Wellbore Fluid Flow Control via Dynamic Valve Adjustment
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Solution Overview
Problem
Current systems for controlling wellbore fluid flow out of an oil and gas wellhead struggle to maintain optimal flow rates and pressure, leading to potential wellbore collapse or clogging, and fail to effectively monitor and manage the composition of vent gases, which can result in erosion, washout, or rupture of equipment.
Innovation Solution
A system that includes sensors to measure fluid levels and pressure, an electronic controller to process data, and actuators to adjust valve positions, using PID algorithms to actively control the volumetric flow rate and pressure of wellbore fluids, and monitor vent gas composition to ensure safe and efficient operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the wellbore fluid flow rate is increased to maximize production, then production efficiency is improved, but the wellbore may collapse or equipment may be damaged due to excessive velocity
Solution Approach 1:
The system employs sensors to continuously monitor wellbore fluid flow rate and velocity, transmitting this data to a controller that automatically adjusts the valve position to maintain flow within safe limits. This closed-loop feedback control prevents wellbore collapse while maximizing production by dynamically optimizing flow conditions.
Solution Approach 2:
The patent implements dynamic control of the valve position based on real-time flow conditions. The system transitions from static flow control to dynamic adjustment, allowing the valve to respond continuously to changing wellbore conditions, thereby maintaining optimal flow rates that prevent collapse while maximizing production.
2Reliability
If the wellbore fluid flow rate is decreased to prevent wellbore collapse, then wellbore integrity is maintained, but production efficiency decreases due to reduced flow
Solution Approach 1:
The feedback control system continuously monitors flow rate and valve position, adjusting the valve to maintain flow within the optimal range that prevents collapse while maximizing production. This eliminates the need to operate at conservatively low flow rates by providing real-time adjustment capability.
Solution Approach 2:
The system dynamically changes the flow rate parameter based on real-time conditions, allowing operation at high flow rates when conditions permit and automatically reducing flow only when necessary to prevent collapse. This optimizes production while maintaining integrity.
3Device complexity
If manual monitoring and control methods are used to manage wellbore fluid flow, then system complexity is reduced, but the ability to respond to changing conditions and maintain optimal flow rates is insufficient
Solution Approach 1:
The control system is designed to autonomously monitor wellbore conditions and adjust valve position without requiring continuous manual intervention. The sensors and controller work together to self-regulate flow conditions, reducing operational complexity while significantly improving flow control efficiency and response to changing conditions.
Solution Approach 2:
The patent replaces manual mechanical control with an automated electronic control system that uses sensors and a controller to monitor and adjust flow conditions. This substitution of manual operation with automated systems reduces complexity in terms of human intervention while dramatically improving control precision and productivity.
4Manufacturing precision
If automated control systems with multiple sensors and actuators are implemented to precisely control flow rates, then flow control precision is improved, but device complexity increases
Solution Approach 1:
The controller is designed as a multi-functional device that performs multiple tasks: receiving sensor data, processing signals, calculating optimal valve position, and actuating the control valve. This universal controller consolidates multiple functions into a single device, achieving high flow control precision while minimizing the number of separate components and overall system complexity.
Solution Approach 2:
The system merges the sensor, controller, and actuator into an integrated control loop. By combining these components into a cohesive automated system with a single controller that manages the entire control process, the patent achieves precise flow control without the complexity of multiple independent control systems.
Data Source
AI summary
According to one aspect, a system is adapted to actively control one or more operating parameters associated with: a wellbore extending in a subterranean formation, and/or wellbore fluid flowing out of the wellbore via a wellhead. The system includes one or more sensors; an electronic controller adapted to receive from the one or more sensors measurement data; and a valve through which the wellbore fluid is adapted to flow. The valve is adapted to be in communication with the electronic controller. The active control of the at least one of the one or more operating parameters is adapted to facilitate: maintenance of the integrity of the wellbore, and/or enhancement of oil and/or gas production out of the wellbore. In one embodiment, the wellbore fluid flow is frac flow-back. In another aspect, a system is adapted to monitor vent gas separated from wellbore fluid flowing out a wellhead.