Dual-Path Flow Control Valve for Autonomous Phase Breakthrough Prevention
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Solution Overview
Problem
Existing inflow control devices (ICDs) for hydrocarbon production suffer from issues such as undesired phase breakthroughs, high flow resistance, and inability to manage harsh well conditions, leading to significant production loss and inefficiencies.
Innovation Solution
A fluid flow control device with a primary and secondary flow path, featuring a movable valve element that autonomously adjusts based on fluid properties, allowing efficient control of fluid communication between a reservoir and a production string, minimizing space requirements and preventing undesired fluid ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional ICDs with fixed flow area are used, then reservoir contact is improved, but production is choked during initial phase and undesired phases cannot be effectively controlled
Solution Approach 1:
The patent applies dynamics by replacing fixed flow area ICDs with a movable valve element that can change position based on fluid properties. The valve element moves between open and closed positions dynamically in response to density differences between oil and water/gas phases, enabling adaptive control rather than static restriction.
Solution Approach 2:
The device employs self-service through autonomous operation without external control systems. The valve element automatically responds to fluid density changes through buoyancy forces, eliminating the need for external actuators, control lines, or power sources while maintaining effective phase control.
2Reliability
If AICDs with valve elements are used to control undesired phases, then phase breakthrough is prevented, but reversible property is not exhibited and control is challenging
Solution Approach 1:
The patent implements feedback through the valve element's automatic response to fluid density changes. When water or gas enters the wellbore, the density change triggers buoyancy forces that move the valve to close the inflow. When oil flow is restored, the density change reverses the buoyancy force, automatically reopening the valve.
Solution Approach 2:
The device utilizes parameter changes by responding to density variations in the flowing fluid. The valve element's position is directly controlled by changes in fluid density, which alter the buoyancy force acting on the element, enabling automatic opening and closing based on phase composition.
3Reliability
If high flow resistance is used to control flow, then undesired phases are choked, but desired oil flow is also reduced significantly
Solution Approach 1:
The patent applies dynamics by using a movable valve element that opens fully for oil flow and closes for water/gas flow. This dynamic positioning allows the device to provide minimal resistance during desired oil production while creating complete blockage during undesired phase influx, eliminating the need for continuous high resistance.
Solution Approach 2:
The device employs self-service by automatically adjusting its flow resistance based on fluid properties without external control. The valve element autonomously opens to allow high oil production rates and closes to prevent water/gas breakthrough, eliminating the need for external actuators or control systems.
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 enhances production efficiency by reducing undesired fluid ingress, maintaining robust operation under harsh conditions, and increasing recovery by at least 10%, while maintaining a compact design that does not interfere with existing production infrastructure.
Implementation Method 1
a first fluid flow restrictor configured to generate a pressure decrease from a pressure p1 upstream of the first fluid flow restrictor to a pressure p2 downstream of the first fluid flow restrictor
Implementation Method 2
a second fluid flow restrictor arranged downstream of the first fluid flow restrictor and configured to generate a pressure decrease from the pressure p2 upstream of the second fluid flow restrictor to a pressure p3 downstream of the second fluid flow restrictor
Implementation Method 3
a movable valve element arranged inside the fluid control device housing and configured to close the primary flow path for fluid flow when exposed to a pressure force from within the chamber exceeding a threshold pressure force
Data Source
Figure 1(A)
Figure 2
Figure 3(A)~3(B)
AI summary
It is provided a fluid flow control device 100 for establishing a controllable fluid communication between an external fluid reservoir 120-122 and a base pipe 102 constituting part of a production string 101, as well as a production string 101 and a method using such a fluid flow control device 100. The fluid flow control device 100 comprises a primary flow path 2 arranged inside a fluid control device housing 8, a secondary flow path 7 and a movable valve element 9 arranged at and/or within the primary flow path 2. The inlet of the secondary flow path 7 is arranged separate from the inlet of the primary flow path 2.