Downhole Flow Regulator with Shape Memory Actuation
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Solution Overview
Problem
Downhole chokes struggle to maintain a constant flow rate across varying pressure differentials and conditions, requiring costly and time-consuming reconfiguration and retrieval for adjustments.
Innovation Solution
A flow regulating system with a closure device, biasing device, and flow restriction that adjusts the flow rate downhole in response to changing conditions, using a temperature-responsive shape memory material and hydraulic actuation to maintain a constant flow rate over a wide range of pressure differentials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a typical downhole choke is installed in the wellbore, then it can regulate flow rate at a specific pressure differential, but it cannot maintain constant flow rate when pressure differential changes
Solution Approach 1:
The flow regulator employs a movable closure device that dynamically adjusts its position in response to changing pressure differentials. The closure device moves automatically along the flow path to maintain substantially constant flow rate despite variations in upstream and downstream pressures, transforming a static choke into a dynamic flow control system.
Solution Approach 2:
The system incorporates automatic feedback mechanisms where the closure device responds to pressure differential changes by adjusting its position. This creates a self-regulating system that continuously adapts to maintain desired flow rates without external intervention, eliminating the need for manual retrieval and reconfiguration.
2Adaptability or versatility
If the choke settings need to be changed due to varying downhole conditions, then the flow rate can be adjusted, but the choke must be retrieved and reconfigured which is expensive and time-consuming
Solution Approach 1:
The flow regulator is equipped with actuators that enable it to adjust its own closure device position automatically in response to changing downhole conditions. This self-service capability allows the device to adapt to varying flow requirements without requiring retrieval, handling, or reconfiguration by personnel, significantly reducing time and operational costs.
Solution Approach 2:
The patent replaces manual mechanical adjustment systems with automated actuation mechanisms (such as hydraulic or electric actuators) that can be controlled from the surface or automatically. This substitution eliminates the need for physical retrieval and manual reconfiguration of the choke settings.
3Ease of operation
If hydraulic control lines are used to adjust the choke from the surface, then the flow rate can be changed, but the choke still cannot respond automatically to varying downhole conditions
Solution Approach 1:
The flow regulator incorporates sensors and control mechanisms that enable it to automatically detect changes in downhole conditions (such as pressure, temperature, or flow rate variations) and adjust its closure device position accordingly. This self-service automation eliminates the need for continuous surface intervention while maintaining adaptive flow control.
4Reliability
If a flow regulator with automatic adjustment is implemented, then it can maintain constant flow rate over wide pressure differentials, but the device complexity increases
Solution Approach 1:
The flow regulator utilizes hydraulic or pneumatic actuators to control the closure device position. These fluid-based actuation systems provide smooth, precise, and reliable control with simple structural requirements, enabling automatic flow rate maintenance while avoiding overly complex mechanical mechanisms.
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 automatic and intelligent adjustment of flow rates in real-time, maintaining a consistent fluid flow despite changes in pressure differentials and fluid density, reducing the need for frequent reconfiguration and retrieval of the choke.
Implementation Method 1
The biasing device applies a biasing force to the closure device in one direction, and the flow restriction operates to apply a restriction force to the closure device in an opposite direction
Implementation Method 2
using a temperature-responsive shape memory material
Data Source
AI summary
A flow regulator for use in a subterranean well. A well flow regulating system includes a flow regulator for regulating a flow rate of a fluid in a wellbore, the flow rate remaining substantially constant while a differential pressure across the flow regulator varies. The flow regulator is adjustable while positioned within the wellbore to change the flow rate. Another well flow regulating system includes a flow regulator for maintaining a desired fluid flow rate between an annulus and an interior passage of a tubular string. The flow regulator includes a closure device, a biasing device which applies a biasing force to the closure device, and a flow restriction which operates to apply a restriction force to the closure device. The biasing force and/or the restriction force is adjustable downhole to change the flow rate.