Level Loop Control via Pressure Sensor and Turbine Flow Meter Comparison
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Solution Overview
Problem
Natural gas well sites face challenges in maintaining accurate liquid level control in separators, leading to potential hazards and inefficiencies due to slow response times of traditional level switches and the reliance on turbine flow meters, which can become inaccurate or stuck, resulting in costly manual interventions and resource wastage.
Innovation Solution
Implementing a comprehensive electric wellhead control system that includes a pressure sensor integrated with the dump valve to estimate liquid volumes based on pressure, comparing pressure outputs from the sensor and turbine flow meter to determine operational states, and using an electric actuator for precise valve control, reducing the need for manual interventions and improving response times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If traditional level switches are used for liquid level control, then the system structure is simple, but the response time is slow
Solution Approach 1:
The patent replaces traditional mechanical level switches with an electric actuator controlled by a controller that receives signals from level switches and uses an electric motor to drive the dump valve. This substitution of mechanical control with an electric control system significantly improves the response time of the liquid level control system while maintaining reasonable system complexity through the use of standard electric control components.
2Reliability
If turbine flow meters are used to measure liquid flow, then the measurement range is wide, but the reliability decreases due to sticking and inaccuracy
Solution Approach 1:
The patent implements a feedback control system where level switches detect the liquid level and send signals to a controller, which then controls the electric actuator to adjust the dump valve position. This closed-loop feedback mechanism ensures reliable liquid level control without the sticking problems of turbine flow meters, as the system continuously monitors and adjusts based on actual level conditions.
Solution Approach 2:
The controller automatically adjusts the dump valve position based on signals from the level switches, eliminating the need for manual intervention or complex flow measurement systems. The system serves itself by using simple level detection and automatic electric actuation to maintain proper liquid levels, improving reliability while keeping the control system manageable.
3Productivity
If manual intervention is used to service turbine flow meters, then the measurement accuracy can be restored, but the loss of time and productivity increases
Solution Approach 1:
The patent replaces the turbine flow meter with an electric actuator system controlled by level switches and a controller. This eliminates the mechanical components that require maintenance and calibration, thereby eliminating downtime for servicing while maintaining or improving operational efficiency through automated electric control.
4Measurement precision
If pressure sensors are integrated with dump valves, then the liquid level control accuracy improves, but the device complexity increases
Solution Approach 1:
The patent integrates the pressure sensor with the dump valve assembly, combining the measurement function with the control actuator. This merging of components improves liquid level measurement accuracy while minimizing the increase in device complexity by using a unified integrated design rather than separate discrete components.
Data Source
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AI summary
Example methods and apparatus for level loop control are disclosed. A disclosed example method includes determining via a sensor a first pressure of a liquid in a tank, determining via a turbine flow meter a second pressure of the liquid in the tank, determining if the first pressure is within a specified range of deviation from the second pressure to determine an operational state of the turbine flow meter, and transmitting a diagnostic message indicating that the turbine flow meter needs to be serviced based on the state of the turbine flow meter.