Wellhead Flow Block Lubricator for Reliable Plunger Travel
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Solution Overview
Problem
Existing wellhead lubricator systems face issues with plunger failure due to incomplete descent into the wellbore when the flow valve or ball valve is not reset, leading to inefficient production and potential plunger malfunction.
Innovation Solution
The integration of a wellhead flow block lubricator assembly with a plunger catcher mechanism and adjustable flow control mechanisms, including choke mechanisms and flow restrictors, ensures controlled fluid flow to facilitate complete plunger ascent and descent, utilizing sensors for optimal plunger positioning and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flow valve or ball valve is not reset, then plunger cannot descend back into wellbore, but plunger failure occurs due to incomplete descent
Solution Approach 1:
The system uses the plunger's own upward motion and the associated fluid flow to automatically reset the flow valve and ball valve mechanisms, eliminating the need for separate reset operations. The plunger's ascent creates pressure differential that self-resets the valves, ensuring reliable plunger descent without additional complexity.
Solution Approach 2:
The system incorporates sensors that detect plunger position and provide feedback to control the flow control mechanisms. This feedback ensures the valves are reset at the appropriate moment during plunger ascent, maintaining reliable operation while managing system complexity through intelligent control.
2Productivity
If flow control mechanisms are added to control plunger movement, then plunger lift efficiency is improved, but device complexity increases
Solution Approach 1:
The system uses fluid pressure differentials created by the plunger's movement to control flow through the wellhead. The upward motion of the plunger creates pressure that opens valves and directs flow, while downward motion creates negative pressure that closes valves. This hydraulic control achieves efficient plunger lift without complex mechanical control systems.
Solution Approach 2:
The system changes flow parameters (pressure, flow rate) dynamically based on plunger position and well conditions. By adjusting these parameters through controllable valves and flow restrictors, the system optimizes plunger lift efficiency while managing complexity through parameter-based control rather than mechanical complexity.
3Productivity
If choke mechanism is used to restrict fluid flow, then plunger ascent is enhanced, but flow control precision is reduced
Solution Approach 1:
The system uses dynamically adjustable flow control mechanisms that can be modified based on real-time well conditions and plunger performance. The choke mechanisms and flow restrictors can be adjusted to optimize production enhancement while maintaining sufficient flow control precision through active management rather than fixed restrictions.
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
Enhances plunger lift efficiency by ensuring consistent plunger travel, reducing premature failure, and optimizing production by controlling fluid flow dynamics within the wellhead system.
Implementation Method 1
the appropriate differential pressure across the plunger is essential for successful plunger cycles to lift liquids to the surface
Implementation Method 2
Control over the flow of gas and fluids through the lubricator makes it possible to control the landing position of the plunger
Implementation Method 3
the natural gas energy propelling the plunger to the surface
Data Source
AI summary
A unitary wellhead flow block lubricator assembly includes a unitary body and flow passageways that extend through the unitary body. Various openings on the exterior of the unitary body allow flow control devices to be mounted in the flow passageways to control the flow of fluid though the flow passageways. One or more of the control devices could be mountable in two or more orientations that alter the way in which the flow control device controls flow through one or more passageways in the unitary body. One or more choke mechanisms may also be mounted on the unitary body. The choke mechanisms may allow an operator to selectively adjust a flow of fluid through one or more of the passageways in the unitary body.