Automated Cement Plug Launch via Single Pneumatic Line
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Solution Overview
Problem
The manual operation of cement plugs in oil and gas wells is hazardous due to the need for manual actuation of valves and removal of retaining devices at high pressure, particularly in hazardous zones where electrical devices are prohibited, and existing pneumatic systems are cumbersome and complex when multiple pneumatic lines are required.
Innovation Solution
A system utilizing a single pneumatic line with varying pressure, actuated by pressure regulators and pneumatically or hydraulically controlled devices to automate the sequence of valve operation and retention device release, allowing remote control via a wireless remote to safely launch multiple cement plugs from a cement head.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operation of valves and retaining devices is used, then operational simplicity is maintained, but safety hazards increase due to high pressure and hazardous zone restrictions
Solution Approach 1:
The patent replaces manual mechanical operation with an automated control system that uses electronic sensors, microprocessors, and control algorithms to operate valves and retaining devices, eliminating the need for personnel to physically handle high-pressure components in hazardous zones
Solution Approach 2:
The patent introduces an intermediary control system that acts as a mediator between the operator and the high-pressure cementing equipment, allowing remote operation through a control room interface while preventing direct human exposure to hazardous conditions
2Extent of automation
If multiple pneumatic lines are used for automating valve operation, then automation capability is improved, but system complexity increases
Solution Approach 1:
The patent combines multiple pneumatic control lines into a single integrated pneumatic distribution system that delivers pressurized air to all valves and actuators through one main line with distributed branch connections, reducing the number of separate pneumatic systems while maintaining full automation capability
Solution Approach 2:
The patent creates a universal pneumatic control architecture where a single pneumatic line serves multiple functions by distributing pressurized air to different valves and actuators at various stages of the cementing process, allowing one system to perform what previously required multiple separate systems
3Ease of operation
If pressure control is simplified, then operational ease is improved, but sequencing precision deteriorates
Solution Approach 1:
The patent implements a feedback control system that continuously monitors pressure, valve position, and stage completion status, automatically adjusting pressure delivery to maintain precise sequencing while keeping the operator interface simple through automated control algorithms
Solution Approach 2:
The patent pre-configures pressure regulators and control valves with predetermined setpoints and sequencing logic programmed into the control system, allowing precise pressure sequencing to be automatically executed without requiring the operator to manually coordinate multiple pressure changes
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
This system ensures safe and automated launching of cement plugs, reducing the risk of accidents by maintaining proper sequence and pressure control, while simplifying the setup by using a single pneumatic line, thus enhancing operational safety and efficiency.
Implementation Method 1
a pneumatic line, the pneumatic line containing a pressurized gas, wherein the pressure within the line may be varied
Data Source
AI summary
A system and method for using a pneumatic line to automate the launch a cement plug from a cement head. The pneumatic line is in communication with the valves and retaining devices normally found on a typical cement head. The system ensures that the proper sequence of opening and closing valves in combination with the removal of the retaining device is used to safely launch a cement plug from the cement head. The pressure in the single pneumatic line may be varied to launch multiple cement plugs from a cement head. The system may be used to remotely launch a cement plug from a cement head. A wireless remote may be used to regulate the pressure in the pneumatic line to launch cement plugs from the cement head as desired.