Underbalance Actuator Operator Translation Mechanism
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Solution Overview
Problem
Current well completion technologies face challenges in efficiently actuating downhole tools using pressure differentials, particularly in underbalanced conditions, where annulus pressure exceeds tubing pressure, limiting remote operation and fluid flow control.
Innovation Solution
An underbalance actuation method and system that axially translates an operator in response to tubing pressure and underbalance pressure differentials, allowing a tool element to change positions remotely, utilizing a counter mechanism and underbalance spring to manage pressure cycles and achieve actuation at specific pressure differentials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If tubing pressure is used to actuate the operator, then the operator can be translated in the first direction, but the operator cannot be positioned precisely at the actuation position under underbalanced conditions
Solution Approach 1:
The patent applies parameter changes by transitioning from a single-pressure system (tubing pressure only) to a dual-pressure system (tubing pressure and annulus pressure). This allows independent control of the operator's movement in two directions: tubing pressure drives movement in the first direction, while annulus pressure enables precise positioning at the actuation position by overcoming the underbalance condition. The pressure differential parameter (ΔP = P_annulus - P_tubing) is specifically utilized to achieve precise actuation positioning.
2Manufacturing precision
If underbalance pressure is applied to move the operator to the actuation position, then precise actuation is achieved, but the system complexity increases due to requiring both tubing and annulus pressure control
Solution Approach 1:
The patent implements self-service by utilizing the naturally occurring pressure differential in underbalanced drilling operations (where annulus pressure exceeds tubing pressure) rather than requiring an active pumping system to create the differential. The system passively harnesses the existing pressure environment to achieve precise operator positioning, eliminating the need for additional complex pressure generation equipment while still enabling controlled actuation at the precise actuation position.
3Device complexity
If a single pressure system is used for operator actuation, then the system is simpler, but remote operation capability is limited
Solution Approach 1:
The patent introduces an intermediary mechanism - the annulus pressure system - that acts as a mediator between the tubing pressure system and the operator. This intermediary allows for two-stage control: tubing pressure provides initial actuation force, while annulus pressure serves as the precise positioning mechanism. This dual-pressure intermediary system enables sophisticated remote operation capabilities, allowing the operator to be positioned exactly at the actuation position without requiring complex mechanical linkages or additional actuators.
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 remote operation of downhole tools, such as valves, by translating the operator to an actuation position under controlled pressure conditions, enhancing fluid flow control and production efficiency in underbalanced well systems.
Implementation Method 1
axially translating an operator in a first direction in response to applying a tubing pressure to a first side in excess of an annulus pressure acting on a second side
Implementation Method 2
axially translating the operator in a second direction to an actuation position in response to applying an underbalance pressure level to the operator
Data Source
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AI summary
An actuation method according to one or more embodiments includes axially translating an operator in a first direction in response to applying a tubing pressure to a first side in excess of an annulus pressure acting on a second side, axially translating the operator in a second direction to an actuation position in response to applying an underbalance pressure level to the operator and operating a tool element from a first position to a second position in response to translating the operator to the actuation position.