Well Fluid Flow Choke with Pressure-Feedback Actuation
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Solution Overview
Problem
Existing well drilling technologies lack efficient and precise control over well fluid flow, particularly in managed pressure and underbalanced drilling operations, where pressure regulation and fluid flow management are critical for safety and efficiency.
Innovation Solution
A remotely controlled flow choke system with a variable flow restrictor, actuator, and sensors, integrated with a control system to manage pressure differentials and flow rates, ensuring precise regulation of well fluid flow through a subterranean well.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flow choke is used to regulate pressure in the wellbore, then pressure control capability is improved, but the system lacks precise control and responsive adjustment
Solution Approach 1:
The patent incorporates pressure sensors that continuously monitor pressure differentials across the flow restrictor and provide real-time feedback to the control system. This feedback mechanism enables the controller to automatically adjust the flow restrictor position to maintain desired pressure levels, achieving precise and responsive pressure control without manual intervention.
Solution Approach 2:
The patent replaces manual mechanical adjustment of the flow choke with an automated electro-hydraulic or electro-pneumatic actuation system. The actuator is controlled by an electronic control system that receives input from pressure sensors, eliminating the need for manual operation and enabling precise, responsive control through electronic signals rather than mechanical adjustment.
2Ease of operation
If remote control capability is added to the flow choke, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single compact control unit that combines the flow restrictor, actuator, pressure sensors, and control electronics. This multi-functional integration enables remote control capability while minimizing the increase in overall system complexity by consolidating components rather than adding separate systems.
Solution Approach 2:
The control system is designed to automatically regulate flow based on pressure feedback without requiring external intervention. The system self-adjusts the flow restrictor position in response to pressure changes, eliminating the need for complex manual control mechanisms or continuous external monitoring, thereby achieving remote control with minimal added complexity.
3Measurement precision
If pressure sensors and control systems are integrated with the flow choke, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent merges the pressure sensors, actuator, and control electronics into an integrated assembly that is directly mounted on or incorporated with the flow choke body. This physical integration reduces the number of external connections and mounting requirements, thereby improving measurement precision through closer proximity to the flow path while minimizing the increase in overall device complexity through compact design.
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
Enables accurate and responsive control of well fluid flow, maintaining desired pressures and flow rates, reducing the risk of fluid loss and wellbore instability, and facilitating safer and more efficient drilling operations.
Implementation Method 1
a variable flow restrictor (42) configured to restrict flow through a flow passage (38)
Implementation Method 2
The actuator (50) displaces a thrust rod or stem (52) connected to the closure member (44), to thereby vary the flow area A between the closure member and the seat (46)
Implementation Method 3
A stem seal (64) may sealingly engage the stem (52) and isolate the actuator (50) from fluid pressure in the flow passage (38)
Implementation Method 4
measuring a pressure differential across the flow restrictor
Data Source
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AI summary
A choke can include a variable flow restrictor, external ports in communication with a flow passage respectively upstream and downstream of the flow restrictor, and sensor(s) in communication with the external ports. A method can include flowing a well fluid through a flow passage in a body of a choke including a variable flow restrictor, measuring a pressure differential between external ports in communication with respective upstream and downstream sides of the flow restrictor, and operating the flow restrictor, thereby varying a restriction to the flow through the flow passage, in response to the measured pressure differential. A well system can include a well fluid pump, a flow choke including a variable flow restrictor operable by an actuator that includes a displaceable stem and a stem seal that isolates the actuator from the well fluid in the flow choke, and a control system that operates the actuator.