Electric Valve Bypass for Scale-Blocked Well Control Devices

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Solution Overview

Problem

Existing control devices in production strings of wells, such as ICDs and AICDs, are prone to scale formation, leading to partial or total blockage and resulting in production losses and high operational costs due to the need for chemical treatments and equipment use.

Innovation Solution

An electric valve with an inner sleeve and motor mechanism that can be actuated to open a communication orifice, bypassing the blocked control devices to maintain production flow and facilitate scale removal, using chemical treatments if necessary.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If pressure drop devices are used to control gas or water flow, then production of undesirable fluid is controlled, but the devices act as traps for scale deposits and lose functionality over time

Engineering Contradiction:

Improvecontrol of gas or water productionVSAvoidfunctionality of pressure drop devices

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system is divided into multiple segments: the original pressure drop device (ICD/AICD) remains in place for flow control, while a separate bypass line with its own pressure drop device and isolation valve is added. This segmentation allows the bypass to handle scale-related flow restrictions independently, preventing scale from affecting the primary control device's functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bypass line acts as an intermediary pathway between the production string and the scale management system. It provides an alternative route for fluid flow that can be activated when scale deposits affect the main control device, mediating between the scale problem and the production maintenance goal.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If AICD valves increase restriction on gas or water flow, then autonomous control of fluid properties is achieved, but an environment conducive to scale formation is created

Engineering Contradiction:

Improveautonomous control of fluid flowVSAvoidscale formation

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The system introduces dynamic adaptability by adding a bypass line that can be activated or deactivated based on production conditions. When scale formation is detected or anticipated, the bypass provides an alternative dynamic pathway, allowing the system to adapt to changing conditions and prevent scale-related failures.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The bypass line allows for parameter changes in the flow path by providing an alternative route with different pressure drop characteristics. This enables the system to change flow parameters dynamically, bypassing scale-deposited areas when necessary while maintaining autonomous control capabilities.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If chemical removal treatments are performed to clear scale, then production loss due to blockage is mitigated, but revenue losses occur due to production stoppage and high operational costs

Engineering Contradiction:

Improveclearance of scale blockageVSAvoidoperational costs and production stoppage

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The bypass line is installed and ready for use before scale blockage occurs. This preliminary preparation allows for quick activation when scale issues arise, avoiding the need for immediate production stoppage and expensive chemical treatments. The system is pre-configured to handle scale problems without interrupting production.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The bypass line serves as a cushioning measure against scale-related production losses. By having this alternative pathway prepared in advance, the system can absorb the impact of scale formation and continue producing, cushioning against the severe financial losses that would otherwise result from production stoppage and emergency interventions.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 electric valve effectively maintains production levels by bypassing blocked control devices, reducing financial losses and operational costs associated with scale-related blockages, allowing for efficient scale removal and device functionality restoration.

Implementation Method 1

an electric motor (20) connected to the electric cable (10)

Methodology Applied

Scientific EffectElectromagnetic conversion: Electromagnetic Induction

Data Source

PatentUS20250270899A1Electric valve for controlling the scaling of control devices in a production string in a well and a method for controlling the scaling using said electric valve

Publication Date: 2025.08.28 PETROLEO BRASILEIRO SA PETROBRAS

AI summary

The present invention discloses an electric valve (100) for controlling the scaling of control devices (200) in a production string (300) in a well, comprising an electric cable (10), an electric motor (20) connected to the electric cable (10) and a communication orifice (30) comprising an inner sleeve (31). Furthermore, there is disclosed a method for controlling the scaling of control devices (200) in a production string (300) in a well using said electric valve (100).