Dual-Path Flow Control for Reversible Water and Gas Shutoff
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Solution Overview
Problem
Current inflow control devices for hydrocarbon production suffer from issues such as significant oil production loss, inadequate control of gas and water breakthrough, irreversible valve closure, high flow resistance, and inability to manage harsh well conditions like high pressure and temperature.
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, allowing for efficient separation of desired and undesired phases, and incorporating a filter to prevent plugging while maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If autonomous ICDs are used to choke flow when water and/or gas enters, then gas and water breakthrough is prevented, but oil production is also choked resulting in significant loss of production during initial phase
Solution Approach 1:
The valve element is made movable rather than fixed, allowing it to dynamically adjust its position based on fluid properties. The valve transitions between open and closed states autonomously in response to changes in fluid viscosity, enabling it to adapt to different production phases without manual intervention.
Solution Approach 2:
The device exploits changes in fluid viscosity as the key parameter to trigger valve closure. When viscosity decreases (indicating water or gas breakthrough), the pressure balance shifts and automatically closes the valve. This parameter-based control mechanism eliminates the need for complex sensors or external control systems.
2Reliability
If valve elements are used to choke flow, then gas and water entry is controlled, but flow resistance increases reducing overall throughput efficiency
Solution Approach 1:
The valve element provides partial closure rather than complete blockage when undesired phases are detected. This partial action is sufficient to control gas and water entry while maintaining some flow capacity, thereby reducing flow resistance compared to fully closed valve designs.
3Productivity
If ICDs are placed at regular intervals along production string, then reservoir contact is maximized, but device complexity and installation difficulty increase
Solution Approach 1:
The flow control device integrates multiple functions into a single unit: it serves as both an inflow control device and an autonomous valve element. This multi-functionality reduces the need for separate components and devices, thereby simplifying the overall system while maintaining effective reservoir contact.
4Reliability
If valve elements close when water/gas enters, then breakthrough is prevented, but the valve cannot reopen when oil flow resumes losing reversibility
Solution Approach 1:
The valve element operates in periodic cycles of opening and closing based on fluid viscosity changes. When viscosity decreases (water/gas breakthrough), the valve closes. When viscosity increases again (oil flow resumes), the pressure balance reverses and the valve automatically reopens, creating a reversible periodic action.
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 prevents unwanted fluid phases from entering the production flow, is reversible, and maintains efficient operation under harsh conditions, leading to increased oil recovery and reduced production costs with minimal protrusion into the base pipe.
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
The movable valve element is configured to at least partly, preferably fully close 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
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.