Modular Control System for Downhole Tools
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Solution Overview
Problem
Completion systems in wells require expensive modifications to incorporate intelligent control systems for downhole valve actuation, increasing the cost of tubing strings and limiting their applicability to standard tubing configurations.
Innovation Solution
A modular control system comprising a removable control module and a clamshell packoff that can be easily attached to existing downhole tools, allowing for intelligent flow control without the need for specialized tubing, using a clamshell packoff with swellable or shape memory elements for sealing and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If intelligent control systems are incorporated into downhole tools, then flow control capability is improved, but device complexity and cost increase
Solution Approach 1:
The control system is divided into separate modular components: a control module that can be removably attached to standard tubing, and a controlled device (valve) integrated into the tubing. This segmentation allows intelligent flow control without modifying the entire tubing string, reducing overall system complexity while maintaining automation capability.
Solution Approach 2:
A removable control module serves as an intermediary between the standard tubing and the controlled device. This intermediary component provides the intelligent control functionality without requiring direct integration into the tubing structure, thereby simplifying the overall system architecture while enabling automated flow control.
2Extent of automation
If intelligent control systems are incorporated into downhole tools, then flow control capability is improved, but manufacturing cost increases
Solution Approach 1:
By segmenting the intelligent control system into a removable module that attaches to standard tubing, the patent avoids the need to manufacture specialized intelligent tubing strings. This allows use of conventional, cost-effective tubing manufacturing processes while still providing intelligent flow control through the attached control module.
Solution Approach 2:
The control module is designed to be universally compatible with standard tubing configurations, allowing a single modular component to provide intelligent flow control across multiple applications without requiring custom-manufactured tubing for each case, thereby reducing manufacturing costs.
3Adaptability or versatility
If control module is removably attached to downhole tool, then adaptability is improved, but connection reliability may worsen
Solution Approach 1:
The control module incorporates pre-configured connection interfaces and mounting mechanisms that are prepared in advance for reliable attachment to standard tubing. This preliminary preparation ensures that when the module is installed, it forms a stable, reliable connection without requiring complex field modifications or 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 low-cost intelligent flow control for downhole tools using standard tubing, providing flexible and modular solutions for various downhole applications while protecting the control system from shocks and impacts.
Implementation Method 1
using a clamshell packoff with swellable or shape memory elements for sealing and protection
Implementation Method 2
using a clamshell packoff with swellable or shape memory elements for sealing and protection
Data Source
AI summary
A modular control system includes a control module removably attachable to an exterior of a downhole tool. A controlled device, the controlled device providing a function for the downhole tool. The controlled device controlled by the control module.