Dual-Piston Control Line System for Fail-Safe Tool Actuation
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Solution Overview
Problem
Existing control line systems used in industries like carbon dioxide sequestration and hydrocarbon recovery become inoperable after a failure occurs, as they rely on a single pressure line for actuation, and there is a need for a system that can maintain functionality even after such failures.
Innovation Solution
A dual-piston control line system where both pistons are in operable communication with a tool, allowing actuation through either control line, with additional features like check valves and fail-safe mechanisms to ensure continued operation even if one control line breaches or fails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single control line system is used for tool actuation, then the system structure is simple, but the system becomes inoperable after a breach occurs
Solution Approach 1:
The single control line system is divided into two separate control lines (first control line and second control line), each capable of independently actuating the tool. This segmentation allows the system to remain operational even if one control line breaches, as the other control line can still function.
Solution Approach 2:
The system changes the operational parameter from a single pressure line to multiple pressure lines, transforming the system from vulnerable to resilient. By introducing a second control line with identical functionality, the system achieves fail-safe operation where tool actuation can proceed through either control line.
2Reliability
If high pressure is applied to move pistons against spring force, then the tool can be actuated reliably, but the pressure requirement increases system energy consumption
Solution Approach 1:
The system employs spring elements that provide a counterbalancing force to the pressure force. The springs are pre-compressed to provide a mechanical advantage, reducing the net pressure required to actuate the tool. The spring force acts as a counterweight that must be overcome, allowing for more efficient energy utilization.
Solution Approach 2:
The system dynamically balances the interaction between pressure force and spring force. By designing the spring compression and piston area ratios appropriately, the system achieves optimal pressure requirements that balance reliability of actuation with energy efficiency. The dynamic equilibrium between these forces allows for tuned pressure requirements.
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
The system enables continued tool actuation after a breach by allowing pressure to be applied to the non-breached control line, and the use of hydrostatic balancing and fail-safe mechanisms reduces the pressure required for piston movement, ensuring system operability in failure scenarios.
Implementation Method 1
Pressure applied to the pressure faces moves the respective piston to actuate the tool
Implementation Method 2
a biasing member configured to bias the tool in a direction opposite the direction the pistons are configured to move the tool
Data Source
AI summary
A control line operating system includes a first piston having a first pressure face and a second pressure face, a first control line in operable communication with the first pressure face of the first piston, a second piston having a third pressure face and a fourth pressure face and a second control line in operable communication with the third pressure face of the second piston. Both the first piston and the second piston are in operable communication with a tool such that pressure increases in either the first control line or the second control line can cause actuation of the tool, the first control line is in operable communication with the fourth pressure face of the second piston and the second control line is in operable communication with the second pressure face of the first piston.