Automated Wellhead Completion System for Long Lateral Reach
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Solution Overview
Problem
Conventional completion systems for wells, particularly those with long lateral boreholes, face challenges such as slow and unsafe insertion of production tubing, limited maximum horizontal insertion distance, and increased operational costs due to the need for larger and more complex rigs, which hinder efficient hydrocarbon production and fracturing in low permeability reservoirs.
Innovation Solution
A long lateral completion system featuring a compact mast assembly, catwalk-pipe arm, and automated control van that allows for precise alignment and automated operation of pipe handling mechanisms, enabling faster and safer insertion of tubing with reduced rig footprint, and enhanced capability to reach longer lateral lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional completion systems are used for wells with long lateral boreholes, then the insertion of production tubing can be performed, but the insertion process is slow and unsafe
Solution Approach 1:
The patent replaces conventional mechanical rig systems with an automated completion system that uses a controlled descent mechanism and automated pipe handling equipment. This substitution enables faster insertion speeds while maintaining safety through automated control systems and reduced human exposure to hazardous environments.
Solution Approach 2:
The system incorporates automated pipe handling mechanisms that can independently position, guide, and insert production tubing into the wellbore without requiring extensive manual intervention. The automated control system manages the entire insertion process, improving both speed and safety by eliminating the need for workers to be in proximity to moving equipment.
2Length of moving object
If conventional completion systems are used, then production tubing insertion is possible, but the maximum horizontal insertion distance is limited
Solution Approach 1:
The completion system is divided into modular components including the rig assembly, automated pipe handling equipment, and control systems. This segmentation allows the system to achieve extended lateral reach through coordinated operation of discrete modules while managing overall system complexity through standardized interfaces and independent functionality of each segment.
Solution Approach 2:
The system extends capability into the horizontal dimension by incorporating lateral movement mechanisms and extended reach equipment that enable production tubing to be inserted into long lateral boreholes. This dimensional extension is achieved through automated positioning systems that can accurately guide pipes along horizontal trajectories without proportionally increasing system complexity.
3Length of moving object
If larger and more complex rigs are used to handle long lateral completions, then longer lateral reach is achieved, but operational costs increase
Solution Approach 1:
The system optimizes operational parameters including insertion speed, pipe handling efficiency, and rig positioning to achieve extended lateral reach while controlling costs. By carefully managing these parameters and using automated systems to maintain optimal operating conditions, the system reduces waste and improves efficiency, thereby lowering operational costs despite the capability for longer lateral completions.
Data Source
AI summary
A rig system and method is provided for use with multiple wellheads in close proximity on a wellsite. A mast assembly is mounted to a rig carrier for alignment with a first wellhead. A pipe handling system is mounted to a skid having a pipe moving member mounted to the skid. A rig platform for use with the mast assembly is vertically moveable for accommodating a second wellhead in close proximity to the first wellhead while allowing operators to work within the mast assembly.