Downhole Flow Control Turbine for Fluid Discrimination
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Solution Overview
Problem
Existing downhole fluid flow control systems in subterranean wells struggle to adjust flow control characteristics in response to changes in formation pressure and fluid composition over the life of the well, particularly in completions requiring sand control and independent control of multiple production intervals without the need for well intervention.
Innovation Solution
A downhole fluid flow control system featuring a fluidic module with a turbine chamber and a flow control turbine that provides fluid discriminating flow resistance, allowing for adjustable pressure drops based on fluid viscosity or density, enabling independent control of production fluids from multiple intervals without requiring well intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed flow control components (flow tubes, nozzles, labyrinths) are used in sand control screen assemblies, then sand control and flow control are achieved, but the flow control characteristics cannot be adjusted in response to changes in formation pressure and fluid composition over the life of the well
Solution Approach 1:
The patent applies the dynamics principle by replacing fixed flow control components with a movable piston that can dynamically adjust its position within the screen assembly. The piston is positioned by fluid pressure differentials created by downhole controllers, allowing the system to adapt flow control characteristics in response to changing formation conditions without requiring complex external intervention mechanisms.
Solution Approach 2:
The system implements self-service through automatic piston positioning driven by fluid pressure differentials. When fluid composition or formation pressure changes, the pressure differential automatically moves the piston to the appropriate position, enabling the system to self-adjust flow control characteristics without requiring external control systems or well intervention.
2Adaptability or versatility
If traditional flow control sections are used in long horizontal completions with numerous production intervals, then production fluids are controlled, but independent control of inflow into each production interval is not achieved
Solution Approach 1:
The patent applies segmentation by dividing the screen assembly into multiple independent zones, each with its own piston and flow control section. This allows each production interval to be independently controlled by its respective piston, enabling selective adjustment of flow characteristics for different intervals without affecting other zones.
Solution Approach 2:
Each segmented zone incorporates a movable piston that can dynamically adjust its position independently of other zones. This dynamic adjustment capability allows each production interval to be individually optimized based on local formation conditions, achieving independent control across multiple intervals.
3Ease of operation
If fixed flow control characteristics are used during well completion, then initial production control is achieved, but flow control characteristics cannot be adjusted without well intervention as fluid composition changes over time
Solution Approach 1:
The system continuously self-adjusts flow control characteristics through automatic piston positioning driven by fluid pressure differentials. As fluid composition changes over time, the pressure differentials automatically move pistons to maintain optimal flow control, eliminating the need for periodic well interventions and associated time losses.
Solution Approach 2:
The system incorporates implicit feedback through the fluid pressure differentials that naturally respond to changes in fluid composition and formation conditions. These pressure differentials continuously feedback to the piston positions, automatically adjusting flow control characteristics in response to real-time conditions without requiring external monitoring or intervention.
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 system effectively controls the inflow of desired fluids while minimizing the production of undesired fluids by adjusting resistance autonomously, enhancing production efficiency and reducing the need for well intervention as fluid compositions change over time.
Implementation Method 1
The flow control turbine is operable to provide fluid discriminating flow resistance such that a pressure drop for a desired production fluid passing through the fluidic module is less than a pressure drop for an undesired production fluid passing through the fluidic module
Implementation Method 2
a pressure drop for a desired production fluid passing through the fluidic module is less than a pressure drop for an undesired production fluid passing through the fluidic module
Implementation Method 3
A flow control turbine is rotatably disposed within the turbine chamber
Data Source
AI summary
A downhole fluid flow control system includes a fluidic module having a turbine chamber. A flow control turbine is rotatably disposed within the turbine chamber. The flow control turbine is operable to provide fluid discriminating flow resistance such that a pressure drop for a desired production fluid passing through the fluidic module is less than a pressure drop for an undesired production fluid passing through the fluidic module. For example, the flow control turbine is operable generate a greater pressure drop in water produced therethrough as compared to oil produced therethrough due to differences in the density, viscosity or other property of the produced fluid.