Hydraulic Indexing System for Downhole Flow Control
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Solution Overview
Problem
Existing downhole well systems with hydraulically actuated flow control valves lack precise control over incremental actuation, often relying on mechanical indexers which are complex and costly.
Innovation Solution
A system comprising a hydraulically actuated tool combined with a control module featuring a hydraulic indexing circuit, which enables incremental movement of the actuator piston in one direction and full stroke movement in the opposite direction based on hydraulic input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a mechanical indexer is combined with the flow control valve to enable indexing of the piston to several operational positions, then the piston can be positioned at multiple operational positions, but the device complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical indexer with a hydraulic indexing circuit that uses hydraulic pressure to control piston positioning. The indexing piston moves between positions based on hydraulic fluid flow controlled by position control valves, eliminating the need for complex mechanical indexing mechanisms while achieving the same multi-position capability.
Solution Approach 2:
The patent employs a hydraulic indexing circuit where hydraulic fluid is directed to different chambers of an indexing piston through controlled valves. This hydraulic system enables precise positioning of the actuator piston at multiple operational positions without requiring mechanical linkages, gears, or other mechanical indexing components.
2Measurement precision
If a mechanical indexer is used for incremental actuation control, then precise positioning is achieved, but the system cost increases
Solution Approach 1:
The patent substitutes expensive mechanical indexing mechanisms with a more cost-effective hydraulic control system. The hydraulic indexing circuit uses readily available hydraulic components (valves, pistons, fluid) to achieve precise incremental positioning, reducing manufacturing costs while maintaining actuation precision.
Solution Approach 2:
The patent controls piston positioning by changing hydraulic parameters such as fluid pressure and flow rate. By adjusting these parameters through position control valves, the system achieves precise incremental actuation without the need for complex mechanical positioning mechanisms, thereby reducing overall system cost.
3Device complexity
If hydraulic control is used for incremental movement, then device complexity is reduced, but control precision over incremental actuation is limited
Solution Approach 1:
The patent segments the hydraulic control into distinct functional components: position control valves that independently control hydraulic flow to the indexing piston, and an indexing piston system with defined chambers. This segmentation allows precise control of incremental movement through coordinated valve operations, achieving both simplicity and precision.
Solution Approach 2:
The hydraulic indexing circuit incorporates feedback mechanisms where the position of the indexing piston controls the flow paths for hydraulic fluid. As the indexing piston moves between positions, it regulates fluid flow that maintains controlled incremental movement, enabling precise positioning through inherent hydraulic feedback without complex external control systems.
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 provides controlled, precise incremental actuation and full stroke movement of hydraulic devices, reducing complexity and cost compared to traditional mechanical indexing mechanisms.
Implementation Method 1
A hydraulic indexing circuit arranged to enable incremental movement of the actuator piston in a first direction and full stroke movement in a second direction based on hydraulic input delivered via control lines
Implementation Method 2
The hydraulic indexing circuit comprises an indexing piston system and at least one check valve working in cooperation with the indexing piston system to enable the incremental and full stroke movements
Data Source
AI summary
A technique provides a desired control over incremental actuation of hydraulic devices. A hydraulically actuated tool is combined with a control module. The hydraulically actuated tool has an actuator piston positioned in a piston chamber and movable between operating positions. The control module comprises a hydraulic indexing circuit arranged to enable incremental movement of the actuator piston in a first direction and full stroke movement in a second direction based on hydraulic input delivered via control lines. The hydraulic indexing circuit comprises an indexing piston system and at least one check valve working in cooperation with the indexing piston system to enable the incremental and full stroke movements.