Wellhead Connector Sensor for Cam Lock Verification
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Solution Overview
Problem
The assembly of wellhead equipment is time-consuming and poses a safety risk due to the reliance on visual observation to confirm proper locking of the locking ring, which can be challenging in high-pressure environments and may lead to catastrophic failures if not properly secured.
Innovation Solution
Integration of a sensor assembly with internal circuitry into the locking ring to sense the proximity of cam locks and produce an electronic signal, allowing for real-time confirmation of proper locking and alerting if any cam locks are not effectively securing the adapter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If visual observation is used to confirm proper locking of the locking ring, then the device complexity is low, but the reliability of locking confirmation deteriorates due to difficulty in observation from a distance and potential for human error
Solution Approach 1:
The patent replaces the manual visual inspection method with an automated sensor system. The sensor assembly includes proximity sensors that detect the position of cam locks and a control system that processes sensor signals to determine proper locking, substituting human visual observation with automated electronic detection and control.
Solution Approach 2:
The patent implements a feedback system where sensors continuously monitor the locking status and provide real-time information to the control system. The control system processes this feedback and can alert operators or automatically adjust the locking mechanism to ensure proper engagement, creating a closed-loop control system that continuously verifies locking status.
2Productivity
If traditional nuts and bolts with wrenches are used for wellhead assembly, then the device complexity is low, but the productivity deteriorates due to time-consuming assembly and disassembly operations
Solution Approach 1:
The patent employs dynamically actuated cam locks that can quickly transition between locked and unlocked positions through hydraulic or pneumatic actuation. This dynamic locking mechanism allows for rapid connection and disconnection of wellhead components, significantly improving assembly speed compared to static bolted connections.
Solution Approach 2:
The patent utilizes hydraulic or pneumatic actuation systems to drive the cam locks into the locked position. This powered actuation mechanism enables rapid and consistent locking without requiring manual wrench operations, thereby increasing productivity while managing the complexity through standardized actuation systems.
3Reliability
If the locking ring is positioned at a distance for operational safety in high-pressure environments, then the safety is improved, but the ease of operation deteriorates due to difficulty in visual confirmation of locking status
Solution Approach 1:
The patent introduces sensor assemblies and control systems as intermediaries between the locking mechanism and the operator. These intermediaries automatically detect and verify the locking status, transmitting this information to the operator without requiring the operator to visually inspect the locking ring from a distance, thus maintaining safety while improving ease of verification.
Solution Approach 2:
The patent replaces manual visual inspection with automated electronic sensing and display systems. The sensor assembly detects locking status and the control system presents this information through indicators or displays, eliminating the need for operators to physically observe the locking ring and enabling verification from a safe distance.
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 solution significantly reduces the risk of improper locking by providing a reliable, real-time confirmation of the locking status, thereby enhancing safety and reducing the time required for wellhead assembly and maintenance.
Implementation Method 1
a sensor assembly integrated with the locking ring and having internal circuitry operably configured to sense proximity of each one of the plurality of cam locks
Data Source
AI summary
A wellhead connector system is improved by the addition of sense circuitry that is used to confirm proper engagement of cam locks that engage an adaptor which may be used for pressure pumping operations, such as hydraulic fracturing, or for perforating an oil or gas well.