Autodiversion Sand Management System for Vessel Collapse Prevention
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Solution Overview
Problem
Sand management systems face challenges in efficiently managing differential pressure and solids accumulation, leading to potential vessel collapse and operator safety risks due to the time-consuming and hazardous process of redirecting flow between vessels, especially when solids accumulation rates are unpredictable.
Innovation Solution
A sand management system with automatic valves and sensors that dynamically monitor pressure and solids accumulation, shifting fluid flow between vessels to prevent threshold exceedance, equalize pressure, and flush vessels to maintain system stability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an operator redirects flow from one vessel to another before reaching the critical threshold, then vessel collapse is prevented, but the process takes up to an hour and exposes operators to high pressure and other well fluids
Solution Approach 1:
The system automatically monitors differential pressure across vessels and triggers flow redirection without operator intervention. The control system detects when differential pressure approaches the critical threshold and automatically actuates valves to divert flow, eliminating the need for manual operator action and reducing exposure time to hazardous conditions.
Solution Approach 2:
The system continuously monitors differential pressure across each vessel using sensors and feedback control mechanisms. When the differential pressure approaches the critical threshold, the control system receives real-time data and automatically initiates flow redirection, creating a closed-loop control system that responds dynamically to changing conditions without requiring operator judgment or manual intervention.
2Reliability
If an operator redirects flow from one vessel to another, then vessel collapse is prevented, but operators are exposed to high pressure and other well fluids
Solution Approach 1:
The automated system performs flow redirection without requiring operator presence in the hazardous environment. The control system automatically actuates valves and manages flow diversion, eliminating direct operator exposure to high pressure and well fluids while maintaining reliable vessel collapse prevention.
Solution Approach 2:
The automated control system acts as an intermediary between the monitoring function and the flow redirection function. Instead of operators directly manipulating valves in hazardous conditions, the control system intermediates by automatically detecting pressure thresholds and triggering valve actuation, thereby protecting operators from harmful exposures while maintaining system reliability.
3Reliability
If the system manually monitors and redirects flow, then vessel collapse is prevented, but the process is time-consuming and hazardous
Solution Approach 1:
The system replaces manual mechanical operation with automated electronic control. Instead of operators manually monitoring and manipulating valves, the system uses electronic sensors to detect differential pressure and electronic control mechanisms to automatically actuate valves, thereby eliminating the time-consuming and hazardous manual process while maintaining reliable vessel collapse prevention.
Solution Approach 2:
The system performs self-monitoring and self-redirection of flow without external operator intervention. The automated control system continuously monitors differential pressure and automatically triggers flow diversion when thresholds are approached, transforming the manual, time-consuming process into an efficient automated operation that maintains high productivity while ensuring reliability.
4Loss of time
If solids fill the vessel at uniform rates, then flow redirection timing is predictable, but solids accumulation rates suddenly and unexpectedly increase when a solids slug comes to surface
Solution Approach 1:
The system uses real-time feedback from pressure sensors to detect changes in solids accumulation rate. When a solids slug approaches the surface, the differential pressure across the vessel changes, and the feedback control system detects this change, allowing the system to respond dynamically to unexpected solids accumulation patterns rather than relying on predictable uniform rates.
Solution Approach 2:
The system transitions from static, predetermined flow redirection timing to dynamic, real-time response based on actual solids accumulation conditions. The automated control system continuously adjusts its response based on feedback from pressure monitoring, allowing it to adapt to changing solids accumulation rates including sudden slug flow events, thereby maintaining reliability despite unpredictable solids behavior.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively manages differential pressure and solids accumulation, preventing vessel collapse and reducing operator exposure to hazards by automating the diversion and flushing processes, ensuring continuous operation and safety.
Implementation Method 1
a first vessel of the two vessels include a cyclone or cyclone-shaped insert configured to initiate a cyclone effect to separate solids from fluids
Implementation Method 2
a first vessel of the two vessels include a cyclone or cyclone-shaped insert configured to initiate a cyclone effect to separate solids from fluids
Implementation Method 3
a second vessel of the two vessels includes a filter element (e.g., a screen insert) configured to separate solids from fluids
Implementation Method 4
the differential pressure between the upstream and downstream flows increases. If this differential pressure reaches about a critical threshold
Data Source
AI summary
A method to perform autodiversion of a sand management system includes determining a first weight of a first vessel. In response to a determination that the first weight is above a first weight threshold, the method also includes actuating a first set of valves to flow the fluid from the first vessel to a second vessel of the sand management system. The method further includes flushing the first vessel.