Downhole Hydraulic Control Tool with Switchable Flow Mechanism
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Solution Overview
Problem
Existing well completion equipment faces challenges in operating downhole devices due to the complexity and slowness of hydraulic control lines, which require multiple lines and a single power source at the surface, limiting response speed and increasing the risk of failure.
Innovation Solution
A downhole hydraulic control tool with a built-in hydraulic power source and switchable flow mechanism, allowing control lines to span only the distance between the power source and the device, and using pressure/time discriminator mechanisms to create trigger signals for operation, eliminating the need for surface-controlled hydraulic lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If hydraulic control lines are run from the surface through the well to downhole devices, then the devices can be actuated remotely, but the response time becomes slow and the system complexity increases
Solution Approach 1:
A downhole hydraulic power source acts as an intermediary, receiving hydraulic fluid through a single control line from surface and converting it to multiple high-pressure output lines locally. This mediator enables remote actuation while reducing the need for multiple surface-to-downhole control lines, thereby improving response time and reducing system complexity.
Solution Approach 2:
The system transitions from a one-dimensional surface-to-downhole control line arrangement to a two-dimensional architecture where a single incoming control line branches into multiple outgoing lines at the downhole location. This dimensional change allows multiple devices to be actuated independently without requiring multiple surface control lines.
2Adaptability or versatility
If multiple hydraulic control lines are run from the surface to operate multiple devices, then each device can be controlled independently, but the installation complexity and risk of failure increase
Solution Approach 1:
Multiple control functions are merged into a single downhole hydraulic power source that receives one control line from surface and generates multiple output lines. This combining approach maintains independent control of multiple devices while reducing the number of surface-to-downhole control lines, thereby simplifying installation and reducing failure points.
3Device complexity
If a single hydraulic control line is used to operate multiple devices, then the installation is simpler, but the response time slows down due to sequential operation
Solution Approach 1:
The hydraulic control function is segmented into multiple independent output lines at the downhole location, each capable of operating a different device simultaneously. While a single control line enters the well, the downhole power source divides this into multiple parallel output paths, enabling simultaneous device operation rather than sequential actuation.
4Area of stationary object
If control lines are made narrow to be unobtrusive in the wellbore, then they occupy less space, but the response time becomes slower
Solution Approach 1:
The downhole hydraulic power source acts as a mediator that receives narrow-diameter control line input and converts it to multiple larger-diameter output lines. This allows the incoming control line to remain narrow and unobtrusive while the local output lines provide sufficient flow capacity for fast device response.
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 faster and more reliable operation of downhole devices by locating the control system closer to the device, reducing the complexity and risk of surface-controlled hydraulic line failures, and allowing multiple devices to be actuated independently with programmable trigger signals.
Implementation Method 1
a pump to drive hydraulic fluid through the control lines
Data Source
AI summary
A downhole hydraulic control tool comprising a substantially tubular body adapted for connection in a tubing string, the body including a throughbore arranged coaxially with a bore of the tubing string and one or more pockets arranged on a wall of the body, the pockets including a hydraulic power source and at least two control lines, wherein the device includes a pump to drive hydraulic fluid through the control lines and a switchable flow mechanism for switching the flow of pumped fluid between the at least two control lines, and a switchable flow mechanism and a method of operating one or more downhole devices from a downhole located hydraulic control tool.