Circumferential Electric Actuators for Precise Downhole Valve Positioning
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Solution Overview
Problem
Hydraulic actuation of downhole valves is difficult to accurately position and introduces complications during installation due to multiple hydraulic lines.
Innovation Solution
An electrically powered actuator assembly system with multiple actuators circumferentially arranged around a production string, providing a combined output force to a sleeve that selectively blocks or allows fluid communication through ports, synchronized by a controller to ensure precise positioning and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If hydraulic actuation is used for downhole valves, then the valve can be actuated, but the positioning accuracy is poor and multiple hydraulic lines complicate installation
Solution Approach 1:
The patent replaces the hydraulic actuation system with an electric motor-based actuation system. The motor assembly converts electrical energy directly into mechanical motion to move the sleeve, eliminating the need for complex hydraulic lines and providing precise control through electrical signals. This substitution resolves the contradiction by achieving accurate positioning through electrical control while simplifying installation by removing multiple hydraulic lines.
Solution Approach 2:
The actuation system is divided into multiple independent motor assemblies arranged circumferentially around the production string. Each motor assembly independently actuates a portion of the sleeve, allowing for distributed control and improved positioning accuracy. This segmentation enables precise control of the valve position while reducing the complexity of any single actuation line.
2Adaptability or versatility
If multiple hydraulic lines are used for actuation, then the valve can be controlled, but installation becomes more complicated
Solution Approach 1:
The patent replaces multiple hydraulic lines with electrical power and control lines. The motor assemblies are powered by electrical connections that are simpler to install and connect compared to hydraulic lines. This substitution maintains full valve control capability while significantly improving installation ease by reducing the number of complex hydraulic connections required.
3Force
If a single large actuator is used, then the shifting force is sufficient, but the outer diameter increases for placement in smaller casings
Solution Approach 1:
Instead of using a single large actuator, the patent divides the actuation function into multiple smaller motor assemblies arranged circumferentially around the production string. Each motor assembly contributes to the total shifting force through its stem, which acts on the sleeve at different circumferential positions. This segmentation achieves the required total force while keeping the outer diameter small enough for placement in smaller casings.
Solution Approach 2:
The patent transitions from a single-point actuation approach to a distributed circumferential arrangement of multiple actuators. By distributing the actuation force around the circumference of the production string, the system achieves sufficient total force without increasing the radial footprint. The motors are arranged in a circular pattern, and their combined linear outputs from the stems produce the necessary force to move the sleeve while maintaining a compact outer diameter.
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 precise control of fluid flow rates and minimizes the overall diameter of the actuation system, allowing it to fit within smaller casings while avoiding binding and eccentric loads.
Implementation Method 1
electrically powered actuator assemblies mounted on the production string
Implementation Method 2
a compliant member between each of the motors and stems for correcting asynchronous motor operation
Data Source
AI summary
A valve system controls flow into a downhole production string, and which includes a downhole valve with a port formed in a sidewall of a production string disposed in a wellbore, and a sleeve that is slidable along the production string to block or allow flow through the port. An actuator assembly exerts a sliding force onto the sleeve, and is made up of multiple actuators arranged along an outer surface of the production string. Each actuator has an electrically powered motor and a stem connected to the motor. An opposite end of each stem connects to an end of the sleeve. Energizing the motors causes linear movement of the stems and connected sleeve to open and close the valve.