High Pressure Valve Control System for Manifold Overpressurization Prevention
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Solution Overview
Problem
In high-pressure wellbore drilling operations, the large number of valves involved increases the risk of overpressurization and 'deadhead' situations, leading to equipment damage and drilling delays, as operators struggle to correctly configure and monitor numerous valves during operations like hydraulic fracturing and cementing.
Innovation Solution
A system that includes processors to receive and analyze valve configurations, prevent proposed manipulations that would lead to overpressurization, and provide warnings or block actions that could result in an overpressured state, allowing operators to override safety checks for specific situations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of valves is increased to handle complex wellbore operations, then the system's adaptability and functionality are improved, but the risk of overpressurization and deadhead situations increases
Solution Approach 1:
The system continuously monitors the state of each valve and the operational status of pumps, providing real-time feedback to the control logic. This enables the system to detect potential overpressurization conditions by tracking valve positions and pump operations, and to alert operators or automatically adjust configurations before dangerous pressure builds up, thus maintaining reliability despite increased system complexity
Solution Approach 2:
A computer system acts as an intermediary between operators and the complex valve-pump system. This intermediary automatically calculates safe operating configurations, monitors actual system state, and prevents unsafe operations by blocking commands that would lead to overpressurization. This mediator layer handles the complexity of coordinating dozens of valves and pumps, reducing the burden on operators while maintaining system adaptability
2Device complexity
If operators manually configure each valve individually, then the system maintains simplicity in control architecture, but the time required for configuration and the risk of human error increase
Solution Approach 1:
The system pre-calculates and stores safe operating configurations for different wellbore operations. When an operator initiates an operation, the system automatically retrieves and applies the appropriate pre-configured valve settings, eliminating the need for manual configuration of each valve. This preliminary preparation of configurations significantly reduces setup time while maintaining simple control architecture through automated application of pre-validated settings
Solution Approach 2:
The system merges the configuration of multiple valves into a single automated operation. Instead of requiring operators to individually set each valve, the control system combines all valve positioning commands into one coordinated action based on the selected operation type. This merging of configuration tasks reduces both time and potential for human error while keeping the underlying control architecture simple and manageable
3Reliability
If safety checks are strictly enforced to prevent overpressurization, then equipment reliability is improved, but operational flexibility and productivity decrease
Solution Approach 1:
The safety check system dynamically adjusts its behavior based on the operational context. During normal operations, the system enforces strict safety checks to prevent overpressurization. However, when operators need to perform maintenance or emergency operations, the system can dynamically modify safety check parameters or temporarily disable specific checks through proper authorization procedures. This dynamic adaptability maintains equipment protection while preserving operational flexibility when needed
Data Source
AI summary
A method of servicing a request during high pressure wellsite pumping operations to manipulate a valve in a manifold system having a plurality of valves includes receiving a plurality of valve configurations that would result in an overpressured manifold system and comparing the request to a proposed valve configuration that would result from a proposed valve manipulation. The method includes determining whether a pump to the manifold system is operating. The method further includes determining whether the proposed valve manipulation inhibits a flow path between the pump and an outlet of the manifold system and would result in an overpressured manifold system. The method also includes in response to a determination that the proposed valve manipulation inhibits the flow path: blocking the proposed valve manipulation and presenting an operator with an override option.