Electronic Actuator Wellbore Sleeve for Flow Control
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Solution Overview
Problem
Existing wellbore completion systems face challenges in deep water offshore and highly deviated wells, where traditional actuation methods like pressurized fluid become difficult to implement, necessitating a more flexible and reliable means to control fluid flow.
Innovation Solution
The integration of electronic actuators with sensors and electro-mechanical components that allow selective control of fluid flow through fluid pathways in response to pressure, pressure waves, or sonic signals, eliminating the need for pressurized fluid actuation, and enabling flexible flow management in complex well configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional pressurized fluid actuation methods are used, then fluid flow control is achieved, but implementation becomes difficult in deep water offshore and highly deviated wells
Solution Approach 1:
The patent replaces traditional pressurized fluid actuation (hydraulic system) with an electronic actuation system comprising electronic actuators, sensors, and a control unit. The electronic actuators receive electrical signals from the control unit to move blocking members between open and closed positions, eliminating the need for complex pressurized fluid delivery infrastructure in challenging well environments.
Solution Approach 2:
The patent introduces a control unit as an intermediary between the sensing system and the actuation system. The control unit processes signals from sensors (which detect well conditions) and translates them into appropriate actuation commands for the electronic actuators, enabling intelligent, adaptive flow control without direct human intervention or complex external control infrastructure.
2Adaptability or versatility
If electronic actuators with sensors are integrated, then flexible flow management is enabled, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single downhole tool assembly: sensors detect well conditions (pressure, flow rate), the control unit processes this data and determines optimal flow settings, and electronic actuators execute the control decisions. This multi-functional integration provides flexible flow management across different well conditions while consolidating what could be separate systems into one unified device.
Solution Approach 2:
The system employs sensors that continuously monitor well conditions and feed this information to the control unit, which automatically adjusts flow pathways via electronic actuators without requiring external intervention. This self-regulating capability provides adaptive flow management while reducing the need for complex external control infrastructure or frequent human intervention.
3Productivity
If selective control of fluid flow pathways is implemented, then production efficiency is enhanced, but control system complexity increases
Solution Approach 1:
The patent divides the flow control system into multiple independent electronic actuators, each controlling a specific blocking member and associated flow pathway. This segmentation allows selective control of individual flow pathways based on real-time sensor data, enabling optimized production from different zones or intervals while maintaining a relatively simple overall system architecture through modular design.
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 provides reliable and flexible control over fluid flow in deep water and deviated wells, enhancing production efficiency by selectively adjusting flow rates and resistance, thereby optimizing the production of desired fluids while minimizing undesired components.
Implementation Method 1
the at least one sensor comprises a pressure sensor, and wherein the suitable signal comprises at least one of a pressure, a pressure wave, one or more pressure pulses, or a sonic signal
Implementation Method 2
at least one of the plurality of electronic actuators comprises a blocking member coupled to an electro-mechanical actuator
Data Source
Figure 1
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Figure 2B
AI summary
A production sleeve assembly for use in a wellbore comprises a wellbore tubular, a plurality of fluid pathways configured to provide fluid communication within the downhole component, a plurality of electronic actuators configured to selectively provide fluid communication through one or more of the plurality of fluid pathways, and at least one sensor coupled to the plurality of electronic actuators. One or more of the plurality of electronic actuators are configured to selectively actuate to allow or prevent fluid flow through a corresponding fluid pathway of the plurality of fluid pathways in response to the at least one sensor receiving a suitable signal.