Modular Electro-Hydraulic Downhole Control for Large Tool Actuation
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Solution Overview
Problem
Current downhole operations in the oil and gas industry face complexity and high costs when using solenoid valves to operate larger tools, as they require wellbore projectiles, tubing jarring sequences, or large downhole motors, which increase operational complexity and costs.
Innovation Solution
The implementation of modular pilot and power modules using electro-hydraulic power and control technology, incorporating two-way and three-way solenoid valves, allows for the operation of both small and large hydraulically operated downhole tools, providing simplicity and robust capability through latching and isolation features that reduce power demand.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If solenoid valves are used to operate larger downhole tools, then operational control is improved, but device complexity and operational costs increase due to requirements for wellbore projectiles, tubing jarring sequences, or large downhole motors
Solution Approach 1:
The system is divided into modular components: pilot modules containing solenoid valves for control functions, and power modules containing hydraulic motors for actuation functions. This segmentation allows each module to be optimized independently and reduces overall system complexity by distributing functions across separate units that can be combined in standardized configurations.
Solution Approach 2:
Pilot modules act as intermediaries between the electrical control system and the hydraulic power system. The solenoid valves in pilot modules control directional flow of hydraulic fluid, which then actuates the power modules. This intermediary approach allows electrical signals to control high-power hydraulic actuation without requiring direct electrical connections or complex mechanical linkages downhole.
2Productivity
If traditional downhole motors and jarring sequences are used, then tool operation is achieved, but loss of time and productivity decrease due to complex operational sequences
Solution Approach 1:
Traditional mechanical jarring sequences and projectile-based actuation methods are replaced with an electro-hydraulic system. Electrical signals transmitted through the conveyance activate solenoid valves that immediately control hydraulic fluid direction, providing rapid and precise actuation without mechanical impact sequences or multiple operational steps.
Solution Approach 2:
The system pre-positions hydraulic fluid under pressure in the conveyance, ready for immediate actuation. When electrical control signals are received, the pre-positioned fluid can immediately actuate the downhole tools without requiring time-consuming mechanical sequences or additional fluid pumping operations.
3Ease of operation
If battery power is used for downhole operations, then portability is improved, but duration of action is limited by finite battery life span
Solution Approach 1:
The system uses hydraulic fluid transmitted through the conveyance (coiled tubing, drill pipe, or wireline) to power downhole actuators. This hydraulic power transmission eliminates the need for onboard batteries, as energy and control signals are delivered continuously from the surface through the existing conveyance infrastructure, enabling indefinite operational duration limited only by surface power availability.
4Device complexity
If modular pilot and power modules are used, then device complexity is reduced, but manufacturing precision requirements increase for hydraulic circuit assembly
Solution Approach 1:
The pilot modules and power modules are designed as universal, standardized units that can be combined in various configurations to operate different downhole tools. Each module contains standardized hydraulic ports and connection interfaces, reducing manufacturing precision requirements for custom fittings and simplifying assembly procedures while maintaining functional versatility across multiple applications.
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 enables efficient and cost-effective operation of downhole tools by using solenoid valves in modular pilot and power modules, reducing electrical and hydraulic power consumption and simplifying the design, while enabling the control of both small and large tools with reduced operational complexity.
Implementation Method 1
solenoid powered directional fluid valves
Implementation Method 2
hydraulically operated downhole tools
Data Source
AI summary
A downhole tool includes a hydraulically operated actuation device to actuate the downhole tool and a control system that regulates flow of hydraulic fluid to the actuation device. The control system includes a pilot module and a power module. The power module has a first solenoid valve and a second solenoid valve fluidly coupled to a pressure source and a fluid return. The power module is fluidly coupled to the actuation device at an output line and a power line. A first power module check valve is arranged in the power line, a second power module check valve is arranged in a control pressure return line fluidly coupled to the fluid return, a first input communicates with the first solenoid valve, and a second input communicates with the second solenoid valve. A pilot-operated check valve is actuatable in response to a pilot signal to drain hydraulic fluid from the power module.