|Publisher||Society of Petroleum Engineers||Language||English|
|Content Type||Conference Paper|
|Title||Design, Analysis, and Full-Scale Erosion Testing of a Downhole Flow Control Device for High Rate Water Injection Wells|
|Authors||Ronnie Russell, Baker Oil Tools; Mark Barrilleaux, Huawen Gai, Jonathan Macrae, Baker Oil Tools|
SPE Annual Technical Conference and Exhibition, 26-29 September 2004, Houston, Texas
|Copyright||2004. Society of Petroleum Engineers|
There is an increased need for flow control devices that will operate at very high flow regimes in production and injection modes. The deepwater locations of these wells require that this equipment and the well casing operate reliably over the life of the well.
This paper presents the design and full-scale injection erosion flow testing of a new sliding sleeve port geometry. An improved flow port shape incorporates features contoured by Computational Fluid Dynamics (CFD) to dramatically lower erosion for high flow rates. Extensive material testing formed the basis of an erosion model used in the design and configuration of the port geometry. The erosion model and design work are compared and contrasted in a full-scale flow test. This test was run on the pumping vessel “HR Hughes” at the flow rates, sand content, and sand type expected at the reservoir.
This project demonstrates the ability of this flow control equipment to operate at downhole flow regimes higher than anything previously encountered. The full-scale testing of the sleeve port design verified aspects of the design analysis and confirmed the value of this type of testing to ensure design integrity and verify that these devices can operate reliably over the life of a given well. The flow control devices will enable producers to maximize production for a given size of tubing and expand operational flexibility.
The development of a high-rate downhole flow control device relies on extensive predictive analysis of flow and erosion conditions associated with the designed flow geometries. Previously this data has been unavailable or extrapolated from lesser flow conditions. A recent set of tests (described in SPE 90734) has increased the database on flow and erosion models. This data and associated models were used extensively in the design and analysis of the port geometries and flow profiles for a high-rate flow control valve. The models were used to shape the port geometry for efficient flow diffusion, to study flow characteristics, and to predict the erosive wear of high flow rates on downhole flow control devices and casing.
The development and testing of the flow erosion models described in SPE 90734 showed a dramatic variance between model predictions and physical results. Because the models were developed using standard geometries there was no flow or erosion data to verify erosion predictions on a complex flow port geometry. Due to the critical nature of this completion equipment, it was determined that a full-scale test was required to provide the maximum design assurance for equipment operation and material erosion. This flow test simulated a full-scale sliding sleeve flow control device. The design and testing focused on several critical areas: flow port geometry, material selection, erosion sand selection, vibration analysis, and casing integrity. The success of this test is not only in the ability to verify the design hardware but also in the ability to benchmark the analytical models used in the project development.
Previous analysis and testing on high rate flow devices has indicated the use of streamlined geometries to mitigate the effect of erosive flow. The complex nature of these geometries requires that CFD modeling be used to predict the flow profiles and the resulting erosion wear of the flow control hardware due to sand entrained in the flow. A series of flow port concepts were modeled using Fluent CFD software. Port concepts were evaluated by the CFD results that show flow velocities near the walls of the ports, tool body, and casing. The concept that diffuses flow the most to reduce flow velocity near part walls was chosen as the best. A full-scale model of the best port shape was chosen as the final port shape for full scale erosion testing. The streamline port geometry used for the flow sleeve device is shown in FIG. 1. It can be seen that the flow velocity pattern is uniform and shows even velocity transitions that indicate an efficient diffuser design.
|File Size||760 KB||11|