Modular Actuator Mounting for Flow Control Systems
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Solution Overview
Problem
Existing wellhead systems require extended downtime for actuator changes, and are excessively costly for low-pressure, low-flow mineral extraction operations, particularly in shale-play hydrocarbons.
Innovation Solution
A modular flow control system that allows seamless transition between manual and powered actuators without interrupting operations, using a combination of durable and less expensive materials for components based on stress exposure, reducing overall system costs and minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional flow control devices are used, then actuator changes can be performed, but extended downtime is required for actuator replacement
Solution Approach 1:
The actuator mounting components are designed as separable, modular elements that can be independently removed and replaced. The mounting bracket and associated components are structured to allow the actuator to be detached from the flow control device without requiring removal of the entire assembly, enabling quick swapping while maintaining system integrity.
Solution Approach 2:
A standardized mounting interface acts as an intermediary between the actuator and the flow control device. This intermediate mounting structure allows different actuator types to be attached to the same flow control device through a common interface, facilitating rapid replacement without modifying the core flow control components.
2Reliability
If expensive flow control devices are used, then high pressure and flow rate control is achieved, but cost becomes prohibitive for low pressure, low flow rate operations
Solution Approach 1:
The system allows changing operational parameters by replacing only the actuator component rather than the entire flow control device. For low pressure, low flow rate operations, a simpler, less expensive actuator can be installed on the same flow control body, thereby adapting the system's performance characteristics and cost structure to match the specific operational requirements without requiring a complete system replacement.
Data Source
AI summary
A system includes a wellhead system, and a flow control system coupled to the wellhead system. The flow control system includes a housing with a flow path between an inlet and an outlet. The flow control system also includes a flow control device disposed in the housing along the flow path. The flow control system also includes a bonnet assembly surrounding the flow control device. The bonnet assembly is configured to selectively mount one of a manual actuator and a powered actuator to actuate the flow control device.