Down-hole Control Module Hydraulic Actuation for Intelligent Wells
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Solution Overview
Problem
Current intelligent well completion systems face challenges in reliable remote actuation of down-hole components due to time delays and reliability issues with physical interventions and wireless communication, especially in noisy environments like gravel packing operations, which limits efficient hydrocarbon production and reservoir management.
Innovation Solution
A well completion system employing a down-hole control module that uses hydraulic pressure to actuate flow control tools, including isolation systems, circulating valves, and shear joints, via a network of control lines to independently manage each annular zone, allowing for precise control of fluid flow and pressure maintenance without occupying valuable wellbore space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If physical intervention with balls or darts is used to remotely actuate down-hole components, then the components can be actuated, but the method causes time delays and the actuating objects may get lost or stuck in unexpected locations
Solution Approach 1:
The patent replaces the mechanical ball/dart actuation system with a hydraulic control system. Hydraulic control lines are installed in the wellbore to deliver pressurized fluid to actuators, replacing the need for physical intervention with balls or darts. This substitution eliminates the reliability issues of lost or stuck actuating objects while maintaining remote actuation capability.
Solution Approach 2:
The patent introduces hydraulic control lines as an intermediary medium between the surface control system and down-hole components. These control lines transmit hydraulic energy to actuate valves and other components, serving as a reliable intermediary that eliminates direct mechanical intervention and its associated reliability problems.
2Reliability
If control lines are installed to send electric or hydraulic signals to down-hole components, then reliable actuation is achieved, but the control lines occupy space in the wellbore completion that limits flow diameter
Solution Approach 1:
The patent segments the wellbore completion into distinct functional zones: control lines are routed through annular spaces between the wellbore wall and production tools, while flow channels are maintained through the tool interiors. This segmentation allows control lines to occupy annular volume rather than blocking the flow diameter, resolving the conflict between control reliability and flow capacity.
3Volume of moving object
If wireless telemetry systems are used for remote communication, then wellbore space is preserved, but communication becomes unreliable in noisy environments like gravel packing operations
Solution Approach 1:
The patent uses hydraulic control lines as an intermediary transmission medium that is immune to noise interference. By embedding sensors and actuators along these hydraulic lines, the system achieves reliable communication and control in noisy gravel packing environments while preserving wellbore space for production flow.
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 reliable and efficient remote operation of down-hole components, optimizing hydrocarbon production by maintaining precise pressure and flow control in each zone, reducing the risk of component sticking and improving communication reliability, especially in noisy conditions.
Implementation Method 1
A well completion system employs a down-hole control module that uses hydraulic pressure to actuate flow control tools
Data Source
AI summary
A system for controlling flow in a wellbore can include a down-hole control module that is hydraulically coupled to multiple components of the system. The control module can include a computer, which can be preprogrammed to operate the various components in a particular sequence, and communicate confirmation or error signals to a surface location. The control module can also include a micro-hydraulic motor and pump that can that can be instructed by the computer to selectively deliver hydraulic fluid to one or more of the components of the system. The system can include isolation members such as packers, hydraulic pressure maintenance devices (PMDs), hydraulic shear joints, inflow control devices or valves (ICDs or ICVs) and a three-position valve that can be actuated by the control module without necessitating communication with a surface location.