of the first hydraulic hose retracts at least one actuator piston to lock the FCHA; a second hydraulic hose, the second hydraulic hose disposed to be connected to the FCHA such that pressurization of the second hydraulic hose extends the at least one actuator piston to unlock the FCHA; a lock switch, the lock switch disposed to selectively energize pressurization of either the first hydraulic hose or the second hydraulic hose; and an indicator light, the indicator light disposed to be addressed by first and second sensors on the FCHA such that the first sensor activates when the FCHA is in a locked condition and the second sensor activates when the FCHA is in an unlocked condition; wherein the indicator light illuminates differently according to a sensed condition detected by the first and second sensors, wherein the sensed condition is from among at least two conditions selected from the group consisting of: (a) the FCHA is in the unlocked condition; (b) the FCHA is in the locked condition; (c) the FCHA is in transition from (1) the locked condition to the unlocked condition, or (2) the unlocked condition to the locked condition; and (d) the FCHA is in a fault condition during transition from (1) the locked condition to the unlocked condition, or (2) the unlocked condition to the locked condition.

In some embodiments according to the first aspect, the control unit further comprises a well pressure display, the well pressure display disposed to be addressed by a well pressure sensor on the FCHA, wherein the well pressure display displays a current well pressure sensed by the well pressure sensor.

In some embodiments according to the first aspect, the control unit is disposed to issue at least one user-perceptible alert selected from the group consisting of: (a) while the first and second sensors detect that the FCHA is in the locked condition, an alert that the FCHA is available to be pressurized; (b) while the first and second sensors detect that the FCHA is in the unlocked condition, an alert that the FCHA is unavailable to be pressurized; and (c) while the first and second sensors detect that the FCHA is in transition from (1) the locked condition to the unlocked condition, or (2) the unlocked condition to the locked condition, an alert that the FCHA is in transition.

In some embodiments according to the first aspect, the control unit is disposed to prevent pressurization of the second hydraulic hose if the first and second sensors detect that the FCHA is in the locked condition and the well pressure sensor senses a current non-zero well pressure.

In some embodiments according to the first aspect, the control unit further comprises a third hydraulic hose, the third hydraulic hose disposed to be connected to a quick test fitting on the FCHA such that pressurization of the third hydraulic hose tests whether a pressure-tight connection has been established between sealing rings inside the FCHA; a quick test pressure display, the quick test pressure display disposed to communicate current pressure in the third hydraulic hose; and a quick test operation switch, the quick test operation switch disposed to selectively energize a quick test function selected from the group consisting of: (a) energizing pressurization of the third hydraulic hose; (b) holding current pressure in the third hydraulic hose; and (c) energizing depressurization of the third hydraulic hose.

In some embodiments according to the first aspect, the control unit further comprises an interactive touch display, the interactive touch display disposed to communicate information regarding control unit status, wherein the information regarding control unit status includes user-perceptible alerts; and wherein the interactive touch display is further disposed to communicate user instructions given to the control unit via screen touch.

In some embodiments according to the first aspect, the control unit further comprises a cellular/location broadcast module operatively connected to at least one broadcast antenna, wherein the cellular/location broadcast module is disposed to transmit information regarding control unit status via the at least one broadcast antenna, wherein the at least one broadcast antenna includes at least one antenna selected from the group consisting of (a) a cellular antenna and (b) a satellite antenna.

In some embodiments according to the first aspect, the at least one antenna includes a satellite antenna, and wherein the cellular/location module is disposed to transmit a current location of the control unit via the satellite antenna.

In accordance with a second aspect, this disclosure describes embodiments of a control unit, comprising: a first hydraulic hose, the first hydraulic hose disposed to be connected to a fluid connection housing assembly (FCHA) such that pressurization of the first hydraulic hose retracts at least one actuator piston to lock the FCHA; a second hydraulic hose, the second hydraulic hose disposed to be connected to the FCHA such that pressurization of the second hydraulic hose extends the at least one actuator piston to unlock the FCHA; a lock switch, the lock switch disposed to selectively energize pressurization of either the first hydraulic hose or the second hydraulic hose; and an indicator light, the indicator light disposed to be addressed by first and second sensors on the FCHA such that the first sensor activates when the FCHA is in a locked condition and the second sensor activates when the FCHA is in an unlocked condition; wherein the indicator light illuminates differently according whether the first and second sensors detect that (a) the FCHA is in the unlocked condition, or (b) the FCHA is in the locked condition.

In some embodiments according to the second aspect, the control unit further comprises a well pressure display, the well pressure display disposed to be addressed by a well pressure sensor on the FCHA, wherein the well pressure display displays a current well pressure sensed by the well pressure sensor.

In some embodiments according to the second aspect, the control unit is disposed to issue at least one user-perceptible alert selected from the group consisting of: (a) while the first and second sensors detect that the FCHA is in the locked condition, an alert that the FCHA is available to be pressurized; and (b) while the first and second sensors detect that the FCHA is in the unlocked condition, an alert that the FCHA is unavailable to be pressurized.

In some embodiments according to the second aspect, the control unit is disposed to prevent pressurization of the second hydraulic hose if the first and second sensors detect that the FCHA is in the locked condition and the well pressure sensor senses a current non-zero well pressure.

In some embodiments according to the second aspect, the control unit further comprises a third hydraulic hose, the third hydraulic hose disposed to be connected to a quick test fitting on the FCHA such that pressurization of the third hydraulic hose tests whether a pressure-tight connection has been established between sealing rings inside the FCHA; a quick test pressure display, the quick test pressure display disposed to communicate current pressure in the third hydraulic hose; and a quick test operation switch, the quick test operation switch disposed to selectively energize a quick test function selected from the group consisting of: (a) energizing pressurization of the third hydraulic hose; (b) holding current pressure in the third hydraulic hose; and (c) energizing depressurization of the third hydraulic hose.

In some embodiments according to the second aspect, the control unit further comprises an interactive touch display, the interactive touch display disposed to communicate information regarding control unit status, wherein the information regarding control unit status includes user-perceptible alerts; and wherein the interactive touch display is further disposed to communicate user instructions given to the control unit via screen touch.

In some embodiments according to the second aspect, the control unit further comprises a cellular/location broadcast module operatively connected to at least one broadcast antenna, wherein the cellular/location broadcast module is disposed to transmit information regarding control unit status via the at least one broadcast antenna, wherein the at least one broadcast antenna includes at least one antenna selected from the group consisting of (a) a cellular antenna and (b) a satellite antenna.

In some embodiments according to the second aspect, the at least one antenna includes a satellite antenna, and wherein the cellular/location module is disposed to transmit a current location of the control unit via the satellite antenna.

In accordance with a third aspect, this disclosure describes embodiments of a control unit, comprising: a first hydraulic hose, the first hydraulic hose disposed to be connected to a fluid connection device such that pressurization of the first hydraulic hose energizes an actuator to lock the fluid connection device; a second hydraulic hose, the second hydraulic hose disposed to be connected to the fluid connection device such that pressurization of the second hydraulic hose energizes the actuator to unlock the fluid connection device; wherein the control unit is disposed to selectively energize pressurization of the first hydraulic hose and the second hydraulic hose; and wherein an indicator alerts differently according to whether (a) the fluid connection device is in the unlocked condition, or (b) the fluid connection device is in the locked condition.

In some embodiments according to the third aspect, the indicator is disposed to be addressed by first and second sensors on the fluid connection device such that the first sensor activates when the fluid connection device is in a locked condition and the second sensor activates when the fluid connection device is in an unlocked condition.

In some embodiments according to the third aspect, the indicator alerts differently according to a sensed condition detected by the first and second sensors, wherein the sensed condition is from among at least two conditions selected from the group consisting of: (a) the fluid connection device is in the unlocked condition; (b) the fluid connection device is in the locked condition; and (c) the fluid connection device is in transition from (1) the locked condition to the unlocked condition, or (2) the unlocked condition to the locked condition.

In some embodiments according to the third aspect, the control unit is disposed to issue a user-perceptible alert when a well pressure sensor senses a current well pressure in excess of a predetermined maximum pressure value.

In some embodiments according to the third aspect, the control unit is disposed to prevent pressurization of the second hydraulic hose if the fluid connection device is in the locked condition and a well pressure sensor senses a current non-zero well pressure.

In some embodiments according to the third aspect, the control unit further comprises: a third hydraulic hose, the third hydraulic hose disposed to be connected to a quick test fitting on the fluid connection device such that pressurization of the third hydraulic hose tests whether a pressure-tight connection has been established between sealing rings inside the fluid connection device; a quick test pressure display, the quick test pressure display disposed to communicate current pressure in the third hydraulic hose; and a quick test operation switch, the quick test operation switch disposed to selectively energize a quick test function selected from the group consisting of: (a) energizing pressurization of the third hydraulic hose; (b) holding current pressure in the third hydraulic hose; and (c) energizing depressurization of the third hydraulic hose.

In some embodiments according to the third aspect, the control unit further comprises a cellular/location broadcast module operatively connected to at least one broadcast antenna, wherein the cellular/location broadcast module is disposed to transmit information regarding control unit status via the at least one broadcast antenna, wherein the at least one broadcast antenna includes at least one antenna selected from the group consisting of (a) a cellular antenna and (b) a satellite antenna.

In accordance with a fourth aspect, this disclosure describes embodiments of a control unit, comprising: a first hydraulic hose, the first hydraulic hose disposed to be connected to a fluid connection housing assembly (FCHA) such that pressurization of the first hydraulic hose retracts at least one actuator piston to lock the FCHA; a second hydraulic hose, the second hydraulic hose disposed to be connected to the FCHA such that pressurization of the second hydraulic hose extends the at least one actuator piston to unlock the FCHA; a lock switch, the lock switch disposed to selectively energize pressurization of either the first hydraulic hose or the second hydraulic hose; an indicator light, the indicator light disposed to be addressed by first and second sensors on the FCHA such that the first sensor activates when the FCHA is in a locked condition and the second sensor activates when the FCHA is in an unlocked condition; wherein the indicator light illuminates differently according to a sensed condition detected by the first and second sensors, wherein the sensed condition is from among at least two conditions selected from the group consisting of: (a) the FCHA is in the unlocked condition; (b) the FCHA is in the locked condition; (c) the FCHA is in transition from (1) the locked condition to the unlocked condition, or (2) the unlocked condition to the locked condition; and (d) the FCHA is in a fault condition during transition from (1) the locked condition to the unlocked condition, or (2) the unlocked condition to the locked condition; and a well pressure display, the well pressure display disposed to be addressed by a well pressure sensor on the FCHA, wherein the well pressure display displays a current well pressure sensed by the well pressure sensor.

In some embodiments according to the fourth aspect, the control unit is disposed to issue at least one user-perceptible alert selected from the group consisting of: (a) while the first and second sensors detect that the FCHA is in the locked condition, an alert that the FCHA is available to be pressurized; (b) while the first and second sensors detect that the FCHA is in the unlocked condition, an alert that the FCHA is unavailable to be pressurized; (c) while the well pressure sensor senses a current well pressure in excess of a predetermined maximum pressure value, an alert that the predetermined maximum pressure value has been exceeded; and (d) while the first and second sensors detect that the FCHA is in transition from (1) the locked condition to the unlocked condition, or (2) the unlocked condition to the locked condition, an alert that the FCHA is in transition.

In some embodiments according to the fourth aspect, the control unit is disposed to prevent pressurization of the second hydraulic hose if the first and second sensors detect that the FCHA is in the locked condition and the well pressure sensor senses a current non-zero well pressure.

In some embodiments according to the fourth aspect, the control unit further comprises: a third hydraulic hose, the third hydraulic hose disposed to be connected to a quick test fitting on the FCHA such that pressurization of the third hydraulic hose tests whether a pressure-tight connection has been established between sealing rings inside the FCHA; a quick test pressure display, the quick test pressure display disposed to communicate current pressure in the third hydraulic hose; and a quick test operation switch, the quick test operation switch disposed to selectively energize a quick test function selected from the group consisting of: (a) energizing pressurization of the third hydraulic hose; (b) holding current pressure in the third hydraulic hose; and (c) energizing depressurization of the third hydraulic hose.

In some embodiments according to the fourth aspect, the control unit further comprises an interactive touch display, the interactive touch display disposed to communicate information regarding control unit status, wherein the information regarding control unit status includes user-perceptible alerts; and wherein the interactive touch display is further disposed to communicate user instructions given to the control unit via screen touch.

In some embodiments according to the fourth aspect, the control unit further comprises a cellular/location broadcast module operatively connected to at least one broadcast antenna, wherein the cellular/location broadcast module is disposed to transmit information regarding control unit status via the at least one broadcast antenna, wherein the at least one broadcast antenna includes at least one antenna selected from the group consisting of (a) a cellular antenna and (b) a satellite antenna.

In some embodiments according to the fourth aspect, the at least one antenna includes a satellite antenna, and wherein the cellular/location module is disposed to transmit a current location of the control unit via the satellite antenna.

The foregoing has outlined rather broadly some of the features and technical advantages of the technology embodied in the disclosed operator interface technology, in order that the detailed description that follows may be better understood. Additional features and advantages of the disclosed technology may be described. It should be appreciated by those skilled in the art that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same inventive purposes of the disclosed technology, and that these equivalent constructions do not depart from the spirit and scope of the technology as described and as set forth in the appended claims.

DETAILED DESCRIPTION

The following description of embodiments provides non-limiting representative examples using Figures and schematics with part numbers and other notation to describe features and teachings of different aspects of the disclosed technology in more detail. The embodiments described should be recognized as capable of implementation separately, or in combination, with other embodiments from the description of the embodiments. A person of ordinary skill in the art reviewing the description of embodiments will be capable of learning and understanding the different described aspects of the technology. The description of embodiments should facilitate understanding of the technology to such an extent that other implementations and embodiments, although not specifically covered but within the understanding of a person of skill in the art having read the description of embodiments, would be understood to be consistent with an application of the disclosed technology.

FIGS. 1A through 6Gof this disclosure illustrate currently preferred embodiments of the disclosed operator interface and control unit technology. For the purposes of the following disclosure,FIGS. 1A through 2Fshould be viewed together as one currently preferred embodiment of a control unit and an associated remote-controlled fluid connection.FIGS. 3Athrough6G describe exemplary alternative embodiments of remote-controlled fluid connections with which further embodiments of the control unit ofFIGS. 1A through 1Gmay be associated. Any part, item, or feature that is identified by part number on one ofFIGS. 1A through 6Gwill have the same part number when illustrated on another ofFIGS. 1A through 6Gin the instant application, or when illustrated or described in the '279 Application or the '990 Application (both incorporated herein by reference). It will be understood that the embodiments as illustrated and described with respect toFIGS. 1A through 6Gare exemplary only and serve to illustrate the larger concept of the technology. The inventive material set forth in this disclosure is not limited to such illustrated and described embodiments.

FIGS. 1A through 1Gillustrate features and aspects of a currently preferred embodiment of an operator interface and control unit100(hereafter “control unit100”) in accordance with this disclosure. Control unit100is configured to allow a remote operator to exercise a variety of controls over one or more separate fluid connections at distant wellheads. The operator may exercise such control over each separate fluid connection independently and concurrently.

In preferred embodiments in fracking deployments, control unit100allows the remote operator to engage and disengage a wellhead fluid connection assembly safely during fracking operations. It will be understood that fracking operations include delivery of fracking fluid into the well at high pressures and flow rates. In preferred fracking implementations of control unit100, fracking fluid delivery is via a fluid connection adapter ultimately connected to a source of fracking fluid. Control unit100allows the remote operator to connect and lock the fluid connection adapter into a fluid connection housing assembly on the wellhead prior to fracking fluid delivery into the well. Control unit100further allows the remote operator to unlock and disconnect the fluid connection adapter from the fluid connection housing assembly once fluid delivery is complete. Embodiments of control unit100further provide safety features to assist the remote operator in safe engagement and disengagement of the fluid connection adapter into the fluid connection housing assembly during initiation and termination of fluid flow. Such safety features include alerting the operator when the fluid connection housing assembly is correctly engaged and locked before fluid flow begins, and when the fluid connection housing assembly is fully depressurized after fluid flow has ended (before unlocking and disengaging the fluid connection adapter from the fluid connection housing assembly). Embodiments of control unit100further provide other alerts and fail-safe features as described below.

Currently preferred implementations of control unit100are in association with embodiments of the fluid connection housing assemblies300described in the '279 Application. The '279 Application is incorporated by reference into the instant application in its entirety.FIGS. 2A through 2G, as further described in detail below, illustrate control and monitoring features on fluid connection housing assembly300as connected to control unit100, via which a remote operator may, for example, unlock and lock a fluid connection adapter200received into fluid connection housing assembly300.

Other implementations of control unit100may be in association with an alternative embodiment of fluid connection housing assembly300described below with reference toFIGS. 3A through 3D. Control unit100offers comparable control and monitoring over this alternative embodiment to the embodiments described with reference toFIGS. 2A through 2G.

Other implementations of control unit100may be in association with various embodiments of pressure control assembly200described in the '990 Application. The '990 Application is incorporated by reference into the instant application in its entirety. Such embodiments of pressure control assembly200are described below with reference toFIGS. 4A through 4H,FIGS. 5A and 5B, andFIGS. 6A through 6G. Control unit100offers comparable control and monitoring over such pressure control assembly200embodiments to the embodiments described with reference toFIGS. 2A through 2G. Some embodiments illustrated onFIGS. 6A through 6Gare also based on disclosure in the '795 Application. The '795 Application is incorporated by reference into the instant application in its entirety.

It will nonetheless be appreciated that the scope of the instant application is not limited to the exemplary embodiments of fluid connection housing assembly300and pressure control assembly200described herein and with which control unit100may be associated.

Looking now at control unit100in more detail,FIG. 1Ais a front perspective of a currently preferred embodiment thereof. Control unit100includes frame101and skid185. The control unit100embodiment ofFIG. 1Ais portable. Other embodiments (not illustrated) may be provided on wheels or on vehicles. Other embodiments (not illustrated) may be more permanently affixed to structures. The scope of this disclosure is not limited in this regard.

As noted above in the Summary section, the embodiment of control unit100onFIG. 1Aenables a remote operator to monitor status and exercise control over four (4) fluid connections independently and concurrently, although the scope of this disclosure is scalable in this regard.FIG. 1Adepicts control unit100generally including upper and lower banks105U,105L of hydraulic hose reels106. Control unit100onFIG. 1Aprovides four (4) reels106on each of upper and lower banks105U,105L so that one reel106in each bank105U,105L is allocated to serve a corresponding fluid connection and wellhead.

Control unit onFIG. 1Afurther provides control enclosure120. Control enclosure120includes an operator interface panel with operator displays, features and controls as described below in more detail with reference toFIGS. 1D through 1F. Control enclosure120also serves as a container to house electrical connections and electronic components enabling the displays, features and controls on the operator interface panel.

FIG. 1Billustrates the control unit100ofFIG. 1Afrom behind.FIG. 1Bshows motor183for powering control unit100. Motor183is a diesel engine in preferred embodiments, and as such is suitable for powering the portable embodiment of control unit100illustrated. Batteries184are provided to start motor183, and in some embodiments may also be a source of auxiliary low voltage DC power.

FIG. 1Bfurther illustrates reels106and bulkhead boxes107in detail. Control unit100allocates one reel106of four in each bank105U,105L, and one bulkhead box107of four, to serve a corresponding fluid connection and wellhead.FIG. 1Bdepicts such an allocation for wellhead W1. Although not illustrated for greater overall clarity, it will be understood that the remaining reels106and bulkhead boxes107may serve three additional wellheads independently and concurrently.

As noted above, currently preferred implementations of control unit100are in association with embodiments of the fluid connection housing assemblies300described in the '279 Application and illustrated with reference toFIGS. 2A through 2G.FIG. 1Bshows hydraulic hoses108A,108B and108C allocated to serve fluid connection housing assembly300embodiments perFIGS. 2A through 2G. With momentary reference toFIG. 2D, fluid connection housing assembly300provides actuator pistons382on actuator assemblies380to raise and lower locking ring318. As described in more detail in the '279 Application, raising and lowering locking ring318enables disengagement and engagement of fluid connection adapter200A inside fluid connection housing assembly300. Referring back now toFIG. 1B, hydraulic hoses108A and108B on upper bank105U of reels106are connected to actuator pistons382on fluid connection housing assembly300. In this way, an operator at control unit100may pressurize and depressurize actuator pistons382via hydraulic hoses108A and108B so as to remotely raise and lower locking ring318, thereby remotely disengaging (unlocking) and engaging (locking) fluid connection adapter200A inside fluid connection housing assembly300. In preferred embodiments, pressurization of hydraulic hose108A and depressurization of hydraulic hose108B raises locking ring318. Conversely, pressurization of hydraulic hose108B and depressurization of hydraulic hose108A lowers locking ring318. The scope of this disclosure is not limited to this convention, however.

Referring again momentarily toFIG. 2D, and again as described in more detail in the '279 Application, wellhead adapter312on fluid connection housing assembly300provides quick test fitting401via quick test port402. Quick test fitting401may be pressurized with hydraulic fluid after fluid connection adapter200A is engaged and locked into wellhead adapter312on fluid connection adapter assembly300. In this way, pressure in the space between sealing rings may be equalized after the introduction of operational fluid flow. Conversely, quick test fitting401enables fluid trapped at pressure in the space between the sealing rings to be relieved after fluid flow has ended and fluid connection housing assembly300has been generally depressurized. In other applications, fluid delivered at pressure through quick test fitting401enables the integrity of the sealing rings to be checked prior to introducing operational fluid flow into the connection between fluid connection adapter200A and wellhead adapter312on fluid connection housing assembly300.

Looking now atFIG. 1B, hydraulic hose108C on lower bank105L of reels106is connected to quick test fitting401on fluid connection housing assembly300. In this way, an operator at control unit100may deliver pressurized hydraulic fluid to quick test fitting401so as to remotely perform the actions described in the previous paragraph.

FIG. 1Bfurther illustrates multi-core control cable109connected to bulkhead box107via multi-pin connector110. Although not specifically illustrated, it will be understood that the displays, features and controls in and on control enclosure120are wired electrically to bulkhead box107. In this way, connection of multi-pin connector110to bulkhead box107allows the various individual cores of multi-core control cable109to address corresponding displays, features and controls in and on control enclosure120.

Referring now toFIG. 2A, for example, fluid connection housing assembly300provides junction box350for receiving multi-core control cable109via a further multi-pin connector110. Junction box350enables the various individual cores of multi-core control cable109to address upper and lower side sensors352U,352L via sensor cables351A. Grommets354seal the openings injunction box350for sensor cables351A. Upper and lower side sensors352U,352L are described in more detail below, but are generally configured to activate when locking ring318is fully raised and lowered respectively. In this way, looking atFIGS. 1B and 2Atogether, multi-core control cable109connects upper and lower side sensors352U,352L to corresponding displays and features on control enclosure120on control unit100. An operator at control unit100may thus monitor the positional status of locking ring318remotely.

FIG. 2Afurther depicts sensor cable351B connecting junction box350to well pressure sensor353. Well pressure sensor353is configured to sense the current pressure in wellhead adapter312on fluid connection housing assembly300. In preferred embodiments, well pressure sensor353is a pressure transducer, although the scope of this disclosure is not limited in this regard. Junction box350allows multi-core control cable109to address well pressure sensor353via sensor cable351B. In this way, looking atFIGS. 1B and 2Aagain together, multi-core control cable109connects well pressure sensor353to corresponding displays and features on control enclosure120on control unit100. An operator at control unit100may thus monitor the current pressure in fluid connection housing assembly300remotely.

FIG. 1Cillustrates the control unit100ofFIG. 1Awith frame101and control enclosure120removed for clarity.FIG. 1Cdepicts skid185, motor183, batteries184, bulkhead boxes107and reels106on upper and lower banks105U,105L as previously described.FIG. 1Cfurther depicts electro-hydraulic module180with hydraulic valves181and hydraulic pumps182. Although not specifically illustrated, it will be understood that electro-hydraulic control module180is in electrical communication with control enclosure120such that controls, features and displays in and on control enclosure120may address electro-hydraulic control module180. In this way, an operator at the operator interface of control unit100may accomplish desired remote hydraulic operations by simply actuating a control on the operator interface. For example, per earlier description, the operator may actuate an operator interface control that in turn actuates selected ones of hydraulic pumps182and hydraulic valves181to pressurize hydraulic hose108A and depressurize hydraulic hose108B, which in turn raises locking ring318on a fluid connection housing assembly300remotely.

FIG. 1Dis a first enlarged inset as shown onFIG. 1A, and illustrates well control module130on control enclosure120. As noted above, the embodiment of control unit100onFIG. 1Aenables a remote operator to monitor status and exercise control over four (4) fluid connections independently and concurrently. Well number131on well control module130identifies to the operator which displays, features and controls on well control module130pertain to a corresponding remote fluid connection (and associated wellhead).

Well control module130further provides a well pressure display132for each well number131. As previously described with reference toFIGS. 1B and 2A, in currently preferred embodiments well pressure display132is addressed by well pressure sensor353at the remote fluid connection housing assembly300, and allows an operator at control unit100to monitor the current pressure in fluid connection housing assembly300remotely.

Well control module130onFIG. 1Dfurther provides indicator light133and lock switch134for each well number131. In some embodiments, lock switch134may be a spring-loaded switch. In some embodiments, lock switch134is disposed to selectively energize pressurization of either hydraulic hose108A or hydraulic hose108B. Turning lock switch134to the “lock” position (and keeping lock switch134turned to “lock”) lowers the locking ring318on fluid connection housing assembly300via hydraulic actuation as previously described. Lowering locking ring318engages and locks fluid connection adapter200A into fluid connection housing assembly. Conversely, turning lock switch134to the “unlock” position (and keeping lock switch134turned to “unlock”) raises the locking ring318on fluid connection housing assembly300, again via hydraulic actuation as previously described. Raising locking ring318unlocks fluid connection adapter200A from fluid connection housing assembly and allows fluid connection adapter200A to be disengaged.

It will be recalled from prior description that side sensors352U,352L are generally configured to activate when locking ring318on fluid connection housing assembly300is fully raised and lowered respectively. In some embodiments, indicator light133is disposed to be addressed by side sensors352U,352L such that lower side sensor352L activates when the fluid connection housing assembly300is in a locked condition and upper side sensor352U activates when fluid connection housing assembly300is in an unlocked condition. Generally, indicator light133illuminates differently according to a sensed condition detected by side sensors352U,352L wherein the sensed condition is from among at least two conditions selected from the group consisting of: (a) fluid connection housing assembly300is in the unlocked condition; (b) fluid connection housing assembly300is in the locked condition; (c) fluid connection housing assembly300is in transition from the locked condition to the unlocked condition or vice versa; and (d) the FCHA is in a fault condition during transition from the locked condition to the unlocked condition or vice versa.

More specifically in preferred embodiments, processing logic in control enclosure120is configured to cause indicator light133to illuminate according to a detected positional status of locking ring318. In preferred embodiments, indicator light133illuminates green when side sensors352U,352L detect that ring318on fluid connection housing assembly300is fully lowered (retracted) such that fluid connection adapter200A is engaged and locked into fluid connection housing assembly300. It is safe to conduct operational fluid flow (or otherwise pressurize fluid connection housing assembly300) in this “green” condition.

Conversely, indicator light133illuminates red when side sensors352U,352L detect that ring318on fluid connection housing assembly300is fully raised (extended) such that fluid connection adapter200A is free to disengage from fluid connection housing assembly300. It is not safe to commence operational fluid flow (or otherwise pressurize fluid connection housing assembly300) in this “red” condition.

Additionally, indicator light133illuminates yellow (constant) when side sensors352U,352L detect that ring318on fluid connection housing assembly300is in transition from a fully raised (extended) position to a fully lowered (retracted) position and vice versa. Additionally, indicator light133illuminates yellow (flashing) when side sensors352U,352L detect a fault condition, such as when ring318on fluid connection housing assembly300is stuck (not moving) in transition from a fully raised (extended) position to a fully lowered (retracted) position and vice versa. It is not safe to commence operational fluid flow (or otherwise pressurize fluid connection housing assembly300) in either of these “yellow” conditions.

It will be appreciated that although currently preferred embodiments of well module130onFIG. 1Dilluminate indicator light133according to the above-described color-coded conditions, the scope of this disclosure is not limited in this regard. Other embodiments may illuminate indicator light133according to different color schemes driven by different processing logic.

Embodiments of control unit100described in this disclosure, including with reference toFIG. 1D, further provide alerts and fail-safe measures to promote jobsite safety. For example, in some embodiments control unit100is disposed to issue at least one user-perceptible alert selected from the group consisting of: (a) while side sensors352U,352L detect that FCHA300is in the locked condition, an alert that FCHA300is available to be pressurized; (b) while side sensors352U,352L detect that FCHA300is in the unlocked condition, an alert that FCHA300is unavailable to be pressurized; (c) while well pressure sensor353senses a current well pressure in excess of a predetermined maximum pressure value, an alert that the predetermined maximum pressure value has been exceeded; and (d) while side sensors352U,352L detect that FCHA300is in transition from (1) the locked condition to the unlocked condition, or (2) the unlocked condition to the locked condition, an alert that FCHA300is in transition. In preferred embodiments, the predetermined maximum pressure value is 15,000 psi, although the scope of this disclosure is not limited in this regard.

Embodiments of control unit100described in this disclosure, including with reference toFIG. 1D, further provide fail-safe measures including preventing pressurization of the hydraulic hose108A (and raising locking ring318) if side sensors352U,352L detect that FCHA300is in the locked condition and well pressure sensor353senses a current non-zero well pressure in FCHA300.

Well control module130onFIG. 1Dfurther provides quick test pressure display135and quick test operation switch136for each well number131. It will be recalled from prior disclosure with reference toFIGS. 1B and 2Dthat quick test fitting401on fluid connection housing assembly300may be pressurized with hydraulic fluid after fluid connection adapter200A is engaged and locked into wellhead adapter312in order to equalize pressure in the space between sealing rings. Pressurization of hydraulic hose108C tests whether a pressure-tight connection has been established between sealing rings inside FCHA300. Conversely, quick test fitting401enables fluid trapped at pressure in the space between the sealing rings to be relieved after fluid connection housing assembly300has been generally depressurized. Fluid delivered at pressure through quick test fitting401further enables the integrity of the sealing rings to be checked prior to introducing operational fluid flow into the connection between fluid connection adapter200A and wellhead adapter312. Generally stated, therefore, control unit100provides hydraulic hose108C disposed to be connected to quick test fitting401such that pressurization of hydraulic hose108C tests whether a pressure-tight connection has been established between sealing rings inside the fluid connection housing assembly300. Control unit100further provides quick test pressure display135disposed to communicate current pressure in hydraulic hose108C. Control unit100further provides quick test operation switch136disposed to selectively energize a quick test function selected from the group consisting of: (a) energizing pressurization of hydraulic hose108C; (b) holding current pressure in hydraulic hose108C; and (c) energizing depressurization of hydraulic hose108C.

More specifically with reference to currently preferred embodiments illustrated onFIG. 1D, turning quick test operation switch136to the “test” position (and keeping switch136in the “test” position) delivers hydraulic fluid to quick test connect fitting401via hydraulic hose108C as previously described, and causes pressure to increase gradually in the space between sealing rings inside fluid connection housing assembly300. Quick test pressure display135onFIG. 1Dallows the operator to monitor the pressure as it increases. When a desired pressure between sealing rings is reached, turning quick test operation switch136to the “hold” position halts the increase in pressure while the operator watches quick test pressure display136for any pressure decay. If there is decay, the operator knows that fluid connection adapter200A may not be seated properly inside fluid connection housing assembly300and that corrective action must be taken before operational fluid flow can commence. If there is no decay, the operator knows that the space between sealing rings inside fluid connection housing assembly is pressure-tight and ready to receive operational fluid flow. Once fluid flow has ended, turning quick test operation switch136to the “dump” position (and keeping switch136in the “dump” position) allows the operator to relieve hydraulic fluid pressure in the space between sealing rings.

FIG. 1Eis a second enlarged inset as shown onFIG. 1A, and illustrates auxiliary pressure display145, auxiliary pressure switch146, motor status display150and cellular broadcast switch155on control enclosure120. Some embodiments of control unit100provide an auxiliary pressurized hydraulic fluid “take-off” option via a separate hydraulic hose connection. In such embodiments, an operator at control unit100may actuate such auxiliary fluid delivery by actuating auxiliary pressure switch146. When such auxiliary fluid delivery is enabled, the operator may monitor the pressure of such auxiliary fluid delivery via auxiliary pressure display146.

Motor status display150onFIG. 1Eallows an operator at control unit100to monitor the status of motor183onFIGS. 1B and 1C. As noted in earlier description, motor183is preferably a diesel engine in illustrated portable embodiments of control unit100. Accordingly, motor display150onFIG. 1Eprovides features allowing an operator to monitor the status of a diesel engine. Motor display150comprises tachometer151, hours display152(indicating total hours run by the diesel engine), electrical power and starter key lock153and engine indicator lights154A though154F. In the illustrated embodiment of motor display150onFIG. 1E, engine indicator lights comprise battery status154A, glow plug status154B, oil pressure status154C, coolant temperature status154D, auxiliary1status154E and auxiliary2status154F.

Cellular broadcast switch155onFIG. 1Eallows the operator to activate and deactivate broadcast of control unit100's current status over a cellular network connection. The cellular network connection enables, for example, an offsite operations center to monitor multiple concurrent well operations and well status potentially far away from control unit100. This cellular broadcast function is described in more detail below with reference toFIG. 1G.

FIG. 1Fis a third enlarged inset as shown onFIG. 1A, and illustrates interactive touch display140on control unit100. In some embodiments, interactive touch display140may also be referred to as a “Human Machine Interface” or “HMI”. In currently preferred embodiments, interactive touch display140provides a touch-enabled menu bar141. An operator may select menu items142on menu bar141by touch. Information and data relating to the selected menu item142is then displayed on display region143. In the example illustrated onFIG. 1F, an operator has selected “System Status” menu item142from menu bar141. In response, display region143shows system status information and data. The system status information and data shown on display region143onFIG. 1Fis self-explanatory. If the operator selects a different menu item142from menu bar141, display region143refreshes to display different information and data pertinent to the menu item142selected. It will be appreciated that illustrated embodiments of interactive touch display140onFIG. 1Fare exemplary only, and that the scope of this disclosure is not limited to the specific menu items142shown on menu bar141, or the information and data that display region143will display responsive to selection of any particular menu item142.

FIG. 1Gis a fourth enlarged inset as shown onFIG. 1A, and illustrates cellular/location broadcast module121inside control enclosure120on control unit100. Referring momentarily back to description above with reference toFIG. 1E, currently preferred embodiments of control unit100allow an operator to activate and deactivate cellular/location broadcast module121via cellular broadcast switch155. Generally, cellular/location broadcast module121is operatively connected to at least one broadcast antenna, wherein cellular/location broadcast module121is disposed to transmit information regarding control unit100's status via the at least one broadcast antenna, wherein the at least one broadcast antenna includes at least one antenna selected from the group consisting of (a) cellular antenna123and (b) satellite antenna122. As shown in more detail onFIG. 1G, cellular/location broadcast module121is equipped with satellite antenna122and cellular antenna123. As described above, cellular antenna123enable cellular/location broadcast module121to broadcast information regarding control unit100's status to, for example, an offsite computer or operations center. The offsite computer or operations center may monitor multiple concurrent well operations and well status potentially far away from control unit100. Alternatively, the offsite computer or operations center may accumulate control unit status data for later analysis.

Cellular/location broadcast module121onFIG. 1Galso provides satellite antenna122. In currently preferred embodiments, an operator may activate cellular/location broadcast module121to send control unit100's current location via GPS to an offsite control center, for example. Satellite antenna122enables transmission of control unit100's current location via GPS. Satellite antenna122may also broadcast information regarding control unit100's status to, for example, an offsite computer or operations center when cellular network coverage is poor (or non-existent), or when cellular transmission is prohibited. Cellular data transmission is generally preferable over satellite transmission when cellular is available. Cellular data transfer rates are generally higher.

FIGS. 2A through 3Dillustrate embodiments of fluid connection adapter200A as received inside fluid connection housing assembly300generally in accordance with the '279 Application, except that such illustrated embodiments onFIGS. 2A through 3Dalso include actuation and sensor features from the instant application. The '279 Application is incorporated by reference into the instant application in its entirety. The reader interested in understanding detailed interoperation of fluid connection adapter200A received into fluid connection housing assembly300as depicted onFIGS. 2Athough2D should refer to the '279 Application. The instant application assumes a general understanding of such interoperation. The instant application uses the same part names and part numbers as the '279 Application wherever practical when referring to items described in both the '279 Application and the instant application.

FIGS. 2A and 2Billustrate an embodiment of fluid connection housing assembly300generally disclosed in the '279 Application deployed with side sensor embodiments352U,352L from the instant application. Referring first toFIG. 2A, fluid connection housing assembly300is in fluid communication with wellhead W via flanged connection313. Actuator assemblies380onFIG. 2Apresent actuator pistons382in an extended position such that locking ring318is in the fully “raised” or “extended” position. Fluid connection housing assembly onFIG. 2Ais thus in an “open” or “unlocked” condition, such that fluid connection adapter200A is free to disengage from fluid connection housing assembly300.

Fluid connection housing assembly300onFIG. 2Afurther provides junction box350. As also described above with reference toFIG. 1B, junction box350receives multi-core control cable109from control unit100. Multi-core control cable109connects to junction box350via multi-pin connector110. Junction box350enables the various individual cores of multi-core control cable109to address upper and lower side sensors352U,352L via sensor cables351A. Grommets354seal the openings in junction box350for sensor cables351A. Upper and lower side sensors352U,352L are described in more detail immediately below with reference toFIGS. 2E and 2F, but are generally configured to activate when locking ring318is fully raised and lowered respectively.

FIG. 2Bis a similar illustration toFIG. 2A, except that actuator assemblies380onFIG. 2Bpresent actuator pistons382in a retracted position such that locking ring318is in the fully “lowered” or “retracted” position. Fluid connection housing assembly onFIG. 2Ais thus in a “closed” or “locked” condition, such that fluid connection adapter200A is engaged and locked inside fluid connection housing assembly300.

FIGS. 2E and 2Fare enlarged insets as shown onFIGS. 2A and 2Brespectively.FIG. 2Eillustrates actuator assembly380onFIG. 2Acut away to reveal upper and lower side sensors352U,352L interacting with side sensor activator355on guide rod381. It will be recalled from above that actuator assemblies380onFIG. 2Apresent actuator pistons382in an extended position such that locking ring318is in the fully “raised” or “extended” position.FIG. 2Eshows that side sensor activator355is positioned on guide rod381so that upper side sensor352U detects the presence of side sensor activator355when actuator piston382is in an extended position such that locking ring318is in a fully raised or extended position.

Similar toFIG. 2E,FIG. 2Fillustrates actuator assembly380onFIG. 2Bcut away to reveal upper and lower side sensors352U,352L interacting with side sensor activator355on guide rod381. It will be recalled from above that actuator assemblies380onFIG. 2Bpresent actuator pistons382in a retracted position such that locking ring318is in the fully “lowered” or “retracted” position.FIG. 2Fshows that side sensor activator355is positioned on guide rod381so that lower side sensor352L detects the presence of side sensor activator355when actuator piston382is in a retracted position such that locking ring318is in a fully lowered or retracted position. In currently preferred embodiments, upper and lower side sensors352U,352L are magnetic sensors. In such magnetic sensor embodiments, guide rods381on which side sensor activator355is deployed are preferably made from a non-ferrous material such as stainless steel, and side sensor activator355is a ferrous portion in the stainless steel guide rod381(such as a ferrous steel grub screw or rivet). The scope of this disclosure is not limited, however, to the type of sensor deployed for upper and lower side sensors352U,3521L or the manner in which the side sensors are activated.

FIGS. 2A and 2Beach depict currently preferred embodiments of fluid connection housing assembly300providing two (2) guide rods381addressed by upper and lower side sensors352U,352L. The guide rods381addressed by upper and lower side sensors352U,352L are preferably positioned either side of junction box350to optimize the length of side sensor cables351A. Two (2) guide rods381are configured to be addressed by upper and lower side sensors352U,352L in order to provide redundancy in case of sensor failure. It will be understood that such redundancy enables an operator at control unit100to perceive that a fault condition may have occurred when a side sensor352U,352L on one guide rod381activates and a corresponding side sensor on the other guide rod381does not. The scope of this disclosure, however, is not limited to any embodiments including specific guide rod and sensor redundancy.

It will be further recalled from above that in currently preferred magnetic sensor embodiments, guide rods381on which side sensor activator355is deployed are preferably made from a non-ferrous material such as stainless steel. In such magnetic sensor embodiments, guide rods381not addressed by upper and lower side sensors352U,352L may be made from a more conventional material, such as carbon steel.

FIGS. 2A and 2Beach further show well pressure sensor353configured to sense the current pressure in wellhead adapter312on fluid connection housing assembly300.FIGS. 2A and 2Bfurther depict sensor cable351B connecting junction box350to well pressure sensor353. Junction box350allows multi-core control cable109from control unit100to address well pressure sensor353via sensor cable351B. As noted above, well pressure sensor353is a pressure transducer in preferred embodiments, although the scope of this disclosure is not limited in this regard.

FIG. 2Cis a top view of the embodiment of fluid connection housing assembly300depicted onFIG. 2B.FIG. 2Dis a section as shown onFIG. 2C.FIG. 2Dillustrates well pressure sensor353connected to needle valve601resident in transducer port602in wellhead adapter312. In the embodiment of fluid connection housing assembly300illustrated onFIG. 2D, wellhead adapter312provides a second needle valve601in a second transducer port602. In such embodiments, second needle valve601and second transducer port602may provide redundancy for well pressure sensor353in case of damage, for example, to the original valve or port601,602. Alternatively, second needle valve601and second transducer port602may be used to drain/equalize pressure within wellhead adapter312during service operations when, for example, fluid connection adapter200is being removed and fluid connection housing assembly300is being exposed to atmospheric pressure. Alternatively, second transducer port602may receive a local pressure gauge allowing well pressure inside wellhead adapter312to be monitored from nearby the wellhead. The scope of this disclosure is not limited to particular uses for transducer ports602or equipment deployed therein.

FIG. 2Dfurther illustrates fluid connection housing assembly300providing quick test fitting401connected to quick test port402. Control, testing and monitoring of pressurization and depressurization operations by control unit100through quick test fitting401is described in detail above with reference toFIGS. 1B and 1D.

FIGS. 3A and 3Billustrate a further embodiment of fluid connection housing assembly300generally disclosed in the '279 Application deployed with under sensor embodiments356from the instant application.FIGS. 3A and 3Bare similar illustrations toFIGS. 2A and 2B, except that actuator assemblies380onFIGS. 3A and 3Bprovide under sensors356instead of upper and lower side sensors352U,352L onFIGS. 2A and 2B.

FIGS. 3C and 3Dare enlarged insets as shown onFIGS. 3A and 3Brespectively.FIG. 3Dillustrates actuator assembly380onFIG. 3Bcut away to reveal under sensor356interacting with under sensor activator357on short guide rod381A. It will be understood that similar toFIG. 2B, actuator assemblies380onFIG. 3Bpresent actuator pistons382in a retracted position such that locking ring318is in the fully “lowered” or “retracted” position.FIG. 3Dshows that under sensor activator357is positioned on the lower end of short guide rod381A so that under sensor356detects the presence of under sensor activator357when actuator piston382is in a retracted position. It will be further understood that the length of short guide rod381A is selected so as to bring under sensor activator357within detection range of under sensor356when actuator pistons382are in a retracted position such that locking ring318is in the fully “lowered” or “retracted” position.

Similar toFIG. 3D,FIG. 3Cillustrates actuator assembly380onFIG. 3Acut away to reveal under sensor356interacting with under sensor activator357on short guide rod381A. It will be understood that similar toFIG. 2A, actuator assemblies380onFIG. 3Apresent actuator pistons382in an extended position such that locking ring318is in the fully “raised” or “extended” position.FIG. 3Cshows that under sensor activator357is positioned on short guide rod381A so that under sensor356is unable to detect the presence of under sensor activator357when actuator piston382is in an extended position such that locking ring318is in a fully raised or extended position. It will thus be appreciated that the embodiments illustrated onFIGS. 3A through 3Ddetect locking ring318in one of the following two states: either (1) in a fully lowered or retracted position, or (2) not in such a position. This is distinction to the embodiments illustrated onFIGS. 2A, 2B, 2E and 2F, which detect locking ring318in one of the following two states: either (1) in a fully lowered or retracted position, or (2) in a fully raised or extended position.

FIGS. 3Athough3D illustrate currently preferred embodiments illustrated in which under sensors356are magnetic sensors. In such magnetic sensor embodiments, short guide rods381A on which under sensor activator357is deployed are preferably made from a non-ferrous material such as stainless steel, and under sensor activator357is a ferrous portion on the end of the stainless steel short guide rod381A (such as a ferrous steel cap). Alternatively, short guide rods381A may be all ferrous. The scope of this disclosure is not limited, however, to the type of sensor deployed for under sensor356or the manner in which the under sensors are activated. Further, “regular length’ guide rods381onFIGS. 3A and 3Bnot addressed by under sensors356may be made from a more conventional material, such as carbon steel.

Similar toFIGS. 2A and 2B,FIGS. 3A and 3Beach depict currently preferred embodiments of fluid connection housing assembly300providing two (2) short guide rods381addressed by under sensors356. The short guide rods381A addressed by under sensors356are preferably positioned either side of junction box350to optimize the length of side sensor cables351A. Two (2) short guide rods381A are configured to be addressed by under sensors356in order to provide redundancy in a similar manner, and for similar reasons, as for embodiments described above with reference toFIGS. 2A and 2B.

FIGS. 4A through 6Gillustrate embodiments of adapter250as received inside pressure control assembly200generally in accordance with the '990 Application, except that such illustrated embodiments onFIGS. 4A through 6Galso include actuation and sensor features from the instant application. The '990 Application is incorporated by reference into the instant application in its entirety. The reader interested in understanding detailed interoperation of adapter250received into pressure control assembly200as depicted onFIGS. 4Athough6G should refer to the '990 Application. The instant application assumes a general understanding of such interoperation. The instant application uses the same part names and part numbers as the '990 Application wherever practical when referring to items described in both the '990 Application and the instant application.

FIGS. 4A and 4Billustrate an embodiment of pressure control assembly200generally disclosed in the '990 Application deployed with magnetic cam sensor embodiments281from the instant application. Referring first toFIG. 4A, pressure control assembly200is in fluid communication with wellhead W. Cam lock pistons222(referFIG. 4B) connect to cam locks220via link arms235. Cam lock actuation ports223A,223B are configured to connect to hydraulic hoses in order to receive hydraulic fluid under pressure. Hydraulic fluid into cam lock actuation port223A extends cam lock pistons. Hydraulic fluid into cam lock actuation port223B retracts cam lock pistons. Locking ring pistons242connect to locking ring240. Locking ring actuation ports243A,243B are also configured to connect to hydraulic hoses in order to receive hydraulic fluid under pressure. Hydraulic fluid into locking ring actuation port243A extends locking ring pistons. Hydraulic fluid into locking ring actuation port243B retracts locking ring pistons.

Cam locks220onFIG. 4Aare down, meaning cam lock pistons222are retracted. Locking ring240onFIG. 4Ais up, meaning locking ring pistons242are extended. When cam locks220are down and locking ring240is up on pressure control assembly200as onFIG. 4A, pressure control assembly200is in an “open” or “unlocked” condition, such that adapter250is free to disengage from pressure control assembly200.FIG. 4Afurther illustrates cam activator surfaces282on cam locks220. It will be seen onFIG. 4Athat when cam locks220are down, cam activator surfaces282are remote from magnetic cam sensors281.

FIG. 4Cis an enlarged inset as shown onFIG. 4A.FIGS. 4A and 4Cshould now be viewed together.FIGS. 4A and 4Cillustrate magnetic cam sensors281positioned on locking ring240. In embodiments depicted onFIGS. 4A and 4C, locking ring240includes crown288superposed on locking ring240, and sensor guard rings289A,289B provided on an outer periphery of locking ring240. Sensor positioning members291attach to crown288so as to hold magnetic cam sensors281in a predetermined fixed position with respect to locking ring240.

FIG. 4Bis a similar illustration toFIG. 4A, except that cam locks220onFIG. 4Bare up, meaning cam lock pistons222are extended. Locking ring240onFIG. 4Bis down, meaning locking ring pistons242are retracted. When cam locks220are up and locking ring240is down on pressure control assembly200as onFIG. 4B, pressure control assembly200is in a “closed and locked” condition, such that cam locks220have engaged adapter250inside pressure control assembly200and locking ring240is retaining cam locks220.

FIGS. 4E and 4Fare enlargements ofFIGS. 4A and 4Brespectively, with assembly components removed for clarity.FIG. 4Eis a similar illustration toFIG. 4A, except with adapter250, tulip201and sensor guard rings289A,289B removed to reveal magnetic cam sensors281more clearly.FIG. 4Eshows pressure control assembly200is in an “open” or “unlocked” condition with cam locks220down and locking ring240up.FIG. 4Edepicts jam nuts290and sensor positioning members291combining to allow magnetic cam sensors to be set at a predetermined fixed position with respect to locking ring240.FIG. 4Ealso shows cam activator surfaces282on cam locks220. Similar toFIG. 4A, it will be seen onFIG. 4Ethat when cam locks220are down, cam activator surfaces282are remote from magnetic cam sensors281.

FIG. 4Fis a similar illustration to4E, except that cam locks220onFIG. 4Fare up and locking ring240onFIG. 4Fis down.FIG. 4Fthus depicts pressure control assembly200in a “closed and locked” condition.FIG. 4Ffurther illustrates that when cam locks220are up and locking ring240is down, magnetic cam sensors281detect the presence of cam activator surfaces282. In embodiments of pressure control assembly200illustrated onFIGS. 4A through 4D, and 4E and 4F, therefore, magnetic cam sensors281may detect when pressure control assembly200is in a “closed and locked” condition. More specifically, magnetic cam sensors281may detect pressure control assembly200in one of the following two states: either (1) in a “closed and locked” condition with cam locks220up and locking ring240down, or (2) not in such a condition.

FIGS. 4E and 4Ffurther illustrate currently preferred embodiments in which magnetic cam sensors281are electrically coupled together in series via sensor cable284. In such embodiments, the failure of any one of magnetic cam sensors281to activate (i.e. detect the presence of a corresponding cam activator surface282) will alert to a potential fault condition when cam locks220are hydraulically actuated to the “up” position and locking ring240is hydraulically actuated to the “down” position.

FIGS. 4A, 4B, 4E and 4Falso depict well pressure sensor353. Similar to description above with reference toFIG. 2A, well pressure sensor353onFIGS. 4A, 4B, 4E and 4Fis configured to sense the current pressure in pressure control assembly200. In preferred embodiments, well pressure sensor353is a pressure transducer, although the scope of this disclosure is not limited in this regard.FIGS. 4A, 4B, 4E and 4Falso show sensor cable351B addressing well pressure sensor353.

FIG. 4Gis a vertical section through the embodiment of pressure control assembly200depicted onFIG. 4B.FIG. 4His an enlarged inset as shown onFIG. 4G.FIG. 4Gillustrates well pressure sensor353connected to needle valve601resident in transducer port602in receptacle260. Similar to the embodiment of fluid connection housing assembly300illustrated onFIG. 2D, receptacle206onFIG. 4Gprovides a second needle valve601in a second transducer port602in receptacle260. Second needle valve601and second transducer port602may provide redundancy for well pressure sensor353in case of damage, for example, to the original valve or port601,602. Alternatively, second needle valve601and second transducer port602may be used to drain/equalize pressure within receptacle260during service operations. Alternatively, second transducer port602may receive a local pressure gauge allowing well pressure inside receptacle260to be monitored from nearby the wellhead. The scope of this disclosure is not limited to particular uses for transducer ports602or equipment deployed therein.

FIG. 4Hillustrates pressure control assembly200onFIG. 4Gproviding quick test port and fitting500. Quick test port500accesses the space between o-rings252when adapter250is fully and operationally received into receptacle260. Control, testing and monitoring of pressurization and depressurization operations through quick test port500onFIG. 4Hare analogous to those described above with reference toFIGS. 1B, 1D and 2Dfor quick test fitting401onFIG. 2D.

FIGS. 5A and 5Billustrate pressure control assembly200according toFIGS. 4E and 4Frespectively, except thatFIGS. 5A and 5Bdeploy contact cam sensor embodiments283instead of magnetic cam sensor embodiments281as depicted onFIGS. 4E and 4F. Similar toFIG. 4E,FIG. 5Ashows pressure control assembly200in an “open” or “unlocked” condition with cam locks220down and locking ring240up. Similar toFIG. 4F,FIG. 5Bshows pressure control assembly200in a “closed and locked” condition with cam locks220up and locking ring240down. Contact cam sensors283onFIGS. 5A and 5Bare preferably mechanical assemblies whose spring-loaded limit switch design activates when biased rotor arms thereon are deflected. Contact cam sensors283are shown onFIG. 5Awith their rotor arms in an undeflected state when cam locks220are down and ring240is up. Referring now toFIG. 5B, the presence of cam activator surfaces282when cam locks220are up and locking ring240is down deflects the rotor arms and activates contact cam sensors283. Similar to magnetic cam sensors281illustrated onFIGS. 4E and 4Fabove, therefore, contact cam sensors283detect when pressure control assembly200is in a “closed and locked” condition. More specifically, contact cam sensors283may detect pressure control assembly200in one of the following two states: either (1) in a “closed and locked” condition with cam locks220up and locking ring240down, or (2) not in such a condition.

Similar to magnetic cam sensors281illustrated onFIGS. 4E and 4Fabove,FIGS. 5A and 5Bfurther illustrate currently preferred embodiments in which contact cam sensors283are electrically coupled together in series via sensor cable284. In such embodiments, the failure of any one of contact cam sensors283to activate (i.e. detect the presence of a corresponding cam activator surface282) will alert to a potential fault condition when cam locks220are hydraulically actuated to the “up” position and locking ring240is hydraulically actuated to the “down” position.

FIGS. 6A and 6Billustrate an embodiment of pressure control assembly200generally disclosed in the '990 Application deployed with cam rod puck and sensor embodiments286,285from the '795 Application.FIGS. 6C and 6Dare enlarged insets as shown onFIGS. 6A and 6Brespectively. Looking atFIGS. 6A through 6Dtogether, cam lock pistons222have cam rod pucks286attached to a lower end thereof. Puck sensor285is positioned on pressure control assembly200to activate when it detects the presence of cam rod puck286. In illustrated embodiments, puck sensor285is a magnetic sensor, and cam rod puck286is ferrous. In other embodiments (not illustrated), puck sensor285may be a mechanical contact sensor, positioned on pressure control assembly200to activate when touched by cam rod puck286. The scope of this disclosure is not limited to any particular design for puck sensor285.

The pressure control assembly200illustrated onFIGS. 6A and 6Cis in an “open” and “unlocked” condition with cam lock pistons222retracted and cam locks220down, and with locking ring pistons242extended and locking ring240up. Puck sensors285will not activate.

In contrast, the pressure control assembly200illustrated onFIGS. 6B and 6Dis in an “closed but unlocked” condition with cam lock pistons222extended and cam locks220up, but with locking ring pistons242still extended and locking ring240still up. Puck sensors285will activate to indicate cam locks220are up. Puck sensors285with cam rod pucks286may thus detect when pressure control assembly200is in a “closed” condition with cam lock pistons222extended and cam locks220up, regardless of whether locking ring240is up or down. More specifically, puck sensors285with cam rod pucks286may detect pressure control assembly200in one of the following two states: either (1) in a “closed” condition with cam locks220up, or (2) not in such a condition.

Although not specifically illustrated onFIGS. 6A through 6D, puck sensors285with cam rod pucks286are preferably electrically coupled together in series. In such embodiments, the failure of any one of puck sensors285to activate (i.e. detect the presence of a corresponding cam rod puck286) will alert to a potential fault condition when cam locks220are hydraulically actuated to the “up” position.

FIG. 6Eillustrates a further embodiment of pressure control assembly200generally disclosed in the '990 Application deployed with ring rod puck and sensor embodiments287,285from the '795 Application and from the instant application.FIGS. 6F and 6Gare enlarged insets as shown onFIG. 6E, in whichFIG. 6Fdepicts ring rod puck and sensor embodiments287,285with ring240down, and in whichFIG. 6Gdepicts ring rod puck and sensor embodiments287,285with ring240up.

Looking atFIGS. 6E through 6Gtogether, locking ring pistons242have ring rod pucks287attached to a lower end thereof. Puck sensor285is positioned on pressure control assembly200to activate when it detects the presence of ring rod puck287. In illustrated embodiments, puck sensor285is a magnetic sensor, and ring rod puck286is ferrous. In other embodiments (not illustrated), puck sensor285may be a mechanical contact sensor, positioned on pressure control assembly200to activate when touched by ring rod puck287. As noted above, the scope of this disclosure is not limited to any particular design for puck sensor285.

The pressure control assembly200illustrated onFIGS. 6E and 6Fis in a “closed and locked” condition with cam lock pistons222extended and cam locks220up, and with locking ring pistons242retracted and locking ring240down. Puck sensors285will not activate.

In contrast, the pressure control assembly200illustrated onFIG. 6Gis in an “unlocked” condition with cam lock pistons222still extended and thus with cam locks220up, but now with locking ring pistons242also extended and thus locking ring240up. Puck sensors285will activate to indicate locking ring240is up. Puck sensors285with ring rod pucks287may thus detect when pressure control assembly200is in an “unlocked” condition with locking ring pistons242extended and locking ring240up, regardless of whether cam locks220are up or down. More specifically, puck sensors285with ring rod pucks287may detect pressure control assembly200in one of the following two states: either (1) in an “unlocked” condition with locking ring240up, or (2) not in such a condition.

Although not specifically illustrated onFIGS. 6E through 6G, puck sensors285with ring rod pucks287are preferably electrically coupled together in series. In such embodiments, the failure of any one of puck sensors285to activate (i.e. detect the presence of a corresponding ring rod puck287) will alert to a potential fault condition when locking ring240is hydraulically actuated to the “up” position.

The embodiments of pressure control assembly200illustrated onFIGS. 4A through 6Gdepict one sensor deployed per cam lock220or locking ring piston242, as applicable, whether the sensor is a magnetic cam sensor281onFIGS. 4A through 4F, a contact cam sensor283onFIGS. 5A and 5B, or a puck sensor onFIGS. 6A through 6G. It will nonetheless be understood that the scope of this disclosure is not limited such illustrated embodiments. Other embodiments (not illustrated) may provide fewer sensors than one deployed per cam lock220or locking ring piston242, as applicable.

Reference is now made to control unit100onFIGS. 1A through 1Gas described in detail above. It is considered to be within the understanding of one of ordinary skill to be able to adapt control unit100onFIGS. 1A through 1G, without undue experimentation, to provide a remoter operator with monitoring and control over embodiments of pressure control assembly200described above with reference toFIGS. 4A through 6G. Such monitoring and control over pressure control assembly200would be similar in scope and function to the monitoring and control provided by control unit100over embodiments of fluid control housing assembly300described above with reference toFIGS. 2A through 3D.

For example, hydraulic hoses108A,108B and108C on control unit100, and remote control thereover, may be adapted and increased/scaled up for control unit100to provide remote control over actuation of cam lock pistons222and locking ring pistons242on pressure control assembly200. Further, processing logic, switches and displays provided in and on control enclosure120on control unit100may be adapted for monitoring and processing remote notifications of activation of magnetic cam sensors281, contact cam sensors283and puck sensors285on pressure control assembly200. All of these electro-hydraulic adaptations and modifications may be made without undue experimentation. The scope of this disclosure is not limited in these regards.

Similarly, control unit100may be reconfigured to monitor well pressure via well pressure monitor353on pressure control adapter200(referFIG. 4A, for example) without undue experimentation. Further, control unit100may be reconfigured to provide remote control, testing and monitoring of pressurization and depressurization operations through quick test fitting500on pressure control adapter200(referFIGS. 4G and 4H) without undue experimentation. The scope of this disclosure is also not limited in these regards.

This disclosure has described sensor embodiments with primary reference to magnetic sensors or contact/mechanical sensors having a spring-loaded limit switch design. The scope of this disclosure is not limited to types of sensor deployed. Other embodiments may deploy, for example and without limitation, combinations of sensor types including capacitive proximity sensors, rotary encoders, accelerometers, inclinometers, optical sensors such as a lamp or LED and photoresistor, and force-sensitive resistors such as strain gauges.

This disclosure has described embodiments of control unit100in association with embodiments of wellhead connections described in the '279 Application and the '990 Application. The scope of this disclosure is not limited, however, to specific wellhead connections with which to associate control unit100. The scope of this disclosure includes associating embodiments of control unit100with a more general category of fluid connection devices. Examples of fluid connection devices falling into a more general category include fluid connection housing assembly300and pressure control assembly200as described herein (and in the '279 and '990 Applications), as well as other fluid connection devices. Similarly, the scope of this disclosure includes associating embodiments of control unit100with a more general category of actuators on fluid connection devices to lock and unlock the fluid connection devices. Examples of actuators falling into a more general category include actuator pistons382and cam lock pistons222as described herein (and in the '279 and '990 Applications) as well as other actuators, such as, for example, a hydraulic motor. Similarly, the scope of this disclosure includes associating embodiments of control unit100with a more general category of indicators disposed to alert differently according to sensed conditions at the fluid connection device. Examples of indicators falling into a more general category include indicator light133as described herein, as well as other indicators. Non-limiting examples of other indicators in the more general category include a screen alert, or a sound alert, or a mechanical indicator that moves within a range of positions according whether the fluid connection device is in the unlocked condition or the locked condition (or is in transition).

Further, embodiments of control unit100may also be configured to control and monitor status of equipment other than wellhead connectors.

Although the disclosed embodiments of control unit100have been described with reference to an exemplary application in hydraulic fracturing (“fracking”), alternative applications could include, for example, areas such as pressure control at a wellhead, deep core drilling, offshore drilling, methane drilling, open hole applications, wireline operations, coil tubing operations, mining operations, and various operations where connections are needed under a suspended or inaccessible load (i.e., underwater, hazardous area).

Exemplary Operation of Control Unit100with Embodiments of Fluid Connection Housing Assembly300Illustrated on FIGS.2A Through2G

Reference is made toFIGS. 1A through 2Gand associated description above to support the following description of an exemplary, non-limiting operation guide for control unit100.

1. Rig Up

Connect hydraulic hoses108A,108B to fittings on fluid connection housing assembly (FCHA)300no. 1.

Repeat above steps for FCHA300nos. 2, 3 and 4.

(Equipment may be color coded for each FCHA300, e.g. red for no. 1, white for no. 2, blue for no. 3 and yellow for no. 4).

Turn the main power switch for control enclosure120to the “ON” position.

Interactive touch display (HMI)140will indicate it is booting up.

Insert key in key lock153and start motor183. Increase engine speed to 2200 rpm as indicated by tachometer151on motor display150.

Touch “well pressure” menu item142on menu bar143on HMI140. Display region143will indicate well pressures. Verify that all well pressure sensors (transducers)353are reading correctly (0 psi). If they do not read 0 psi, touch “settings” menu item142on menu bar143on HMI140and perform a “coarse zero” function.

3. Remote Operation of FCHA300

Keep switch134turned to the “unlock” position until the indicator light133for no. 1 turns red. FCHA300no. 1 is now unlocked and safe to change out equipment at wellhead, perform visual inspection, etc.

To lower the locking ring318for FCHA300no. 1, turn lock switch134for no. 1 to the “lock” position.

Keep switch134turned to the “lock position until the indicator light133for no. 1 turns green. FCHA300no. 1 is now locked and ready for operational fluid flow.

Once the connection is made and locked, perform a quick test on the connection.

If indicator light133is steady yellow, locking ring318is in mid-stroke and FCHA300is not yet ready to receive operational pressure.

If indicator light133is flashing yellow, there is a sensor fault on locking ring318. Fault should be repaired before proceeding.

Set “QTS SET PRESSURE” on HMI display region143to desired pressure by using the slider bar or touching the display region143. **Note** The quick test sub set pressure is programmed to build 500 psi above the input set pressure and then automatically stop. This is to allow the pressure to “settle in” around the desired pressure as a slight amount of bleed off will always be present when energizing hydraulic fluid to such high pressures.
Turn quick test operation switch136to the “test” position. Keep switch136turned to “test” position until desired pressure is displayed on quick test pressure display135and/or the HMI display region143.
Turn switch136to “hold” position and monitor for excessive pressure decay on quick test pressure display135and/or the HMI display region143.
When test is complete, release pressure by turning quick test operation switch136to the “dump” position, and keeping switch136in “dump” position until quick test pressure display135and/or the HMI display region143indicates pressure is released.

5. Safety Features and Protocols.

a. When well pressure is present as indicated by the well pressure sensor353and well pressure display132in a locked FCHA300, and if an operator attempts to raise locking ring318, hydraulic pressure will not be delivered to FCHA300. An alarm will sound and be logged in an alarm screen. Alarms cannot be deleted from the system's memory, only acknowledged by the operator. Also, when an alarm sounds, a message is triggered and sent through a cellular network to predetermined personnel via email or text message.
b. An alarm is also triggered when well pressure exceeds 15,000 psi and service personnel are alerted remotely. This allows service personnel to determine if the equipment needs to be removed and re-certified due to an overpressure event.
c. If the lock switch134is turned and not kept in a turned position until the locking ring318achieves full stroke, an alarm will sound, will show on HMI display region143, and will be sent remotely to service personnel.
d. The programming in control unit100is equipped with logic to “zero” calibrate a transducer if a cable run becomes compromised or a transducer's internal resistance changes. This course zero correction provides a convenient way to ensure accurate measurements from this type of transducer. It also prevents a potential safety hazard of an operator zeroing the transducer value when well pressure is actually present and then trying to raise locking ring318. The “coarse zero” calibration is accomplished with a password protected calibration that also causes an alarm to trigger and the override action is logged remotely.
e. Filter restriction pressure switches are installed on the main hydraulic fluid manifold. Alarms and pop up messages are presented on HMI display region143when these filters need to be changed to ensure maintenance is performed.
f. Alarms are also triggered when system hours reach predetermined values to alert the operator of when engine services need performed.
g. A solenoid function test is integrated into the HMI display region143's diagnostic screen. This test can be used by the service technician to be able to force voltage to solenoids. This aids in troubleshooting speed and accuracy in the event repairs need to be made.
h. Control of the main system pressure, as seen on the HMI display region143under the “Settings” menu tem142on the menu bar101on HMI140, can be made by controlling the proportional valve driver output. This function is password protected for service personnel use only.
i. HMI140can be securely remotely monitored to supervise operations and adjust the logic program.
j. Cellular transmission can be disabled on jobsites when cellular communication is not allowed, or where local cellular network coverage is insufficient. The cellular transmission signal can be disabled via cellular broadcast switch155or on the HMI display region143under the “System status” menu tem142on the menu bar101on HMI140. Message reminders will pop up on the HMI display region143until the cellular connection is restored. Data will continue to be logged, stored and accumulated locally while cellular transmission is disabled, and will be transmitted remotely once the cellular connection is restored. In units providing a satellite broadcasting feature, data may be transmitted remotely via satellite instead cellular where cellular transmission is either not allowed or insufficient due to poor (or no) cellular network coverage. Satellite broadcast may also identify and transmit control unit100's local position using GPS.

Although the material in this disclosure has been described in detail along with some of its technical advantages, it will be understood that various changes, substitutions and alternations may be made to the detailed embodiments without departing from the broader spirit and scope of such material as set forth in the following claims.