Versatile Manifold Actuates Downhole Devices
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Solution Overview
Problem
Existing downhole control systems are limited by the number of control line penetrations, restricting the number of hydraulically controlled devices that can be actuated, as they typically require more control lines than are available, especially in N+1 control systems.
Innovation Solution
A versatile manifold system that utilizes N+1 control lines to actuate at least N+1 hydraulically controlled devices by employing a common control line in conjunction with dedicated control lines, allowing for increased device actuation without exceeding the limit of control line penetrations, and includes mechanisms to prevent actuation of unnecessary devices and disable communication to devices no longer requiring actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional N+1 control system is used with limited control line penetrations, then the number of control line penetrations is reduced, but the number of hydraulically controlled devices that can be actuated is limited to no more than one less than the number of control line penetrations
Solution Approach 1:
The control system is segmented into two distinct sets of hydraulically controlled devices: a first set (N devices) that can be actuated during a first operation, and a second set (at least one additional device) that can be actuated during a second operation. This segmentation allows the same N+1 control lines to serve multiple functions across different operational phases, effectively doubling the utility of the limited control line infrastructure.
Solution Approach 2:
The system performs preliminary actions by configuring the control lines for a first operation to actuate devices in the first set, then transitions to a second operation where the same control lines actuate devices in the second set. The manifold is pre-configured with valve assemblies that can be switched between operations, allowing the system to prepare for and execute sequential actuation of different device sets without requiring additional control line penetrations.
2Ease of operation
If hydraulic pressure is applied to a common control line to actuate devices in the first set, then those devices are actuated, but actuation of devices in the second set is prevented
Solution Approach 1:
The manifold incorporates dynamic valve assemblies that can change their configuration based on the operational phase. During the first operation, valve assemblies route hydraulic pressure from the common control line to actuate devices in the first set. During the second operation, the same valve assemblies reconfigure to route pressure to actuate devices in the second set. This dynamic reconfiguration enables the system to adapt its actuation targets while maintaining the same physical control line infrastructure.
Solution Approach 2:
The system changes the operational parameter of which device set is active based on the operation phase. By switching between first and second operations, the system changes which subset of devices responds to hydraulic pressure on the common control line. This parameter change allows selective actuation of different device sets using the same control lines, resolving the conflict between actuation control and device selection flexibility.
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 the control of more hydraulically controlled devices than conventional systems with the same number of control lines, optimizing device actuation and reducing the need for additional penetrations, thereby enhancing the operational flexibility and efficiency of downhole control systems.
Implementation Method 1
a hydraulic actuator and a control valve, wherein the control valve is in fluid communication with the hydraulic actuator through a control line
Data Source
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AI summary
A downhole control system for actuating hydraulically controlled devices positioned in a well. The system includes a first set of N hydraulically controlled devices positioned in the well and a second set of at least one hydraulically controlled device positioned in the well. A common control line is ported to a first side of each of the hydraulically controlled devices in the first set. N control lines are each ported to a second side of one of the hydraulically controlled devices in the first set. A first control line of the N control lines is ported to a first side of a first hydraulically controlled device of the second set and a second control line of the N control lines is ported to a second side of the first hydraulically controlled device of the second set, such that N+1 control lines are operable to actuate N+1 hydraulically controlled devices.