Downhole Flow Control Device Signal Actuation

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Solution Overview

Problem

Current downhole flow control devices, such as frac valves, rely on balls or darts for control, which cause restrictions in tubing strings and require complex pumping operations, especially in horizontal wellbores, and often necessitate costly workover operations for resetting.

Innovation Solution

A downhole flow control device with a movable barrier member and actuator that can be controlled by signals, using fluid pressure or chemical reactions to selectively open and close flow paths between external and internal regions of a tubing string, allowing for remote operation and reduced complexity in pumping and maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If balls or darts are used to control flow devices, then flow control is achieved, but restrictions are generated within the tubing string

Engineering Contradiction:

Improveflow control capabilityVSAvoidtubing string restriction

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention extracts the control function from physical balls or darts and transfers it to a signal-based control system. The barrier member is actuated by signals transmitted through the tubing string, eliminating the need for physical control objects that would restrict flow while maintaining reliable flow control capability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical ball or dart system is replaced with a signal-based actuation system. Instead of using physical objects to control the flow device, electrical or electromagnetic signals are transmitted through the tubing string to actuate the barrier member, eliminating mechanical restrictions while maintaining control functionality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If balls or darts are used for control, then flow devices can be actuated, but complex pumping operations are required especially in horizontal wellbores

Engineering Contradiction:

Improvedevice actuation capabilityVSAvoidpumping operation complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The mechanical pumping system required to transport balls or darts through horizontal wellbores is replaced with an electrical or electromagnetic signal transmission system. Signals can be transmitted through the tubing string without requiring complex pumping operations, significantly reducing operational complexity while maintaining reliable device actuation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

An electrical or electromagnetic signal acts as an intermediary to transmit control commands through the tubing string. This intermediary enables actuation of the flow device without requiring direct mechanical transport of control objects, eliminating the need for complex pumping operations in horizontal wellbores.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If balls or darts are used to control flow, then valve opening is achieved, but workover operations are needed to reset and remove the ball or dart

Engineering Contradiction:

Improvevalve control functionalityVSAvoiddevice reset complexity

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The physical ball or dart that requires removal during reset operations is extracted from the system. The control function is transferred to a signal-based system where the barrier member can be actuated and reset electronically, eliminating the need for workover operations to remove physical control objects while maintaining reliable valve control functionality.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The flow control device becomes self-service capable through signal-based actuation. The barrier member can be actuated and reset by transmitting signals through the tubing string without requiring external intervention or workover operations, significantly improving ease of repair and maintenance while maintaining reliable valve control.

Inventive Principle:

Principle #25Self-service

4Reliability

If balls or darts are deployed in horizontal wellbores, then flow control is possible, but complex pumping equipment is necessary

Engineering Contradiction:

Improveflow control capabilityVSAvoidpumping equipment complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The complex mechanical pumping equipment required to transport balls or darts through horizontal wellbores is replaced with an electrical or electromagnetic signal transmission system. Signals can be transmitted through the tubing string without requiring pumping equipment, eliminating complexity while maintaining flow control capability in horizontal wellbores.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11434722B2Downhole flow control device and method

Publication Date: 2022.09.06 TENDEKA AS

AI summary

A downhole flow control device and associated method, wherein the downhole flow device is configured for use with a tubing string, the downhole flow device including a flow path configured to permit flow between external and internal locations of a tubing string; a barrier member configured to selectively vary the flow path; and a receiver configured to receive a control signal to permit control of the barrier member. Beneficially, the downhole flow device may be at least partially operable by fluid or fluid pressure from the tubing string or wellbore. Corresponding fracking valve assemblies, completion assemblies, inflow control device and hydraulic distribution modules may be provided.