Pilot-Pressure Flow Control for Smooth Downhole Valve Response
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Solution Overview
Problem
Existing downhole flow control devices struggle to autonomously adjust flow rates based on fluid properties, often relying on the Bernoulli effect and requiring restrictive mechanisms, which can lead to undesirable rapid transitions and inefficiencies in hydrocarbon production.
Innovation Solution
A downhole flow control device with a valve member that moves based on fluid properties, utilizing a sealed pilot pressure chamber and a secondary flow path to autonomously adjust flow rates without the Bernoulli effect, allowing for smooth transitions between open and closed positions based on fluid viscosity and density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a flow control device switches instantaneously between fully open and fully closed positions when undesired fluid begins to be produced, then the device can quickly respond to fluid changes, but this causes loss of sinkhole (pressure drawdown) around the wellbore and possible loss or reduced production of desired wellbore fluid
Solution Approach 1:
The valve member is designed to move dynamically between fully open, fully closed, and intermediate positions rather than switching instantaneously. The pilot pressure chamber controls the valve member to transition smoothly through intermediate positions, enabling gradual flow adjustment that maintains sinkhole while responding to fluid changes
Solution Approach 2:
A pilot pressure chamber is introduced as an intermediary control mechanism between the fluid property changes and the valve member position. The pilot pressure system mediates the valve actuation by translating fluid property changes into controlled pressure changes that move the valve member gradually through intermediate positions
2Productivity
If a flow control device switches from fully closed to fully open position when desired fluid begins to be produced, then the device can maximize desired fluid production, but rapid onset of undesired fluid may occur
Solution Approach 1:
The valve member transitions dynamically from fully closed to fully open position through intermediate positions rather than switching instantaneously. This dynamic movement allows gradual increase in desired fluid production while preventing rapid onset of undesired fluid by maintaining progressive flow control
Solution Approach 2:
The pilot pressure system provides continuous feedback control by monitoring fluid properties and adjusting valve member position accordingly. The system detects changes in fluid properties and responds by moving the valve member through intermediate positions, providing feedback control that prevents rapid undesired fluid onset
3Productivity
If existing flow control devices rely on the Bernoulli effect and use restrictive mechanisms, then they can control flow rates, but they require complex restrictive structures that lead to inefficiencies and undesirable rapid transitions
Solution Approach 1:
The patent replaces the Bernoulli effect-based mechanical restrictive mechanisms with a pressure-based control system. The pilot pressure chamber uses pressure differentials to control valve member position, substituting complex restrictive structures with a simpler pressure-driven actuation mechanism
Solution Approach 2:
The invention uses pneumatic/hydraulic principles by introducing a pilot pressure chamber that controls valve actuation through pressure differentials. This pneumatic control mechanism replaces mechanical restrictive structures and enables smooth, controlled transitions without complex mechanical components
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 device effectively controls flow rates by autonomously adapting to fluid properties, optimizing hydrocarbon production while minimizing water and gas production, without the need for restrictive mechanisms, ensuring stable and efficient fluid management.
Implementation Method 1
the pilot pressure is provided as a function of a property of fluid flowing through the primary flow path... when a fluid with a first fluid property (such as a first viscosity) is flowing along the primary flow path... When a fluid with the second fluid property (such as a second viscosity, wherein the second viscosity differs from the first viscosity), begins to flow along the primary flow path
Implementation Method 2
the pilot pressure is provided as a function of a property of fluid flowing through the primary flow path... based upon one or more properties of a fluid flowing along the primary flow path
Implementation Method 3
a sealed pilot pressure chamber defining a pilot pressure inlet for receiving a pilot pressure, the valve member being in pressure communication with the sealed pilot pressure chamber such that pilot pressure may act to bias the valve member
Implementation Method 4
a biasing mechanism providing a biasing force for biasing the valve member in one of the first and second directions
Data Source
Figure 1~2
Figure 3A~3B
Figure 3C
AI summary
A flow control device and associated method are provided, the flow control device comprising: a body locatable within a wall of a tubular and defining a primary inlet and a primary outlet, wherein a primary flow path is defined between the primary inlet and primary outlet; a valve member is disposed within the body, the valve member being moveable in reverse first and second directions to selectively vary a flow area of the primary flow path; and, a sealed pilot pressure chamber defining a pilot pressure inlet for receiving a pilot pressure, the valve member being in pressure communication with the sealed pilot pressure chamber such that pilot pressure may act to bias the valve member in one of the first and second directions, wherein the pilot pressure is provided as a function of a property of fluid flowing through the primary flow path.