Wellbore Manifold Valve Configuration to Prevent Overpressurization
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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 complex operations like hydraulic fracturing and cementing.
Innovation Solution
A system that includes processors to receive and analyze valve configurations, prevent overpressurization by blocking inappropriate valve manipulations, and provide automated checks to ensure valves are set correctly, using a control system to monitor and manage valve states and configurations in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of valves in the manifold system is increased to handle complex wellbore operations, then the system's versatility and operational capability are improved, but the risk of overpressurization and deadhead situations increases due to the complexity of manually configuring and monitoring numerous valves
Solution Approach 1:
The system continuously monitors the state of each valve and the operational status of pumps, automatically comparing actual configurations against predefined safe configurations. This real-time feedback mechanism prevents overpressurization by detecting unsafe states and alerting operators or automatically adjusting valve positions to maintain system reliability while supporting complex operations
Solution Approach 2:
The system performs self-configuration by automatically setting valve positions based on the selected operational mode and predefined configurations. This eliminates manual valve-by-valve configuration, reducing human error while maintaining the versatility needed for complex wellbore operations across multiple manifolds and pumps
2Ease of operation
If operators manually configure each valve individually at the onset of an operation, then the system can be set up for specific operations, but the chances of improperly setting one or more valves increase as the number of valves increases
Solution Approach 1:
The system merges the configuration of multiple valves into a single automated operation. When an operator selects an operational mode, the system simultaneously configures all relevant valves across multiple manifolds according to predefined configurations, ensuring consistent and accurate setup without manual intervention for each individual valve
Solution Approach 2:
The system performs preliminary configuration by pre-defining safe valve configurations for various operational modes before operations begin. These predefined configurations are automatically applied when an operation is initiated, ensuring valves are correctly positioned before pumping starts, thereby preventing improper settings
3Ease of operation
If operators are charged with ascertaining the state of each valve and timing actuation to accomplish particular tasks, then operational control is maintained, but the large number of valves makes it difficult to track and respond to valve states and potential overpressured conditions
Solution Approach 1:
The system implements comprehensive feedback by continuously monitoring the state of each valve and pump operation, automatically tracking configurations across all manifolds. This centralized monitoring provides real-time visibility of valve states and detects potential overpressured conditions before they occur, eliminating the need for operators to manually track each valve while preventing information loss
Solution Approach 2:
The system provides universal monitoring capability that handles multiple functions simultaneously: tracking valve states, detecting unsafe configurations, preventing overpressurization, and coordinating pump operations across all manifolds through a single integrated interface, thereby maintaining operational control without overwhelming operators
4Extent of automation
If the system uses electronic control for valves, then automation and responsiveness are improved, but the large number of electronically controlled valves still requires operators to verify and time actuation for each valve
Solution Approach 1:
The system merges the control of multiple electronically controlled valves into a single coordinated action. When an operational mode is selected, the system simultaneously actuates all required valves according to the predefined configuration, eliminating the need for operators to individually time and verify each valve actuation while maintaining full electronic automation
Data Source
AI summary
An example method of setting a plurality of valves into a predetermined configuration for use in a wellbore servicing operation includes presenting a schematic display of the plurality of valves with a visual indication of the current state of each valve. The method also includes displaying a list of predefined valve configurations. The method further includes overlaying on the schematic display a predefined valve configuration selected from the list and visually indicating on the overlay the state of each valve if the predefined valve configuration is implemented.