Field Implementation of a New Inflow Control Device Design in Surmont I SAGD

Abstract Inflow Control Devices (ICDs) are increasingly employed in Steam-Assisted Gravity Drainage (SAGD) operations to improve steam chamber conformance, delay steam breakthrough, and enhance bitumen recovery. More recently, Inflow Control Devices (ICDs) incorporating internal flashing—a phenomenon where water vaporizes due to localized pressure drops inside the ICD tool, mostly at the Vena contracta—have gained attention for their potential to further optimize steam and fluid control. Industry designs often aim to increase the extent of flashing, assuming this leads to improved performance. However, this approach may result in over-choking, which restricts flow unnecessarily and can negatively impact oil production. This paper introduces the EQUALIZER Dart ICD, a novel steam-sensitive flow control device designed to restrict the production of steam and low-subcool liquids while allowing higher mobility of oil-phase fluids. By preferentially limiting flow from zones with high steam saturation or low subcool, the EQUALIZER Dart ICD helps retain steam energy within the reservoir, directs heat to colder regions, minimizes sandface erosion, and supports the growth of a more uniform steam chamber. This approach enhances thermal efficiency, promotes bitumen mobilization, and may accelerate overall production rates. A central concept presented is sandface subcool, defined as the temperature difference between actual reservoir temperature and saturation temperature at the sandface, based on localized pressure. When sandface subcool approaches zero, the likelihood of steam flashing increases, which may lead to steam coning and early steam breakthrough. The EQUALIZER Dart ICD contributes by increasing upstream backpressure, thereby raising sandface subcool to just above zero. Importantly, this study challenges some operators practice of maximizing subcool (to combat vapor returns), showing that excessive increases can be counterproductive and reduce flow performance. This paper presents the first field implementation of the EQUALIZER Dart ICD in the Athabasca McMurray oil sands reservoir, specifically within the Surmont I SAGD operation. Field production data was analyzed using a newly developed modeling tool, the Eushaw Dynamic Simulator (EDS), which captures both micro- and macro-scale flow behavior. At the micro scale, the model was calibrated using nozzle-level pressure drop data matched against CFER flow loop experiments. This calibration was then integrated into full well-pair simulations to evaluate field-scale performance. Results demonstrated improved well conformance; however, early oil production was impacted by cold-toe conditions. To mitigate this issue, alternative ICD configurations and completion strategies are proposed for future brownfield applications. Additionally, a novel diagnostic chart is introduced, leveraging Distributed Temperature Sensing (DTS) data to monitor ICD performance and steam chamber development throughout the production lifecycle.

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