Multi-zone Hydraulic Flow Control Module for Horizontal Wells

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Solution Overview

Problem

Achieving desired control over fluid inflow across multiple zones in horizontal wellbores is challenging due to difficulties in managing sand screen plugging and sand breakthrough in open hole horizontal completions, particularly in sandstone and carbonate formations.

Innovation Solution

A multi-zone control system with hydraulically actuated flow control devices distributed along the completion, controlled by an electrically controllable control module that selectively directs hydraulic actuating fluid to specific flow control devices, allowing for precise control of fluid inflow by shifting them to open or closed positions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If flow control devices are distributed along the entire completion, then control over fluid inflow at multiple zones is improved, but device complexity and difficulty of operation increase

Engineering Contradiction:

Improvecontrol over fluid inflow at multiple zonesVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The completion is divided into multiple discrete zones with individual flow control devices at each zone. Each zone can be independently controlled, allowing selective opening or closing of specific intervals while leaving others unaffected. This segmentation enables precise multi-zone control without requiring complex centralized management.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A compressed gas intermediary system is introduced to transmit control signals from a single surface location to multiple downhole flow control devices. The compressed gas acts as a mediator that carries the control function through the completion, eliminating the need for direct electrical or mechanical connections to each individual device and simplifying the overall system architecture.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If flow control devices are distributed along the entire completion, then control over fluid inflow at multiple zones is improved, but ease of operation deteriorates

Engineering Contradiction:

Improvecontrol over fluid inflow at multiple zonesVSAvoidoperation difficulty

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

A single compressed gas supply system performs multiple functions: it transmits control signals to all flow control devices, provides the actuating force for opening/closing operations, and enables selective zone control throughout the entire completion. This universal system replaces what would otherwise require multiple separate control mechanisms, greatly simplifying operation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The compressed gas serves as an intermediary that translates surface operator actions into downhole device responses. By injecting compressed gas at a single accessible location, the operator can control multiple distributed flow control devices without directly accessing or manipulating each individual device, making the system easy to operate from the surface.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If a control module is positioned in the middle region, then ease of operation is improved, but device complexity increases

Engineering Contradiction:

Improvecontrol accessibilityVSAvoidcontrol module complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The control module positioned in the middle region acts as an intermediary hub that receives compressed gas from the surface and distributes it to flow control devices on both the upper and lower sides. This central location provides easy surface accessibility while the module's internal distribution mechanism handles the complexity of multi-directional control, separating operational simplicity from mechanical complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 active, surface-controlled management of fluid flow into multiple well zones, enhancing the ability to isolate undesirable fluids and maintain efficient production by simplifying the operation of flow control devices through a single electric line and hydraulic system, thereby improving wellbore management and reducing well failure risks.

Implementation Method 1

distribution of hydraulic actuating fluid under pressure to selected flow control devices so as to shift the selected flow control devices to a desired open or closed flow position

Methodology Applied

Scientific EffectHydraulic pressure: Pressure Increase

Data Source

PatentUS10428619B2Active flow control with multizone hydraulic power distribution module

Publication Date: 2019.10.01 SCHLUMBERGER TECH CORP

AI summary

A controllable, multi-zone control system is provided for controlling the inflow of fluids into a completion, e.g. a lateral completion, at a plurality of well zones. According to an embodiment, flow control devices are distributed along the completion and a control module is positioned between the flow control devices, e.g. in a middle region of the completion. The control module is supplied with hydraulic actuating fluid and is electrically controllable to enable selective distribution of the hydraulic actuating fluid to selected flow control devices. The control module may be controlled via electric signals, thus controlling distribution of hydraulic actuating fluid under pressure to selected flow control devices so as to shift the selected flow control devices to a desired open or closed flow position.