Bidirectional Flow Control Device for Subterranean Stimulation
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Solution Overview
Problem
Current inflow control devices (ICDs) in oil and gas wells have fixed flow restrictions, which are optimized for specific fluid types and narrow production rates, leading to issues during stimulation or injection operations, where higher flow rates can cause structural failure and non-uniform flow profiles, and require complex and risky mechanical interventions.
Innovation Solution
A bidirectional flow control device with a nozzle insert and cover plate that adjusts flow restriction based on internal tubular pressure, allowing for different flow capabilities during production and stimulation/injection modes, utilizing a biasing member to seal and unseal orifices accordingly, enabling a single integrated device to manage varying flow requirements without the need for multiple components or interventions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed flow restriction is used in ICDs during installation, then the device is optimized for a certain fluid type and narrow production rate range, but the device cannot accommodate stimulation operations with several times higher flow rates without structural failure
Solution Approach 1:
The patent applies a dynamic flow restriction system where a movable plug or ball valve can adjust the flow area in real-time. During production, the restriction maintains a small flow area for controlled rates. During stimulation, the restriction opens to accommodate high flow rates. This dynamic adjustment resolves the contradiction by making the flow restriction adaptable rather than fixed, allowing the same device to handle both low-rate production and high-rate stimulation without structural failure.
Solution Approach 2:
The patent changes the flow restriction parameter from a fixed value to a variable value that can be adjusted based on operational mode. The restriction size changes from small during production to large during stimulation. This parameter change enables the device to adapt to different flow rate requirements while maintaining structural integrity under both operating conditions.
2Adaptability or versatility
If additional check valve style devices are added to allow flow from one direction during stimulation and close during production, then bidirectional flow control is achieved, but the risk of mechanical failure increases due to having a large number of individual components
Solution Approach 1:
The patent merges the bidirectional flow control function into a single integrated device rather than using multiple separate check valves and ICDs. The movable plug or ball valve mechanism combines both production flow control and stimulation flow control in one component, reducing the number of individual parts and potential failure points while maintaining reliable bidirectional operation.
Solution Approach 2:
The patent creates a universal flow control device that performs multiple functions: it controls production flow in one direction and allows stimulation flow in the opposite direction. The single device replaces what would traditionally require multiple specialized components, thereby reducing mechanical complexity and failure risk while achieving bidirectional control.
3Adaptability or versatility
If controllable inflow devices (ICV) with hydraulic lines, electric lines or radio-frequency control tags are used, then flow area can be changed based on operator input, but the device complexity and requirement for well intervention accessibility increases
Solution Approach 1:
The patent employs a self-actuating mechanism where the movable plug or ball valve responds automatically to pressure differential changes without requiring external control systems. During stimulation, high pressure differential opens the restriction; during production, normal pressure differential keeps it closed. This self-service approach eliminates complex hydraulic lines, electric lines, or radio-frequency control tags, reducing device complexity while maintaining flow area adaptability.
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 device provides a cost-effective solution by ensuring a uniform flow profile during production and increased flow capability during stimulation or injection, reducing the risk of mechanical failure and the need for complex interventions, while maintaining well integrity and optimizing reservoir depletion.
Implementation Method 1
a biasing member, the biasing member positioned between the first biasing member seat and the second biasing member seat, the biasing member structured and arranged to exert a biasing force sufficient to place first sealable surface and the second sealable surface in sealing engagement when the internal tubular pressure is below a set-point value
Implementation Method 2
increasing the internal tubular pressure of the internal flow passage of the tubular member above the set-point value unseats the second sealable surface of the nozzle insert from the first sealable surface of the bore
Data Source
AI summary
Bidirectional flow control device for attachment to a tubular member including a nozzle insert comprising a first sealable surface, the nozzle insert comprising a nozzle passage, and a second sealable surface for mating with the first sealable surface, and a first biasing member seat; a cover plate positioned adjacent the first end of the nozzle insert, the cover plate comprising a production orifice and a plurality of stimulation orifices in fluid communication with a plurality of stimulation passages, the cover plate further comprising a second biasing member seat and a biasing member positioned between the first biasing member seat and the second biasing member seat, the biasing member to exert a biasing force to place first sealable surface and second sealable surface in sealing engagement when internal tubular pressure is below a set-point value.