Physics-Based Digital Modeling, Validation, and Failure Scenario Analysis of Multi-Position Interval Control Valves in Intelligent Completion Systems

Background: Intelligent Completion Systems enable real-time monitoring and remote control of offshore wells through hydraulic actuation of multi-position Interval Control Valves (ICVs). This study develops, calibrates, and quantitatively evaluates a physics-based Digital Model of the Intelligent Completion Hydraulic System and investigates its behavior under simulated degradation conditions. Methods: Developed in MATLAB/Simulink using Simscape Fluids, the model integrates hydraulic and mechanical subsystems. Calibration involved iterative adjustment of numerical component parameters, guided by equipment specifications and comparisons with field measurements. Simulated pressure responses were subsequently compared with selected offshore operational records. Two degradation mechanisms were investigated: increased equivalent mechanical resistance and external hydraulic leakage. Results: The model reproduced transient hydraulic pressure responses with Mean Absolute Percentage Error (MAPE) values below 2.5% and Coefficient of Determination (R2) values between 0.98 and 0.99. Increased mechanical resistance restricted actuator displacement, with severe conditions causing incomplete valve positioning and reduced fluid transfer. External leakage progressively reduced circuit pressurization as severity increased. Conclusions: The calibrated model reproduces the investigated nominal hydraulic behavior and characterizes distinct responses under simulated degradation conditions. These findings provide a foundation for future condition monitoring and fault diagnosis applications, although diagnostic capabilities require independent experimental or field validation. The model also supports future Digital Twin development.