Flow Control Module for Sand Screen Transition
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Solution Overview
Problem
The transition from gravel packing mode to intelligent production mode in well completions requires a reduction in flow area in sand screen systems to manage varying permeability and prevent disproportionate hydrocarbon production, which existing technologies fail to effectively address.
Innovation Solution
A tool and system that includes a mandrel with a bore and flow path configurations, along with a gate that can move to control fluid flow, facilitating the transition from gravel packing to intelligent production mode by connecting with sand control devices and other devices in the bottom hole assembly, allowing for controlled fluid flow and pressure containment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the flow area in sand screen systems is reduced to manage varying permeability and prevent disproportionate hydrocarbon production, then intelligent production control is improved, but the transition from gravel packing mode becomes more complex
Solution Approach 1:
The patent employs a movable gate mechanism that can dynamically change the flow area within the sand control device. The gate transitions between an initial position (allowing gravel passage during packing) and a second position (restricting flow for production control), enabling the system to adapt to different operational modes without requiring multiple separate devices or complex activation systems.
2Ease of operation
If a gate mechanism is added to control fluid flow and enable mode transition, then flow control capability is improved, but the device structure becomes more complex
Solution Approach 1:
The patent integrates the gate mechanism directly into the existing sand control device structure, combining the flow control function with the sand screening function. The gate is positioned within the device housing and works in conjunction with the screen assembly, eliminating the need for separate control systems or additional components that would further increase complexity.
Solution Approach 2:
The sand control device is designed to perform multiple functions: sand screening, gravel packing, and intelligent production control. The gate mechanism enables the device to switch between gravel packing mode (with high flow area) and production mode (with restricted flow area), making the device versatile and eliminating the need for separate devices for each function.
3Productivity
If the flow area is reduced during production mode, then hydrocarbon production optimization is improved, but the gravel packing operation becomes more difficult
Solution Approach 1:
The gate is pre-configured in an initial position that provides a large flow area during gravel packing operations, allowing easy passage of gravel and carrier fluid. After the packing operation is complete, the gate is then actuated to the second position to restrict flow for production control. This preliminary positioning ensures that gravel packing is not hindered while still enabling later production optimization.
Data Source
AI summary
A tool includes a mandrel and at least one gate. The mandrel includes a bore, and the mandrel is able to connect in-line with at least one sand control device of a bottom hole assembly such that the mandrel is coaxial with the at least one sand control device. The mandrel also includes a flow path configuration, such as, at least one flow path connecting the at least one sand control device to the bore, at least one flow path connecting the bore to at least two sand control devices, and at least one flow path connecting the bore to the at least one sand control device and to another device of the bottom hole assembly. The at least one gate has an initial position, and the at least one gate is configured to move from the initial position into a different position to control fluid flow.