Full-Bore Electric Flow Control Valve With External Actuation
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Solution Overview
Problem
Existing downhole flow control valves (FCVs) in oil and injection wells are limited by the number of hydraulic penetrators, restricting the number of valves that can be installed, and converting to electric operation poses challenges in providing sufficient force for full bore valves.
Innovation Solution
Designing a flow control valve with an electrically powered actuator externally mounted via a linkage, utilizing electro-mechanical or electro-hydraulic actuators, and integrating a pump system with hydraulic circuitry to operate the internal piston, allowing for mechanical intervention when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hydraulic control lines are used to operate flow control valves, then the valves can be operated from surface, but the number of valves that can be installed is restricted due to limited penetrators at the well head
Solution Approach 1:
The patent replaces the hydraulic control system with an electrically powered actuator system. The actuator converts electrical energy to mechanical motion to operate the flow control valve, eliminating the need for hydraulic control lines and penetrators at the well head. This substitution enables multiple valves to be installed without increasing infrastructure complexity.
2Adaptability or versatility
If electrically powered actuators are used to operate full bore flow control valves, then multiple valves can be installed on a single electrical cable, but sufficient force for actuation must be provided
Solution Approach 1:
The patent employs a hybrid approach where an electrically powered pump generates hydraulic pressure to drive a hydraulic actuator. This electro-hydraulic system combines the advantages of electric control (multiple valves on single cable) with hydraulic force multiplication (sufficient actuation force for full bore valves). The hydraulic fluid serves as the energy transmission medium between the electric pump and the mechanical actuator.
Solution Approach 2:
The system changes the energy transmission parameter from direct electrical-mechanical conversion to electro-hydraulic-mechanical conversion. By introducing hydraulic pressure as an intermediate parameter, the system achieves both the control versatility of electric systems and the force capabilities of hydraulic systems, enabling full bore valve actuation with multiple valves on a single electrical cable.
3Device complexity
If the actuator is externally mounted to the flow control valve, then the system design is simplified, but mechanical intervention may be required for maintenance
Solution Approach 1:
The patent segments the actuator from the flow control valve body, mounting the actuator externally rather than integrating it internally. This segmentation simplifies the overall system design and allows the actuator to be a separate, modular component. The external mounting facilitates independent access to the actuator for maintenance and repair operations, reducing the need for complex disassembly procedures.
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 multiple electrically powered flow control devices on a single electrical cable, reducing subsea infrastructure costs and complexity, and maintaining high flow rates through full bore valves while simplifying the system design.
Implementation Method 1
an electro-hydraulic actuator (EHA)... The pump system is configured to pump hydraulic control fluid from a reservoir through the manifold to the actuator
Implementation Method 2
The manifold can include at least one solenoid operated valve (SOV)... activating a selected solenoid operated valve (SOV) in a manifold comprising hydraulic circuitry
Implementation Method 3
The pump system is configured to pump hydraulic control fluid from a reservoir through the manifold to the actuator
Implementation Method 4
an electrically powered actuator is mounted externally to the flow control valve and connected to the internal piston via a linkage
Data Source
AI summary
A technique facilitates flow control downhole via at least one flow control valve. According to an example, a flow control valve has an internal piston. Additionally, an electrically powered actuator is mounted externally to the flow control valve and connected to the internal piston via a linkage. The electrically powered actuator is responsive to electrical inputs to shift the internal piston to desired flow positions of the flow control valve.