Smart Choke Valve Feedback Control for Well Sand Production

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Solution Overview

Problem

Controlling hydrocarbon well production rates is challenging due to sand production, which can lead to premature well depletion, water breakthrough, and equipment wear, necessitating effective monitoring and regulation of sand production to maintain optimal production rates.

Innovation Solution

A smart choke valve system with a sand production sensor and onboard control system that automatically adjusts choke valve settings based on real-time sand production measurements to maintain target ranges, minimizing sand-related issues and optimizing production flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If production rate is increased to optimize hydrocarbon extraction, then productivity improves, but sand production increases causing well depletion and equipment wear

Engineering Contradiction:

Improvehydrocarbon production rateVSAvoidsand production

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system employs a closed-loop feedback mechanism where sand production sensors continuously monitor sand levels in the produced fluid, and the choke valve controller automatically adjusts the choke opening based on this feedback to maintain sand production within acceptable limits while optimizing hydrocarbon extraction

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The smart choke valve system performs self-regulation by automatically adjusting its own opening based on real-time sand production measurements, eliminating the need for manual intervention and enabling the system to self-optimize production while preventing sand-related damage

Inventive Principle:

Principle #25Self-service

2Device complexity

If manual monitoring and adjustment of choke valve is used, then device complexity is reduced, but response time to sand production changes increases

Engineering Contradiction:

Improvecontrol system complexityVSAvoidresponse time to sand production changes

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

The system replaces manual mechanical monitoring and adjustment with an automated electronic control system that uses sensors to detect sand production levels and electronically actuates the choke valve, significantly reducing response time while maintaining manageable complexity through modular architecture

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If choke valve opening is increased to maintain production rate, then productivity is maintained, but sand production increases causing plugging and erosion

Engineering Contradiction:

Improveproduction flow rateVSAvoidwellbore and equipment reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system dynamically adjusts the choke valve opening based on real-time sand production conditions rather than maintaining a fixed position, allowing the system to optimize production flow rate while adapting to changing sand production levels to prevent plugging and erosion damage

Inventive Principle:

Principle #15Dynamics

Data Source

PatentEP4121632B1Smart choke valve to regulate well sand production

Publication Date: 2024.08.07 SAUDI ARABIAN OIL CO

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AI summary

A choke valve system operable to obtain sand production measurements from a sand production sensor, compare the sand production measurements to a target sand production range for a current setting of a choke valve, and, in response to determining that the sand production measurements are outside of the target sand production range, adjust the setting of the choke valve in an effort to bring the sand production of the well into a target sand production range, and generate an alert regarding the out of range sand production measurements and the corresponding adjustment of the choke valve.