Downhole Flow Regulator Valve for High-Permeability Flow Restriction
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Solution Overview
Problem
In oil and gas operations, significant contrasts in relative permeability between formation regions lead to preferential fluid flow through high permeability areas, bypassing oil in low permeability regions, causing inefficient hydrocarbon production and issues like 'short cutting' and water breakthrough.
Innovation Solution
A downhole flow control device with a body locatable in a tubular, featuring a flow regulator with a valve arrangement and biasing mechanism that restricts fluid flow when differential pressure exceeds a threshold, using a shroud arrangement to inhibit debris and fluid ingress, ensuring backpressure is applied to limit flow through high permeability paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fluid injection is used to assist hydrocarbon production, then production efficiency is improved, but preferential flow through high permeability regions causes bypassing of oil in low permeability regions
Solution Approach 1:
The patent applies local quality by providing different flow resistance characteristics to different regions of the formation. Flow control devices are placed in high permeability regions to create localized flow restriction, while low permeability regions maintain their natural flow characteristics. This allows injection fluid to be redirected from high permeability pathways into low permeability regions containing oil, thereby improving sweep efficiency and reducing oil bypassing while maintaining overall production productivity.
2Loss of substance
If flow restriction is applied to high permeability regions, then preferential flow is prevented, but device complexity increases
Solution Approach 1:
The patent segments the wellbore into multiple zones with different flow control characteristics. Individual flow control devices are placed at specific intervals within the tubular, each device independently controlling flow in its local zone. This segmentation allows targeted flow restriction in high permeability regions without requiring complex control mechanisms across the entire wellbore, thereby preventing fluid short-cutting while keeping individual device complexity manageable.
Solution Approach 2:
The flow control devices are designed to automatically respond to flow conditions without requiring external control systems. The devices utilize the natural pressure differential and flow characteristics to self-regulate, with mechanisms that automatically adjust or maintain flow restriction based on local conditions. This self-service capability prevents fluid short-cutting through high permeability regions while avoiding the complexity of externally controlled systems.
3Productivity
If backpressure is maintained to limit flow, then hydrocarbon recovery is improved, but energy consumption increases
Solution Approach 1:
The patent applies backpressure locally at specific high permeability zones rather than maintaining uniform backpressure throughout the entire wellbore. Flow control devices create localized pressure drops only where needed to redirect flow into oil-bearing low permeability regions. This localized approach improves hydrocarbon recovery by enhancing sweep efficiency while minimizing the overall energy consumption compared to maintaining system-wide backpressure.
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 effectively restricts fluid flow through high permeability regions, ensuring more even distribution and increased hydrocarbon recovery by maintaining backpressure, thereby preventing preferential flow paths and enhancing production efficiency.
Implementation Method 1
a biasing mechanism configured to urge the valve arrangement towards an open configuration from a restricted configuration in which fluid flow though the flow path is restricted
Implementation Method 2
the shroud arrangement comprising two shroud members, wherein the shroud members cooperate in a sliding arrangement to maintain a tortuous path that inhibits fluid/debris entering the biasing mechanism
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
Described is a flow control device comprising a body locatable with a tubular and a flow regulator, housed within the body. The flow regulator defines a flow path through the body to accommodate flow between internal and external locations of a tubular in use. The flow regulator comprises a valve arrangement forming part of the flow path, and a biasing mechanism configured to urge the valve arrangement towards an open configuration from a restricted configuration in which fluid flow though the flow path is restricted. The biasing mechanism and the flow path through the flow control device are configured such that a differential pressure acting across the flow regulator, in excess of a particular threshold, moves the valve arrangement from the open configuration towards the restricted configuration in order to limit flow through the flow control device.