Smart com-unit for monitoring, controlling, and operating wellheads in oil and gas wells

Abstract

A com-unit for monitoring, controlling, and operating wellheads in oil and gas wells is provided. In particular, the Smart com-unit of the present invention allows for remote monitoring of the pressure in the wells in real time. The Smart com-unit ensures the safe and efficient operation of wells used in oil and gas production. The Smart com-unit assembly preferably comprises multiple digital pressure transmitters for transmitting digital pressure information to an internet module, wherein the internet module transmits the pressure information to a cloud-based computer network system. A user of the system can interface with the cloud-based computer network system to receive pressure information.

Description

SMART COM-UNIT FOR MONITORING, CONTROLLING, AND OPERATING WELLHEADS IN OIL AND GAS WELLSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The application claims the benefit of U.S. Provisional Patent Application No. 63 / 638,880 filed April 25, 2024, the entire disclosure of which is hereby incorporated by reference.BACKGROUND OF THE INVENTIONField of the Invention

[0002] The present invention relates generally to a com-unit for monitoring, controlling, and operating wellheads in oil and gas wells. In particular, the Smart com-unit of the present invention allows for remote monitoring of the fluid pressure in the wells in real time. The Smart com-unit of the present invention ensures the safe and efficient operation of wells used in oil and gas production.Brief Review of the Related Art

[0003] Comtromatic units (“com-units”) generally refer to wellhead control modules that ensure the safe and efficient operation of wells used in oil and gas production. Com -units are complex systems that have many different components. The com-unit monitors, controls, and operates safety valves such as surface safety valves and surface controlled sub-surface safety valves, choke valves, and the like on a wellhead. Conventional com-units can include hydraulic power units (HPUs) that provide the hydraulic fluid and pressure necessary to operate the valves. Different valves are used for controlling the flow of fluids in the well and are actuated by the control module. Pressure gauges, sensors, and other instruments are used to monitor well conditions. The com-unit can also include emergency shutdown systems (ESD).

[0004] Traditional com-units control the down hole sub-surface safety valve and trip the well on low pressure only and are limited in real time remote monitoring of wellhead control parameters.

[0005] A wellhead system may be used to control the flow of fluids recovered from an oil and gas well in a safe and efficient manner. The wellhead system may include a variety of flow control devices, such as valves, which are operable for direct fluid flow through a tubing system connected to the wellhead system. Fluids can be directed downstream of the wellhead system via the tubing system for further processing and / or storage.

[0006] The wellhead system may include surface and sub-surface safety valves that are connected to the tubing system and are operable to shut off fluid flow through the tubing system in the event of an emergency in the well or at a location downstream of the wellhead system. Prior art safety valves are generally in fluid communication with the tubing system, and they utilize the fluids therein for operation.

[0007] For example, the pressure in the tubing system may be directly tied into the safety valves to actuate the valves into an open position, thereby allowing fluid flow through the system. In the event of an emergency, such as a rupture in the tubing system downstream of the safety valve or a drop in pressure in the well, as the pressure in the tubing system drops, so does the pressure in the safety valves.

[0008] The safety valves are configured to move into a closed position after the pressure therein falls below a minimum pressure, thereby closing fluid flow through the tubing system and shutting in the wellhead system. Some safety valves may also be equipped with relief valves that are operable to block pressure from entering the valve and exhaust the pressure in the valve, thereby allowing the valve to move into a closed position. One drawback of previous systems includes the reliance of the safety valves on fluid pressure in the tubing system. The com-unit provides an independent source of fluid and pressurizing device that gives the safety valve the relevant fluid pressure from external source independent of the tubing pressure to keep the valve in open position. The com-unit makes it possible to operate the safety valve unilaterally asdesired. However, there are numerous drawbacks to conventional com-unit systems particularly in the overall aspect and real time monitoring of the oil and gas well.

[0009] In FIG. 1, a schematic diagram illustrating the components of a conventional com- unit is provided. As shown in FIG. 1, a conventional dual-purpose com-unit has various components. Air from the air inlet isolation valve Al goes into the air regulator Bl which reduces high air pressure to a specified lower pressure. Air regulator B2 & B3 shared the regulated air pressure of regulator Bl and further regulate the air to a desire air pressure value required to operate the instrument line from 30 to 50 psi and Sprague pump P to the ratio of 1:60 psi respectively. The pressure gauge Cl records the actual regulated pressure of Bl.

[0010] Air from regulator B2 goes through the air cut-off valve D (which limit air flow to the Sprague pump P), the air filter E (which cleans air from impurities), and the oil lube cup F (which traps moisture in air) before entering the Sprague pump P. the pressure gauge C3 record the regulator pressure of B2. The air operated Sprague pump P, suck liquid from the reservoir tank N, through the strainer O into the pressure manifold Q.

[0011] Air from air regulator B3 is fed to the emergency shut-off valve G1 which connects with the pressure sensor Hl and may be operated manually or on auto-system. The pressure sensor Hl senses pressure from the wellhead flow line, which determines the behavior of PVR relay II. The PVR relay II feeds air to DCP Pilot JI. When required pressure is maintained on the DCP Pilot JI from the PVR relay 11, the DCP Pilot JI actuates to an open position and allows liquid (from the pressure manifold Q) through the isolation valve KI to the output valves Ml & M2 to maintain set liquid pressure. The pressure gauge C2 measures the regulated pressure of air regulator B3. The output valves, Ml & M2 are connected to the oil well sub surface safety valves which, at required pressure, remains open during normal operation.

[0012] When the pressure sensor Hl senses limited or excess pressure (depending on configuration) from the flow line, the PVR relay 11 will reset to normally close and withdraw air pressure from the DCP Pilot JI, causing liquid to return to the reservoir tank N. This depressurizes the system, thereby shutting the oil well sub-surface safety valve. The check valveR1 & R2 is one valve that helps to maintain flow in one direction between pressure manifold Q and DCP pilot JI & J2, respectively.

[0013] The pressure gauge C4 records pressure between the isolation valve KI and the output valves Ml & M2. The relief valve LI & L2 allows liquid to return to the reservoir tank N when actuated.

[0014] The pressure sensor S is used to monitor the pressure manifold Q and send a signal to air cut off valve D to maintain a specific set pressure for a down hole safety valve and relief valve T. The excess pressure from pressure manifold Q in case the pressure sensor S failed to sense the pressure.

[0015] One problem with conventional com-units, for example, such units as shown in FIG. 1, is that they do not allow for remote monitoring of the pressure in the well in real time. However, the com-unit of the present invention allows for such remote monitoring of the pressure in the well in real time. Thus, the com-unit of the present has many key features and provides many benefits to a manager of the oil or gas well. For example, the manager can access parameters of the well, monitor conditions of the well, and survey the well environment remotely. The manager can use the com-unit of the present invention to ensure the safe and efficient operation of wells used in oil and gas production. The com-unit of the present invention has many additional advantages, features, and benefits as described further below.SUMMARY OF THE INVENTION

[0016] A com-unit for monitoring, controlling, and operating wellheads in oil and gas wells is provided. In particular, the Smart com-unit of the present invention allows for remote monitoring of the pressure in the wells in real time. The Smart com-unit of the present invention ensures the safe and efficient operation of wells used in oil and gas production.

[0017] A Smart com-unit assembly for monitoring safety valves of oil and gas wells is provided. The com-unit assembly preferably comprises multiple digital pressure transmitters for transmitting digital pressure information to an internet module, wherein the internet moduletransmits the digital pressure information to a cloud-based computer network system. A user of the system can interface with the cloud-based computer network system to receive the digital pressure information

[0018] The com-unit of the present invention allows an operator to perform remote monitoring of the pressure in the well in real time. Thus, the com-unit of the present has many key features and provides many benefits to a manager of the oil or gas well. For example, the manager can access parameters of the well, monitor conditions of the well, and survey the well environment remotely.

[0019] In one embodiment, the digital pressure information is received by a user using computing devices selected from the group consisting of mobile phones, personal computers, laptops, and hand-held tablets. The digital pressure information is preferably collected and transmitted using a telemetry transport system such as Message Queuing Telemetry Transport (MQTT).

[0020] The digital pressure information preferably relates to pressure in the flow lines and to a valve selected from the group consisting of surface safety valves, sub-surface safety valves, choke valves, and combinations thereof. The com-unit can further comprise a closed-circuit television camera for providing surveillance of the com-unit and area surrounding the com-unit. A power pack can be used for powering the closed-circuit television camera. A solar panel system for providing solar energy to the power pack can be used. The com-unit is preferably located within an enclosure for protecting the com-unit from environmental conditions.BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The novel features that are characteristic of the present invention are set forth in the appended claims. However, the preferred embodiments of the invention, together with further objects and attendant advantages, are best understood by reference to the following detailed description in connection with the accompanying drawings in which:

[0022] FIG. 1 is a block diagram showing a com-unit assembly of the prior art;

[0023] FIG. 2 is a schematic diagram showing one embodiment of the Smart com-unit assembly of the present invention integrated with the prior art com-unit assembly of FIG. 1;

[0024] FIG. 3 is a close-up view of one section of the prior art com-unit assembly shown in FIG. 1 and further showing the oil reservoir tank, Sprague pump, and instrument control for a surface safety valve (SSV) pressure control in more detail;

[0025] FIG. 4 is a close-up view of one section of the prior art com-unit assembly shown in FIG. 2 and further showing the instruments for air regulation in more detail;

[0026] FIG. 5 is a close-up of the section of the prior art com-unit assembly shown in FIG. 4 and further showing the output pressure monitor and controls in more detail;

[0027] FIG. 6 is a schematic diagram showing one embodiment of the Smart com-unit assembly of the present invention;

[0028] FIG. 7 is a perspective view of one embodiment of a suitable enclosure for the Smart com-unit assembly of the present invention;

[0029] FIG. 8 is a cu-away view of the enclosure shown in FIG. 7, showing a remote monitoring box; and

[0030] FIG. 9 is a block diagram showing one embodiment of the Smart com-unit assembly of the present invention integrated with a prior art com-unit assembly.DETAILED DESCRIPTION OF THE INVENTION

[0031] As discussed above, conventional com-units, as shown in FIG. 1, are generally known in the industry, but have some drawbacks. For example, conventional com-units do not allow for remote monitoring of the pressure in the well in real time.

[0032] The smart-com unit assembly of the present invention has many advantageous features as discussed further below. One key feature is that the smart-com unit assembly of the present invention can be integrated or embedded with a conventional com-unit as shown in FIG. 2. In FIG. 3, a close-up view of one section of the prior art com-unit assembly showing the oil reservoir tank, Sprague pump, and instrument control for a surface safety valve (SSV) pressure control is provided. FIG. 4 provides another close-up view of one section of the prior art com- unit assembly containing the instruments for air regulation. In FIG. 5, yet another close-up of the section of the prior art com-unit assembly showing the output pressure monitor and controls is provided. FIGS. 2-5 are discussed in further detail below.

[0033] The new “Smart” Comtromatic unit (Com-Unit) of the present invention is a system designed to control the operation of a wellhead. It works by keeping the down-hole valve open to ensure a continuous flow while also managing the safety of the flow line. This means that in the event of a loss of pressure, which could indicate a potential leak, the system will shut down the well to prevent hydrocarbon loss into the environment. Additionally, if the pressure in the flow line becomes too high, the system will shut down the down hole safety valve to avoid rupture of the line. The system also comes with an embedded system leveraging advanced technological systems and Internet of Things (loT). Different embodiments of the invention relate to systems and methods for an emergency shut down control system, particularly for surface and subsurface safety valves. Different embodiments of the invention further relate to systems and methods for monitoring the surface and subsurface valve control system and overall monitoring of the oil and gas well.

[0034] One key distinctive feature of the new Smart com-unit assembly of the present invention is that it enables a user to remotely monitor the well pressure in a real time situation. There are further improved applications including, but not limited to, the following:1. Pressure monitoring of Up to 10,000 psi;2. Live analogue monitoring;3. Multiple alert methods;4. Easy setup and configuration;5 Reliable hardware;6. Inbuilt power pack with solar panel;7. Intrinsically safe system;8. Monitored using a PC or mobile device;9. Sim enabled;10. Camera for total surveillance;11. It compensates in terms of pressure loss in case of the leakage in sub-surface safety valve; and.12. It responds automatically when there is an emergency along the flow line.

[0035] Referring to FIG. 2, a schematic diagram showing one embodiment of the Smart com-unit assembly (100) of the present invention integrated with the prior art com -unit assembly (90) is provided.

[0036] The new Smart com-unit assembly (100) of the present invention is designed to control the operation of a wellhead. It works by keeping the down hole valve open to ensure a continuous flow while also managing the safety of the flow line. This means that in the event of a loss of pressure, which could indicate a potential leak, the system will shut down the well to prevent hydrocarbon loss into the environment. Additionally, if the pressure in the flow line becomes too high, the system will shut down the down hole safety valve to avoid rupture of the line. The system also comes with an embedded system leveraging advanced technological systems and internet of things. Different embodiments of the invention relate to systems and methods of an emergency shut down control system for surface and subsurface safety valves. Differentembodiments of the invention further relate to systems and methods of surface and subsurface control system and overall monitoring of the oil and gas well.

[0037] As shown in FIG. 2, the Smart com -unit assembly (100) of the present invention can be integrated or embedded with a conventional com-unit assembly (90). The Smart com-unit assembly (100) is an improvement over the conventional com-unit assembly (90). The Smart com-unit assembly is designed to provide real time monitoring of the well environment and transmit well parameters remotely. This will enable seamless monitoring and timely responses from operators of the well. As shown in FIG. 2, the Smart com -unit assembly includes distinctive digital pressure transmitting systems CT1, CT2, CT3 & CT4. The pressure transmitters, CT1, CT2, CT3 & CT4. send-out digital signals and are collected by a high-speed internet module U, which transmits the digital signals to the cloud-based computer network V. The digital signals can be transmitted form the control room and received remotely by smart devices (such as desktop computers and laptops W and mobile computing devices X).

[0038] Any suitable electronic processing device that can receive input information and transmit and / or receive information via a network can be used in accordance with the present invention. For example, a mobile phone, laptop, hand-held tablet, or the like, which is capable of running computer software applications, can be used. In one preferred embodiment, the electronic processing device uses an Application Programming Interface (API) that runs on a native operating system such as IOS™ or Android™. In another embodiment, the electronic processing device can execute computer applications (for example, a web-based application) to interact with a computer network. The network can include an electronic storage device such as a computer server.

[0039] The CCTV camera AB provides detailed surveillance of the well environment and data is also transmitted for advanced monitoring in real time. The electronic devices are powered by an intrinsically safe rechargeable battery Y, which is charged by a solar system Z. Energy from the solar system goes through the charge controller AA for safe charging of the battery.

[0040] The embedded system in the Smart Com-Unit of the present invention provides safer and more effective sub-surface monitoring and control of the sub-surface safety valve and flow line. Another advantage of the embedded system of the present invention is that it can trip on high and low wellhead pressure in contrast to conventional com units which trip on low pressure only.

[0041] Referring to FIG. 6, a schematic diagram showing one embodiment of the Smart com-unit assembly of the present invention, wherein it is not integrated with another assembly is provided. In FIG. 9, a block diagram showing one embodiment of the Smart com-unit assembly of the present invention integrated with a prior art com-unit assembly is provided. As shown in FIGS. 6 and 9, the integrated Smart com-unit assembly of this invention comprises several unique and advantageous features including, but not limited to the following:

[0042] A) The embedded Smart com-unit assembly comprises pressure sensors CT1, CT2, CT3, and CT4 with outputs of 4-20 mA having accuracy levels of + / -0.5% on the full scale. The pressure sensors CT1, CT2, CT3, and CT4 are improvements over the manual / analog pressure gauges, Cl, C2, C4, C5 used in conventional com-units. The pressure sensors CT1, CT2, CT3, and CT4 of the present invention sense the pressure and transmits a signal to Remote terminal unit module U. The remote terminal unit module U (RTU) has an advanced Internet of Thing (loT) technology V, wherein the high speed internet module is configured for a com-unit application for connecting the pressure sensors, CT1, CT2, CT3, and CT4 to a smart cloud platform-based information system V.

[0043] B) The embedded Smart com-unit assembly comprises a smart cloud platformbased information system V that queries the pressure sensors, CT1, CT2, CT3, and CT4 parameters at an interval using Message Queuing Telemetry Transport protocol. This enables the information system V to obtain the pressure sensors, CT1, CT2, CT3 & CT4 information for oil well sub- surface safety valves as well as com-unit operating pressure condition. The data can be stored on the computer cloud network or remote monitoring through personal computer (PC) W or mobile computing devices X.

[0044] Telemetry transport generally refers to the process of collecting and transmitting data from remote devices or systems. In the present invention, one piece of data is the pressure information relating to the pressure of the flow lines and particularly surface safety valves, subsurface safety valves, choke valves, and combinations thereof. In the present invention, the pressure data is transmitted and received in real time. Preferably, a Message Queuing Telemetry Transport (MQTT) system is used. MQTT is a lightweight, messaging protocol designed for low-bandwidth, high-latency networks making it suitable for transmitting telemetry data from Internet of Thigs (loT) devices and machine-to-machine (M2M).

[0045] C) The embedded Smart com-unit assembly comprises a closed-circuit television AB (CCTV) camera, wherein, the CCTV camera provides 360 degrees coverage around the installed environment. The CCTV camera comprises 4-lenses and a rotating shaft configured to face four cardinal points and be rotated to collect surveillance footage of the entire well environment. This key feature is beneficial, since it provides clear vision remotely up to 50 m above, from, and around the wellhead.

[0046] D) The embedded Smart com-unit assembly comprises an explosion proof power pack Y. The power pack Y is embedded in the Smart com-unit to power the CCTV camera AB, pressure sensors, CT1, CT2, CT3, and CT4 and Remote Terminal Unit module U (RTU).

[0047] E) The embedded Smart com-unit assembly comprises a solar panel system Z, wherein the solar panel is connected to a charge controller AA which controls current to the required amount needed to recharge the power pack Y.

[0048] F) The embedded Smart com-unit assembly comprises safety switches for tripping on HIGH and LOW readings of the wellhead pressure. In contrast, conventional com-unit only have switches for tripping on LOW readings.

[0049] G) The embedded Smart com-unit assembly comprises an enclosure system that protects the Smart com-unit from several situations including, but not limited to, adverse environmental conditions, against unauthorized operation, and theft. In contrast, conventionalcom-units do not have such enclosures and are not protected from any such conditions. One embodiment of an enclosure system of the present invention is shown in FIGS. 7 and 8.

[0050] The enclosure provides highly durable and mechanically strong packaging for the Smart com -unit. In particular, the enclosure has the following features:

[0051] A) Stainless-Steel Construction: The enclosure is built with high-quality stainless- steel for corrosion resistance and longevity, maximum durability, and tamper-resistance.

[0052] B) Four-Legged Stand: The enclosure has four (4) stable and adjustable legs that provide flexibility for various installations and environments.

[0053] C) Camera-Equipped: The integrated camera has enhanced surveillance and monitoring.

[0054] D) High-Security Design: The enclosure has advanced security features that maximize equipment protection. The enclosure houses critical communication equipment that protects against theft and tampering. These high-security features are achieved using an anti-theft electronic locking system with a special locking device, which can be monitored and tracked.

[0055] E) Tamper-Resistant Design: The enclosure has a tamper-resistant design that prevents unauthorized access into the enclosure.

[0056] It should be understood that the assemblies, sub-assemblies, enclosures, systems, methods, products, materials, constructions, and the like described and illustrated herein represent only some embodiments of the invention. It is appreciated by those skilled in the art that various changes and additions can be made to the assemblies, sub-assemblies, enclosures, systems, methods, products, materials, and constructions and the like without departing from the spirit and scope of this invention. It is intended that all such embodiments be covered by the appended claims.

Claims

CLAIMSWe claim:

1. A com -unit assembly for monitoring safety valves of oil and gas wells, the com-unit assembly comprising multiple digital pressure transmitters for transmitting digital pressure information to an internet module, wherein the internet module transmits the digital pressure information to a cloud-based computer network system, and wherein a user can interface with the cloud-based computer network system to receive the digital pressure information.

2. The com-unit assembly of claim 1, wherein the digital pressure information is received by a user using computing devices selected from the group consisting of mobile phones, personal computers, laptops, and hand-held tablets.

3. The com-unit assembly of claim 1, wherein the digital pressure information is collected and transmitted using a telemetry transport system.

4. The com-unit assembly of claim 3, wherein the telemetry transport system is Message Queuing Telemetry Transport.

5. The com -unit assembly of claim 1, wherein the digital pressure transmitters transmit digital pressure information relating to a valve selected from the group consisting of surface safety valves, sub-surface safety valves, choke valves, and combinations thereof.

6. The com-unit assembly of claim 5, wherein the digital pressure transmitters transmit digital pressure information relating to a surface safety valve.

7. The com-unit assembly of claim 5, wherein the digital pressure transmitters transmit digital pressure information relating to a sub-surface safety valve.

8. The com-unit assembly of claim 5, wherein the digital pressure transmitters transmit digital pressure information relating to a choke valve.

9. The com-unit assembly of claim 1, wherein the com-unit further comprises a closed-circuit television camera for providing surveillance of the com-unit and area surrounding the com-unit.

10. The com-unit assembly of claim 9, wherein the com-unit further comprises a power pack for powering the closed-circuit television camera.

11. The com-unit assembly of claim 10, wherein the com-unit further comprises a solar panel system for providing solar energy to the power pack, sub-surface safety valve.

12. The com-unit assembly of claim 1, wherein the com-unit is positioned within an enclosure for protecting the com-unit from environmental conditions.

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