Downhole Inflow Control Valve Stroking Optimization
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Solution Overview
Problem
The installation and maintenance of inflow control valves (ICVs) in hydrocarbon wells are time-consuming and costly, and malfunctions are common due to obstructing materials, with limited options for repair or replacement, leading to increased operational costs and reduced well performance.
Innovation Solution
A method and system for monitoring ICV performance data to determine an optimal stroking frequency, identifying defective and non-defective ICVs, and calculating a probability of failure to minimize maintenance costs and failures, involving the use of cumulative probability distribution functions and stroking duration analysis to determine the best stroking schedule.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If ICVs are installed to regulate production flow, then flow control capability is improved, but maintenance complexity and cost increase
Solution Approach 1:
The system enables self-diagnosis by monitoring valve position commands versus actual positions to detect malfunctions, and self-maintenance through automated stroking operations that prevent sticking. The ICV system monitors its own performance and performs preventive maintenance without requiring continuous human intervention or complex manual diagnostics.
2Reliability
If ICVs are monitored continuously to detect malfunctions, then reliability is improved, but measurement and detection complexity increases
Solution Approach 1:
The system uses feedback by comparing the commanded valve position with the actual valve position to detect malfunctions. When a discrepancy is detected between the position command sent to the ICV and the actual position reported by the ICV, the system identifies a malfunction and triggers appropriate maintenance actions.
3Reliability
If ICVs are stroked frequently to prevent malfunction, then reliability is improved, but loss of production time increases
Solution Approach 1:
The system implements periodic stroking of the ICV as a preventive maintenance measure. Rather than continuous operation, the valve is stroked at predetermined intervals to prevent sticking and ensure proper operation, balancing reliability maintenance with minimal production interruption.
4Ease of repair
If ICV malfunction detection is implemented, then maintenance cost is reduced, but device complexity increases
Solution Approach 1:
The system replaces complex mechanical monitoring and diagnostic procedures with electronic and software-based solutions. Automated sensors, processors, and control systems substitute for manual mechanical inspections and diagnostics, reducing long-term maintenance costs despite initial technological complexity.
Data Source
AI summary
Provided are systems and method for operating and maintaining downhole inflow control valves (ICVs) of hydrocarbon wells, including monitoring the operations of ICVs to identify failure and non-failure times of defective and non-defective ICVs, respectively, determining a probability of failure of the ICVs (Pf) based on the failure and non-failure times, determining an operational stroking duration based on the probability of failure of the ICVs (Pf), and operating ICVs in accordance with the operational stroking duration determined.