Ball Check Valve Integration in ICD Assembly
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Solution Overview
Problem
Existing wellbore production systems face challenges in balancing fluid production along long intervals, leading to uncontrolled water and gas coning, which reduces oil production efficiency, as current devices require physical intervention for actuation and may interfere with fluid flow.
Innovation Solution
A production sleeve assembly with an integrated valve system that includes a rupture disk and a plug, allowing fluid communication between the wellbore tubular and the exterior through a chamber, where the plug is releasably engaged and disengages to prevent fluid loss and interference, enabling unobstructed fluid flow upon actuation without physical intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a valve is integrated into the ICD to prevent fluid loss, then reliability is improved, but device complexity increases
Solution Approach 1:
The check valve is integrated directly into the ICD assembly, merging two separate functions (flow restriction and fluid loss prevention) into a single unified device. The valve body is formed as part of the ICD structure, with the ball check valve mechanism incorporated within the flow restriction assembly, eliminating the need for separate valve components and reducing overall system complexity despite adding functionality.
2Reliability
If a plug is used to maintain pressure, then reliability is improved, but ease of operation deteriorates due to requiring physical intervention
Solution Approach 1:
The ball check valve mechanism operates automatically based on pressure differential across the ICD. When wellbore pressure exceeds formation pressure, the ball is forced against the seat by the pressure differential, automatically sealing the flow path and maintaining pressure without requiring any external actuation or physical intervention. The system self-regulates based on operating conditions.
3Productivity
If flow restriction is applied to balance production, then productivity is improved, but harmful factors increase due to water and gas coning
Solution Approach 1:
The ball check valve provides automatic feedback control of fluid flow based on pressure conditions. When water or gas coning causes pressure fluctuations or exceeds safe production thresholds, the pressure differential automatically actuates the ball valve to close, preventing further fluid loss and stabilizing production. This creates a self-regulating system that responds to changing well conditions in real-time.
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 integrated valve system effectively balances fluid production by allowing controlled fluid flow while preventing interference, maintaining production efficiency and reducing the need for physical intervention, thus enhancing oil recovery by minimizing water and gas coning.
Implementation Method 1
pressurizing an interior of a wellbore tubular to a first pressure, where the first pressure is greater than a second pressure in an exterior of the wellbore tubular, actuating a rupture disk in response to the first pressure
Implementation Method 2
a plug releasably engaged in the fluid pathway in series with the rupture disk. The valve is configured to allow production from the exterior of the wellbore tubular to the interior of the wellbore tubular through the chamber without producing past the plug
Data Source
AI summary
A production sleeve assembly for use downhole includes a fluid pathway configured to provide fluid communication between an exterior of a wellbore tubular and an interior of the wellbore tubular through a chamber, a flow restriction disposed in the fluid pathway, and a valve disposed in series with the flow restriction in the fluid pathway. The valve comprises a rupture disk, and a plug releasably engaged in the chamber in series with the rupture disk. The valve is configured to allow production from the exterior of the wellbore tubular to the interior of the wellbore tubular through the chamber once the rupture disk is actuated, and the valve is configured to release the plug from the chamber when the rupture disk is actuated and the pressure within the exterior of the wellbore tubular is greater than the pressure within the interior of the wellbore tubular.