Casing-Based Intelligent Completion Assembly for Well Flow Control
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Solution Overview
Problem
Current well completion systems face delays and increased costs due to the need for miles of hydraulic and electrical lines to actuate valves and power sensors, which also restrict fluid flow rates because of the smaller diameter of the lower completion string compared to the casing, leading to inefficiencies in well production operations.
Innovation Solution
A casing-based intelligent completion assembly with a downhole closed-loop hydraulic system and integrated sensors and inflow control devices, where the hydraulic system is self-contained and isolated from surface systems, allowing for rapid actuation of inflow control devices and increased fluid flow rates without the need for extensive hydraulic lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If miles of hydraulic lines are used to actuate valves from the surface, then the valves can be controlled, but the response time is delayed and the cost increases
Solution Approach 1:
The hydraulic system is extracted from the surface location and placed downhole with the valves. A downhole hydraulic power source and reservoir are provided, eliminating the need for miles of hydraulic lines to extend from the surface. This extraction resolves the contradiction by enabling immediate valve actuation without the time delay caused by long hydraulic line transmission from the surface.
Solution Approach 2:
The downhole hydraulic system is self-contained with its own power source and fluid reservoir, allowing it to operate independently without continuous surface intervention. The system can actuate valves autonomously using locally stored hydraulic fluid and power, eliminating the response time delay associated with surface-controlled systems and reducing operational costs.
2Device complexity
If a lower completion string with smaller inner diameter is used to house valves and sensors, then the casing structure is maintained, but the fluid flow rate is restricted
Solution Approach 1:
The hydraulic power source and reservoir are positioned on the exterior of the completion string rather than inside it. This dimensional relocation allows the interior of the completion string to remain unobstructed, maintaining full fluid flow capacity while still providing the necessary hydraulic components for valve actuation on the outside.
Solution Approach 2:
The hydraulic system components (power source, reservoir, actuation mechanisms) are segmented and distributed along the exterior of the completion string rather than being consolidated in a single internal housing. This segmentation allows the completion string to maintain its structural integrity and full bore flow capacity while accommodating all necessary hydraulic components externally.
3Reliability
If miles of electrical lines are run from the surface to sensors and components, then the system can be monitored and controlled, but the cost and system complexity increase
Solution Approach 1:
The power source is extracted from the surface location and placed downhole with the sensors and control components. This creates a self-powered downhole system that does not require miles of electrical lines to extend from the surface, thereby reducing system complexity while maintaining full monitoring and control capabilities through local power generation.
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 solution reduces response time for actuating inflow control devices and increases well fluid flow rates by eliminating the dependency on surface hydraulic systems, thereby enhancing operational efficiency and reducing costs.
Implementation Method 1
a hydraulic system that is isolated from any hydraulic system located at the surface of the well such that the hydraulic system is independent from any hydraulic line that extends to the surface of the well
Data Source
AI summary
A downhole control method for use in a wellbore that includes deploying a first stand-alone hydraulic reservoir downhole; measuring a first downhole fluid parameter; and actuating a first inflow control device, based on the first measured downhole fluid parameter, using the first stand-alone hydraulic reservoir. In one aspect, the first stand-alone hydraulic reservoir and the first inflow control device comprise an open-hole completion system.