Wellhead Flow Block Assembly for Plunger Ascent Control
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Solution Overview
Problem
Existing wellhead lubricator systems face challenges in ensuring the plunger fully ascends into the receiving position due to inadequate control over fluid flow, leading to potential failure of the plunger to descend back into the wellbore.
Innovation Solution
The integration of a wellhead flow block lubricator assembly with a plunger catcher mechanism and adjustable choke mechanisms to control fluid flow, ensuring the plunger fully ascends by managing backpressure and flow rates through multiple passageways, utilizing sensors to detect plunger arrival and seating, and incorporating replaceable inserts to reduce wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a plunger is used to enhance production, then production efficiency is improved, but the plunger may fail to fully ascend into the receiving position due to inadequate flow control
Solution Approach 1:
The system employs dynamically adjustable choke mechanisms that can modify flow restrictions in real-time based on plunger position and well conditions. The choke allows operators to adjust the degree of flow restriction to optimize plunger ascent behavior, transforming a static flow control system into a dynamic one that adapts to varying operational requirements.
Solution Approach 2:
The invention changes the flow parameters (pressure, flow rate) through adjustable choke mechanisms and multiple passageways with different restriction levels. By modifying these parameters, the system can control the plunger's ascent speed and ensure it reaches the receiving position reliably, while still maintaining production enhancement benefits.
2Manufacturing precision
If flow restriction is increased to control plunger position, then plunger landing position control is improved, but backpressure increases which may affect well performance
Solution Approach 1:
The flow control system is segmented into multiple independent passageways (first passageway with first choke, second passageway with second choke) that can be adjusted separately. This allows differential flow control where different restrictions can be applied to different flow paths, enabling precise plunger positioning without uniformly high backpressure that would harm well performance.
Solution Approach 2:
The choke mechanisms act as intermediaries between the wellbore and the lubricator, providing controlled flow restriction. Rather than creating a single point of high restriction, the chokes mediate the flow transition, allowing gradual adjustment of backpressure levels to balance positioning accuracy with well performance maintenance.
3Device complexity
If traditional lubricator design is used, then device simplicity is maintained, but plunger may not fully ascend leading to valve reset failure
Solution Approach 1:
The invention merges the flow block and lubricator functions into an integrated assembly, combining multiple functions (flow control, plunger reception, valve resetting) in a single unified device. This integration achieves reliable plunger ascent and valve reset without requiring multiple separate complex systems, maintaining operational simplicity while improving reliability.
Solution Approach 2:
The lubricator assembly is designed with multi-functionality, serving as both a flow control device and a plunger reception/processing device. The same structure handles both production flow management and plunger cycle operations, reducing the need for additional specialized equipment while ensuring reliable plunger ascent for valve reset.
4Reliability
If flow control mechanisms are added to ensure plunger ascent, then plunger system reliability is improved, but device complexity increases
Solution Approach 1:
The flow control system is designed to be self-regulating through the interaction of multiple passageways and chokes that automatically respond to pressure and flow conditions. The system uses the well's own flow dynamics to assist plunger ascent, reducing the need for complex active control mechanisms while maintaining reliable plunger reception.
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 operation of the plunger system by guaranteeing the plunger's full ascent and descent, enhancing production efficiency and reducing mechanical wear, while allowing adaptability to varying well conditions.
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 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. This creates less restriction or less back pressure at the upper outlet, which forces the plunger to travel upward towards 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.