Reverse Flow Cleaning for Wellbore Inflow Control Devices

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Solution Overview

Problem

In unconsolidated formations, horizontal and deviated wells with integrated sand screens and inflow control devices (ICDs) often experience screen plugging due to mud cake and invaded mud solids, leading to poor well performance and productivity, as existing cleaning methods are ineffective in reaching and clearing these areas.

Innovation Solution

A method and apparatus for cleaning flow control apparatuses in wellbores, involving a treatment fluid that flows in reverse direction through the inflow control devices and screens, dislodging, dissolving, or dispersing material, with a treatment tool targeting specific ICDs and circulating back through the apparatus to effectively remove near-wellbore damage and screen plugging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If conventional drilling mud containing solids is used for bridging purposes and preventing fluid loss, then wellbore stability is improved, but screen plugging occurs due to mud cake and invaded mud solids

Engineering Contradiction:

Improvewellbore stabilityVSAvoidscreen plugging

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The patent applies reverse flow cleaning where treatment fluid is injected through the screen from the production side and flows backward through the screen pores and annulus, opposite to the normal production flow direction. This reverse flow effectively removes mud cake and solids that cause plugging while maintaining wellbore stability achieved by conventional drilling mud

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The system discards the harmful mud cake and solids by circulating treatment fluid that carries these contaminants away from the screen. The treatment fluid picks up the plugging materials and transports them through the reverse flow path to be removed from the system, thereby recovering screen functionality

Inventive Principle:

Principle #34Discarding and recovering

2Ease of manufacture

If ICD screen completions are lowered into unconditioned mud containing solids, then well completion is achieved, but screen plugging occurs leading to poor well performance

Engineering Contradiction:

Improvewell completionVSAvoidwell performance

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent implements preliminary cleaning action by circulating treatment fluid through the screen and annulus before production begins. This pre-cleaning removes potential plugging materials from mud cake and invaded solids, preventing future productivity losses while allowing the well completion to proceed with conventional drilling mud

Inventive Principle:

Principle #10Preliminary action

3Object-affected harmful factors

If treatment fluid is circulated through the completion to clean the screen, then screen plugging is removed, but ICDs designed to choke or restrict flow prevent effective cleaning

Engineering Contradiction:

Improvescreen pluggingVSAvoidcleaning effectiveness

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The patent overcomes the ICD flow restriction by reversing the flow direction. Treatment fluid is injected through the screen from the production side and flows backward through the screen pores and annulus, bypassing the ICD restriction mechanism. This reverse flow enables effective cleaning of screen plugging despite the ICD's flow-choking design

Inventive Principle:

Principle #13The other way round (Inversion)

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 solution efficiently cleans the flow control apparatuses, improving well performance by effectively reaching and clearing screen plugging issues, enhancing reservoir management, and providing a backup ICD for continued operation, thus maintaining productivity.

Implementation Method 1

delivering the treatment fluid such that the fluid flows in a reverse direction along the fluid inflow path. Thus, the treatment fluid may pass through the inflow control device and then through or over the screen and dislodge, dissolve or disperse material on or in the screen

Methodology Applied

Scientific EffectDislodging: Impact Force

Implementation Method 2

Methodology Applied

Scientific EffectDissolving: Solvation

Implementation Method 3

Methodology Applied

Scientific EffectDispersing: Dispersion (of waves)

Data Source

PatentUS8967265B2Flow control apparatus

Publication Date: 2015.03.03 WEATHERFORD UK LIMITED

AI summary

A flow control apparatus for use in a wellbore comprises a screen, a first inflow control device and a second inflow control device, wherein a fluid inflow path is provided through the screen and from an outer portion to an inner portion of each inflow control device. A method of cleaning a flow control apparatus such as that described above comprises providing in a wellbore a flow control apparatus comprising at least one screen and at least one inflow control device wherein a fluid inflow path is provided through the at least one screen and from an outer portion to an inner portion of the at least one inflow control device, targeting the at least one inflow control device with a treatment fluid and delivering the treatment fluid such that the fluid flows in a reverse direction along the fluid inflow path.