Well Orifice Curve Control for Target Flow Rate Compliance

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Solution Overview

Problem

Existing well operations often deviate from optimal flow rates, leading to non-compliant wells that affect well life and hydrocarbon recovery, necessitating frequent manual adjustments and potential void replacement issues.

Innovation Solution

A method and system using orifice performance curves to monitor and adjust well operations in real-time, determining actual fluid flow rates and differential pressures to bring non-compliant wells into compliance, reducing the need for manual interventions and optimizing well performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual monitoring and adjustment of well flow rates is performed, then wells can be operated at target rates, but frequent manual interventions are required and operational efficiency decreases

Engineering Contradiction:

Improvewell compliance with target rateVSAvoidtime for manual adjustments

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system enables automatic self-monitoring and self-adjustment of well flow rates through automated differential pressure measurement, rate calculation, and choke position control, eliminating the need for continuous manual intervention while maintaining compliance with target rates

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system implements continuous feedback loops where actual flow rates are measured via differential pressure, compared against target rates, and automatically adjusted by controlling choke positions to bring non-compliant wells back into compliance, creating a closed-loop control system

Inventive Principle:

Principle #23Feedback

2Productivity

If automated real-time monitoring using orifice performance curves is implemented, then operational efficiency improves and manual adjustments are minimized, but system complexity increases

Engineering Contradiction:

Improveoperational efficiencyVSAvoidmonitoring system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system replaces manual mechanical monitoring and adjustment processes with automated electronic measurement and control systems that use differential pressure sensors, orifice performance curve databases, and automated choke control to monitor and adjust well rates in real-time

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system introduces a centralized monitoring and control platform that acts as an intermediary between wellhead sensors and choke actuators, processing differential pressure measurements through orifice performance curves to calculate actual rates and automatically adjusting choke positions to maintain compliance

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If frequent manual rate testing and adjustments are performed, then well compliance can be maintained, but well life is shortened and hydrocarbon recovery is reduced

Engineering Contradiction:

Improvewell complianceVSAvoidwell life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The automated system continuously monitors and self-adjusts well flow rates without requiring physical well interventions, thereby extending well life by reducing mechanical stress and operational disruptions while maintaining compliance with optimal production rates

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system ensures continuous compliance with target rates through real-time monitoring and automatic adjustment, eliminating the intermittent disruptions caused by manual rate testing and adjustments, thereby maximizing hydrocarbon recovery over the well's productive life

Inventive Principle:

Principle #20Continuity of useful action

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 maintains optimal well operations, minimizes manual adjustments, and enhances hydrocarbon recovery by ensuring compliance with target flow rates, thereby prolonging well life and improving reservoir performance.

Implementation Method 1

obtaining, for each target rate, a corresponding target differential pressure using orifice performance curves stored in a database established for the plurality of wells

Methodology Applied

Scientific EffectOrifice flow measurement principle: Pressure Drop

Data Source

PatentUS12480389B2Method and system for operating wells at optimum rates using orifice performance curves

Publication Date: 2025.11.25 SAUDI ARABIAN OIL CO

AI summary

A method for operating water wells at optimum rates involves obtaining, for each of a multitude of wells, a target rate of fluid flow, obtaining, for each target rate of fluid flow, a corresponding target differential pressure using orifice performance curves stored in a database associated with the multitude of wells, and monitoring each of the multitude of wells for noncompliance. Noncompliance is determined based on a rate deviation of an actual rate of fluid flow from the target rate of fluid flow exceeding a predetermined threshold. The rate deviation is determined based on a differential pressure deviation of a measured differential pressure corresponding to the actual rate of fluid flow from the target differential pressure corresponding to the target rate of fluid flow. The method further involves bringing a non-compliant well of the multitude of wells into compliance.