Circumferential Intake Manifold for Stratified Wellbore Flow Control
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Solution Overview
Problem
Existing flow control devices in wellbores struggle to accurately control fluid flow in highly deviated or horizontal wells, leading to inefficient production of hydrocarbons due to fluid stratification and the inability to react to the composition of the reservoir fluid, resulting in potential loss of recoverable hydrocarbons.
Innovation Solution
A fluid intake system with a manifold featuring circumferentially arranged inlet ports that collect fluid from multiple stratified layers, providing an accurate representation of the fluid composition, which is then communicated to a flow control device to enable autonomous control based on the actual fluid properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single point of inflow is provided within a production tubular in highly deviated/horizontal wellbores, then the flow control device can be simplified, but the device will only be exposed to a single separated fluid layer and may curtail production of hydrocarbons
Solution Approach 1:
The manifold is segmented into multiple inlet ports arranged circumferentially around the production tubular, allowing each port to access different fluid layers. This segmentation enables the flow control device to receive feedback from multiple fluid phases (oil, water, gas) simultaneously, preventing premature shutdown of hydrocarbon production while maintaining the simplicity of the overall device structure.
2Reliability
If an autonomous inflow control device switches instantaneously from fully open to fully closed position when undesired fluid is detected, then water production can be limited, but loss of sinkhole (pressure drawdown) around the wellbore and possible loss or reduced production of desired wellbore fluid occurs
Solution Approach 1:
The manifold provides continuous feedback about the composition of all fluid layers to the flow control device through multiple inlet ports. This feedback mechanism allows the control device to make informed decisions about flow regulation, switching from instantaneous on/off control to more nuanced modulation that maintains sinkhole pressure and optimizes hydrocarbon production while still limiting water influx.
3Productivity
If an autonomous inflow control device switches from fully closed to fully open position when desired fluid begins to be produced, then hydrocarbon production can be maximized, but rapid onset of undesired fluid may occur
Solution Approach 1:
The manifold is configured to detect the presence and composition of different fluid layers before they reach the main flow path. By providing advance warning of approaching water or gas layers through its circumferential inlet ports, the system allows the flow control device to prepare for composition changes, enabling gradual transition and prevention of rapid undesired fluid onset while maintaining high hydrocarbon production rates.
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
Ensures optimal production rates by accurately representing the fluid composition, allowing the flow control device to react autonomously and maintain efficient hydrocarbon recovery, even in conditions of stratification.
Implementation Method 1
fluid phases of the reservoir fluid separate due to their differing densities (e.g. water, oil and gas separate into different fluid 'layers' in a highly deviated/horizontal wellbore, given their differing densities)
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
A fluid intake system is disclosed for use with a flow control device which controls fluid flow into a tubular. The fluid intake system comprises a manifold configured to circumscribe a tubular which includes a flow control device, the manifold comprising a plurality of circumferentially arranged inlet ports for receiving a fluid into the manifold. The system includes a fluid outlet to be arranged in communication with the flow control device to, in use, communicate fluid from the manifold to the flow control device.