Self-automated choke valve with hydraulic control

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Solution Overview

Problem

Conventional methods for controlling fluid production in hydrocarbon wells are prone to human errors and require frequent manual interventions, leading to inefficient operations and increased non-productive time due to fluctuating well performance and the need for manual adjustment of choke valves.

Innovation Solution

A self-automated adjustable choke valve system integrated with a smart module and hydraulic control unit, which uses upstream and downstream pressure sensors and Inflow Performance Relationship and Vertical Lift Performance Relationship curves to automatically adjust the choke size in real-time, maintaining a predetermined production rate without human intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual intervention is used to adjust choke valve settings, then operational flexibility is maintained, but human errors increase and non-productive time increases

Engineering Contradiction:

Improveoperational reliabilityVSAvoidautomation level

Core Design Contradiction:

ReliabilityVSExtent of automation

Solution Approach 1:

The system enables self-service automation where the choke valve adjusts its own settings based on real-time pressure data from upstream and downstream sensors. The smart module processes this data and automatically actuates the choke valve without human intervention, eliminating human errors while maintaining operational flexibility through automated decision-making algorithms

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system implements continuous feedback loops where pressure sensors monitor upstream and downstream conditions, the smart module analyzes this feedback data against target production rates, and automatically adjusts choke valve settings in response. This closed-loop feedback mechanism ensures reliable automated operation that adapts to changing well performance conditions

Inventive Principle:

Principle #23Feedback

2Productivity

If frequent rate testing is conducted to maintain production targets, then production rate accuracy is improved, but time consumption and operational costs increase

Engineering Contradiction:

Improveproduction rate accuracyVSAvoidnon-productive time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system maintains continuous automated monitoring and adjustment of choke valve settings based on real-time pressure data, eliminating the need for discontinuous manual rate testing. The smart module continuously processes sensor data and makes incremental adjustments to maintain target production rates, converting intermittent testing into continuous optimized operation

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system replaces manual mechanical testing procedures with automated electronic sensing and control. Pressure sensors continuously monitor well conditions, and the smart module electronically controls choke valve positioning, substituting time-consuming manual testing and adjustment with rapid automated measurement and actuation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If manual choke adjustment is performed based on historical trends, then system complexity is reduced, but measurement precision and response time deteriorate

Engineering Contradiction:

Improvecontrol system complexityVSAvoidpressure measurement precision

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The smart module serves multiple functions: it processes pressure data from sensors, compares readings against target production rates, determines optimal choke settings, and actuates the choke valve. This multi-functional device consolidates what would otherwise require separate testing equipment, analysis tools, and manual adjustment mechanisms into a single integrated system

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This system reduces operational costs, minimizes human errors, and maintains consistent well production by automatically adjusting the choke valve to meet production targets, thereby improving efficiency and reducing non-productive time.

Implementation Method 1

The hydraulic control unit hydraulically actuates the choke valve. The controller may manage a transmission of hydraulic pressure from the hydraulic control unit to actuate the choke valve based on the generated commands.

Methodology Applied

Scientific EffectHydraulic pressure: Hydraulic Press

Data Source

PatentUS11814913B2System and method for use of a self-automated adjusted choke valve

Publication Date: 2023.11.14 SAUDI ARABIAN OIL CO

AI summary

A choke valve is coupled to a Christmas tree on a wellhead. A smart module is coupled to the choke valve. A hydraulic control is coupled to the smart module and the choke valve. The hydraulic control unit hydraulically actuates the choke valve. A first sensor is attached upstream of the choke valve and a second sensor is attached downstream of the choke valve. The first sensor measures an upstream pressure and the second sensor measures a downstream pressure. A controller is coupled to the smart module and the hydraulic control unit. The smart module receives the upstream pressure, the downstream pressure, and well data to generate commands to adjust a choke size of the choke valve corresponding with a required production rate of a well. The controller manages a transmission of hydraulic pressure from the hydraulic control unit to actuate the choke valve based on the generated commands.