Demand for inflow control devices (ICDs) in injection applications is increasing, leading to design initiatives by operators and service companies. These initiatives address the more rigorous conditions of injection applications including acidizing, SAGD, and cyclic steam stimulation. This paper will demonstrate the success of an iterative design and qualification process to develop a robust tortuous path ICD that can withstand higher pressures and higher stimulation rates operators desire for injection applications.
The design process started with computation fluid dynamics (CFD) modeling to predict the stimulation flow performance and resulting pressure gradient underneath the ICD's outer housing. This information was input to the finite element analysis (FEA) model to determine the stress and deformation of the housing. Results of a dynamic flow test with strain gages attached to the housing were compared to the simulated deflection. Additional iterations of the FEA model resulted in the final ICD design. An endurance test verified the final design could withstand full length stimulation operations.
The implementation of the design and qualification method enabled the ICD to withstand higher injection rates without losing any ICD functionality. Overall, the maximum allowable injection rate was increased by 50% compared to the proven ICD design used in production wells.
Previous ICD qualification testing mainly involved characterizing the ICD in production, not the rigorous conditions during stimulation. Thus, designs were not subjected to such intensive mechanical integrity testing. However, in carbonate reservoirs it is often imperative to stimulate wells to bypass damage induced during the drilling and completion phases [Bachar, November 2014]. As stimulation techniques for horizontal wells continue to improve, it is important for well completion technology to keep pace. Differential improvements in ICD design enable a much wider range of well stimulation capabilities increasing well productivity over the life of the well.