Automated Choke Control for Hydrocarbon Well Liquid Loading
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Solution Overview
Problem
Hydrocarbon wells face production inefficiencies and premature shutdown due to liquid loading, where liquids accumulate and reduce gas flow rates, leading to meta-stable production rates and potential well shutdowns, with existing solutions being either inefficient or requiring manual, human-dependent operations.
Innovation Solution
An automated remote control and monitoring system that uses a choke with an actuator and data acquisition means to perform cyclic shut-in and opening cycles based on measured parameters like wellhead pressure and flow rate, optimizing production efficiency and extending well life by preventing liquid accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual well control operations are used, then operational flexibility is maintained, but human error and operational costs increase
Solution Approach 1:
The control system performs cyclic shut-in and opening operations autonomously based on pre-programmed parameters and real-time sensor data, eliminating the need for continuous manual intervention. The system monitors wellhead pressure, temperature, and flow rate, and automatically executes control decisions according to the cyclic pattern designed to prevent liquid loading.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated electronic control system that uses sensors, microprocessors, and actuators. The system substitutes human decision-making and physical valve manipulation with electronic monitoring and automated control mechanisms, thereby reducing human error while maintaining operational flexibility through programmable parameters.
2Reliability
If cyclic shut-in control is implemented, then liquid accumulation is prevented, but production time is reduced due to intermittent shut-ins
Solution Approach 1:
The system implements cyclic shut-in and opening operations with specific duration and frequency parameters. By periodically shutting in the well for short intervals, the system prevents liquid accumulation that would otherwise cause prolonged shutdowns. The cyclic pattern is optimized to maintain gas production stability while minimizing total shut-in time, creating a balance between prevention and productivity.
Solution Approach 2:
The control system performs preliminary shut-in actions before liquid loading becomes severe. By detecting early signs of liquid accumulation through sensor monitoring and executing shut-ins proactively, the system prevents the condition from worsening to the point where extended shutdowns would be necessary, thereby maintaining higher average production rates.
3Productivity
If well production continues without cyclic control, then maximum gas flow rate is maintained, but liquid loading causes premature well shutdown
Solution Approach 1:
The system continuously monitors wellhead pressure, temperature, and flow rate, and uses this feedback to detect early signs of liquid loading. When parameters indicate approaching liquid loading conditions, the control system automatically adjusts operations by initiating cyclic shut-ins, thereby preventing the condition from developing into severe liquid loading that would force premature well shutdown and extend productive well life.
Solution Approach 2:
The control system executes preliminary cyclic shut-in operations before liquid loading becomes critical. By acting in advance to prevent liquid accumulation, the system avoids the need for extended shutdowns or well abandonment, thereby extending the productive life of the well while maintaining gas flow rates near maximum levels for longer periods.
Data Source
AI summary
The present invention relates to a remote control and monitoring system to improve the production efficiency of a hydrocarbon well, including a choke located between a wellhead production tree and the production line of hydrocarbons, an actuator operating the choke, the actuator being in communication with a remote control and monitoring unit, a power supply source supplying power to the control and monitoring unit, and a plurality of data acquisition means including transducers arranged upstream and downstream of the choke, where the data acquisition means sends information related to the wellhead pressure, the production line pressure, and optionally, the wellhead temperature to the control and monitoring unit, where the control and monitoring unit is configured to carry out well shut-in cycles and well opening cycles determined based on compliance with a plurality of well shut-in and opening criteria by which a measured or calculated value of a parameter is compared to a preset value for the parameter, where the measured or calculated parameters are selected from wellhead pressure, production line pressure, wellhead pressure to production line pressure ratio, shut-in or opening time of the well, flow rate and critical flow rate. A method for improving the production efficiency of a hydrocarbon well employing the same is also provided.