Downhole Well Completion System with Three-Line Hydraulic Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current downhole well completion systems face limitations in controlling multiple zones due to the number of hydraulic lines required, with hydraulic systems limited to 12 zones, electro-hydraulic systems struggling with axial force, and electrical systems being unsuitable for high flow rates and deepwater environments.
Innovation Solution
A three-line hydraulic control architecture that uses a command module with a ratchet rod and pilot valve to selectively control interval control valves, allowing for unlimited zone control by varying pressure signatures and axial movement, enabling remote operation without mechanical intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic control lines are used to control interval control valves, then reliability and life expectancy are improved, but the number of zones that can be controlled independently is limited to 12 zones with 4 hydraulic lines
Solution Approach 1:
The control system segments the hydraulic control into three functional lines: a command line for pressure signals, a common-open line for activating valves, and a common-close line for deactivating valves. This segmentation allows multiple valves to be controlled independently through pressure sequencing rather than requiring separate control lines for each valve, resolving the contradiction between reliability and the number of controllable zones.
Solution Approach 2:
The invention introduces a temporal dimension to hydraulic control by sequencing pressure application across multiple valves in a specific order. Instead of controlling valves simultaneously through parallel hydraulic lines, the system uses time-sequenced pressure application, allowing unlimited valves to be controlled with only three lines.
2Adaptability or versatility
If electro-hydraulic systems are used to control more ICVs, then the number of controlled zones is improved, but axial force delivery is insufficient for full-size ICVs
Solution Approach 1:
The invention replaces electro-hydraulic actuation with pure hydraulic actuation. Instead of using electrical motors that generate insufficient axial force, the system uses hydraulic pressure directly applied through the three-line control architecture, providing the necessary force for full-size ICV actuation while maintaining the ability to control multiple zones.
3Adaptability or versatility
If pure electrical control systems are used, then the number of ICVs controllable is improved, but axial force is insufficient and flow rate capability is limited
Solution Approach 1:
The invention uses hydraulic principles to overcome the limitations of electrical systems. By applying hydraulic pressure through the three-line control architecture, the system achieves both high flow rate capability (greater than 10,000 liquid barrels per day) and the ability to control multiple zones, resolving the contradiction between productivity and adaptability.
4Adaptability or versatility
If multiple hydraulic control lines are used to control more zones, then the number of controllable zones is improved, but device complexity increases
Solution Approach 1:
The invention makes the three hydraulic lines universal by designing them to serve multiple functions through pressure sequencing. The command line delivers pressure signals to command modules, while the common-open and common-close lines can activate or deactivate any number of valves depending on the pressure sequence applied. This multi-functionality allows unlimited zone control with only three lines, reducing device complexity.
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
Enables the selective control of an unlimited number of interval control valves using only three hydraulic lines, improving operational efficiency and reducing intervention costs, particularly in offshore and subsea environments, while supporting high flow rates.
Implementation Method 1
a first hydraulic control line is a command line to deliver applied pressure to the command module, which translates hydraulic pressure signals into axial movement of an inner ratchet rod that determines the position of an integral pilot valve
Implementation Method 2
the inner ratchet rod comprises several ratchet teeth, wherein the spacing of the ratchet teeth determines the level of pressure, that must be applied to cause a command pawl to engage the next ratchet teeth
Implementation Method 3
The control lines can convey hydraulic fluids or electrical power which drives the ICV sleeve up or down to expose or isolate flowports in the ICV housing
Data Source
AI summary
Downhole well completion system for control of flow to or from multiple compartments (1a,1b,1c,1d) in a targeted subterranean reservoir (30), comprising a plurality of interval control valves (2) connected in series forming a downhole string (24), said interval control valves (2) are manipulated from surface via hydraulic control lines (4a, 4b, 4c) to open or close flowports (20) of each interval control valve (2), wherein each interval control valve (2) comprises a command module (5) connected to at least two of said hydraulic control lines (4a, 4b), a first hydraulic control line is a command line (4a) to deliver applied pressure to the command module (5), which translates hydraulic pressure signals into axial movement of an inner ratchet rod (6) that determines the position of an integral pilot valve (7), a second hydraulic control line is a common-open or common-close line (4b), to provide hydraulic power to either open or close the flowports (20) of each interval control valve (2), and the inner ratchet rod (6) comprises several ratchet teeth (12), wherein the spacing of the ratchet teeth (12) determines the level of pressure, that must be applied to cause a command pawl (11) to engage the next ratchet teeth (12).