Downhole Electronic Valve Assembly for Remote Well Control
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Solution Overview
Problem
Existing well completion methods using wireline plugs and hydraulically controlled valves face challenges such as increased completion time and cost, safety risks, and reliability issues due to debris ingress and pressure cycle confusion, especially in hostile well conditions like deviated or horizontal wells.
Innovation Solution
A remotely operable through-tubing valve assembly with a downhole electronic actuating mechanism, battery-powered hydraulic pump, and hydraulically operated ball valve that can be opened and closed within the well bore without surface control lines, allowing for autonomous operation and reduced debris accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wireline plugs are used to control tubing flow, then the valve can be operated remotely, but the completion time increases and costs increase due to multiple trips required
Solution Approach 1:
The invention extracts the control mechanism from the surface and places it downhole with the valve. The electronic actuating mechanism and battery-powered hydraulic pump are integrated into the valve assembly, eliminating the need for wireline or hydraulic control lines to pass through the production packer. This allows the valve to be operated autonomously downhole, resolving the contradiction by enabling remote operation without requiring repeated trips or surface control infrastructure.
Solution Approach 2:
The valve assembly is designed to be self-sufficient with an integrated battery-powered hydraulic pump and electronic control system. The valve can autonomously control its own operation using downhole electronics and stored energy, without requiring external control lines or surface intervention. This self-service capability eliminates the productivity losses associated with wireline trips while maintaining ease of operation.
2Ease of operation
If control lines are run to the surface for hydraulic valve operation, then the valve can be controlled remotely, but the system complexity increases and reliability decreases due to additional leak paths
Solution Approach 1:
The invention removes the control lines from the system entirely by extracting the hydraulic control function and placing it downhole with the valve. The battery-powered hydraulic pump and electronic actuating mechanism are integrated into the valve assembly, eliminating the need for control lines to pass through the production packer or extend to the surface. This resolves the contradiction by enabling remote control without the complexity and reliability issues of control lines.
Solution Approach 2:
The invention merges the control system with the valve assembly by integrating the electronic actuating mechanism, battery-powered hydraulic pump, and valve body into a single unified downhole device. This consolidation eliminates the need for separate control lines and reduces system complexity while maintaining the ability to operate the valve remotely from the surface via wireless communication or during the completion run.
3Adaptability or versatility
If wireline plugs are used in deviated or horizontal wells, then the plug can be positioned below the packer, but wireline access becomes impossible due to high angle deviation
Solution Approach 1:
The invention replaces the mechanical wireline delivery system with a completion-run integration approach. The valve assembly is run into the well on the completion string itself, eliminating the need for wireline access. The electronic actuating mechanism is powered by a downhole battery, removing the dependency on wireline for both positioning and power. This resolves the contradiction by enabling plug positioning in highly deviated wells where wireline cannot reach, while maintaining the ability to operate the valve below the packer.
4Reliability
If the valve is closed during run-in to prevent fluid loss, then pressure testing can be achieved, but debris accumulates above the plug causing jamming and pressure transmittal issues
Solution Approach 1:
The invention opens the valve automatically upon reaching a predetermined depth or upon detecting specific downhole conditions, before pressure testing begins. This preliminary opening action prevents debris from accumulating above the valve during the run-in phase, while still allowing the valve to be closed later for pressure testing. The electronic control system monitors depth and conditions, opening the valve at the optimal moment to avoid debris jamming while maintaining pressure testing capability.
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 reliable fluid control in well completions by eliminating the need for surface control lines, reducing debris-related issues, and ensuring the valve remains open during failures, thus minimizing operational costs and enhancing safety and efficiency.
Implementation Method 1
a battery-powered hydraulic pump to deliver hydraulic fluid to the ball valve mechanism to control movement of the ball
Implementation Method 2
the actuating mechanism operates the hydraulic pump to pump fluid through at least one hydraulic control line to control movement of the valve member
Data Source
Figure 1~3
Figure 4~8
AI summary
Apparatus and method for a providing a completion assembly for running at an end of a completion string which provides a remotely operable tubing mounted valve used to control the flow of fluids through the tubing in hostile well conditions. The tubing mounted completion assembly has a tubular body for connection in the string below a production packer with a through bore from a first inlet and a first outlet coaxially aligned with the string; a downhole electronic actuating mechanism, a downhole hydraulic pump and a hydraulically operated ball valve member. The actuating mechanism operates the hydraulic pump to provide a hydraulic control line to control movement the valve member from a first position, where the member is open and a through bore is created between the inlet and outlet of the assembly, to a second position, where the valve seals the throughbore and, finally, back to the first position.