Wellhead Valve Regulation With Sensor-Verified Actuation Lockout

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Solution Overview

Problem

Well pads with multiple wells often experience miscommunication and accidents due to differing operational requirements, leading to unsafe actuation of wellhead control mechanisms, such as valves, which can result in costly downtime and safety risks.

Innovation Solution

An apparatus and system for regulating wellhead control mechanisms through indirect and direct control methods, using sensors and actuators to ensure safe actuation by locking or unlocking valves based on operational conditions and safety protocols, and a process that includes receiving information from fluid-based, object-based, and valve-position sensors to assess safety before actuating valves.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple wells are developed on a single well pad to increase efficiency, then productivity increases, but the risk of miscommunication and accidents increases due to complicated operations

Engineering Contradiction:

Improvehydrocarbon recovery efficiencyVSAvoidoperational safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system continuously monitors well pad operations through sensors and communication devices, providing real-time feedback to the central controller. This enables dynamic adjustment of wellhead control mechanisms based on current operational conditions, ensuring safety while maintaining high productivity across multiple wells.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

A central control system acts as an intermediary between multiple well operations and the wellhead control mechanisms. This mediator coordinates activities across different wells and service companies, preventing miscommunication and accidents while enabling efficient multi-well operations on the same pad.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If direct control of wellhead control mechanism is implemented, then ease of operation improves, but the risk of unsafe actuation increases without proper safety verification

Engineering Contradiction:

Improvevalve actuation convenienceVSAvoidsafe actuation assurance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system performs preliminary safety verification through sensor monitoring and operational condition assessment before allowing actuation of wellhead control mechanisms. This preliminary check ensures that direct control operations are safe while maintaining operational convenience.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The control system automatically monitors operational conditions and manages safety protocols without requiring manual intervention for each actuation. This self-service approach maintains ease of operation while ensuring reliable safety verification through automated sensor-based monitoring.

Inventive Principle:

Principle #25Self-service

3Reliability

If indirect control with physical actuation is used, then safety verification is improved, but productivity decreases due to additional manual steps

Engineering Contradiction:

Improvesafety verificationVSAvoidoperational efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system replaces manual physical actuation with automated electronic control mechanisms. Sensors and controllers automatically manage wellhead valve actuation based on monitored operational conditions, eliminating the need for manual intervention while maintaining rigorous safety verification, thus preserving productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If wellhead control mechanisms are locked to prevent unsafe actuation, then reliability improves, but downtime increases when valves need to be actuated

Engineering Contradiction:

Improveaccident preventionVSAvoidvalve actuation downtime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system performs preliminary safety assessments and pre-conditions verification before locking wellhead control mechanisms. This allows valves to be actuated quickly when conditions are favorable, minimizing downtime while maintaining accident prevention through the lockout mechanism when conditions are unsafe.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The lockout mechanism dynamically adjusts based on real-time operational conditions monitored by sensors. When conditions are safe, the system allows actuation; when conditions are unsafe, it locks the mechanism. This dynamic approach prevents accidents while minimizing unnecessary downtime for valve operations.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20250223885A1Apparatus, system and process for regulating a control mechanism of a well

Publication Date: 2025.07.10 INTELLIGENT WELLHEAD SYST INC

AI summary

Embodiments of the present disclosure relate to an apparatus, a system and a process for regulating a wellhead control mechanism. The apparatus is configured to control actuation of a wellhead control mechanism by moving a moveable body of the apparatus between a first position and a second position. When the apparatus is in the first position a valve actuator is actuatable and when the apparatus is in the second position the valve actuator is physically interfered from actuating. When the apparatus is in the second position, the wellhead control mechanism cannot be actuated and is held in either an open, a partially open or a closed position. Other embodiments of the present disclosure relate to a system that directly controls actuation of a wellhead actuation mechanism.