Variable-Aperture Cleaning Head for Conduit Blockage Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cleaning systems for fluid conduits in hydrocarbon production face challenges such as the need for large and heavy equipment, limitations in flexibility and deployment depth, and difficulties in distinguishing between tension variations caused by fluid flow rate changes and blockages, especially in deviated or convoluted paths, leading to inefficiencies and potential damage.
Innovation Solution
A cleaning head with a variable aperture valve that regulates differential pressure and tension variations, allowing for controlled fluid flow rates and thrust, and a composite tubing system with a jetting and bypass fluid mechanism to enhance debris removal efficiency and reduce equipment size and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coiled tubing injection methods are used for cleaning fluid conduits, then cleaning capability is improved, but equipment size and weight increase substantially
Solution Approach 1:
The invention extracts the cleaning function from the heavy coiled tubing injector system by using a piggyback cleaner that travels through the existing fluid conduit. The cleaner is propelled by fluid pressure differential created by blocking the conduit, eliminating the need for substantial ground-based injection equipment while maintaining effective cleaning capability.
Solution Approach 2:
The invention introduces a fluid intermediary to transfer energy for propelling the cleaner. By blocking the fluid conduit and creating pressure differential, the system uses the process fluid itself as a mediator to drive the cleaner through the conduit, replacing the need for mechanical injection equipment.
2Ease of operation
If coiled tubing is made rigid to enable injection into wellbores, then injection capability is improved, but flexibility and adaptability to deviated paths deteriorate
Solution Approach 1:
Instead of forcing rigid tubing into the conduit, the invention inverts the approach by using a flexible piggyback cleaner that is propelled by fluid pressure. The cleaner's flexible body naturally conforms to deviated and convoluted paths while the fluid pressure provides the injection force, eliminating the contradiction between rigidity and flexibility.
Solution Approach 2:
The invention uses hydraulic pressure differential created by blocking the fluid conduit to propel the cleaner through the wellbore. This pneumatic-hydraulic approach replaces mechanical injection of rigid tubing, allowing the cleaner to navigate deviated paths flexibly while still achieving deep wellbore access.
3Productivity
If fluid flow rate is increased to improve cleaning efficiency, then productivity is improved, but tension variations make blockage detection more difficult
Solution Approach 1:
The invention incorporates sensors that provide feedback on cleaner position, differential pressure, and flow rate. This feedback mechanism allows real-time monitoring to distinguish between tension variations caused by high flow rates and those indicating blockages, enabling blockage detection even during high-productivity cleaning operations.
Solution Approach 2:
The cleaner serves multiple functions simultaneously: it cleans the conduit while also acting as a sensing platform for detecting blockages. The integrated sensors monitor pressure differential and flow rate, providing dual functionality that resolves the contradiction between cleaning efficiency and detection capability.
4Area of stationary object
If equipment is made compact to reduce footprint, then ease of deployment is improved, but cleaning thrust and power may be insufficient
Solution Approach 1:
The cleaner is designed to be self-propelled by the fluid pressure differential created when blocking the conduit. Instead of requiring external heavy-duty propulsion equipment, the system uses the process fluid itself to provide the cleaning thrust, achieving compact equipment size while maintaining sufficient cleaning force.
Solution Approach 2:
The invention replaces mechanical propulsion systems with a fluid pressure-based propulsion mechanism. By using hydraulic pressure differential to drive the cleaner, the system eliminates the need for heavy mechanical drive mechanisms while maintaining effective cleaning thrust.
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 enables efficient cleaning with reduced equipment footprint, increased fluid flow rates, and improved detection of blockages, minimizing tubing deformation and damage, while being suitable for various conduit geometries.
Implementation Method 1
a variable aperture valve defining a variable aperture which varies in response to a variation in fluid flow rate through the bypass fluid flow path
Implementation Method 2
pumping bypass fluid along an annulus through the bypass fluid flow path to provide a thrust on the cleaning head
Implementation Method 3
pumping jetting fluid through the tubing and out of one or more jetting apertures into the fluid conduit to remove debris, scale and accumulated matter such as wax and/or hydrates
Data Source
AI summary
A cleaning head for a cleaning system for use in cleaning a fluid conduit for transporting hydrocarbons and/or a fluid conduit in a hydrocarbon wellbore, comprises a body defining an outer surface having a cross-section which is configured to match, or be comparable to, a cross-section of an inner surface of the fluid conduit. The body defines a jetting fluid flow path extending from a jetting fluid input port to a jetting fluid output port, and wherein the body defines a bypass fluid flow path extending from a bypass fluid input port to a bypass fluid output port, the bypass fluid flow path being separate from the jetting fluid flow path. The cleaning head comprises a jetting head defining one or more jetting apertures, wherein the jetting head is coupled to the jetting fluid output port so that the one or more jetting apertures are in fluid flow communication with the jetting fluid flow path. The cleaning head comprises a variable aperture valve in the bypass fluid flow path, the variable aperture valve defining a variable aperture which varies in response to a variation in fluid flow rate through the bypass fluid flow path.