Downhole Fluid Flow Control System with Bridge Network Valve
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Solution Overview
Problem
Existing downhole fluid flow control systems in subterranean wells lack the ability to adjust flow control characteristics dynamically in response to changes in formation pressure and fluid composition, particularly in completions requiring sand control and multiple production intervals, often necessitating well intervention.
Innovation Solution
A downhole fluid flow control system featuring a fluidic module with a bridge network and valve mechanism, utilizing pressure differences between branch fluid pathways with varying fluid flow resistors to control fluid flow, allowing independent control of inflow and outflow without intervention, by shifting the valve based on fluid properties like viscosity and composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed flow control components are installed in sand control screen assemblies, then sand control and initial flow control are achieved, but the ability to adjust flow control characteristics dynamically is lost
Solution Approach 1:
The patent applies dynamics by making the flow control system adjustable through a valve mechanism that can change its flow control characteristics dynamically. The valve responds to pressure differences generated by fluid flow through the bridge network, automatically adjusting between open and closed positions to adapt to changing formation conditions without requiring complex external control systems.
Solution Approach 2:
The system employs self-service through the autonomous operation of the valve mechanism. The pressure differential across the bridge network naturally drives the valve to appropriate positions based on fluid composition and flow conditions, eliminating the need for external intervention or complex control systems while maintaining adaptability.
2Ease of operation
If multiple flow control devices are installed to independently control multiple production intervals, then independent flow control is achieved, but the requirement for well intervention increases
Solution Approach 1:
Each production interval is equipped with an autonomous valve mechanism that automatically responds to pressure differences generated by fluid flow through its associated bridge network. This self-service capability allows independent control of each interval without requiring well intervention, as the valves autonomously adjust based on local fluid composition and flow conditions.
Solution Approach 2:
The completion system is segmented into multiple independent flow control modules, each with its own valve and bridge network. This segmentation enables independent control of each production interval while maintaining simplicity, as each module operates autonomously without requiring intervention in other intervals.
3Reliability
If traditional flow control screens are used in completions requiring sand control, then sand control is achieved, but the ability to respond to changes in formation pressure and fluid composition is limited
Solution Approach 1:
The valve mechanism provides dynamic response to changing formation conditions by automatically adjusting its position based on pressure differences generated by fluid flow through the bridge network. This allows the system to adapt to changes in formation pressure and fluid composition, optimizing production reliability without sacrificing sand control capability.
Solution Approach 2:
The system utilizes parameter changes in fluid flow (pressure differential) to control valve position and thereby adjust flow control characteristics. As fluid composition and formation pressure change, the resulting pressure differences automatically shift the valve between open and closed positions, providing reliable production optimization through parameter-based adaptation.
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
Enables dynamic adjustment of flow control characteristics to optimize production of desired fluids and minimize production of undesired fluids, such as water or gas, without requiring well intervention, thereby enhancing production efficiency and extending the life of the well.
Implementation Method 1
The pressure difference between the pressure output terminals of the first and second branch fluid pathways is operable to control fluid flow through the fluidic module
Implementation Method 2
The two fluid flow resistors of each branch fluid pathway may have different responses to a fluid property such as fluid viscosity, fluid density, fluid composition or the like
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A downhole fluid flow control system includes a fluidic module (150) having a main fluid pathway (152), a valve (162) and a bridge network. The valve (162) has a first position wherein fluid flow through the main fluid pathway (152) is allowed and a second position wherein fluid flow through the main fluid pathway (152) is restricted. The bridge network has first and second branch fluid pathways (163, 164) each having a common fluid inlet (166, 168) and a common fluid outlet (170, 172) with the main fluid pathway (152) and each including two fluid flow resistors (174, 176, 180, 182) with a pressure output terminal (178, 184) positioned therebetween. In operation, the pressure difference between the pressure output terminals (178, 184) of the first and second branch fluid pathways (163, 164) shifts the valve (162) between the first and second positions.