Retrievable Downhole Flow Control Node for Wellbore Adjustment
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Solution Overview
Problem
Existing wellbore fluid flow control systems, particularly in horizontal wellbores, face challenges in achieving even oil flow while inhibiting water and gas flow, and require costly and time-consuming adjustments to inflow control devices to alter flow rates.
Innovation Solution
A retrievable communication device and control node system that allows for downhole adjustment of flow control devices using wireless communication, enabling real-time monitoring and control of fluid flow rates through sensors and flow control devices, reducing the need for surface adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pre-set passive flow control devices are used, then flow rate control is achieved, but downhole adjustments require pulling out the production string which is expensive and time-consuming
Solution Approach 1:
The flow control device transitions from a static pre-set configuration to a dynamic adjustable system. The actuator mechanism allows the flow control element to change its position and opening degree in response to control signals, enabling real-time adjustment of flow rates without requiring physical retrieval of the device from the wellbore.
Solution Approach 2:
The patent replaces the traditional mechanical system requiring physical access to the production string for adjustment with an automated control system. Sensors detect flow conditions and transmit signals to actuators that automatically adjust the flow control device, substituting manual mechanical adjustment with an automated sensing-actuating mechanism.
2Manufacturing precision
If multiple spaced apart flow control devices are deployed, then flow distribution can be controlled, but uneven flow of oil through various devices occurs due to formation variations
Solution Approach 1:
Sensors are installed at each flow control device location to detect local flow conditions, pressure, and temperature. This feedback information is transmitted to the control system, which then adjusts each device's opening degree individually to compensate for formation variations, achieving more uniform overall flow distribution across all zones.
Solution Approach 2:
Each flow control device is equipped with independent sensing and actuation capabilities, allowing local adaptation to specific formation conditions at each location. This localized control enables each device to optimize its flow rate based on local porosity and permeability variations, rather than using a uniform control approach for all devices.
3Adaptability or versatility
If passive inflow control devices are used, then initial flow rate control is achieved, but no downhole adjustments can be made without retrieving the production string
Solution Approach 1:
The control node serves multiple functions: it receives control signals, processes sensor data, transmits commands to actuators, and monitors flow conditions. This multi-functional integration allows the system to provide both flow control and adjustment capabilities within a single downhole unit, reducing the need for separate control systems at each location.
Solution Approach 2:
The system employs a hierarchical nested structure where the control node contains multiple actuators and sensors, which in turn contain control elements. This nested arrangement allows complex control functionality to be achieved through layered integration, where higher-level control signals are translated into specific actuator movements for precise flow regulation.
Data Source
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AI summary
In one aspect, an apparatus for controlling fluid flow between a formation and a tubular is provided, wherein the apparatus includes a retrievable communication device configured to be conveyed to a selected location in the tubular downhole. The apparatus also includes a control node configured to communicate with the retrievable communication device at the selected location, a flow control device coupled to and controlled by the control node and a sensor coupled to the control node, wherein the sensor and flow control device are downhole of the control node.