Autonomous Fluidic Sticky Switch for Wellbore Flow Control
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Solution Overview
Problem
Existing flow control systems for hydrocarbon-bearing subterranean formations are not reliable in varying fluid flow conditions and require surface signals or mechanical parts prone to breakdown, especially in erosive or clogging environments.
Innovation Solution
An autonomous fluid flow control system using a 'sticky switch' mechanism with a biasing mechanism that alters fluid flow based on changing fluid characteristics, such as viscosity, density, or velocity, by employing widening passageways, contour elements, or fluid diodes to direct fluid flow through a vortex assembly, selecting for desired fluid properties without moving mechanical parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional flow control systems with mechanical parts are used, then flow control capability is achieved, but reliability deteriorates due to breakdown from erosion and clogging
Solution Approach 1:
The patent replaces mechanical flow control parts with a fluidic system using viscous fluid effects. The biasing mechanism uses a viscous fluid to create asymmetric flow patterns that bias the switch state without mechanical moving parts, eliminating erosion and clogging issues associated with traditional mechanical valves and flow control devices.
Solution Approach 2:
The patent employs hydraulic principles by using a viscous fluid in the biasing mechanism to control flow distribution. The fluid's viscosity creates resistance differences that bias the flow toward one outlet, providing reliable flow control through fluid dynamics rather than mechanical means.
2Adaptability or versatility
If autonomous flow control is implemented, then response to changing fluid conditions is improved, but system complexity increases
Solution Approach 1:
The system is self-regulating through the passive viscous fluid biasing mechanism. The viscous fluid automatically adjusts flow distribution in response to changing upstream pressure and flow conditions without external control signals, allowing the system to adapt autonomously while maintaining relatively simple structure.
Solution Approach 2:
The patent exploits changes in fluid parameters (viscosity, pressure, flow rate) to control switch state. As upstream pressure or flow characteristics change, the viscous fluid's resistance characteristics cause the flow distribution to shift, automatically adapting the system to different operating conditions through parameter-dependent behavior.
3Ease of operation
If surface signals are used for flow control, then precise control is achieved, but operational independence deteriorates
Solution Approach 1:
The viscous fluid biasing mechanism provides autonomous control by automatically adjusting flow distribution based on local upstream conditions. The system operates independently without surface signals, using the fluid's inherent viscosity to sense and respond to changing conditions, achieving both operational independence and adequate control precision.
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 system effectively controls fluid flow autonomously, reducing production of undesired components and maximizing desired fluid production by adapting to changing fluid conditions without surface signals or mechanical parts susceptible to breakdown.
Implementation Method 1
The fluid flow is altered to a second flow distribution across the outlet of the flow biasing mechanism in response to a change in the fluid characteristic over time
Implementation Method 2
The fluid flow through the downstream vortex assembly is altered, thereby altering fluid flow patterns in a downstream vortex assembly. The fluid flow through the vortex assembly 'selects' for fluid of a preferred characteristic by inducing more or less spiraled flow through the vortex.
Data Source
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AI summary
Apparatus and methods are described for autonomously controlling fluid flow in a tubular in a wellbore. A fluid is flowed through an inlet passageway into a biasing mechanism. A fluid flow distribution is established across the biasing mechanism. The fluid flow distribution is altered in response to a change in the fluid characteristic over time. In response, fluid flow through a downstream sticky switch assembly is altered, thereby altering fluid flow patterns in a downstream vortex assembly. The method "selects" based on a fluid characteristic, such as viscosity, density, velocity, flow rate, etc. The biasing mechanism can take various forms such as a widening passageway, contour elements along the biasing mechanism, or a curved section of the biasing mechanism passageway. The biasing mechanism can include hollows formed in the passageway wall, obstructions extending from the passageway wall, fluid diodes, Tesla fluid diodes, a chicane, or abrupt changes in passageway cross-section.