Development of Robust ICD Designs to Provide 30 Year Life by an In-Depth Qualification Program

Edmonstone, Graham; Kofoed, Curtis; Mayer, Christian S. J.; Troshko, Andrey; Jackson, M.

doi:10.2118/183338-ms

Cited by 5 publications

(1 citation statement)

References 8 publications

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“…While studying this phenomenon, the authors gave the main recommendation to replace the grade of pipe material with a more corrosion-resistant one. In [ 5 ], the authors focused on the corrosion resistance of the ICD itself and did not pay proper attention to the influence of the ICD on the corrosion wear of the base pipe and methods of combating it, except for the change in the tube material. In this regard, the authors believe that it is necessary to more fully investigate the mechanisms of corrosion wear of the base pipe under the influence of ICD operation, as well as to develop more effective and less costly methods to reduce the level of corrosion wear of the base pipe than replacing the material of which it is made.…”

Section: Introductionmentioning

confidence: 99%

The Effect of the Operation of Downhole Equipment on the Processes of Corrosive Wear (by the Example Inflow Control Devices of Nozzle Type)

Kruk¹,

Golubev²,

Shaposhnikov³

et al. 2022

Materials

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Existing approaches to assessing the reliability and safe operation of downhole equipment provide for assessing only the direct impact of erosion and corrosion processes on the degradation of the material. At the same time, the influence of downhole equipment operating modes on the intensity of corrosion and erosion processes is not evaluated. The necessity of using inflow control devices is shown. The necessity of selecting inflow control devices for specific operating modes of the well is highlighted in order to avoid increased erosion wear due to increased sand production. In this article, a series of studies was conducted to assess the influence of the hydrodynamic characteristics of the fluid flow, which vary depending on the operating modes of the nozzle-type inflow control device, on corrosion processes in the well. It was shown that the level of wall shear stress (WSS) of the base pipe, immediately after the flow control device in the direction of fluid flow, affects the intensification of corrosion processes in downhole equipment. Studies of WSS on the pipe wall were carried out using a dynamic autoclave and elements of mathematical modeling. The design factors (the angle of inclination of the main hydraulic channel of the inflow control device relative to the base pipe) affecting the change in tangential stresses on the wall of the base pipe were investigated. The mechanism of corrosion wear of the base pipe was revealed.

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Section: Introductionmentioning

confidence: 99%

The Effect of the Operation of Downhole Equipment on the Processes of Corrosive Wear (by the Example Inflow Control Devices of Nozzle Type)

Kruk¹,

Golubev²,

Shaposhnikov³

et al. 2022

Materials

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Inflow Control Device Injection and Production Dynamic Integrity Testing – Best Practices

Jackson

Mayer

Shuchart

et al. 2017

Day 3 Wed, October 11, 2017

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In recent years, the application envelope for inflow control devices (ICDs) has significantly shifted toward harsher environments, for example, to high temperature changes for SAGD, high production pressure differentials in wells with high reservoir permeability contrast, and extreme pressure differentials during short-duration acid stimulation. To confirm whether ICDs are able to withstand these extreme conditions, representative and reproducible equipment testing must be performed. The objective of this paper is to describe testing methods and results for a new type of design validation test related to mechanical integrity of production ICDs when operated at high pressure differentials with both injection and production flow as might be observed during either short-duration acid treatments or initial clean-up operations. A method is presented for validating multiple ICD designs via full-scale testing at high pressure differentials. The first part of this test consists of a flow-to-failure test where the flow rate is incrementally increased until the ICD design flow characteristics are altered (permanently or temporarily). ICD performance may change due to shifting, deformation, and/or loss of sealing surface contact of critical internal components under the loading condition, causing an increase in flow area. A notable change in the ICD flow characteristics is considered to represent the critical upper differential pressure limit. A separate endurance test is also performed with a new ICD at a safety factor adjusted burst rating to determine the integrity of the ICD design over an extended flow period. This new test method has been applied to several ICD designs over the past few years. Testing outcomes range from unexpected changes in performance characteristics of some ICD designs (cracking of internals, ballooning of the ICD housing, and failure of critical seals) to no apparent failure up to the pressure limit of the flow loop. Lessons learned from testing via this protocol have encouraged service companies to improve their ICD designs, thereby providing more reliable and robust products to the industry. When these testing programs were initiated, there wasn't an industry-wide accepted best practice for testing ICDs. To build a base of accepted test procedures and methods for ICDs, this paper describes the fundamentals of a new method involving flow-to-failure and endurance validation testing. The methods represent a specific procedure that can be used by oil-field operators as guidelines for specifying validation techniques for untested ICD designs. These methods have now been incorporated into the AWES RP 3362-78 Annex F (2017).

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A Systematic Approach to Design and Development of a New ICD to Minimize Erosion and Erosion-Corrosion

Woiceshyn

Dikshit

Hagel

2019

Day 4 Thu, November 14, 2019

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To prevent or minimize problems associated with water coning in horizontal oil producers, inflow control devices (ICDs) are installed along the wellbore to better equalize the toe-to-heel flux. Nozzle-based ICDs are popular because they are: 1) easy to model accurately, 2) virtually viscosity independent, and 3) easy to install at the wellsite with many unique settings. Nozzles can be installed either in the wall of the base pipe (radial orientation) or in the annulus between the base pipe and housing (axial orientation). The advantages of the former are: 1) smaller max running OD, and 2) no need for a leak-tight, pressure-rated housing. One disadvantage is the high exit velocity that raises concern of erosion or erosion-corrosion of the basepipe. To overcome this disadvantage, a new nozzle had been developed with a novel geometry that reduces the exit velocity about ten-fold compared to a conventional nozzle for the same pressure drop and flow rate. Computational fluid dynamics (CFD) was used to first fine tune the design to meet strict erosion-corrosion prevention requirements on the wall shear stress downstream of the nozzle for both production and (acid) injection directions, and then to develop flow performance curves for four different nozzles "sizes" that vary in their choking ability, thereby allowing many unique settings per joint at the wellsite. Full scale prototype manufacturing and flow loop testing were then performed to validate the CFD flow performance predictions and to demonstrate mechanical integrity and erosion resistance for high rate production and injection. The results, as presented herein, demonstrate a robust and commercially viable ICD design that: 1) has predictable flow performance using CFD, 2) minimizes erosion and erosion-corrosion in either direction, 3) minimizes running OD, 4) simplifies the housing design, and 5) allows easy installation at the wellsite with 34 unique settings per joint. Also discussed are two new advantages over other ICDs that were not anticipated in the original development.

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Development of Robust ICD Designs to Provide 30 Year Life by an In-Depth Qualification Program

Cited by 5 publications

References 8 publications

The Effect of the Operation of Downhole Equipment on the Processes of Corrosive Wear (by the Example Inflow Control Devices of Nozzle Type)

The Effect of the Operation of Downhole Equipment on the Processes of Corrosive Wear (by the Example Inflow Control Devices of Nozzle Type)

Inflow Control Device Injection and Production Dynamic Integrity Testing – Best Practices

A Systematic Approach to Design and Development of a New ICD to Minimize Erosion and Erosion-Corrosion

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