Explosion-Proof Choke Control via Air Purge and Segmentation
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Solution Overview
Problem
Electric chokes are limited in use at wellheads and hazardous areas due to safety concerns related to electrical components generating heat and sparks that can ignite flammable gases, necessitating the development of a safe and reliable electric control system for pressure control devices.
Innovation Solution
A pressure control system comprising a choke assembly with an explosion-proof motor, air purge system, remote and local operating panels, and actuators, designed to operate safely in hazardous environments by using air-tight housings and explosion-proof components to prevent ignition, allowing for remote and manual control of pressure within a wellbore.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If electric components are used in hazardous areas, then remote control capability and operational consistency are improved, but safety risk increases due to potential heat and spark generation that can ignite flammable gases
Solution Approach 1:
The system divides the control function into two separate locations: an electric control panel positioned in a safe area away from hazardous gases, and a hydraulic actuator located at the choke in the hazardous area. The electric panel generates control signals, while the hydraulic actuator executes the physical action using hydraulic fluid transmitted through sealed conduits. This segmentation isolates electrical components from flammable atmospheres, eliminating ignition risks while preserving remote control capability.
Solution Approach 2:
Hydraulic fluid serves as an intermediary medium between the electric control panel and the choke actuator. The electric panel controls a hydraulic valve, which directs hydraulic fluid through sealed lines to actuate the choke mechanism. This intermediary transmission system allows electrical signals to control hydraulic actions at a distance, maintaining operational consistency while preventing direct contact between electrical components and hazardous gases.
2Productivity
If electric chokes are used at the wellhead, then operational efficiency and digital capabilities are improved, but compliance with safety standards becomes difficult to achieve
Solution Approach 1:
The system segments the choke control into an electric control panel located in a safe area that provides digital capabilities and operational efficiency, and a hydraulic actuator at the wellhead that ensures compliance with safety standards. The electric panel handles signaling and control functions, while the hydraulic actuator performs the physical choke adjustment at the wellhead, maintaining both productivity and safety compliance.
Solution Approach 2:
The invention employs a hydraulic transmission system to connect the electric control panel to the choke actuator. Hydraulic fluid is used to transmit force and motion through sealed conduits, allowing the electric panel to control the choke at the wellhead without electrical components being present in the hazardous area. This hydraulic intermediary maintains operational efficiency while ensuring compliance with safety standards for hazardous locations.
3Object-affected harmful factors
If manual chokes are used, then safety in hazardous areas is improved by eliminating electrical components, but operational complexity and exposure to hazardous environments increase
Solution Approach 1:
The system segments the control functions so that the operator interacts with an electric control panel in a safe area, while the hydraulic actuator performs the choke adjustment at the wellhead. This eliminates the need for operators to physically handle choke components in hazardous environments, reducing exposure to harmful factors while maintaining safety by keeping electrical components away from flammable gases.
Solution Approach 2:
The invention replaces the manual mechanical operation of the choke with a hydraulic actuation system. Instead of the operator directly manipulating the choke plate through mechanical means in the hazardous area, the operator uses an electric control panel to activate a hydraulic valve, which directs hydraulic fluid to move the choke plate. This substitution eliminates operator exposure to hazardous environments while maintaining precise control capability.
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
The system meets Class 1, Division 1 standards, enabling safe and reliable operation of electric chokes in hazardous areas by preventing the entry of hazardous gases into electronic components and ensuring the system's safety and effectiveness in controlling pressure within wellbores.
Implementation Method 1
air from the air purge system is circulated through the housing
Implementation Method 2
a motor in an explosion-proof housing coupled to the choke plate and operable to adjust the orifice through the choke plate
Implementation Method 3
a position indicator coupled to the choke plate for sensing the orifice opening and providing feedback of the choke plate position to the motor
Data Source
AI summary
An apparatus operable is a hazardous area for controlling a choke assembly includes an air source, an air purge system in fluid communication with the air source, a remote operating panel receiving data from at least one remotely located wellbore sensor, a local operating panel in electronic communication with the remote operating panel, and an actuator coupled to the assembly to control pressure within the wellbore. The remote operating panel includes an airtight housing in fluid communication with the air purge system, wherein air from the air purge system is circulated through the housing, a plurality of operator controls for manually controlling operation of the pressure control assembly, and a display for visually displaying values of data received from the wellbore sensor. The local operating panel includes an airtight panel housing in fluid communication with the air purge system, wherein air from the air purge system is circulated through the panel housing, and a local operator controller having an operator interface for receiving operator instruction input into the local panel, and operable to receive operator instructions from the remote panel and transmit operator instructions. The actuator includes a motor in an explosion-proof housing coupled to the choke plate and operable to adjust the orifice through the choke plate, wherein the motor receives electronic communication of the operator instructions transmitted by the local operator controller, and a position indicator coupled to the choke plate for sensing the orifice opening and providing feedback of the choke plate position to the motor.