Downhole Valve Assembly with Single Cable Control
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Solution Overview
Problem
Conventional downhole valves in the oil and gas industry face challenges such as the need for multiple hydraulic control lines, increased surface pressure for actuation, safety hazards, and failure of a single return line rendering all valves inoperable, limiting their number and efficiency in wellbore fluid production and injection applications.
Innovation Solution
A valve assembly comprising a motor, motor controller, and sensors that allows remote electronic control and monitoring of downhole valves through a single cable, enabling fine control over valve opening and fluid flow, with multiple valves interconnected by a single cable for power and data transmission, and equipped with sensors for real-time data telemetry and feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional hydraulic control lines are used to actuate downhole valves, then valve actuation is achieved, but the number of control lines increases and system complexity increases
Solution Approach 1:
The patent combines multiple control functions into a single hydraulic control line by using a selectively permeable membrane that responds to pressure changes from a single control line to actuate multiple valves at different depths, eliminating the need for separate control lines for each valve
Solution Approach 2:
The single control line serves multiple functions by controlling the opening and closing of multiple different valves (inflow control valves, outflow control valves, gas lift valves) at various depths through the selective permeability mechanism, making the control system universal rather than dedicated to single valves
2Ease of operation
If deep wells require increased surface pressure to actuate downhole valves, then valve actuation in deep wells is achieved, but safety hazards increase
Solution Approach 1:
The patent segments the pressure control function by using selectively permeable membranes at each valve location that locally convert small pressure changes from the control line into the mechanical force needed to actuate the valve, avoiding the need to transmit high pressures through the entire depth of the well
Solution Approach 2:
The selectively permeable membrane acts as an intermediary mechanism that amplifies small pressure signals from the surface into sufficient mechanical force to actuate valves at depth, eliminating the need for direct high-pressure transmission from surface to downhole valves
3Device complexity
If a single return line is used for all downhole valves, then system complexity is reduced, but reliability decreases as failure of one line renders all valves inoperable
Solution Approach 1:
The patent incorporates sensors that monitor the operational status of each valve and the integrity of the control line, providing feedback signals that can detect failures and trigger automated responses or alerts to maintain system reliability even with a single control line
4Ease of operation
If conventional hydraulic valves are used, then valve actuation is achieved, but the number of control lines and wellhead exits increases
Solution Approach 1:
The patent merges multiple control line functions into a single hydraulic control line that serves all valves through the selective permeability mechanism, directly reducing the number of wellhead exits required from multiple separate connections to a single unified connection
Data Source
AI summary
The present disclosure provides a valve assembly comprising a valve section, a power section, and an electronics section. The valve assembly is configured to mate with a tubing sub (and/or mandrel) inserted in-line with a tubing string inserted into a wellbore. The valve allows for injection into or production from the tubing string. The valve assembly comprises an electric motor and a motor controller permitting fine control over the valve, as well as sensors which measure various parameters, such as fluid flow, valve position, pressure, temperature, and/or water cut. A cable connects the valve assembly to the surface and provides power and data telemetry and allows control of the valve assembly with a remote electronic signal. Multiple valve assemblies may be provided at spaced intervals along the tubing string and individually monitored and/or controlled by a remote location. Also disclosed is a method for operation of such valve assemblies.