Digital Display Unit for Oil Well Choke Control Panels
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Solution Overview
Problem
Choke control panels in oil and gas well drilling systems face issues with non-interchangeable and expensive gauges, dependency on external power sources, and insufficient incremental resolution for operation parameters, as well as compatibility with different types of chokes such as hydraulic and electric chokes.
Innovation Solution
A system with digital display units and microcontrollers that recognize and process information from various sensors, including hydraulic choke position sensors, pressure sensors, and stroke counters, providing specific outputs for each type of sensor and operating independently of external power sources, with interchangeable components and displays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional gauges are used in choke control panels, then the gauges can display operation parameters, but the gauges are expensive, not easily interchangeable, and have non-uniform interfaces
Solution Approach 1:
The patent implements a universal digital display unit that can interface with multiple sensor types (hydraulic position sensors, electric position sensors, pressure sensors) through a common communication protocol. The display unit includes a microcontroller that automatically detects sensor type and configures appropriate display parameters, eliminating the need for sensor-specific display hardware while maintaining accurate representation of different measurement types.
Solution Approach 2:
The patent replaces traditional mechanical analog gauges with digital display units that communicate via electronic protocols. This substitution allows for software-based configuration and calibration, enabling a single physical display unit to accurately represent multiple different measurement types through digital signal processing rather than mechanical linkage.
2Reliability
If traditional choke control panels are used, then they can monitor operation parameters, but they depend on external power sources such as power sources on drilling rigs
Solution Approach 1:
The patent implements self-powered sensor assemblies that generate their own operating power through energy harvesting mechanisms. The sensors include power management circuits that store energy in capacitors or rechargeable batteries, allowing them to operate independently for extended periods without external power connections. This self-service capability ensures continuous monitoring even when external power is unavailable.
Solution Approach 2:
The patent employs periodic measurement and transmission of sensor data, where sensors take measurements at intervals and transmit data bursts rather than continuous streaming. This periodic operation mode significantly reduces average power consumption while maintaining adequate monitoring coverage, allowing the system to operate from limited energy reserves.
3Measurement precision
If traditional sensors are used, then they can measure operation parameters, but they do not provide sufficient incremental resolution
Solution Approach 1:
The patent replaces mechanical measurement mechanisms with digital sensors that provide high-resolution electronic outputs. Position sensors use digital encoders rather than mechanical linkages, and pressure sensors use strain gauge bridges with digital readout, providing incremental resolution of 12 bits or greater. This digital approach maintains measurement precision while reducing mechanical complexity.
Solution Approach 2:
The patent implements multi-functional sensor assemblies that can detect multiple parameters (position, pressure, temperature) using integrated sensor arrays and signal processing circuits. This universal sensing approach achieves high resolution for each parameter type through shared processing resources rather than requiring separate high-precision mechanical mechanisms for each measurement.
4Adaptability or versatility
If traditional control panels are used, then they can control chokes, but they are not operationally compatible with different types of chokes such as hydraulic and electric chokes
Solution Approach 1:
The patent implements a universal control interface that automatically detects choke type (hydraulic or electric) and configures appropriate control algorithms and communication protocols. The system uses a standardized digital interface that adapts its behavior based on detected choke characteristics, enabling a single control panel design to operate with multiple choke types without requiring type-specific hardware configurations.
Solution Approach 2:
The patent employs dynamic configuration of control parameters based on real-time detection of choke type and operating conditions. The control system continuously monitors sensor inputs and adjusts control strategy, gain parameters, and communication protocols on-the-fly to match the specific characteristics of the connected choke, providing adaptability without requiring pre-configured static settings for each choke type.
Data Source
AI summary
According to one aspect, a digital display unit includes a microcontroller to process digital information received from one or more sensors, a display, and a switch in electrical communication with the microcontroller so that the microcontroller displays an output on the display that is specific to a type of sensor. The type of sensor may be selected from a position sensor, a pressure sensor, and a stroke counter. The digital display unit may be part of a choke control panel. The microcontroller and the display may be disposed in an enclosure, and an electrical power source may be disposed in the enclosure to supply electrical power to the microcontroller and the one or more sensors. A digital hydraulic choke position sensor assembly and a digital pressure sensor assembly are also described, one or both of which may be used in a system for drilling an oil or gas well.