Smart Choke Valve Control Using Sand Sensing and Well Profiles

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Solution Overview

Problem

Hydrocarbon well production is challenged by sand production, which can lead to wellbore plugging, erosion of components, and inefficient production rates, requiring effective monitoring and regulation to maintain optimal production levels.

Innovation Solution

A smart choke valve system with a sand production sensor and onboard control system that automatically adjusts choke valve settings to maintain target sand production ranges, utilizing a locally stored well profile to quickly assess and respond to sand production measurements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If sand production is not monitored and regulated, then production rate can be maintained at high levels, but wellbore plugging and component erosion occur

Engineering Contradiction:

Improveproduction rateVSAvoidwellbore plugging and component erosion

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent implements a feedback control system where sand production measurements are continuously obtained by sensors, compared to target ranges, and used to automatically adjust choke valve settings. This closed-loop feedback mechanism allows the system to maintain high production rates while preventing sand production from reaching levels that cause wellbore plugging and component erosion.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The smart choke valve system performs self-adjustment based on onboard sand production measurements and locally stored well profiles. The system autonomously assesses sand production levels and modifies choke valve settings without requiring external control system intervention, enabling self-service regulation that prevents harmful sand production effects while maintaining optimal productivity.

Inventive Principle:

Principle #25Self-service

2Ease of operation

If external control systems are used for sand production regulation, then centralized monitoring is achieved, but system complexity and response time increase

Engineering Contradiction:

Improvecentralized monitoringVSAvoidcontrol system architecture

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent segments the control function by embedding intelligence directly in the choke valve system with onboard processors and locally stored well profiles. This segmentation allows the choke valve to independently assess sand production measurements and adjust settings without relying on complex external control systems, reducing overall system complexity while maintaining monitoring capabilities.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The smart choke valve system acts as an intermediary between sand production sensors and choke valve actuation. By incorporating onboard control logic and well profiles locally, it mediates the control function independently, eliminating the need for complex external control system infrastructure and enabling faster local response to sand production changes.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11333010B2Smart choke valve to regulate well sand production

Publication Date: 2022.05.17 SAUDI ARABIAN OIL CO

AI summary

A choke valve system operable to obtain sand production measurements from a sand production sensor, compare the sand production measurements to a target sand production range for a current setting of a choke valve, and, in response to determining that the sand production measurements are outside of the target sand production range, adjust the setting of the choke valve in an effort to bring the sand production of the well into a target sand production range, and generate an alert regarding the out of range sand production measurements and the corresponding adjustment of the choke valve.