Programmable Wellbore Relief Valves for Dynamic Casing Pressure
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Solution Overview
Problem
Existing wellbore casing pressure management systems lack the ability to dynamically adjust set-points in response to changing well conditions over the production life, leading to potential catastrophic failures due to overpressure, corrosion, and geological events, especially in aging fields with varying reservoir pressures.
Innovation Solution
A wellbore integrity monitoring system with programmable pressure relief valves and a processor/controller that adjusts set-points based on real-time pressure measurements, enabling remote monitoring and control, and includes a data storage and communication module for proactive management of casing pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed set-point pressure relief valves are used, then the system is simple and reliable, but it cannot adapt to changing well conditions over production life
Solution Approach 1:
The patent implements a programmable pressure relief valve with a processor that dynamically adjusts the set-point pressure based on real-time well conditions. The system transitions from static fixed set-points to dynamic adjustable set-points, allowing the relief valve to adapt to changing reservoir pressures, temperature variations, and well integrity requirements throughout the production lifecycle.
Solution Approach 2:
The system incorporates pressure sensors that continuously monitor casing pressure and provide feedback to the processor. This feedback loop enables the processor to compare actual pressure readings against the programmed set-point and automatically activate the relief valve when necessary, creating a closed-loop control system that responds to real-time well conditions.
2Productivity
If visual inspection of pressure gauges is performed, then no additional electronic systems are required, but frequent manual intervention is needed and response time is delayed
Solution Approach 1:
The system enables self-monitoring and self-activation of the pressure relief valve through electronic sensors and a processor. The pressure sensor continuously monitors casing pressure and automatically triggers the relief valve when the set-point is exceeded, eliminating the need for manual visual inspection and enabling immediate response to pressure events without human intervention.
Solution Approach 2:
The patent replaces manual visual inspection of mechanical pressure gauges with electronic pressure sensors and a digital processing system. This substitution transitions from mechanical-analog monitoring to electronic-digital monitoring, enabling automated decision-making and faster response times while reducing the need for human intervention.
3Adaptability or versatility
If simple rupture disks are used, then the system is simple and cost-effective, but it provides only single set-point protection and cannot be adjusted
Solution Approach 1:
The patent implements a programmable pressure relief valve where the set-point pressure can be modified through software programming rather than being fixed at manufacturing. The processor stores adjustable set-point values in memory that can be changed remotely or on-site, allowing the system to adapt to different production stages, reservoir conditions, and well integrity requirements without replacing the entire relief valve hardware.
4Adaptability or versatility
If multiple safety valves with different set points are installed, then broader pressure range protection is provided, but system complexity and cost increase
Solution Approach 1:
The patent implements a single programmable pressure relief valve that can be configured with different set-point values through software programming. This multi-functional approach allows one valve to replace multiple fixed set-point valves, as the same hardware can be reprogrammed to provide different pressure thresholds based on changing well conditions, reducing the number of physical components while maintaining broad pressure range protection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system allows for proactive adjustment of casing relief pressures, reducing the risk of catastrophic failures, extending well life, and optimizing maintenance schedules through remote monitoring and data analysis.
Implementation Method 1
a pressure sensor which is arranged to measure fluid pressure in the casing annulus
Implementation Method 2
a fluid flow line which extends from the casing annulus to a vent, a pressure relief valve which is provided in the fluid flow line... allowing flow of fluid along the fluid flow line from the casing annulus to the vent
Data Source
AI summary
A remotely operable Wellbore Integrity System for large scale monitoring of annular pressure on production wells. The system enhances the integrity of annular casing strings associated with mineral wellbores. The system can be autonomously deployed and has programmable pressure relief valves enabling remote adjustment of the casing pressure.