U.S. patent application number 09/729545 was filed with the patent office on 2001-08-23 for wellbore flow control device.
Invention is credited to Leismer, Dwayne D., Milligan, Clay W. JR., Pringle, Ronald E..
Application Number | 20010015276 09/729545 |
Document ID | / |
Family ID | 22711309 |
Filed Date | 2001-08-23 |
United States Patent
Application |
20010015276 |
Kind Code |
A1 |
Pringle, Ronald E. ; et
al. |
August 23, 2001 |
Wellbore flow control device
Abstract
A device for regulating fluid flow in a well is provided. The
device may include: a body member having a central bore extending
therethrough, at least one flow port, and a first valve seat; a
sleeve member movably disposed within the central bore of the body
member, and having a second valve seat adapted for cooperable
sealing engagement with the first valve seat; means for selectively
controlling movement of the sleeve member to regulate fluid flow
through the at least one flow port; and conduit means for
transmitting energy to the movement means. The conduit means may
include a first and a second hydraulic control line, a single
hydraulic control line, or a single electrical conductor. The
movement means may include: a piston connected to the sleeve member
and movable in response to a combination of hydraulic fluid,
pressurized gas, spring force, and/or annulus pressure; or an
electric motor connected to the sleeve member.
Inventors: |
Pringle, Ronald E.;
(Houston, TX) ; Milligan, Clay W. JR.; (Missouri
City, TX) ; Leismer, Dwayne D.; (Pearland,
TX) |
Correspondence
Address: |
Patent Counsel
Schlumberger Reservoir Completions
Schlumberger Technology Corporation
P.O. Box 1590
Rosharon
TX
77583-1590
US
|
Family ID: |
22711309 |
Appl. No.: |
09/729545 |
Filed: |
December 4, 2000 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09729545 |
Dec 4, 2000 |
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09192855 |
Nov 17, 1998 |
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6237683 |
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09192855 |
Nov 17, 1998 |
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08638027 |
Apr 26, 1996 |
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5918669 |
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Current U.S.
Class: |
166/320 ;
166/321 |
Current CPC
Class: |
E21B 43/305 20130101;
E21B 21/10 20130101; E21B 34/08 20130101; E21B 43/14 20130101; E21B
23/02 20130101; Y10T 137/87772 20150401; E21B 34/10 20130101; E21B
23/03 20130101; E21B 23/12 20200501; E21B 34/102 20130101; E21B
43/121 20130101; E21B 17/028 20130101 |
Class at
Publication: |
166/320 ;
166/321 |
International
Class: |
E21B 034/10 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 23, 1997 |
US |
PCTGB/97/01119 |
Claims
1. A selectively operable flow control device for regulating fluid
flow in a well, comprising: a body member having a central bore
extending therethrough, at least one flow port, and a first valve
seat; a sleeve member movably disposed within the central bore of
the body member, and having a second valve seat adapted for
cooperable sealing engagement with the first valve seat; a piston
connected to the sleeve member and movably disposed within the
central bore of the body member in response to application of
pressurized fluid; a first and a second hydraulic conduit connected
between a source of pressurized fluid and the body member, the
first hydraulic conduit being in fluid communication with a first
side of the piston, and the second hydraulic conduit being in fluid
communication with a second side of the piston; and a position
holder cooperably engageable with a retaining member, one of the
position holder and the retaining member being connected to the
sleeve member, and the other of the position holder and the
retaining member being connected to the body member.
2. The flow control device of claim 1, wherein the sleeve member
further includes at least one flow slot.
3. The flow control device of claim 1, wherein the position holder
includes a recessed profile in which a portion of the retaining
member is engaged and movably disposed to hold the sleeve member in
a plurality of discrete positions.
4. The flow control device of claim 3, wherein the recessed profile
includes a plurality of axial slots of varying lengths disposed
circumferentially about the position holder and in substantially
parallel relationship, each axial slot having a recessed portion
and an elevated portion, and each axial slot being connected to its
immediately neighboring axial slots by ramped slots leading between
corresponding recessed and elevated portions of each neighboring
axial slot.
5. The flow control device of claim 3, wherein the recessed profile
is disposed in an indexing cylinder rotatably disposed about the
sleeve member.
6. The flow control device of claim 5, wherein the indexing
cylinder and the sleeve member are adapted to restrict longitudinal
movement therebetween.
7. The flow control device of claim 1, wherein the retaining member
includes an elongate body having a cam finger at a distal end
thereof engaged with and movably disposed within a recessed
profiled in the position holder, and a proximal end of the elongate
body being hingedly attached to one of the sleeve member and body
member.
8. The flow control device of claim 1, further including means for
biasing the retaining member into engagement with the position
holder.
9. The flow control device of claim 1, wherein the retaining member
is a spring-loaded detent pin.
10. The flow control device of claim 1, further including means for
causing pressure within a well annulus to force the first and
second valve seats towards each other.
11. The flow control device of claim 1, wherein the piston is an
annular piston.
12. The flow control device of claim 1, wherein the piston is at
least one rod piston.
13. A selectively operable flow control device for regulating fluid
flow in a well, comprising: a body member having a central bore
extending therethrough, at least one flow port, and a first valve
seat; a sleeve member movably disposed within the central bore of
the body member, having a second valve seat adapted for cooperable
sealing engagement with the first valve seat, and being biased
towards the first valve seat; a piston connected to the sleeve
member and movably disposed within a cylinder in the body member in
response to application of pressurized fluid; a hydraulic conduit
in fluid communication with a source of pressurized fluid and a
first side of the piston; and a position holder cooperably
engageable with a retaining member, one of the position holder and
the retaining member being connected to the piston, and the other
of the position holder and the retaining member being connected to
the body member.
14. The flow control device of claim 13, further including means
for biasing the sleeve member and the second valve seat towards the
first valve seat.
15. The flow control device of claim 14, wherein the biasing means
includes pressurized gas.
16. The flow control device of claim 15, further including a gas
conduit containing at least a portion of the pressurized gas.
17. The flow control device of claim 15, further including a
charging port connected to the body member through which
pressurized gas is loaded into the device.
18. The flow control device of claim 14, wherein the biasing means
includes a spring.
19. The flow control device of claim 14, wherein the biasing means
includes pressure in a well annulus.
20. The flow control device of claim 13, wherein the first valve
seat is slidably disposed within the central bore and about the
sleeve member, and movable between a first position and a second
position.
21. The flow control device of claim 20, wherein the first valve
seat is biased towards its first position by a spring.
22. The flow control device of claim 21, wherein the spring is
compressed between a shoulder in the central bore and the first
valve seat.
23. The flow control device of claim 13, wherein the sleeve member
includes a first annular sealing surface for cooperable sealing
engagement with a second annular sealing surface on the central
bore, the second valve seat on the sleeve member being engageable
with the first valve seat on the body before the first and second
annular sealing surfaces are engageable.
24. The flow control device of claim 13, wherein the sleeve member
further includes at least one flow slot.
25. The flow control device of claim 13, wherein the piston
includes a first recess in which a shoulder portion of an annular
end cap is received, the end cap being secured to the sleeve
member.
26. The flow control device of claim 13, wherein the position
holder includes a recessed profile in which a portion of the
retaining member is engaged and movably disposed to hold the sleeve
member in a plurality of discrete positions.
27. The flow control device of claim 26, wherein the recessed
profile includes a plurality of axial slots of varying lengths
disposed circumferentially about the position holder and in
substantially parallel relationship, each axial slot having a
recessed portion and an elevated portion, and each axial slot being
connected to its immediately neighboring axial slots by ramped
slots leading between corresponding recessed and elevated portions
of each neighboring axial slot.
28. The flow control device of claim 26, wherein the recessed
profile is disposed in an indexing cylinder rotatably disposed
within a sealably enclosed annular space in the body member.
29. The flow control device of claim 28, wherein the indexing
cylinder includes a flange received within a second recess in the
piston.
30. The flow control device of claim 13, wherein the retaining
member includes an elongate body having a cam finger at a distal
end thereof engaged with and movably disposed within a recessed
profiled in the position holder, and a proximal end of the elongate
body being hingedly attached to one of the piston and the body
member.
31. The flow control device of claim 13, further including means
for biasing the retaining member into engagement with the position
holder.
32. The flow control device of claim 13, wherein the retaining
member is a spring-loaded detent pin.
33. The flow control device of claim 13, further including means
for causing pressure within a well annulus to force the first and
second valve seats towards each other.
34. The flow control device of claim 13, wherein the piston is an
annular piston.
35. The flow control device of claim 13, wherein the piston is at
least one rod piston.
Description
RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser.
No. 09/192,855, filed Apr. 16, 1999, which is a
continuation-in-part of U.S. application Ser. No. 08/638,027, filed
Apr. 26, 1996, now U.S. Pat. No. 5,918,669.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to subsurface well completion
equipment and, more particularly, to methods and related apparatus
for remotely controlling fluid recovery from multiple laterally
drilled wellbores.
[0004] 2. Description of the Related Art
[0005] Hydrocarbon recovery volume from a vertically drilled well
can be increased by drilling additional wellbores from that same
well. For example, the fluid recovery rate and the well's economic
life can be increased by drilling a horizontal or highly deviated
interval from a main wellbore radially outward into one or more
formations. Still further increases in recovery and well life can
be attained by drilling multiple deviated intervals into multiple
formations. Once the multilateral wellbores have been drilled and
completed there is a need for the recovery of fluids from each
wellbore to be individually controlled. Currently, the control of
the fluid recovery from these multilateral wellbores has been
limited in that once a lateral wellbore has been opened it is not
possible to selectively close off and/or reopen the lateral
wellbores without the need for the use of additional equipment,
such as wireline units, coiled tubing units and workover rigs.
[0006] The need for selective fluid recovery is important in that
individual producing intervals usually contain hydrocarbons that
have different physical and chemical properties and as such may
have different unit values. Co-mingling a valuable and desirable
crude with one that has, for instance, a high sulfur content would
not be commercially expedient, and in some cases is prohibited by
governmental regulatory authorities. Also, because different
intervals inherently contain differing volumes of hydrocarbons, it
is highly probable that one interval will deplete before the
others, and will need to be easily and inexpensively closed off
from the vertical wellbore before the other intervals.
[0007] The use of workover rigs, coiled tubing units and wireline
units are relatively inexpensive if used onshore and in typical
oilfield locations; however, mobilizing these resources for a
remote offshore well can be very expensive in terms of actual
dollars spent, and in terms of lost production while the resources
are being moved on site. In the case of subsea wells (where no
surface platform is present), a drill ship or workover vessel
mobilization would be required to merely open/close a downhole
wellbore valve.
[0008] The following patents disclose the current multilateral
drilling and completion techniques. U.S. Pat. No. 4,402,551 details
a simple completion method when a lateral wellbore is drilled and
completed through a bottom of an existing traditional, vertical
wellbore. Control of production fluids from a well completed in
this manner is by traditional surface wellhead valving methods,
since improved methods of recovery from only one lateral and one
interval is disclosed. The importance of this patent is the
recognition of the role of orienting and casing the lateral
wellbore, and the care taken in sealing the juncture where the
vertical borehole interfaces with the lateral wellbore.
[0009] U.S. Pat. No. 5,388,648 discloses a method and apparatus for
sealing the juncture between one or more horizontal wells using
deformable sealing means. This completion method deals primarily
with completion techniques prior to insertion of production tubing
in the well. While it does address the penetration of multiple
intervals at different depths in the well, it does not offer
solutions as to how these different intervals may be selectively
produced.
[0010] U.S. Pat. No. 5,337,808 discloses a technique and apparatus
for selective multi-zone vertical and/or horizontal completions.
This patent illustrates the need to selectively open and close
individual intervals in wells where multiple intervals exist, and
discloses devices that isolate these individual zones through the
use of workover rigs.
[0011] U.S. Pat. No. 5,447,201 discloses a well completion system
with selective remote surface control of individual producing zones
to solve some of the above described problems. Similarly, U.S. Pat.
No. 5,411,085, commonly assigned hereto, discloses a production
completion system which can be remotely manipulated by a
controlling means extending between downhole components and a panel
located at the surface. Each of these patents, while able to solve
recovery problems without a workover rig, fails to address the
unique problems associated with multilateral wells, and teaches
only recovery methods from multiple interval wells. A multilateral
well that requires reentry remediation which was completed with
either of these techniques has the same problems as before: the
production tubing would have to be removed, at great expense, to
re-enter the lateral for remediation, and reinserted in the well to
resume production.
[0012] U.S. Pat. No. 5,474,131 discloses a method for completing
multi-lateral wells and maintaining selective re-entry into the
lateral wellbores. This method allows for re-entry remediation into
deviated laterals, but does not address the need to remotely
manipulate downhole completion accessories from the surface without
some intervention technique. In this patent, a special shifting
tool is required to be inserted in the well on coiled tubing to
engage a set of ears to shift a flapper valve to enable selective
entry to either a main wellbore or a lateral. To accomplish this,
the well production must be halted, a coiled tubing company called
to the job site, a surface valving system attached to the wellhead
must be removed, a blow out preventer must be attached to the
wellhead, a coiled tubing injector head must be attached to the
blow out preventer, and the special shifting tool must be attached
to the coiled tubing; all before the coiled tubing can be inserted
to the well.
[0013] There is a need for a system to allow an operator standing
at a remote control panel to selectively permit and prohibit flow
from multiple lateral well branches drilled from a common central
wellbore without having to resort to common intervention
techniques. Alternately, there is a need for an operator to
selectively open and close a valve to implement re-entry into a
lateral branch drilled from the common wellbore. There is a need
for redundant power sources to assure operation of these automated
downhole devices, should one or more power sources fail. Finally,
there is a need for the fail safe mechanical recovery tools, should
these automated systems become inoperative.
SUMMARY OF THE INVENTION
[0014] The present invention has been contemplated to overcome the
foregoing deficiencies and meet the above described needs.
Specifically, the present invention is a system to recover fluids
from a well that has either multiple producing zones adjacent to a
central wellbore or has multiple lateral wellbores which have been
drilled from a central wellbore into a plurality of intervals in
proximity to the central wellbore. In accordance with the present
invention an improved method is disclosed to allow selective
recovery from any of the well's intervals by remote control from a
panel located at the earth's surface. This selective recovery is
enabled by any number of well known controlling means, i.e. by
electrical signal, by hydraulic signal, by fiber optic signal, or
any combination thereof, such combination comprising a piloted
signal of one of these controlling means to operate another.
Selective control of producing formations would preclude the
necessity of expensive, but commonly practiced workover techniques
to change producing zones, such as: (1) standard tubing conveyed
intervention, should a production tubing string need to be removed
or deployed in the well, or (2) should a work string need to be
utilized for remediation, and would also reduce the need and
frequency of either (3) coiled tubing remediation or (4) wireline
procedures to enact a workover, as well.
[0015] Preferably, these controlling means may be independent and
redundant, to assure operation of the production system in the
event of primary control failure; and may be operated mechanically
by the aforementioned commonly practiced workover techniques to
change producing zones, should the need arise.
[0016] In a preferred embodiment, a well comprising a central
casing adjacent at least two hydrocarbon producing formations is
cemented in the earth. A production tubing string located inside
the casing is fixed by any of several well known completion
accessories. Packers, which are well known to those skilled in the
art, straddle each of the producing formations and seal an annulus,
thereby preventing the produced wellbore fluids from flowing to the
surface in the annulus. A surface activated flow control valve with
an annularly openable orifice, located between the packers, may be
opened or closed upon receipt of a signal transmitted from the
control panel, with each producing formation between a wellhead at
the surface, and the lowermost producing formations having a
corresponding flow control valve. With such an arrangement, any
formation can be produced by opening its corresponding flow control
valve and closing all other flow control valves in the wellbore.
Thereafter, co-mingled flow from the individual formations is
prevented, or allowed, as is desired by the operations personnel at
the surface control panel. Further, the size of the annularly
openable orifice can be adjusted from the surface control panel
such that the rate of flow of hydrocarbons therefrom can be
adjusted as operating conditions warrant.
[0017] In accordance with this preferred embodiment, should the
flow control valve lose communication with the surface control
panel, or become otherwise inoperable by remote control, mechanical
manipulation devices that may be deployed by coiled tubing are
within the scope of this invention and are disclosed herein.
[0018] In another aspect, the present invention is a selectively
operable flow control device for regulating fluid flow in a well,
comprising: a body member having a central bore extending
therethrough, at least one flow port, and a first valve seat; a
sleeve member movably disposed within the central bore of the body
member, and having a second valve seat adapted for cooperable
sealing engagement with the first valve seat; a piston connected to
the sleeve member and movably disposed within the central bore of
the body member in response to application of pressurized fluid; a
first and a second hydraulic conduit connected between a source of
pressurized fluid and the body member, the first hydraulic conduit
being in fluid communication with a first side of the piston, and
the second hydraulic conduit being in fluid communication with a
second side of the piston; and a position holder cooperably
engageable with a retaining member, one of the position holder and
the retaining member being connected to the sleeve member, and the
other of the position holder and the retaining member being
connected to the body member. Another feature of this aspect of the
present invention is that the sleeve member further includes at
least one flow slot. Another feature of this aspect of the present
invention is that the position holder includes a recessed profile
in which a portion of the retaining member is engaged and movably
disposed to hold the sleeve member in a plurality of discrete
positions. Another feature of this aspect of the present invention
is that the recessed profile includes a plurality of axial slots of
varying lengths disposed circumferentially about the position
holder and in substantially parallel relationship, each axial slot
having a recessed portion and an elevated portion, and each axial
slot being connected to its immediately neighboring axial slots by
ramped slots leading between corresponding recessed and elevated
portions of each neighboring axial slot. Another feature of this
aspect of the present invention is that the recessed profile is
disposed in an indexing cylinder rotatably disposed about the
sleeve member. Another feature of this aspect of the present
invention is that the indexing cylinder and the sleeve member are
adapted to restrict longitudinal movement therebetween. Another
feature of this aspect of the present invention is that the
retaining member includes an elongate body having a cam finger at a
distal end thereof engaged with and movably disposed within a
recessed profiled in the position holder, and a proximal end of the
elongate body being hingedly attached to one of the sleeve member
and body member. Another feature of this aspect of the present
invention is that the device may further include means for biasing
the retaining member into engagement with the position holder.
Another feature of this aspect of the present invention is that the
retaining member is a spring-loaded detent pin. Another feature of
this aspect of the present invention is that the device may further
include means for causing pressure within a well annulus to force
the first and second valve seats towards each other. Another
feature of this aspect of the present invention is that the piston
is an annular piston. Another feature of this aspect of the present
invention is that the piston is at least one rod piston.
[0019] In another aspect, the present invention may be a
selectively operable flow control device for regulating fluid flow
in a well, comprising: a body member having a central bore
extending therethrough, at least one flow port, and a first valve
seat; a sleeve member movably disposed within the central bore of
the body member, having a second valve seat adapted for cooperable
sealing engagement with the first valve seat, and being biased
towards the first valve seat; a piston connected to the sleeve
member and movably disposed within a cylinder in the body member in
response to application of pressurized fluid; a hydraulic conduit
in fluid communication with a source of pressurized fluid and a
first side of the piston; and a position holder cooperably
engageable with a retaining member, one of the position holder and
the retaining member being connected to the piston, and the other
of the position holder and the retaining member being connected to
the body member. Another feature of this aspect of the present
invention is that the device may further include means for biasing
the sleeve member and the second valve seat towards the first valve
seat. Another feature of this aspect of the present invention is
that the biasing means includes pressurized gas. Another feature of
this aspect of the present invention is that the device may further
include a gas conduit containing at least a portion of the
pressurized gas. Another feature of this aspect of the present
invention is that the device may further include a charging port
connected to the body member through which pressurized gas is
loaded into the device. Another feature of this aspect of the
present invention is that the biasing means includes a spring.
Another feature of this aspect of the present invention is that the
biasing means includes pressure in a well annulus. Another feature
of this aspect of the present invention is that the first valve
seat is slidably disposed within the central bore and about the
sleeve member, and movable between a first position and a second
position. Another feature of this aspect of the present invention
is that the first valve seat is biased towards its first position
by a spring. Another feature of this aspect of the present
invention is that the spring is compressed between a shoulder in
the central bore and the first valve seat. Another feature of this
aspect of the present invention is that the sleeve member includes
a first annular sealing surface for cooperable sealing engagement
with a second annular sealing surface on the central bore, the
second valve seat on the sleeve member being engageable with the
first valve seat on the body before the first and second annular
sealing surfaces are engageable. Another feature of this aspect of
the present invention is that the sleeve member further includes at
least one flow slot. Another feature of this aspect of the present
invention is that the piston includes a first recess in which a
shoulder portion of an annular end cap is received, the end cap
being secured to the sleeve member. Another feature of this aspect
of the present invention is that the position holder includes a
recessed profile in which a portion of the retaining member is
engaged and movably disposed to hold the sleeve member in a
plurality of discrete positions. Another feature of this aspect of
the present invention is that the recessed profile includes a
plurality of axial slots of varying lengths disposed
circumferentially about the position holder and in substantially
parallel relationship, each axial slot having a recessed portion
and an elevated portion, and each axial slot being connected to its
immediately neighboring axial slots by ramped slots leading between
corresponding recessed and elevated portions of each neighboring
axial slot. Another feature of this aspect of the present invention
is that the recessed profile is disposed in an indexing cylinder
rotatably disposed within a sealably enclosed annular space in the
body member. Another feature of this aspect of the present
invention is that the indexing cylinder includes a flange received
within a second recess in the piston. Another feature of this
aspect of the present invention is that the retaining member
includes an elongate body having a cam finger at a distal end
thereof engaged with and movably disposed within a recessed
profiled in the position holder, and a proximal end of the elongate
body being hingedly attached to one of the piston and the body
member. Another feature of this aspect of the present invention is
that the device may further include means for biasing the retaining
member into engagement with the position holder. Another feature of
this aspect of the present invention is that the retaining member
is a spring-loaded detent pin. Another feature of this aspect of
the present invention is that the device may further include means
for causing pressure within a well annulus to force the first and
second valve seats towards each other. Another feature of this
aspect of the present invention is that the piston is an annular
piston. Another feature of this aspect of the present invention is
that the piston is at least one rod piston.
[0020] In another aspect, the present invention may be a
selectively operable flow control device for regulating fluid flow
in a well, comprising: a body member having a central bore
extending therethrough, at least one flow port, and a first valve
seat; a sleeve member movably disposed within the central bore of
the body member, and having a second valve seat adapted for
cooperable sealing engagement with the first valve seat; an
electric motor connected to the body member and adapted to move the
sleeve member longitudinally within the central bore of the body
member upon electrical actuation thereof; and an electrical
conductor connected between a source of electricity and the motor.
Another feature of this aspect of the present invention is that the
device may further include an actuating member connected between
the sleeve member and the motor. Another feature of this aspect of
the present invention is that the actuating member includes a
piston movably disposed within a cylinder in the body member.
Another feature of this aspect of the present invention is that the
motor further includes a threaded rod, and the piston further
includes a threaded cylinder, the threaded rod being threadably
disposed for longitudinal movement within the threaded cylinder.
Another feature of this aspect of the present invention is that the
piston includes a first recess in which a shoulder portion of an
annular end cap is received, the end cap being secured to the
sleeve member. Another feature of this aspect of the present
invention is that the piston is an annular piston. Another feature
of this aspect of the present invention is that the piston is at
least one rod piston. Another feature of this aspect of the present
invention is that the electric motor is disposed in a sealably
enclosed space in the body member, and the device further includes
a compensator piston movably disposed within a compensator cylinder
in the body member, a first side of the compensator piston being in
fluid communication with a well annulus, and a second side of the
compensator piston being in fluid communication with the enclosed
space. Another feature of this aspect of the present invention is
that the device may further include means connected to the electric
motor for providing a signal to a control panel indicating a
distance between the first and second valve seats. Another feature
of this aspect of the present invention is that the first valve
seat is slidably disposed within the central bore and about the
sleeve member, and movable between a first position and a second
position. Another feature of this aspect of the present invention
is that the first valve seat is biased towards its first position
by a spring. Another feature of this aspect of the present
invention is that the spring is compressed between a shoulder in
the central bore and the first valve seat. Another feature of this
aspect of the present invention is that the sleeve member includes
a first annular sealing surface for cooperable sealing engagement
with a second annular sealing surface on the central bore, the
second valve seat on the sleeve member being engageable with the
first valve seat on the body before the first and second annular
sealing surfaces are engageable. Another feature of this aspect of
the present invention is that the sleeve member further includes at
least one flow slot. Another feature of this aspect of the present
invention is that the device may further include means for causing
pressure within a well annulus to force the first and second valve
seats towards each other.
[0021] In another aspect, the present invention may be a
selectively operable flow control device for regulating fluid flow
in a well, comprising: a body member having a central bore
extending therethrough, at least one flow port, and a first valve
seat; a sleeve member movably disposed within the central bore of
the body member, and having a second valve seat adapted for
cooperable sealing engagement with the first valve seat; means for
selectively controlling movement of the sleeve member to regulate
fluid flow through the at least one flow port; and conduit means
for transmitting energy to the movement means.
[0022] The features and advantages of the present invention will be
appreciated and understood by those skilled in the art from the
following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a schematic representation of a wellbore completed
using one preferred embodiment of the present invention.
[0024] FIGS. 2A-G taken together form a longitudinal section of one
preferred embodiment of an apparatus of the present invention with
a lateral access door in the open position.
[0025] FIGS. 3A-H taken together form a longitudinal section of the
apparatus of FIGS. 2A-G with a work string shown entering a
lateral, and a longitudinal section of a selective orienting
deflector tool located in position.
[0026] FIGS. 4A-B illustrate two cross sections of FIG. 3 taken
along line "4-4", without the service tools as shown therein. FIG.
4-A depicts the cross section with a rotating lateral access door
shown in the open position, while FIG. 4-B depicts the cross
section with the rotating lateral access door shown in the closed
position.
[0027] FIG. 5 illustrates a cross section of FIG. 3E taken along
line "5-5", without the service tools as shown therein.
[0028] FIG. 6 illustrates a cross section of FIG. 3F taken along
line "6-6", and depicts a locating, orienting and locking mechanism
for anchoring the multilateral flow control system to the
casing.
[0029] FIG. 7 illustrates a longitudinal section of FIG. 5 taken
along line "7-7", and depicts an opening of the rotating lateral
access door shown in the open position, and the sealing mechanism
thereof.
[0030] FIG. 8 illustrates a cross section of FIG. 3E taken along
line "8-8", and depicts an orienting and locking mechanism for a
selective orienting deflector tool and is located therein.
[0031] FIGS. 9A-D taken together form a longitudinal section of one
preferred embodiment of an apparatus for remote control of fluid
flow within a well.
[0032] FIG. 10 illustrates a cross section of FIG. 9A taken along
line "10-10".
[0033] FIG. 11 illustrates a cross section of FIG. 9A taken along
line "11-11".
[0034] FIG. 12 illustrates a cross section of FIG. 9B taken along
line "12-12".
[0035] FIG. 13 illustrates a cross section of FIG. 9C taken along
line "13-13".
[0036] FIG. 14 illustrates a cross section of FIG. 9D taken along
line "14-14".
[0037] FIG. 15 illustrates a planar projection of an outer
cylindrical surface of a position holder shown in FIG. 9C.
[0038] FIG. 16 illustrates a side view of an upper portion of the
embodiment shown in FIGS. 9A-D.
[0039] FIGS. 17A-D taken together form a longitudinal section of
another preferred embodiment of an apparatus for remote control of
fluid flow within a well.
[0040] FIG. 18 illustrates a cross section of FIG. 17B taken along
line "18-18".
[0041] FIG. 19 illustrates a cross section of FIG. 17B taken along
line "19-19".
[0042] FIG. 20 illustrates a cross section of FIG. 17C taken along
line "20-20".
[0043] FIG. 21 illustrates a cross section of FIG. 17C taken along
line "21-21".
[0044] FIG. 22 illustrates a cross section of FIG. 17D taken along
line "22-22".
[0045] FIG. 23 illustrates a cross section of FIG. 17D taken along
line "23-23".
[0046] FIGS. 24A-C taken together form a longitudinal section of
another preferred embodiment of an apparatus for remote control of
fluid flow within a well.
[0047] FIG. 25 illustrates a cross section of FIG. 24A taken along
line "25-25".
[0048] FIG. 26 illustrates a cross section of FIG. 24A taken along
line "26-26".
[0049] FIG. 27 illustrates a cross section of FIG. 24B taken along
line "27-27".
[0050] FIG. 28 illustrates a cross section of FIG. 24C taken along
line "28-28".
[0051] FIG. 29 illustrates a cross section of FIG. 24C taken along
line "29-29".
[0052] FIG. 30 illustrates a cross section of FIG. 24C taken along
line "30-30".
[0053] FIG. 31 illustrates a longitudinal cross section of FIG. 27
taken along line "31-31".
DETAILED DESCRIPTION OF THE INVENTION
[0054] The present invention is a system for remotely controlling
multilateral wells, and will be described in conjunction with its
use in a well with three producing formations for purposes of
illustration only. One skilled in the art will appreciate many
differing applications of the described apparatus. It should be
understood that the described invention may be used in multiples
for any well with a plurality of producing formations's where
either multiple lateral branches of a well are present, or multiple
producing formations that are conventionally completed, such as by
well perforations or uncased open hole, or by any combination of
these methods. Specifically, the apparatus of the present invention
includes enabling devices for automated remote control and access
of multiple formations in a central wellbore during production, and
allow work and time saving intervention techniques when remediation
becomes necessary.
[0055] For the purposes of this discussion, the terms "upper" and
"lower", "up hole" and "downhole", and "upwardly" and "downwardly"
are relative terms to indicate position and direction of movement
in easily recognized terms. Usually, these terms are relative to a
line drawn from an upmost position at the surface to a point at the
center of the earth, and would be appropriate for use in relatively
straight, vertical wellbores. However, when the wellbore is highly
deviated, such as from about 60 degrees from vertical, or
horizontal these terms do not make sense and therefore should not
be taken as limitations. These terms are only used for ease of
understanding as an indication of what the position or movement
would be if taken within a vertical wellbore.
[0056] Referring now to FIG. 1, a substantially vertical wellbore
10 is shown with an upper lateral wellbore 12 and a lower lateral
wellbore 14 drilled to intersect an upper producing zone 16 and an
intermediate producing zone 18, as is well known to those skilled
in the art of multilateral drilling. A production tubing 20 is
suspended inside the vertical wellbore 10 for recovery of fluids to
the earth's surface. Adjacent to an upper lateral well junction 22
is an upper fluid flow control apparatus 24 of the present
invention while a lower fluid flow control apparatus 26 of the
present invention is located adjacent to a lower lateral well
junction 28. Each fluid flow control apparatus 24 and 26 are the
same as or similar in configuration. In one preferred embodiment,
the fluid flow control apparatus 24 and 26 generally comprises a
generally cylindrical mandrel body having a central longitudinal
bore extending therethrough, with threads or other connection
devices on one end thereof for interconnection to the production
tubing 20. A selectively operable lateral access door is provided
in the mandrel body for alternately permitting and preventing a
service tool from laterally exiting the body therethrough and into
a lateral wellbore. In addition, in one preferred embodiment, a
selectively operable flow control valve is provided in the body for
regulating fluid flow between the outside of the body and the
central bore.
[0057] In the fluid flow control apparatus 24 a lateral access door
30 comprises an opening in the body and a door or plug member. The
door may be moved longitudinally or radially, and may be moved by
one or more means, as will be described in more detail below. In
FIG. 1 the door 30 is shown oriented toward its respective adjacent
lateral wellbore. A pair of permanent or retrievable elastomeric
packers 32 are provided on separate bodies that are connected by
threads to the mandrel body or, preferably, are connected as part
of the mandrel body. The packers 32 are used to isolate fluid flow
between producing zones 16 and 18 and provide a fluidic seal
thereby preventing co-mingling flow of produced fluids through a
wellbore annulus 34. A lowermost packer 36 is provided to anchor
the production tubing 20, and to isolate a lower most producing
zone (not shown) from the producing zones 16 and 18 above. A
communication conduit or cable or conduit 38 is shown extending
from the fluid flow control apparatus 26, passing through the
isolation packers 32, up to a surface control panel 40. A tubing
plug 42, which is well known, may be used to block flow from the
lower most producing zone (not shown) into the tubing 20.
[0058] A well with any multiple of producing zones can be completed
in this fashion, and a large number of flow configurations can be
attained with the apparatus of the present invention. For the
purposes of discussion, all these possibilities will not be
discussed, but remain within the spirit and scope of the present
invention. In the configuration shown in FIG. 1, the production
tubing 20 is plugged at the lower end by the tubing plug 42, the
lower fluid flow control apparatus 26 has a flow control valve that
is shown closed, and the upper fluid flow control apparatus 24 is
shown with its flow control valve in the open position. This
production configuration is managed by an operator standing on the
surface at the control panel 40, and can be changed therewith by
manipulation of the controls on that panel. In this production
configuration, flow from all producing formations is blocked,
except from the upper producing zone 16. Hydrocarbons 44 present
therein will flow from the formation 16, through the upper lateral
12, into the annulus 34 of the vertical wellbore 10, into a set of
ports 46 in the mandrel body and into the interior of the
production tubing 20. From there, the produced hydrocarbons move to
the surface.
[0059] Turning now to FIGS. 2A-G, which, when taken together
illustrate the fluid flow control apparatus 24. An upper connector
48 is provided on a generally cylindrical mandrel body 50 for
sealable engagement with the production tubing 20. An elastomeric
packing element 52 and a gripping device 54 are connected to the
mandrel body 50. A first communication conduit 56, preferably, but
not limited to electrical communication, and a second communication
conduit 58, preferably, but not limited to hydraulic control
communication, extend from the earth's surface into the mandrel 50.
The first 56 and second 58 communication conduits communicate their
respective signals to/from the earth's surface and into the mandrel
50 around a set of bearings 60 to slip joint 62. The electrical
communication conduit or cable 56 connects at this location, while
the hydraulic communication conduit 58 extends therepast. The
bearings 60 reside in a rotating swivel joint 64, which allows the
mandrel body 50 and its lateral access door 30 to be rotated
relative to tubing 20, to ensure that the lateral access door 30 is
properly aligned with the lateral wellbore. Further, the electrical
communication conduit or cable 56 communicates with a first
pressure transducer 66 to monitor annulus pressure, a temperature
and pressure sensor 68 to monitor temperature and hydraulic
pressure, and/or a second pressure transducer 70 to monitor tubing
pressure. Signals from these transducers are communicated to the
control panel 40 on the surface so operations personnel can make
informed decisions about downhole conditions.
[0060] In this preferred embodiment, the electrical communication
conduit or cable also communicates with a solenoid valve 72, which
selectively controls the flow of hydraulic fluid from the hydraulic
communication conduit 58 to an upper hydraulic chamber 74, across a
moveable piston 76, to lower hydraulic chamber 78. The differential
pressures in these two chambers 74 and 78 move the operating piston
76 and a sleeve extending therefrom in relation to an annularly
openable port or orifice 80 in the mandrel body 50 to allow
hydrocarbons to flow from the annulus 34 to the tubing 20. Further,
the rate of fluid flow can be controlled by adjusting the relative
position of the piston 76 through the use of a flow control
position indicator 82, which provides the operator constant and
instantaneous feedback as to the size of the opening selected.
[0061] In some instances, however, normal operation of the flow
control valve may not be possible for any number of reasons. An
alternate and redundant method of opening or closing the flow
control valve and the annularly operable orifice 80 uses a coiled
tubing deployed shifting tool 84 landed in a profile in the
internal surface of the mandrel body 50. Weight applied to this
shifting tool 84 is sufficient to move the flow control valve to
either the open or closed positions as dictated by operational
necessity, as can be understood by those skilled in the art.
[0062] The electrical communication conduit or cable 56 further
communicates electrical power to a high torque rotary motor 88
which rotates a pinion gear 90 to rotate a lateral access plug
member or door 92. This rotational force opens and closes the
rotating lateral access door 92 should entry into the lateral
wellbore be required. In some instances, however, normal operation
of the rotating lateral access door 92 may not be possible for any
number of reasons. An alternate, and redundant method of opening
the rotating lateral access door 92 is also provided wherein a
coiled tubing deployed rotary tool 94 is shown located in a lower
profile 96 in the interior of the mandrel body 50. Weight applied
to this rotary tool 94 is sufficient to rotate the rotating lateral
access door 92 to either the open or closed positions as dictated
by operational necessity, as would be well known to those skilled
in the art.
[0063] When the fluid flow apparatus 24 and 26 are set within the
wellbore the depth and azimuthal orientation is controlled by a
spring loaded, selective orienting key 98 on the mandrel body 50
which interacts with an orienting sleeve within a casing nipple,
which is well known to those skilled in the art. Isolation of the
producing zone is assured by the second packing element 52, and the
gripping device 54, both mounted on the mandrel body 50, where an
integrally formed lower connector 100 for sealable engagement with
the production tubing 20 resides.
[0064] Referring now to FIGS. 3A-H, which, when taken together
illustrate the upper fluid flow control apparatus 24, set and
operating in a well casing 102. In this embodiment, an upper valve
seat 104 on the mandrel 50 and a lower 106 valve seat on the piston
76 are shown sealably engaged, thereby blocking fluid flow. The
lateral access door 92 is in the form of a plug member that is
formed at an angle to facilitate movement of service tools into and
out of the lateral. Once so opened, a coiled tubing 108, or other
well known remediation tool, can be easily inserted in the lateral
wellbore. For purposes of illustration, a flexible tubing member
110 is shown attached to the coiled tubing 108, which is in turn,
attached to a pulling tool 112, that is being inserted in a cased
lateral 114.
[0065] A selective orienting deflector tool 116 is shown set in a
profile 118 formed in the interior surface of the upper fluid flow
control apparatus 24. The deflector tool 116 is located, oriented,
and held in position by a set of locking keys 120, which serves to
direct any particular service tool inserted in the vertical
wellbore 10, into the proper cased lateral 114.
[0066] The depth and azimuthal orientation of the assembly as
hereinabove discussed is controlled by a spring loaded, selective
orienting key 98, which sets in a casing profile 122 of a casing
nipple 124. Isolation of the producing zone is assured by the
second packing element 52, and the gripping device 54, both mounted
on the central mandrel 50.
[0067] FIGS. 4A-B is a cross section taken at "A-A" of FIG. 3-D,
shown without the flexible tubing member 110 in place, and
represents a view of the top of the rotating lateral access door
92. FIG. 4-A illustrates the relationship of the well casing 102,
the cased lateral 114, the pinion gear 90, and the rotating lateral
access door 92, shown in the open position. FIG. 4-B illustrates
the relationship of the well casing 102, the cased lateral 114, the
pinion gear 90, and the rotating lateral access door 92, shown in
the closed position. Referring now to FIG. 5, which is a cross
section taken at "5-5" of FIG. 3-E, and is shown without the
flexible tubing member 110 in place, at a location at the center of
the intersection of the cased lateral 114, and the well casing 102.
This diagram shows the rotating lateral access door 92 in the open
position, and a door seal 126. FIG. 6 is a cross section taken at
"6-6" of FIG. 3-F and illustrates in cross section the manner in
which the selective orienting key 98 engages the casing nipple 124
assuring the assembly described herein is located and oriented at
the correct position in the well.
[0068] Turning now to FIG. 7, which is a longitudinal section taken
at "7-7" of FIG. 5. This diagram primarily depicts the manner in
which the door seal 126 seals around an elliptical opening 128
formed by the intersection of the cylinders formed by the cased
lateral 114 and the rotating lateral access door 92. This view
clearly shows the bevel used to ease movement of service tools into
and out of the cased lateral 114. The final diagram, FIG. 8, is a
cross section taken at "8-8" of FIG. 3-E. This shows the
relationship of the casing nipple 124, the orienting deflector tool
116, the profile 118 formed in the interior surface of the upper
fluid flow control apparatus 24, and how the locking keys 120
interact with the profile 118.
[0069] In a typical operation, the oil well production system of
the present invention is utilized in wells with a plurality of
producing formations which may be selectively produced. Referring
once again to FIG. 1, if it were operationally desirable to produce
from the upper producing zone 16 without co-mingling the flow with
the hydrocarbons from the other formations; first a tubing plug 42
would need to be set in the tubing to isolate the lower producing
zone (not shown). The operator standing at the control panel would
then configure the control panel 40 to close the lower fluid flow
control apparatus 26, and open the upper fluid flow control
apparatus 24. Both rotating lateral access doors 30 would be
configured closed. In this configuration, flow is blocked from both
the intermediate producing zone 18, and the lower producing zone
and hydrocarbons from the upper producing zone would enter the
upper lateral 12, flow into the annulus 34, through the set of
ports 46 on the upper fluid flow control apparatus 24, and into the
production tubing 20, which then moves to the surface. Different
flow regimes can be accomplished simply by altering the arrangement
of the open and closed valves from the control panel, and moving
the location of the tubing plug 42. The necessity of the tubing
plug 42 can be eliminated by utilizing another flow control valve
to meter flow from the lower formation as well.
[0070] When operational necessity dictates that one or more of the
laterals requires re-entry, a simple operation is all that is
necessary to gain access therein. For example, assume the upper
lateral 12 is chosen for remediation. The operator at the remote
control panel 40 shuts all flow control valves, assures that all
rotating lateral access doors 30 are closed except the one adjacent
the upper lateral 12, which would be opened. If the orienting
deflector tool 116 is not installed, it would become necessary to
install it at this time by any of several well known methods. In
all probability, however, the deflector tool 116 would already be
in place. Entry of the service tool in the lateral could then be
accomplished, preferably by coiled tubing or a flexible tubing such
as CO-FLEXIP brand pipe, because the production tubing 20 now has
an opening oriented toward the lateral, and a tool is present to
deflect tools running in the tubing into the desired lateral.
Production may be easily resumed by configuring the flow control
valves as before.
[0071] Another specific embodiment of the selectively operable flow
control valve of the present invention is shown in FIGS. 9 through
16.
[0072] With reference to FIGS. 9A-D, this specific embodiment of
the selectively operable flow control valve of the present
invention is identified generally by the reference numeral 130.
Referring to FIG. 9A, the valve 130 includes a generally
cylindrical body 132 having a central bore 134 extending
therethrough, at least one flow port 136 through a sidewall
thereof, and a first valve seat 138. The valve 130 further includes
a sleeve member 140 that is disposed for longitudinal movement
within the central bore 134 of the body 132. The sleeve member 140
may include at least one flow slot 142, and a second valve seat 144
for cooperable sealing engagement with the first valve seat 138 on
the body 132. In this embodiment, as shown in FIG. 9B, a piston 146
may be connected to, or a part of, the sleeve 140, and may be
sealably, slidably disposed within the central bore 134 of the body
132. In a specific embodiment, the piston 146 may be an annular
piston or at least one rod piston. As best shown in FIG. 16, in
this embodiment of the present invention, a first hydraulic conduit
148 and a second hydraulic conduit 150 are connected between a
source of hydraulic fluid, such as at the earth's surface (not
shown), and the valve body 132. The first hydraulic conduit 148 is
in fluid communication with a first side 152 of the piston 146, and
the second hydraulic conduit 150 is in fluid communication with a
second side 154 of the piston 146 via a passageway 156 in the body
132.
[0073] Longitudinal movement of the sleeve 140 within the central
bore 134 of the body 132 is controlled by application and/or
removal of pressurized fluid from the first and second hydraulic
conduits 148 and 150 to and from the piston 146. Specifically,
removal of pressurized fluid from the first side 152 of the piston
146 by bleeding pressurized fluid from the first hydraulic conduit
148, and/or application of pressurized fluid to the second side 154
of the piston 146 by applying pressurized fluid from the second
hydraulic conduit 150, results in upward movement of the sleeve
member 140. Similarly, removal of pressurized fluid from the second
side 154 of the piston 146 by bleeding pressurized fluid from the
second hydraulic conduit 150, and/or application of pressurized
fluid to the first side 152 of the piston 146 by applying
pressurized fluid from the first hydraulic conduit 148, results in
downward movement of the sleeve member 140. As best shown in FIG.
9A, when the sleeve member 140 is biased in its maximum upward
position, the first and second valve seats 138 and 144 are
cooperably engaged to restrict fluid flow through the at least one
flow port 136 in the valve body 132. But when the sleeve member 140
is moved downwardly so as to disengage the first and second valve
seats 138 and 144, fluid flow is permitted through the at least one
flow port 136 in the valve body 132, and through the at least one
flow slot 142 in the sleeve member 140.
[0074] The valve 130 may be provided with a position holder to
enable an operator at the earth's surface to remotely locate and
maintain the sleeve member 140 in a plurality of discrete
positions, thereby providing the operator with the ability to
remotely regulate the rate of fluid flow through the at least one
flow port 136 in the valve body, and/or through the at least one
flow slot 142 in the sleeve member 140. The position holder may be
provided in a variety of configurations. In a specific embodiment,
as shown in FIGS. 9C-9D and 13-15, the position holder may include
a cammed indexer 160 having a recessed profile 162 (FIG. 15), and
be adapted so that a retaining member 164 (FIGS. 9C-9D) may be
biased into cooperable engagement with the recessed profile 162, as
will be more fully explained below. In a specific embodiment, one
of the position holder and the retaining member may be connected to
the sleeve member 140, and the other of the position holder and the
retaining member may be connected to the valve body 132. In a
specific embodiment, the recessed profile 162 may be formed in the
sleeve member 140, or it may be formed in an indexing cylinder 166
disposed about the sleeve member 140 (FIG. 9C). In this embodiment,
the indexing cylinder 166 and the sleeve member 140 are fixed to
each other so as to prevent longitudinal movement relative to each
other. As to relative rotatable movement between the two, however,
the indexing cylinder 166 and sleeve member 140 may be fixed so as
to prevent relative rotatable movement between the two, or the
indexing cylinder 166 may be slidably disposed about the sleeve
member 140 so as to permit relative rotatable movement. In the
specific embodiment shown in FIGS. 9C and 9D, in which the recessed
profile 162 is formed in the indexing cylinder 166, the indexing
cylinder 166 is disposed for rotatable movement relative to the
sleeve member 140, as per roller bearings 168 and 170, and ball
bearings 172 and 174 (see FIG. 9C). The valve body 132 may include
linear bearings 176-180 (FIGS. 9B-9D) to facilitate axial movement
of the sleeve member 140 within the central bore 134.
[0075] In a specific embodiment, with reference to FIGS. 9C and 9D,
the retaining member 164 may include an elongate body 182 having a
cam finger 184 at a distal end thereof (see also FIG. 13) and a
hinge bore 186 at a proximal end thereof (see also FIG. 14). A
hinge pin 188 is disposed within the hinge bore 186 and connected
to the valve body 132, as shown in FIGS. 9D and 14. In this manner,
the retaining member 164 may be hingedly connected to the valve
body 132. As best shown in FIG. 9C, a biasing member 190, such as a
spring, may be provided to bias the retaining member 164 into
engagement with the recessed profile 162. Other embodiments of the
retaining member 164 are within the scope of the present invention.
For example, the retaining member 164 may be a spring-loaded detent
pin (not shown) that may be attached to the valve body 132.
[0076] The recessed profile 162 will now be described, primarily
with reference to FIG. 15, which illustrates a planar projection of
the recessed profile 162 in the indexing cylinder 166. As shown in
FIG. 15, the recessed profile 162 preferably includes a plurality
of axial slots 192 of varying length disposed circumferentially
around the indexing cylinder 166, in substantially parallel
relationship, each of which are adapted to selectively receive the
cam finger 184 on the retaining member 164. While the specific
embodiment shown includes eleven axial slots 192, this number
should not be taken as a limitation. Rather, it should be
understood that the present invention encompasses a cammed indexer
160 having any number of axial slots 192. Each axial slot 192
includes a lower portion 194 and an upper portion 196. The upper
portion 196 is recessed, or deeper, relative to the lower portion
194, and an inclined shoulder 198 separates the lower and upper
portions 194 and 196. An upwardly ramped slot 200 leads from the
upper portion 196 of each axial slot 192 to the elevated lower
portion 194 of an immediately neighboring axial slot 192, with the
inclined shoulder 198 defining the lower wall of each upwardly
ramped slot 200.
[0077] In operation, the pressure in the second hydraulic conduit
150 is preferably normally greater than the pressure in the first
hydraulic conduit 148 such that the sleeve member 140 is normally
biased upwardly, so that the cam finger 184 of the retaining member
164 is positioned against the bottom of the lower portion 194 of
one of the axial slots 192. When it is desired to change the
position of the sleeve member 140, however, the pressure in the
first hydraulic conduit 148 should momentarily be greater than the
pressure in the second hydraulic conduit 150 for a period long
enough to shift the cam finger 184 into engagement with the
recessed upper portion 196 of the axial slot 192. Then the pressure
differential between the first and second hydraulic control lines
148 and 150 should be changed so that the pressure in the second
control line 150 is greater than the pressure in the first control
line 148 so as to move the sleeve member 140 upwardly, thereby
causing the cam finger 184 to engage the inclined shoulder 198 and
move up the upwardly ramped slot 200 and into the lower portion 194
of the immediately neighboring axial slot 192 having a different
length. It is noted that, in the specific embodiment shown, the
indexing cylinder 166 will rotate relative to the retaining member
164, which is hingedly secured to the valve body 132. By changing
the relative pressure between the first and second hydraulic
control lines 148 and 150, the cam finger 184 may be moved into the
axial slot 192 having the desired length corresponding to the
desired position of the sleeve member 140. This enables an operator
at the earth's surface to shift the sleeve member 140 into a
plurality of discrete positions and control the distance between
the first and second valve seats 138 and 144 (FIG. 9A), and thereby
regulate fluid flow through the at least one flow port 136 in the
valve body 132.
[0078] It is noted that, when the valve 130 is positioned within a
well (not shown), the sleeve member 140 is exposed to annulus
pressure through the at least one flow port 136 in the valve body
132. In a specific embodiment, the valve 130 may be designed such
that the annulus pressure imparts an upward force to the sleeve
member 140 to assist in maintaining it in its closed, or sealed,
position. For example, this may be accomplished by making the outer
diameter of the sleeve member 140 adjacent the interface of the
first and second valve seats 138 and 144 (FIG. 9A) greater than the
outer diameter of the sleeve member at some point below the at
least one flow port 136, such as at dynamic seal 145 (FIG. 9B).
This difference in outer diameters at these sealing points will
result in the annulus pressure acting to force the sleeve member
140 upwardly when the first and second valve seats 138 and 144 are
in contact.
[0079] Another specific embodiment of the selectively operable flow
control valve of the present invention is shown in FIGS. 17 through
23.
[0080] With reference to FIGS. 17A-D, this specific embodiment of
the selectively operable flow control valve of the present
invention is identified generally by the reference numeral 202.
Referring to FIG. 17A, the valve 202 includes a generally
cylindrical body 204 having a central bore 206 extending
therethrough, at least one flow port 208 through a sidewall
thereof, and a first valve seat 210. In a specific embodiment, as
shown in FIG. 17B, the first valve seat 210 may be slidably
disposed within the central bore 206, and movable between a first,
or uncompressed, position (not shown), and a second, or compressed,
position, which is the position illustrated in FIG. 17B. The body
204 may include a downstop shoulder 209 against which first valve
seat 210 abuts when in its first, or uncompressed, position (not
shown). In this specific embodiment, the valve 202 may further
include a biasing mechanism, such as a wave spring 205, disposed
within the central bore 206 and contained between the
slidably-disposed first valve seat 210 and a shoulder 207 on the
valve body 204. The manner in which the wave spring 205 cooperates
with the first valve seat 210 will be explained below. The valve
202 further includes a sleeve member 212 (FIGS. 17B and 17C) that
is disposed for longitudinal movement within the central bore 206
of the body 204. The sleeve member 212 may include at least one
flow slot 214, and a second valve seat 216 for cooperable sealing
engagement with the first valve seat 210 on the body 204. As shown
in FIG. 17C, the sleeve member 212 may also include a first annular
sealing surface 217 for cooperable sealing engagement with a second
annular sealing surface 219 disposed about the central bore 206 of
the valve body 204. As will be more fully explained below, valve
202 is designed so that when the sleeve member 212 is being moved
from an open position (not shown) to a closed position, as shown in
FIGS. 17B and 17C, the second valve seat 216 on the sleeve member
212 will come into contact with the first valve seat 210 on the
valve body 204 before the first annular sealing surface 217 on the
sleeve member 212 comes into contact with the second annular
sealing surface 219 on the valve body 204.
[0081] In this embodiment, as shown in FIG. 17C, at least one
piston, such as a rod piston 218, may be connected to, or in
contact with, the sleeve member 212, and may be sealably, slidably
disposed within at least one upper cylinder 220 and at least one
lower cylinder 223 in the valve body 204. In a specific embodiment,
the piston 218 may be an annular piston. A first end 221 of the rod
piston 218 is in fluid communication with a source of pressurized
fluid that is transmitted from a remote location (not shown), such
as at the earth's surface (not shown), through a hydraulic conduit
226 that is connected to the valve body 204. As shown in FIG. 20,
in a specific embodiment, the valve 202 may include three rod
pistons 218, 218a and 218b, and pressurized fluid may be
transmitted from the hydraulic conduit 226 to the rod pistons 218a
and 218b via a first and a second fluid passageway 228 and 230,
respectively. In a specific embodiment, the rod piston 218 may
include an upper recess 222 in which a shoulder portion 224 of an
annular end cap 225 may be received. The annular end cap 224 is
connected, as by threads, to a lower end of the sleeve member 212.
As pressurized fluid is applied to the first end(s) 221 of the rod
piston(s) 218, they will move downwardly within the upper
cylinder(s) 220, thereby causing downward movement of the sleeve
member 212.
[0082] The valve 202 may also be provided with a mechanism for
causing upward movement of the sleeve member 212. In this regard,
with reference to FIG. 17A, in a specific embodiment, the valve 202
may include a source of pressurized gas, such as pressurized
nitrogen, which may be contained within a sealed chamber, such as a
gas conduit 232. An upper portion of the gas conduit 232 may be
coiled within a housing 234 formed within the body 204, and a lower
portion 236 of the gas conduit 232 (FIGS. 17B and 17C) may extend
outside the body 204 and terminate at a fitting 238 (FIG. 17C)
connected to the body 204. As shown in FIG. 17C, the gas conduit
232 is in fluid communication with a gas passageway 240 within the
body 204 (see also FIG. 21), which is in fluid communication with a
second end 242 of the at least one rod piston 218 through a
sealably enclosed annular space 241 within the body 204.
Appropriate seals are provided to contain the pressurized gas. The
gas conduit 232 may further include a fluid barrier, such as oil or
silicone. With reference to FIG. 17D, the body 204 may include a
charging port 244 through which pressurized gas may be introduced
into the valve 202. Mechanisms other than pressurized gas for
causing upward movement of the sleeve member 212 are within the
scope of the present invention, and may include, for example, a
spring (not shown), annulus pressure, tubing pressure, or any
combination of pressurized gas, annulus pressure, tubing pressure,
and a spring.
[0083] With reference to FIGS. 17C and 17D, the valve 202 may
include a position holder, similar to the position holder discussed
above in connection with the embodiment shown in FIGS. 9-16. In
this specific embodiment, the position holder may include an
indexing cylinder 246 that is slidably disposed within the annular
space 241. The indexing cylinder 246 may also be rotatably disposed
within the annular space 241, as per bearings 248 and 250. The
indexing cylinder 246 may also include a recessed profile, as
discussed above and illustrated in FIG. 15. As shown in FIG. 17C,
the indexing cylinder 246 may include a flange 252 that is received
within a second recess 253 in the second end 242 of the rod piston
218. In this manner, the rod piston 218 is connected to the
indexing cylinder 246, so that the indexing cylinder 246 is movable
in response to movement of the piston 218. The position holder also
includes a retaining member 254, the structure and operation of
which is as described above in connection with the embodiment shown
in FIGS. 9-16.
[0084] The operation of this embodiment will now be explained. The
valve 202 is pre-charged through the charging port 244 with
sufficient pressurized gas to maintain the sleeve member 212 biased
into its maximum upward, or normally-closed, position, as shown in
FIGS. 17A-D, so that the first and second valve seats 210 and 216
are engaged to restrict fluid flow through the at least one flow
port 208 in body 204. When it is desired to permit fluid flow
through the at least one flow port 208, hydraulic fluid is applied
from the hydraulic conduit 226 to the first end 221 of the rod
piston 218, with sufficient magnitude to overcome the upward force
imparted to the piston 218 by the pressurized gas, thereby forcing
the piston 218 downwardly, along with the sleeve member 212 and the
indexing cylinder 246. The desired position of the sleeve member
212 is selected by increasing and decreasing pressure in the
hydraulic conduit 226 as needed to move the retaining member 254
into the appropriate slot of the recessed profile (recall FIG. 15),
during which process the indexing cylinder 246 will rotate and move
longitudinally within the enclosed space 241. By adjusting the
position of the sleeve member 212, an operator at the earth's
surface may remotely regulate fluid flow through the at least one
flow port 208 in the body 204 and/or through the at least one flow
slot 214 in the sleeve member 212. As noted above, when the sleeve
member 212 is being returned to its fully-closed position, the
second valve seat 216 on the sleeve member 212 will come into
contact with the first valve seat 210 on the valve body 204 before
the first annular sealing surface 217 on the sleeve member 212
comes into contact with the second annular sealing surface 219 on
the valve body 204. The sleeve member 212 will continue to move
upwardly, thereby shifting the first valve seat 210 relative to the
body 204 and compressing the wave spring 205, until the first
annular sealing surface 217 on the sleeve member 212 comes into
contact with the second annular sealing surface 219 on the valve
body 204.
[0085] Another specific embodiment of the selectively operable flow
control valve of the present invention is shown in FIGS. 24 through
31.
[0086] With reference to FIGS. 24A-C, this specific embodiment of
the selectively operable flow control valve of the present
invention is electrically-operated and identified generally by the
reference numeral 256. Referring to FIG. 24A, the valve 256
includes a generally cylindrical body 258 having a central bore 260
extending therethrough, at least one flow port 262 through a
sidewall thereof, and a first valve seat 264. In a specific
embodiment, as shown in FIG. 24A, the first valve seat 264 may be
slidably disposed within the central bore 260, and movable between
a first, or uncompressed, position (not shown), and a second, or
compressed, position, which is the position illustrated in FIG.
24A. The body 258 may include a downstop shoulder 267 against which
the first valve seat 264 abuts when in its first, or uncompressed,
position (not shown). In this specific embodiment, the valve 256
may further include a biasing mechanism, such as a wave spring 266,
disposed within the central bore 260 and contained between the
slidably-disposed first valve seat 264 and a shoulder 270 on the
valve body 258. The manner in which the wave spring 266 cooperates
with the first valve seat 264 is as explained above in connection
with the embodiment shown in FIGS. 17-23. The valve 256 further
includes a sleeve member 272 (FIGS. 24A and 24B) that is disposed
for longitudinal movement within the central bore 260 of the body
258. The sleeve member 272 may include at least one flow slot 274,
and a second valve seat 276 for cooperable sealing engagement with
the first valve seat 264 on the body 258. As shown in FIG. 24B, the
sleeve member 272 may also include a first annular sealing surface
278 for cooperable sealing engagement with a second annular sealing
surface 280 disposed about the central bore 260 of the valve body
258. In the same manner as discussed above in connection with FIGS.
17-23, the valve 256 is designed so that when the sleeve member 272
is being moved from an open position (not shown) to a closed
position, as shown in FIGS. 24A-24C, the second valve seat 276 on
the sleeve member 272 will come into contact with the first valve
seat 264 on the valve body 258 before the first annular sealing
surface 278 on the sleeve member 272 comes into contact with the
second annular sealing surface 280 on the valve body 258.
[0087] The mechanism of this embodiment for remotely shifting the
sleeve member 272 within the central bore 260 is
electrically-operated, as will now be more fully explained. With
reference to FIGS. 24A and 24B, an electrical conduit 282 having at
least one electrical conductor 284 disposed therein is connected
between a remote source of electrical power (not shown), such as at
the earth's surface (not shown), and the valve body 258, such as at
fitting 286 (FIG. 24B). The at least one electrical conductor 284
may be passed through a sealed electrical passageway 288 in the
valve body 258 to a sealably enclosed annular space 290 in the
valve body 258, where it is connected to an electric motor 292. The
electric motor 292 is attached to the valve body 258 and adapted to
move the sleeve member 272 upon electrical actuation thereof. In a
specific embodiment, the electric motor 292 may include, or be
connected to, a threaded rod 294, or ball screw, a distal end 296
of which may be threadably received within a threaded cylinder 298
in a proximal end 300 of an actuating member 302. Referring to FIG.
24B, in a specific embodiment, the actuating member 300 may be a
rod piston that is movably disposed within a lower cylinder 304 and
an upper cylinder 306, both of which cylinders 304 and 306 may be
disposed within the valve body 258. In a specific embodiment, the
rod piston 300 may include a recess 308 in which a shoulder portion
310 of an annular end cap 312 may be received. In a specific
embodiment, the actuating member 300 may be an annular piston. The
annular end cap 312 is connected, as by threads, to a lower end of
the sleeve member 272. Referring to FIG. 24C, the threaded rod 294
may be rotated in a clockwise or counter-clockwise direction upon
electrical actuation of the motor 292, thereby resulting in
longitudinal movement of the threaded rod 294 within the threaded
cylinder 298. This causes longitudinal movement of the rod piston
300 within the lower and upper cylinders 304 and 306, which results
in longitudinal movement of the sleeve member 272 within the
central bore 260. In this manner, fluid flow may be remotely
regulated through the at least one flow port 262 in the valve body
258 and/or through the at least one flow slot 274 in the sleeve
member 272.
[0088] In a specific embodiment, as shown in FIGS. 28 and 29, the
valve 256 may also include a position indicator 314 that is
connected to the at least one electrical conductor 284 and to the
motor 292. The position indicator 314 will provide a signal to a
control panel (not shown) at the earth's surface to indicate the
position of the threaded rod 294, which will provide an indication
to the operator at the earth's surface of the distance between the
first and second valve seats 264 and 276 (FIG. 24A). This
information will assist the operator in regulating fluid flow
through the at least one flow port 262 in the valve body 258 and/or
through the at least one flow slot 274 in the sleeve member 272. In
a specific embodiment, the position indicator 314 may be a rotary
variable differential transformer (RVDT). In a specific embodiment,
the RVDT 314, the motor 292, and the threaded rod 294 may be an
integral unit, of the type available from Astro Corp., of
Dearfield, Fla., such as Model No. 800283. In another specific
embodiment, the position indicator 314 may be an electromagnetic
tachometer. In another specific embodiment, if the motor 292 is a
stepper motor, the position indicator 314 may be a step counter for
counting the number of times the stepper motor 292 has been
advanced. In another specific embodiment, the position indicator
314 may be an electrical resolver. In a specific embodiment, the
valve 256 may further include an electronic module 316 connected
between the electrical conductor 284 and the motor 292 to control
operation thereof. The module 316 may include hard-wired circuitry,
and/or a microprocessor and associated software.
[0089] Referring now to FIGS. 27 and 31, this embodiment of the
present invention may also include a mechanism for compensating for
temperature-induced pressure variations between pressures in the
well annulus (not shown) and in the enclosed annular space 290,
which may contain an incompressible fluid. As shown in FIG. 31, the
compensating mechanism may include a compensator housing 318 having
a compensator cylinder 320 in which a compensator piston 322 is
movably disposed. The compensator housing 318 may be connected to
or a part of the valve body 258. A first side 324 of the
compensator piston 322 is in fluid communication with the well
annulus, such as through an aperture 325, and a second side 326 of
the compensator piston 322 is in fluid communication with the
enclosed space 290. As the valve experiences fluctuations in
temperature and pressure, the compensator piston 322 will move
within the compensator cylinder 320 to maintain equilibrium between
annulus pressure and the pressure in the enclosed space 290.
[0090] Whereas the present invention has been described in
particular relation to the drawings attached hereto, it is to be
understood that the invention is not limited to the exact details
of construction, operation, exact materials or embodiments shown
and described, as obvious modifications and equivalents will be
apparent to one skilled in the art. Accordingly, the invention is
therefore to be limited only by the scope of the appended
claims.
* * * * *