Single-Solenoid Hydraulic Valve Control for Low-Power Downhole Tools
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Solution Overview
Problem
Existing systems for controlling downhole tools in hydrocarbon wells require substantial power consumption, making them incompatible with disconnect tools using inductive coupling.
Innovation Solution
A single solenoid electro-hydraulic control system that uses low power consumption to control downhole tools, utilizing a control module coupled with an ICV via two hydraulic lines and an electric line, featuring a normally closed solenoid valve to operate the ICV with minimal electrical power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional electro-hydraulic control systems are used to control downhole tools, then the control function is achieved, but substantial electrical power is consumed
Solution Approach 1:
The patent inverts the traditional control approach by using a normally closed solenoid valve that requires power only to open, rather than a normally open valve requiring power to close. This inversion allows the system to maintain control reliability while minimizing power consumption during the majority of operation when the valve remains closed.
Solution Approach 2:
The system employs periodic action by using brief energization pulses of the solenoid valve to transition between states, rather than continuous power consumption. The control module sends periodic signals to open or close the ICV as needed, maintaining reliability through controlled transitions while minimizing overall power usage.
2Adaptability or versatility
If high power is supplied to control downhole tools, then reliable operation is achieved, but compatibility with disconnect tools using inductive coupling is lost
Solution Approach 1:
The patent changes the power consumption parameter by utilizing a normally closed solenoid valve configuration that consumes minimal power during normal operation. This parameter change enables compatibility with inductive coupling disconnect tools, which cannot supply substantial continuous power, while still achieving reliable valve control through strategic energization.
3Ease of operation
If multiple sliding sleeves and interval control valves are placed in tubing sections, then fluid flow control is improved, but system complexity increases
Solution Approach 1:
The patent applies universality by designing a standardized electro-hydraulic control module that can be deployed in multiple tubing sections with sliding sleeves and ICVs. This multi-functional approach allows the same control architecture to manage fluid flow across different wellbore sections, improving ease of operation while avoiding the need for complex custom control systems for each section.
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 achieves efficient control of downhole tools with low power consumption, enabling compatibility with inductive coupling and reducing energy requirements.
Implementation Method 1
The control module includes a normally closed (NC) solenoid valve (SOV) that is coupled to the electric line and can be controlled from the surface to open or close
Implementation Method 2
The opening or closing of the NC SOV in cooperation with hydraulic pressure on an 'open' or 'close' line of the hydraulic lines operates (i.e., closes or opens) the ICV
Data Source
AI summary
A method comprises charging a first hydraulic line to have greater pressure than a second hydraulic line and energizing a solenoid valve, wherein charging the first hydraulic line and energizing the solenoid valve initiates transition of an interval control valve (ICV) from a first state to a second state. The method comprises discontinuing energizing the solenoid valve and maintaining the greater pressure in the first hydraulic line until the ICV reaches a desired state.