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.

In recent years, the industry has been pushing the application window for inflow control technology, e.g. inflow control devices (ICDs), to harsher environments, including low-permeability formation rock, high-rate stimulation, and stricter inflow conformance for improved reservoir management. These trends result in significantly increased pressure drops and flow velocities across the equipment leading to an increased failure risk due to mechanical limitations and higher erosion/corrosion potential, as recently observed in a Middle East application. To understand long-term reliability of the equipment, accurate predictions of ICD performance are crucial. This paper presents the initial part of a comprehensive program to characterize the performance and operational envelope of commonly available ICDs. The focus of the current work is on two-phase (immiscible liquid) flow performance testing using water and three oil viscosities (2–60 cP at a test temperature of 200 °F) and on single-phase gas testing using nitrogen. As a test sample, a 6-5/8 inch liner is used with perforation diameters similar to commonly available ICD nozzle sizes. For the two-phase flow testing, data for five different water cuts and five pressure drops for all three viscosities will be presented, while for the single-phase gas testing, performance correlations for several upstream pressures and five different ratios of upstream to downstream pressure will be discussed. The detailed experimental setup and the testing methods will be outlined in order to highlight the necessary factors that need to be considered to approximate downhole flow behavior in a laboratory environment. Moreover, the results will help to establish standardized testing procedures for inflow control devices in order to provide operators reliable data mandatory for ICD completion design, long-term well performance and completion lifetime predictions.

This research effort focused on identifying equipment and processes that can be applied at compressor and pump stations to improve station operating efficiency, thereby reducing greenhouse gas (GHG) emissions. The project approach included a literature review and a PRCI member-company survey followed by evaluation and analysis and reporting tasks. This report has a corresponding webinar.