Smart Circulation Sub With Electronic Valve Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current hydraulically operated circulation subs in subterranean wells lack real-time monitoring and have mechanical uncertainties in port position, leading to fluid loss and limited actuation cycles, with potential bursting pressure issues and restricted fluid flow due to ball-based actuation and mechanical port movement.
Innovation Solution
A smart circulation sub system with an electronic control system, isolated hydraulic actuation, and wireless communication for real-time monitoring and control, eliminating the need for balls and differential pressure, allowing the valve to move between open and closed positions an unlimited number of times, and providing independent activation within the circulation sub body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ball-based actuation system is used to open ports, then the circulation sub can be activated, but fluid is lost during the time for the ball to reach the circulation sub
Solution Approach 1:
The invention extracts and eliminates the ball-based actuation system from the circulation sub. Instead of using a ball that must travel down the drill string to activate the ports, the patent employs an electronic control system with solenoid-operated valves that can be activated remotely and instantly, removing the source of fluid loss and positional uncertainty
Solution Approach 2:
The invention replaces the mechanical ball-based actuation system with an electronic control system. The solenoid-operated valves are controlled electronically rather than mechanically, allowing for precise, instant activation without the delays and fluid losses associated with dropping a ball down the drill string
2Reliability
If differential pressure is used to move ports to open position, then the ports can be opened, but the added pressure can approach the bursting pressure of the drilling string
Solution Approach 1:
The invention replaces the differential pressure-based mechanical actuation system with an electronic solenoid control system. Instead of relying on high differential pressure to move ports open, the solenoids electronically actuate the valve members, eliminating the need for extreme pressure differentials that approach bursting pressure limits
Solution Approach 2:
The invention changes the actuation parameter from differential pressure to electrical signal. The solenoid-operated valves respond to electrical commands rather than pressure differentials, fundamentally changing the actuation mechanism to operate at much lower and safer pressure levels
3Productivity
If mechanical ports are used in circulation sub, then fluid can be diverted, but there is no positive indication of port position
Solution Approach 1:
The invention incorporates feedback mechanisms through electronic sensors and control systems that provide positive indication of valve member position. The electronic control system can detect and report whether the ports are open or closed, eliminating the informational gap present in purely mechanical systems
Solution Approach 2:
The invention replaces the mechanical port system with an electronically controlled valve system. The electronic nature of the control system enables monitoring and feedback of valve position, providing information that purely mechanical systems cannot provide
4Device complexity
If a limited number of balls are seated, then the system is simpler, but the number of times ports can be moved is limited
Solution Approach 1:
The invention replaces the mechanical ball seating system with an electronic control system using solenoid-operated valves. This substitution allows for unlimited actuation cycles since the electronic system can be reset and reused indefinitely, unlike the limited number of times a mechanical ball system can be cycled
Solution Approach 2:
The invention makes the valve member position dynamic and controllable through electronic signals rather than fixed mechanical constraints. The solenoid-operated valves can be opened and closed repeatedly on demand, providing unlimited adaptability for different circulation needs
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 real-time monitoring and control of fluid circulation, reduces fluid loss, and increases the reliability and durability of the circulation sub by providing precise and continuous operation of the valve, independent of other downhole tools, with wireless communication ensuring efficient and reliable fluid management in subterranean wells.
Implementation Method 1
An actuation assembly includes an isolated hydraulic fluid system operable to move the valve member between the closed position and the open position
Implementation Method 2
A control system includes an electronic processor, a memory, a data transmitter, and a data receiver... Information gathered within the wellbore of the subterranean well can be delivered to the earth's surface by way of radio waves
Data Source
AI summary
A circulation sub assembly for circulating fluids in a subterranean well includes a circulation sub body that is a generally tubular shaped member with a sub central bore. A circulation port extends through a sidewall of the circulation sub body. A valve member is moveable between a closed position where the valve member prevents a flow of fluid through the circulation port and an open position where the valve member provides a fluid flow path through the circulation port. An actuation assembly includes an isolated hydraulic fluid system operable to move the valve member between the closed position and the open position. A control system includes an electronic processor, a memory, a data transmitter, and a data receiver. The control system is operable to instruct the actuation assembly to move the valve member between the closed position and the open position.