MPFM Testing Augmentation via Virtual Flow Meter
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Solution Overview
Problem
Multiphase flow meters (MPFMs) in oil, gas, and water production systems often malfunction, leading to inaccurate or unavailable flowrate measurements, which can disrupt reservoir monitoring and production optimization.
Innovation Solution
A Testing Augmentation and Engineering Enhancement Manager (TASSMEEM) system using artificial intelligence and machine-learning models to verify MPFM performance, validate calibration, and provide recommended actions, including virtual flow meter (VFM) measurements when actual MPFM data is unreliable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If MPFM is used to measure flowrate, then production monitoring capability is improved, but measurement accuracy deteriorates when MPFM malfunctions
Solution Approach 1:
The patent introduces a virtual flow meter (VFM) as an intermediary system that uses machine learning models to estimate flowrates when the physical MPFM malfunctions. The VFM processes available sensor data and historical information to provide continuous flowrate estimates, bridging the gap between the faulty MPFM and the need for accurate production monitoring.
Solution Approach 2:
The system performs preliminary validation and verification assessments continuously to detect potential MPFM malfunctions before they cause complete measurement failure. By monitoring diagnostic parameters and comparing measurements against expected ranges, the system proactively identifies issues and switches to VFM estimation in advance of total system failure.
2Measurement precision
If traditional MPFM calibration schedule is followed, then calibration is performed periodically, but measurement accuracy deteriorates between calibration events
Solution Approach 1:
The system implements continuous feedback loops that monitor MPFM performance by comparing measurements against validation criteria and historical data. When degradation is detected through the verification and calibration assessments, the system triggers alerts and switches to VFM estimation, providing real-time feedback on measurement quality without waiting for the next scheduled calibration.
Solution Approach 2:
The VFM system provides self-service measurement capability that operates independently of the physical MPFM calibration schedule. When the MPFM is determined to be malfunctioning or uncalibrated, the VFM automatically takes over flowrate estimation using its own machine learning model trained on historical data, eliminating the need for manual intervention or strict adherence to calibration schedules.
3Reliability
If MPFM malfunction detection is implemented, then measurement reliability is improved, but system complexity increases
Solution Approach 1:
The verification and calibration assessment modules serve multiple functions: they detect MPFM malfunctions, validate measurement accuracy, trigger alerts, and determine when to switch between MPFM and VFM. This multi-functionality reduces the need for separate dedicated systems for each function, thereby limiting the increase in overall system complexity while improving reliability.
Data Source
AI summary
Methods and systems for a testing augmentation and engineering enhancement manager include: obtaining operating data, input diagnostic parameter data, and calibration data regarding a multi-phase flow meter (MPFM) in a production system, determining a verification assessment using a first machine-learning model comprising a functional status for the MPFM, and determining a validation assessment by comparing the current the historical flowrate measurement data. The methods and systems further include determining a virtual flow meter (VFM) measurement using a second machine-learning model based on a plurality of VFM inputs in the operating data, determining a calibration assessment comprising a health report identifying whether the MPFM requires a second recommended action, and transmitting, in response to the validation assessment, the VFM measurement, the verification assessment, and the calibration assessment, an action point for the MPFM. The action point includes an alarm for a procedure that adjusts or replaces the MPFM.