Pilot-Operated Flow Control Assembly for Wellbore Pressure Management
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Solution Overview
Problem
Existing flow control systems in well systems, particularly chemical injection systems, fail to reliably prevent the flow of chemicals from the surface into the wellbore when a high differential pressure exists across the check valve.
Innovation Solution
A flow control assembly actuated by pilot pressure, which includes a pilot-operated valve and a pilot control valve, is positioned between the pressure source and the target tool, allowing fluid flow only when a specific pilot pressure is communicated, thereby preventing backflow from the wellbore to the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a check valve is used in a chemical injection system, then fluid flow can be prevented in normal conditions, but the system fails to reliably prevent chemical flow from surface into wellbore when high differential pressure exists across the check valve
Solution Approach 1:
A pilot-operated valve is introduced as an intermediary device between the control line and the check valve. This pilot valve receives a pilot pressure signal and uses it to control the opening and closing of the main check valve, providing reliable flow prevention that overcomes the limitations of a simple check valve under high differential pressure conditions
Solution Approach 2:
The system uses hydraulic pressure (pilot pressure) communicated through a control line to actuate the pilot-operated valve. This pneumatic/hydraulic actuation mechanism provides reliable control of the check valve opening, ensuring that chemicals are prevented from flowing into the wellbore even when high differential pressures are present
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
Effectively prevents the flow of production fluids from the wellbore into the control line and allows controlled injection of chemicals by opening the pilot-operated valve in response to pilot pressure, ensuring reliable fluid management across varying pressure conditions.
Implementation Method 1
The pilot-operated valve can be opened in response to a pilot pressure being communicated to the pilot-operated valve via the pilot control valve
Implementation Method 2
The pilot control valve can control the pilot pressure. For example, a 'cracking pressure' (i.e., an opening pressure) can be communicated from the pressure source to the pilot control valve to open the pilot control valve
Data Source
AI summary
A flow control assembly can include a pilot-operated valve and a pilot control valve. The pilot-operated valve includes a closure element between inlet port and outlet ports of the pilot-operated valve and an actuating element adjacent to the closure element. The closure element can move between an open position allowing fluid flow between the inlet and outlet ports and a closed position preventing fluid flow between the inlet and outlet ports. A pilot pressure communicated to the actuating element can cause the actuating element to apply force that moves the closure element to the open position. The pilot control valve can include a closure element between inlet port and outlet ports of the pilot control valve. Communicating an actuation pressure to the closure element of the pilot control valve can open the pilot control valve. Opening the pilot control valve can allow communication of pilot pressure to the pilot-operated valve.