Sensor-Guided Control Line Clamp Installation Near the Wellbore
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Solution Overview
Problem
The installation of control line clamps on oil and gas wells is labor-intensive and poses safety risks due to the need for manual assembly in close proximity to the wellbore, known as the 'red zone', where personnel are at high risk of injury.
Innovation Solution
A control line clamp installation system that includes a first and second load plate, a retention lid positioner, a sensor system, and an indication device to automate the positioning and pressing of clamp members around the tubular string, reducing the need for manual assembly and minimizing personnel presence in the red zone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wrap-around control line clamps are installed manually by positioning clamp sections around the tubular and attaching fasteners, then the clamp can be securely fastened to the tubular, but the installation becomes labor-intensive and requires personnel to be in the red zone at high risk of injury
Solution Approach 1:
The system enables self-service installation where the automated clamp application device positions and secures clamps without requiring personnel to manually handle clamp sections in the red zone. The device autonomously performs the securement function while personnel operate from a safe distance, eliminating the harmful exposure to injury risk while maintaining reliable clamp attachment.
Solution Approach 2:
The manual mechanical assembly of positioning clamp sections and attaching fasteners is replaced by an automated mechanical system. The automated device uses mechanical actuators and positioning mechanisms to apply clamps securely, substituting human manual labor with automated machinery that eliminates personnel exposure to the dangerous red zone while achieving the same securement result.
2Ease of operation
If personnel manually assemble and install control line clamps in close proximity to the wellbore, then the installation can be performed with simple equipment, but the safety risk to personnel increases significantly
Solution Approach 1:
An automated clamp application device serves as an intermediary between the operator and the clamp installation process. The operator controls the device from a safe distance, and the intermediary device performs the actual clamp application in the red zone. This intermediary eliminates direct personnel exposure to hazards while maintaining operational control and simplicity through remote operation.
Solution Approach 2:
The simple manual mechanical installation process is replaced by an automated mechanical system that performs clamp application. The automated device incorporates positioning mechanisms, actuators, and control systems that maintain ease of operation through standardized interfaces while eliminating the need for personnel to physically be in the dangerous proximity to the wellbore.
3Object-affected harmful factors
If automated systems are introduced to reduce personnel presence in the red zone, then safety is improved, but the device complexity increases
Solution Approach 1:
The automated clamp application device is segmented into modular functional components: positioning system, clamp holding mechanism, actuation system, and control unit. Each module performs a specific function and can be independently maintained or replaced. This segmentation manages device complexity by breaking down the automated system into manageable, standardized subsystems that reduce the burden of operation and maintenance despite the overall automation.
Data Source
AI summary
An installation system for installing a control line clamp onto a tubular string includes a first load plate, a second load plate that is offset from the first load plate, the first and second load plates being configured to engage a first clamp member and a second clamp member, respectively, positioned on a tubular string, a retention lid positioner configured to couple the retention lid with the first and second clamp members, a sensor system configured to provide feedback signals representing that the first and second load plates are received around the tubular and aligned with a control line, the retention lid is positioned at a target location and aligned with the control line, and the first and second load plates are adducted together to press the first and second clamp members together, and an indication device configured to indicate a state of the installation system.