Concentric Smart Well Completion with Independent Zone Control
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Solution Overview
Problem
Existing methods for producing oil, gas, or other resources from subterranean zones often struggle to independently control fluid flow from multiple production zones without commingling the fluids, which poses safety and pressure management challenges.
Innovation Solution
A method and system involving a tubular production string with an upper and lower string portion, a crossover assembly with a seal receptacle, and interval control valves (ICVs) positioned near each production zone perforation, allowing for simultaneous and independent flow of fluids from the upper and lower production zones without commingling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fluids from multiple production zones are produced concurrently, then productivity is improved, but fluid commingling occurs causing safety and pressure management issues
Solution Approach 1:
The production string is segmented into multiple sections with separate flow paths. Each production zone has its own dedicated flow channel through the tubular insert or annular space, allowing independent control and prevention of fluid commingling while maintaining concurrent production from multiple zones
Solution Approach 2:
The tubular insert is nested within the production string, creating concentric flow paths. The tubular insert provides an inner flow path while the annular space between the insert and production string provides an outer flow path, enabling simultaneous production from different zones without fluid mixing
2Reliability
If independent control of each production zone is implemented, then reliability is improved, but device complexity increases
Solution Approach 1:
The interval control valves serve multiple functions: they control flow from specific production zones, maintain pressure differentials, and prevent fluid commingling. The seal receptacle and tubular insert assembly provide both flow separation and structural support, reducing the need for additional dedicated components
3Reliability
If a tubular insert with downhole end inserted into seal receptacle is used, then fluid separation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The tubular insert and seal receptacle are designed with asymmetric features including tapered surfaces and offset sealing elements. This asymmetry creates a self-aligning mechanism that guides the insert into proper position within the receptacle, reducing the tolerance requirements compared to symmetric designs
Data Source
AI summary
A method includes disposing a tubular production string in a wellbore, the string having an upper portion with inner diameter greater than the inner diameter of a lower portion of the string. A tubular insert is disposed within the production string uphole of the lower portion. Opening an upper interval control valve (ICV) on the production string permits a flow of fluids from an upper production zone through the upper ICV to the surface through an interior annular volume formed by the exterior of the tubular insert and the interior of the upper portion, and opening a lower ICV on the production string permits a flow of fluids from a lower production zone through the lower ICV to the surface through the tubular insert, simultaneously and without commingling with fluids flowing through the upper ICV.