Electric Actuator Open-Hole Completion for Pre-Salt Wells
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Solution Overview
Problem
Current hydraulic control technologies in well completion systems are limited by the number of remotely controlled zones, leading to inefficiencies in managing high-pressure, large-diameter pre-salt wells with high scaling potential and fluid loss, and lack the flexibility to handle complex formations effectively.
Innovation Solution
The system employs a fault-tolerant automation network with a proximity coupler and axial magnetic flux motor-based electric actuators for multiple inflow and outflow control zones in an open hole uncoupled completion, enabling flexible and reliable control through a distributed power-over-communication architecture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hydraulic control technology is used with multiple packers and control lines, then zone control capability is improved, but device complexity and operational complexity increase significantly
Solution Approach 1:
The patent replaces the hydraulic control system with an electrical control system. Electric actuators mounted on the production string control valves through electrical signals transmitted via the WCT SCM, eliminating the need for hydraulic control lines and complex mechanical hydraulic actuators while maintaining zone control capability
Solution Approach 2:
The patent removes multiple packers and hydraulic control lines from the system. By using an uncoupled bottom completion system with electric actuators on the production string, the system extracts the unnecessary hydraulic infrastructure while preserving the essential function of zone control
2Adaptability or versatility
If hydraulic control technology is used with multiple packers, then zone control capability is improved, but ease of operation during installation and workover deteriorates
Solution Approach 1:
The patent replaces hydraulic control lines and actuators with electrical control systems. Electric actuators on the production string receive commands through the WCT SCM, simplifying installation and workover operations by eliminating complex hydraulic connections and making valve control more accessible and easier to operate
Solution Approach 2:
The patent introduces the WCT SCM as an intermediary control module that receives electrical signals from the surface and controls the electric actuators. This intermediary simplifies the control architecture, making the system easier to operate during installation and workover by providing a centralized control interface
3Ease of operation
If uncoupled bottom completion system is used, then ease of operation is improved, but the number of remotely controlled zones is limited
Solution Approach 1:
The patent makes the production string universal by mounting electric actuators directly on it, allowing the same production string to control multiple valves in multiple zones. This multi-functional approach enables the uncoupled bottom completion system to control more than two zones by distributing electric actuators along the production string at different depths
Solution Approach 2:
The patent segments the control function by distributing multiple electric actuators along the production string, with each actuator controlling a specific valve at a different depth. This segmentation allows independent control of multiple zones while maintaining the simplicity of the uncoupled bottom completion system
4Productivity
If electric actuators with axial magnetic flux motor are used, then productivity is improved, but use of energy increases
Solution Approach 1:
The patent changes the design parameters of the electric actuators by using axial magnetic flux motors with optimized winding configurations and magnetic circuit designs. These parameter optimizations reduce the energy consumption of the actuators while maintaining their productivity and control capabilities
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
This solution allows for efficient management of multiple zones with reduced fluid loss and scaling issues, enhancing productivity and reliability in high-pressure, large-diameter pre-salt wells by enabling precise control and monitoring of fluid flow and pressure.
Implementation Method 1
the use of an electric actuator based on an axial magnetic flux motor
Data Source
AI summary
The present invention relates to a system and method to be applied to multiple inflow and outflow control zones in an open-hole uncoupled completion. The invention can handle, for example, the complexities and limitations of hydraulic control found in carbonate reservoirs in the Brazilian Pre-Salt, which are characterized by high pressures and flows, large vertical extensions of the reservoir, high scaling potential, and high potential for losses during drilling and completion operations.