Flow Rate Regulators in Sand Control Assemblies for Multi-Zone Production
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Solution Overview
Problem
Current sand control systems for multi-zone formations are expensive and complex, requiring separate production tubing strings and intelligent well completion systems to manage varying pressure and permeability across zones, which adds length and cost to the completion assembly.
Innovation Solution
Incorporating first and second flow rate regulators within sand control assemblies in different wellbore intervals, allowing reservoir fluid to flow simultaneously into a single tubing string, thereby regulating and commingling the fluid stream to achieve a consistent flow rate across zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate production tubing strings are used for each zone, then flow rate control for each zone is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines multiple zone production functions into a single tubing string by integrating flow rate regulators directly into the sand control assembly. This allows multiple zones to produce through one string while maintaining individual flow control via regulators positioned at each zone interval, eliminating the need for separate tubing strings per zone.
Solution Approach 2:
Flow rate regulators serve as intermediary devices positioned within the sand control assembly at different wellbore intervals. These regulators mediate between the formation zones and the single tubing string, controlling flow from each zone independently while allowing all fluids to converge into one production string.
2Ease of operation
If intelligent well completion systems are used to manage varying pressure and permeability, then flow regulation is improved, but device complexity and cost increase
Solution Approach 1:
The flow rate regulators are designed to automatically regulate flow based on pressure differential across the device. The regulators self-adjust flow rates from different zones with varying pressure and permeability characteristics without requiring external intelligent control systems, achieving autonomous flow management.
Solution Approach 2:
The patent merges the flow regulation function traditionally provided by intelligent well completion systems directly into the passive sand control assembly. By integrating flow rate regulators into the sand control screen structure, the system combines sand control and flow regulation functions in a single integrated assembly, eliminating the need for separate intelligent control systems.
3Productivity
If multiple tubing strings are used for multi-zone production, then flow rate consistency is improved, but device complexity and cost increase
Solution Approach 1:
Flow rate regulators act as intermediary devices positioned at different wellbore intervals within a single tubing string. Each regulator controls flow from its respective zone to ensure consistent flow rates into the common tubing string, achieving flow rate consistency without requiring multiple separate tubing strings.
Solution Approach 2:
The flow rate regulators modify flow parameters (flow rate, pressure) from different zones to achieve consistency. By adjusting the flow resistance at each zone interval, the regulators ensure that despite variations in zone pressure and permeability, the flow rates into the tubing string remain consistent and balanced.
Data Source
AI summary
A sand control completion system comprises: (A) a first flow rate regulator, wherein the first flow rate regulator is positioned in a first interval of a wellbore, wherein the first flow rate regulator is part of a first sand control assembly; and (B) a second flow rate regulator, wherein the second flow rate regulator is positioned in a second interval of the wellbore, wherein the second flow rate regulator is part of a second sand control assembly, wherein a reservoir fluid is caused or allowed to simultaneously flow through the first and second flow rate regulators into a tubing string, wherein the reservoir fluid is commingled into a single fluid stream within the tubing string. A method of using the sand control completion system to simultaneously produce a reservoir fluid from more than one zone of a subterranean formation is also provided.