Horizontal Well Flow Control Valve for Gas Slug Prevention
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Solution Overview
Problem
In horizontal well production systems, gas slugs can block liquid flow, leading to reduced production rates and pump damage due to increased wellbore pressure, as all produced fluids must flow to a single pump intake, causing uneven delivery from multiple production zones.
Innovation Solution
A flow control system with a valve having an orifice, coupled to a tube within a casing, and an actuator that opens for liquid presence and closes for gas presence near the intake opening, directing liquids into the tube while preventing gas entry, thereby optimizing fluid flow and reducing gas pressure buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If all production fluids flow to a single pump intake, then the pump can lift fluids to the surface, but gas slugs block liquid flow causing reduced production rates and pump damage
Solution Approach 1:
The single pump intake system is segmented into multiple intake passages, each serving different production zones. This segmentation allows separate control of liquid and gas flow paths, preventing gas slugs from blocking liquid flow to the pump while maintaining reliable pump operation.
Solution Approach 2:
Gas is extracted from the mixed fluid stream by providing a separate gas flow path through the casing annulus. The gas separator removes gas slugs from the liquid flow before it reaches the pump intake, preventing pump damage and maintaining production rates.
2Adaptability or versatility
If production zones further from the pump intake deliver fluids, then more production zones can be accessed, but flow resistance increases reducing delivery effectiveness
Solution Approach 1:
The wellbore is segmented into multiple production zones with dedicated intake passages for each zone. This segmentation allows each zone to deliver fluids independently to the pump, reducing the cumulative flow resistance that would occur in a single long horizontal flow path.
Solution Approach 2:
The system transitions from a single horizontal flow dimension to a multi-dimensional flow architecture with vertical and radial components. Production zones at different locations can deliver fluids through different pathways (casing annulus, tubing, or both), reducing flow resistance by utilizing multiple spatial dimensions.
3Reliability
If a valve system is added to control gas and liquid flow separately, then gas slugs can be prevented from entering the pump, but device complexity increases
Solution Approach 1:
A gas separator acts as an intermediary device between the production zones and the pump intake. It mediates the separation of gas and liquid phases, directing gas through the casing annulus and liquid through the tubing to the pump, thereby protecting the pump from gas slugs without requiring complex valve systems at each intake passage.
Solution Approach 2:
The gas separator extracts gas from the mixed fluid stream before it reaches the pump intake. By removing gas slugs from the liquid flow path upstream of the pump, the system protects the pump without requiring active valve control, reducing overall system 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
This solution enhances production rates by ensuring efficient liquid delivery from multiple zones while preventing gas interference, thereby maximizing resource recovery and reducing pump damage.
Implementation Method 1
an actuator coupled to the valve and configured to open the valve in response to a presence of a liquid in the gap
Implementation Method 2
to permit flow of the liquid into the tube via the intake opening, and to close the valve in response to a presence of a gas in the gap
Data Source
AI summary
A flow control system is provided for a horizontal well production system having a casing, a tube having an intake opening and disposed within the casing, and a gap formed between the casing and the tube. The flow control system includes a valve having an orifice, coupled to the tube and disposed proximate to the intake opening. The flow control system further includes an actuator coupled to the valve and configured to open the valve in response to a presence of a liquid in the gap, proximate to the intake opening, to permit flow of the liquid into the tube via the intake opening, and to close the valve in response to a presence of a gas in the gap, proximate to the intake opening, to prevent flow of the gas into the tube via the intake opening.