3D-Printed Venturi Nozzles for Steam Flashing in Tubing

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Solution Overview

Problem

Flow control devices in oil well operations face issues such as steam breakthrough, reduced oil production, erosion, corrosion, and increased drilling costs due to traditional nozzle designs that compromise tubing strength and efficiency, particularly in Steam Assisted Gravity Drainage (SAGD) and Cyclical Steam Stimulation (CSS) processes.

Innovation Solution

The development of one-piece, 3D printed inflow and outflow control nozzles with a venturi restriction and curved profiles that eliminate angular bends, reducing steam entry into producing wells, enhancing oil production, and made from hardened materials like tungsten carbide, which allows for complex designs without compromising tubing integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional nozzles are sized with steam flashing as the main design focus, then steam can be flashed into liquid water form, but the nozzle protrudes into the inner bore of the tubing reducing inside diameter and flow capacity

Engineering Contradiction:

Improvesteam flashing capabilityVSAvoidflow capacity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The nozzle is designed to extend in the radial direction rather than protruding axially into the tubing bore. By orienting the nozzle body radially outward from the tubing wall, the steam flashing function is achieved without reducing the axial inside diameter of the tubing, thus maintaining flow capacity while accomplishing the steam control function.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If traditional nozzles are sized with steam flashing as the main design focus, then steam can be flashed into liquid water form, but the nozzle extends out of the outside diameter of the tubing requiring more clearance of the wellbore

Engineering Contradiction:

Improvesteam flashing capabilityVSAvoidoutside diameter clearance

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

The nozzle is nested within or against the exterior surface of the tubing, with its body positioned radially outward. This nesting arrangement allows the nozzle to perform steam flashing while minimizing the overall outside diameter envelope, thereby reducing the clearance requirements in the wellbore and avoiding interference with surrounding structures.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Ease of manufacture

If traditional nozzles are accommodated by cutting an opening into the wall of the tubing as large as the nozzle, then the nozzle can be installed, but the torsional and tensile strength of the tubing is compromised

Engineering Contradiction:

Improvenozzle installationVSAvoidtubing strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The nozzle assembly is segmented into separate components: the nozzle body and the tubing. Instead of creating a large opening in the tubing wall to accommodate the entire nozzle, only a small opening is cut for nozzle insertion, while the majority of the nozzle body extends radially outward from the tubing surface. This segmentation preserves the structural integrity of the tubing while allowing nozzle installation.

Inventive Principle:

Principle #1Segmentation

4Speed

If steam is injected at high temperature and high speed to penetrate the formation, then steam can effectively stimulate hydrocarbon production, but steam temperature drops by as much as 50° C. in traditional straight bore nozzles

Engineering Contradiction:

Improvesteam speedVSAvoidsteam temperature

Core Design Contradiction:

SpeedVSTemperature

Solution Approach 1:

The nozzle incorporates a curved inner bore passage instead of a straight bore. This curved geometry allows the steam to follow a curved path through the nozzle, reducing turbulent mixing and thermal losses that occur in straight nozzles. The curved design helps maintain higher steam temperature while still achieving the necessary injection speed for formation penetration.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 solution effectively flashes steam into liquid, maintains high steam temperature, reduces erosion, and minimizes wellbore diameter requirements, thereby increasing oil production efficiency and reducing drilling costs while maintaining tubing strength.

Implementation Method 1

a venturi restriction

Methodology Applied

Scientific EffectPressure drop: Pressure Drop

Implementation Method 2

flash the steam into liquid water form

Methodology Applied

Scientific EffectCondensation: Condensation

Implementation Method 3

redirect fluid between the outside of the tubing and the inside of the tubing

Methodology Applied

Scientific EffectFluid flow redirection:

Data Source

PatentUS11994007B2Flow control nozzles, method of manufacture and use thereof

Publication Date: 2024.05.28 KLIMACK HLDG

AI summary

An inflow control nozzle is provided for use with a tubing. The nozzle includes a one-piece, 3D printed body, the body including a fluid inlet in communication with an outside of the tubing said inlet having an oval cross section; a fluid outlet in communication with an inside of the tubing; and an inner bore connecting the fluid inlet to the fluid outlet, said inner bore including a venturi restriction. The inner bore comprises a flared profile from the fluid inlet to the venturi restriction, and a flared and curved profile from the venturi restriction to the fluid outlet, said curved profile being free of angular bends or sharp direction change. An outflow control nozzle is also provided for use with a tubing and an inflow-outflow control nozzle is further provided for use with a casing.