Smart Wellhead Ultrasonic Hanger Position Verification
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Solution Overview
Problem
Current methods for verifying the landing and locking of casing hangers within wellheads are manual and lack quantitative verification of concentricity, leading to potential safety issues and inefficiencies due to the need for corrective actions.
Innovation Solution
The implementation of sensors, such as ultrasonic sensors, on the wellhead to detect the precise location and locking of hangers, enabling real-time verification of landing and locking operations, and ensuring concentricity within the wellhead bore.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual tally process and manual measurement are used to verify hanger landing, then the operation is simple and does not require additional equipment, but the measurement precision and reliability of verification are insufficient
Solution Approach 1:
The patent replaces manual mechanical measurement methods with an automated sensor-based detection system. Sensors mounted on the wellhead assembly automatically detect the landing position of the hanger, converting mechanical positioning into electrical signals for precise measurement and verification, thereby eliminating manual measurement errors.
Solution Approach 2:
The wellhead assembly performs self-verification of hanger landing through integrated sensors. The system automatically detects and records landing parameters without requiring external manual intervention, enabling the equipment to verify its own operational state and provide real-time feedback on installation quality.
2Reliability
If manual counting of lockdown ring turns and vertical travel distance measurement are used, then the operation is simple and does not require additional equipment, but the reliability of lock down verification is insufficient
Solution Approach 1:
The patent replaces manual counting and measurement methods for lockdown verification with automated sensor systems. Sensors mounted on the wellhead assembly continuously monitor the position and movement of lockdown components, converting mechanical movements into precise electrical measurements that automatically verify lock-down completion and provide reliable verification data.
3Productivity
If manual methods are used for hanger installation verification, then the device complexity is low, but the productivity and installation efficiency are reduced due to lack of real-time verification
Solution Approach 1:
The patent implements real-time feedback mechanisms where sensors continuously monitor hanger installation parameters and immediately provide verification results. This feedback loop enables operators to confirm proper installation during the process itself, eliminating the need for separate verification steps and significantly improving installation productivity through immediate confirmation of correct positioning and lock-down.
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 approach enhances safety and efficiency by providing accurate, real-time verification of wellhead operations, reducing non-productive time and ensuring proper installation, thereby improving installation reliability and service quality.
Implementation Method 1
using the at least one ultrasonic sensor to detect when the hanger is at the target location
Data Source
AI summary
Smart wellhead assemblies with sensors for detecting positions of components within the bores of the wellhead assemblies are provided. In some instances, the sensors can be used to detect one or more of landing, locking, or concentricity of hangers, packoffs, or other internal wellhead components within bores. In one example, a method of installing a hanger within a wellhead includes lowering the hanger within the wellhead and using one or more sensors to detect when the hanger is at a target location. The method can also include activating a locking mechanism of the hanger and using the one or more sensors to detect when the locking mechanism has secured the hanger within the wellhead. Additional systems, devices, and methods are also disclosed.