Electromagnetic Downhole Valve for Multi-Stage Fracturing Control
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Solution Overview
Problem
Existing fracturing valve systems for oil and gas wells face challenges in controlling the location of fracturing operations due to limited control over fluid pressure and seal reliability, particularly in open hole fracturing, and are limited by the number of stages that can be performed due to size constraints of ball-drop valves.
Innovation Solution
A downhole valve system using direct electrical surface control via a conducting cable, featuring a stationary sleeve with coils and a microcontroller to control the alignment of ports, allowing for precise opening and closing of the valve using a magnetic field, and a fracturing system with a series of such valves for independent operation and remote control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If ball-drop valves are used for fracturing operations, then the valve can be actuated by dropping balls, but the number of stages is limited due to size constraints of the valves
Solution Approach 1:
The patent replaces the mechanical ball-drop actuation system with an electromagnetic actuation system. A coil generates a magnetic field that moves a magnetized piston to open the valve, eliminating the need for mechanical balls and ball seats. This substitution allows for more stages without increasing valve size constraints, as the electromagnetic system is more compact and scalable than mechanical ball-drop mechanisms.
2Productivity
If open hole fracturing is performed, then the formation can be fractured directly, but control over the location of fracturing operations is limited
Solution Approach 1:
The patent incorporates a Hall sensor that detects the position of the magnetized piston and provides feedback to a microcontroller. This feedback mechanism enables precise control and monitoring of the valve position, ensuring accurate control over the location of fracturing operations. The microcontroller can adjust the coil activation timing based on the sensor feedback to achieve precise positioning of the fracturing event.
Solution Approach 2:
The electromagnetic actuation system with coil and magnetized piston provides more precise control over valve opening timing and position compared to mechanical ball-drop systems. The magnetic field can be precisely controlled and timed, enabling better localization of fracturing operations in open hole conditions.
3Reliability
If mechanical intervention is used for valve operation, then the valve can be actuated, but the efficiency and reliability are reduced
Solution Approach 1:
The patent replaces mechanical intervention systems with an automated electromagnetic actuation system. The coil generates a magnetic field that automatically moves the magnetized piston to open the valve, eliminating the need for mechanical balls, ball seats, and associated mechanical components. This automation increases reliability by removing mechanical wear points and simplifying the actuation mechanism.
Solution Approach 2:
The electromagnetic system is self-actuating through the interaction between the coil-generated magnetic field and the magnetized piston. Once electrical power is supplied to the coil, the system automatically actuates the valve without requiring external mechanical intervention, enhancing both reliability and automation.
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
Enables precise control over fracturing operations, allowing for an unlimited number of stages and reducing the need for mechanical intervention, improving the efficiency and reliability of hydrocarbon production by allowing for repeated fracturing and independent operation of each valve.
Implementation Method 1
the inner sleeve moveable within the stationary sleeve under power provided by a magnetic field generated by electrical current passing through the coil
Data Source
AI summary
A valve is provided which is based on a stationary sleeve. The stationary sleeve includes at least one coil in communication with an electrical power source and one or more openings in the body of the stationary sleeve open to the hollow interior of the stationary sleeve. The valve has a microcontroller configured to control flow of electrical current independently to the coil and an inner sleeve configured to fit within the stationary sleeve. The inner sleeve has an internal or external magnetized portion and one or more ports open to the hollow interior of the inner sleeve. The inner sleeve is moveable within the stationary sleeve under power provided by a magnetic field generated by the electrical current passing through the coil to either align the ports with the openings to open the valve or to remove alignment of the ports with the openings to close the valve.