Electromechanical actuation techniques for scale buildup mitigation

Abstract

A system includes a controller having one or more processors. The system also includes a memory, and instructions stored on the memory, and executable by the one or more processors to output a control signal that causes an actuation of a valve to move a test distance via an electromechanical actuator; receive electrical property data corresponding to the actuation over the test distance by the electromechanical actuator; evaluate a condition of the valve based on the electrical property data; and generate an output based on the condition of the valve.

Description

ELECTROMECHANICAL ACTUATION TECHNIQUES FOR SCALE BUILDUP MITIGATIONCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 CFR 1.57. The present application claims priority benefit of U.S. Provisional Application No. 63 / 695,691, filed September 17, 2024, No. 63 / 725,923, filed November 27, 2024, and No. 63 / 745,408, filed January 15, 2025, the entirety of each of which is incorporated by reference herein and should be considered part of this specification.BACKGROUND

[0002] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and / or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it may be understood that these statements are to be read in this light, and not as admissions of prior art.

[0003] Actuators may be used to move a variety of equipment, such as surface equipment, downhole equipment, valves, or a combination thereof, associated with wells coupled to subterranean reservoirs (e.g., oil and / or gas reservoirs). For example, the actuators may be used to open and close valve elements in the valves coupled to pipelines, trees coupled to the wells, downhole equipment, and so forth. The actuators also may be used to move other movable elements of equipment. Unfortunately, the equipment and / or valves may operate under conditions that result in precipitation of solid materials (e.g., scale, asphaltenes, bitumen, and the like) on the valve elements and / or moveable elements being actuated by the actuator. When the equipment and / or valves are operated frequently (e.g., at least once an hour, at least once a week, or at least once a month), a relatively small amount of precipitation forms on surfaces of the valve elements and / or moveable elements. The frequent operation of the equipment and / or valves may be sufficient for removing at least a portion of the precipitation, such that the equipment and / or valves may continue to operate in an expected manner. However, if the equipment and / or valves are operated infrequently, or otherwise remains unused for relatively long amounts of time (e.g., atleast 1, 2, 3, 4, 5, or 6 months), the amount of precipitation that forms on the valve elements and / or moveable elements may render the equipment and / or valves inoperable or otherwise operate in an unexpected manner. For example, the amount of scale that builds up over time on the valve elements and / or moveable elements may prevent the actuators from moving using conventional control systems without physical intervention or specialty chemical treatment. Further, maintenance on the equipment and / or valves may be relatively costly, and thus is generally undesirable. Accordingly, it may be desirable to develop techniques that prevent precipitation above a threshold amount that may render the equipment and / or valves inoperable.BRIEF DESCRIPTION

[0004] Certain embodiments commensurate in scope with the originally claimed invention are summarized below. These embodiments are not intended to limit the scope of the claimed invention, but rather these embodiments are intended only to provide a brief summary of possible forms of the invention. Indeed, the invention may encompass a variety of forms that may be similar to or different from the embodiments set forth below.

[0005] In certain embodiments, a system includes a controller having one or more processors. The system also includes a memory, and instructions stored on the memory, and executable by the one or more processors to output a control signal that causes an actuation of equipment to move a test distance via an electromechanical actuator; receive electrical property data corresponding to the actuation over the test distance by the electromechanical actuator; evaluate a condition of the equipment based on the electrical property data; and generate an output based on the condition of the valve.

[0006] In certain embodiments, a method includes outputting a control signal that causes an actuation of a valve to move a test distance via an electromechanical actuator. The method also includes receiving electrical property data corresponding to the actuation over the test distance by the electromechanical actuator. Further, the method includes evaluating a condition of the valve based on the electrical property data. Further still, the method includes generating an output based on the condition of the valve.

[0007] In certain embodiments, a system includes an electromechanical actuator configured to control a valve. The system also includes a controller including one or more processors. The controller is configured to: output a control signal that causes an actuation of a valve to move a test distance via an electromechanical actuator; receive electrical property data corresponding to the actuation over the test distance by the electromechanical actuator; evaluate a condition of the valve based on the electrical property data; and generate an output based on the condition of the valve.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

[0009] FIG. l is a schematic diagram of a hydrocarbon extraction system having one or more valves, in accordance with the present disclosure;

[0010] FIG. 2 is a cross-sectional side view of a valve that may be part of the hydrocarbon extraction system of FIG. 1, in accordance with the present disclosure;

[0011] FIG. 3 is a flow diagram of an example process for actuating a valve a test distance, in accordance with the present disclosure;

[0012] FIG. 4 is a flow diagram of an example process for determining an actuation schedule based on actuation parameters, in accordance with the present disclosure;

[0013] FIG. 5 is a flow diagram of an example process for generating outputs based on determined conditions of a valve, in accordance with the present disclosure; and

[0014] FIG. 6 shows a cross-section of equipment including a valve, in accordance with the present disclosure.

[0015] FIG. 7 schematically illustrates an example PHM workflow.

[0016] FIG. 8 schematically illustrates a simplified field oriented control block diagram.DETAILED DESCRIPTION

[0017] One or more specific embodiments of the present disclosure will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers’ specific goals, such as compliance with system -related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0018] When introducing elements of various embodiments of the present invention, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.” Also, any use of any form of the terms “connect,” “engage,” “couple,” “attach,” or any other term describing an interaction between elements is intended to mean either an indirect or a direct interaction between the elements described. In addition, as used herein, the terms “axial” and “axially” generally mean along or parallel to a central axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean perpendicular to the central axis. For instance, an axial distance refers to a distance measured along or parallel to the central axis, and a radial distance means a distance measured perpendicular to the central axis. The use of “top,” “bottom,” “above,” “below,” and variations of these terms is made for convenience but does not require any particular orientation of the components.

[0019] As mentioned above, operation of equipment and / or valves in scale-containing or other environments containing heavy molecules or oxides (e.g., scale, asphaltene, bitumen, and the like) may result in precipitation of the heavy molecules or oxides on the equipment and / or valves (e.g., movable elements and / or valve elements). In turn, the precipitation may increase the resistance of movable elements and / or valve elements, thereby prevent the equipment and / or valves from operating in a desirable manner. Such resistance can be a particular problem for valves including and actuated by an electromechanical actuator (EMA), as the drive force generated by EMAs can be less than that of hydraulic or hydro-electric actuators. It may therefore be difficult for an EMA to overcome added resistance due to scale. In certain instances, it may be desirable to perform maintenance on the equipment and / or valves. However, this may be relatively expensive and timeconsuming for the equipment and / or valves. It is presently recognized that it is desirable to develop techniques that mitigate precipitation build-up in equipment and / or valves in a hydrocarbon extraction system, thereby ensuring proper operation when needed in the hydrocarbon extraction system. For example, in the case of permanent downhole completion components, such as flow control valves, preventing or inhibiting formation of scale can be critical due to the difficulty of accessing the tool to perform maintenance. Predicting, measuring, and / or mitigating scale formation can advantageously improve reliability, availability, and performance of downhole valves and other equipment.

[0020] Accordingly, this disclosure relates to techniques for adjusting operation of equipment and / or valves, such that the equipment and / or valves may continue to operate in a desirable manner despite the scale build-up and / or precipitation of other oxides, heavy molecules, and the like. In general, the disclosed techniques include operating electromechanical actuators to actuate the equipment and / or valves, such as tools having valves. Further, the disclosed techniques include measuring, acquiring, or otherwise obtaining electrical property data indicative of the amount of the current utilized by the electromechanical actuators to actuate equipment and / or valves. It is presently recognized that the electrical property data may be indicative of a condition (e.g., a health condition, a performance, condition, a maintenance condition, and the like) or amount of scale buildup (e.g., or other types of precipitation as discussed herein) on movable elements of the equipment and / or valve elements of the valves. For example, with increasing scale build-up within a valve controlled by an electromechanical actuator, the electromechanical actuator may utilize more current to actuate the valve. That is, an increase in the amount of current to actuate the valve a known amount indicates a change in the condition of the valve to a less desirable state. As such, an output can be generated to mitigate scale build-up to a point where the valve should receive maintenance. As discussed in further detail herein, the output may include generating and / or performing a chemical injection protocol, generating an alert indicating the amount of precipitation, or determining a time period for actuating equipment as discussed in more detail below.

[0021] It is presently recognized that at least one technique for mitigating scale build-up is to determine a time period for actuating equipment and / or valves, such as by partial actuation of the electromechanical actuator to move a test distance that is less than a full actuation distance of the equipment and / or valve. As discussed herein, certain equipment and / or valves may remain unusedfor relatively long periods of time. As scale builds-up while the equipment and / or valves is unused, the equipment and / or valves may eventually operate in a less than desirable manner. Accordingly, it may be advantageous to actuate (e.g., periodically or continuously) equipment and / or valves over the test distance less than the full actuation distance without changing any operational conditions of the equipment and / or valves. For example, if the valve is in a fully closed state or a fully open state, then the test distance may generally maintain the state (e.g., fully closed state or fully open state) to maintain the same operational conditions of the valve (e.g., same flow conditions), while removing scale build-up and analyzing a condition of the valve. In some configurations, the test distance is on the order of a few mm. In some configurations, movement of the test distance in a first direction can be followed by an equal movement in the opposite direction, returning the valve or equipment to its original position or state. In general, the time period may be a single instance of time or a time schedule (e.g., multiple instances of time) to actuate the equipment.

[0022] With the foregoing in mind, FIG. 1 illustrates an embodiment of a hydrocarbon extraction system 10 having one or more valves 12 (e.g., gate valves). As discussed in further detail below, the valves 12 (or any other type of valve or equipment) may be operated in a manner for testing purposes, scale prevention, condition analysis, and so forth, via partial actuation of the valves 12, such as by actuating the valves 12 to move a test distance that is less than a full actuation distance between open and closed valve positions. In the illustrated embodiment, the hydrocarbon extraction system 10 is configured to facilitate the extraction of a resource, such as oil or natural gas, from a well 14. As shown, the hydrocarbon extraction system 10 includes a variety of equipment, such as surface equipment 16 and stack equipment 20 (e g., equipment), for extracting the resource from the well 14 via a wellhead 22. The surface equipment 16 may include a variety of devices and systems, such as pumps, conduits, valves, power supplies, cable and hose reels, control units, a diverter, a gimbal, a spider, and the like. As shown, the stack equipment 20 includes a production tree 24, also commonly referred to as a “Christmas tree.” The tree 24 may include components that control the flow of an extracted resource out of the well 14 and upward toward the surface equipment 16 and / or that control the flow of injected fluids into the well 14. In some embodiments, the tree 24 may include various conduits, flow meters, sensors, and valves, such as the valve 12. While one embodiment of the valve 12 is a gate valve, the valve 12 may include a variety of flow control components, such as gate valves, ball valves, blowout preventers(BOPs), chokes, or a combination thereof. While the valve 12 is shown within the tree 24 in FIG. 1, it should be understood that the valve 12 disclosed herein may be used in any portion of the hydrocarbon extraction system 10, such as the surface equipment 16, the stack equipment 20, the wellhead 22, and / or downhole in the well 14, for example. Thus, the following discussion is not limited to any particular type of valve 12, and is applicable to a variety of electro-mechanical actuated equipment (e.g., equipment) that is susceptible to the buildup of solid materials (e.g., scale, asphaltenes, bitumen, and the like) on movable elements.

[0023] FIG. 2 is a cross-sectional side view of the valve 12 of FIG. 1 that may be operated in a manner for testing purposes, scale prevention, condition analysis, and so forth, via partial actuation of the valve 12, such as by actuating the valve 12 to move a test distance that is less than a full actuation distance between open and closed valve positions. Again, the valve 12 is one example of a valve and / or equipment that may be used with the techniques described in further detail below. In the illustrated embodiment, the valve 12 is a gate valve having seal grooves 30 (e.g., annular grooves) formed in seats 32 (e.g., annular seats). The valve 12 is generally configured to control a flow of fluid in various applications. The valve 12 has a bore 40 that may be sized for the given application. For example, the bore 40 of the valve 12 may be at least approximately 4 centimeters (cm) in diameter. In other embodiments, the bore 40 of the valve 12 may be less than approximately 12 cm. In certain embodiments, the valve 12 is configured to operate at a high pressure of at least approximately 10, 100, or 200 Megapascals (MPa). In some embodiments, the valve 12 is configured to operate at pressure lower than approximately 10, 100, 200, or 300 MPa or between approximately 0.5 and 10, 0.5 and 100, 0.5 and 200, or 0.5 and 300 MPa.

[0024] In the illustrated embodiment, the valve 12 includes an actuator 44, such as an electromechanical actuator. For example, the actuator 44 may include an electric drive, motor, such as a brushless DC motor, or a combination thereof. In certain embodiments, the actuator 44 may further include a spring configured to bias the valve 12 to a desired valve position (e.g., normally closed position or normally open position). However, the following discussion is primarily focused on electromechanical actuators capable of relatively fine and / or precision control of the actuation distances, such that a test distance is possible without changing the conditions (e.g., flow conditions) of the valve 12. The actuator 44 may be coupled to a top portion of a valve body 46 via a bonnet 48, or the actuator 44 may be directly coupled to the valve body46. The valve 12 includes a movable flow control element or valve element 42 (e.g., a gate) disposed within a cavity 50 of the valve body 46. As will be appreciated, the actuator 44 applies a force to a stem 60 coupling the gate 42 to the actuator 44. In this manner, the gate 42 moves between an illustrated open position and a closed position within the cavity 50 as shown by arrow 62. The valve body 46 of the valve 12 includes an inlet 52 and an outlet 54 configured to support a flow of a fluid (e.g., well production fluid, oil, natural gas, water, drilling mud, hydraulic fluid, chemical injection fluid, etc.) through the bore 40 of the valve body 46 of the valve 12. The valve body 46 may be constructed of cast iron, ductile iron, cast carbon steel, gun metal, stainless steel, alloy steels, corrosion resistant alloys, and / or forged steels.

[0025] As shown, each seat 32 is disposed between the valve body 46 and the gate 42. More specifically, one seat 32 is disposed on an upstream side of the gate 42, and another seat 32 is disposed on a downstream side of the gate 42. Each seat 32 includes one or more seal grooves 30 configured to support a sealing ring 80 (e.g., an annular sealing ring or a loop, such as a loop having a circular, square, or rectangular shape) disposed between the valve body 46 and the seat 32. In the illustrated embodiment, the sealing ring 80, the seal groove 30, and the seat 32 extend circumferentially about the bore 40. As discussed in more detail below, in the disclosed embodiments, the sealing ring 80 may have any of a variety of cross-sectional shapes and may have a variable cross-sectional thickness. The variable cross-sectional thickness may impart desirable stiffness characteristics to particular portions of the sealing ring 80. Additionally or alternatively, the variable cross-sectional thickness of the sealing ring 80 may positively affect deflections of the sealing ring 80, stress on the sealing ring 80, contact locations and / or forces between the sealing ring 80 and the seal groove 30 and / or the valve body 46, wear on the sealing ring 80, the seat 32, and / or the valve body 46, and / or the sealing ability of the sealing ring 80, for example. To facilitate discussion, the sealing ring 80, the seal groove 30, the seat 32, and / or other components of the valve 12 may be described with reference to an axial axis or direction 70, a radial axis or direction 72, and a circumferential axis or direction 74.

[0026] The actuator 44 may be an electromechanical actuator that is controlled by the control system 90. As shown, the control system 90 includes a processor 92, memory 94 and / or storage, input / output port 96, communication circuitry 98, and / or electrical sensors 100. The processor 92 may include one or more processors. The memory 94 and / or the storage 44 of the transmitter subsystem 38 may be any suitable article of manufacture that can store the instructions. In someembodiments, the memory 94 is a tangible, non-transitory, machine-readable-medium that may store machine-readable instructions for the processor 92 to execute. The memory 94 may include ROM, flash memory, a hard drive, or any other suitable optical, magnetic, or solid-state storage medium, or a combination thereof. The memory 94 may store data, instructions, and any other suitable data. Additionally, the control system 90 may include an input / output (I / O) port 96, which may include interfaces coupled to various components such as input devices (e.g., keyboard, mouse), input / output (I / O) modules, sensors (e.g., surface sensors and / or sensors), and the like. For example, the I / O port 96 may include a display (e.g., an electronic display) that may provide a visualization or other operating parameters of related to operation of the valve 12.

[0027] In operation, the processor 92 may output controls signals that cause the actuator 44 to actuate the valve 12. For example, in some embodiments, the stem 60 may include a threaded shaft (e.g., male threads) and the bonnet 48 may have a complementary threading (e.g., female threads or threaded bore), thereby defining a threaded interface that converts rotational motion of the actuator 44 into linear motion of the gate 42. However, the threaded interface may be disposed in other portions of the valve 12 and / or in the actuator 44. Advantageously, the threaded interface enables fine motion control of the gate 42 by the actuator 44, because each revolution of the stem 60 provides a known linear actuation distance of the gate 42. In some embodiments, the memory 94 may store reference information that indicates relationships between a degree of rotation of the stem 60 and / or the actuator 44 and a corresponding distance along the direction of the arrow 62 (e.g., up or down towards the seat 32). It is presently recognized that scale may build up within the valve 12, such as along the sealing ring 80 and / or surface of the gate 42. The scale may resist the movement of the gate 42 and, in some instances, prevent the gate 42 from operating (e.g., partially or completely closing or opening). It may be advantageous to move the gate 42 a test distance along the direction of the arrow 62 to reduce the likelihood that the gate 42 cannot close or open, or otherwise not operate properly. As referred to herein, the “test distance” may an opening amount or closing amount that does not change the operating parameters (e.g., flow conditions) of the valve 12, or other component, outside of a threshold range. For example, the test distance may be configured to move the gate 42 by a sufficient amount that reduces the scale buildup and / or enables an analysis of condition of the valve 12. In some configurations, actuation of the valve 12 by the test distance in a first direction can be followed by an equal movement in the opposite direction, thereby returning the valve 12 to its original position or state.

[0028] To that end, the electrical sensors 100 may measure an amount of current or other electrical property supplied to the actuator 44 to cause the gate 42 to move the test distance without changing an operational condition (e.g., flow condition) of the valve 12. For example, if the valve 12 is currently in a fully closed valve position, then the test distance may move the gate 42 without opening the valve 12. By further example, if the valve 12 is currently in a fully open valve position, then the test distance may move the gate 42 without closing the valve 12. By further example, if the valve 12 is currently in an intermediate valve position (e.g., partially open, partially closed), then the test distance may move the gate 42 with a change in operational condition (e.g., flow condition) of less than or equal to 1%, 2%, 3%, 4%, or 5%. However, in certain embodiments, a test of the valve 12 using the test distance may only occur in the fully closed valve position or the fully open valve position, such that no change in the operation condition (e.g., flow condition) of the valve 12 occurs as a result of the test. In certain embodiments, the test distance may be less than or equal to 1%, 2%, 3%, 4%, 5%, 6%, 10%, and so on, of a total actuation distance of the valve 12 (e.g., gate 42) via the actuator 44. In certain embodiments, the test distance may be the axial distance corresponding to less than or equal to 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 revolutions of a threaded shaft of the actuator 44 and / or the valve 12 (e.g., stem 60). In certain embodiments, the test distance may be less than or equal to 1, 2, 3, 4, 5, 6, or more than 6 millimeters (mm).

[0029] In this way, the control system 90 may receive electrical property data (e.g., the amount of current or power) applied to the actuator 44 to move the gate 42 of the valve 12 during a test (e.g., condition test and / or scale test), wherein the electrical property data may vary depending on how much electrical power is needed to move the gate 42 of the valve 12 over the test distance. If the valve 12 is new and / or operating normally, then the electrical property data may indicate a current or power that correspondences to a baseline current or power. If the valve 12 has any scale buildup or other resistance to movement of the gate 42, then the electrical property data may indicate an elevated current or power needed to overcome the scale buildup or other resistance to movement. As appreciated, other resistance to movement of the gate 42 may be attributed to damage or wear to one or more of the seats 32, the surface of the gate 42, annular bearings, seals, and / or packings around the stem 60, the actuator 44, or any combination thereof. The greater the scale buildup or other resistance to movement, the greater the elevated current or power measured in the test.

[0030] To illustrate another non-limiting example of the disclosed systems and methods, FIG. 6 schematically shows a cross-sectional view of another configuration of valve 12, which may be a flow control valve or inflow control valve, for example, an electric flow control or inflow control valve. In the configuration of FIG. 6, the valve 12 includes a movable valve element 42 in the form of a piston or sleeve slidably disposed within a valve body or housing 46 having one or more flow ports 52, 54. The valve 12 includes an actuator 44, such as an electromechanical actuator, operably coupled to the sleeve 42. Electromechanical actuators are advantageously capable of relatively fine and / or precision control of the actuation distances, such that a test distance is possible without changing the conditions (e.g., flow conditions) of the valve 12. The actuator 44 is operable to move sleeve 42 forwards (e.g., to close) and / or backwards (to open) along the direction 183. In some configurations, a choke sleeve can be disposed between (radially or circumferentially between) the sleeve 42 and housing 46. The choke sleeve can have a plurality of ports that are in fluid communication with flow ports 52, 54 and allow for choking or finer control of the amount of flow permitted between a fully closed and fully open state of the valve 12. The actuator 44 can be controlled by control system 90.

[0031] As shown, the control system 90 can include one or more processor(s) 92, memory 94 and / or storage, input / output port 96, communication circuitry 98, and / or one or more electrical sensor(s) 100. In some configurations, the control system 90, or components thereof, can be part of, co-located, or co-housed with the actuator 44 or components thereof. In operation, the processor 92 can output control signals that cause the actuator 44 to actuate the valve 12.

[0032] In use, the actuator 44 may actuate the valve 12 to move sleeve 42 the distance 184 to open and close the valve such that the sleeve 42 is within the box 186. In accordance with the present disclosure, the control system 90 may be capable of causing the sleeve 42 to move the test distance 188 such that the sleeve 42 is within the box 190. In particular, although the sleeve 42 is moved the test distance 188, within the box 190, the sleeve 42 does not substantially cover the port(s) 52, 54. As such, moving the sleeve 42 the test distance 188 may not cause a change in operational condition (e.g., flow condition) of the valve 12, or cause a change in operational condition that is less than or equal to a threshold value, such as 1%, 2%, 3%, 4%, or 5% of the original flow throughput of the valve 12. While FIG. 6 illustrates the valve 12 in a fully open position and movement of the sleeve 42 the test distance 188 maintains the valve 12 in the fully open position, in various configurations in use, the sleeve 42 may be positioned such that the valve12 is fully closed or in an intermediate choke position, and movement of the sleeve 42 the test distance does not change, or does not significantly change, the operational or flow condition of the valve 12.

[0033] In use, scale may build up with the valve 12, such as along the surface(s) of the sleeve 42 and / or housing 46. For example, scale may tend to accumulate at or near the end of the sleeve 42 (e.g., along a portion of the ID of the housing 46 proximate or adjacent the end of the sleeve 42), due to a slight change in flow path area between a flow area defined by the ID of the housing 46 and a flow area defined by the ID of the sleeve 42. Additionally, initiation of movement may require the greatest force, or a greater amount of force than needed to continue movement once initiated. Therefore, small actuations or movements of the sleeve 42, i.e., by the test distance, can advantageously help break up and remove at least a portion of the scale buildup. In some configurations, actuation of the valve 12 by the test distance in a first direction can be followed by an equal movement in the opposite direction, thereby returning the valve 12 to its original position or state.

[0034] Electrical sensors 100 and / or inherent sensors or circuitry of the EMA may measure an amount of current or other electrical property supplied to the actuator 44 to cause the sleeve 42 to move the test distance and provide such measurements and / or data to the control system 90. In some configurations, the electrical property data received by the control system 90 is a parameter of the actuator 44 motor’s current, which is proportional, e g., directly proportional, to its output force. Typically, in ideal operating conditions, the output force of a valve 12 is constant within a specific range, or can be evaluated by design over the full range of valve choking. In use, a change in the output force, determined by measuring motor current, compared to the expected output force can indicate scale formation. Compared to common methods to predict scale, for example, use of software to predict rate of scale formation and / or use of experimental techniques to measure rate of scale formation under controlled conditions, use of the motor’s current to determine scale advantageously allows for scale evaluation in-situ, while the tool is in production and across its lifecycle. Additionally, such systems and methods can use embedded measurements of an electric flow control valve, without requiring addition of external sensors, which would not be possible with hydraulic flow control valves lacking digital capabilities and sensing elements of electrical flow control valve electronics.

[0035] Scale formation can be determined or evaluated by measuring the scale contribution (Tscaie) to the output torque of the motor. The mechanical torque produced by the motor is proportional to the motor current Iq, which is measured by the electronics of the flow control valve (see the simplified control diagram of FIG. 8, indicating the current measurement source 400). The challenge of this method lies in the evaluation of Tmechanicai seal and Tmechanicai friction, which requires a characterization of the flow control valve over the operating envelope of pressure and temperature (see Equation 1). The characterization of Tmechanicai seal and Tmechanicai friction are evaluated with design calculations and qualification tests of the technology. Therefore, monitoring the evolution of Tmotor during the life of the tool can provide a good estimate of TSCaie and in turn, a good evaluation of the scale and its impact on performance of the tool. Additionally, the measure of Tscaie associated with the position of the choke can help identify the location of the scale.(Equation 1)

[0036] The control system 90 may evaluate the real-time electrical property data, other realtime sensor feedback (e.g., temperature, pressure, flow rate, fluid composition, vibration, etc.) historical data (e.g., electrical property data and sensor feedback), computer models, and / or machine learning algorithms of the valve 12 and / or the entire hydrocarbon extraction system 10, such that the control system 90 can output or generate a condition assessment and / or scale assessment of the valve 12. In certain embodiments, the scale assessment may be part of the overall condition assessment. The scale assessment may score the amount of scale buildup (or any type of solids buildup on the valve 12 / gate 42), such as a numerical score between 0 to 10 or 0 to 100 (e.g., 0 score is no scale buildup and 100 score is maximum buildup), a grading score of A, B, C, D, E, or F (e.g., A grade is excellent condition with no scale buildup and F grade is failing condition with excessive scale buildup), or a thickness-based score or indicator (e.g., increasing value that indicates increasing thickness), or any combination thereof. In some embodiments, the score or grading of the precipitation build up will or may utilize machine learning technologies. As such, the control system 90 may determine a grading or scoring by accessing data beyond one product installation, and instead, comparing data with same product in different environments and similar products with same environments. That in turn will be used to build a grading model to give a more detailed advice to the operator of the product. In certain embodiments, the scale assessment may be the entire condition assessment or may be one of multiple condition assessments withdifferent weighting factors. For example, the condition assessment may also include condition scores, similar to those discussed above for the scale assessment, for one or more of: a responsiveness of the valve (e.g., time duration to move over the test distance and / or the total actuation distance), a pressure drop over the valve 12 (e.g., pressure drop when fluid flow occurs through the valve 12 in a fully opened valve position), an age of the valve 12 (e.g., number of operating hours, weeks, months, and / or years of the valve 12), a number of valve cycles or movements (e.g., number of actuations of the test distances, total actuation distances, and / or partial actual distances), a duration of exposure to certain detrimental fluid flows (e.g., number of operating hours, weeks, months, and / or years of exposure to particle laden flows, corrosive fluid flows, etc.), or any combination thereof. It should be noted that although the above description relates to scale build up and / or resistance to movement in the valve 12, the description may be applied to other components that may be susceptible to scale build up and / or resistance to movement, such as a piston, a downhole tool, a rotatable steering system (RSS) of a bottom hole assembly (BHA), and the like.

[0037] The control system 90 may output the condition assessment and / or the scale assessment as a report to a computer display, such that a user can review report and make operational decisions for the valve 12 and / or the hydrocarbon extraction system 10. Additionally, control system 90 may output an alert or alarm, schedule a maintenance or service event to inspect the valve 12, output a control signal to control the valve 12 and / or other equipment (e.g., chemical injection system 104), or any combination thereof, depending on the condition assessment and / or the scale assessment. For example, if the condition assessment and / or the scale assessment indicates that scale buildup exceeds a threshold value, then the control system 90 may automatically control the valve 12 and / or output an alert or alarm to control the valve 12 to perform a complete cycle of the valve 12 over the total actuation distance, perform one or more additional cycles of the valve 12 over the test distance, or any combination thereof. While operators may have existing or default strategies for cycling valves (e.g., every 1 month, every 6 months, every year, never), the systems and / or methods of the present disclosure advantageously allow the operators to make more educated decisions on appropriate times and intervals for cycling the valve and / or using chemical injection. These systems and methods also allow the operators to measure effects of such actions.

[0038] By further example, if the condition assessment and / or the scale assessment indicates that scale buildup exceeds a threshold value, then the control system 90 may alter a schedule for additional tests (e.g., test distances) in the future (e.g., more frequent tests) and / or control one or more scale prevention measures (e.g., chemical injection). In certain embodiments, if the condition assessment and / or the scale assessment indicates a relatively low amount of scale buildup since a previous test, then the control system 90 may increase the duration of time until a subsequent test of the valve 12. In contrast, if the condition assessment and / or the scale assessment indicates a relatively high amount of scale buildup since a previous test, then the control system 90 may decrease the duration of time until a subsequent test of the valve 12.

[0039] In some embodiments, the control system 90 may control operation of a chemical injection system 104. In general, the chemical injection system 104 may include one or more flow conduits that provide a fluid along the flow path including the valve 12, in a borehole that includes the stack equipment 20, or otherwise into fluid that is in contact with components. For example, the chemical injection system 104 may inject one or more chemicals (e.g., acids, bases, surfactants, and the like) along a flow path fluidly coupled to the fluid flow 102, such that the chemicals help to inhibit scale buildup and / or to remove scale buildup or other precipitation from the gate 42. Thus, the chemicals may help to ensure proper actuation and operation of the valve 12 In certain embodiments, the test of the valve 12 may indicate an undesirable amount of scale buildup and / or other precipitation on the valve 12 (e.g., above a threshold value), and thus trigger operation of the chemical injection system 104 to inject and / or increase injection of the chemicals into the flow path of the valve 12 to help reduce the scale buildup and / or other precipitation.

[0040] As one example of a process for preventing the scale from building up within the valve 12, FIG. 3 illustrates an embodiment of a process 110 for generating an output, such as an alert or a control signal to modify operation of components of a tool system 10, adjust a position of the valve 12, generating a model, and the like. Although the process 110 is described as being performed by the control system 90, any suitable machine or processor-based device capable of communicating with other components of the tool system 10 may perform the disclosed process 110.

[0041] At block 112, the control system 90 actuates an electromechanical actuator. For example, the control system 90 may output a control signal that causes an actuation of a valve to move a test distance via an electromechanical actuator 44. As used herein, the “test distance” is anamount of an adjustment that does not change the operating parameters of downhole equipment outside of a threshold range. For example, the test distance may include actuating an electromechanical actuator that causes the gate 42 of the valve 12 to move less than or equal to 1, 2,3 4, 5, 6, 7, 8, 9 or 10 mm.

[0042] At block 114, the control system 90 receives electrical property data corresponding to the electromechanical actuator 44. For example, the control system 90 may receive data indicating an amount of current or resistance corresponding to the actuation of the valve 12 over the test distance by the electromechanical actuator 44. To do so, the control system 90 may control operation of the electrical sensors 100 that measure the amount of current supplied to the electromechanical actuator 44.

[0043] At block 116, the control system 90 evaluates the condition of electrical property data corresponding to the electromechanical actuator 44. As described herein, the electrical property data may indicate an amount of scale build-up within the valve 12 or other equipment. As such, in some embodiments, evaluating the condition of the electromechanical actuator 44 may include providing the condition assessment discussed in detail above. For example, if the valve 12 is new and / or operating normally, then the electrical property data may indicate a current or power that correspondences to a baseline current or power. If the valve 12 has any scale buildup or other resistance to movement of the valve 12, then the electrical property data may indicate an elevated current or power needed to overcome the scale buildup or other resistance to movement. The greater the scale buildup or other resistance to movement, the greater the elevated current or power measured in the test. In certain embodiments, the condition assessment may include a scale assessment that scores the amount of scale buildup (or any type of solids buildup on the valve 12), as discussed above. Additionally, in certain embodiments, the condition assessment may include condition scores, similar to those discussed above for the scale assessment, for one or more of: a responsiveness of the valve 12, a pressure drop over the valve 12, an age of the valve 12, a number of valve cycles or movements, a duration of exposure to certain detrimental fluid flows, or any combination thereof.

[0044] At block 118, the control system 90 generates an output based on the condition of the electrical property data. The output could be one or more time periods, a time schedule, or combination thereof, for subsequent tests of the valve 12 using one or more of the test distance,the total actuation distance, or any combination thereof. The output also may include an alert, an alarm, and / or a report based on the condition assessment, which may be output on a computer display for analysis by a user. The output also may include automatic control of the valve 12 and / or a recommended control of the valve 12 to: perform a complete cycle of the valve 12 over the total actuation distance, perform one or more additional cycles of the valve 12 over the test distance, or any combination thereof, immediately in real-time and / or at one or more future times.

[0045] In some embodiments, the output may be a model storing relationships between a magnitude of the electrical property data and control adjustments related to operation of the component. For example, the control system 90 may provide inputs to generate or train the model such as relationships between time the valve 12 remained idle or otherwise unused versus scale buildup for a particular operational environment. As used herein, the operational environment may include data such as the type of water or other fluids in contact with the valve 12 or other component, composition of a surrounding geological formation, and the like. As such, the model may be used by other systems including electromechanical actuators 44 to determine time schedules for performing control adjustments or other outputs (e.g., chemical injection or actuation schedules), as described herein.

[0046] FIG. 4 illustrates a non-limiting example of a process 120 for generating the output as described in FIG. 3, such as an alert or a control signal to modify operation of components of a hydrocarbon extraction system 10, adjust a position of the valve 12, and the like. Although the process 120 is described as being performed by the control system 90, any suitable machine or processor-based device capable of communicating with other components of the tool system 20 may perform the disclosed process 120.

[0047] At block 124, the control system 90 receives actuation parameters 122. In general, the actuation parameters 122 may include data indicating a time period or time periods when the control system 90 should cause the adjust the electromechanical actuator 44. In some embodiments, the time period may be a single time period or multiple time periods. For example, in an embodiment when the time period is a single time period, the actuation parameters 122 may indicate that the control system 90 should adjust the electromechanical actuator 44 in 1 second, 5 seconds, 10 seconds, 1 minute, 30 minutes, 1 hour, 5 hours, 10 hours, 24 hours, and so on, afterreceipt of the actuation parameters 122. In some embodiments, the time period may indicate a particular date when the control system 90 should adjust the electromechanical actuator 44.

[0048] In an embodiment when the time period is multiple time periods, the actuation parameters 122 may indicate time intervals when the control system 90 should adjust the electromechanical actuator 44. For example, the actuation parameters 122 may indicate that the control system 90 should adjust the electromechanical actuator 44 one or more times every 30 seconds, 1 hour, 2, 3, 4, 5, 6 or more hours, for a predetermined amount of time, such as 1, 2, 3, 4, 5, or more than 6 days, weeks, or months. As one non-limiting example, the actuation parameters 122 may indicate that the control system 90 should adjust the electromechanical actuator 44 every 12 hours.

[0049] In some instances, the actuation parameters 122 may indicate an amount of adjustment for the electromechanical actuator 44 for the one or more time periods. For example, in an embodiment where the electromechanical actuator 44 operates a valve 12 that controls fluid flowing along a fluid flow path, the actuation parameters 122 may indicate an amount of adjustment of the electromechanical actuator 44 to cause the valve 12 (e.g., gate 42 or other valve element) to move 1, 2, 3, 4, 5, 6, 7, or more millimeters. As discussed in further detail below, in some instances, the control system 90 may determine the amount of adjustment based on reference data.

[0050] At block 126, the control system 90 determines an actuation schedule based on the actuation parameters 122. For example, in an embodiment where the actuation parameters 122 indicate a single time period, the control system 90 may set a timer and adjust the electromechanical actuator 44 after the time period has elapsed or the timer has otherwise reached the time period. In an embodiment when the actuation parameters 122 indicate multiple time periods, the control system 90 may set a reoccurring time and adjust the electromechanical actuator 44 once each time period is reached or the time periods have elapsed.

[0051] In some embodiments, determining the actuation schedule may include obtaining an amount of adjustment for the electromechanical actuator 44. As discussed above, the control system 90 may receive the amount of adjustment as part of the actuation parameters 122. As such, the control system 90 may adjust the electromechanical actuator 44 in accordance with the amount of adjustment indicated by the actuation parameters 122.

[0052] Tn some embodiments, the control system 90 may access reference data to determine the amount of adjustment. In general, the reference data may indicate a type of device controlled by the electromechanical actuator 44, fluid properties where the device is operating, subterranean properties where the device is operating, and the like. In any case, if the time period to adjust the electromechanical actuator 44 has elapsed, then the control system 90 proceeds to block 128.

[0053] At block 128, the control system 90 adjusts the electromechanical actuator 44. In general, the control system 90 may perform block 128 in a generally similar manner as described with respect to block 112 of the process 110. At block 130, the control system 90 measures electrical property data corresponding to the electromechanical actuator 44. In general, the control system 90 may perform block 130 in a generally similar manner as described with respect to block 114 of the process 110. At block 132, the control system 90 determines whether the electrical property data exceeds a threshold. In general, the threshold may be an electrical property threshold, such as an amount of current that corresponds to the valve 12 operating in an expected manner. In some embodiments, the control system 90 may determine that the electrical property data exceeds a threshold by determining the relative increase of the electrical property data relative to the threshold. For example, the control system 90 may determine that the electrical property data exceeds a threshold when the electrical property data indicates that the amount of current utilized by the electromechanical actuator increases by greater than or equal to 10%, 20%, 30%, 40%, 50%, and so on. If the electrical property data exceeds a threshold, the process 120 moves to block 138.

[0054] At block 134, the control system 90 generates a control adjustment output 136. In some embodiments, the control adjustment output is an alert, a visualization, or a control signal that indicates the electrical property data exceeds a threshold, and thus, the scale build-up may exceed a threshold amount. In some embodiments, the control adjustment output is a control signal that remedies or reduces the amount of scale build-up. For example, the control adjustment output may cause the chemical injection system 104 (e g., as described in FIG. 2) to operate to inject one or more chemicals (e.g., scale inhibitors), such as an acid or other fluid, along a flow path that is fluidly coupled to the equipment and / or the valve 12. As another non-limiting example, the control adjustment output may include actuating the equipment and / or the valve 12 at a determined time period. As another non-limiting example, the control adjustment output may be a modification to a time schedule for actuating the equipment and / or the valve 12. That

[0055] FIG. 5 illustrates a non-limiting example of a process 140 for generating the output as described in FIG. 3, such as an alert or a control signal to modify operation of components of a hydrocarbon extraction system 10, adjust a position of the valve 12, and the like. Although the process 120 is described as being performed by the control system 90, any suitable machine or processor-based device capable of communicating with other components of the tool system 20 may perform the disclosed process 140.

[0056] At block 142, the control system 90 sets an initial time period of actuation and activates the system. In some embodiments, the control system 90 may determine the initial time period for actuation based on reference information indicating the type of fluids or formation that may be present around the equipment and / or valve 12 that include the electromechanical actuator 44. For example, the reference information may include data that indicates a time period and / or time schedule for a corresponding fluid and / or formation. As such, the control system 90 may determine the initial time period using the reference information.

[0057] At block 144, the control system 90 initiates movement of the electromechanical actuator 44 coupled to the equipment and / or valve 12. As described herein, the control system 90 may initiate movement of the electromechanical actuator 44 such that the equipment and / or valve 12 moves a test distance as discussed in detail above. In some embodiments, the control system 90 may initiate the movement based on a time schedule. As such, the control system 90 may set a timer or retrieve time information, and upon the timer ending or otherwise an amount of time elapsing, the control system 90 may actuate the electromechanical actuator 44 to adjust a position of the equipment and / or valve 12, for example.

[0058] At block 146, the control system 90 moves the electromechanical actuator 44 a predetermined distance. In general, the control system 90 may perform block 146 in a generally similar manner as block 112 of the process 110. At block 148, the control system 90 moves the electromechanical actuator 44 to its original position. In some embodiments, blocks 146 and 148 may be performed together as a test by the control system 90 to determine whether the electromechanical actuator 44 is capable of moving a predetermined distance (e.g., corresponding to a health condition). In general, the control system 90 may perform block 148 in a generally similar manner as block 112 of the process 110, but in an opposite direction (e.g., along the direction 62). At block 150, the control system 90 analyzes electrical current values during bothmovements (e.g., in blocks 146 and 148). In general, the control system 90 may perform block 150 in a generally similar manner as block 114 of the process 110.

[0059] At block 152, the control system 90 generates a report based on the analyzed current values. In general, the report may be a visualization to display on a computing device that aids a user or operator in determining a condition of the equipment and / or valve 12. As such, the report may include a time period when the electrical current values (e g., electrical property data) were measured, a time period corresponding to a previous measurement, an estimated amount of scale formation, a current time schedule for actuating the equipment and / or valve 12, and other information that may aid a user in determining the condition of the equipment and / or valve 12.

[0060] At block 154, the control system 90 determines an adjustment based on the report. In general, the control system 90 may perform block 154 in a generally similar manner as described in block 126 of the process 120. Blocks 156, 158, and 160 show example determinations and outcomes for controlling the equipment and / or valve 12.

[0061] At block 156, the control system 90 compares the electrical current value to a reference current value. If the electrical current value is within a first threshold (e.g., the electrical property data is 15% or less, 10% or less, 8% or less, or 5% or less than a previously measured electrical property data), the control system 90 may increase the amount of time between time periods for actuating the electromechanical actuator 44. In this way, the control system 90 may prevent damage to the electromechanical actuator 44 and the equipment and / or valve 12 that may result from repeated use of the electromechanical actuator 44. At block 158, if the control system 90 determines the electrical current value is above the first threshold, but below a second threshold, then the control system 90 may output an alert and / or decrease the amount of time between time periods for actuating the electromechanical actuator 44. At block 160, if the control system 90 determines the electrical current value is above the first threshold and the second threshold, the control system 90 may output an alert and / or perform a control adjustment output such as repetitive actuation, which may facilitate removing the scale build-up. The control system 90 may perform the repetitive actuation for a predetermined amount of time (e.g., 10 or more seconds, 30 or more seconds, 1 or more minutes, 5 or more minutes and so on). After performing the repetitive action, the control system 90 may return to block 150. In this way, the process 140 provides techniques for equipment to automatically diagnose and mitigate scale build-up.

[0062] Systems and methods of the present disclosure can advantageously provide PHM (prognostic health monitoring or prognostics and health management). As described, in some configurations, a PHM module can be integrated or used in conjunction with a valve 12 and chemical injection system or process 104. Whereas currently, and with mechanical / hydraulic systems, operators must rely on human analysis and experience to manually determine if chemical injection is required, such integration systems and methods according to the present disclosure can automatically correlate downhole conditions, e.g., scale on downhole flow control valves, with chemical injection, for example, the necessity for chemical injection and / or efficiency of chemical injection. FIG. 7 schematically illustrates an example PHM workflow that allows for automatically optimizing and / or adjusting of chemical injection parameters based on data collected from one or more valves 12, e.g., one or more flow control valves. In some configurations, a system according to the present disclosure includes a PHM model 300 (e.g., PHM model software block), an acquisition system 216 for communication with downhole tools, one or more electric flow control valves 12, and a chemical injection system 104, for example, an electrical chemical injection system 104. The acquisition system 216 and / or PHM model 300 may be part of or included in surface equipment 16. The PHM model 300 may be included in or operated by control system 90. The control system 90 may be, or be part of, the acquisition system 216 or vise versa.

[0063] As schematically shown in FIG. 7, in operation, the PHM model 300 can trigger the PHM workflow by sending signal(s) to the acquisition system 216. The PHM model 300 and / or acquisition system 216 triggers small (test distance) actuations of the flow control valve(s) 12 that do not impact, or do not significantly impact, production. The PHM model 300 and / or acquisition system 216 can request data from the flow control valve(s) 12 and receive data from flow control valve(s) 12. In some configurations the flow control valve data is sent to and / or received by the acquisition system 216, which inputs the data into the PHM model 300. The PHM model 300 can process and / or interpret the received flow control valve data, and generate one or more output(s). The output(s) may be provided to the acquisition system 216. In the example workflow configuration illustrated in FIG. 7, the output(s) can include PHM chemical injection (e.g., electric chemical injection) insights. In some configurations, such as shown in FIG. 7, the PHM model 300 provides the output(s), e.g., chemical injection insights, to the acquisition system 216. The PHM model 300 and / or acquisition system 216 can output chemical injection (e.g., electricchemical injection) commands based on or as indicated by the chemical injection insights output by the PHM model 300.

[0064] To help create the PHM model 300, the well can be characterized to map the expected behavior of the valve 12 under the specific well conditions. During operation or the lifecycle of the well, the PHM model 300 can compare actual conditions with the expected parameters to help identify scale is building in a particular zone. In various configurations, the PHM model 300 can operate on a continuous monitoring basis or periodic monitoring basis. If providing continuous monitoring, the PHM model 300 can receive input data from the downhole flow control valve(s) 12 continuously (e.g., every second). If providing periodic monitoring, the PHM model 300 can receive input data either at designated time intervals, or upon trigger / request from an operator. With either continuous or periodic monitoring, the PHM model 300 can receive the input data from the valve 12, process the received input data, and generate output(s).

[0065] The PHM model 300 can generate various outputs, which may be, for example, various reports or insights for manual operation of the chemical injection system 104 and / or automatic operation of the chemical injection system 104. For example, if scale is identified, the output can be or include, for example, insights to the operator to help make a decision on chemical injection and / or automatically determining chemical injection is needed and sending such commands to the chemical injection system 104. If chemical injection is initiated, the PHM model 300 can continue to perform test distance actuations to provide realtime feedback. If the valve 12 returns to normal or expected operation, for example due to successful chemical injection removing the scale, the PHM model 300 can generate an output signaling that chemical injection is no longer required, as an output to an operator and / or an automatic output to the chemical injection system 104 to stop injection. Alternatively, if no changes or improvements result, the PHM model 300 can generate an output indicating that other chemicals or actions may be required.

[0066] Technical effects of this disclosure include techniques for mitigating scale build-up to a point where it may be desirable to perform maintenance on equipment, which may involve relatively expensive operations such as removing the equipment. The disclosed techniques may provide outputs that can reduce the amount of scale or otherwise break up scale (e.g., performing a chemical injection actuating an electromechanical actuator).

[0067] A system, comprising a controller having one or more processors, a memory, and instructions stored on the memory, and executable by the one or more processors to: output a control signal that causes an actuation of equipment to move a test distance via an electromechanical actuator; receive electrical property data corresponding to the actuation over the test distance by the electromechanical actuator; evaluate a condition of the equipment based on the electrical property data; and generate an output based on the condition of the equipment.

[0068] The system of any preceding clause, wherein the test distance is less than or equal to 5 percent of a total actuation distance of the equipment by the electromechanical actuator.

[0069] The system of any preceding clause, wherein the equipment comprises a valve, and wherein the electromechanical actuator comprises a shaft coupled to the valve, wherein the shaft comprises threads coupled to mating threads along a threaded interface, and the electromechanical actuator is configured to actuate the shaft to move along the threaded interface to actuate the valve.

[0070] The system of any preceding clause, wherein the equipment comprises a gate valve, a flow control valve, a safety valve, a barrier valve, a ball valve, a blowout preventer (BOP), a choke, or any combination thereof.

[0071] The system of any preceding clause, wherein evaluating the condition of the equipment comprises estimating a scale buildup on the equipment.

[0072] The system of any preceding clause, wherein generating the output comprises outputting a control signal and / or a control recommendation to cycle the equipment over a total actuation distance to remove the scale buildup on the equipment.

[0073] The system of any preceding clause, wherein generating the output comprises outputting a schedule for a future test of the equipment over the test distance.

[0074] The system of any preceding clause, wherein the generating the output comprises at least one of: outputting an alert, an alarm, or a condition report based on the condition of the equipment; outputting a control signal and / or a control recommendation to cycle the equipment over a total actuation distance based on the condition of the equipment; scheduling a future test of the equipment over the test distance based on the condition of the equipment; or any combination thereof.

[0075] The system of any preceding clause, wherein the electrical property data indicates an amount of current or power provided to the electromechanical actuator over the test distance, a time period to actuator the electromechanical actuator over the test distance over the test distance, or a combination thereof.

[0076] A method, comprising outputting a control signal that causes an actuation of a valve to move a test distance via an electromechanical actuator; receiving electrical property data corresponding to the actuation over the test distance by the electromechanical actuator; evaluating a condition of the valve based on the electrical property data; and generating an output based on the condition of the valve.

[0077] The method of any preceding clause, wherein the generating the output comprises: determining a time period to transmit a subsequent control signal; and outputting, in accordance with the time period, a subsequent control signal that causes an additional actuation of the valve to move the test distance via the electromechanical actuator.

[0078] The method of any preceding clause, further comprising: receiving actuating parameters indicating a time schedule for actuation of the valve via the electromechanical actuator; and outputting the control signal that causes the actuation in accordance with the time schedule.

[0079] The method of any preceding clause, wherein evaluating the condition of the valve comprises: determining the electrical property data exceeds a threshold; and modifying the time schedule to move the valve based on the electrical property data exceeding the threshold.

[0080] The method of any preceding clause, wherein evaluating the condition of the valve comprises: determining the electrical property data exceeds a threshold; and modifying the test distance to move the valve based on the electrical property data exceeding the threshold.

[0081] The method of any preceding clause, wherein the output comprises a model storing relationships between a magnitude of the electrical property data and control adjustments related to operation of the component.

[0082] A system comprising: an electromechanical actuator configured to control a valve; and a controller, comprising one or more processors, wherein the controller is configured to: output a control signal that causes an actuation of a valve to move a test distance via an electromechanical actuator; receive electrical property data corresponding to the actuation over the test distance bythe electromechanical actuator; evaluate a condition of the valve based on the electrical property data; and generate an output based on the condition of the valve.

[0083] The system of any preceding clause, wherein the output comprises an actuation schedule having a frequency for adjusting the electromechanical actuator, and wherein the frequency is variable depending on the condition of the valve.

[0084] The system of any preceding clause, wherein the output comprises an actuation schedule at least partially based on an operational environment of the valve.

[0085] The system of any preceding clause, wherein the test distance is less than or equal to 5 percent of a total actuation distance of the valve by the electromechanical actuator.

[0086] The system of any preceding clause, wherein the valve comprises a gate valve, a flow control valve, a safety valve, a barrier valve, a ball valve, a blowout preventer (BOP), a choke, or any combination thereof.

[0087] The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for (perform)ing (a function)...” or “step for (perform )ing (a function)...”, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f).

Claims

CLAIMS:

1. A system, comprising: a controller having one or more processors, a memory, and instructions stored on the memory, and executable by the one or more processors to: output a control signal that causes an actuation of equipment to move a test distance via an electromechanical actuator; receive electrical property data corresponding to the actuation over the test distance by the electromechanical actuator; evaluate a condition of the equipment based on the electrical property data; and generate an output based on the condition of the equipment.

2. The system of claim 1, wherein the test distance is less than or equal to 5 percent of a total actuation distance of the equipment by the electromechanical actuator.

3. The system of claim 1, wherein the equipment comprises a valve, and wherein the electromechanical actuator comprises a shaft coupled to the valve, wherein the shaft comprises threads coupled to mating threads along a threaded interface, and the electromechanical actuator is configured to actuate the shaft to move along the threaded interface to actuate the valve.

4. The system of claim 1, wherein the equipment comprises a gate valve, a flow control valve, a safety valve, a barrier valve, a ball valve, a blowout preventer (BOP), a choke, or any combination thereof.

5. The system of claim 1, wherein evaluating the condition of the equipment comprises estimating a scale buildup on the equipment.

6. The system of claim 5, wherein generating the output comprises outputting a control signal and / or a control recommendation to cycle the equipment over a total actuation distance to remove the scale buildup on the equipment.

7. The system of claim 5, wherein generating the output comprises outputting a schedule for a future test of the equipment over the test distance.

8. The system of claim 1, wherein the generating the output comprises at least one of outputting an alert, an alarm, or a condition report based on the condition of the equipment; outputting a control signal and / or a control recommendation to cycle the equipment over a total actuation distance based on the condition of the equipment; scheduling a future test of the equipment over the test distance based on the condition of the equipment; performing a chemical injection protocol; or any combination thereof.

9. The system of claim 1, wherein the electrical property data indicates an amount of current or power provided to the electromechanical actuator over the test distance, a time period to actuator the electromechanical actuator over the test distance over the test distance, or a combination thereof.

10. A method, comprising: outputting a control signal that causes an actuation of a valve to move a test distance via an electromechanical actuator; receiving electrical property data corresponding to the actuation over the test distance by the electromechanical actuator; evaluating a condition of the valve based on the electrical property data; and generating an output based on the condition of the valve.

11. The method of claim 10, wherein the generating the output comprises: determining a time period to transmit a subsequent control signal; and outputting, in accordance with the time period, a subsequent control signal that causes an additional actuation of the valve to move the test distance via the electromechanical actuator.

12. The method of claim 10, further comprising:receiving actuating parameters indicating a time schedule for actuation of the valve via the electromechanical actuator; and outputting the control signal that causes the actuation in accordance with the time schedule.

13. The method of claim 12, wherein evaluating the condition of the valve comprises: determining the electrical property data exceeds a threshold; and modifying the time schedule to move the valve based on the electrical property data exceeding the threshold.

14. The method of claim 12, wherein evaluating the condition of the valve comprises: determining the electrical property data exceeds a threshold; and modifying the test distance to move the valve based on the electrical property data exceeding the threshold.

15. The method of claim 10, wherein the output comprises a model storing relationships between a magnitude of the electrical property data and control adjustments related to operation of the component.

16. The method of claim 10, wherein generating the output comprises performing a chemical injection protocol.

17. A system, comprising: an electromechanical actuator configured to control a valve; and a controller, comprising one or more processors, wherein the controller is configured to: output a control signal that causes an actuation of a valve to move a test distance via an electromechanical actuator; receive electrical property data corresponding to the actuation over the test distance by the electromechanical actuator; evaluate a condition of the valve based on the electrical property data; and generate an output based on the condition of the valve.

18. The system of claim 17, wherein the output comprises an actuation schedule having a frequency for adjusting the electromechanical actuator, and wherein the frequency is variable depending on the condition of the valve.

19. The system of claim 17, wherein the output comprises an actuation schedule at least partially based on an operational environment of the valve.

20. The system of claim 17, wherein the test distance is less than or equal to 5 percent of a total actuation distance of the valve by the electromechanical actuator.

21. The system of claim 17, wherein the valve comprises a gate valve, a flow control valve, a safety valve, a barrier valve, a ball valve, a blowout preventer (BOP), a choke, or any combination thereof.

22. The system of claim 17, further comprising a chemical injection system, wherein the controller is configured to generate the output in the form of control signals to operate the chemical injection system.

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