To promote efficient recovery of bitumen hydrocarbons using the steam assisted gravity drainage (SAGD) process, it is vital that steam be used effectively because steam generation constitutes one of the largest operational expenses during the SAGD process. To optimize this process, steam-injection flow-control devices (FCDs) have been developed. These devices are designed to enhance the operator's ability to distribute steam along the wellbore and to cease steam injection at a particular injection point if necessary, as the steam chamber matures. This paper discusses the design and capabilities of FCDs.The project initiated with a design requirement of two core components-the axial distribution of steam exiting the device and a device to incorporate a sliding sleeve mechanism. The basis for FCD design decisions was developed initially by reviewing worst-case operating conditions FCDs could encounter and then using this information as the operating envelope criteria that the design should meet. SAGD completion tools are required to endure everything from temperature fluctuations and corrosive formation fluids to erosive wet steam and severe wellbore trajectories. To design a tool that would survive the erosive effects of varying steam quality, the critical velocities and erosive mechanisms were defined. API RP 14E provides a conservative basis to determine the maximum allowable fluid velocity in a given system, but several studies have sought to push the boundaries of acceptable fluid velocities. The most conservative nozzle exit velocities were used to limit risks to casing. The risks caused by high velocities in the nozzle inside/inner diameter (ID) to the injection tool were mitigated through the use of computational fluid dynamics (CFD) analyses and material selection/treatment.Because of the high temperatures under which SAGD operates, consideration of mechanical property degradation and possible deformation had to be considered, specifically to the collet of the sliding sleeve. To prevent diminishing performance during the operational lifetime, FCDs that use sliding sleeves with collet mechanisms require a robust design that recognizes and addresses maximum stress loads and limits plastic deformation at peak temperatures. The testing of the sliding sleeve was conducted throughout a wide range of temperatures where the forces to shift the sleeve were monitored and compared to previous finite elements analyses (FEA) for compliance.ISO 14998 Annex D provided the basis for function testing of the FCD (i.e., cycling the sleeve and pressure testing at temperature). All pressure and function testing was performed at or above the operating temperature, and pressure and results were qualified to ISO 14998 V1. Field performance is discussed in the paper.

A new class of Autonomous Inflow Control Devices, AICDs, has been developed which balances production flow and restricts unwanted production fluids, even when there is no viscosity difference in the produced fluids. This novel AICD senses the density difference between oil and water and uses artificial gravity to amplify the buoyancy forces while eliminating the need for downhole orientation in the completion. AICDs have effectively reduced water production and increased oil recovery since their introduction in the early 2010s. During initial production, AICDs balance the flow across the production zone. In later production, AICDs automatically restrict the rate from zones producing water. Commercially available AICDs primarily operate by sensing the viscosity difference between oil and water. In very-light oil reservoirs, such as in parts of the Middle East, there is no significant viscosity difference. Previous density-based AICDs have been rejected because buoyancy forces are often overwhelmed by fluid forces and because they needed to be oriented with respect to Earth's gravity. Density-AICDs use floats that are buoyant in water and sink in oil to control fluid production. The key to the new density-AICD is that that the floats are housed in a spinning centrifugal rotor. This spinning density selector creates centripetal forces that multiply the buoyancy force thereby magnifying the difference between oil and water. The magnified buoyancy forces are stronger than fluid friction forces and are sufficient to overcome suction forces on the valve seats. The centripetal acceleration creates an artificial gravity that is much larger than Earth's gravity, eliminating the need to orient the density-AICD downhole. The density selector is spun by the production fluid so that larger centripetal forces are created in response to a larger drawdown. The result is a density-AICD that will operate in real-world conditions, especially in the light oil formations of the Middle East. The performance of this novel density-AICD has been measured in flow loop testing and demonstrated in computer modeling. The flow loop testing achieved substantial water restriction and continued oil flow using oil and water with identical viscosities.