Downhole Inflow Control Device with Dissolvable Coatings
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Solution Overview
Problem
Premature water breakthrough in hydrocarbon production from reservoirs, due to reservoir heterogeneity, adversely impacts hydrocarbon recovery, well life, and economics, as existing inflow control devices rely on viscosity or density differences that are not consistently reliable.
Innovation Solution
An autonomous inflow control device (ICD) with a funnel and core coated with multiple layers of dissolvable materials, where each layer dissolves at different rates in response to water or hydrocarbons, gradually obstructing fluid flow and effectively shutting off water influx without relying on viscosity or density differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional inflow control devices are used, then water production can be controlled, but the control reliability is poor due to dependence on viscosity or density differences
Solution Approach 1:
The core is divided into multiple functional segments with different coating layers (first coating layer, second coating layer, third coating layer), each dissolving at different rates to provide staged control of water inflow. This segmentation allows reliable control without complex mechanical mechanisms.
Solution Approach 2:
The device uses dissolvable coatings that are consumed over time to control water inflow. The coatings are designed to dissolve completely, providing a simple, reliable control mechanism that does not require complex moving parts or external power sources.
2Manufacturing precision
If single-rate dissolvable materials are used, then device structure is simple, but control precision over different time periods is insufficient
Solution Approach 1:
Different regions of the core are coated with materials having different dissolution rates. The first coating layer dissolves quickly for immediate control, the second coating layer dissolves at moderate rate for intermediate control, and the third coating layer dissolves slowly for long-term control. This local quality variation enables precise multi-stage inflow control.
Solution Approach 2:
The device employs composite coating structures combining multiple materials with different dissolution characteristics. Each coating layer is a composite material designed to dissolve at a specific rate, allowing precise control of water inflow at different time periods while managing structural complexity.
3Productivity
If the core outer diameter is reduced to allow passage through outlet port, then device can be deployed, but flow control capability is reduced
Solution Approach 1:
The core is initially coated with multiple layers that maintain a larger outer diameter during deployment and initial operation. As the coatings dissolve over time, the core gradually reduces in diameter, allowing it to eventually pass through the outlet port while maintaining flow control capability during the dissolution period.
Solution Approach 2:
The core diameter is made dynamic through the dissolvable coating layers. The diameter changes over time from a larger initial size (providing flow control capability) to a smaller final size (allowing passage through outlet port). This dynamic dimension change resolves the contradiction between flow control capability and deployability.
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 ICD automatically controls and reduces water inflow across various producing locations in a well, increasing well lifespan, improving hydrocarbon recovery, and reducing operational costs by eliminating the need for costly interventions, while maintaining reservoir pressure and enhancing well efficiency.
Implementation Method 1
The first coating is configured to dissolve at a first dissolution rate in response to being exposed to water or a fluid including water
Implementation Method 2
The second coating is configured to dissolve at a second dissolution rate different from the first dissolution rate in response to being exposed to water or a fluid including water
Implementation Method 3
The third coating is configured to dissolve in response to being exposed to a hydrocarbon or a fluid including a hydrocarbon. The third coating can be configured to be resistant to dissolving in response to being exposed to water
Data Source
AI summary
An apparatus includes a funnel, a core, a first coating, a second coating, and a third coating. The funnel includes multiple inlet ports and an outlet port. The core is disposed within the funnel. The first coating is disposed on and surrounds an outer surface of the core. The first coating is configured to dissolve in response to being exposed to water. The second coating is disposed on and surrounds an outer surface of the first coating. The second coating is configured to dissolve in response to being exposed to water. The third coating is disposed on and surrounds an outer surface of the second coating. The third coating is configured to dissolve in response to being exposed to a hydrocarbon.