U.S. patent application number 10/445818 was filed with the patent office on 2004-02-26 for fluid flow control device and method for use of same.
Invention is credited to Echols, Ralph H..
Application Number | 20040035591 10/445818 |
Document ID | / |
Family ID | 31887554 |
Filed Date | 2004-02-26 |
United States Patent
Application |
20040035591 |
Kind Code |
A1 |
Echols, Ralph H. |
February 26, 2004 |
Fluid flow control device and method for use of same
Abstract
A fluid flow control device (136) for use in a wellbore to
control the inflow of production fluids comprises a tubular member
(134) having at least one fluid passageway (136) and a sand control
screen (132) positioned exteriorly therearound. The sand control
screen (132) has a filter medium section (142) that defines a first
annular region (144) with the tubular member (134) and a housing
section (146) that defines a second annular region (148) with the
tubular member (134) adjacent to the fluid passageway (136). A
sealing member (150) is positioned within the second annular region
(148). A hydraulic pressure source (152) is selectively in fluid
communication with the sealing member (150) to operate the sealing
member (150) from a nonsealing position wherein fluid flow through
the fluid passageway (136) is allowed, to a sealing position
wherein fluid flow through the fluid passageway (136) is
prevented.
Inventors: |
Echols, Ralph H.; (Dallas,
TX) |
Correspondence
Address: |
LAWRENCE R. YOUST
Danamraj & Youst, P.C.
Suite 1200, LB 15
12900 Preston Road
Dallas
TX
75230-1328
US
|
Family ID: |
31887554 |
Appl. No.: |
10/445818 |
Filed: |
May 27, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10445818 |
May 27, 2003 |
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10227935 |
Aug 26, 2002 |
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Current U.S.
Class: |
166/386 |
Current CPC
Class: |
E21B 43/08 20130101;
E21B 43/12 20130101; E21B 47/09 20130101 |
Class at
Publication: |
166/386 |
International
Class: |
E21B 033/12 |
Claims
What is claimed is:
1. A fluid flow control device for use in a wellbore to control the
inflow of production fluids comprising: a tubular member having at
least one fluid passageway in a sidewall section thereof; a sand
control screen positioned exteriorly around the tubular member, the
sand control screen having a filter medium section defining a first
annular region with the tubular member and a housing section
defining a second annular region with the tubular member adjacent
to the fluid passageway; a sealing member positioned within the
second annular region, the sealing member having a first position
wherein fluid flow is permitted through the fluid passageway and a
second position wherein fluid flow is prevented through the fluid
passageway; and a pressure source that is selectively in fluid
communication with the sealing member to operate the sealing member
from the first position to the second position.
2. The fluid flow control device as recited in claim 1 wherein the
sealing member further comprises a sliding sleeve.
3. The fluid flow control device as recited in claim 1 wherein the
sealing member further comprises an expandable bladder.
4. The fluid flow control device as recited in claim 1 further
comprising a cylinder positioned within the second annular region,
the cylinder and the housing section forming first and second
chambers therebetween, the first and second chambers having a
piston therebetween, the first chamber selectively being in fluid
communication with the pressure source and the second chamber being
in fluid communication with an expandable bladder sealing
member.
5. The fluid flow control device as recited in claim 1 further
comprising a piston positioned within the second annular region,
the piston, the tubular member and the housing section forming a
first chamber therebetween that is selectively in fluid
communication with the pressure source and the piston and the
housing section forming a second chamber that is in fluid isolation
from the pressure source.
6. The fluid flow control device as recited in claim 1 wherein the
pressure source further comprises a hydraulic control line
extending from a surface location to the sand control screen, the
hydraulic control line having a first section with a terminus that
is selectively in fluid communication with the sealing member, the
hydraulic control line having a second section that passes through
the first annular region and extends downhole of the sand control
screen.
7. The fluid flow control device as recited in claim 1 wherein the
pressure source further comprises a wellbore pressure source.
8. The fluid flow control device as recited in claim 1 further
comprising a valve positioned within a fluid communication path
between the pressure source and the sealing member to selectively
prevent and permit fluid communication between the pressure source
and the sealing member.
9. The fluid flow control device as recited in claim 8 wherein the
valve is a eutectic valve.
10. The fluid flow control device as recited in claim 8 wherein the
valve is a rupture disk.
11. The fluid flow control device as recited in claim 1 further
comprising a sensor positioned on the fluid flow control device to
sense at least one downhole parameter selected from the group
comprising temperature, pressure and fluid composition.
12. The fluid flow control device as recited in claim 1 further
comprising an energy conductor extending from a surface location to
the sand control screen, the energy conductor passing through the
first annular region and extending downhole of the sand control
screen.
13. The fluid flow control device as recited in claim 11 wherein
the energy conductor further comprising an electrical
conductor.
14. The fluid flow control device as recited in claim 11 wherein
the energy conductor further comprising a fiber optic
conductor.
15. The fluid flow control device as recited in claim 14 wherein
the fiber optic conductor provides information relating to at least
one downhole parameter selected from the group comprising
temperature and pressure to the surface location from a location
proximate the sand control screen.
16. A method for controlling production fluid flow through multiple
sand control screens in a sand control screen assembly positioned
within a wellbore, the method comprising the steps of: coupling a
hydraulic fluid conduit to the multiple sand control screens in the
sand control screen assembly; increasing the pressure within the
hydraulic fluid conduit to a first predetermined level to prevent
production fluid flow through a first sand control screen; and
increasing the pressure within the hydraulic fluid conduit to a
second predetermined level that is greater than the first
predetermined level to prevent production fluid flow through a
second sand control screen.
17. The method as recited in claim 16 wherein each of the steps of
increasing the pressure within the hydraulic fluid conduit further
comprises bursting a rupture disk operably associated with one of
the first and the second sand control screens.
18. The method as recited in claim 16 wherein each of the steps of
increasing the pressure within the hydraulic fluid conduit further
comprises sliding a sleeve operably associated with one of the
first and the second sand control screens.
19. The method as recited in claim 16 wherein each of the steps of
increasing the pressure within the hydraulic fluid conduit further
comprises expanding a bladder operably associated with one of the
first and the second sand control screens.
20. The method as recited in claim 16 wherein each of the steps of
increasing the pressure within the hydraulic fluid conduit further
comprises shifting a piston between first and second chambers and
expanding a bladder operably associated with one of the first and
the second sand control screens.
21. The method as recited in claim 16 wherein the first sand
control screen is uphole of the second sand control screen.
22. The method as recited in claim 16 wherein the first sand
control screen is downhole of the second sand control screen.
23. A method for controlling production fluid flow through multiple
flow control devices positioned within a wellbore, the method
comprising the steps of: coupling a hydraulic fluid conduit to the
multiple flow control devices; increasing the pressure within the
hydraulic fluid conduit to a first predetermined level to prevent
production fluid flow through a first flow control device; and
increasing the pressure within the hydraulic fluid conduit to a
second predetermined level that is greater than the first
predetermined level to prevent production fluid flow through a
second flow control device.
24. The method as recited in claim 23 wherein each of the steps of
increasing the pressure within the hydraulic fluid conduit further
comprises bursting a rupture disk operably associated with one of
the first and the second flow control devices.
25. The method as recited in claim 23 wherein each of the steps of
increasing the pressure within the hydraulic fluid conduit further
comprises sliding a sleeve operably associated with one of the
first and the second flow control devices.
26. The method as recited in claim 23 wherein each of the steps of
increasing the pressure within the hydraulic fluid conduit further
comprises expanding a bladder operably associated with one of the
first and the second flow control devices.
27. The method as recited in claim 23 wherein each of the steps of
increasing the pressure within the hydraulic fluid conduit further
comprises shifting a piston between first and second chambers and
expanding a bladder operably associated with one of the first and
the second flow control devices.
28. The method as recited in claim 23 wherein the first flow
control device is uphole of the second flow control device.
29. The method as recited in claim 23 wherein the first flow
control device is downhole of the second flow control device.
30. The method as recited in claim 23 wherein the first and second
flow control devices further comprise sand control screens.
31. A system for controlling production fluid flow in a wellbore
comprising: first and second sand control screens in a sand control
screen assembly positioned within the wellbore; and a hydraulic
fluid conduit coupled to the first and second sand control screens
such that increasing the pressure within the hydraulic fluid
conduit to a first predetermined level prevents production fluid
flow through the first sand control screen and increasing the
pressure within the hydraulic fluid conduit to a second
predetermined level that is greater than the first predetermined
level prevents production fluid flow through the second sand
control screen.
32. The system as recited in claim 31 wherein the first sand
control screen has a rupture disk operably associated therewith
that bursts at a pressure less than the first predetermined level
and the second sand control screen has a rupture disk operably
associated therewith that bursts at a pressure between the first
predetermined level the second predetermined level.
33. The system as recited in claim 31 wherein the first and the
second sand control screens each further comprises a sliding sleeve
operably associated therewith.
34. The system as recited in claim 31 wherein the first and the
second sand control screens each further comprises an expandable
bladder operably associated therewith.
35. The system as recited in claim 31 wherein the first sand
control screen is uphole of the second sand control screen.
36. The system as recited in claim 31 wherein the first sand
control screen is downhole of the second sand control screen.
37. A system for controlling production fluid flow in a wellbore
comprising: first and second flow control devices positioned within
the wellbore; and a hydraulic fluid conduit coupled to the first
and second flow control devices such that increasing the pressure
within the hydraulic fluid conduit to a first predetermined level
prevents production fluid flow through the first flow control
device and increasing the pressure within the hydraulic fluid
conduit to a second predetermined level that is greater than the
first predetermined level prevents production fluid flow through
the second flow control device.
38. The system as recited in claim 37 wherein the first flow
control device has a rupture disk operably associated therewith
that bursts at a pressure less than the first predetermined level
and the second flow control device has a rupture disk operably
associated therewith that bursts at a pressure between the first
predetermined level and the second predetermined level.
39. The system as recited in claim 37 wherein the first and the
second flow control devices each further comprises a sliding sleeve
operably associated therewith.
40. The system as recited in claim 37 wherein the first and the
second flow control devices each further comprises an expandable
bladder operably associated therewith.
41. The system as recited in claim 37 wherein the first flow
control device is uphole of the second flow control device.
42. The system as recited in claim 37 wherein the first flow
control device is downhole of the second flow control device.
43. A method for controlling production fluid flow through multiple
sand control screens in a sand control screen assembly positioned
within a wellbore, the method comprising the steps of: coupling a
hydraulic fluid conduit to the multiple sand control screens in the
sand control screen assembly; coupling an energy conductor to the
multiple sand control screens in the sand control screen assembly;
signaling a valve operably associated with a first sand control
screen to actuate to an open position via the energy conductor;
communicating hydraulic pressure from the hydraulic fluid conduit
to the first sand control screen to prevent production fluid flow
therethrough; signaling a valve operably associated with a second
sand control screen to actuate to an open position via the energy
conductor; and communicating hydraulic pressure from the hydraulic
fluid conduit to the second sand control screen to prevent
production fluid flow therethrough.
44. The method as recited in claim 43 wherein each of the steps of
communicating hydraulic pressure from the hydraulic fluid conduit
further comprises sliding a sleeve operably associated with one of
the first and the second sand control screens.
45. The method as recited in claim 43 wherein each of the steps of
increasing the pressure within the hydraulic fluid conduit further
comprises expanding a bladder operably associated with one of the
first and the second sand control screens.
46. The method as recited in claim 43 wherein each of the steps of
signaling a valve further comprises electrically signaling.
47. The method as recited in claim 43 wherein each of the steps of
signaling a valve further comprises optically signaling.
48. The method as recited in claim 43 further comprising the step
of sensing at least one downhole parameter proximate the first sand
control screen prior to signaling the valve operably associated
with the first sand control screen.
49. The method as recited in claim 48 further comprising the step
of sensing at least one downhole parameter proximate the second
sand control screen prior to signaling the valve operably
associated with the second sand control screen.
50. A method for controlling production fluid flow through multiple
flow control devices positioned within a wellbore, the method
comprising the steps of: coupling a hydraulic fluid conduit to the
multiple flow control devices; coupling an energy conductor to the
multiple flow control devices; signaling a valve operably
associated with a first flow control device to actuate to an open
position via the energy conductor; communicating hydraulic pressure
from the hydraulic fluid conduit to the first flow control device
to prevent production fluid flow therethrough; signaling a valve
operably associated with a second flow control device to actuate to
an open position via the energy conductor; and communicating
hydraulic pressure from the hydraulic fluid conduit to the second
flow control device to prevent production fluid flow
therethrough.
51. The method as recited in claim 50 wherein each of the steps of
communicating hydraulic pressure from the hydraulic fluid conduit
further comprises sliding a sleeve operably associated with one of
the first and the second flow control devices.
52. The method as recited in claim 50 wherein each of the steps of
increasing the pressure within the hydraulic fluid conduit further
comprises expanding a bladder operably associated with one of the
first and the second flow control devices.
53. The method as recited in claim 50 wherein each of the steps of
signaling a valve further comprises electrically signaling.
54. The method as recited in claim 50 wherein each of the steps of
signaling a valve further comprises optically signaling.
55. The method as recited in claim 50 further comprising the step
of sensing at least one downhole parameter proximate the first flow
control device prior to signaling the valve operably associated
with the first flow control device.
56. The method as recited in claim 55 further comprising the step
of sensing at least one downhole parameter proximate the second
flow control device prior to signaling the valve operably
associated with the second flow control device.
57. A system for controlling production fluid flow in a wellbore
comprising: first and second sand control screens in a sand control
screen assembly positioned within the wellbore; a hydraulic fluid
conduit coupled to the first and second sand control screens; and
an energy conductor coupled to the first and second sand control
screens, the energy conductor providing a signal to open a valve
operably associated with the first sand control screen such that
hydraulic pressure is communicated from the hydraulic fluid conduit
to the first sand control screen to prevent production fluid flow
therethrough and the energy conductor providing a signal to open a
valve operably associated with the second sand control screen such
that hydraulic pressure is communicated from the hydraulic fluid
conduit to the second sand control screen to prevent production
fluid flow therethrough.
58. A system for controlling production fluid flow in a wellbore
comprising: first and second flow control devices positioned within
the wellbore; a hydraulic fluid conduit coupled to the first and
second flow control devices; and an energy conductor coupled to the
first and second flow control devices, the energy conductor
providing a signal to open a valve operably associated with the
first flow control device such that hydraulic pressure is
communicated from the hydraulic fluid conduit to the first flow
control device to prevent production fluid flow therethrough and
the energy conductor providing a signal to open a valve operably
associated with the second flow control device such that hydraulic
pressure is communicated from the hydraulic fluid conduit to the
second flow control device to prevent production fluid flow
therethrough.
59. A method for controlling the flow of production fluids through
a fluid flow control device, the method comprising the steps of:
positioning the fluid flow control device downhole, the fluid flow
control device including a tubular member having at least one fluid
passageway in a sidewall section thereof and a sand control screen
positioned exteriorly around the tubular member, the sand control
screen having a filter medium section defining a first annular
region with the tubular member and a housing section defining a
second annular region with the tubular member adjacent to the fluid
passageway; flowing fluid through the sand control screen and the
fluid passageway; applying a pressure from a pressure source to a
sealing member positioned within the second annular region; and
operating the sealing member from a nonsealing position to a
sealing position such that fluid flow through the fluid passageway
is prevented.
60. The method as recited in claim 59 wherein the step of applying
a pressure from a pressure source to a sealing member positioned
within the second annular region further comprises applying the
pressure to a sliding sleeve.
61. The method as recited in claim 59 wherein the step of applying
a pressure from a pressure source to a sealing member positioned
within the second annular region further comprises applying the
pressure to an expandable bladder.
62. The method as recited in claim 59 wherein the step of applying
a pressure from a pressure source to a sealing member positioned
within the second annular region further comprises: applying the
pressure into a first chamber defined between a cylinder and the
housing section; shifting a piston positioned within the cylinder
and the housing section between the first chamber and a second
chamber; and forcing fluid from the second chamber into an
expandable bladder.
63. The method as recited in claim 59 wherein the step of applying
a pressure from a pressure source to a sealing member positioned
within the second annular region further comprises: applying the
pressure into a first chamber defined between a piston, the tubular
member and the housing section; shifting the piston such that the
volume of a second chamber defined between the piston and the
housing section and that is in fluid isolation from the pressure
source is reduced.
64. The method as recited in claim 59 wherein the step of applying
a hydraulic pressure to a sealing member positioned within the
second annular region further comprises applying a hydraulic
pressure from a hydraulic control line extending from a surface
location to the sand control screen and passing the hydraulic
control line through the first annular region to extend the
hydraulic control line downhole of the sand control screen.
65. The method as recited in claim 59 wherein the step of applying
a hydraulic pressure to a sealing member positioned within the
second annular region further comprises applying a hydraulic
pressure from an annular region between the sand control screen and
the wellbore.
66. The method as recited in claim 59 wherein the step of applying
a hydraulic pressure to a sealing member positioned within the
second annular region further comprises operating a valve
positioned within a fluid communication path between the hydraulic
pressure source and the sealing member to selectively permit fluid
communication between the hydraulic pressure source and the sealing
member.
67. The method as recited in claim 66 wherein the step of operating
the valve further comprises melting a eutectic valve.
68. The method as recited in claim 59 further comprising the step
of sensing at least one downhole parameter selected from the group
comprising temperature, pressure and fluid composition with a
sensor positioned on the fluid flow control device.
69. The method as recited in claim 59 further comprising the step
of extending an energy conductor from a surface location to the
sand control screen, passing the energy conductor through the first
annular region and extending the energy conductor downhole of the
sand control screen.
70. The method as recited in claim 69 further comprising the step
of conducting electricity through the energy conductor.
71. The method as recited in claim 69 further comprising the step
of conducting light energy through the energy conductor.
72. The method as recited in claim 69 further comprising the step
of sending information relating to at least one downhole parameter
selected from the group comprising temperature and pressure to the
surface location from a location proximate the sand control screen
via the energy conductor.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation-in-part application of co-pending
application Ser. No. 10/227,935, entitled Fluid Flow Control Device
and Method for Use of Same, filed on Aug. 26, 2002.
TECHNICAL FIELD OF THE INVENTION
[0002] This invention relates, in general, to sand control and flow
control in a well that traverses a hydrocarbon bearing subterranean
formation and, in particular, to a fluid flow control device
including a sand control screen that selectively controls the
inflow of formation fluids.
BACKGROUND OF THE INVENTION
[0003] Without limiting the scope of the present invention, its
background will be described with reference to producing fluid from
a subterranean formation, as an example.
[0004] After drilling each of the sections of a subterranean
wellbore, individual lengths of relatively large diameter metal
tubulars are typically secured together to form a casing string
that is positioned within each section of the wellbore. This casing
string is used to increase the integrity of the wellbore by
preventing the wall of the hole from caving in. In addition, the
casing string prevents movement of fluids from one formation to
another formation. Conventionally, each section of the casing
string is cemented within the wellbore before the next section of
the wellbore is drilled.
[0005] Once this well construction process is finished, the
completion process may begin. The completion process comprises
numerous steps including creating hydraulic openings or
perforations through the production casing string, the cement and a
short distance into the desired formation or formations so that
production fluids may enter the interior of the wellbore. The
completion process may also include installing a production tubing
string within the well casing which is used to produce the well by
providing the conduit for formation fluids to travel from the
formation depth to the surface.
[0006] To selectively permit and prevent fluid flow into the
production tubing string, it is common practice to install one or
more sliding sleeve type flow control devices within the tubing
string. Typical sliding sleeve type flow control devices comprise a
generally tubular body portion having side wall inlet openings
formed therein and a tubular flow control sleeve coaxially and
slidably disposed within the body portion. The sleeve is operable
for axial movement relative to the body portion between a closed
position, in which the sleeve blocks the body inlet ports, and an
open position, in which the sleeve uncovers the ports to permit
fluid to flow inwardly therethrough into the interior of the body
and thus into the interior of the production tubing string. The
sliding sleeves thus function as movable valve elements operable to
selectively permit and prevent fluid inflow. Generally, cylindrical
shifter tools, coaxially lowered into the interior of the tubing
string, are utilized to shift selected ones of the sliding sleeves
from their closed positions to their open positions, or vice versa,
to provide subsurface flow control in the well.
[0007] It has been found, however, that typical sliding sleeve type
flow control devices are not suitable in completions requiring sand
control as they are not compatible with typical sand control
screens. Recently, a device has been proposed that combines sand
control and fluid flow control, which was disclosed in U.S. Pat.
No. 5,896,928. Specifically, the device includes a generally
tubular body for placement into the wellbore. The tubular body has
a sand control screen at an outer surface for preventing sand from
entering into tubular body. After the fluid flows through the sand
control screen it must pass through a labyrinth. A slidable sleeve
on the labyrinth controls the fluid velocity therethrough. The
slidable sleeve is moved by a remotely and electrically-operated
device placed in the tubular body. The fluid leaving the labyrinth
passes to the tubing string for carrying the fluid to the
surface.
[0008] It has been found, however, the labyrinth type flow control
devices are difficult and expensive to manufacture and can be
unreliable under certain inflow conditions. Accordingly, need has
arisen for a fluid flow control device for controlling the inflow
of formation fluids in a completion requiring sand control. A need
has also arisen for such a fluid flow control device that is not
difficult or expensive to manufacture. Further, a need has arisen
for such a fluid flow control device that is reliable in a variety
of flow conditions.
SUMMARY OF THE INVENTION
[0009] The present invention disclosed herein comprises a fluid
flow control device for controlling the inflow of formation fluids
in completions requiring sand control and a method for use of the
same. The fluid flow control device of the present invention is not
difficult or expensive to manufacture. In addition, the fluid flow
control device of the present invention is reliable in a variety of
flow conditions.
[0010] The fluid flow control device comprises a tubular member
having at least one fluid passageway in a sidewall section thereof.
A sand control screen is positioned exteriorly around the tubular
member. The sand control screen has a filter medium section that
defines a first annular region with the tubular member and a
housing section that defines a second annular region with the
tubular member that is adjacent to the fluid passageway.
[0011] A sealing member is positioned within the second annular
region. The sealing member has a first position wherein fluid flow
is permitted through the fluid passageway and a second position
wherein fluid flow is prevented through the fluid passageway. A
hydraulic pressure source is selectively in fluid communication
with the sealing member and is used to operate the sealing member
from the first position to the second position.
[0012] In one embodiment of the present invention, the sealing
member is a sliding sleeve. In another embodiment, the sealing
member is an expandable bladder. In embodiments using the
expandable bladder, the hydraulic pressure may be applied directly
to the interior of the expandable bladder. Alternatively, the fluid
flow control device may include a cylinder positioned within the
second annular region. Together, the cylinder and the housing
section form first and second chambers therebetween with the first
and second chambers having a piston therebetween. In this
configuration, the first chamber is selectively in fluid
communication with the hydraulic pressure source and the second
chamber is in fluid communication with the expandable bladder
sealing member.
[0013] In one embodiment, the hydraulic pressure source is a
control line extending from a surface location to the sand control
screen. The hydraulic control line has a first section with a
terminus that is selectively in fluid communication with the
sealing member. The hydraulic control line also has a second
section that passes through the first annular region and extends
downhole of the sand control screen. In another embodiment, the
pressure source is the wellbore fluid surrounding the sand control
screen in the wellbore.
[0014] The fluid flow control device may include a valve positioned
within a fluid communication path between the hydraulic pressure
source and the sealing member to selectively prevent and permit
fluid communication between the hydraulic pressure source and the
sealing member. In one embodiment, the valve is a eutectic valve.
In another embodiment the valve is a rupture disk. The fluid flow
control device may also include a sensor positioned on the fluid
flow control device to sense at least one downhole parameter such
as temperature, pressure, fluid composition and the like.
[0015] The fluid flow control device of the present invention may
further include an energy conductor that extends from a surface
location to the sand control screen. The energy conductor provides
power and communications to the sensor and the valve. The energy
conductor may pass through the first annular region and extend
downhole of the sand control screen. In one embodiment, the energy
conductor is an electrical conductor. In another embodiment, the
energy conductor is a fiber optic conductor. In this embodiment,
the fiber optic conductor may provide information relating to
downhole parameters, such as temperature and pressure, to the
surface location from a location proximate the sand control
screen.
[0016] In another aspect, the present invention comprises a system
for controlling production fluid flow in a wellbore that comprises
first and second sand control screens in a sand control screen
assembly positioned within the wellbore. A hydraulic fluid conduit
is coupled to the first and second sand control screens such that
increasing the pressure within the hydraulic fluid conduit to a
first predetermined level prevents production fluid flow through
the first sand control screen and increasing the pressure within
the hydraulic fluid conduit to a second predetermined level that is
greater than the first predetermined level prevents production
fluid flow through the second sand control screen.
[0017] In one embodiment, the first sand control screen may have a
rupture disk operably associated therewith that bursts at a
pressure less than the first predetermined level. In this
embodiment, the second sand control screen may have a rupture disk
operably associated therewith that bursts at a pressure between the
first predetermined level the second predetermined level.
[0018] In yet another aspect, the present invention comprises a
system for controlling production fluid flow in a wellbore that
comprises first and second flow control devices positioned within
the wellbore. A hydraulic fluid conduit is coupled to the first and
second flow control devices such that increasing the pressure
within the hydraulic fluid conduit to a first predetermined level
prevents production fluid flow through the first flow control
device and increasing the pressure within the hydraulic fluid
conduit to a second predetermined level that is greater than the
first predetermined level prevents production fluid flow through
the second flow control device.
[0019] In a further aspect, the present invention comprises a
system for controlling production fluid flow in a wellbore that
comprises first and second sand control screens in a sand control
screen assembly positioned within the wellbore. A hydraulic fluid
conduit is coupled to the first and second sand control screens. An
energy conductor is coupled to the first and second sand control
screens. The energy conductor provides a signal to open a valve
operably associated with the first sand control screen such that
hydraulic pressure is communicated from the hydraulic fluid conduit
to the first sand control screen to prevent production fluid flow
therethrough. Likewise, the energy conductor provides a signal to
open a valve operably associated with the second sand control
screen such that hydraulic pressure is communicated from the
hydraulic fluid conduit to the second sand control screen to
prevent production fluid flow therethrough.
[0020] In another aspect, the present invention comprises a system
for controlling production fluid flow in a wellbore that comprises
first and second flow control devices positioned within the
wellbore. A hydraulic fluid conduit is coupled to the first and
second flow control devices. An energy conductor is coupled to the
first and second flow control devices. The energy conductor
provides a signal to open a valve operably associated with the
first flow control device such that hydraulic pressure is
communicated from the hydraulic fluid conduit to the first flow
control device to prevent production fluid flow therethrough.
Likewise, the energy conductor provides a signal to open a valve
operably associated with the second flow control device such that
hydraulic pressure is communicated from the hydraulic fluid conduit
to the second flow control device to prevent production fluid flow
therethrough.
[0021] The present invention also comprises a method for
controlling production fluid flow through multiple sand control
screens in a sand control screen assembly positioned within a
wellbore that involves coupling a hydraulic fluid conduit to the
multiple sand control screens in the sand control screen assembly,
increasing the pressure within the hydraulic fluid conduit to a
first predetermined level to prevent production fluid flow through
a first sand control screen and increasing the pressure within the
hydraulic fluid conduit to a second predetermined level that is
greater than the first predetermined level to prevent production
fluid flow through a second sand control screen.
[0022] The present invention further comprises a method for
controlling production fluid flow through multiple flow control
devices positioned within a wellbore that involves coupling a
hydraulic fluid conduit to the multiple flow control devices,
increasing the pressure within the hydraulic fluid conduit to a
first predetermined level to prevent production fluid flow through
a first flow control device and increasing the pressure within the
hydraulic fluid conduit to a second predetermined level that is
greater than the first predetermined level to prevent production
fluid flow through a second flow control device.
[0023] In addition, the present invention comprises a method for
controlling production fluid flow through multiple sand control
screens in a sand control screen assembly positioned within a
wellbore that involves coupling a hydraulic fluid conduit to the
multiple sand control screens in the sand control screen assembly,
coupling an energy conductor to the multiple sand control screens
in the sand control screen assembly, signaling a valve operably
associated with a first sand control screen to actuate to an open
position via the energy conductor, communicating hydraulic pressure
from the hydraulic fluid conduit to the first sand control screen
to prevent production fluid flow therethrough, signaling a valve
operably associated with a second sand control screen to actuate to
an open position via the energy conductor and communicating
hydraulic pressure from the hydraulic fluid conduit to the second
sand control screen to prevent production fluid flow
therethrough.
[0024] Further, the present invention comprises a method for
controlling production fluid flow through multiple flow control
devices positioned within a wellbore that involves coupling a
hydraulic fluid conduit to the multiple flow control devices,
coupling an energy conductor to the multiple flow control devices,
signaling a valve operably associated with a first flow control
device to actuate to an open position via the energy conductor,
communicating hydraulic pressure from the hydraulic fluid conduit
to the first flow control device to prevent production fluid flow
therethrough, signaling a valve operably associated with a second
flow control device to actuate to an open position via the energy
conductor and communicating hydraulic pressure from the hydraulic
fluid conduit to the second flow control device to prevent
production fluid flow therethrough.
[0025] In another aspect, the present invention involves a method
for controlling the flow of production fluids through a fluid flow
control device. The method comprises positioning the fluid flow
control device downhole, the fluid flow control device including a
tubular member having at least one fluid passageway and a sand
control screen positioned exteriorly around the tubular member, the
sand control screen having a filter medium section defining a first
annular region with the tubular member and a housing section
defining a second annular region with the tubular member adjacent
to the fluid passageway. The method also involves flowing fluid
through the sand control screen and the fluid passageway, applying
a hydraulic pressure to a sealing member positioned within the
second annular region and operating the sealing member from a
nonsealing position to a sealing position when it is desirable to
prevent fluid flow through the fluid passageway.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] For a more complete understanding of the features and
advantages of the present invention, reference is now made to the
detailed description of the invention along with the accompanying
figures in which corresponding numerals in the different figures
refer to corresponding parts and in which:
[0027] FIG. 1 is a schematic illustration of an offshore oil and
gas platform operating a plurality of fluid flow control devices
according to the present invention;
[0028] FIG. 2 is a half sectional view of a fluid flow control
device according to the present invention positioned in its fully
open position;
[0029] FIG. 3 is a half sectional view of a fluid flow control
device according to the present invention positioned in a choking
position;
[0030] FIG. 4 is a half sectional view of a fluid flow control
device according to the present invention positioned in a choking
position;
[0031] FIG. 5 is a half sectional view of a fluid flow control
device according to the present invention positioned in a choking
position;
[0032] FIG. 6 is a half sectional view of a fluid flow control
device according to the present invention positioned in its fully
closed position;
[0033] FIG. 7 is a half sectional view of a fluid flow control
device according to the present invention positioned in its fully
open position;
[0034] FIG. 8 is a half sectional view of a fluid flow control
device according to the present invention positioned in its open
position;
[0035] FIG. 9 is a half sectional view of a fluid flow control
device according to the present invention positioned in its closed
positions;
[0036] FIG. 10 is a half sectional view of a fluid flow control
device according to the present invention having a sleeve
positioned exteriorly of the base pipe and positioned in its open
position;
[0037] FIG. 11 is a half sectional view of a fluid flow control
device according to the present invention positioned in its open
position;
[0038] FIG. 12 is a half sectional view of a fluid flow control
device according to the present invention positioned in its closed
positions;
[0039] FIG. 13 is a half sectional view of a fluid flow control
device according to the present invention positioned in its open
position;
[0040] FIG. 14 is a half sectional view of a fluid flow control
device according to the present invention positioned in its closed
positions;
[0041] FIG. 15 is a half sectional view of a fluid flow control
device according to the present invention positioned in its open
position; and
[0042] FIG. 16 is a half sectional view of a fluid flow control
device according to the present invention positioned in its closed
positions.
DETAILED DESCRIPTION OF THE INVENTION
[0043] While the making and using of various embodiments of the
present invention are discussed in detail below, it should be
appreciated that the present invention provides many applicable
inventive concepts which can be embodied in a wide variety of
specific contexts. The specific embodiments discussed herein are
merely illustrative of specific ways to make and use the invention,
and do not delimit the scope of the present invention.
[0044] Referring initially to FIG. 1, an offshore oil and gas
platform operating a plurality of fluid flow control devices is
schematically illustrated and generally designated 10. A
semi-submersible platform 12 is centered over submerged oil and gas
formations 14, 16 located below sea floor 18. A subsea conduit 20
extends from a wellhead installation 22 to a subsea installation
24. A wellbore 26 extends through the various earth strata
including formations 14, 16. A casing string 28 is cemented within
wellbore 26 by cement 30. Casing string 28 includes perforations 32
and perforations 34 that respectively allow formation fluids from
formations 14, 16 to enter the interior of casing string 28.
[0045] Positioned within casing string 28 and extending from
wellhead installation 22 is a tubing string 36. Tubing string 36
provides a conduit for formation fluids to travel from formations
14, 16 to the surface. A pair of packers 38, 40 provide a fluid
seal between tubing string 36 and casing string 28 and define a
production interval adjacent to formation 14. Likewise, packers 42,
44 provide a fluid seal between tubing string 36 and casing string
28 and define a production interval adjacent to formation 16.
[0046] Positioned within tubing string 36 in the production
interval adjacent to formation 14 are fluid flow control devices
46, 48 and 50. Likewise, positioned within tubing string 36 within
the production interval adjacent to formation 16 are fluid flow
control devices 52, 54 and 56. As explained in greater detail
below, each of the fluid flow control devices 46-56 may provide not
only fluid flow control capability but also sand control
capability. In those cases, fluid flow control devices 46-50 and
fluid flow control devices 52-56 represent multiple sand control
screens in a sand control screen assembly.
[0047] In the illustrated embodiment, there are three fluid flow
control devices 46, 48, 50 associated with formation 14 and three
fluid control devices 52, 54, 56 associated with formation 16.
Accordingly, the inflow of fluid from formation 14 and formation 16
may be controlled. For example, if the reservoir pressure of
formation 14 is significantly higher than the reservoir pressure of
formation 16, fluid flow control devices 46, 48, 50 may be used to
choke the fluid flow from formation 14 to a greater extent than
fluid flow control devices 52, 54, 56 will choke the fluid flow
from formation 16. In addition, the fluid flow control devices of
the present invention are independently controllable within each
production interval via one or more control conduits 58 that extend
from the surface to each of the flow control devices 46-56. For
example, certain ones of fluid flow control devices 46, 48, 50 may
be used to choke or even close off certain sections of the
production interval adjacent to formation 14 to prevent the
production of water or other undesirable fluids. Similarly, one or
all of the fluid flow control devices associated with a particular
production interval may be adjusted over time as the adjacent
formation becomes depleted or as downhole equipment experiences
wear.
[0048] It should be understood by those skilled in the art that
even though FIG. 1 has depicted three fluid flow control devices
associated with each production interval, any number of fluid flow
control devices either greater than or less than three may
alternatively be used without departing from the principles of the
present invention. Also, even though FIG. 1 has depicted a vertical
wellbore, the fluid flow control devices of the present invention
are equally well suited for use in wellbores having other
directional configuration such as incline wellbores, deviated
wellbores or horizontal wellbores.
[0049] It should be understood by those skilled in the art that
even though FIG. 1 has depicted an offshore production operation,
the fluid flow control devices of the present invention are equally
well suited for onshore operations. Also, even though FIG. 1 has
depicted a cased wellbore, the fluid flow control devices of the
present invention are equally well suited for use in open hole
completions. Further, even though FIG. 1 has depicted a single
wellbore 26, it should be understood by those skilled in the art
that the fluid flow control devices of the present invention are
equally well suited for use in wellbores having other
configurations such as wellbores having multilateral
configurations. For example, one of the flow control devices of the
present invention may be positioned proximate the junction in a
primary completion string with additional flow control devices of
the present invention positioned adjacent to production intervals
traversed by the main wellbore. In this case, fluids from the
branch wellbore flow through the flow control device into the
primary completion string at the junction and are commingled with
fluids from the other production intervals traversed by the main
wellbore. As explained in greater detail below, the inflow into the
primary completion string from the intervals traversed by the main
wellbore as well as the branch wellbore may be controlled by
operating the various fluid flow control devices of the present
invention.
[0050] Referring next to FIG. 2, a fluid flow control device of the
present invention is depicted and generally designated 60. Fluid
flow control device 60 includes a sand control screen 62. Sand
control screen 62 includes a base pipe 64 that has a plurality of
openings 66 that allow the flow of production fluids into the
production tubing. Even though openings 66 are depicted as round
openings, it should be understood by those skilled in the art that
openings of other configurations may alternatively be used and are
considered within the scope of the present invention. For example,
openings 66 could alternatively have a non circular shape such as
an oval shape, a square shape, a rectangular shape or other similar
shapes. Accordingly, the term openings as used herein is intended
to encompass any type of discontinuity in base pipe 64 that allows
for the flow of fluids therethrough including, but not limited to,
perforations, holes and slots of any configuration that are
presently known in the art or subsequently discovered. In addition,
the exact number and size of opening 66 are not critical to the
present invention, so long as sufficient area is provided for fluid
production and the integrity of base pipe 64 is maintained.
Openings 66 form a particular hole pattern in base pipe 64, the
importance of which will be explained in more detail below.
[0051] Positioned around base pipe 64 is a filter medium 68. In the
illustrated embodiment, filter medium 68 is a fluid-porous,
particulate restricting material such as a plurality of layers of a
wire mesh that are diffusion bonded or sintered together to form a
porous wire mesh screen designed to allow fluid flow therethrough
but prevent the flow of particulate materials of a predetermined
size from passing therethrough. Disposed around filter medium 68 is
an outer shroud 70. Outer shroud 70 has a plurality of openings 72
which allow the flow of production fluids therethrough. The exact
number, size and shape of openings 72 are not critical to the
present invention, so long as sufficient area is provided for fluid
production and the integrity of outer shroud 70 is maintained.
Outer shroud 70 is designed to protect filter medium 68 during
installation of fluid flow control device 60 into the wellbore as
well as during production therethrough.
[0052] Positioned coaxially within base pipe 64 is a sleeve 74.
Sleeve 74 is slidable coupled within base pipe 64 using detents
such as collets or pins (not pictured) or other suitable devices
that are well known to those skilled in the art. Sleeve 74 has a
plurality of openings 76. As with openings 66 of base pipe 64,
openings 76 of sleeve 74 may have any geometric configuration that
is suitable for allowing the flow of production fluids
therethrough. While the illustrated embodiment depicts openings 76
of sleeve 74 as having the same shape and size as openings 66 of
base pipe 64, this relationship is not required by the present
invention. For example, a fluid flow control device of the present
invention could have slotted openings in sleeve 74 while having
round openings in base pipe 64. In the illustrated embodiment, the
hole pattern of openings 66 of base pipe 64 and openings 76 of
sleeve 74 have substantially the same geometry. In addition,
openings 66 of base pipe 64 and openings 76 of sleeve 74 are
substantially aligned with one another. Accordingly, when fluid
flow control device 60 is in the depicted configuration, the
pressure drop in the production fluids traveling therethrough is at
a minimum and fluid flow control device 60 is considered to be in
its fully opened position. Specifically, to enter in the interior
of fluid flow control device 60, the fluid must travel through an
entry opening, one of the openings 66 of base pipe 64, an annulus
78 between base pipe 64 and sleeve 74 and an exit opening, one of
the openings 76 of sleeve 74. As openings 66 of base pipe 64 and
openings 76 of sleeve 74 are substantially aligned with one
another, the distance the fluid is required to flow in annulus 78
is at a minimum.
[0053] Referring now to FIG. 3, therein is depicted a fluid flow
control device of the present invention that is generally
designated 80. The construction of fluid flow control device 80 is
substantially identical to the construction of fluid flow control
device 60 of FIG. 2. Fluid flow control device 80 is operated using
a mechanical shifter 82 that may be carried downhole on a wireline
84. To allow shifter tool 84 to interact with sleeve 74, the
interior side surfaces of sleeve 74 may have formed therein a
longitudinally spaced series of annular, traversed notches, that
receive a key set carried on mechanical shifter 82. Once mechanical
shifter 82 is received by sleeve 74, sleeve 74 may be slidably
shifted in the axial direction as can be seen by comparing the
position of sleeve 74 relative to base pipe 64 in FIGS. 2 and
3.
[0054] In the illustrated embodiment, sleeve 74 has been axially
repositioned to increase the pressure drop experienced by
production fluids traveling through annulus 78. Specifically, as
the set of openings 66 of base pipe 64 and the set of openings 76
of sleeve 74 have substantially the same hole pattern, when
openings 66 and openings 76 are axially misaligned, the distance
the formation fluids must travel within annulus 78 is increased,
thereby increasing the pressure drop in the formation fluids. The
amount of this pressure drop or choking is determined based upon a
number of factors including the extent of the misalignment of
openings 66 relative to openings 76, the thickness of annulus 78,
the viscosity of the formation fluids and the like. In addition,
the surface characteristics of either the exterior of sleeve 74 or
the interior of base pipe 64 or both may be configured to further
control the pressure drop. For example, grooves, channels,
knurling, other turbulizing surfaces or the like may be added to
one or both of the surfaces to increase the turbulence in the fluid
flow thereby increasing the pressure drop across a given distance.
Accordingly, once fluid flow control device 80 is installed
downhole, the desired amount of pressure drop may be obtained by
selectively misaligning openings 66 relative to openings 76 by
axially shifting sleeve 74 relative to base pipe 64. Also, it
should be noted that sensors, such as position sensors, pressure
sensors, temperature sensors, fluid composition sensors and the
like may be used in conjunction with mechanical shifter 82 to
determined the desired extent of the misaligning of openings 66
relative to openings 76, as explained in greater detail below.
[0055] Referring next to FIG. 4, therein is depicted a fluid flow
control device of the present invention that is generally
designated 90. Fluid flow control device 90 is constructed in a
manner substantially identical to fluid flow control device 60 of
FIG. 2. In the illustrated embodiment, fluid flow control device 90
is operated by an electromechanical shifter 92 that is run downhole
on an electric line 94. Electromechanical shifter 94 may be
received within sleeve 74 in a manner similar to that described
above with reference to mechanical shifter 82 of FIG. 3. Once in
place, electromechanical shifter 92 may be energized via electric
line 94 such that sleeve 74 may be rotatably shifted relative to
base pipe 64.
[0056] In the illustrated embodiment, sleeve 74 has been rotated
ninety degrees relative to base pipe 64. This rotation increases
the distance between openings 76 of sleeve 74 and openings 66 of
base pipe 64. Accordingly, the formation fluid being produced into
fluid flow control device 90 must travel an increased distance in
annulus 78 relative to the position shown in FIG. 2. This increased
distance equates to an increased pressure drop in the formation
fluids. The desired amount of pressure drop may be achieved by
selecting the amount of circumferential misalignment between
openings 76 of sleeve 74 and openings 66 of base pipe 64. Also, it
should be noted that sensors, such as position sensors, pressure
sensors, temperature sensors, fluid composition sensors and the
like may be used in conjunction with electromechanical shifter 92,
these sensors may be permanently disposed downhole or may be
carried downhole with the electromechanical shifter 92.
[0057] Referring next to FIG. 5, therein is depicted a fluid flow
control device of the present invention that is generally
designated 100. Fluid flow control device 100 is constructed in
substantially the same manner as fluid flow control device 60 of
FIG. 2. Fluid flow control device 100 is operated using a downhole
electrical motor 102 that is positioned within annulus 78 between
sleeve 74 and base pipe 64. Downhole electrical motor 102 receives
power from energy conductors 104 that may extend to the surface or
may extend to a downhole electrical power source such as a battery
pack or a downhole electrical generator. Downhole electrical motor
102 includes a control circuit that commands downhole electrical
motor 102 to shift sleeve 74 relative to base pipe 64 when it is
desirable to adjust the pressure drop in the production fluids
being produced therethrough. A pair of pressure sensors 106, 108
are used to monitor the pressure on the exterior of fluid flow
control device 100 and the pressure on the interior of fluid flow
control device 100, respectively.
[0058] The pressure information may be carried to the surface via
energy conductors 104 where it may be processed then command
signals may be returned to the control circuit of downhole
electrical motor 102 via energy conductors 104 to initiate the
operation of downhole electrical motor 102. Alternatively, the
pressure information may be sent directly to the control circuit of
downhole electrical motor 102 from pressure sensors 106, 108 to
initiate operation of downhole electrical motor 102. Additionally,
sleeve 74 may include a position sensor that identifies the
relative position of sleeve 74 and base pipe 64 to further refine
the operation of shifting sleeve 74. The position sensor may be
powered by energy conductors 104 and may send signals to the
surface or directly to the control circuit of downhole electric
motor 102.
[0059] In the illustrated embodiment, downhole electrical motor 102
is operable to axially adjust the position of sleeve 74 relative to
base pipe 64 and rotatably adjust the position of sleeve 74
relative to base pipe 64. By comparing FIGS. 2 and 5, it can be
seen that sleeve 74 has been axially and rotatably adjusted
relative to base pipe 64. Accordingly, the distance between
openings 76 of sleeve 74 and openings 66 of base pipe 64 has been
increased, which in turn increases the distance the production
fluids must travel in annulus 78 resulting in an increase in the
pressure drop in the production fluids. This embodiment of fluid
flow control device 100 is particularly suitable for precision
control of the pressure drop due to the interaction of pressure
sensors 106, 108, the position sensor and the control circuit of
downhole electrical motor 102.
[0060] Referring now to FIG. 6, therein is depicted another
embodiment of a fluid flow control device of the present invention
that is generally designated 110. Fluid flow control device 110 is
constructed in substantially the same manner as fluid flow control
device 60 of FIG. 2 with the exception that fluid flow control
device 110 includes a plurality of seals 112 carried by base pipe
64. The operation of fluid flow control device 110 is hydraulically
controlled in a conventional manner by increasing and decreasing
the pressure within hydraulic control lines 114, 116 which allows
sleeve 74 to axially shift relative base pipe 64. As described
above, as openings 76 of sleeve 74 become misaligned with openings
66 of base pipe 64, the pressure drop in the formation fluids being
produced therethrough increases. In the illustrated embodiment,
however, when sleeve 74 is shifted to the illustrated position
relative to base pipe 64, fluid production through fluid flow
control device 110 is prevented as each of the openings 76 of
sleeve 74 are positioned between a pair of seals 112. Accordingly,
fluid flow control device 110 can be operated from a fully opened
position (see FIG. 2) to a fully closed positioned as well as
various choking positions therebetween.
[0061] Referring next to FIG. 7, therein is depicted a fluid flow
control device of the present invention that is generally
designated 120. Fluid flow control device 120 is constructed in
substantially the same manner as fluid flow control device 60 of
FIG. 2, however, sleeve 74 as depicted in FIG. 2 has been replaced
with sleeve 122. Sleeve 122 includes a plurality of openings 124
that form a hole pattern with a geometry that is different from the
hole pattern of openings 66 of base pipe 64. Fluid flow control
device 120 is operated using a downhole electrical motor 126 which
is operable to rotatably shift sleeve 122 relative to base pipe 64.
This rotation aligns the various columns of openings 124 of sleeve
122 with openings 66 of base pipe 64. In the illustrated
configuration, each opening 66 of base pipe 64 is aligned with an
opening 124 of sleeve 122. When sleeve 122 is rotated using
downhole electrical motor 126, however, some of the openings 66 of
base pipe 64 will no longer be aligned with an opening 124 of
sleeve 122. Accordingly, the pressure drop in the production fluids
is controlled by adjusting the relative alignment of openings 124
of sleeve 122 with openings 66 of base pipe 64.
[0062] Referring now to FIG. 8, therein is depicted another
embodiment of a fluid flow control device of the present invention
that is generally designated 130. Fluid flow control device 130
includes a sand control screen 132. Sand control screen 132
includes a base pipe 134 that has a series of openings 136 that are
circumferentially spaced therearound. Sand control screen 132 has a
pair of screen connectors 138, 140 that attach a sand control
screen 142 to base pipe 134. Screen connectors 138, 140 may be
attached to base pipe 134 by welding or other suitable technique.
Sand control screen 142 may comprise a screen wire wrapped around a
plurality of ribs to form turns having gaps therebetween which
allow the flow of formation fluids therethrough but which block the
flow of particulate matter therethrough. The number of turns and
the size of the gaps between the turns are determined based upon
the characteristics of the formation from which fluid is being
produced and the size of the gravel to be used during a gravel
packing operation, if any.
[0063] Screen connectors 138, 140 attach sand control screen 142 to
base pipe 134 such that an annulus 144 is formed between sand
control screen 142 and base pipe 134. It should be noted that
centralizers or other support members may be disposed within
annulus 144 to support sand control screen 142 and maintain the
standoff between sand control screen 142 and base pipe 134. Coupled
to the upper end of screen connector 140 is a housing member 146.
Housing member 146 forms an annulus 148 with base pipe 134 adjacent
to openings 136. Disposed within annulus 148 is a sliding sleeve
150 having a collet member on its lower end and having a pair of
seals 151 disposed on the interior side thereof to provide a seal
against base pipe 134 and a pair of seals 153 disposed on the
exterior side thereof to provide a seal against housing member
146.
[0064] Disposed exteriorly of base pipe 134 and extending from the
surface is a hydraulic fluid conduit 152. One portion of hydraulic
fluid conduit 152 extends into a fluid passageway 154 within
housing member 146. Disposed within fluid passageway 154 is a valve
156, such as a eutectic valve, a rupture disk or the like. Another
portion of hydraulic fluid conduit 152 extends into and through
housing member 146 and screen connector 140 into annulus 144. This
portion of hydraulic fluid conduit 152 extends through annulus 144
to exit sand control screen 132 through screen connector 138.
[0065] Importantly, this portion of hydraulic fluid conduit 152
runs within a recess or channel in housing member 146 and on the
inside of sand control screen 142, instead of the outside of sand
control screen 142, which removes the need to band hydraulic fluid
conduit 152 to the exterior of sand control screen 142 which would
block the inflow of formation fluids through those portions of sand
control screen 142 covered by the banding material. Also, this
portion of hydraulic fluid conduit 152 is protected by having sand
control screen 142 positioned exteriorly thereof. Alternatively,
the channel on the exterior of housing member 146 could be extended
along the exterior of sand control screen 142 such that hydraulic
fluid conduit 152 could be positioned within the channel for
protection. As can be seen in FIG. 8, hydraulic fluid conduit 152
is capable of providing operating fluid to fluid flow control
device 130 and is also capable of providing operating fluid to
other devices downhole of fluid flow control device 130 such as
additional fluid flow control devices positioned further
downhole.
[0066] For example, in the case of valves 156 being rupture disks,
the burst rating of the rupture disks for the various flow control
devices may be selected such that the flow control devices may be
sequentially or selectively operated from their open to their
closed positions by incrementally increasing the pressure within
hydraulic fluid conduit 152 to various preselected levels. In a
substantially vertical well, the burst rating for the rupture disks
may be progressively increased for each flow control device from
the downhole end of an interval to the uphole end of an interval.
Likewise, a substantially horizontal well, the burst rating for the
rupture disks may be progressively increased for each flow control
device from the heal to the toe of the interval. In this example,
the production profile within an interval and within the wellbore
is entirely controlled by varying the hydraulic pressure within
hydraulic fluid conduit 152.
[0067] In the illustrated embodiment, a sensor 158 is positioned on
the exterior of housing member 146. Sensor 158 may provide
information relating to a variety of downhole parameters such as
pressure, temperature, fluid composition or the like. Sensor 158 is
in communication with the surface via energy conductors 160. Energy
conductors 160 may provide power and communication capabilities to
sensor 158 as well as to valve 156. Alternatively, sensors 158 may
be powered by a downhole power source such as a battery, downhole
generator or the like. Likewise, communication between sensors 158
and the surface could be achieved using a wireless telemetry system
such as acoustic telemetry, electromagnetic telemetry or the like.
In the illustrated embodiment and when valve 156 is a eutectic
valve, fluid flow control device 130 may be operated to the closed
position by conducting energy to valve 156 via energy conductors
160 to melt the eutectic material such that operating fluid from
hydraulic fluid conduit 152 may be communicated to sliding sleeve
150. Energy conductors 160 also extend through fluid flow control
device 130 in a manner similar to hydraulic fluid conduit 152 by
passing through housing member 146, screen connector 140, annulus
144 and screen connector 138 such that energy can be conducted to
melt the eutectic material of other valves 156 in other fluid flow
control devices either uphole or downhole of fluid flow control
device 130. Alternatively, instead of using sensor 158 to obtain
information relating to downhole parameters, energy conductors 160
may include a fiber optic cable which may be used to obtain certain
downhole parameters such as temperature and pressure at particular
locations.
[0068] In operation and referring both to FIGS. 8 and 9, fluid flow
control device 130 is used to filter particulate matter out of
production fluids and control the flow of fluids into the tubing
string. More specifically, when fluid flow control device 130 is in
its open position as depicted in FIG. 8, formation fluids are
produced through sand control screen 142 into annulus 144. These
formation fluids then travel upwardly through screen connector 140
that has a plurality of axially extending openings allowing the
formation fluids to pass into annulus 148 above screen connector
140. From annulus 148, fluid communication is allowed through
openings 136 such that the formation fluids may travel to the
surface via the tubing string.
[0069] If it is determined that production through fluid flow
control device 130 should no longer continue, fluid flow control
device 130 may be operated to its closed position as depicted in
FIG. 9. For example, if sensor 158 has sensed that the formation
fluids being produced through fluid flow control device 130 contain
an undesirable percentage of water, then a signal may be sent from
sensor 158 to the surface or directly to valve 156 via energy
conductors 160 indicating such a fluid composition. Thereafter,
power may be sent to valve 156 via energy conductors 160 and
through appropriate switching or addressing circuitry such that the
eutectic material of valve 156 is melted, thereby allowing fluid
communication through fluid passageway 154. Thereafter, operating
fluid from hydraulic fluid conduit 152 may act on sliding sleeve
150 such that openings 136 of base pipe 134 are no longer in
communication with annulus 148. Once in this configuration, fluid
flow control device 130 no longer permits formation fluids to flow
therethrough.
[0070] Referring now to FIG. 10, therein is depicted another
embodiment of a fluid flow control device of the present invention
that is generally designated 170. Fluid flow control device 170
includes a sand control screen 172. Sand control screen 172
includes a base pipe 174 that has a series of openings 176. Sand
control screen 172 also has a screen support member 178 that is
attached by welding or other suitable technique at opposite ends to
base pipe 174 and has a series of openings 180. The filter media of
sand control screen 172 is depicted as a wire wrapped screen 182
such as that described above with reference to FIG. 8.
[0071] Unlike the previously disclosed fluid flow control devices,
fluid flow control device 170 is constructed with a sleeve 184
coaxially positioned exteriorly of base pipe 174. Sleeve 184 has a
plurality of openings 186 that have substantially the same geometry
as openings 176 of base pipe 174. In the illustrated embodiment,
sleeve 184 is closely received around base pipe 174 such that there
is a friction fit therebetween. This friction fit can operate
substantially as a seal to provide significant resistance to flow
between sleeve 184 and base pipe 174 when openings 186 are not
aligned with openings 176. Alternatively, an annulus may be formed
between sleeve 184 and base pipe 174 operating substantially as
annulus 78 discussed above. The operation of fluid flow control
device 170 is hydraulically controlled in a conventional manner by
increasing and decreasing the pressure within hydraulic control
lines 188, 190 which allows sleeve 184 to axially shift relative
base pipe 174.
[0072] Referring now to FIG. 11, therein is depicted another
embodiment of a fluid flow control device of the present invention
that is generally designated 200. Fluid flow control device 200
includes a sand control screen 202. Sand control screen 202
includes a base pipe 204 that has a series of openings 206 that are
circumferentially spaced therearound. Sand control screen 202 has a
pair of screen connectors 208, 210 that attach sand control screen
212 to base pipe 204. Screen connectors 208, 210 may be attached to
base pipe 204 by welding or other suitable technique. Sand control
screen 212 may comprise any type of filter medium such as the
depicted wire wrapped screen which allows the flow of formation
fluids therethrough but which blocks the flow of particulate matter
therethrough.
[0073] Screen connectors 208, 210 attach sand control screen 212 to
base pipe 204 such that an annulus 214 is formed between sand
control screen 212 and base pipe 204. Coupled to the upper end of
screen connector 210 is a housing member 216. Housing member 216
forms an annulus 218 with base pipe 204 adjacent to openings 206.
Disposed within annulus 218 is an expandable bladder sealing member
220 that is selectively expandable to provide an annular seal
between the exterior of base pipe 204 and interior of housing
member 216.
[0074] Disposed exteriorly of base pipe 204 and extending from the
surface is a hydraulic fluid conduit 222. One portion of hydraulic
fluid conduit 222 extends into a fluid passageway 224 within
housing member 216. Disposed within fluid passageway 224 is a valve
226, such as a eutectic valve, a rupture disk or the like. Another
portion of hydraulic fluid conduit 222 extends into and through
housing member 216 and screen connector 210 into annulus 214. This
portion of hydraulic fluid conduit 222 extends through annulus 214
to exit sand control screen 202 through screen connector 208.
[0075] A sensor 228 is positioned on the exterior of housing member
216. Sensor 228 may provide information relating to a variety of
downhole parameters such as pressure, temperature, fluid
composition or the like. Sensor 228 is in communication with the
surface via energy conductors 230. Energy conductors 230 may
provide power and communication capabilities to sensor 228 as well
as to valve 226. More specifically, energy conductors 230 may
provide communications and power to open valve 226 such that
operating fluid from hydraulic fluid conduit 222 may be
communicated to expandable bladder sealing member 220 when it is
desirable to operate fluid flow control device 200 from the open
position to the closed position. Energy conductors 230 also extend
through fluid flow control device 200 in a manner similar to
hydraulic fluid conduit 222 by passing through housing member 216,
screen connector 210, annulus 214 and screen connector 208.
[0076] In operation and referring both to FIGS. 11 and 12, fluid
flow control device 200 is used to filter particulate matter out of
production fluids and control the flow of fluids into the tubing
string. More specifically, when fluid flow control device 200 is in
its open position as depicted in FIG. 11, formation fluids are
produced through sand control screen 212 into annulus 214. These
formation fluids then travel upwardly through screen connector 210
that has a plurality of axially extending openings allowing the
formation fluids to pass into annulus 218 above screen connector
210. From annulus 218, fluid communication is allowed through
openings 206 such that the formation fluids may travel to the
surface via the tubing string.
[0077] If it is determined that production through fluid flow
control device 200 should no longer continue, fluid flow control
device 200 may be operated to its closed position as depicted in
FIG. 12. For example, if sensor 228 has sensed that the formation
fluids being produced through fluid flow control device 200 contain
an undesirable percentage of water, then a signal may be sent from
sensor 228 to the surface or directly to valve 226 indicating such
a fluid composition. Valve 226 is then opened, thereby allowing
fluid communication through fluid passageway 224. Thereafter,
operating fluid from hydraulic fluid conduit 222 may enter the
interior of expandable bladder sealing member 220 such that
expandable bladder sealing member 220 is expanded to provide an
annular seal between the exterior of base pipe 204 and interior of
housing member 216 preventing fluid communication between openings
206 of base pipe 204 and annulus 218. Once fluid flow control
device 200 is in this configuration, it may be operated between the
open and closed positions by increasing and decreasing the fluid
pressure within hydraulic fluid conduit 222 above and below the
formation pressure exerted on the exterior of expandable bladder
220.
[0078] Referring now to FIG. 13, therein is depicted another
embodiment of a fluid flow control device of the present invention
that is generally designated 240. Fluid flow control device 240
includes a sand control screen 242. Sand control screen 242
includes a base pipe 244 that has a series of openings 246 that are
circumferentially spaced therearound. Sand control screen 242 has a
pair of screen connectors 248, 250 that attach sand control screen
252 to base pipe 244. Screen connectors 248, 250 may be attached to
base pipe 244 by welding or other suitable technique. Sand control
screen 252 may comprise any type of filter medium such as the
depicted wire wrapped screen which allows the flow of formation
fluids therethrough but which blocks the flow of particulate matter
therethrough.
[0079] Screen connectors 248, 250 attach sand control screen 252 to
base pipe 244 such that an annulus 254 is formed between sand
control screen 252 and base pipe 244. Coupled to the upper end of
screen connector 250 is a housing member 256. Housing member 256
forms an annulus 258 with base pipe 244 adjacent to openings 246.
Disposed within annulus 258 is a cylinder 260 and an expandable
bladder sealing member 262 that is selectively expandable to
provide an annular seal with the exterior of base pipe 244.
Disposed between cylinder 260 and housing member 256 is a piston
264 which defines a pair of chambers 266, 268 between cylinder 260
and housing member 256. Chamber 266 may initially be at atmospheric
pressure or prepressurized and may contain a compressible fluid
such as air or nitrogen, an incompressible fluid such as water or
hydraulic fluid or a combination thereof. Likewise, chamber 268 may
initially be at atmospheric pressure or prepressurized and may
contain a compressible fluid, an incompressible fluid or a
combination thereof.
[0080] Disposed exteriorly of base pipe 244 and extending from the
surface is a hydraulic fluid conduit 272. One portion of hydraulic
fluid conduit 272 extends into a fluid passageway 274 of cylinder
260. Disposed within fluid passageway 274 is a valve 276. Another
portion of hydraulic fluid conduit 272 extends into and through
housing member 256 and screen connector 250 into annulus 254. This
portion of hydraulic fluid conduit 272 extends through annulus 254
to exit sand control screen 242 through screen connector 248.
[0081] A sensor 278 is positioned on the exterior of housing member
256. Sensor 278 may provide information relating to a variety of
downhole parameters such as pressure, temperature, fluid
composition or the like. Sensor 278 is in communication with the
surface via energy conductors 280. Energy conductors 280 may
provide power and communication capabilities to sensor 278 as well
as to valve 276, such as a eutectic valve. More specifically,
energy conductors 280 may provide communications and power to open
valve 276 such that operating fluid from hydraulic fluid conduit
272 may be communicated to chamber 266 when it is desirable to
operate fluid flow control device 240 from the open position to the
closed position. Energy conductors 280 also extend through fluid
flow control device 240 in a manner similar to hydraulic fluid
conduit 272 by passing through housing member 256, screen connector
250, annulus 254 and screen connector 248. Alternatively, hydraulic
fluid pressure may be used to burst a rupture disk serving as valve
276 and likewise be communicated to chamber 266.
[0082] In operation and referring both to FIGS. 13 and 14, fluid
flow control device 240 is used to filter particulate matter out of
production fluids and control the flow of fluids into the tubing
string. More specifically, when fluid flow control device 240 is in
its open position as depicted in FIG. 13, formation fluids are
produced through sand control screen 252 into annulus 254. These
formation fluids then travel upwardly through screen connector 250
that has a plurality of axially extending openings allowing the
formation fluids to pass into annulus 258 above screen connector
250. From annulus 258, fluid communication is allowed through
openings 246 such that the formation fluids may travel to the
surface via the tubing string.
[0083] If it is determined that production through fluid flow
control device 240 should no longer continue, fluid flow control
device 240 may be operated to its closed position as depicted in
FIG. 14. For example, if sensor 278 has sensed that the formation
fluids being produced through fluid flow control device 240 contain
an undesirable percentage of water, then a signal may be sent from
sensor 278 to the surface or directly to valve 276 indicating such
a fluid composition. Valve 276 is then opened, thereby allowing
fluid communication through fluid passageway 274. Thereafter,
operating fluid from hydraulic fluid conduit 272 may enter chamber
266 and act on piston 264 to downwardly shift piston 264. The
downward movement of piston 264 forces the fluid within chamber 268
into the interior of expandable bladder sealing member 262 such
that expandable bladder sealing member 262 is expanded to provide
an annular seal with the exterior of base pipe 244 preventing fluid
communication between openings 246 of base pipe 244 and the portion
of annulus 258 below expandable bladder sealing member 262. Once
fluid flow control device 240 is in this configuration, it may be
operated between the open and closed positions by increasing and
decreasing the fluid pressure within hydraulic fluid conduit 272
above and below the formation pressure exerted on the exterior of
expandable bladder 262.
[0084] Referring now to FIG. 15, therein is depicted another
embodiment of a fluid flow control device of the present invention
that is generally designated 290. Fluid flow control device 290
includes a sand control screen 292. Sand control screen 292
includes a base pipe 294 that has a series of openings 296 that are
circumferentially spaced therearound. Sand control screen 292 has a
pair of screen connectors 298, 300 that attach sand control screen
302 to base pipe 294. Screen connectors 298, 300 may be attached to
base pipe 294 by welding or other suitable technique. Sand control
screen 302 may comprise any type of filter medium such as the
depicted wire wrapped screen which allows the flow of formation
fluids therethrough but which blocks the flow of particulate matter
therethrough.
[0085] Screen connectors 298, 300 attach sand control screen 302 to
base pipe 294 such that an annulus 304 is formed between sand
control screen 302 and base pipe 294. Coupled to the upper end of
screen connector 300 is a housing member 306. Housing member 306
forms an annulus 308 with base pipe 294 adjacent to openings 296.
Disposed within annulus 308 is a piston 310 and an annular sealing
member 312 that is selectively positionable against an annular seat
314. Piston 310 defines chambers 316, 318, 320. Chambers 316, 318
may initially contain a compressible fluid, an incompressible or a
combination thereof and is preferably at atmospheric pressure.
Chamber 320 is in communication with annulus 308 via port 322. A
fluid passageway 324 extends through housing member 306 having
valve 326 such as a eutectic valve positioned therein to
selectively permit and prevent fluid communication between chamber
316 and the well annulus. An energy conductors 328 may provide
power to valve 326 such that when it is desirable to operate fluid
flow control device 290 to the closed position, energy is conducted
to valve 326 via energy conductors 328 to melt the eutectic
material such that operating fluid from the well annulus may be
communicated to chamber 316. Energy conductors 328 also extend
through fluid flow control device 290 by passing through housing
member 302, screen connector 300, annulus 302 and screen connector
298.
[0086] In operation and referring both to FIGS. 15 and 16, fluid
flow control device 290 is used to filter particulate matter out of
production fluids and control the flow of fluids into the tubing
string. More specifically, when fluid flow control device 290 is in
its open position as depicted in FIG. 15, formation fluids are
produced through sand control screen 302 into annulus 304. These
formation fluids then travel upwardly through screen connector 300
that has a plurality of axially extending openings allowing the
formation fluids to pass into annulus 308 above screen connector
300. From annulus 308, fluid communication is allowed through
openings 296 such that the formation fluids may travel to the
surface via the tubing string.
[0087] If it is determined that production through fluid flow
control device 290 should no longer continue, fluid flow control
device 290 may be operated to its closed position as depicted in
FIG. 16 by opening valve 326, thereby allowing fluid communication
of through fluid passageway 324. Thereafter, formation fluids from
the well annulus may enter chamber 316 and act on piston 310 to
downwardly shift piston 310. The downward movement of piston 310
forces annular sealing member 312 against annular seat 314
preventing fluid communication between openings 296 of base pipe
294 and the portion of annulus 308 below annular sealing member
312. Once in this configuration, fluid flow control device 290 no
longer permits formation fluids to flow therethrough.
[0088] While this invention has been described with reference to
illustrative embodiments, this description is not intended to be
construed in a limiting sense. Various modifications and
combinations of the illustrative embodiments as well as other
embodiments of the invention, will be apparent to persons skilled
in the art upon reference to the description. It is, therefore,
intended that the appended claims encompass any such modifications
or embodiments.
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