Wellhead Hanger Landing Verification Using Ultrasonic Echo Sensing
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Solution Overview
Problem
Existing wellhead installation methods in the oil and gas industry rely on manual techniques prone to human error, leading to issues like false landed indicators, wellhead misalignment, and potential fluid trapping, which can cause operational delays and safety risks.
Innovation Solution
A digital position sensing system using ultrasonic transducers and a binary classification neural network to verify the proper landing of wellhead components by analyzing reflected ultrasonic pulses, reducing reliance on manual inspections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection methods are used to verify wellhead installation, then the device complexity is low, but the reliability and measurement precision of installation verification deteriorate due to human error and false landed indicators
Solution Approach 1:
The patent replaces manual mechanical inspection methods with an automated ultrasonic sensing system. The ultrasonic transducer emits sound waves that reflect off the hanger landing on the wellhead, and the reflected waves are detected and analyzed by a neural network to automatically determine proper installation, eliminating human error while maintaining system reliability.
Solution Approach 2:
The patent introduces ultrasonic waves as an intermediary to verify hanger landing. The ultrasonic transducer sends pulses through the wellhead structure, and the reflected waves serve as a mediator to indicate whether the hanger has properly landed, providing reliable verification without direct human inspection.
2Measurement precision
If visual inspection through wellhead side outlets is performed, then the measurement precision may be improved, but the ease of operation deteriorates when fluid is trapped inside the wellhead during drilling operations
Solution Approach 1:
The patent replaces visual inspection through side outlets with ultrasonic sensing. The ultrasonic transducer is coupled to the wellhead housing and emits sound waves that travel through the structure to detect hanger landing, providing precise measurement without requiring operator access to side outlets or concern about trapped fluid.
Solution Approach 2:
The patent uses ultrasonic waves as an intermediary to detect hanger landing status. The waves penetrate through the wellhead structure and reflect off the hanger, providing precise measurement information without requiring direct visual access through side outlets that may be blocked by trapped fluid.
3Productivity
If manual techniques are used to check wellhead installation, then the device complexity is low, but the productivity deteriorates due to costly nonproductive time and operational delays
Solution Approach 1:
The patent replaces time-consuming manual inspection techniques with an automated ultrasonic sensing system that provides rapid, real-time verification of hanger landing. This eliminates costly nonproductive time and operational delays while the neural network automatically processes the ultrasonic signals to determine installation status.
Solution Approach 2:
The patent implements a self-verify system where the ultrasonic transducer and neural network automatically detect and determine hanger landing status without requiring manual intervention. The system performs self-inspection and provides immediate feedback, eliminating the need for operators to spend time on manual verification procedures.
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
The system provides real-time feedback and accurate verification of wellhead component installation, enhancing reliability and safety by minimizing human error and operational delays.
Implementation Method 1
The ultrasonic transmitter is configured to detect the input pulse and one or more echo pulses associated with the input pulse. The ultrasonic pulses reflect off one or more internal surfaces of the wellhead housing.
Implementation Method 2
A digital position sensing system using ultrasonic transducers and a binary classification neural network to verify the proper landing of wellhead components by analyzing reflected ultrasonic pulses
Data Source
AI summary
A system including a casing hanger; a wellhead housing, including a landing shoulder configured to contact the casing hanger during installation of the casing hanger in a wellhead; a transducer disposed on an exterior of the wellhead housing, wherein the transducer is configured to emit an input pulse toward the landing shoulder; and an ultrasonic transmitter coupled to the transducer, wherein the ultrasonic transmitter is configured to detect the input pulse and one or more echo pulses associated with the input pulse.