Flow Control Device Using Fluid Pressure Biasing
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Solution Overview
Problem
Permanent downhole instrumentation in oil wells has a limited lifetime due to harsh wellbore conditions, leading to frequent failures and high costs for maintenance and replacement, with existing solutions requiring electrical supply and communication lines that are prone to damage and lengthy installation times.
Innovation Solution
A flow control device with a regulator assembly that uses fluid pressure fluctuations to bias the regulator assembly, allowing for wireless communication and reduced power requirements, and can maintain an open or closed flow path configuration even in the event of drive arrangement failure, facilitating easier maintenance and reduced risk of equipment damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If permanent downhole instrumentation is installed, then data acquisition capability is improved, but equipment lifetime is reduced due to harsh wellbore conditions
Solution Approach 1:
The regulator assembly uses the kinetic energy of the flowing fluid itself to generate the biasing force, eliminating the need for external power sources or complex mechanical spring systems. The fluid flow directly drives the pressure differential that biases the regulator, making the system self-sufficient and highly reliable in harsh environments.
Solution Approach 2:
The invention uses fluid pressure differentials created by flow through the flow path to bias the regulator assembly. The compensation chamber captures pressure from a localized region of the first surface, creating a hydraulic biasing mechanism that eliminates mechanical springs and reduces moving parts subject to wear in harsh wellbore conditions.
2Reliability
If traditional downhole pressure and temperature sensors with cables are used, then monitoring functionality is achieved, but installation time is prolonged and failure risk increases
Solution Approach 1:
The invention extracts and eliminates the cable and electrical connection components from the downhole monitoring system. By using wireless communication through pressure fluctuations in the fluid, the system removes the vulnerable cable infrastructure including clamps, splices, and connectors that require time-consuming installation and are prone to failure.
Solution Approach 2:
The invention replaces mechanical cable connections with a wireless communication system that uses pressure fluctuations in the fluid to transmit data. This substitution eliminates the need for physical electrical connections, reducing installation complexity and eliminating failure nodes associated with cables and connectors.
3Use of energy by moving object
If electrical supply lines are installed for downhole equipment, then power supply is enabled, but system complexity and vulnerability to damage increase
Solution Approach 1:
The regulator assembly harvests energy from the kinetic flow of the fluid itself to generate the biasing force, eliminating the need for external electrical power supply lines. The system uses the fluid's own motion to create the pressure differential, making it self-powered and highly suitable for remote downhole applications.
Solution Approach 2:
The invention uses hydraulic principles to convert the kinetic energy of flowing fluid into pressure differentials that bias the regulator assembly. This hydraulic energy conversion eliminates electrical power lines and associated complexity, using only the fluid medium already present in the wellbore.
4Ease of operation
If permanent borehole completion equipment is installed, then production control capability is improved, but maintenance cost and risk increase when equipment fails
Solution Approach 1:
The regulator assembly is designed as a relatively simple, modular component with few moving parts that can be easily replaced if needed. By eliminating complex cable systems and electrical connections, the device becomes a more straightforward replacement unit, reducing the cost and risk associated with maintenance and repair operations.
Solution Approach 2:
The self-biasing mechanism using fluid pressure eliminates the need for complex electrical systems and external power supplies, creating a simpler device that is easier to install, maintain, and replace. The absence of vulnerable electrical connections reduces maintenance requirements and lowers the risk profile of well intervention operations.
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 device ensures continuous operation of the flow path, minimizes power consumption, and simplifies maintenance by using fluid pressure to bias the regulator assembly, reducing the need for electrical supply and communication lines, thereby extending equipment life and reducing maintenance costs.
Implementation Method 1
fluid flowing through the flow path establishes a pressure which varies across the first surface of the regulator assembly
Implementation Method 2
the compensation chamber is in pressure communication with a localised region of the first surface which is selected to establish a compensation chamber pressure which acts against the second surface of the regulator assembly
Data Source
AI summary
The flow control device includes a flow path, a compensation chamber and a regulator assembly defining a first surface exposed to the flow path and an opposing second surface which is exposed to the compensation chamber. A drive arrangement is provided for moving the regulator assembly to vary the flow path. Fluid flowing through the flow path establishes a pressure which varies across the first surface of the regulator assembly. The compensation chamber is in pressure communication with a localised region of the first surface which is selected to establish a compensation chamber pressure which acts against the second surface of the regulator assembly to bias the regulator assembly in a desired direction. The first surface of the regulator assembly may define a profile configured to minimise the variation in pressure applied over the first surface by action of fluid flowing through the flow path.