Downhole Smart Control System for Zone Isolation
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Solution Overview
Problem
Current methods for frac operations in oilfields, such as using balls and seats in sliding sleeves, are costly and limited in the number of zones that can be created due to size constraints, and lack control over hydrocarbon flow in laterals, as hydraulic or electrical lines cannot be deployed from the main bore into the laterals.
Innovation Solution
An electromechanical downhole smart control system that replaces traditional ball and seat mechanisms with movable port seals and plugs, controlled by an electronic module, allowing for precise control of fluid flow and zone isolation within the wellbore, enabling deployment in both conventional and deepwater environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional ball and seat mechanisms are used in sliding sleeves, then zone isolation can be achieved, but the number of zones is limited due to ball size constraints and milling costs
Solution Approach 1:
The patent replaces the traditional mechanical ball and seat system with an electromechanical control system featuring an electronic control module that receives signals from the surface and actuates port seals and plugs electronically, eliminating the need for multiple balls and seats of different diameters
Solution Approach 2:
The electromechanical control system serves multiple functions: it controls port seals to isolate zones, deploys plugs to seal laterals, and can be controlled from the surface through electronic signals, making it a multi-functional replacement for multiple specialized components
2Ease of operation
If hydraulic or electrical lines are deployed from main bore into laterals, then control of hydrocarbon flow in laterals would be possible, but the system complexity and deployment difficulty increase
Solution Approach 1:
The patent extracts the control functionality from the main bore and places it directly at the lateral entry point through the plug assembly, which can be actuated by electronic signals transmitted through the production pipe wall, eliminating the need for separate hydraulic or electrical lines into the laterals
Solution Approach 2:
The electronic control module acts as an intermediary that receives electrical signals from the surface through the production pipe wall and translates them into mechanical actions of the plug and port seals, enabling control without direct hydraulic or electrical line deployment into laterals
Data Source
AI summary
A wellbore insert comprises a housing that further comprises an inner annulus and one or more ports dimensioned and configured to provide a fluid pathway between the inner annulus of the housing and the outer surface of the housing. A selectively movable port seal, operable via a port seal mover, is dimensioned and configured to selectively occlude or open these ports. A movable plug, controlled by a plug mover, operates within the housing to selectively permit or occlude fluid flow within the housing. A power supply and a detector are typically present within the housing. An individually addressable electronic control module is operable to effect a change in the position of the selectively movable port seal and/or the movable plug. The wellbore insert can be used for downhole operations such as frac operations.