FloSure AICD Screens & Subs
Autonomous Inflow Control Devices (AICDs) are the next generation of inflow control technology which not only provides a more uniform inflow profile and enhanced production but they do this autonomously. Our FloSure Autonomous Inflow Control Device (AICD) is a proven solution for increasing oil production over the life of the field. It has been deployed successfully in light and heavy oil wells to overcome water or gas breakthrough and ensure uniform production longevity. The device preferentially chokes unwanted produced fluids whilst promoting production of oil from the entire length of the well.
Tendeka’s FloSure AICDs are fully interchangeable, field adjustable and engineering for a wide range of applications. Deployed as part of the lower completion using zonal isolation packers to divide the reservoir into compartments, the AICD can be integrated with sand control screens for soft formations. Tendeka offers the following FloSure AICD sand screen options:
- FloSure Eliteis the lighter version of the product line with a lighter metal mesh which has been specifically engineered to reduce costs whilst maintaining performance and strength. It is rated for most field applications.
- FloSure Ultraoffers the ultimate in sand retention and fines tolerance. The premium design features a five-layer metal mesh filtration system for support, drainage, filtration, convergence and protection. The innovative pressure-fit assembly ensures the premium mesh layers achieve the highest burst and collapse rating, and results in a mechanically robust screen. This can be mechanically handled at surface and deployed through milled windows and tight doglegs downhole.
- Tendeka’s FloSure Directwire wrapped screens range offers both conventional slip-on and wrap-on pipe variations. Jackets are available in standard service 316LSS or CRA alloy as required. Wire profiles are available with a heavy-duty design for maximum erosion resistance. Wrapped screens are shrink fitted to the perforated base pipe via the end-rings, providing maximum strength to withstand high shear, compaction and torque loads.
- FloSure Compactslip-on sand screen provides sand control whilst allowing flexibility to re-dress on site.
FloSure Shrouded Subs
Tendeka’s Autonomous Inflow Control Device can also be integrated within short subs for harder formations. In conventional production wells, fluids tend to cone at the heel of the well. This can lead to early water or gas break, resulting in lost recovery, lost revenues and reduced well life. Evening out the inflow profile results in better coning control, thereby delaying the water or gas breakthrough.
FloSure AICD subs can be used along with the Tendeka range of mechanical or swellable packers and appropriate inflow profile as per client requirements.
Case Study:
FloSure AICD improves heavy oil cold production in Western Canada
Background
This is a mature, brownfield play that has been developed for 30+ years. Wells in this area have a very high water cut, often above 99% for many years. The reservoir is supported by a strong water aquifer, so the pressure is high, but the oil/water mobility ratio keeps oil production low.
The operator requested a fit-for-purpose completion to be developed that would be economical in this challenging heavy oil environment. The goal was to reduce water production and increase oil rates with an AICD completion system for both new wells and retrofits.
Tendeka Solution
A horizontal completion can be segregated into stages (10-30 per well) by Tendeka’s low-temp, hybrid swellable packers, and each of these stages is controlled by AICD valves. Regardless of where the water is entering the wellbore (heel area, high-permeability streaks, swept zones, proximity to the oil-water-contact), each stage autonomously controls and limits the volume of water that can enter through the AICD. This allows for higher pressure drawdowns to be applied to the zones that are “drier”, allowing for increased oil production and lower water volumes.
Economically speaking, advanced inflow control technology is often considered overly expensive for low-rate heavy oil wells with no thermal injection. However, a single AICD valve with low-cost sand screens and packers allowed us to design an open-hole AICD completion solution that was virtually cost neutral vs. a traditional cemented and perforated wellbore.Tendeka’s new hybrid swell rubber compound was extensively tested to optimise its reaction in low temperature conditions. This advanced compound is activated by both oil and water, and has the fastest swell
performance at temperatures as low as 30°C. With more than a dozen AICD-completed wells now online, there is considerable evidence that these multi-stage AICD completions consistently control water cut and improve oil production. The onset of water is delayed, and it is limited, allowing for a more aggressive production strategy to accelerate recovery and improve the return on investment by up to 250%.
Project results
Well designs were modified, and production strategies were tweaked to optimise deliverability, with the results being truly significant. Oil production is increased by 150-250%, and water volumes are reduced by 40-50%. The overall result is a return on investment that is improved by more than 250% per well, with a far lower risk of water problems. – New wells are completed with 4-1/2” AICD screens and swellable packers – Older wells are re-completed with 2-7/8” AICD subs and swellable packers – PCP pump selection is optimised to produce wells with higher drawdown, lower total fluid volumes – Reduced water production per well, allows more wells to be produced into surface facilities – Wells can be drilled through depleted/swept zones in the reservoir and maintain productivity
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