Electric chemical injection valve

Abstract

An electric chemical injection (eCI) system may comprise a first injection line, a first on-off valve, and a screen. The screen may comprise a bypass, the screen being positioned between the first injection line and the first on-off valve. A first T-connector may be positioned between the first injection line and the screen. A choke may be configured to allow a given amount of fluid to flow, and the choke may comprise an indexer. A calibration pressure device may be included. A check valve may be provided, and the check valve may comprise a check valve ball and a spring. The check valve may be configured to allow fluid flow from a surface to a well through the first injection line while preventing reverse fluid flow.

Description

IS24.1319Electric Chemical Injection ValveCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims the benefit of U.S. Provisional Application No. 63 / 725,872 filed November 27, 2024, U.S. Provisional Application No. 63 / 725,907 filed November 27, 2024, and U.S. Provisional Application No. 63 / 725,973 filed November 27, 2024, the entirety of which is incorporated by reference herein and should be considered part of this specification.BACKGROUNDField

[0002] The present disclosure generally relates to electrical chemical injection.SUMMARY

[0003] In some configurations, an electric chemical injection (eCi) system may comprise a first injection line, a first on-off valve, and a screen. The screen may comprise a bypass and may be positioned between the first injection line and the first on-off valve. A first T-connector may be positioned between the first injection line and the screen. A choke may be configured to allow a given amount of fluid to flow, and the choke may comprise an indexer. A calibration pressure device may be included. A check valve may be provided, and the check valve may comprise a check valve ball and a spring. The check valve may be configured to allow fluid flow from a surface to a well through the first injection line while preventing reverse fluid flow. The choke may optionally be a discrete choke. The on-off valve may optionally be an on-off solenoid valve (SOV).

[0004] A helical path may be provided and may be configured for a flow of an injected chemical, whereby a pressure drop may be induced by friction as the injected chemical flows along the helical path. The choke may further comprise one or more bypass holes. A second injection line, a second T-connector, and a second on-off valve may optionally be included. The check valve may be configured to be opened via a sliding rod that may move along one or more bypass holes. The sliding rod may have a beveled head that may force the check valve ball against a spring. A sliding rod may be configured to move along a first indexer ratchet to enable incremental movement in a first direction.IS24.1319

[0005] A second indexer ratchet may be configured to allow the sliding rod to move incrementally in a second direction. The indexer may be configured to shift the first ratchet and the second ratchet at an end of a stroke of the sliding rod. A bistable actuator (BSA) may be configured to generate a force to operate the first ratchet and the second ratchet. A compensating bellow may be configured to balance pressure and to isolate injected fluid. When a filter may not be saturated, the screen comprising a bypass may be configured to allow fluid to burst a disc and flow through the screen. A manifold assembly may be provided and may comprise the choke, the indexer, and the first on-off valve.

[0006] A method of electric chemical injection (eCi) may comprise sliding a rod, actuating two ratchets with the force of a bistable actuator to shift the two ratchets at an end of a sliding rod stroke, opening or closing a valve, and injecting a fluid from an injection line through a screen and through an on-off solenoid valve. The method may further comprise dropping pressure of the fluid by moving the fluid along a helical path, opening a valve when the sliding rod may be over the valve, closing a valve when the sliding rod may not be over the valve, and discretely moving the sliding rod along indexer ratchets.BRIEF DESCRIPTION OF THE FIGURES

[0007] Certain embodiments, features, aspects, and advantages of the disclosure will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements. It should be understood that the accompanying figures illustrate the various implementations described herein and are not meant to limit the scope of various technologies described herein.

[0008] Figure 1 shows a schematic of a chemical injection mandrel.

[0009] Figure 2 shows a view of a chemical injection system.

[0010] Figure 3 shows a view of an electric chemical injection valve architecture.

[0011] Figure 4 shows a schematic of a chemical injection mandrel.

[0012] Figures 5A and 5B shows another view of a chemical injection system.

[0013] Figure 6 shows a view of the chemical injection system.

[0014] Figure 7 shows another view of the chemical injection system.

[0015] Figure 8 shows an electric chemical injection valve.

[0016] Figure 9 shows an electrical chemical injection valve architecture.IS24.1319

[0017] Figure 10 shows a hydraulic diagram for an electrical chemical injection system.

[0018] Figure 11 shows another hydraulic diagram for an electrical chemical injection system.

[0019] Figure 12 shows yet another hydraulic diagram for an electrical chemical injection system.

[0020] Figure 13 shows a discrete choke mandrel as part of an electrical chemical injection.

[0021] Figure 14 shows the architecture of solenoid-operated valves for an electrical chemical injection mandrel.

[0022] Figure 15 shows a discrete choke mechanism for an electrical chemical injection system.

[0023] Figure 16 shows an indexer mechanism for an electrical chemical injection system.

[0024] Figure 17 shows another indexer mechanism for an electrical chemical injection system.

[0025] Figure 18 shows manifold details for an electrical chemical injection system.

[0026] Figure 19 shows the flow path for an electrical chemical injection system.

[0027] Figure 20 shows a screen sub device for an electrical chemical injection system.

[0028] Figure 21 shows a screen sub at bypass mode for an electrical chemical injection system.DETAILED DESCRIPTION

[0029] In the following description, numerous details are set forth to provide an understanding of some embodiments of the present disclosure. It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the disclosure. These are, of course, merely examples and are not intended to be limiting. However, it will be understood by those of ordinary skill in the art that the system and / or methodology may be practiced without these details and that numerous variations or modifications from the described embodiments are possible. This description is not to be taken in a limiting sense, but rather made merely for the purpose of describing general principles of the implementations. The scope of the described implementations should be ascertained with reference to the issued claims.IS24.1319

[0030] Certain chemical injection valves utilize check valves (unidirectional flow) in series, forming a double barrier to prevent well fluid to enter in the injection line, and allow the injection of chemical liquids in the well to improve oil recovery, reduce or inhibit corrosion, or address other oil flow issues. The unidirectional valves are normally spring loaded, and pressure actuated, without any control of the opening or flow rate. This disclosure may permit the operator to have remote control over the differential pressure (cracking pressure) and flow rate of the chemicals injected into the well.

[0031] A chemical valve may refer to a flow control device configured to regulate or permit the passage of chemical fluids into a wellbore or pipeline. The chemical valve may comprise stainless steel, alloy steel, or corrosion-resistant metals such as Inconel, and may optionally include elastomeric seals or polymer inserts for leak prevention. Functional alternatives may include ball valves, gate valves, or needle valves that perform similar chemical flow control functions. A conduit may refer to a tubular passage configured to transport fluids from one point to another. The conduit may comprise stainless steel tubing, alloy steel, or polymer-lined hoses for corrosion resistance, and alternatives may include flexible hoses, composite tubing, or coiled tubing assemblies that perform similar fluid transport functions.

[0032] A check valve may refer to a unidirectional flow control device configured to allow fluid flow in one direction while preventing reverse flow. The check valve may comprise stainless steel or alloy steel bodies with elastomeric seals, and alternatives may include swing check valves, lift check valves, or diaphragm check valves that perform similar one-way flow control functions. A spring may refer to an elastic component configured to apply force to maintain the check valve ball against its seat. The spring may comprise stainless steel or alloy steel and alternatives may include elastomeric bands or magnetic biasing systems that perform similar force application functions. A check valve ball may refer to a spherical component configured to seal against a valve seat under spring force to prevent reverse flow. The ball may comprise stainless steel, ceramic, or polymer composites, and alternatives may include poppets or tapered plugs that perform similar sealing functions.

[0033] This design also compatible with a standard chemical valve having a single conduit from the surface to the valve to deliver the chemical fluid, meaning that number of injection points is limited by the number of hydraulic lines penetrators in the wellhead. The embodiments described herein are intended to overcome these issues.IS24.1319

[0034] Some embodiments are directed to an electrical chemical injection valve that is solenoid controlled and / or AC powered. The electrical chemical injection valve may be a permanent or semi-permanent downhole completion valve that injects scale inhibiting chemicals into the tubing string. One of the benefits of these embodiments is back pressure retention (BPR) using a solenoid-controlled valve spool. Another advantage of these embodiments is synchronized and / or metered injection of chemicals based on feedback from one or more sensors in the completion string.

[0035] An electric chemical injection valve may refer to a valve configured to control the injection of chemicals into a wellbore or tubing string using electrical actuation. The valve may comprise stainless steel or corrosion-resistant alloys such as Inconel for structural integrity, and may optionally include elastomeric seals or polymer components for isolation and sealing. Functional alternatives may include hydraulic or pneumatic chemical injection valves that perform similar chemical dosing functions. A solenoid may refer to an electromagnetic actuator configured to convert electrical energy into linear motion for valve actuation. The solenoid may comprise a coil wound around a ferromagnetic core and a movable plunger, and alternatives may include pneumatic actuators, hydraulic pistons, or bistable actuators that perform similar actuation functions. A valve spool may refer to a cylindrical component configured to regulate fluid flow by aligning or blocking internal passages within the valve body. The spool may comprise stainless steel or alloy steel and alternatives may include sliding plates or rotary discs that perform similar flow regulation functions.

[0036] The electric chemical injection mandrel 100 is shown FIG. 1. The mandrel body 102 is a cylindrical bar, with a through hole for production flow and threads in both ends to connect to the completion string. The body has an eccentric section with cuts to accommodate the electric chemical injection valve 104 and the electronic section 106. A single chemical injection line 108 may bypass the mandrel and has an internal derivation to feed the electric chemical injection valve. Turning to the electric chemical injection system 200 FIG. 2, the same line may deliver the chemical to other chemical mandrels in the completion string. Electric chemical injection system 200 may comprise bypass chemical injection line 202, electrical chemical injection valve 204, production tubing 206, chemical injection mandrel 1 208, chemical injection mandrel 2 210, chemical injection mandrel 3 212. There may be 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 chemical injection mandrels.IS24.1319

[0037] An electric chemical injection mandrel may refer to a structural component configured to house an electric chemical injection valve and associated electronics within a completion string. The mandrel may comprise stainless steel, alloy steel, or corrosion-resistant metals such as Inconel for high-pressure and high-temperature environments, and alternatives may include composite mandrels or modular housings that perform similar integration functions. A mandrel body may refer to a cylindrical section configured to provide structural support and fluid passage through a completion string. The mandrel body may comprise stainless steel or alloy steel and alternatives may include polymer-lined housings or composite structures that perform similar support and flow functions. A chemical injection line may refer to a conduit configured to transport chemicals from a surface source to a downhole injection point. The chemical injection line may comprise stainless steel tubing, alloy steel, or flexible hoses reinforced with braided stainless steel or polymer layers to withstand high pressure and corrosive fluids. Alternatives may include composite tubing or coiled tubing assemblies that perform similar chemical transport functions. Production tubing may refer to a tubular conduit configured to transport produced fluids from the wellbore to the surface. The production tubing may comprise carbon steel or alloy steel and alternatives may include polymer-lined tubing or composite tubing that perform similar production fluid transport functions.

[0038] An electric chemical injection system may refer to an assembly configured to deliver chemicals into a wellbore or pipeline using electrically powered components. The system may include pumps, valves, connectors, and control devices designed to regulate chemical flow for corrosion inhibition, scale prevention, hydrate control, and flow assurance. Materials for structural components may include stainless steel, carbon steel, or corrosion-resistant alloys such as Inconel or Monel, while housings may optionally comprise polymer composites for weight reduction. Functional alternatives may include pneumatic or hydraulic chemical injection systems that perform similar chemical dosing functions.

[0039] An electric chemical injection system may refer to a configuration that may comprise one or more electrically actuated valves, conduits, and control mechanisms designed to inject chemicals into a wellbore or pipeline. The system may optionally include sensors, electronic controllers, and power supply units for remote operation and monitoring. Materials for structural components may comprise stainless steel, alloy steel, or corrosion-resistant metals such as Inconel or Monel, and housings may optionally comprise polymer composites or elastomeric seals forIS24.1319 isolation. Functional alternatives may include hydraulic or pneumatic chemical injection systems that perform similar chemical dosing and flow control functions.

[0040] An injection line may refer to a conduit configured to transport chemicals from a surface source to a downhole or pipeline injection point. The injection line may comprise stainless steel tubing, alloy steel, or flexible hoses reinforced with braided stainless steel or polymer layers to withstand high pressure and corrosive fluids. Alternatives may include composite tubing or coiled tubing assemblies that perform similar chemical transport functions.

[0041] An injection line may refer to a tubular passage configured to convey chemicals from a surface facility to a downhole injection point or pipeline. The injection line may comprise stainless steel, alloy steel, or corrosion-resistant metals such as Inconel for high-pressure environments, and may optionally include polymer liners or elastomeric coatings for chemical compatibility. Functional alternatives may include composite tubing, coiled tubing, or flexible hoses reinforced with metallic braids that perform similar chemical transport functions.

[0042] Turning to the electric chemical injection valve architecture 300 in FIG. 3, the electric chemical injection valve architecture 300 may be composed by an electric on / off solenoid valve 302, mounted in series with a unidirectional valve 304 forming a double barrier to prevent the well fluid to be injected into the chemical line up to the surface. Please note that the flow path is delineated by the dashed lines within the tubes / valves, while the direction is marked by the arrow. The order of mounting may be either as shown in FIG. 3 or reversed, that is, the unidirectional valve 304 first, with respect to the fluid inlet, and the electric on / off solenoid valve 302 after, followed by the rupture disc 306. Between the unidirectional valve 304, (or the on / off solenoid valve 302) and the injection port, there is a rupture disc 306 to allow the operator to test the tightness of the chemical injection lines and valves before the installation in the well.

[0043] An on-off solenoid valve may refer to a flow control device configured to permit or restrict chemical flow through an injection line using electromagnetic actuation. The valve may comprise stainless steel or alloy steel bodies with elastomeric or metal-to-metal seals for leak prevention, and alternatives may include gate valves, ball valves, or needle valves that perform similar flow control functions. A unidirectional valve may refer to a check valve configured to allow fluid flow in one direction while preventing reverse flow. The unidirectional valve may comprise stainless steel or corrosion-resistant alloys such as Inconel, and alternatives may include swing check valves, lift check valves, or diaphragm check valves that perform similar one-wayIS24.1319 flow control functions. A rupture disc may refer to a thin component configured to burst under a predetermined pressure to allow fluid flow through a bypass or to verify system integrity. The rupture disc may comprise stainless steel, alloy steel, or polymer composites, and alternatives may include rupture diaphragms or pressure relief valves that perform similar pressure release functions.

[0044] A rupture disc 306 may refer to a thin component configured to burst under pressure to allow fluid flow through a bypass. The disc may comprise stainless steel, alloy steel, or polymer composites and alternatives may include rupture diaphragms or pressure relief valves that perform similar pressure release functions.

[0045] A rupture disc may refer to a pressure-sensitive component configured to fail at a predetermined pressure threshold to permit fluid passage and verify system integrity. The rupture disc may comprise stainless steel, alloy steel, or corrosion-resistant metals such as Inconel, and may optionally include polymer composites for chemical compatibility. Functional alternatives may include rupture diaphragms, burst plugs, or pressure relief valves that perform similar pressure release and safety functions.

[0046] In other embodiments, the chemical injection valve may have a choke, controlled by a direct current (DC) electromechanical actuator (EMA), and / or deliver to the downhole injection node a metered flow, from a single bypass injection line. This configuration may aid in Reverse Flow Prevention (RFP) and Back pressure retention (BPR) using the choke EMA controlled. An advantage of this configuration is the adjustable choke, allowing a more accurate control of injection flow.

[0047] A choke may refer to a flow control device configured to restrict or regulate the amount of fluid passing through an injection line. The choke may comprise stainless steel, alloy steel, or corrosion-resistant metals such as Inconel, and may optionally include elastomeric seals or polymer inserts for sealing. Functional alternatives may include adjustable orifice plates, throttling valves, or variable flow restrictors that perform similar flow regulation functions. An electromechanical actuator (EMA) may refer to a device configured to convert electrical energy into mechanical motion to operate a choke or valve. The EMA may comprise stainless steel housings, electric motors, and gear assemblies, and alternatives may include hydraulic actuators, pneumatic actuators, or solenoids that perform similar actuation functions.IS24.1319

[0048] Reverse Flow Prevention (RFP) may refer to a functionality configured to prevent well fluids from flowing back into the chemical injection line, thereby maintaining chemical integrity and protecting surface equipment. RFP may be achieved through one or more check valves, unidirectional valves, or other flow control devices. Functional alternatives may include backflow preventers, isolation valves, or pressure-actuated seals that perform similar reverse flow prevention functions. Back Pressure Retention (BPR) may refer to a functionality configured to maintain a predetermined pressure within the chemical injection system to ensure controlled chemical dosing and prevent uncontrolled flow. BPR may be achieved through adjustable chokes, solenoid-operated valves, or pressure regulators. Functional alternatives may include spring- loaded valves, hydraulic regulators, or electronic pressure control devices that perform similar back pressure retention functions.

[0049] A choke may refer to a flow control device configured to restrict or regulate the amount of fluid passing through an injection line. The choke may comprise stainless steel, alloy steel, or corrosion-resistant metals such as Inconel, and may optionally include elastomeric seals or polymer inserts for sealing. Functional alternatives may include adjustable orifice plates, throttling valves, or variable flow restrictors that perform similar flow regulation functions.

[0050] The electric chemical injection mandrel 400 is shown in FIG. 4. The mandrel body 402 is a cylindrical bar, with a through hole for production flow and threads in both ends to connect to the completion string. The body may have an eccentric section with cuts to accommodate the electric chemical injection valve 404, the electronic section 406 and the electromechanical actuator (EMA) 408. A single chemical injection line 410 bypasses the mandrel and has an internal derivation to feed the electric chemical injection valve 404. The same line may deliver one or more chemicals to other chemical mandrels in the completion string, as illustrated in FIG. 2. Turning to FIGs. 5 A and 5B, electric chemical injection valve 500 may be composed of an actuation rod 502, connected to the electromechanical actuator (EMA) 408 (see FIG. 4). The actuation rod may slide inside a sealed housing 506 and allow a choke control 504. This mechanism may be mounted in series with a unidirectional valve 508 forming a double barrier to prevent the well fluid to be injected into the chemical line up to the surface. The order of mounting may be either as shown in FIG. 5B or reversed, that is, the unidirectional valve may be first with respect the fluid inlet and the electric valve after, followed by the rupture disc. Between the unidirectional valve 508, (or theIS24.1319 choke control) and the injection port, there may be a rupture disc 510 to allow the operator to test the tightness of the chemical injection lines and valves before the installation in the well.

[0051] An actuation rod may refer to an elongated component configured to transmit motion from an actuator to a valve or choke mechanism. The actuation rod may comprise stainless steel, alloy steel, or polymer composites for reduced weight, and alternatives may include sliding plates, telescopic shafts, or rotary actuators that perform similar actuation functions. A sealed housing may refer to an enclosure configured to isolate internal components from external fluids and contaminants. The sealed housing may comprise stainless steel or alloy steel with elastomeric seals, and alternatives may include polymer-lined housings or composite enclosures that perform similar isolation functions. A choke control may refer to a mechanism configured to adjust the position of a choke to regulate fluid flow. The choke control may comprise stainless steel or alloy steel components and alternatives may include gear-driven throttling systems, adjustable orifice plates, or electronically controlled valves that perform similar flow regulation functions.

[0052] In some embodiments, an electric chemical injection valve may utilize a ball valve operated by a stepper motor and / or a gear box to open or close a ball valve. This configuration may aid in Back Pressure Retention (BPR), Reverse Flow Prevention (RFP) in an electric chemical injection valve. This configuration may also result in low power consumption and higher debris tolerance.

[0053] A ball valve may refer to a flow control device configured to regulate fluid passage by rotating a spherical closure element within a valve body. The ball valve may comprise stainless steel, alloy steel, or corrosion-resistant metals such as Inconel, and may optionally include polymer seats or elastomeric seals for leak prevention. Functional alternatives may include gate valves, plug valves, or butterfly valves that perform similar flow control functions. A stepper motor may refer to an electromechanical device configured to convert electrical pulses into discrete rotational movements for precise positioning. The stepper motor may comprise steel housings, copper windings, and permanent magnets, and alternatives may include servo motors, linear actuators, or pneumatic actuators that perform similar controlled motion functions. A gear box may refer to a mechanical assembly configured to transmit torque and adjust rotational speed between a motor and a driven component. The gear box may comprise hardened steel gears and alloy housings, and alternatives may include belt-driven systems, chain drives, or harmonic drives that perform similar torque transmission functions.IS24.1319

[0054] Turning to FIG. 6, an electric chemical injection valve 600 may be composed by a stepper motor 602 connected to a gear head 604. The torque from the gear head may be transmitted to the ball valve 606 through a connecting rod 608. When an electric command is given to the stepper motor 602, it may actuate and close or open the ball valve 606, allowing a remote control of the fluid injected in the well.

[0055] A gear head may refer to a mechanical assembly configured to reduce speed and increase torque (or increase speed and reduce torque) from a motor to a driven component. The gear head may comprise hardened steel gears and alloy housings, and alternatives may include planetary gear systems, harmonic drives, or belt-driven mechanisms that perform similar torque transmission functions. A connecting rod may refer to an elongated component configured to transmit linear or rotational motion between a gear head and a valve element. The connecting rod may comprise stainless steel or alloy steel for strength and durability, and alternatives may include linkages, shafts, or couplers that perform similar motion transfer functions.

[0056] Turning to the electric chemical injection valve 700 of FIG. 7, the stepper motor mechanism may be mounted in series with a unidirectional valve 704 forming a double barrier to prevent the well fluid to be injected into the chemical line up to the surface. The order of mounting may be either as shown in FIG. 6 or the reverse, that is, the unidirectional valve 704 first with respect the fluid inlet and the electric valve after, followed by the rupture disc. Between the unidirectional valve 704, (or ball valve) and the injection port, there may be a rupture disc to allow the operator to test the tightness of the chemical injection lines and valves before the installation in the well. A unidirectional valve may refer to a flow control component configured to allow fluid movement in one direction while preventing reverse flow. The unidirectional valve may comprise stainless steel or corrosion-resistant alloys such as Inconel, and may optionally include elastomeric seals or polymer inserts for leak prevention. Functional alternatives may include swing check valves, lift check valves, or diaphragm valves that perform similar one-way flow control functions.

[0057] Turning to FIG. 8, the electric chemical injection valve 800 may be solenoid operated, with a plunger connected to a spool. The spool may have a transversal hole that intercepts two adjacent holes, one that supplies chemical and other that injects the well. One or more metal - to-metal seals in the spool may isolate the supply from the injection port. This configuration may aid in Back Pressure Retention (BPR) and Reverse Flow Prevention (RFP) functions in an electric chemical injection valve. This configuration also has the advantage of aiding in low powerIS24.1319 consumption and synchronized and / or metered chemical injection based on one or more pressure sensor readings from production zones and string. Some embodiments may include a hydraulic control valve (HCV) and / or be self-equalizing. Some embodiments may comprise an indexer.

[0058] A spool may refer to a cylindrical component configured to regulate fluid flow by aligning or blocking internal passages within a valve body. The spool may comprise stainless steel or alloy steel and alternatives may include sliding plates or rotary discs that perform similar flow regulation functions. A plunger may refer to a movable element within a solenoid assembly configured to transmit linear motion for valve actuation. The plunger may comprise stainless steel or ferromagnetic alloys and alternatives may include rods or pistons that perform similar actuation functions. Metal-to-metal seals may refer to sealing interfaces configured to prevent fluid leakage by direct contact between metallic surfaces. These seals may comprise stainless steel or alloy steel and alternatives may include elastomeric seals, polymer seals, or composite sealing systems that perform similar isolation functions. A hydraulic control valve (HCV) may refer to a valve configured to regulate fluid flow using hydraulic actuation. The HCV may comprise stainless steel or alloy steel bodies with elastomeric seals, and alternatives may include pneumatic valves or electrically actuated valves that perform similar flow control functions.

[0059] An indexer may refer to a positioning mechanism configured to enable incremental movement or alignment of a component such as a sliding rod. The indexer may comprise hardened steel or alloy components for durability and may optionally include polymer bushings for reduced friction. Alternatives may include ratchet-based indexing systems, gear-driven positioners, or cambased actuators that perform similar incremental positioning functions.

[0060] A sliding rod may refer to an elongated component configured to move linearly within a guide or housing to actuate valves or indexing mechanisms. The sliding rod may comprise stainless steel, alloy steel, or polymer composites for reduced weight, and alternatives may include sliding plates, telescopic shafts, or rotary actuators that perform similar actuation functions.

[0061] In FIG. 9, the electrical chemical injection system 900 may comprise an electrical safety valve 914, electrical gas lift valve 916, chemical injection line A 904, chemical injection line B 902, electric line 908, zone 1 918, zone 2 920, zone 3 922, one or more flow control valves 910, one or more packers 912, wetmate disconnect tool 924, and a chemical injection valve 906 (e.g., MIQ: multi-injection qualified). Multi -injection qualified (MIQ) may refer to a configuration or device designed to enable multiple chemical injections into a wellbore through a single systemIS24.1319 or mandrel, either sequentially or selectively. The MIQ system may comprise stainless steel or alloy steel housings with corrosion-resistant coatings, and may optionally include elastomeric seals or polymer components for isolation. Functional alternatives may include modular injection systems, multi-zone injection valves, or dual-line chemical injection assemblies that perform similar multi-chemical injection functions.

[0062] An electrical safety valve may refer to a valve configured to shut off fluid flow in a wellbore under emergency or abnormal conditions using electrical actuation. The electrical safety valve may comprise stainless steel or alloy steel bodies with elastomeric seals, and alternatives may include hydraulic safety valves or pneumatic safety valves that perform similar emergency shutoff functions. An electrical gas lift valve may refer to a valve configured to control gas inj ection into a wellbore for artificial lift using electrical actuation. The gas lift valve may comprise stainless steel or corrosion-resistant alloys and alternatives may include hydraulic gas lift valves or pneumatic valves that perform similar gas injection functions. A wetmate disconnect tool may refer to a device configured to enable electrical and hydraulic connections to be made or broken under subsea or downhole conditions without retrieval of the completion string. The wetmate disconnect tool may comprise stainless steel housings, elastomeric seals, and electrical connectors, and alternatives may include drymate connectors or mechanical disconnect tools that perform similar connection and disconnection functions. A packer may refer to a downhole sealing device configured to isolate zones within a wellbore. The packer may comprise elastomeric sealing elements and metallic bodies such as stainless steel or alloy steel, and alternatives may include inflatable packers or mechanical isolation tools that perform similar zonal isolation functions. A flow control valve may refer to a valve configured to regulate fluid flow within a wellbore or completion string. The flow control valve may comprise stainless steel or alloy steel bodies with elastomeric seals, and alternatives may include sliding sleeve valves, choke valves, or ball valves that perform similar flow regulation functions.

[0063] In FIG 10, the electrical chemical injection valve architecture 1000 may comprise injection line 1 1002, injection line 2 1004, single-use isolation (SUI) and / or screen with bypass 1006, back pressure retention (BPR) 1008, reverse flow prevention (RFP) 1010, flow control device and / or calibration pressure device 1014, and / or single-use isolation (SUI) 1012.

[0064] Single-use isolation (SUI) may refer to a sealing mechanism configured to provide a one-time isolation of a fluid path, typically by rupturing or permanently closing after activation.IS24.1319The SUT may comprise stainless steel or alloy steel housings with elastomeric seals, and alternatives may include rupture discs, burst plugs, or disposable sealing elements that perform similar isolation functions.

[0065] A calibration pressure device may refer to a component configured to measure or regulate pressure within the injection system for calibration purposes. The device may comprise stainless steel housings, elastomeric diaphragms, and pressure sensors, and alternatives may include pressure regulators, gauge assemblies, or electronic transducers that perform similar calibration functions.

[0066] In FIG. 11, the electrical chemical injection valve architecture 1100 may comprise injection line 1 1102, injection line 2 1104, screen with bypass 1106, discrete choke 1108, calibration pressure device 1110, T-connector 1112, on-off solenoid-operated valve (SOV) 1114, checkvalve 1116, and indexer mechanism 1118. The fluid pumped from the surface flows through either line 1 or line 2. Then, the fluid flows through the T-connector and a screen with a bypass. On-off solenoid valves (SOV) allow flow from lines 1 or 2 to go flow control device. The second line could be used to inject different chemicals in the same well, but never simultaneously in the same mandrel. Also, the second line could be used as a spare injection line, in case the main line is inoperative. The mandrel accommodates the electronics, indexer mechanism, T-connectors, and screens with a bypass. The manifold assembly includes the threaded choke, an indexer mechanism, two on-off solenoid valves (SOV). The tool also incorporates two barriers: an on-off solenoid valve (SOV) and a check valve. The check valve allows fluid to flow from the surface to the well through the injection line while preventing reverse flow.

[0067] A manifold assembly may refer to a structural component configured to house multiple flow control devices such as chokes, indexers, and / or valves within a single integrated unit. The manifold may comprise stainless steel or alloy steel and alternatives may include modular valve blocks or distributed piping assemblies that perform similar integration functions.

[0068] A check valve may refer to a unidirectional flow control device configured to allow fluid flow in one direction while preventing reverse flow. The check valve may comprise stainless steel or alloy steel bodies with elastomeric seals, and alternatives may include swing check valves, lift check valves, or diaphragm check valves that perform similar one-way flow control functions.

[0069] A T-connector may refer to a pipe fitting configured to join two or three flow paths, enabling chemical distribution between multiple lines. The T-connector may comprise stainlessIS24.1319 steel, carbon steel, or polymer composites for corrosion resistance. Functional alternatives may include Y-connectors or cross-connectors that perform similar fluid distribution functions.

[0070] An on-off valve may refer to a flow control device configured to permit or restrict chemical flow through the injection line. The valve may comprise stainless steel, carbon steel, or alloy steel bodies with elastomeric or metal seals for leak prevention. A valve may include gate valves, ball valves, or needle valves that perform similar flow control functions.

[0071] In FIG. 12, the electrical chemical injection valve architecture 1200 may comprise two chemical injection lines 1204, electric on / off solenoid valves 1206, unidirectional valve 1208, and flow control device 1202.

[0072] In some embodiments, the flow control valve uses a helical flow path, provided by a fixed thread connection, to promote a pressure drop and flow rate variation. The thread engagement length is increased in fixed increments by means of a set of bypass holes aligned in a row, along with the thread connection. There may be 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16„ 17, 18, 19, or 20 bypass holes. Each bypass hole has a check valve that allows the flow when mechanically opened. A sliding rod moves along the check valves row and opens each one as the beveled head pushes the ball from the seat. The sliding rod is connected to a ratchet mechanism that promotes a discrete incremental movement. An indexer mechanism promotes the direction of the sliding rod movement. The ratchet mechanism is operated by a solenoid.

[0073] A ratchet mechanism may refer to a toothed component configured to allow incremental movement of a sliding rod in one direction while preventing reverse motion. The ratchet mechanism may comprise hardened steel or alloy components for durability, and alternatives may include gear trains, pawl systems, or detent mechanisms that perform similar incremental movement functions. A solenoid may refer to an electromagnetic actuator configured to convert electrical energy into linear motion for valve or mechanism actuation. The solenoid may comprise a coil wound around a ferromagnetic core and a movable plunger, and alternatives may include pneumatic actuators, hydraulic pistons, or bistable actuators that perform similar actuation functions.

[0074] Bypass holes may refer to openings configured to allow fluid to flow around a primary restriction or component. The bypass holes may be formed in stainless steel or alloy housings and alternatives may include slots, channels, or secondary conduits that perform similar bypass functions.IS24.1319

[0075] The electrical chemical injection valve system 1300 of FIG. 13 may comprise injection line 1 1302, injection line (e.g., spare) 1304, electronic section 1306, T-connector 1308, screen with bypass 1310, on-off SOV 1312, indexer mechanism 1314, discrete choke 1316, and / or choke valve 1318. In the flow control device, the chemical flows through a fixed stub Acme thread, navigating the clearance between the male and female threads. A pressure drop is induced by fluid friction as the chemical moves along the helical path. By adjusting the bypass holes along the thread engagement, the effective length of the choke can be increased or decreased, thereby regulating the pressure drop. Each check valve can be opened at a time, by means of a sliding rod that moves along the bypass holes. The sliding rod has a beveled head that forces the check valve ball against its spring to open it.

[0076] A helical path may refer to a spiral-shaped conduit, or any other-shaped conduit, configured to induce frictional pressure drop as fluid flows through it. The helical path may comprise stainless steel tubing or polymer-lined channels and alternatives may include serpentine paths, coiled tubing, or labyrinth passages that perform similar pressure reduction functions.

[0077] A check valve ball may refer to a spherical component configured to seal against a valve seat under spring force to prevent reverse flow. The ball may comprise stainless steel, ceramic, or polymer composites, and alternatives may include poppets or tapered plugs that perform similar sealing functions.

[0078] A spring may refer to an elastic component configured to apply force to maintain the check valve ball against its seat. The spring may comprise stainless steel or alloy steel and alternatives may include elastomeric bands or magnetic biasing systems that perform similar force application functions.

[0079] A screen comprising a bypass may refer to a filtration component configured to remove particles, contaminates, solids, dust, asphaltenes, coagulates, non-desirable material and / or impurities from injected chemicals while allowing fluid to pass through an alternate path when the primary filter becomes obstructed. The screen may comprise stainless steel mesh or sintered metal, and the bypass may include a secondary channel integrated into the housing. Alternatives may include inline filters, strainers, or perforated plates that perform similar filtration and bypass functions. A filter may refer to a component configured to remove particulates from fluid before injection. The filter may comprise stainless steel mesh, sintered metal, or polymer screens andIS24.1319 alternatives may include strainers, cartridge filters, or cyclone separators that perform similar filtration functions.

[0080] In the flow control system 1400 of FIG. 14, the flow control device 1404 is assembled externally to a mandrel 1402 in the completion string. The mandrel has a section to accommodate the chemical injection flow control device 1404, the electronic section 1406 that controls the solenoids, the 2way / 2position directional solenoid valves 1410 and the second reverse flow prevention valve (check valve) 1412. Two chemical injection lines 1408, running from the FPSO (Floating Production Storage and Offloading) to the injection mandrels, bypasses the mandrel and has an internal derivation to feed the electric chemical injection valve. The same line will deliver chemicals to other mandrels in the completion string.

[0081] A 2-way / 2-position directional solenoid valve may refer to a valve configured to control fluid flow between two ports using two discrete positions, actuated by an electromagnetic solenoid. The valve may comprise stainless steel or alloy steel bodies with elastomeric seals, and alternatives may include pneumatic directional valves or hydraulic directional valves that perform similar flow switching functions. FPSO (Floating Production Storage and Offloading) may refer to a floating vessel configured to process and store hydrocarbons and offload them to shuttle tankers or pipelines. The FPSO may comprise steel hulls and integrated topside processing equipment, and alternatives may include fixed platforms or subsea processing units that perform similar production and storage functions.

[0082] The electric on / off solenoid valve 1410, mounted in series with the unidirectional valve 1412, forms a double barrier to prevent the well fluid from being injected into the chemical line up to the surface. The discrete flow control device may be assembled in series between the on / off solenoid valve and the last check valve.

[0083] Turning to FIG. 15, the flow control device 1500 is essentially composed of a threaded connection 1502 with a fixed thread engagement. The flow, pumped from the surface, is forced to pass through the formed gap between the male and female threads. The pressure drop occurs due to friction of the fluid along the helical path 1512. Bypass holes 1504 along the thread will give different engagement lengths and consequently, different pressure drops. Each thread engagement length is associated with a respective flow rate and fluid properties. The different engagement lengths will give different adjustments of pressure drop and flow rates, serving as a discrete flow control device. The thread radial gap can be also variable for adjustments to differentIS24.1319 fluid viscosities. Each bypass hole is maintained close by check valves 1506. Each check valve can be opened at a time, by means of a sliding rod 1508 that moves along the bypass holes. The sliding rod has a beveled head 1510 that forces the check valve ball against its spring to open it. Flow control device 1500 may comprise flow inlet 1514 and flow outlet 1516.

[0084] Turning to the mechanism flow control device 1600 in FIG. 16, the sliding rod is connected to a ratchet mechanism 1602 that promotes a unidirectional incremental movement. To allow the movement of the rod in two directions, a second ratchet is used. An indexer 1604 shifts the ratchets at the end of the sliding rod stroke promoting the direction movement change. A solenoid 1606 is used to promote the force necessary to move the ratchet mechanism. The bellow (also known as a ‘compensating bellow”) 1608 is used for pressure balancing (e.g., compensating) and to isolate the injecting fluid from the fluid in the ratchet mechanism.

[0085] The bellow may refer to a flexible component configured to balance pressure and isolate injected fluid from external environments. The bellow may comprise stainless steel, elastomeric materials, or polymer composites and alternatives may include diaphragms, seals, or expansion joints that perform similar pressure compensation and isolation functions.

[0086] The sliding rod moving mechanism 1700 of FIG. 17 may comprise a BSA 1702, bellow 1704, sliding rod 1706, indexer ratchets 1710, and indexer movement change 1708. The sliding rod is connected to an indexer mechanism that enables unidirectional incremental movement. To allow the rod to move in both directions, a second ratchet is used. An indexer shifts the ratchets at the end of the sliding rod stroke promoting the direction movement change. A bistable actuator (BSA) is used to generate the force required to operate the ratchet mechanism. One or more compensating bellows 1608 are used for pressure balancing and to isolate the fluid injected from the ratchet mechanism fluid. The thread radial gap and the engagement can be adjusted for optimization to specific fluid properties.

[0087] A bistable actuator (BSA) may refer to a device configured to generate force to operate ratchets or valves, maintaining two stable positions without continuous energy input. The actuator may comprise stainless steel housings, magnetic or spring-based mechanisms, and alternatives may include solenoids, pneumatic actuators, or hydraulic pistons that perform similar actuation functions.

[0088] An indexer ratchet may refer to a toothed mechanism configured to enable incremental movement of a sliding rod in one direction. The ratchet may comprise hardened steelIS24.1319 or alloy components and alternatives may include gear trains, pawl systems, or detent mechanisms that perform similar incremental movement functions.

[0089] In some embodiments, the second line could be used to inject different chemicals in the same well. The injections from both lines may happen alternately or simultaneously in the same mandrel. Also, the second line could be used as a spare injection line, in case the main line is inoperative.

[0090] The manifold view 1800 of the chemical injection system in FIG. 18 may comprise an on-of SOV 1802, and SOV operated flow 1804, and check valve 1806. The functionality involves the injection of fluids through either Line 1 or Line 2, passing through a T-connector and a filtration system.

[0091] Flow path 1900 of FIG. 19 shows the flow from injection line 1 1902 and injection line 2 1904. The flow continues through the On-Off SOV, which is responsible for selecting the fluid to be injected, and subsequently through a solenoid-operated flow control valve.

[0092] A solenoid is an electromagnetic actuator that converts electrical energy into linear motion. It consists of a coil wound around a ferromagnetic core and a movable plunger. When current flows through the coil, a magnetic field is generated, pulling the plunger and producing motion, which shows the basic structure and operating principle of a solenoid. The operation of a solenoid is based on the magnetic force produced by the coil. The actuator generates sufficient force to overcome external forces, such as springs or load resistance, to ensure proper movement. In this project, solenoids were sized to exceed the spring force, allowing reliable actuation under limited power conditions.

[0093] The principle of the solenoid can be applied to control fluid flow in practical applications through a solenoid-controlled valve (SOV). These valves are actuated by a solenoid to open or close the fluid flow and operate in a binary mode: fully open or fully closed. When energized, the solenoid moves the plunger to open the valve. When de-energized, the valve returns to its default position, assisted by a spring. The solenoid may overcome the spring force and the fluid pressure to actuate the valve.

[0094] An electrical chemical injection valve system may utilize two actuators: one for the On-Off valve and another for the Flow Control Device. For the On-Off valve, the standard spring- biased solenoid may be configured to fail-open, fail-close, or fail-as-is. A bistable actuator (BSA) may comprise a fail-as-is failure mode. For the Flow Control Device, a ratchet mechanism may beIS24.1319 designed to fail-as-is, meaning that in the event of a loss of power, the flow regulation will remain in its last set position.

[0095] A Bistable Actuator (BSA) may be a type of magnetic actuator designed to maintain its position in one of two stable states without requiring continuous electrical power. It is mainly composed of a ferromagnetic core, a movable plunger, electromagnetic coils and permanent magnets. Unlike conventional solenoids, which require a constant current to hold the plunger in position, the bistable actuator relies on residual magnetic forces, springs and permanent magnets to keep its position even after the electrical supply is removed. This characteristic greatly reduces energy consumption and heat generation, making BSA highly efficient for systems that require long-term stable positions

[0096] The screen sub device 2000 of FIG. 20 may comprise a rupture disk 2002, inner sleeve 2006, and screen 2004. The Electric Chemical Valve may have a filter, e g., Secondary Chemical Injection Screen (SCIS), integral or externally mounted, with a bypass device to allow continuity of the injection in case of obstruction of the filter element. Several embodiments propose the use of the Screen Sub Device.

[0097] An inner sleeve may refer to a cylindrical component configured to provide structural support and alignment within a screen sub assembly. The inner sleeve may comprise stainless steel or alloy steel and alternatives may include polymer-lined sleeves or composite inserts that perform similar support and alignment functions. A Secondary Chemical Injection Screen (SCIS) may refer to a filtration device configured to remove particulates from injected chemicals before entry into the wellbore. The SCIS may comprise stainless steel mesh or sintered metal, and alternatives may include cartridge filters, strainers, or perforated plates that perform similar filtration functions.

[0098] FIG. 21 depicts a screen sub (also known as Safety Screen Filter Sub) at bypass mode 2100. The Safety Screen Filter Sub is a downhole screen device designed to filter debris from the surface equipment and injection lines. The device includes a bypass mechanism that is automatically actuated if the screen 2004 becomes clogged to ensure injection is not interrupted. In the normal flow condition (filter not saturated), the fluid bursts the disc 2002 (if included) and flows through the screen, preventing debris from entering the subsequent elements of the chemical valve. When the filter element becomes saturated, the flow is restricted, causing an increase in theIS24.1319 differential pressure across it. This pressure creates a piston force that moves the sliding sleeve, redirecting the flow through the bypass holes.

[0099] The electrical Chemical Valve may include an On-Off Solenoid Valve (SOV) installed upstream of the flow control device and the check valve. The positioning of the On-Off SOV allows the operator to perform a watertightness test of the injection lines after installation. Additionally, as mentioned above, it is possible to incorporate a rupture disc into the Screen Sub to conduct the watertightness test of the lines using this device.

[0100] As used herein, the terms “connect”, “connection”, “connected”, “in connection with”, and “connecting” are used to mean “in direct connection with” or “in connection with via one or more elements”; and the term “set” is used to mean “one element” or “more than one element”. Further, the terms “couple”, “coupling”, “coupled”, “coupled together”, and “coupled with” are used to mean “directly coupled together” or “coupled together via one or more elements”. As used herein, the terms "up" and "down"; "upper" and "lower"; "top" and "bottom"; and other like terms indicating relative positions to a given point or element are utilized to more clearly describe some elements. Commonly, these terms relate to a reference point at the surface from which drilling operations are initiated as being the top point and the total depth being the lowest point, wherein the well (e.g., wellbore, borehole) is vertical, horizontal or slanted relative to the surface.

[0101] Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and / or within less than 0.01% of the stated amount. As another example, in certain embodiments, the terms “generally parallel” and “substantially parallel” or “generally perpendicular” and “substantially perpendicular” refer to a value, amount, or characteristic that departs from exactly parallel or perpendicular, respectively, by less than or equal to 15 degrees, 10 degrees, 5 degrees, 3 degrees, 1 degree, or 0.1 degree.

[0102] Although a few embodiments of the disclosure have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, suchIS24.1319 modifications are intended to be included within the scope of this disclosure as defined in the claims. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments described may be made and still fall within the scope of the disclosure. It should be understood that various features and aspects of the disclosed embodiments can be combined with, or substituted for, one another in order to form varying modes of the embodiments of the disclosure. Thus, it is intended that the scope of the disclosure herein should not be limited by the particular embodiments described above.

Claims

IS24.1319CLAIMSWhat is claimed is:

1. An electric chemical injection (eCi) system comprising: a first injection line; a first on-off valve; a screen comprising a bypass, wherein the screen is positioned between the first injection line and the first on-off valve; a first T-connector positioned between the first injection line and the screen; a choke configured to allow a given amount of fluid to flow, the choke comprising an indexer; a calibration pressure device; and a check valve, comprising a check valve ball and a spring, the check valve configured to allow fluid flow from a surface to a well through the first injection line while preventing reverse fluid flow.

2. The eCi system of claim 1, where the choke is a discrete choke.

3. The eCi system of claim 1, wherein the on-off valve is an on-off solenoid valve (SOV).

4. The eCi system of claim 1, further comprising a helical path configured for a flow of an injected chemical, whereby a pressure drop is induced by friction as the injected chemical flows along the helical path.

5. The eCi system of claim 1 , wherein the choke further compri ses one or more bypass holes.

6. The eCi system of claim 1, further comprising a second injection line, a second T- connector, and a second on-off valve.IS24.13197. The eCi system of claim 1 , wherein the check valve is configured to be opened via a sliding rod that moves along one or more bypass holes.

8. The eCi system of claim 7, wherein the sliding rod has a beveled head that forces the check valve ball against a spring.

9. The eCi system of claim 1, wherein a sliding rod is configured to move along a first indexer ratchet to enable incremental movement in a first direction.

10. The eCi system of claim 9, further comprising a second indexer ratchet configured to allow the sliding rod to move incrementally in a second direction.

11. The eCi system of claim 10, wherein the indexer is configured to shift the first ratchet and the second ratchet at an end of a stroke of the sliding rod.

12. The eCi system of claim 11, further comprising a bistable actuator (BSA) configured to generate a force to operate the first ratchet and the second ratchet.

13. The eCi system of claim 12, further comprising a compensating bellow configured to balance pressure and to isolate injected fluid.

14. The eCi system of claim 1, wherein when a filter is not saturated, the screen comprising a bypass is configured to allow fluid to burst a disc and flow through the screen.

15. The eCi system of claim 1, further comprising a manifold assembly that comprises the choke, the indexer, and the first on-off valve.

16. A method of electric chemical injection (eCi), the method comprising: sliding a rod;IS24.1319 actuating two ratchets, with the force of a bistable actuator BSA, to shift the two ratchets at an end of a sliding rod stroke; opening or closing a valve; and injecting a fluid from an injection line through a screen and through an on- off solenoid valve (SOV).

17. The method of claim 16, further comprising dropping pressure of the fluid by moving the fluid along a helical path.

18. The method of claim 16, further comprising opening a valve when the sliding rod is over the valve.

19. The method of claim 16, further comprising closing a valve when the sliding rod is not over the valve.

20. The method of claim 16, further comprising discretely moving the sliding rod along indexer ratchets.

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