Low-Profile Flow Control Device for Steam Injection
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Solution Overview
Problem
Conventional flow control devices and packers in steam injection systems for hydrocarbon recovery face issues such as increased friction and drag forces, non-uniform steam distribution, and ineffective hydraulic sealing, leading to stuck tubing and reduced efficiency in heavy oil fields.
Innovation Solution
The development of a low-profile flow control device with a recess for nozzle installation and a static mixer with crisscross threading to enhance steam distribution and phase splitting, along with a sealing assembly for packers that maintains hydraulic integrity at high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional flow control devices with large outside diameters are used, then steam distribution capability is improved, but friction and drag forces increase leading to tubing sticking
Solution Approach 1:
The flow control device is segmented into multiple smaller nozzles distributed around the tubing perimeter, allowing steam to be injected at multiple locations simultaneously. This segmentation reduces the overall outside diameter of the device while maintaining effective steam distribution capability across the formation.
Solution Approach 2:
The invention transitions from a single large-diameter steam injection point to multiple small-diameter nozzles arranged in a distributed pattern around the tubing. This dimensional redistribution allows the device to maintain steam distribution effectiveness while reducing the maximum outside diameter, thereby reducing friction and drag forces.
2Reliability
If conventional packers are used, then hydraulic isolation of wellbore segments is achieved, but sealing effectiveness deteriorates at high steam temperatures above 300°F
Solution Approach 1:
The packer sealing elements utilize composite material construction combining heat-resistant polymers with reinforcement layers. This composite structure maintains flexibility and sealing effectiveness at high steam temperatures above 300°F while preserving the hydraulic isolation capability of the packer.
Solution Approach 2:
The sealing materials are specifically formulated with elevated temperature resistance parameters, allowing them to maintain their elastic properties and sealing force at steam temperatures exceeding 300°F. This parameter change enables the packer to sustain reliable hydraulic isolation in high-temperature steam injection operations.
3Speed
If conventional mixers are used, then steam flow is directed, but phase splitting becomes non-uniform reducing heat delivery uniformity
Solution Approach 1:
The mixer design incorporates dynamic flow elements that adapt to varying steam flow rates and phases. The internal geometry creates turbulent mixing patterns that promote uniform phase distribution regardless of inlet conditions, ensuring consistent phase splitting and uniform heat delivery to the formation.
Solution Approach 2:
The mixer utilizes multiple identical flow diversion elements arranged in sequence, each replicating the same mixing function. This repetitive structure ensures uniform phase splitting across the entire steam flow, creating consistent heat delivery patterns throughout the treated formation zone.
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
The low-profile flow control device minimizes friction and drag, ensuring uniform steam distribution and reducing the likelihood of tubing sticking, while the static mixer improves phase splitting, and the sealing assembly maintains effective steam injection and hydrocarbon recovery by ensuring reliable hydraulic sealing.
Implementation Method 1
a static mixer with crisscross threading to enhance steam distribution and phase splitting
Implementation Method 2
Steam, through its latent heat, reduces the viscosity of the oil and makes the oil move toward the production wellbores
Data Source
AI summary
Provided herein are embodiments of flow control devices, static mixers, and wellbore assemblies for use in the injection of steam into a formation. Usage of one or more of these items may increase recovery of hydrocarbon from the formation.