Integrated Flow Control Module for Reservoir Leak Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current flow control modules in hydrocarbon reservoirs are complex, large, and prone to leaks due to multiple connections and extensive arrangements of flow spools and machined blocks, leading to increased capital expenditure and maintenance costs.
Innovation Solution
A fully-integrated flow control module (FI-FCM) with a unibody structure that integrates a choke and flow meter, eliminating joints and reducing complexity by using a single-piece machined body, which can be manufactured through additive manufacturing or CNC, allowing for compact packaging and reduced footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional flow control modules use multiple connections and extensive arrangements of flow spools and machined blocks, then flow control functionality can be achieved, but device complexity increases and reliability decreases due to multiple potential leak paths
Solution Approach 1:
The patent merges multiple separate flow control components (choke, flow meter, sensors, valves) into a single integrated module with a unified body structure. This consolidation eliminates multiple connections between separate components, thereby reducing potential leak paths and improving reliability while maintaining all necessary flow control functions.
Solution Approach 2:
The integrated flow control module performs multiple functions (flow control, measurement, monitoring, and regulation) within a single device. The universal design allows the module to handle various flow control tasks that would traditionally require separate specialized components, reducing overall system complexity and connection points.
2Productivity
If traditional flow control modules use extensive arrangements of flow spools and machined blocks, then flow control functionality is achieved, but the footprint increases leading to higher capital expenditure
Solution Approach 1:
By combining multiple flow control functions into a single integrated module, the patent significantly reduces the space required compared to traditional separate arrangements of flow spools and machined blocks. The unified structure eliminates redundant components and connections, achieving compact packaging that maintains flow control efficiency while reducing the overall footprint.
3Ease of operation
If traditional flow control modules use multiple connections and extensive arrangements, then flow control functionality is achieved, but maintenance costs and time increase
Solution Approach 1:
The integrated module consolidates multiple components into a single unit, reducing the number of parts that require maintenance. This merging of components simplifies maintenance operations by eliminating the need to service multiple separate connections and assemblies, thereby reducing both maintenance time and costs while maintaining operational ease.
Data Source
AI summary
A system and method for a fully-integrated flow control module (FI-FCM) in a hydrocarbon reservoir is disclosed. The FI-FCM is a unibody structure or a single-piece machined body having a flow meter integrated to the unibody structure. A choke is to be associated within a provision of the FI-FCM that also has an entry flow path for reservoir fluid and an exit flow path for the reservoir fluid. The entry flow path and the exit flow path inside the unibody structure or the single-piece machined body. Fluid communication is enabled between the flow meter, which is upstream relative to the choke, and an entry flow path. The choke is to control flow between the entry flow path and the exit flow path.