Movable Orifice Plate for Wellbore Flow Monitoring
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Solution Overview
Problem
In hydrocarbon recovery operations, monitoring fluid flow in wellbores is challenging due to varying production rates, pressure profiles, and laminar fluid flow, which complicates the measurement of flow-related properties, especially in unconventional wells with rapidly declining production rates and low signal amplitudes.
Innovation Solution
The use of orifice plates positioned within the wellbore casing, which can be secured using dissolvable materials or moved between open and closed configurations, to alter the flow area and generate detectable changes in downhole attributes, allowing for accurate flow rate determination through sensors and fiber optic sensing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If distributed fiber optic sensing systems are used to monitor fluid flow in wellbores, then monitoring capability is provided, but measurement precision deteriorates due to laminar fluid flow and low signal amplitude in low production rate wells
Solution Approach 1:
The orifice plate is deployed dynamically into the fluid flow path using a deployment mechanism (such as a deployable arm or movable barrier) that transitions from a retracted state during installation to an active state during monitoring. This dynamic deployment allows the system to adapt to different flow conditions and maintain measurement capability across varying production rates.
Solution Approach 2:
The orifice plate fundamentally changes the flow parameters by creating a restricted flow path that transforms laminar flow into turbulent flow. This parameter change increases the signal amplitude detected by fiber optic sensors, enabling accurate measurement even in low production rate wells where the original flow conditions produced undetectable signals.
2Measurement precision
If orifice plates are deployed into the wellbore to alter flow area and increase signal amplitude, then measurement capability improves, but device complexity increases due to deployment mechanisms
Solution Approach 1:
The deployment mechanism is designed to be self-activating through interaction with the wellbore environment. For example, the mechanism may use the flow of fluid itself, thermal expansion from downhole temperatures, or pressure differential to automatically deploy the orifice plate into position, eliminating the need for complex external actuation systems.
Solution Approach 2:
The deployment mechanism is designed as a separate, extractable component that can be removed or left behind after deploying the orifice plate. This allows the complex deployment mechanism to be handled and tested separately, while only the simple orifice plate remains in the wellbore for long-term monitoring.
3Measurement precision
If orifice plates are used to create turbulent flow for better signal detection, then flow monitoring capability improves, but energy consumption increases due to flow restriction
Solution Approach 1:
The orifice plate creates turbulence locally at the measurement point rather than throughout the entire wellbore flow path. By restricting flow only at the specific location where measurement is needed, the system achieves the required signal amplitude increase with minimal impact on overall fluid flow and energy consumption.
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 enables precise monitoring of fluid flow rates by altering the flow area and detecting changes in downhole attributes, improving the accuracy of flow rate measurements even in wells with low production rates and complex flow regimes.
Implementation Method 1
the orifice plate is movable between a first position and a second position after being positioned in the tubular to alter a flow area of the flow of fluid moving through the tubular
Implementation Method 2
detecting a change in a downhole attribute that changes in response to the alteration of the flow area of the flow of fluid
Data Source
AI summary
Some embodiments of the inventive subject matter improve techniques for measuring downhole attributes. A method for determining a flow rate of a fluid includes positioning a tubular within a wellbore formed in a subsurface formation, wherein a flow of fluid is to move through the tubular. An orifice plate is positioned in the tubular. The orifice plate is movable between a first position and a second position to alter a flow area of the flow of fluid moving through the tubular. The method includes detecting a change in a downhole attribute that changes in response to the alteration of the flow area of the flow of fluid. Sensors positioned within or in communication with an interior of the tubular can detect the change in the downhole attribute. The method further includes determining a flow rate of the flow of fluid based on the detected change in the downhole attribute.