Horizontal Steam Injection Liner Deployed Flow Control Device Design Development and Testing

Abstract

Controlling steam conformance in the horizontal injectors of SAGD projects is widely accepted as being critical for commercial success. This work is focused on steam distribution in horizontal injectors in mobile, heavy oil (non-bitumen), thermal development projects. Steam Conformance can be achieved by tubing or liner deployed FCD's (flow control devices). Liner deployed FCD's have several advantages over tubing-deployed FCD's which includes: smaller tubulars, lower capital costs, reduced well interventions, and potentially reduced surveillance requirements. This paper provides an overview of a collaborative development methodology for liner-deployed FCD's in horizontal steam service between a service company and operator. This methodology included: Establishing functional, operational and dimensional basis of designComputational fluid dynamics (CFD) analysis of the FCD design and phase-split testing in the Horizontal Steam Injection Test Facility (HSITF)Design revisions based on CFD, HSITF and shift testing resultsField installations results based upon fiber optic, thermo-hydraulic, and mechanical analysis These FCD's were designed with sliding-sleeve technology to enable opening or closing of each device. Different specifications of electroless nickel (EN) coatings were also tested to determine the performance for scaling and corrosion resistance. Within 6 months, three versions of the FCD's were tested in the HSITF with accompanying CFD. For each version the shifting forces before and after ~6 weeks of steam injection were measured. Each generation was improved based on the data from the prior version. In December 2018, three FCD's were installed in a large bore horizontal steam injector in a tubing deployed completion for field qualification of the devices. This installation was the first step of a one-year field qualification test. The full test will involve multiple interventions to opening and closing the FCD's. A capillary tubing with fiber optic wrapped around the tubing and devices can confirm FCD openings or closings. The field qualification will also test the local operational capability to shift the FCD's. At the end of the field qualification, the flow devices will be retrieved for inspection and identification of further design improvements.

Impact of Inflow and Outflow Rate Control to Minimize Freshwater Usage: Historical Canadian Steam-Assisted Gravity Drainage Operations versus Numerical Simulations

“…12 Gorham et al implemented LDFCDs in injector wells at the Kern River, suggesting advantages like enabling longer horizontal steam injectors without substantial cost increases, yet their study overlooked certain crucial factors, such as the normalization of varying steam injection strategies and the verification of successful FCD activation in injector wells. 13 Zhu and Uzcategui examined FCDs in an industrial application, emphasizing their role in high-pressure recovery and cSOR reduction when used in injector wells. 14 They also highlighted the steam-choking capability of FCDs in the producer wells.…”

“…Lastiwka et al conducted an extensive review encompassing laboratory and field testing, confirming that FCDs result in improved oil production and enhanced steam distribution . Gorham et al implemented LDFCDs in injector wells at the Kern River, suggesting advantages like enabling longer horizontal steam injectors without substantial cost increases, yet their study overlooked certain crucial factors, such as the normalization of varying steam injection strategies and the verification of successful FCD activation in injector wells . Zhu and Uzcategui examined FCDs in an industrial application, emphasizing their role in high-pressure recovery and cSOR reduction when used in injector wells .…”

New Design Method of a Supersonic Steam Injection Nozzle and Its Numerical Simulation Verification

“…OCDs were specifically designed for horizontal steam injection wells, facilitating the regulation of steam flow within the horizontal section and the formation of steam chambers. At that time, the installation of OCDs in the steam injection column of horizontal wells had emerged as a promising technology for addressing the issue of nonuniform steam injection . However, only a limited number of oil companies, such as Weatherford, Halliburton, and ConocoPhillips, have devoted resources to the research and experimentation of OCDs.…”

“…At that time, the installation of OCDs in the steam injection column of horizontal wells had emerged as a promising technology for addressing the issue of nonuniform steam injection. 35 However, only a limited number of oil companies, such as Weatherford, Halliburton, and ConocoPhillips, have devoted resources to the research and experimentation of OCDs. Although nozzle-type OCD devices were employed in the field, there was a lack of relevant foundations for optimizing the design of nozzle structures.…”