Proportional Surface Control for Downhole Choke Actuation
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Solution Overview
Problem
Existing control systems for downhole well tools are complex, expensive, and prone to failure in hostile environments, and lack direct indicators for the actual position of downhole actuators, leading to uncertainty in operation due to non-linear fluid volume changes at low pressures.
Innovation Solution
A direct proportional surface control system is developed, where a remote control system piston displacement is proportional to the actuator piston displacement, allowing for accurate positioning through a visible indicator or measurement, and utilizing a closed-loop fluid circuit to maintain direct proportionality and compensate for friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If open-loop hydraulic control systems are used, then the system is simpler, but gas entrained in the fluid causes non-linear changes in volume and produces uncertainty in piston displacement
Solution Approach 1:
The patent implements a feedback mechanism where the actual position of the downhole actuator is continuously monitored and fed back to the surface control system. This allows the system to compensate for non-linear fluid volume changes and gas entrainment effects, maintaining accurate displacement measurement despite the simplified open-loop hydraulic configuration.
Solution Approach 2:
The patent replaces traditional mechanical linkage systems with a hydraulic control system that uses fluid pressure transmission. This substitution allows for simpler system architecture while maintaining control precision through the use of pressure-sensitive indicators and feedback mechanisms that account for fluid compressibility and gas content.
2Ease of operation
If existing control systems are used, then the system can control downhole tools, but the operator has no direct physical indicator of the actuator's actual position
Solution Approach 1:
The patent employs visual indicators that change appearance or position to reflect the actual position of the downhole actuator. These color-changing or position-changing indicators provide operators with direct visual feedback about actuator status, eliminating information loss and improving operational awareness without requiring complex electronic displays.
Solution Approach 2:
The patent introduces intermediate visual indicators as mediators between the downhole actuator and the surface operator. These indicators physically or optically transmit position information from the actuator to the operator, ensuring that the operator always knows the actual position of the actuator regardless of the complexity of the underlying control system.
3Reliability
If complex control systems are used, then the system can provide precise control, but the system becomes expensive and susceptible to failure in hostile well environments
Solution Approach 1:
The patent employs simple, robust hydraulic components and visual indicators that are inexpensive and resistant to corrosion, heat, and debris. Rather than using complex electronic sensors and actuators, the system uses durable mechanical and hydraulic elements that are less susceptible to failure in hostile well environments, even if they have shorter operational lifetimes.
Solution Approach 2:
The patent optimizes hydraulic parameters such as fluid pressure, flow rate, and viscosity to ensure reliable operation in varying well conditions. By adjusting these parameters dynamically, the system maintains reliability across different temperature, pressure, and fluid composition conditions without requiring complex adaptive control algorithms.
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 system provides reliable and accurate control of downhole tools by ensuring proportional displacement of pistons, reducing uncertainty and improving operational precision in hostile environments.
Implementation Method 1
A displacement of the control system member causes a displacement of the actuator member, the control system member displacement being proportional to the actuator member displacement
Implementation Method 2
utilizing a closed-loop fluid circuit to maintain direct proportionality and compensate for friction
Data Source
AI summary
A direct proportional control system for remotely controlling actuation of a tool. A well control system includes an actuator for a downhole well tool, the actuator including an actuator member which displaces to operate the well tool. A control system member is positioned at a remote location. A displacement of the control system member is proportional to a displacement of the actuator member.