Electrically Activated Downhole Valve for Repeat Flow Path Switching
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Solution Overview
Problem
Existing downhole tools for oil and gas drilling often require mechanical activation methods that are limited to a single 'on' position, lack flexibility in flow parameters, and necessitate tripping out of the hole for deactivation, especially when drilling multiple lateral sections.
Innovation Solution
An electrically activated downhole valve system that responds to downhole measurements, allowing for precise activation and deactivation of fluid flow paths using sensors and processors, including features like valve poppets and rotary valves, to manage vibration tools effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If mechanical activation methods (dropping ball or spring mechanism) are used, then the valve can be activated, but it only allows for a single 'on' activation and limits available flow parameters
Solution Approach 1:
The patent replaces traditional mechanical activation systems (ball drop, spring mechanisms) with an electrical activation system that uses an electric motor and ball screw mechanism. This substitution enables precise control of the valve poppet position through electrical signals, allowing for variable flow parameters and repeated activation/deactivation cycles without requiring mechanical intervention from the surface.
Solution Approach 2:
The patent implements a dynamic valve control system where the valve poppet can be positioned at multiple locations along its travel path, not just fully open or fully closed. The electric motor and ball screw mechanism allow the valve to be dynamically adjusted to any position within its range, enabling continuous variation of flow parameters and adaptive control based on downhole conditions.
2Ease of operation
If mechanical activation methods are used, then the valve can be activated, but the drilling string must be tripped out of hole to remove the projectile and reset the tool
Solution Approach 1:
The patent replaces mechanical activation methods that require surface intervention with an electrical control system that can be operated remotely or automatically from the surface. The electric motor receives electrical signals through the drilling string to activate or deactivate the valve without requiring the string to be pulled out, enabling rapid repeated operations during multi-leg drilling.
Solution Approach 2:
The valve system is equipped with its own electrical motor and control mechanisms, allowing it to activate and deactivate itself based on electrical signals without requiring external mechanical intervention. The system can be reset and reactivated multiple times simply by sending electrical commands, making the tool self-sufficient for repeated operations.
3Productivity
If vibration tool is activated throughout the entire wellbore, then weight transfer is aided, but it can cause damage to casing and reduce component life
Solution Approach 1:
The patent uses a dynamically controllable valve system that can be activated only when needed (in the lateral section) and deactivated when not needed (in the vertical section). The electric motor and ball screw mechanism allow for precise control of vibration tool activation, enabling the system to adapt to different wellbore sections and operational requirements, providing weight transfer assistance only where beneficial.
Solution Approach 2:
The patent implements a controlled activation system that can respond to downhole conditions and operational requirements. The electrical control system allows for selective activation of the vibration tool based on the wellbore section being drilled, preventing unnecessary vibration that could damage casing while providing vibration assistance when needed in lateral sections.
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 on-demand activation of downhole tools, reducing mechanical intervention and extending tool life by allowing controlled activation and deactivation based on downhole conditions, optimizing drilling operations.
Implementation Method 1
An electrically activated linear activation system is connected to the valve poppet to move the valve poppet axially
Implementation Method 2
The linear activation system further comprises an electric motor and a ball screw
Data Source
AI summary
There is a downhole valve for use in a standpipe. A valve body defines a flow path through the valve body. A valve poppet within the valve body is axially movable in a direction parallel with the standpipe when in use. An electrically activated linear activation system is connected to the valve poppet to move the valve poppet axially. The flow through the flow path varies as the valve poppet is moved axially. There is a method of activating a downhole valve for use in a standpipe. A condition downhole is detected using a sensor. The downhole valve is electrically activated based on the detected condition downhole. The valve and method may be used to turn on and off a vibration tool when a drill string is in the horizontal section of a well.