Downhole Valve Automated Maintenance via Diagnostics Comparison
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Solution Overview
Problem
Manual scheduling of downhole valve maintenance in well systems is inefficient and ineffective due to unknown valve conditions and the large number of valves, leading to potential valve failures and reduced lifetime.
Innovation Solution
An automated preventive and predictive maintenance system that uses sensors to collect diagnostics data from downhole valves, compares data at different positions, and schedules maintenance operations based on valve condition analysis, including valve attribute data, well production attribute data, and fault detection attribute data, to predict valve failures and extend valve lifetime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual scheduling of maintenance operations is used, then operational simplicity is maintained, but maintenance efficiency and effectiveness deteriorate due to unknown valve conditions and large number of valves
Solution Approach 1:
The system enables automated self-monitoring and self-diagnosis of valve conditions through sensors and processors that continuously collect and analyze diagnostic data, eliminating the need for manual inspection and scheduling while improving maintenance efficiency
Solution Approach 2:
Manual mechanical scheduling operations are replaced with an automated electronic system comprising sensors, processors, and communication networks that monitor valve conditions and generate maintenance schedules automatically
2Reliability
If automated diagnostic data collection and analysis is implemented, then maintenance effectiveness is improved through predictive capabilities, but system complexity and initial operational burden increase
Solution Approach 1:
The system implements continuous feedback loops where sensors monitor valve conditions, processors analyze the diagnostic data, and maintenance schedules are adjusted based on actual valve health status, enabling predictive maintenance that improves reliability
Solution Approach 2:
The system performs preliminary diagnostic assessments and predicts potential valve failures before they occur, allowing maintenance operations to be scheduled proactively rather than reactively, thereby improving valve reliability
3Measurement precision
If frequent diagnostic data collection is performed, then valve condition monitoring precision is improved, but energy consumption and operational time increase
Solution Approach 1:
The system dynamically adjusts the frequency of diagnostic data collection based on valve operating conditions and risk assessments, collecting data more frequently when conditions warrant closer monitoring and less frequently when valves are stable, thereby optimizing monitoring precision while minimizing operational time loss
Data Source
AI summary
A method of automated preventive and predictive maintenance for downhole valves in a well system includes receiving, at a plurality of first times, first diagnostics data of the plurality of downhole valves, where each downhole valve is at a respective first valve position at a respective first time, and the diagnostics data represents a valve condition of each downhole valve at a respective valve position and at a respective time. The method also includes receiving, at a plurality of second times, second diagnostics data of the plurality of downhole valves, where each downhole valve has been moved from the respective first valve position at the respective first time to a respective second valve position at a respective second time. The first diagnostics data and the second diagnostics data are compared. Based on results of comparing, a valve maintenance operation is selected for each downhole valve.