Gravel Packing System with External Solid Tubes and Permeable Dehydration
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Solution Overview
Problem
In gravel packing operations in wells, existing inflow control devices provide insufficient open area for the return flow of carrier fluid, hindering the efficient formation of gravel packs and carrier fluid separation.
Innovation Solution
A system that delivers gravel slurry downhole through solid walled tubes positioned externally to a base pipe, using a structure to facilitate the flow past base pipe joints and into downstream tubes, with permeable dehydration tubes for separating the carrier fluid and returning it to the surface, and a flow control mechanism to manage the carrier fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If inflow control devices are combined with the screen assembly to provide control over the inflow of production fluids, then inflow control is improved, but the open area for flow of the returning carrier fluid back into the production tubing becomes insufficient
Solution Approach 1:
The base pipe is divided into multiple sections with individual control mechanisms. Each section can independently control carrier fluid flow through its own flow control mechanism, allowing distributed flow management that maintains sufficient total open area while providing localized inflow control where needed.
Solution Approach 2:
A carrier fluid flow control mechanism is introduced as an intermediary component between the screen assembly and production tubing. This mechanism regulates carrier fluid flow separately from production fluid control, allowing both functions to operate independently without interfering with each other's flow paths.
2Productivity
If gravel slurry is delivered downhole through solid walled tubes externally to the base pipe, then gravel delivery efficiency is improved, but the complexity of the system increases due to additional tubes and joint connections
Solution Approach 1:
The solid walled tubes serve multiple functions: they deliver gravel slurry downhole, provide structural support, and facilitate flow distribution through their integration with the base pipe system. This multi-functionality reduces the need for separate components, thereby managing system complexity while maintaining high gravel delivery efficiency.
Solution Approach 2:
The solid walled tubes are positioned externally to and in parallel with the base pipe, creating a nested configuration where gravel delivery occurs in an outer annulus while carrier fluid returns through the inner base pipe. This nested arrangement efficiently utilizes space and simplifies the overall system architecture by avoiding complex interlocking mechanisms.
3Reliability
If a structure is used to enable connection of base pipe joints and facilitate flow of gravel slurry past the base pipe joint connection, then joint connection reliability is improved, but the device complexity increases
Solution Approach 1:
The joint connection structure is merged with the flow path design, where the connection mechanism itself facilitates gravel slurry flow rather than requiring separate flow channels. This integration ensures reliable joint connections while maintaining straightforward gravel delivery, reducing overall system complexity.
Solution Approach 2:
The joint connection structure is designed to pre-establish proper flow alignment and positioning before gravel slurry arrives. This preliminary configuration ensures that joints are properly sealed and aligned, guaranteeing reliable connections and smooth gravel flow without requiring complex real-time adjustment mechanisms.
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 approach enhances the formation of gravel packs by ensuring efficient delivery and separation of gravel slurry and carrier fluid, improving the return flow path and facilitating optimal gravel packing operations.
Implementation Method 1
The separated carrier fluid is returned back through at least one permeable dehydration tube
Implementation Method 2
the carrier fluid flows through the screen assembly, through base pipe perforations, and into a production tubing which routes the returning carrier fluid back to the surface
Data Source
AI summary
A technique facilitates formation of a gravel pack. Gravel slurry is delivered downhole through at least one solid walled tube disposed externally to a base pipe positioned in a wellbore. A structure is used to enable connection of base pipe joints while enabling flow of the gravel slurry past the base pipe joint connection and into a corresponding downstream tube or tubes. The gravel slurry is then discharged at a desired location to help form the gravel pack by depositing the gravel and separating the carrier fluid. The separated carrier fluid is returned back through at least one permeable dehydration tube.