Downhole Inflow Valve with Autonomous Sensor Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing downhole well systems face challenges in safely and reliably adjusting fluid inflow from different production zones without risking leaks or blowouts, as current autonomous valves are not sufficiently reliable and often irreversible.
Innovation Solution
A downhole well system with an inflow valve assembly that includes a sensor unit and control unit, powered by a self-sustaining power supply, which measures fluid properties and adjusts the inflow valve without external control lines or tools, using expandable metal sleeves and a three-port valve to isolate production zones and control fluid communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If control lines are used on the outside of the metal casing to adjust valves from surface, then valve adjustment is achieved, but the risk of leaks and blowouts increases due to potential line failures through main barriers
Solution Approach 1:
The valve assembly performs self-adjustment of fluid inflow based on sensor measurements of fluid properties (water content, pressure, temperature). The control unit automatically activates the closing member to regulate flow without requiring external control lines or surface intervention, thereby eliminating the safety risks associated with control lines while maintaining operational capability.
2Ease of operation
If a tool is submerged into the well to engage and adjust the valve, then valve adjustment is achieved, but the process takes significant time
Solution Approach 1:
The valve assembly autonomously adjusts fluid inflow based on real-time sensor measurements of fluid properties. The control unit processes sensor data and automatically activates the closing member to regulate flow, eliminating the need for time-consuming manual tool intervention and enabling immediate responsive adjustment.
Solution Approach 2:
The sensor unit continuously measures fluid properties (water content, pressure, temperature) and provides feedback to the control unit, which automatically adjusts the closing member position. This closed-loop feedback system enables real-time autonomous adjustment without requiring periodic tool interventions, significantly reducing adjustment time.
3Extent of automation
If autonomous valves with swellable elements or vortex principles are used, then some automation is achieved, but reliability is insufficient and adjustment may be irreversible
Solution Approach 1:
The valve assembly autonomously measures fluid properties using sensors and automatically adjusts the closing member position based on control unit processing of sensor data. This electronic control system provides reliable and reversible adjustment capability, overcoming the limitations of passive autonomous mechanisms like swellable elements or vortex principles that lack precise control and reversibility.
Solution Approach 2:
The patent replaces unreliable passive mechanical autonomous mechanisms (swellable elements, vortex principles) with an active electronic control system comprising sensors, a control unit, and an electrically actuated closing member. This substitution provides superior reliability, precision, and reversibility while maintaining autonomous operation.
4Extent of automation
If control lines or wiring are used to power sensors and communicate data, then sensor operation is enabled, but the complexity and safety risks increase
Solution Approach 1:
The sensor unit is powered by a self-contained power supply (battery or capacitor) integrated within the valve assembly, eliminating the need for external wiring to transmit power or data. The control unit processes sensor data locally and activates the closing member autonomously, significantly reducing system complexity and eliminating safety risks associated with control lines running through well barriers.
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The present invention relates to a downhole well system for producing hydrocarbon-containing fluid from a reservoir downhole, comprising a well tubular structure having an inside, a first and a second annular barrier for isolating an annulus outside the well tubular structure, each annular barrier comprising a tubular part adapted to be mounted as part of the well tubular structure, the tubular part having an outer face, an expandable metal sleeve surrounding the tubular part and having an inner sleeve face facing the tubular part and an outer sleeve face facing a wall of a borehole, each end of the expandable sleeve being connected with the tubular part, and an annular space between the inner sleeve face of the expandable sleeve and the tubular part, the first and second annular barriers being adapted to isolate a production zone when expanded, and an inflow valve assembly arranged between the first and the second annular barriers opposite the production zone for providing fluid communication between the production zone and the inside of the well tubular structure through a passage in the inflow valve assembly by adjusting a closing member in relation to the passage, wherein the inflow valve assembly comprises a sensor unit comprising a sensor adapted to measure at least one property of the fluid, a power supply for powering at least the sensor, and a control unit for activating the adjustment of the closing member based upon the measurement of the sensor. Furthermore, the present invention relates to an inflow regulation method for adjusting the inflow of fluid in the downhole well system according to the invention.