Smart Wellhead System
25% improved reliability with parametric modeling and real-time monitoring
Project Overview
Designed a next-generation smart wellhead system with integrated sensors and remote monitoring capabilities for oil and gas applications. The system improves safety and reliability while reducing maintenance costs through predictive analytics.
Key Design Features
- Monoblock construction with forged steel body
- Integrated pressure, temperature, vibration, and corrosion sensors
- Real-time data transmission to cloud monitoring platform
- Modular design for easy field maintenance
Key Challenges
- High-pressure containment (up to 15,000 psi working pressure)
- Harsh environmental conditions (-40°C to 120°C)
- Integration of sensor packages without compromising structural integrity
- Compliance with multiple industry standards
Design Process
Requirements Analysis
Conducted field studies at 12 operational sites to identify pain points in existing wellhead systems. Defined key performance indicators including:
- Minimum 10,000 pressure cycles at 15,000 psi
- Corrosion resistance for 25-year service life
- Mean time between failures > 5 years
- API 6A PR2 sealing requirements
Concept Development
Created 5 distinct design concepts evaluating:
- Traditional flanged vs. monoblock construction
- Sensor integration approaches
- Material options for body and seals
- Manufacturing feasibility
Selected monoblock design with modular sensor ports for optimal performance and manufacturability.
Parametric Modeling
Developed configurable Inventor models with iLogic automation to quickly generate design variants:
' Sample iLogic rule for flange sizing
If Pressure_Rating <= 5000 Then
Flange_Standard = "ASME B16.5 Class 300"
ElseIf Pressure_Rating <= 10000 Then
Flange_Standard = "ASME B16.5 Class 600"
Else
Flange_Standard = "ASME B16.5 Class 900"
End If
Implemented design tables for standard component sizes, reducing design time by 40%.
FEA Validation
Performed nonlinear FEA analysis accounting for:
- Internal pressure loading (15,000 psi)
- Thermal stresses (-40°C to 120°C)
- Seismic loads (0.5g acceleration)
- Fatigue analysis for 10,000 cycles
Optimized material distribution to achieve safety factor of 3.5 while minimizing weight.
Technical Specifications
Materials
- Body: ASTM A694 F60 forged steel
- Seals: HNBR with PTFE backup rings
- Fasteners: ASTM A193 B7 studs with A194 2H nuts
- Coating: High-performance epoxy with cathodic protection
Performance
- Working Pressure: 15,000 psi (1034 bar)
- Temperature Range: -40°C to 120°C
- Design Life: 25 years
- Sealing Efficiency: 99.99% (API 6A PR2)
Sensors
- Pressure: 0-20,000 psi ±0.1% FS
- Temperature: RTDs with ±0.5°C accuracy
- Vibration: 3-axis accelerometers
- Corrosion: Linear polarization resistance probes
Results & Impact
"Uche's design expertise was instrumental in developing our next-generation wellhead system. His attention to detail in material selection and FEA validation resulted in a product that exceeded our reliability targets while reducing manufacturing costs."
Key Achievements
- Reduced part count by 30% through monoblock design
- Achieved 99.99% sealing efficiency in API 6A PR2 testing
- Developed 5 configurable product variants from single model
- Reduced design time by 40% through parametric modeling