Pressure-Actuated Flow Control Device for Horizontal Well Bore Management
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Solution Overview
Problem
Well systems face challenges in controlling fluid flow, particularly in horizontal wells where the heel-toe effect causes uneven fluid influx, leading to premature gas or water breakthrough and reduced production, and existing inflow control devices require expensive well intervention for reconfiguration.
Innovation Solution
A flow control system that includes a changeable flow control device and a control unit, actuated by pressure changes, allowing reconfiguration of fluid communication paths between the well's tubular conduit and annulus without the need for well intervention, using hydraulic signals and rupture disks to switch between different flow states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing inflow control devices are used to control fluid flow in horizontal wells, then fluid influx can be balanced along the length of the well, but expensive well intervention is required for reconfiguration
Solution Approach 1:
The flow control device incorporates a movable gate that can transition between different positions to dynamically change flow paths. The gate is actuated by a control unit that responds to pressure signals, enabling the device to adapt its configuration without requiring well intervention. This dynamic capability allows the same device to serve multiple flow control functions throughout the well's production life.
Solution Approach 2:
The control unit is actuated automatically by pressure changes within the well system itself, eliminating the need for external control lines or surface intervention. When pressure exceeds a predetermined threshold, the control unit triggers the gate to move, allowing the system to reconfigure itself based on downhole conditions. This self-service mechanism significantly reduces operational costs and complexity.
2Adaptability or versatility
If inflow control devices are installed to address heel-toe effect, then fluid inflow can be balanced along the well length, but the system lacks flexibility for future reconfiguration
Solution Approach 1:
The flow control device is divided into distinct functional segments: a body housing, a movable gate, a control unit, and a rupture disk. This segmentation allows each component to perform its specific function independently while working together as an integrated system. The modular structure enables the device to provide both initial flow control and future reconfiguration capabilities without requiring an overly complex monolithic design.
Solution Approach 2:
The control unit acts as an intermediary between the pressure sensing function and the gate actuation function. It translates pressure changes into mechanical movement of the gate through a controlled release mechanism involving the rupture disk. This intermediary structure allows the system to respond to pressure conditions while maintaining a relatively simple overall design that doesn't require complex control lines or external intervention systems.
3Productivity
If conventional flow control methods are used, then initial flow balancing can be achieved, but operational costs increase due to required well intervention for adjustments
Solution Approach 1:
The control unit is actuated automatically by pressure changes within the well system itself, eliminating the need for external control lines or surface intervention. When pressure exceeds a predetermined threshold, the control unit triggers the gate to move, allowing the system to reconfigure itself based on downhole conditions. This self-service mechanism significantly reduces operational costs and complexity.
Solution Approach 2:
The device utilizes pressure as a triggering parameter to initiate flow path changes. By monitoring pressure conditions and using them to actuate the gate, the system can adapt to changing production conditions without requiring external intervention. This parameter-based control approach maintains productivity while minimizing the operational costs associated with well intervention.
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 solution enables cost-effective and efficient reconfiguration of fluid flow in well systems, improving production performance by adjusting flow paths without the need for expensive equipment or surface control lines, thereby reducing operational costs and enhancing resource extraction efficiency.
Implementation Method 1
rupturing of a rupture disk between the hydraulic chamber and the interior of the tubular conduit allows fluid from the interior of tubular conduit into the hydrostatic chamber when the pressure in the tubular conduit exceeds the specified pressure
Implementation Method 2
Pressure in the hydraulic chamber moves the piston and moving the piston changes the flow control device from the first state to the second state
Data Source
AI summary
A system for installation in a well bore includes a flow control device and a control unit coupled to the flow control device. The flow control device is changeable from a first state to a second state. The first state corresponds to a first mode of fluid communication between an interior of a tubular conduit of a completion string and an annulus between the tubular conduit and a wall of the well bore. The second state corresponds to a second, different mode of fluid communication between the interior of the tubular conduit and the annulus. The control unit is coupled to the flow control device to change the flow control device between the first and second states. The control unit is actuated to change the flow control device in response to pressure in the well bore.