Autonomous Choke Valve Control System for Well Safety
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Solution Overview
Problem
The oil and gas industry faces challenges in safely and efficiently controlling hydrocarbon reservoirs, particularly in environments where manual operation of equipment poses risks and there is a need for improved environmental safety and compliance throughout the well lifecycle.
Innovation Solution
A control system is developed that includes a controller with an interface for receiving sensor data, memory for tuning parameter values, and a loader to issue control signals to a choke valve actuator based on selected parameter values and sensor data, enabling autonomous operation and enhanced safety features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operation of equipment is used, then ease of operation is maintained, but operational safety deteriorates due to risks posed to crew members
Solution Approach 1:
The patent replaces manual mechanical operation with an automated control system that uses sensors to detect well conditions and a controller to actuate choke valves. This substitution eliminates direct human exposure to hazardous environments while maintaining precise control over hydrocarbon reservoir operations.
Solution Approach 2:
The control system operates autonomously by continuously monitoring sensor data and automatically adjusting choke valve positions based on detected well conditions. The system serves itself by making real-time decisions without requiring manual intervention, thereby improving safety while maintaining operational efficiency.
2Reliability
If automated control system is implemented, then operational safety is improved, but device complexity increases
Solution Approach 1:
The controller is designed to perform multiple functions: receiving sensor data, processing well condition information, determining optimal choke valve positions, and actuating valves. This multi-functionality consolidates what could be separate complex systems into a single integrated unit, reducing overall system complexity while maintaining safety benefits.
Solution Approach 2:
The controller acts as an intermediary between sensors and choke valve actuators, processing information and making control decisions. This intermediary layer simplifies the system architecture by centralizing intelligence, allowing sensors and actuators to remain relatively simple components while achieving sophisticated control through the mediating controller.
3Object-affected harmful factors
If precise control of fluid flow is achieved, then environmental compliance is enhanced, but manufacturing precision requirements increase
Solution Approach 1:
The system uses sensors to continuously monitor well conditions such as pressure and flow rate, feeding this data back to the controller. The controller adjusts choke valve positions based on this feedback to maintain precise control over fluid flow. This closed-loop feedback mechanism achieves the necessary precision for environmental compliance without requiring extremely tight manufacturing tolerances on individual components.
Solution Approach 2:
The control system dynamically adjusts choke valve positions in real-time based on changing well conditions detected by sensors. This dynamic adaptation allows the system to maintain precise control over fluid flow and pressure, ensuring environmental compliance even as reservoir conditions vary, without requiring static high-precision manufacturing.
Data Source
AI summary
A control system can include a controller that includes an interface for receipt of sensor data generated by sensors operatively coupled to a fluid flow system; memory that includes sets of tuning parameter values; and a loader that loads a selected set of the sets of tuning parameter values into the controller for issuance of control signals to a choke valve actuator for a choke valve of the fluid flow system according to the selected set of tuning parameter values and sensor data generated by one or more of the sensors.