Configurable Adaptive Chemical Inflow Control Device Component Level Design and Evaluation
Authors: AlMusharraf N. , Asthana P. , Sulaiman A. , Jacob S. , Bukhamseen A. 
Published: April 2024

A novel type of Chemistry based Autonomous Inflow Control Devices (Chemical-AICDs or C-AICDs) is introduced with the capability of restricting unwanted fluids based on chemically altering the fluid path structure in response to surrounding fluids. These devices are completely viscosity and density independent and don't require any intervention for water shutoff, resulting in saving time and cost during life of well. We discuss design elements, optimization, testing and evaluation methods of a selected configuration of the C-AICD.

C-AICD construction includes ported funnel and multi-core ball. As part of multi-core ball design, novel inorganic coating processes are synthesized and optimized to create multilayer coatings that have strong interlayer bonding to provide sealing integrity and controlled dissolution to facilitate uniform change of diametrical positions of the ball. The ported funnel design is optimized using Computer Aided Design and 3D printed to confirm fit-form with the multi-core ball at various operational positions. The C-AICD flow performance was evaluated by a custom flow calculator based on orifice theory. Initial Computational Fluid Dynamics simulations (CFD) was carried out on one configuration of the ICD assembly. This calculator will be calibrated through CFD and function tested in a flow loop to validate flow performance and compatibility with system.

While advanced completion technology is created to enhance well performance, it is often more complex in design and field installation and comes at a higher cost than existing field-proven technologies. The revolutionary C-AICD design allows applications for oil production in fields while being sustainable, cost effective and efficient. The C-AICD incorporates a time and environment trigger selective water/oil dissolvable mechanism on thin coatings applied on a ball, formulating a mechanism for the world's first chemically configurable adaptive ICD. Novel methods and configurations to build a C-AICD using the dissolvable ball coatings concept packaged in a ported funnel are discussed. The time/environment dependent selective dissolution changes the diametrical position of the ball in the funnel changing flow port area available for inflow. Preliminary device efficiency and performance optimization of system was carried out through analytical flow calculation using physics based mathematical models. Study revealed the relationship between flow-rate, velocity, and pressure drop across C-AICD. This ensures a design standard for appropriate selection and sizing for efficient system performance. Individual elements like multi-core ball materials and coatings were optimized through careful synthesis and characterization.

This paper presents design, analysis, and optimization roadmap philosophy of a new cost-effective C-AICD that discriminates oil versus water with time/environment dependent selective dissolution of coatings on a ball. The process alters the diametrical position of the ball in the flow funnel/cylinder autonomously restricting flow port area available for inflow. Design and optimization methodology are presented with preliminary results of system mechanical and flow performance analysis. Further, the synthesis and characterization of the selective dissolvable layers is discussed.