Patent Application
20250230724
In the oil and gas industry, wellhead and Christmas tree valves are essential for production operations. It is common during operations for a “stick valve issue” to occur to one or more of the valves. A “stick valve issue” refers to when a valve is not operating as smoothly or freely as the valve should. A “sticking valve issue” disrupts normal functioning of valves within wellhead assemblies or other equipment. Timely maintenance, proper lubrication, and vigilant monitoring are essential to prevent and address these problems to ensure safe and efficient operations.
Accordingly, there exists a need for an automated health monitoring system for valves that prevents valve sticking and ensures smooth operation of valves for oil and gas facilities.
This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.
In one aspect, embodiments disclosed herein relate to a health monitoring system for a wellhead valve, the system comprising: a plurality of sensors disposed on the wellhead valve configured to measure a plurality of parameters comprising resistance data, pressure data, temperature data, and position data; an automated rotating tool configured to rotate the wellhead valve; a central monitoring system comprising a computer processor connected to the plurality of sensors and the automated rotating tool configured to control and rotate the automated rotating tool at a predefined schedule to observe integrity data; process, via the computer processor, the plurality of parameters and integrity data; determine, via the computer processor, a health report related to the wellhead valve based, at least in part, on the processed plurality of parameters; and transmit, via the computer processor, an alert comprising a maintenance notification based on the health report using a wireless connection to a display; and a solar panel coupled to the plurality of sensors, the automated rotating tool, and the central monitoring system configured to harness solar energy to power the plurality of sensors, the automated rotating tool, and the central monitoring system.
In one aspect, embodiments disclosed herein relate to a method for a health monitoring system for a wellhead valve, the method comprising: measuring, via a plurality of sensors disposed on the wellhead valve, a plurality of parameters comprising resistance data, pressure data, temperature data, and position data; connecting a central monitoring system comprising a computer processor to the plurality of sensors and an automated rotating tool; rotating, via the automated rotating tool controlled by the central monitoring system, the wellhead valve at a predefined schedule to observe integrity data; processing, via the computer processor, the plurality of parameters and integrity data; determining, via the computer processor, a health report related to the wellhead valve based, at least in part, on the processed plurality of parameters and integrity data; transmitting, via the computer processor, an alert comprising a maintenance notification based on the health report using a wireless connection to a display; performing a maintenance operation on the wellhead valve based, at least in part, on the alert on the display; and powering, via a solar panel, the plurality of sensors, the automated rotating tool, and the central monitoring system by harnessing solar energy.
Other aspects and advantages of the claimed subject matter will be apparent from the following description and the appended claims.
In the following detailed description of embodiments of the disclosure, numerous specific details are set forth in order to provide a more thorough understanding of the disclosure. However, it will be apparent to one of ordinary skill in the art that the disclosure may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.
Throughout the application, ordinal numbers (e.g., first, second, third, etc.) may be used as an adjective for an element (i.e., any noun in the application). The use of ordinal numbers is not to imply or create any particular ordering of the elements nor to limit any element to being only a single element unless expressly disclosed, such as using the terms “before,” “after,” “single,” and other such terminology. Rather, the use of ordinal numbers is to distinguish between the elements. By way of an example, a first element is distinct from a second element, and the first element may encompass more than one element and succeed (or precede) the second element in an ordering of elements.
In the following description of
It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a force applicator” includes reference to one or more of such force applicators.
In one aspect, embodiments disclosed herein relate to a health monitoring system for a wellhead valve in a well. The health monitoring system includes an automated rotating tool, sensors, and computer capabilities. The sensors measure various parameters related to the valve to be processed by a computer system. The health monitoring system is equipped with solar panels for environmentally friendly and self-sustaining operations. In on or more embodiments, the health monitoring system calculates the health of the valve using mathematical equations and algorithms. The health monitoring system is equipped with Wi-Fi or cellular connectivity capabilities for transmitting data and alerts for automation purposes.
Embodiments of the present disclosure may provide at least one of the following advantages. The health monitoring system prevents a valve from sticking to ensure smooth operation of oil and gas wells. The health monitoring system is capable of being used in remote areas with limited connectivity.
In the oil and gas industry, fluids produced from a hydrocarbon reservoir may include natural gas, oil, and water. As illustrated in
A tree structure, also known as a “Christmas tree” (109), is disposed on top of the wellhead (108) to control the flow of fluids into or out of the wellbore (103), depending on whether it is an injection well or a production well. The Christmas tree (109) includes a configuration of valves to control the fluids being injected into or pumped out of the wellbore (103). For example, the Christmas tree (109) may have an injection wing valve (110), a swab valve (111), a production wing valve (112), an upper master valve (113), and a lower master valve (114).
When an operator is ready to conduct well operations the valves (110, 111, 112, 113, 114) are either opened or closed to control the fluids being injected into or pumped out of the wellbore (103). During injection, the production wing valve (112) and the swab valve (111) are closed while the injection wing valve (110), the upper master valve (113), and the lower master valve (114) are open to allow for fluids to be injected through the Christmas tree (109) and into the wellbore (103). The wellbore (103) may include any well completion design, such as vertical, deviated, or varied orientation. During production, the injection wing valve (110) and the swab valve (111) are closed while the production wing valve (112), the upper master valve (113), and the lower master valve (114) are open to control or isolate fluid flow through a choke valve (115). From the choke valve (115), the fluids are transported, via a production flow line (116), to a production storage, transport, or facility.
The choke valve (115) is a mechanical device to control flow rates and pressure drops of the produced fluids. For example, an operational function of the choke valve (115) is to produce the fluids from the wellbore (103) at the desired rates by the introduction of human intervention to manually control the drawdown pressure. A choke size of the choke valve (115) is changeable to allow for the operator to adjust the amount of pressure dropped across the choke valve (115) in order to maintain a downstream pressure in the production flow line (116) at the desirable value which will lead to achieving the desirable rate.
The handwheel (202) may be any valve actuator used to regulate the opening and closing of the gate valve (200) manually. The handwheel (202) may be large enough to transmit a large amount of force or torque required to turn. The handwheel (202) includes a ball screw (222) and bearings (224) for turning the handwheel (202) with the operating stem (204), gate (210), and balancing stem (208). Once the handwheel (202) is turned, the gate (210) turns along with it to control whether the gate valve (200) is open, partially open, or closed. The gate valve (200) may include further components including a bonnet packing (226), upper bonnet (228), bonnet seal ring (230), a lower bonnet (232), and a grease fitting (234). A person of ordinary skill in the art would appreciate that the gate valve (200) operates similar to an industry standard gate valve and requires the same components.
The health monitoring system (300) of
The resistance sensor (304) or torque sensor is used to monitor resistance data including measuring the amount of force/resistance/torque that is required to move or operate the gate valve (200) during rotations or turns of the gate valve. Resistance data may include units in pounds or newtons. Resistance data may be crucial in monitoring the performance of the gate valve (200). An increase in resistance may indicate that the gate valve (200) is stuck or partially closed. An example of resistance data consists of a percentage change in torque (RSH) calculation shown in EQ1. In EQ1, RSHc represents the current torque value and RSHb represents the baseline torque value. The current torque value is the torque measured by the resistance sensor (304) at the present time. The baseline torque value is the torque measured during initial installation of the gate valve (200) or at the time the gate valve (200) was deemed in good condition.
In one or more embodiments, the percentage change in torque in EQ1 may indicate whether the torque required to operate the gate valve (200) has increased compared to an initial condition (i.e., RSHb) of the gate valve (200). For example, if the current torque value (RSHc) is 120 foot-pound (ftlb) and the baseline torque value (RSHb) is 100 ftlb, then the percentage change in torque (RSH) is calculated into EQ 1 as 20%. A person of ordinary skill in the art would appreciate that a predetermined threshold for RSH may be set by a manufacturer of the gate valve (200). For example, the predetermined threshold for RSH may be 10%, meaning that any RSH value exceeding the threshold of 10% may trigger further investigation or maintenance of the gate valve (200). In this example, the RSH is 20%, meaning the health monitoring system (300) flags the gate valve (200) for attention since RSH exceeds the 10% threshold. In one or more embodiments, the health monitoring system (300) may flag the gate valve (200) for attention or trigger further investigation or maintenance to a user. The user may be field personnel or engineers.
The temperature sensor (306) monitors the temperature of the gate valve (200) and its surroundings. Temperature data may be consistently monitored to help detect anomalies in temperature, such as increases in temperature of the gate valve (200). An unexpected increase in temperature of the gate valve (200) or surroundings may be an early warning sign of an issue with the gate valve (200). For example, if the gate valve (200) is stuck partially closed, heat may generate during operation thereby increasing temperature data. The pressure sensor (308) measures fluid pressure on each side of the gate valve (200). The gate valve (200) has two sides, a first side (316) and a second side (318), as illustrated in
In some embodiments, the first side (316) is the inlet of the gate valve (200) and the second side (318) is the outlet of the gate valve (200). The fluid pressure at the first side (316) may be the inlet pressure. The fluid pressure at the second side (318) may be the outlet pressure. A person of ordinary skill in the art will appreciate that if the outlet pressure is significantly lower than the inlet pressure when the gate valve (200) is presumed to be fully open, it suggests an issue with the operation of the gate valve (200). The issue with the operation of the gate valve (200) may include a stuck or partially closed valve.
The automated rotating tool (310) is designed to rotate the gate valve (200). The automated rotating tool (310) may be designed to rotate any wellhead or Christmas tree valve. The automated rotating tool (310) may be placed on the handwheel of the gate valve (200) as illustrated in
The central monitoring system (312) includes a computer processor (320) (e.g., computer system (502)), further described in
Using the health report (324), the central monitoring system (312) then transmits an alert (326) wirelessly (328) to the display (322). The alert (326) includes a maintenance notification (330). The health report (324) may include the resistance data in the alert (326) to actuate rotation at the specific torque, RSH. The alert (326) may be displayed on the display (322) to a user or to a maintenance team. The wireless connection (328) may be a Wi-Fi or cellular connectivity connection enabling remote work in limited connectivity areas. The central monitoring system (312) may use mathematical equations and algorithms for data processing to calculate the health report (324), such as EQ1.
The health report (324) may further include an overall valve health calculation (OVH), as shown in EQ 2. Regarding EQ2, PSH represents position data, RSH represents resistance data, TSH represents temperature data, and PS represents pressure data. OVH is a calculation that represents the master valve health score, which provides a quantitative measure of the valve's condition. Additionally, the user may assign weights to each data representative. Data used to assign weights may vary depending on operational context and type of system implemented. Factors considered in assigning weights include historical data, expert input, simulation and testing, and safety and environmental concerns. The assigned weights are subject to change over time. A person of ordinary skill in the art will appreciate that regular review and updates to the weighting process is necessary to ensure relevance and accuracy when assessing valve health. For example a weight for PSH, RSH, TSH, and PS are represented at WPSH, WRSH, WTSH, WPS, respectively.
As an example, weights may be assigned as follows: PSH—30%, RSH—20%, TSH—20%, PS—30%). Using EQ 2 above, OMVH=(0.30*PSH)+(0.20*RSH)+(0.20*TSH)+(0.30*PS) and OMVH=(0.30*50)+(0.20*75)+(0.20*30)+(0.30*80)=61.
A user may define specific thresholds in the central monitoring system (312) regarding the health report (324) of the gate valve (200). For example, if the health report (324) indicates OVH>70%, the gate valve (200) is considered in “good health”. If the health report (324) indicates 30≤OVH≤70%, the alert (326) includes a maintenance notification (330) to the user. The maintenance notification (330) may indicate to a user to apply lubrication to the gate valve (200). Applying lubrication to the gate valve (200) allows for the gate valve (200) to move freely to prevent sticking. If the health report (324) indicates an OVH<30%, the maintenance notification (330) includes a remote diagnostic indicating to the user for an urgent replacement operation on the display (322). The replacement operation entails replacing the gate valve (200). Integrated remote diagnostic capabilities provide maintenance teams and users access to the situation of the gate valve (200) before physically going to the valve site. Remote diagnostic capabilities may save time and resources, especially with implementing the display (322).
The central monitoring system (312) is capable of calculating both equations, EQ1 and EQ2, and transmitting results to the display (322). Based on the results on the display (322), the user may perform a maintenance operation including replacing or lubricating the gate valve (200).
The solar panel (314) is coupled to the sensors (302, 304, 306, 308), automated rotating tool (310), and the central monitoring system (312). The solar panel (314) harnesses solar energy in order to power the sensors (302, 304, 306, 308), the automated rotating tool (310), and the central monitoring system (312). The solar panel (314) may be environmentally friendly and self-sustainable. The solar panel (314) may provide the health monitoring system (300) with continuous operation eliminating the need for battery replacements.
In Block 400, a plurality of sensors, an automated rotating tool, and a central monitoring system are powered by harnessing solar energy via a solar panel. In Block 410, parameters are measured via the sensors disposed on the wellhead valve. Parameters include resistance data, pressure data, temperature data, and position data. Position data may include a physical position monitored by a position sensor. The physical position may be a value indicating that the wellhead valve is open, closed, or partially open. Resistance data may include a torque measurement required to move the wellhead valve made by a resistance sensor. Temperature data may include the temperature of the wellhead valve measured by a temperature sensor. Pressure data may include a fluid pressure measurement on the first side and the second side of the wellhead valve via a pressure sensor. In Block 420, the central monitoring system is connected to the sensors and automated rotating tool. The central monitoring system includes a computer processor. The parameters may be continuously monitored for real-time monitoring via the central monitoring system. In Block 430, the wellhead valve is rotated using the automated rotating tool at a predefined schedule to observe integrity data. The automated rotating tool is actuated by the central monitoring system.
In Block 440, parameters and integrity data are processed, and a health report is determined related to the wellhead valve. A quantitative value may be calculated regarding the condition of the wellhead valve. The health report may include the quantitative value. In Block 450, an alert including a maintenance notification is transmitted to a display using a wireless connection. The wireless connection may be a Wi-Fi or cellular connectivity connection. The alert is based on the health report and the parameters. A maintenance notification may be communicated based on a pre-set threshold for the health report, when the alert is transmitted. The maintenance notification may indicate a replacement operation to a user via a remote diagnostic. In Block 460, a maintenance operation is performed on the wellhead valve. The maintenance operation may be based on the alert and maintenance notification on the display. The maintenance operation may include the replacement operation or lubrication of the wellhead valve.
Embodiments may be implemented on a computer system.
The computer (502) can serve in a role as a client, network component, a server, a database or other persistency, or any other component (or a combination of roles) of a computer system for performing the subject matter described in the instant disclosure. The illustrated computer (502) is communicably coupled with a network (530). In some implementations, one or more components of the computer (502) may be configured to operate within environments, including cloud-computing-based, local, global, or other environment (or a combination of environments).
At a high level, the computer (502) is an electronic computing device operable to receive, transmit, process, store, or manage data and information associated with the described subject matter. According to some implementations, the computer (502) may also include or be communicably coupled with an application server, e-mail server, web server, caching server, streaming data server, business intelligence (BI) server, or other server (or a combination of servers).
The computer (502) can receive requests over network (530) from a client application (for example, executing on another computer (502)) and responding to the received requests by processing the said requests in an appropriate software application. In addition, requests may also be sent to the computer (502) from internal users (for example, from a command console or by other appropriate access method), external or third-parties, other automated applications, as well as any other appropriate entities, individuals, systems, or computers.
Each of the components of the computer (502) can communicate using a system bus (503). In some implementations, any or all of the components of the computer (502), both hardware or software (or a combination of hardware and software), may interface with each other or the interface (504) (or a combination of both) over the system bus (503) using an application programming interface (API) (512) or a service layer (513) (or a combination of the API (512) and service layer (513). The API (512) may include specifications for routines, data structures, and object classes. The API (512) may be either computer-language independent or dependent and refer to a complete interface, a single function, or even a set of APIs. The service layer (513) provides software services to the computer (502) or other components (whether or not illustrated) that are communicably coupled to the computer (502). The functionality of the computer (502) may be accessible for all service consumers using this service layer. Software services, such as those provided by the service layer (513), provide reusable, defined business functionalities through a defined interface. For example, the interface may be software written in JAVA, C++, or other suitable language providing data in extensible markup language (XML) format or other suitable format. While illustrated as an integrated component of the computer (502), alternative implementations may illustrate the API (512) or the service layer (513) as stand-alone components in relation to other components of the computer (502) or other components (whether or not illustrated) that are communicably coupled to the computer (502). Moreover, any or all parts of the API (512) or the service layer (513) may be implemented as child or sub-modules of another software module, enterprise application, or hardware module without departing from the scope of this disclosure.
The computer (502) includes an interface (504). Although illustrated as a single interface (504) in
The computer (502) includes at least one computer processor (505). Although illustrated as a single computer processor (505) in
The computer (502) also includes a memory (506) that holds data for the computer (502) or other components (or a combination of both) that can be connected to the network (530). For example, memory (506) can be a database storing data consistent with this disclosure. Although illustrated as a single memory (506) in
The application (507) is an algorithmic software engine providing functionality according to particular needs, desires, or particular implementations of the computer (502), particularly with respect to functionality described in this disclosure. For example, application (507) can serve as one or more components, modules, applications, etc. Further, although illustrated as a single application (507), the application (507) may be implemented as multiple applications (507) on the computer (502). In addition, although illustrated as integral to the computer (502), in alternative implementations, the application (507) can be external to the computer (502).
There may be any number of computers (502) associated with, or external to, a computer system containing computer (502), each computer (502) communicating over network (530). Further, the term “client,” “user,” and other appropriate terminology may be used interchangeably as appropriate without departing from the scope of this disclosure. Moreover, this disclosure contemplates that many users may use one computer (502), or that one user may use multiple computers (502).
In some embodiments, the computer (502) is implemented as part of a cloud computing system. For example, a cloud computing system may include one or more remote servers along with various other cloud components, such as cloud storage units and edge servers. In particular, a cloud computing system may perform one or more computing operations without direct active management by a user device or local computer system. As such, a cloud computing system may have different functions distributed over multiple locations from a central server, which may be performed using one or more Internet connections. More specifically, cloud computing system may operate according to one or more service models, such as infrastructure as a service (IaaS), platform as a service (PaaS), software as a service (SaaS), mobile “backend” as a service (MBaaS), serverless computing, artificial intelligence (AI) as a service (AIaaS), and/or function as a service (FaaS).
Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims.
