Downhole Well Management System for Flow Control
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Solution Overview
Problem
Current well management systems require new production pipe deployment or removal to optimize hydrocarbon fluid flow, which is inefficient and increases risks due to multiple components and wellhead penetrations, especially in wells without production pipes or where pipes have been deployed.
Innovation Solution
A downhole integrated well management system that can be deployed inside existing production tubing, casing, or open holes, using electrically operated flow control modules with integrated sensors and communication capabilities to seal and redirect hydrocarbon flows, monitor pressure, and transfer power, allowing for remote operation and reduced component installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If hydraulically actuated sliding sleeves or standard sleeves are used for remote control of fluid flow, then flow control capability is improved, but the system requires new production pipe deployment or removal which increases complexity and risk
Solution Approach 1:
The flow control device is deployed inside existing production tubing through a delivery device, nesting the control mechanism within the existing well infrastructure rather than requiring replacement of the production pipe itself. This allows flow control functionality to be added without removing or replacing the production tubing.
Solution Approach 2:
A delivery device acts as an intermediary mechanism that transports and deploys the flow control device into the wellbore through existing openings. This intermediary system enables installation without direct manipulation of the production tubing, reducing the risk associated with wellhead penetrations and pipe handling.
2Adaptability or versatility
If multiple components are installed in the well to achieve flow control and monitoring, then functionality is improved, but the number of wellhead penetrations and installation risks increase
Solution Approach 1:
The flow control device integrates multiple functions including flow control, pressure monitoring, and communication capabilities into a single unified component. This consolidation reduces the number of separate installations and wellhead penetrations required, thereby improving installation safety while maintaining comprehensive functionality.
Solution Approach 2:
The device performs multiple functions simultaneously - flow control, sensor monitoring, and communication - making it a universal component that replaces what would traditionally require multiple separate devices. This multi-functionality reduces the overall system complexity and number of installation points.
3Stability of the object's composition
If cement is used to seal the space between different casing diameters, then wellbore sealing is improved, but pressure buildup between casings can cause casing collapse
Solution Approach 1:
The flow control device provides an alternative flow path that extracts or redirects hydrocarbon flow away from the cemented annular spaces between casings. By diverting the flow through the production tubing, the system prevents pressure buildup in the annular regions, thereby protecting casing structural integrity while maintaining effective wellbore sealing.
Data Source
AI summary
Components of a downhole integrated well management system, and its method of use, can be deployed through tubing, a liner, or casing in existing wells without the need to deploy new pipe or remove and re-install pipe in the well. The system can seal the flow of hydrocarbon fluid and re-direct it into the claimed internal flow control module which, in embodiments, comprises a mandrel comprising one or more ports providing fluid communication between the interior of the mandrel and the outside of the mandrel and corresponding controllable port covers and/or seals that are adapted to open, partially open, or fully close a corresponding port; a flow controller; one or more sensor modules adapted to monitor a predetermined set of activities in a well; one or more communications module; and one or more power electronic modules. A surface module may be present and adapted to generate and transmit commands to the flow control modules and receive information from them.