Single and Multi-Phase Flow Loop Testing for Characterization and Optimization of Flow Control Devices Used in SAGD: The Effect of Viscosity and Gas-to-Liquid Ratio on Tool Performance

The design of Flow Control Devices (FCDs) requires performance data of an FCD’s internal nozzle under a wide range of flow scenarios. The current study specifically considers the effect of nozzle diameter and wall profile on the induced pressure loss, and subsequently the recovery performance of an FCD. For this study, a flow measurement facility is developed to test the performance of different orifice/nozzle geometries. The flow of single- and two-phase fluid at various flow rates and mass fractions, is experimented. The pressure drop data from the experiments is used to produce performance curves that characterize pressure loss across the geometries. The pressure loss for two-phase flows are compared to their single-phase counterparts to characterize the performance of the tested geometries in the two scenarios. A detailed protocol for performance testing of FCDs is followed as per Advanced Well Equipment Standard (AWES: recommended practice3362). The testing protocol was utilized to characterize the performance of different FCDs geometries under single- and two-phase flow conditions. The results showed the pressure loss characteristic obtained from the flow loop experiments match the corresponding theories. The study has thus provided promising results for the successful application of direct flow loop testing to obtain reliable data which can be used in FCD design, performance investigation, and reservoir simulation.