Annulus 6-Zone Control Manifold Hydraulic Coding
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Solution Overview
Problem
Existing systems for differentially controlling downhole tools in oil and gas production are complex, prone to failure, and require multiple hydraulic lines, which are limited by space constraints and costly, especially when dealing with multiple zones and tools.
Innovation Solution
A novel hydraulic coding system using four lines to control six downhole valves, where one line addresses two zones, another line actuates one zone, and a fourth line closes all actuated tools, eliminating the need for differential pressure coding and complex components like relief and pilot-operated valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple hydraulic lines are used to control more downhole tools, then the number of controllable tools increases, but the system complexity and cost increase
Solution Approach 1:
The patent merges the addressing and actuating functions into a single hydraulic line system. By using binary coding on four hydraulic lines, the system can address and actuate up to 16 tools simultaneously, eliminating the need for separate complex control systems for each tool and reducing overall system complexity while increasing controllability
Solution Approach 2:
Each hydraulic line serves multiple functions: it can address multiple zones (1-6) and actuate multiple tools through binary coding combinations. The same four lines can control different tools at different times by varying the pressure patterns, making the system universal and adaptable to various downhole tool configurations without requiring additional dedicated lines for each tool
2Measurement precision
If differential pressure coding is used to control tools, then tool selection precision improves, but the number of required components increases
Solution Approach 1:
The patent extracts the differential pressure coding mechanism and replaces it with a simpler binary pressure presence/absence system. Instead of using complex differential pressure comparisons requiring multiple valves and sensors, the system uses simple binary coding where the presence or absence of pressure on each of the four lines directly encodes the tool address, achieving precise tool selection with minimal components
Solution Approach 2:
The patent replaces the mechanical differential pressure coding system with a hydraulic binary coding system. Rather than mechanically comparing pressure differences through multiple valves and levers, the system uses hydraulic pressure signals in binary patterns (present/absent on each line) to directly address and select tools, significantly reducing the mechanical component count while maintaining precise selection capability
3Adaptability or versatility
If more hydraulic lines are added to control additional zones, then zone coverage increases, but space constraints and cost increase
Solution Approach 1:
The patent transitions from a linear one-dimensional approach (one line per zone) to a two-dimensional binary coding approach (four lines with binary patterns). This dimensional change allows 2^4 = 16 possible combinations, enabling control of up to 16 tools across 6 zones using only four hydraulic lines, effectively doubling the control capacity per line and reducing the space required for hydraulic line routing in the annulus
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system simplifies the control of multiple downhole tools with fewer and more robust parts, reducing complexity and cost, while operating with any valve design and allowing for incremental control of piston and indexing type valves.
Implementation Method 1
Multiple hydraulic lines are connected to a plurality of tools, and the lines used in a binary fashion to address and actuate individual tools
Data Source
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AI summary
A method of controlling a plurality of downhole tools in a wellbore, using first and second codes transmitted by hydraulic line to first address and then actuate the desired tool. A dedicated line is provided for terminating all actuated tools.