Dual-Path Flow Control Valve for Autonomous Water and Gas Choking
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Solution Overview
Problem
Existing fluid flow control devices for subterranean hydrocarbon production face challenges such as significant oil production loss, inadequate control of gas and water ingress, high flow resistance, and difficulty in managing harsh well conditions, particularly due to complex designs and plugging issues.
Innovation Solution
A fluid flow control device with a primary and secondary flow path, featuring movable valve elements and radially offset secondary flow path inlets, which allows for controllable fluid communication and efficient separation of oil and unwanted phases, using flow restrictors to generate different fluid flow characteristics and a self-cleansing filter to prevent plugging.
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 oil production is choked 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 from an open position during initial oil production to a closed position when gas or water breakthrough occurs, enabling the system to adapt to changing flow conditions and resolve the contradiction between initial production and coning prevention
Solution Approach 2:
The device detects changes in fluid parameters (viscosity, density) to trigger valve closure. By monitoring fluid property changes that indicate gas or water breakthrough, the system can respond by closing the valve, thus preventing coning while allowing unrestricted flow during the initial oil production phase when fluid properties differ
2Reliability
If complex valve mechanisms are used to control flow, then gas and water ingress is prevented, but device complexity increases
Solution Approach 1:
The valve mechanism is designed to operate autonomously without external control systems. The valve element automatically responds to fluid property changes through pressure differential forces, eliminating the need for complex electronic sensors, actuators, or control circuits. This self-service approach achieves reliable undesired phase control while minimizing device complexity
Solution Approach 2:
Complex electronic or hydraulic control systems are replaced with a simple mechanical valve element that responds directly to pressure differentials caused by fluid property changes. This mechanical substitution achieves effective flow control while dramatically reducing device complexity compared to electronically controlled systems
3Reliability
If flow restrictors are used to control inflow, then gas and water flow is reduced, but flow resistance during oil throughput increases
Solution Approach 1:
The valve element dynamically adjusts between fully open and closed positions based on fluid properties. During oil throughput, the valve remains fully open minimizing flow resistance. When gas or water breakthrough occurs, the valve closes to choke undesired phases. This dynamic positioning resolves the contradiction by providing low resistance during desired flow and high resistance during undesired flow
Solution Approach 2:
Instead of using continuous flow restrictors that create constant resistance, the device uses a valve that provides partial action (fully open) during oil production and excessive action (fully closed) during gas/water breakthrough. This binary control approach minimizes flow resistance during normal operation while providing sufficient choking capability when needed
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 while being robust, compact, and autonomous, with a significant increase in oil production and recovery rate, and a slim design that minimizes protrusion into the base pipe, reducing operational costs and improving well maintenance.
Implementation Method 1
The first fluid flow restrictor is 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
the second fluid flow restrictor are 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
Figure 1(A)
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.