Wellhead Flow Block Lubricator for Reliable Plunger Capture
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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 damage.
Innovation Solution
The integration of a plunger catcher mechanism with a wellhead flow block lubricator assembly that includes internal passageways and a choke mechanism to control fluid flow, ensuring the plunger fully ascends into the receiving position by managing fluid pressure and flow rates, and the use of sensors to monitor plunger position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the plunger is not fully driven into the plunger catcher mechanism, then the flow valve or ball valve cannot be reset, but the plunger may still be released and descend into the wellbore
Solution Approach 1:
The system performs preliminary action by ensuring the plunger is fully driven into the plunger catcher mechanism before allowing valve reset. The flow block lubricator assembly actively propels the plunger upward using fluid pressure to guarantee complete insertion into the catcher mechanism, thereby ensuring the flow valve or ball valve is properly reset before the plunger can be released for descent.
2Productivity
If the plunger is released before full ascent into the receiving position, then the cycle time is reduced, but the flow valve or ball valve remains unreset causing plunger failure
Solution Approach 1:
The system implements feedback by using sensors to monitor plunger position and provide this information to the control system. The control system receives feedback about whether the plunger has reached the receiving position and uses this feedback to determine when to release the plunger. This ensures the plunger is only released after confirming full ascent and proper valve reset, preventing premature release while optimizing cycle timing.
3Device complexity
If the plunger catcher mechanism is integrated in the lubricator body, then the system complexity is reduced, but the plunger may not be fully captured leading to valve reset failure
Solution Approach 1:
The system applies merging by integrating the plunger catcher mechanism directly into the lubricator body, combining multiple functions into a single integrated assembly. This reduces overall system complexity while maintaining reliability through the active driving mechanism that ensures complete plunger capture. The flow block lubricator assembly and plunger catcher mechanism work as unified components rather than separate systems.
Solution Approach 2:
The integrated system performs preliminary action by actively driving the plunger into the catcher mechanism using fluid pressure from the flow control mechanisms. This preliminary action ensures complete plunger insertion and valve reset occurs before the plunger can be released, guaranteeing reliable operation even within the compact integrated design.
4Duration of action of stationary object
If the flow valve or ball valve is not reset, then the plunger cannot descend back into the wellbore, but continuing operation without reset causes premature plunger failure
Solution Approach 1:
The system performs preliminary action by ensuring the flow valve or ball valve is completely reset before allowing the plunger to descend. The active driving mechanism propels the plunger into the catcher mechanism to guarantee valve reset occurs. This preliminary valve reset action extends plunger operational lifespan by preventing damage from incomplete reset conditions, while the automated control system maintains production continuity by promptly initiating the next cycle.
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
Ensures reliable plunger operation by ensuring full ascent into the receiving position, preventing premature failure and optimizing production efficiency.
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
The plunger catcher mechanism is configured to hold and release a plunger
Implementation Method 3
The lower outlet typically has a ball valve or choke mechanism to allow the operator to adjust or restrict the flow of liquid out of the lower outlet, thereby forcing more flow to the upper outlet
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.