Dual-Path Flow Control for Gas and Water Breakthrough
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Solution Overview
Problem
Existing inflow control devices (ICDs) for hydrocarbon production struggle with significant oil production loss, inadequate control of gas and water breakthrough, high flow resistance, and difficulty in managing harsh well conditions, leading to inefficient oil recovery.
Innovation Solution
A fluid flow control device with a primary and secondary flow path, featuring movable valve elements and flow restrictors that adjust based on pressure changes to control fluid flow, preventing unwanted phases like gas and water from entering the production string while maintaining efficient oil flow, and incorporating a self-cleansing filter to prevent plugging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional ICDs with fixed flow area are used, then reservoir contact is improved, but oil production is choked during initial phase resulting in significant production loss
Solution Approach 1:
The patent applies dynamics by replacing fixed flow area ICDs with movable valve elements that can dynamically adjust their position and flow area. The valve elements respond to fluid properties (oil vs water/gas) by moving between open and closed positions, enabling the system to adapt its characteristics in real-time rather than being static.
Solution Approach 2:
The invention changes the flow control parameter from a fixed geometric flow area to a dynamically variable flow area controlled by movable valve elements. The valve elements change their position parameter in response to fluid property changes, allowing the system to optimize flow characteristics for different fluid phases.
2Productivity
If ICDs are used to increase reservoir contact, then production capacity is improved, but control of gas and water breakthrough is inadequate
Solution Approach 1:
The patent implements feedback mechanisms where the movable valve elements automatically respond to changes in fluid properties (density, viscosity, flow characteristics). When water or gas enters the device, the valve elements detect these changes through pressure differential mechanisms and automatically adjust their position to choke or close the flow, providing closed-loop control without external intervention.
Solution Approach 2:
The valve elements perform self-service by autonomously detecting fluid property changes and adjusting their own position to control flow. The system uses the fluid's own properties (pressure, density differences) to actuate the valve elements, eliminating the need for external control systems or additional sensing mechanisms.
3Reliability
If flow restrictors are used to control fluid flow, then unwanted phases are choked, but high flow resistance is created during throughput of desired phases
Solution Approach 1:
The system uses dynamic valve elements that change their flow resistance characteristics based on fluid properties. During oil flow, the valves remain open with minimal resistance. When water or gas is detected, the valves dynamically adjust to create high resistance selectively for unwanted phases, rather than maintaining constant high resistance as in traditional restrictors.
Solution Approach 2:
The invention applies local quality by creating different flow resistance characteristics in different parts of the device depending on the fluid phase present. The movable valve elements locally adjust the flow path geometry to provide low resistance for oil while creating high resistance for water/gas, rather than applying uniform resistance throughout the flow path.
4Reliability
If autonomous ICDs with valve elements are used, then control of undesired phases is improved, but challenging conditions (high pressure, temperature, fouling) are difficult to manage
Solution Approach 1:
The valve elements are designed to be self-actuating using the energy inherent in the fluid flow itself. The pressure differential created by the fluid properties (density, viscosity) directly drives the valve element movement, eliminating the need for external actuators, power sources, or control systems that would be vulnerable to harsh conditions.
Solution Approach 2:
The system adapts to harsh conditions by changing its operational parameters dynamically. The valve elements respond to changes in pressure, temperature, and fluid composition by adjusting their position to maintain effective flow control. The design allows the control mechanism to exploit the energy available in the flowing fluid rather than being defeated by the harsh environmental parameters.
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 stops unwanted fluids from entering the production flow, is robust and compact, and reversibly adjusts to fluid property changes, enhancing oil recovery by up to 10% and reducing production costs.
Implementation Method 1
a first fluid flow restrictor (3) configured to generate a pressure decrease from a pressure p1 upstream of the first fluid flow restrictor (3) to a pressure p2 downstream of the first fluid flow restrictor (3)
Implementation Method 2
a second fluid flow restrictor (4) arranged downstream of the first fluid flow restrictor (3) and configured to generate a pressure decrease from the pressure p2 upstream of the second fluid flow restrictor (4) to a pressure p3 downstream of the second fluid flow restrictor (4)
Implementation Method 3
The movable valve element is configured to close, fully or partly, the primary flow path for primary fluid flow (F0) when exposed to a pressure force from within the chamber (B) exceeding a threshold pressure force
Data Source
Figure 1
Figure 2
Figure 3(A)~3(B)
AI summary
It is provided a fluid flow control device for establishing a controllable fluid communication between an external fluid reservoir and a base pipe constituting part of a production string, as well as a production string and a method using such a fluid flow control device. The fluid flow control device comprises a primary flow path arranged inside a fluid control device housing, a secondary flow path and a movable valve element arranged at and/or within the primary flow path. The inlet of the secondary flow path is arranged separate from the inlet of the primary flow path.