Degradable Orifice Production Sub for Flow Control
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Solution Overview
Problem
Production subs with multiple production ports face pressure balance issues due to intact pressure barriers, limiting flow area during later production phases, and are prone to cement and debris accumulation in the ports.
Innovation Solution
Incorporating a fluid flow assembly in each production port with a radially interior and exterior burst disc, along with a sealing member that engages radially outward, and optionally a degradable fluid flow orifice or dissolvable plug to maintain pressure differential and prevent debris entry until the cement cures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple production ports are equipped with pressure barriers (burst discs), then pressure differential can be maintained during cementing, but flow area is limited during later production phases
Solution Approach 1:
The pressure barrier system is segmented into multiple burst discs positioned at different radial locations (interior and exterior). Each burst disc can fail independently at different pressures, allowing the system to transition from a sealed state to a progressively more open state, resolving the contradiction between maintaining pressure differential and enabling high flow volume.
Solution Approach 2:
The burst discs are designed with different burst pressure ratings to create a staged pressure release mechanism. As pressure increases during production, different burst discs fail at different pressure thresholds, dynamically changing the flow area from restricted to expanded, thus resolving the contradiction between pressure maintenance and flow volume.
2Reliability
If pressure barriers are kept intact to maintain pressure differential, then cementing operation is protected, but cement and debris can accumulate in production ports
Solution Approach 1:
The pressure barrier system is divided into multiple segmented burst discs at different radial positions. This segmentation allows selective failure of individual discs while maintaining overall system integrity, enabling debris protection during cementing while allowing controlled access during production.
Solution Approach 2:
The burst discs are pre-positioned and designed to fail at specific pressure thresholds before cement and debris can cause blockage. This preliminary action of controlled failure prevents harmful accumulation while maintaining pressure barrier functionality during the critical cementing phase.
3Reliability
If all production ports are sealed with pressure barriers, then pressure differential is maintained, but flow volume is restricted until all barriers fail
Solution Approach 1:
Each production port is equipped with multiple segmented burst discs at different radial locations rather than a single barrier. This segmentation allows progressive failure and gradual expansion of flow area, resolving the contradiction between maintaining pressure differential and enabling adequate flow volume.
Solution Approach 2:
Multiple burst discs are nested within each production port assembly, with interior and exterior discs positioned concentrically. This nested configuration allows sequential failure from interior to exterior discs, progressively increasing flow area while maintaining pressure differential until all discs fail.
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
Ensures all burst discs burst before achieving pressure balance, increasing flow volume and preventing cement/debris entry, thus enhancing production efficiency and port functionality over time.
Implementation Method 1
maintain the pressure differential across the inside diameter and outside diameter of the tubular
Implementation Method 2
a degradable fluid flow orifice positioned radially outside of the radially interior burst disk, the degradable fluid flow orifice configured to degrade over time after the radially interior burst disc has burst to increase a flow volume through the production port
Implementation Method 3
a sealing member positioned in a chamber created between the radially interior burst disc and the radially exterior burst disc
Data Source
AI summary
The present disclosure, in at least one aspect, provides a production sub, a well system, and a method. The production sub, in one aspect, includes a tubular having a length (l), an inside diameter (ID), an outside diameter (OD), and a sidewall thickness (t), a plurality of production ports extending through the sidewall thickness (t) and coupling the inside diameter (ID) and the outside diameter (OD), and a fluid flow assembly positioned in each of the plurality of production ports. Each fluid flow assembly, in one aspect, includes a radially interior burst disc, as well as a degradable fluid flow orifice positioned radially outside of the radially interior burst disk, the degradable fluid flow orifice configured to degrade over time after the radially interior burst disc has burst to increase a flow volume through the production port.