Flow Controller Backflow Restriction for Injection Wells
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Solution Overview
Problem
Current hydrocarbon well completion systems face challenges in efficiently restricting backflow during water injection operations, particularly due to the need for expensive and time-consuming shifting tools and potential hang-ups during retrieval.
Innovation Solution
A completion system comprising a packer, a flow isolation valve, and a mechanical assembly with a tubing closure member and flow controller, which automatically prevents backflow by actuating to block fluid flow in an uphole direction when the injection operation is stopped, allowing fluid flow in a downhole direction even when the tubing closure member is closed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ball valve is used for flow isolation and actuated by pressure pulses, then the system can control fluid flow automatically, but the ball valve may fail to actuate reliably requiring expensive and time-consuming shifting tools
Solution Approach 1:
The flow controller is designed to automatically actuate based on injection fluid flow without requiring external shifting tools. The valve opens in response to injection fluid flow and closes when flow stops, making the system self-regulating and eliminating the need for complex intervention tools.
Solution Approach 2:
The patent replaces the mechanical pressure pulse actuation system with a flow-based actuation mechanism. Instead of relying on pressure pulses that may fail to actuate the ball valve, the new system uses the presence and absence of injection fluid flow directly to control the valve state, simplifying the actuation mechanism.
2Ease of operation
If a shifting tool is run downhole to engage the ball valve, then the valve can be actuated, but the process involves removing the removable choke via an expensive and time-consuming separate run
Solution Approach 1:
The system performs valve actuation automatically through flow detection without requiring human intervention or separate tool runs. The valve responds autonomously to injection fluid flow, eliminating the time-consuming shifting tool operation entirely.
Solution Approach 2:
The flow controller is pre-configured to automatically respond to injection fluid flow conditions. This preliminary setup eliminates the need for subsequent intervention with shifting tools, as the valve is already programmed to actuate and deactivate based on flow presence.
3Reliability
If the shifting tool is run down through the flapper valve, then the ball valve can be actuated, but the tool can get hung up during retrieval back through the flapper valve
Solution Approach 1:
The automatic flow-based actuation eliminates the need to run tools through the flapper valve entirely. The valve responds directly to injection fluid flow, avoiding the mechanical intervention that causes tool hang-ups during retrieval.
Solution Approach 2:
The patent removes the shifting tool operation from the system by implementing automatic flow-based valve control. This extraction of the problematic tool-based actuation method eliminates the source of tool hang-up issues while maintaining reliable valve actuation.
4Reliability
If a mechanical assembly with flow controller is added below the formation isolation valve, then automatic backflow restriction is achieved, but the device complexity increases
Solution Approach 1:
The flow controller is integrated with the existing mechanical assembly components (tubing closure member and flow controller housing) to create a unified backflow prevention system. This merging approach achieves automatic backflow restriction while minimizing the addition of separate discrete components.
Solution Approach 2:
The mechanical assembly with flow controller serves multiple functions: it provides tubing closure, flow control, and automatic backflow prevention. This multi-functionality reduces the need for separate dedicated backflow prevention devices, thereby limiting the increase in overall device 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
Enables efficient and automatic restriction of backflow during water injection operations, reducing the need for costly shifting tools and minimizing hang-ups, thereby enhancing operational efficiency and safety.
Implementation Method 1
The flow controller is automatically actuatable to enable a flow of injection fluid in a downhole direction while blocking fluid flow in an uphole direction
Data Source
AI summary
A technique facilitates injection via an injector well while providing automatic restriction of unwanted back flow. A completion positioned in a borehole facilitates the injection operation. The completion includes a packer coupled with a tubing and oriented to enable formation of a seal between the tubing and a surrounding casing. A formation isolation valve is coupled to the tubing. Additionally, a mechanical assembly is coupled to the tubing at, for example, a location below the formation isolation valve. The mechanical assembly may include a mechanical formation isolation valve and a flow controller. The flow controller is automatically actuatable to enable a flow of injection fluid in a downhole direction while blocking fluid flow in an uphole direction while the mechanical formation isolation valve is in a closed position. The flow controller includes a plurality of flow restrictors positioned to control flow between an interior and an exterior of the tubing.