Swirl-Induced Inflow Control Valve for Phase Breakthrough Shutoff
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Solution Overview
Problem
Existing inflow control devices (ICDs) in hydrocarbon production systems suffer from issues such as undesired phase breakthrough, high flow resistance, inability to manage harsh well conditions, and inefficient control of fluid flow, leading to significant production losses and operational challenges.
Innovation Solution
A fluid flow control device with a primary and secondary flow path, featuring a movable valve element and swirl inducer, which separates phases based on density differences to autonomously control fluid flow, preventing undesired phases from entering the production string.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional ICDs with fixed flow area are used, then reservoir contact is improved, but production is choked during initial phase leading to significant production loss
Solution Approach 1:
The patent applies dynamics by replacing fixed flow area ICDs with a movable valve element that can dynamically adjust the flow area. The valve element moves between a first position (fully open) and a second position (choked/closed) based on fluid density changes, allowing the system to maintain high initial production rates while preventing coning. This dynamic adjustment resolves the contradiction between maintaining reservoir contact and avoiding production choking.
Solution Approach 2:
The patent changes the parameter of flow area from fixed to variable by using a movable valve element. The valve element's position changes in response to fluid density variations, allowing the flow area to adapt to different production phases. This parameter change enables the system to achieve both high initial production and effective coning prevention.
2Reliability
If autonomous ICDs are used to choke undesired phases, then coning is mitigated, but undesired phases are not fully halted at the moment of breakthrough
Solution Approach 1:
The patent applies preliminary anti-action by positioning the valve element upstream of the ICD to preemptively close the flow path when undesired phases are detected. The valve element responds to density changes by moving to a choked position before significant coning can occur, preventing rather than merely mitigating the harmful effect. This preliminary action ensures undesired phases are fully halted at breakthrough.
3Reliability
If valve elements are used to control flow, then phase separation is improved, but high flow resistance occurs during throughput of desired phases
Solution Approach 1:
The patent applies dynamics by making the valve element movable rather than fixed. During desired phase flow, the valve element remains in a fully open position minimizing resistance. When undesired phases are detected through density changes, the valve element dynamically moves to a choked position. This dynamic behavior eliminates continuous high flow resistance while maintaining phase separation capability.
4Area of stationary object
If ICDs are placed in production string wall, then reservoir contact is maximized, but device complexity increases due to multiple components
Solution Approach 1:
The patent merges the valve element control function with the ICD structure itself. The movable valve element is integrated into the ICD housing, and the flow path is designed so that valve movement directly controls the ICD opening. This merging reduces device complexity by eliminating separate control mechanisms while maintaining the ability to maximize reservoir contact through multiple ICDs.
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 device effectively minimizes production of low-density phases by early closure or choking, maintaining production of high-density phases, thus optimizing recovery and managing harsh well conditions.
Implementation Method 1
a swirl inducer inducing a swirl of the fluid flow F around and/or upstream the primary flow path inlet
Implementation Method 2
a first fluid flow restrictor configured to generate a pressure decrease from a pressure p1 upstream of the first fluid flow restrictor to a pressure p2 downstream of the first fluid flow restrictor
Implementation Method 3
The movable valve element inside the main housing is configured to close the primary flow path for fluid flow F, or at least significantly choke the fluid flow F, when exposed to a pressure force from within the chamber B exceeding a threshold pressure force
Data Source
AI summary
A fluid flow control device, which is for establishing a controllable fluid communication of a fluid flow between an external fluid reservoir and a base pipe of a production string, includes a primary flow path and a secondary flow path. The primary flow path is arranged inside a main housing. The primary flow path includes a primary flow path inlet configured to guide a primary fluid flow constituting a major portion of the fluid flow into the main housing during operation and a primary flow path outlet configured to guide the primary fluid flow from the main housing and into the base pipe during operation. The secondary flow path is configured to guide a secondary fluid flow constituting the remaining portion of the fluid flow. The secondary flow path includes a first fluid flow restrictor configured to generate a pressure decrease from a pressure p1 upstream of the first fluid flow restrictor to a pressure p2 downstream of the first fluid flow restrictor, a second fluid flow restrictor arranged downstream of the first fluid flow restrictor and configured to generate a pressure decrease from the pressure p2 upstream of the second fluid flow restrictor to a pressure p3 downstream of the second fluid flow restrictor and a chamber arranged downstream the first fluid flow restrictor and upstream the second fluid flow restrictor. A movable valve element is arranged inside the main housing and configured to close the primary flow path for fluid flow when exposed to a pressure force from within the chamber exceeding a threshold pressure force. The fluid flow control device further includes a top housing covering the primary flow path inlet of the main housing. The top housing includes a fluid flow inlet allowing the fluid flow to flow from the external fluid reservoir and at least partly into the primary flow path inlet, a swirl inducer inducing a swirl of the fluid flow between the fluid flow inlet and the primary flow path inlet, and a secondary flow path inlet configured to guide a secondary fluid flow into the secondary flow path.