Adjustable Orifice Inflow Control Device for Borehole Flow Balancing
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Solution Overview
Problem
In the drilling and completion industry, existing inflow control devices struggle to evenly distribute fluid flow along the length of a borehole, particularly in horizontal wells, leading to uneven production rates and issues like water or gas coning due to varying pressure and differential pressures between the exterior and interior of the completion string.
Innovation Solution
An adjustable orifice inflow control device with a plug-shaped body and a selectable insert that can be inserted into an orifice, allowing for adjustment of the flow path between the exterior and interior of a tubular, enabling precise control of fluid flow by varying the inner diameter of the insert to balance differential pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed orifice ICD is used, then the device structure is simple, but the flow distribution along the completion string cannot be adjusted to balance differential pressures
Solution Approach 1:
The patent implements adjustability by allowing the orifice size to be changed through different inserts or positioning mechanisms, enabling the ICD to adapt to varying flow conditions along the completion string while maintaining a relatively simple base structure
Solution Approach 2:
The patent changes the orifice parameter (size/area) to control flow distribution, allowing optimization of differential pressures at different locations by selecting appropriate orifice dimensions without redesigning the entire device
2Productivity
If a tortuous pathway is used to slow flow rate, then flow distribution is improved, but the device complexity and pressure loss increase
Solution Approach 1:
The patent applies flow control at specific critical locations within the ICD rather than throughout the entire pathway, using the adjustable orifice to regulate flow where needed most, thereby reducing overall device complexity while maintaining effective flow management
Solution Approach 2:
The patent introduces an intermediary orifice element that mediates between the high-pressure exterior environment and the lower-pressure interior completion string, controlling flow transition without requiring complex tortuous pathways throughout the entire device
3Adaptability or versatility
If multiple ICDs are installed along the completion string, then flow distribution improves, but the device complexity and installation difficulty increase
Solution Approach 1:
The patent designs a universal ICD module with adjustable orifices that can be used at multiple locations along the completion string, allowing the same standardized component to serve different flow control needs through parameter adjustment rather than requiring custom-designed devices for each location
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 balances fluid flow, reducing production from high zones and stimulating low or non-producing zones, thereby reducing water or gas coning and ensuring a more even flow profile, which is cost-effective and resistant to erosion and corrosion.
Implementation Method 1
the orifice in fluid communication with the opening... providing a flow path between the exterior and interior of the tubular
Data Source
AI summary
An inflow control device laterally insertable in a wall of a tubular, the inflow control device includes a plug shaped body having a first section and a second section, the first section having an orifice accessible to an interior of the tubular and the second section having an opening accessible to an exterior of the tubular, the orifice in fluid communication with the opening; and a selectable insert insertable into the orifice, the insert having an inner periphery providing a flow path between the exterior and interior of the tubular. Also, included is a production string and adjustable orifice inflow control device combination.