Advanced Computational Aided Development of Autonomous Inflow Control Device (AICD)

Abstract

Autonomous inflow control devices (AICDs) represent a successful technology utilized in maximizing reservoir sweep and increased oil recovery. They are an evolutionary enhancement over the passive inflow control device (ICD) such as a nozzle or helix type, which have a choke that is fixed for the lifetime of the well. This paper discusses a technique which accelerated the AICD development from defining the operational parameters to delivering a fully functional product, while considering the various mechanical and hydraulic loads that are critical in providing robustness during operations. Due to limited space availability between the AICD sub-assembly, basepipe dimensions, and complex loading conditions, iterative designs were established to meet the operational parameters. Simulations using finite element analysis (FEA) facilitated the development via performance evaluation of each design under various load conditions. The FEA simulation results provided the direction to refine, optimize and finalize the design. Mechanical loads evaluated in the simulations included: tension, torque, bending, and impact shock, while hydraulic loads included: collapse, burst, and injection pressure. On finalizing the design, the simulation results were validated with prototype testing. The final design met the operational parameters through FEA, that enabled the successful development of the product, saving more than 50% of a typical development cycle time. The FEA simulations provided stress information of each feature, modelling the anticipated loading during the service life, which contributed to the improved robustness and complex features reliability. Prototype test samples were manufactured based on the final design. A full range of validation tests were conducted to validate the final design of the simulation model and to establish appropriate operational limitations of the AICD assembly when subjected to various loads. A leak test was performed before and after the applicable tests to verify that a leak path had not developed. At the conclusion of every test, each AICD element (manufactured from tungsten carbide) was inspected for damage to verify the device had not failed. The test results proved the final design could achieve or exceed the minimum requirements under various load conditions using the simulation technique that accelerated the development process. This design has been used as the basis for various other sizes, with a similar mounting system, which have been successfully deployed in field applications. The use of this technique significantly accelerated the development process. It involved several design iterations and FEA simulations to evaluate various designs throughout the development cycle. FEA has been applied as a value adding tool to guide design optimization, which has been verified by testing, to successfully anticipate the loadings as per operational parameters. In addition to the shortened development process, the validation test development cost was significantly minimized, using FEA, and a robust product was delivered. The validation test results aligned with the FEA predictions.