Electric Downhole Flow Control Tool Using Rotating Spheres
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Solution Overview
Problem
Current downhole flow control systems for oil and gas wells rely heavily on hydraulic operations, which are inefficient and lack precise control, limiting the ability to manage fluid flow effectively and reducing oil recovery rates.
Innovation Solution
A fully electric tool utilizing independent shafts with piles of spheres to control fluid flow by varying the communication area between the well annulus and production string, enabling continuous and precise flow control through the rotation of spheres, eliminating the need for hydraulic power units and infrastructure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic operation is used for downhole valve control, then the system is highly dependable for twin positions (ON/OFF), but it lacks continuous opening control and requires complex hydraulic power units and infrastructure
Solution Approach 1:
The patent replaces the hydraulic mechanical system with an electric system. Instead of using hydraulic power units, hoses, and fluid pressure to operate the valve, the invention employs electric motors or electromagnetic actuators that receive electrical signals from the surface through a single cable. This substitution eliminates the complex hydraulic infrastructure while maintaining operational reliability through precise electronic control of the valve opening position.
2Reliability
If hydraulic operation is used for downhole valve control, then the system is highly dependable for twin positions (ON/OFF), but it occupies restricted space and consumes high energy
Solution Approach 1:
The patent replaces the hydraulic mechanical system with an electric system. Instead of using hydraulic power units, hoses, and fluid pressure to operate the valve, the invention employs electric motors or electromagnetic actuators that receive electrical signals from the surface through a single cable. This substitution eliminates the complex hydraulic infrastructure while maintaining operational reliability through precise electronic control of the valve opening position.
3Device complexity
If conventional solenoids are used at the wellhead for electric control, then the number of supply lines is reduced, but the control is not continuous and precision is limited
Solution Approach 1:
The patent implements dynamic control by replacing static solenoid switches with electric motors or electromagnetic actuators that can continuously adjust the valve opening position. The motor-driven mechanism allows the valve to achieve any opening degree between fully closed and fully open, enabling continuous flow control. This dynamic system responds to variable electrical signals from the surface, providing precise positioning control while still reducing supply line complexity by using a single multi-functional cable for both power and control signals.
4Measurement precision
If fully electric tool with piled spheres is used, then continuous and precise flow control is achieved, but the investment cost is higher
Solution Approach 1:
The patent segments the valve control function into multiple independent spherical elements that can be individually positioned. Each sphere in the pile can be rotated independently to control flow through its internal passages, allowing granular control of the overall valve opening. This segmentation enables precise flow control by adjusting each sphere's position, while the modular spherical design simplifies manufacturing compared to traditional multi-component valve mechanisms, potentially reducing long-term costs despite higher initial investment.
Data Source
AI summary
A fully electric tool for continuous downhole flow control is described, said tool comprising a body and along the said body, actuating set(s), each actuating set comprising a passage system comprised of shaft(s) radially disposed along said cylindrical body, each of said shaft (s) being actuated with its opposed pair or in an independent way in a well-defined position or not, said shaft(s) being provided of spherical element(s) or sphere(s), provided of at least one window forming piles of sphere(s) in shaft(s), the rotation of said shaft(s)(108) of piles of sphere(s) enabling the opening or total or partial obstruction of holes by the total or partial coincidence of said window(s) of sphere(s) with said bore(s) of said cylindrical body.