Automatic Well Killing Through Flow Sensing and HCR Valve Actuation
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Solution Overview
Problem
Existing well killing operations, which involve manually initiating kill fluid flow to prevent formation fluid from reaching the surface, pose risks to well, equipment, and personnel due to manual intervention during detection and execution phases.
Innovation Solution
A system with a wellhead assembly, sensors, hydraulic control remote (HCR) valves, and a controller that automatically detect problematic fluid flow and initiate kill fluid injection through modified HCR valves to overcome formation pressure, sealing the wellhead and injecting kill fluid to prevent further flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual well killing operations are performed with operator intervention, then the well killing process can be controlled and executed, but the risk to well, equipment, and personnel increases due to manual intervention during detection and execution phases
Solution Approach 1:
The system enables automatic detection of formation fluid flow and automatic initiation of well killing operations through a controller that receives sensor signals and actuates HCR valves without operator intervention, allowing the system to serve itself and eliminate human exposure to hazards
Solution Approach 2:
The patent replaces manual mechanical valve operation with an automated control system that uses sensors, controllers, and hydraulic actuators to detect flow conditions and actuate HCR valves automatically, substituting human mechanical action with an automated electromechanical system
2Reliability
If automated well killing is implemented using sensors and controllers, then operator safety is improved and human error is reduced, but the device complexity increases
Solution Approach 1:
The controller serves multiple functions by receiving signals from flow sensors, determining whether well killing is needed based on predetermined conditions, and actuating HCR valves automatically, consolidating detection, decision-making, and execution functions into a single multi-functional device
Solution Approach 2:
The HCR valves act as intermediaries between the control system and the kill fluid delivery mechanism, providing remote hydraulic control that enables automated valve actuation without requiring direct mechanical connection or manual intervention at the valve location
3Loss of time
If near-instantaneous automated well killing is achieved, then response time to blowout events is reduced and damage is prevented, but the system requires rapid actuation capabilities that increase technical complexity
Solution Approach 1:
The system performs preliminary actions by continuously monitoring flow conditions through sensors and maintaining readiness to initiate well killing operations immediately upon detecting predetermined conditions, eliminating detection and decision delays
Solution Approach 2:
The system uses hydraulic control mechanisms in the HCR valves to achieve rapid actuation, leveraging hydraulic force transmission to open valves quickly and allow immediate kill fluid flow in response to automated detection signals
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
Enables near-instantaneous, automated well killing, reducing human error and ensuring operator safety by preventing damage and danger during blowout events.
Implementation Method 1
a sensor operable to detect a characteristic of a fluid flow in the passageway indicative of a need for a well killing operation
Implementation Method 2
introducing a heavy fluid (known as 'kill fluid' or 'kill mud’) into the well in order to overcome the pressure of the formation fluids flowing from the subterranean formation
Implementation Method 3
a hydraulic control remote (HCR) valve installed in the kill fluid line, the HCR valve including a gate movable between closed and open positions with respect to the kill fluid line and an actuator to open and close the gate
Data Source
AI summary
A system includes a wellhead assembly installed above a well, the wellhead assembly including a passageway extending therethrough in fluid communication with the well, a sensor operable to detect a characteristic of a fluid flow in the passageway indicative of a need for a well killing operation, a kill fluid line extending between a source of kill fluid and the passageway, a hydraulic control remote (HCR) valve installed in the kill fluid line, the HCR valve including a gate movable between closed and open positions with respect to the kill fluid line and an actuator to open and close the gate, and a controller communicatively coupled to the flow sensor and the HCR valve operable to instruct the actuator of the HCR valve to open in response to determining the characteristic of the fluid flow in the passageway is indicative of a need for a well kill operation.