Wellhead Port Plug Assembly Spool Unit Design
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Solution Overview
Problem
Existing wellhead port plug assemblies require wells to be taken out of production for plug body replacement, which is a major disadvantage in hydrocarbon production where uptime is critical.
Innovation Solution
A wellhead port plug assembly with a spool unit, a second plug body, and a blind flange that allows for the removal and replacement of plug bodies without interrupting production, using a plug placement and removal tool to manage the process through a through-channel and valve system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plug body is positioned in a wellhead port for sealing and monitoring, then the port is sealed and monitoring is enabled, but the well must be taken out of production to replace the plug body
Solution Approach 1:
The system is divided into multiple independent plug bodies (first plug body in the port, second plug body in the spool) that can be independently replaced. The spool unit acts as a separate module that can be isolated from the wellhead port, allowing the first plug body to be replaced without affecting the sealed monitoring function.
Solution Approach 2:
The spool unit with the second plug body serves as an intermediary device between the wellhead port and the monitoring system. It provides a backup sealing capability that allows the primary plug body to be replaced while maintaining the sealed environment through the spool's second plug body.
2Reliability
If a blind plug is used to block the port when not in use, then leakage is prevented, but the port cannot be accessed for deploying monitoring systems
Solution Approach 1:
The system transitions from a static blind plug configuration to a dynamic system where plug bodies can be inserted and removed. The first plug body can be replaced with a monitoring-equipped plug body when needed, while the second plug body in the spool provides dynamic sealing capability to maintain leakage prevention during transitions.
Solution Approach 2:
The plug bodies are designed with multi-functionality - they can serve as simple sealing elements (like blind plugs) or as monitoring stations with sensors. The spool unit with the second plug body provides universal sealing capability that supports both the blocked port configuration and the active monitoring configuration.
3Reliability
If the well is taken out of production to replace a leaking plug body, then a new plug body can be installed, but production downtime occurs
Solution Approach 1:
The system is prepared in advance with a spool unit containing a second plug body that can serve as a backup. When the first plug body leaks, the pre-positioned spool unit can be quickly deployed to maintain sealing while the first plug body is replaced, eliminating the need to shut in the well and avoiding production downtime.
Solution Approach 2:
The first plug body can be discarded (removed and replaced) without affecting the overall system functionality because the spool unit with the second plug body maintains the sealed environment. The monitoring system and sealing capability are recovered immediately through the spool unit while the replacement is performed.
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
Enables the replacement of plug bodies while maintaining well production, ensuring fluid-tight seals and preventing leakage, thus enhancing operational efficiency and reducing downtime.
Implementation Method 1
a spool unit displaying an axial through-channel extending between a first end and a second end of the spool unit, which spool unit comprises a first flange section arranged at the first end for sealingly mounting the spool unit to the wellhead aligning the through-channel with the port
Implementation Method 2
the first plug body comprises connection elements allowing the first plug body to be sealingly and removably mounted in a port of a wellhead
Implementation Method 3
a second plug body comprising connection elements allowing the second plug body to be sealingly and removably mounted in the through-channel
Implementation Method 4
a blind flange which is sealingly and removably mounted to the second flange section allowing the second plug body and the first plug body to be removed from the wellhead via the through-channel
Data Source
AI summary
A wellhead port plug assembly includes a first plug body including connection elements allowing the first plug body to be sealingly and removably mounted in a port of a wellhead of a hydrocarbon well. The plug assembly includes a spool unit displaying an axial through-channel extending between a first end and a second end of the spool unit, which spool unit includes a first flange section arranged at the first end for sealingly mounting the spool unit to the wellhead aligning the through-channel with the port, and a second flange section arranged at the second end; a second plug body including connection elements allowing the second plug body to be sealingly and removably mounted in the through-channel; and a blind flange which is sealingly and removably mounted to the second flange section allowing the second plug body and the first plug body to be removed from the wellhead via the through-channel.