Dual-Path Flow Control Valve for Breakthrough-Free Oil Production
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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, inability to manage harsh well conditions, and complex designs that lead to plugging and increased production loss.
Innovation Solution
A fluid flow control device with a primary and secondary flow path, featuring a movable valve element and fluid flow restrictors, that autonomously adjusts to fluid properties to prevent undesired phases while maintaining efficient oil production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If autonomous ICDs are used to prevent gas and water breakthrough, then coning effects are mitigated, but production is choked during the initial phase resulting in significant production loss
Solution Approach 1:
The valve element is made movable and responsive to fluid properties, transitioning from a static fixed choke to a dynamic control mechanism. The valve automatically adjusts its position based on fluid density differences, remaining open for oil (high density) and closing for gas/water (low density), thereby resolving the contradiction between preventing breakthrough and maintaining initial production.
Solution Approach 2:
The device utilizes changes in fluid density as the key parameter to control valve opening/closing. By designing the buoyancy mechanism to respond to density variations, the system automatically distinguishes between desired oil flow and undesired gas/water influx, enabling selective control without choking initial production.
2Reliability
If fixed flow area ICDs are used, then reservoir contact is achieved, but high flow resistance occurs during throughput of desired phases
Solution Approach 1:
The flow area is made dynamic through the movable valve element that adjusts opening degree based on fluid properties. During oil production, the valve remains fully open providing maximum flow area and minimal resistance, while during gas/water breakthrough, the valve closes to prevent influx. This resolves the contradiction by providing both adequate reservoir contact and low flow resistance for desired phases.
3Extent of automation
If valve elements are made movable to respond to fluid properties, then autonomous control is achieved, but device complexity increases
Solution Approach 1:
The valve mechanism is designed to be self-actuating using the kinetic energy and density differences of the flowing fluid itself. The buoyancy mechanism and movable valve element automatically respond to fluid properties without external control systems, sensors, or power sources. This achieves autonomous control while minimizing device complexity by using the fluid's own properties to drive the control action.
4Productivity
If production strings are equipped with multiple ICDs at regular intervals, then maximum reservoir contact is obtained, but the risk of plugging increases
Solution Approach 1:
The device changes its operational parameter (valve opening degree) based on fluid density, allowing it to remain open for oil production and close for gas/water breakthrough. This dynamic response prevents plugging by automatically shutting off when undesired phases are detected, while maintaining maximum openness during oil flow to ensure adequate reservoir contact and productivity.
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 undesired fluid phases from entering the production flow, enhances recovery by 10%, and maintains a compact design that minimizes interference with existing well infrastructure.
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 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
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.