Wellhead Hanger Surface Textures for Position Sensing and Sealing
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Solution Overview
Problem
Existing mineral extraction systems face challenges in effectively sealing and supporting tubing and casing within wellheads under high pressure conditions, leading to potential leaks and structural instability.
Innovation Solution
A hanger system with surface textures on the radially-outer annular surfaces of tubing and casing hangers, combined with a compression system and sensors for alignment and seal monitoring, to facilitate secure engagement and sealing with the wellhead housing, ensuring effective sealing and support under high pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional smooth sealing surfaces are used in hanger systems, then manufacturing is simpler, but sealing reliability under high pressure deteriorates
Solution Approach 1:
The patent applies local quality by creating surface textures only in specific sealing regions rather than throughout the entire surface. The radially-outer annular surfaces of the hanger and housing are textured with patterns (cross-hatching, grooves, or protrusions) that increase friction and sealing effectiveness, while other surfaces remain smooth for manufacturing simplicity. This localized texturing resolves the contradiction by providing enhanced sealing reliability only where needed.
Solution Approach 2:
The patent employs curved or rounded surface features in the sealing interface, such as radially-outer annular surfaces that engage in a curved geometry. The hanger and housing surfaces are designed with specific radii and curvature profiles that promote conformal contact under pressure, improving sealing reliability while maintaining manufacturability through standard machining operations.
2Stability of the object's composition
If hanger installation is performed without precise alignment monitoring, then the installation process is faster, but structural stability and seal effectiveness deteriorate
Solution Approach 1:
The patent implements feedback by using sensors (such as acoustic emission sensors, strain gauges, or position sensors) to monitor the hanger installation process in real-time. These sensors detect alignment status, sealing contact forces, and positional accuracy, providing feedback to operators or automated control systems. This enables precise alignment monitoring without significantly extending installation time, as the monitoring occurs concurrently with the installation process.
Solution Approach 2:
The patent replaces manual alignment checking methods with sensor-based detection systems. Instead of relying on mechanical alignment tools or visual inspection, the system uses electronic sensors to detect hanger position, orientation, and sealing engagement. This substitution reduces the time required for alignment monitoring while improving the precision and reliability of the alignment process.
3Reliability
If compression force is applied without controlled monitoring, then the sealing process is simpler, but seal effectiveness and prevention of leaks deteriorate
Solution Approach 1:
The patent uses compression monitoring systems with sensors (such as load cells, strain gauges, or pressure sensors) that provide real-time feedback on the compression force applied to the hanger. This feedback enables operators or automated systems to control the compression process, ensuring that the optimal force is applied to achieve effective sealing without over-compression. The monitoring system integrates seamlessly with the compression mechanism, adding minimal complexity while significantly improving seal effectiveness.
Solution Approach 2:
The patent incorporates self-adjusting compression mechanisms that automatically regulate the compression force based on sensor feedback. The system can autonomously maintain the optimal compression level without requiring constant manual intervention, reducing the operational complexity of the monitoring system while ensuring consistent seal effectiveness throughout the hanger installation process.
Data Source
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AI summary
A system includes a hanger with a radially-outer surface with a hanger surface texture. The system also includes a sensor configured to detect vibrations induced by the hanger surface texture as the hanger moves through a housing of a wellhead. The system further includes a controller configured to receive signals indicative of the vibrations from the sensor and to process the signals to determine a position of the hanger within the housing of the wellhead.