Dual-Type Inflow Control Device for Steam-Assisted Oil Recovery
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Solution Overview
Problem
Current inflow control devices (ICDs) fail to simultaneously provide high resistance to plugging and erosion, viscosity insensitivity, and effective flow control for complex flow profiles in enhanced oil recovery methods like SAGD, especially during startup and steam blocking phases.
Innovation Solution
A dual-type ICD design combining helical and hybrid flow geometries, which can be arranged in series or parallel, and optionally controlled by a temperature-sensitive switch, to optimize performance for startup, increased fluid flow, and steam blocking, respectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a nozzle-based ICD is used to generate flow resistance, then the flow control capability is improved, but the device becomes susceptible to plugging and erosion
Solution Approach 1:
The patent combines two different ICD types (helical channel ICD and hybrid channel ICD) into a single dual-type device. The helical channel provides erosion and plugging resistance through its distributed pressure drop mechanism, while the hybrid channel provides effective flow control through its restrictive elements. This merging allows the device to simultaneously achieve both flow control capability and reliability.
2Reliability
If a helical channel ICD is used to generate flow resistance, then the resistance to erosion and plugging is improved, but the viscosity dependence increases causing delayed startup
Solution Approach 1:
The dual-type ICD merges the helical channel design (which provides erosion and plugging resistance) with the hybrid channel design (which has lower viscosity dependence). The hybrid channel portion allows viscous fluids to flow more easily during startup, while the helical channel portion maintains reliability against erosion and plugging, thus resolving the contradiction between reliability and productivity.
3Device complexity
If a single type of ICD is used, then the device complexity is reduced, but the adaptability to different flow conditions (viscous and less viscous) is limited
Solution Approach 1:
The patent merges two ICD types into a unified dual-type device that can adapt to different flow conditions. The device includes both helical channel flow paths and hybrid channel flow paths, allowing it to handle both viscous and less viscous fluids effectively. This merging maintains relatively simple device complexity while significantly improving adaptability to different viscosity conditions.
Solution Approach 2:
The dual-type ICD is designed to perform multiple functions within a single device: it can control flow for both viscous and less viscous hydrocarbons, provide erosion and plugging resistance, and adapt to different production phases (startup and steady-state). This multi-functionality improves universality without proportionally increasing complexity.
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 dual-type ICD configuration enhances steam block behavior and fluid flow management, improving the cumulative steam-to-oil ratio (CSOR) by adapting to changing viscosity and temperature conditions, thereby delaying water or gas breakthrough and optimizing production in heavy oil reservoirs.
Implementation Method 1
The helical channel ICD uses surface friction to generate a differential pressure across the device
Implementation Method 2
The nozzle-based ICD uses fluid constriction to generate an instantaneous differential pressure across the device by forcing the fluid from a larger area down through small diameter port, creating a flow resistance
Implementation Method 3
a temperature-sensitive switch, to optimize performance for startup, increased fluid flow, and steam blocking, respectively
Data Source
AI summary
Inflow control devices that can be used for both viscous and less viscous hydrocarbons. Optimized configurations for passive inflow control devices or ICDs having two types of fluidic pathways are combined in the same device or well in series or in parallel. Also provided, are well configurations that can be used for e.g., steam assisted oil recovery methods, wherein steam flashing is prevented by included dual type passive inflow control devices in the completion.