Control Line Fabrication with Thermal Gas Purging
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Solution Overview
Problem
Existing methods for fabricating control lines for fiber optic deployment in hydrocarbon wells face contamination issues due to residual lubricants and solvents, which can prevent successful fiber pumping operations, especially with the restriction on using chlorinated solvents.
Innovation Solution
A fabrication process involving a thermal profile with multiple stages and pressure-controlled gas purging to remove contaminants from the inner bore of tubular segments, monitored in real-time to ensure cleanliness and prevent irreversible chemical transitions, allowing for the deployment of optical fibers without obstacles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fabrication methods are used to manufacture control lines, then production efficiency is maintained, but contamination from residual lubricants and solvents prevents successful fiber pumping operations
Solution Approach 1:
The patent applies preliminary action by performing thermal treatment and gas purging on the control line segments during fabrication, before fiber optic deployment. This pre-cleaning process removes lubricants and solvents from the inner surface, preventing contamination issues that would otherwise occur during subsequent fiber pumping operations.
Solution Approach 2:
The patent utilizes parameter changes by implementing a thermal profile with multiple stages at different temperatures. The process cycles through heating phases to vaporize contaminants and cooling phases to condense and remove them, transforming the physical state of residual lubricants and solvents to achieve effective cleaning without requiring chlorinated solvents.
2Reliability
If thermal processing is applied to remove contaminants, then internal cleanliness is improved, but risk of irreversible chemical transitions in the tubular material increases
Solution Approach 1:
The patent applies periodic action through a cyclic thermal profile that alternates between heating phases (to vaporize contaminants) and cooling phases (to condense and remove vapors). This periodic cycling achieves effective contaminant removal while limiting the duration of high-temperature exposure, thereby preventing irreversible chemical transitions in the tubular material.
Solution Approach 2:
The patent maintains continuity of useful action by implementing multiple sequential thermal cycles rather than a single prolonged heating process. Each cycle achieves partial contaminant removal, and the cumulative effect of multiple cycles achieves thorough cleaning while distributing thermal stress over time, reducing the risk of material degradation.
3Productivity
If gas flow rate is increased to improve contaminant removal efficiency, then cleaning speed increases, but energy consumption and process complexity increase
Solution Approach 1:
The patent implements feedback by monitoring the gas flow for the presence of vaporized contaminants and using this information to control the thermal processing duration. The process continues until contaminant removal is detected to be sufficient, at which point heating is terminated. This feedback mechanism optimizes energy consumption by avoiding unnecessary prolonged heating while ensuring adequate contaminant removal.
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 process ensures a high degree of internal cleanliness in control lines, enhancing the operational efficiency and cost-effectiveness by accurately controlling the removal of contaminants and reducing uncertainties, thereby facilitating successful fiber optic deployment in hydrocarbon wells.
Implementation Method 1
A gas is flowed through the passageway to purge or react with contaminants during a process cycle
Implementation Method 2
A fabrication process involving a thermal profile with multiple stages and pressure-controlled gas purging to remove contaminants
Implementation Method 3
The gas flow is monitored downstream to determine the amount of contaminants exiting the passageway
Data Source
AI summary
A control line assembly and technique for fabricating the control line assembly are disclosed. The assembly includes drawn tubular segments through which a gas is flowed to purge contaminants. The outflow of contaminants due to the gas flow is monitored and the gas flow can be controlled and terminated when a sufficient quantity of contaminants has been extracted. The gas flow can be combined with a heat treatment cycle to further extract contaminants. The heat treatment cycle can include multiple heating stages that can be controlled based on the monitoring of the exiting contaminants.