Reservoir flow control is important for maximizing hydrocarbon production. Traditional in-flow control devices (ICDs) attempt to balance the completion pressure differential with the reservoir pressure differential so that even flow across production zones is maintained. This maximizes oil production by delaying unwanted fluids from breaking through. Unfortunately, when lower viscosity fluids do break through, they take over the well, significantly reducing production of the desired hydrocarbon. This paper describes the design and function of a new self-adjusting in-flow control device (AICD). When hydrocarbons are producing from all zones, the AICD will behave as a traditional ICD, balancing flow. However, when low-viscosity fluids break through, the AICD chokes them, significantly slowing flow from the zone producing the undesirable fluids. This autonomous function enables the well to continue producing the desired hydrocarbons for a longer time, maximizing total production. The paper describes the laboratory testing performed to evaluate the performance of the new AICD in field-like conditions. Results from single phase experimental flow testing with model fluids are presented and discussed. The testing results proved that the AICD could restrict flow from zones producing undesirable fluids. The discussion further shows that if technology such as the new AICD is applied to new well completion designs, total hydrocarbon recovery will be enhanced, providing a significant benefit for production companies and those involved in design and modeling of new well completions.
Traditionally, first-generation inflow control devices (ICDs) were designed to balance completion pressure differential with reservoir pressure differential so that even flow across production zones could be maintained. The purpose of maintaining even flow was to delay influx of unwanted fluids, and thus, help maximize oil production. However, if low-viscosity fluids were present and did succeed in breaking through, a traditional passive ICD could not control the flow, and the unwanted fluid flow would take over. To provide more effective control in these conditions, a newly developed, autonomous Inflow- control device (AICD) has been introduced to theIndustry. This device will improve production by balancing desired production fluids across the completion, while restricting the production from zones with unwanted fluids. This paper discusses 1) how the AICD detects the fluid properties and 2) how the production of the undesired fluid can be restricted without the use of any moving parts. The autonomous ICD is designed to function without moving parts, without intervention, without electronics, and without control lines. It is a solid-state design with improved reliability, erosion resistance, corrosion resistance, and plugging resistance that can maintain high mechanical integrity. An autonomous ICD operates by detecting whether the production fluid is undesirable, and then, if unwanted, it restricts the production of the unwanted fluid. The fluidic diode-type AICD operates using a combination of fluid mechanics, computer modeling, and measured performance data, and this paper explains how these devices are capable of restricting undesirable fluid breakthrough without intervention so that a well can continue to produce the desirable hydrocarbon. Testing procedures and results, which include numerical simulation and experimental testing, also will be presented.
Evenly distributed production along the length of the wellbore is important for maximizing the oil recoverables over the life of the well. Traditional, passive in-flow control devices (ICDs) perform well at balancing the completion pressure differential with the reservoir pressure differential so that an even influx across production zones is maintained. This helps to delay unwanted fluid break through. When unwanted fluids, typically of lower viscosity, do finally break through, they can take over the well, significantly reducing the production of oil. Autonomous Inflow Control Devices (AICDs) are a new generation of ICDs. When oil is producing from all zones, the AICD will behave as a passive ICD, balancing flow. However, when lower viscosity (undesired) fluids break through, the AICD chokes them, significantly reducing flow from the zone producing these fluids. This autonomous function enables the well to drain the oil producing zones faster than the undesirable fluid zones, thereby maximizing total oil production. The AICD creates this change in behavior without control lines, moving parts, or electronics.The paper describes the laboratory testing performed to evaluate the performance of the fluidic diode type AICD Range 2A in field-like conditions and compares flow performance curves to a traditional nozzle type ICD. The AICD Range 2A utilizes similar fluid vectoring as the Range 3B (Least et al, 2013), but includes more of an autonomous on/off type switching function instead of a gradual change in performance. The range 2A is currently best suited for oil viscosities of 1.5-10 cP. Results from single-phase experimental flow testing with model oil, water, and nitrogen are presented and discussed.The test results demonstrated that the AICD could restrict flow rates of undesirable fluids. The discussion further shows that if technology such as the new AICD is applied to new well completion designs, total oil recovery can be enhanced, by increasing the life of the well and reducing production of undesirable fluids.
Many operators are considering installation of flow-control devices (FCDs) in horizontal wells to improve steam-oil ratios (SOR) in steam-assisted gravity drainage (SAGD) recovery processes in heavy oil/bitumen reservoirs. The flow-control devices are used to help balance both the steam injection and fluid production in order to increase the oil recovery efficiency and use the full length of the horizontal wells. SAGD injector and producer horizontal wells are typically 3 to 6 meters apart, vertically. Because of this proximity, steam breakthrough to the producer well is possible. In order to reduce the steam loss following a steam breakthrough, operators typically try to slow the total rate of production. This paper will discuss the testing of passive inflow control devices (ICDs) and an autonomous inflow control device (AICD) in a steam-flow test loop along with testing results to help control the breakthrough of steam. Heated water flow through the ICDs and AICDs was used as the baseline case. Saturated steam simulating steam flow conditions (pressure and temperature) in a SAGD environment was flowed through the devices at two different temperatures, and the resulting flow rates were recorded at several pressure differentials. The laboratory flow testing has helped demonstrate how the ICDs and AICDs can either help prevent steam breakthrough from occurring or limit the rate of steam breakthrough in the zones of concern. By limiting the flow rate of steam breakthrough, the flow control devices will also help to protect the sand screen from erosion caused by high velocity flow.
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