Density-Based Flow Control Using Rotating Baffles for Fluid Separation
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Solution Overview
Problem
Undesirable fluids mixed with desirable fluids in fluid flows increase costs, time, and tool wear without providing any benefit, necessitating improved separation technologies.
Innovation Solution
A density-based flow control configuration using rotationally movable baffles and density floats that align or misalign openings based on fluid density to automatically separate target from nontarget fluids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If manual flow control methods are used to separate desirable from undesirable fluids, then flow control can be achieved, but operational costs increase and tool wear increases due to continuous monitoring and adjustment requirements
Solution Approach 1:
The flow control device uses density floats that automatically respond to fluid density changes, causing baffles to rotate and align or misalign openings without external control. The system self-regulates flow separation based on inherent density differences between desirable and undesirable fluids, eliminating the need for continuous manual monitoring and adjustment.
Solution Approach 2:
The patent replaces complex electronic sensing and control systems with a simple mechanical density-based mechanism. Density floats convert density differences directly into mechanical rotation of baffles, which automatically control flow paths. This mechanical substitution eliminates costly electronic systems while achieving automatic flow separation.
2Extent of automation
If density-based automatic flow control is implemented, then operational costs decrease and automation increases, but device complexity increases due to additional components like rotationally movable baffles and density floats
Solution Approach 1:
The device exploits natural parameter changes in fluid density to drive the separation process. Density floats respond to density variations in the fluid stream, converting these parameter changes into mechanical motion that automatically controls flow separation. This approach uses inherent fluid properties rather than requiring complex external control systems.
Solution Approach 2:
The patent employs rotationally movable baffles that dynamically adjust their position based on real-time fluid density conditions. The baffles can rotate to align or misalign openings, creating dynamic flow control that adapts to changing fluid compositions. This dynamic mechanism provides automatic adaptation without complex electronics.
3Reliability
If flow separation technologies are added to remove undesirable fluids, then fluid purity improves, but device complexity and manufacturing costs increase
Solution Approach 1:
The flow control device segments the fluid stream using multiple density floats and baffles positioned at different locations. Each float-baffle combination handles specific density ranges or fluid types, dividing the separation task into simpler segments. This segmentation achieves effective multi-fluid separation while keeping individual components simple and manageable.
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
Automatically separates desirable from undesirable fluids, optimizing flow control and reducing operational costs and tool wear by aligning openings based on fluid density.
Implementation Method 1
a first selected density float associated with the rotationally movable one of the first or second baffles, the first float imparting torque to the associated baffle dependent upon a density of a fluid to which the first float is exposed
Implementation Method 2
a first selected density float associated with the rotationally movable one of the first or second baffles, the first float imparting torque to the associated baffle dependent upon a density of a fluid
Data Source
AI summary
A density-based flow control configuration includes a housing and a first baffle having a first flow opening, a second baffle having a second flow opening adjacent the first baffle, one of the baffles being rotationally movable relative to the housing and to the other of the baffles, a first density float associated with the movable baffle, to impart torque to the associated baffle, the torque causing alignment or misalignment of the first and second openings. A method for allowing flow of a target fluid and choking flow of a nontarget fluid, including exposing a density-based flow control configuration to a fluid, imparting torque to a first baffle, and aligning or misaligning an opening in the first baffle with another opening to allow or choke flow of the fluid. A wellbore system, including a density-based flow control configuration.