Mechanical Actuation Control System Using Pilot Circuit

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Solution Overview

Problem

Existing well completion systems face challenges in controlling fluid flows without relying on electronics or control lines, particularly in downhole environments where these components may be unreliable or impractical.

Innovation Solution

A fully mechanical actuation control system using a spool valve coupled with a pilot control circuit that shifts operational positions based on pressure inputs along the wellbore annulus, establishing a reference pressure to actuate valves without the need for downhole electronics or control lines.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If electronics and control lines are used to control valves in downhole environments, then control precision and automation are improved, but reliability deteriorates due to problematic downhole conditions

Engineering Contradiction:

Improvecontrol automationVSAvoidsystem reliability

Core Design Contradiction:

Extent of automationVSReliability

Solution Approach 1:

The patent replaces electronic control systems with a fully mechanical control system. The spool valve mechanism uses pressure differential forces to mechanically shift between positions, eliminating electronics and control lines from the downhole environment. This substitution maintains automated control functionality while improving reliability in harsh downhole conditions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses hydraulic pressure from the wellbore annulus to control the spool valve positions. Pressure inputs are transmitted through the spool valve mechanism to actuate control valves, replacing electronic signaling with hydraulic actuation. This approach eliminates the need for downhole electronics while maintaining precise control capability.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Reliability

If a fully mechanical actuation control system is used, then reliability is improved by eliminating downhole electronics, but device complexity increases due to mechanical components

Engineering Contradiction:

Improvesystem reliabilityVSAvoidmechanical complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The spool valve mechanism serves multiple functions: it acts as a pressure amplifier, a position controller, and a flow distributor simultaneously. By making the spool valve multi-functional, the patent reduces the number of separate mechanical components needed, thereby reducing overall system complexity while maintaining reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The spool valve system is self-actuating through pressure differential forces. The pressure inputs from the wellbore annulus automatically shift the spool valve to appropriate positions without requiring external mechanical actuation or complex control mechanisms. This self-service capability simplifies the system while improving reliability.

Inventive Principle:

Principle #25Self-service

3Ease of operation

If pressure inputs are used to shift spool valve positions, then ease of operation is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvecontrol operationVSAvoidspool valve precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent uses pressure as the control parameter to shift spool valve positions. By changing pressure parameters from the wellbore annulus, the system achieves easy operation. The spool valve design incorporates pressure differential forces that naturally amplify small pressure changes into significant positional shifts, reducing the impact of manufacturing tolerances.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The spool valve is designed with preliminary pressure balancing features that pre-compensate for manufacturing variations. Pressure inputs are distributed through the spool valve in a way that anticipates and compensates for tolerances, allowing easier operation without requiring extremely tight manufacturing precision.

Inventive Principle:

Principle #10Preliminary action

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 reliable and efficient mechanical operation of valves and other components by utilizing pressure inputs to shift between operational positions, overcoming temperature and other limitations associated with downhole electronics and control lines.

Implementation Method 1

a spool valve (42) coupled with a pilot control circuit (44) which establishes a reference pressure that can be used to shift the spool valve (42) to different operational positions

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Data Source

PatentUS10392900B2Actuation control system using pilot control circuit

Publication Date: 2019.08.27 SCHLUMBERGER TECH CORP

AI summary

A technique facilitates mechanical operation of components, e.g. valves, without utilizing electronics at the components or control lines routed to the components. An actuation control system is fully mechanical in the sense that it is constructed to mechanically shift to different control positions via pressure input, such as pressure input supplied along a wellbore annulus. The actuation control system utilizes a spool valve coupled with a pilot control circuit which establishes a reference pressure that can be used in shifting the spool valve to different operational positions.