Downhole Fluid Flow Control with Dissolvable Plug and Viscosity Discriminator
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Solution Overview
Problem
Current downhole fluid flow control systems in hydrocarbon wells face limitations such as fatigue failure, complexity, lack of sensitivity to fluid property differences, and inability to restrict unwanted fluid flow without well intervention, especially in long horizontal completions with multiple production intervals.
Innovation Solution
A downhole fluid flow control system featuring a fluid control module with a valve element maintained by a dissolvable prop member, a viscosity discriminator, and a differential pressure switch that adjusts based on fluid viscosity, allowing independent control of fluid flow through main and secondary pathways without biasing devices or complex structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If autonomous inflow control devices with valve elements are used to control fluid flow, then fluid flow control capability is improved, but the system becomes susceptible to fatigue failure of biasing devices and failure of intricate components
Solution Approach 1:
The patent removes the biasing device and intricate valve mechanism from the system. Instead of using a valve element that requires actuation, the invention uses a dissolvable plug that simply dissolves to allow flow. This extraction of the problematic components eliminates fatigue failure while maintaining flow control capability through the dissolvable plug's temporary blocking function.
Solution Approach 2:
The dissolvable plug is designed as a temporary, disposable component that performs its function by dissolving over time. Rather than being a durable mechanical component subject to fatigue, it is a consumable element that naturally degrades through dissolution, eliminating reliability issues associated with mechanical fatigue and complex structures.
2Ease of operation
If current autonomous inflow control devices are used, then some fluid flow control is achieved, but they lack sensitivity to minor fluid property differences such as light oil viscosity versus water viscosity
Solution Approach 1:
The patent applies different properties to different parts of the system: the dissolvable plug responds to chemical composition (solubility), while the viscosity-sensitive channel responds to fluid viscosity. This local differentiation of response mechanisms enables the system to detect and respond to minor fluid property differences that a single uniform mechanism could not detect.
Solution Approach 2:
The invention changes the operational parameter from mechanical valve actuation to chemical dissolution and viscosity-based pressure differential detection. The dissolvable plug's dissolution rate and the pressure differential across the viscosity-sensitive channel are both sensitive to fluid properties, enabling detection of minor differences in viscosity and composition.
3Ease of operation
If autonomous inflow control devices are used to restrict unwanted fluid flow, then some flow restriction is achieved, but they cannot highly restrict or shut off flow due to requiring substantial flow or flow through main flow path to operate
Solution Approach 1:
The patent segments the flow control function into two independent pathways: a main flow path blocked by the dissolvable plug and a viscosity-sensitive channel that detects fluid properties. This segmentation allows the system to control flow through the main path based on detection from the separate channel, enabling shutdown capability without requiring substantial flow through the main path for operation.
Solution Approach 2:
The viscosity-sensitive channel acts as an intermediary that detects fluid properties and translates them into pressure differential signals. This intermediary mechanism enables the system to respond to fluid composition changes and shut off flow in the main path without requiring substantial flow through the main path itself, as the detection occurs through the separate viscosity-sensitive channel.
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 independent control of fluid flow from multiple production intervals, sensitive to minor fluid property changes, and effectively restricts or shuts off unwanted fluid flow, addressing the limitations of existing systems.
Implementation Method 1
The dissolvable prop member is operable to be dissolved by a dissolution solvent downhole to allow the valve element to operate between the open and closed positions
Implementation Method 2
The viscosity discriminator has a viscosity sensitive channel that forms at least a portion of the secondary fluid pathway
Implementation Method 3
The differential pressure switch includes a first pressure signal from the upstream side, a second pressure signal from the downstream side and a third pressure signal from the secondary fluid pathway
Data Source
AI summary
A downhole fluid flow control system includes a fluid control module having an upstream side, a downstream side and a main fluid pathway in parallel with a secondary fluid pathway each extending between the upstream and downstream sides. A valve element disposed within the main fluid pathway has open and closed positions. A viscosity discriminator including a viscosity sensitive channel forms at least a portion of the secondary fluid pathway. A differential pressure switch operable to open and close the valve element includes a first pressure signal from the upstream side, a second pressure signal from the downstream side and a third pressure signal from the secondary fluid pathway. The fluid control module includes a dissolvable member operable to temporarily lockout the valve element in the open position or temporarily prevent fluid flow through the main and secondary fluid pathways. The dissolvable member is dissolvable by a dissolution solvent downhole.