Rotary Actuated Variable Choke Plug for Wellbore Flow Control
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Solution Overview
Problem
Existing wellbore plugs require multiple trips into the wellbore to adjust fluid flow rates, which is costly and time-consuming, especially in deeper wells, due to the need to retrieve and reposition the plug with different orifice sizes to achieve desired flow restrictions.
Innovation Solution
A rotary actuated variable choke plug that allows mechanical adjustment of flow rates downhole without removing the plug from the wellbore, using a rotary actuator to rotate a closure member and control fluid flow through the plug, eliminating the need for directly connected control lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional plugs with fixed orifice sizes are used, then flow rate adjustment is achieved by retrieving and repositioning the plug, but this requires multiple trips into the wellbore which is costly and time-consuming
Solution Approach 1:
The patent applies the dynamics principle by transforming the static fixed orifice plug into a dynamic system with a variable choke that can be adjusted in real-time. The closure member can rotate to different positions (0° for fully open, 90° for fully closed) to dynamically control the flow area, enabling flow rate adjustment without retrieving the plug from the wellbore.
Solution Approach 2:
The patent implements parameter changes by modifying the flow area parameter through rotation of the closure member. The choke geometry allows the flow area to vary continuously as the closure member rotates, changing the flow parameters without changing the physical plug structure or requiring plug replacement.
2Ease of operation
If conventional plugs require multiple trips for adjustment, then flow rate control is achieved, but operational cost and downtime increase significantly
Solution Approach 1:
The plug incorporates a dynamic closure member that can rotate to adjust the choke opening, transforming a static flow control device into a dynamic one. This allows operators to control flow rates by simple rotation without complex retrieval and repositioning operations.
Solution Approach 2:
The variable choke mechanism provides multiple functions within a single device: it can fully open for maximum flow, fully close for complete restriction, and provide intermediate positions for partial flow control. This multi-functionality replaces the need for multiple fixed-orifice plugs with different flow characteristics.
3Productivity
If fixed orifice plugs are used, then simple plug structure is maintained, but multiple trips are required to change flow restrictions
Solution Approach 1:
The invention transforms the static orifice into a dynamic variable choke with a rotatable closure member. This allows real-time flow adjustment by simply rotating the closure member to different angles, enabling productivity improvement while maintaining operational simplicity.
Solution Approach 2:
The patent replaces the mechanical system of retrieving and repositioning entire plugs with a simpler mechanical rotation of a closure member. This substitution maintains ease of operation by using simple rotational motion instead of complex retrieval and installation 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 efficient and timely adjustment of fluid flow rates in real-time, reducing the number of trips required and minimizing downtime, while maintaining simplicity and reliability compared to conventional inflow control devices.
Implementation Method 1
a rotary actuator to rotate a closure member and control fluid flow through the plug
Data Source
AI summary
A method for controlling fluid flow through a wellbore by introducing a plug with a variable choke into the wellbore, setting the plug in the wellbore, and mechanically adjusting the variable choke in the wellbore, thereby controlling a flow rate of a fluid through the plug. A plug that can control fluid flow through a flow passage in a wellbore, where the plug can include a body, an annular seal element that prevents fluid flow through an annulus between the plug and the wellbore, and a variable choke, where a closure member of the choke is mechanically rotated downhole to adjust a fluid flow rate through the choke. A method that can include producing fluids from two zones and using a plug to control a ratio of the fluids in a produced mixture.