U.S. patent application number 11/803835 was filed with the patent office on 2008-11-20 for apparatus for autonomously controlling the inflow of production fluids from a subterranean well.
Invention is credited to Travis T. Hailey, JR., William Mark Richards.
Application Number | 20080283238 11/803835 |
Document ID | / |
Family ID | 40010688 |
Filed Date | 2008-11-20 |
United States Patent
Application |
20080283238 |
Kind Code |
A1 |
Richards; William Mark ; et
al. |
November 20, 2008 |
Apparatus for autonomously controlling the inflow of production
fluids from a subterranean well
Abstract
A flow control apparatus (100) for controlling the inflow of
production fluids (134, 140) from a subterranean well includes a
tubular member (118) having at least one opening (138) that allows
fluid flow between an exterior of the tubular member (118) and an
interior flow path of the tubular member (118) and a flow
restricting device (120) operably positioned in a fluid flow path
between a fluid source and the at least one opening (138). The flow
restricting device (120) includes a valve (128, 130) and an
actuator (126). The actuator (126) includes a material that swells
in response to contact with an undesired fluid (140), such as water
or gas. The flow restricting device (120) is operable to
autonomously reduce the fluid flow through the flow control
apparatus (100) in response to contact between the material and the
undesired fluid (140).
Inventors: |
Richards; William Mark;
(Frisco, TX) ; Hailey, JR.; Travis T.; (Sugar
Land, TX) |
Correspondence
Address: |
LAWRENCE R. YOUST
2001 Ross Avenue, Suite 3000
DALLAS
TX
75201
US
|
Family ID: |
40010688 |
Appl. No.: |
11/803835 |
Filed: |
May 16, 2007 |
Current U.S.
Class: |
166/228 ;
166/205; 166/332.1 |
Current CPC
Class: |
E21B 43/12 20130101;
E21B 43/08 20130101; E21B 43/14 20130101; E21B 34/08 20130101; E21B
23/04 20130101 |
Class at
Publication: |
166/228 ;
166/205; 166/332.1 |
International
Class: |
E21B 34/14 20060101
E21B034/14; E21B 43/08 20060101 E21B043/08 |
Claims
1. A sand control screen positionable within a wellbore, the sand
control screen comprising: a base pipe having at least one opening
that allows fluid flow between an exterior of the base pipe and an
interior flow path of the base pipe; a filter medium positioned
exteriorly of the base pipe, the filter medium selectively allowing
fluid flow therethrough and preventing particulate flow of a
predetermined size therethrough; and a flow restricting device
operably positioned in a fluid flow path between the filter medium
and the at least one opening, the flow restricting device including
a valve and an actuator, the actuator including a material that
swells in response to contact with an undesired fluid such that the
flow restricting device is operable to autonomously reduce the
fluid flow through the screen in response to contact between the
material and the undesired fluid.
2. The sand control screen as recited in claim 1 wherein the fluid
flow through the screen is increasingly restricted in response to
contact between the material and the undesired fluid.
3. The sand control screen as recited in claim 1 wherein the fluid
flow through the screen is substantially completely restricted in
response to contact between the material and the undesired
fluid.
4. The sand control screen as recited in claim 1 wherein the
undesired fluid is water.
5. The sand control screen as recited in claim 1 wherein the
undesired fluid is gas.
6. The sand control screen as recited in claim 1 wherein the valve
further comprises a sliding sleeve.
7. The sand control screen as recited in claim 1 wherein the valve
further comprises a longitudinally shiftable valve element.
8. The sand control screen as recited in claim 1 wherein the valve
further comprises a valve element having a fluid flow passageway
with a cross sectional area that is reduced in response to contact
between the material and the undesired fluid.
9. The sand control screen as recited in claim 1 wherein the
actuator further comprises a biasing member that biases a valve
element in a first direction and wherein the material prevents
movement of the valve element in the first direction until the
material is contacted by the undesired fluid.
10. The sand control screen as recited in claim 1 wherein the
material remains in a swelled state as long as the material stays
in contact with the undesired fluid and returns to an unswelled
state when contact with the undesired fluid ceases.
11. A flow control apparatus for controlling the inflow of
production fluids from a subterranean well, the flow control
apparatus comprising: a tubular member having at least one opening
that allows fluid flow between an exterior of the tubular member
and an interior flow path of the tubular member; and a flow
restricting device operably positioned in a fluid flow path between
a fluid source and the at least one opening, the flow restricting
device including a valve and an actuator, the actuator including a
material that swells in response to contact with an undesired fluid
such that the flow restricting device is operable to autonomously
reduce the fluid flow through the flow control apparatus in
response to contact between the material and the undesired
fluid.
12. The flow control apparatus as recited in claim 11 wherein the
fluid flow through the flow control apparatus is increasingly
restricted in response to contact between the material and the
undesired fluid.
13. The flow control apparatus as recited in claim 11 wherein the
fluid flow through the flow control apparatus is substantially
completely restricted in response to contact between the material
and the undesired fluid.
14. The flow control apparatus as recited in claim 11 wherein the
undesired fluid is water.
15. The flow control apparatus as recited in claim 11 wherein the
undesired fluid is gas.
16. The flow control apparatus as recited in claim 11 wherein the
valve further comprises a sliding sleeve.
17. The flow control apparatus as recited in claim 11 wherein the
valve further comprises a longitudinally shiftable valve
element.
18. The flow control apparatus as recited in claim 11 wherein the
valve further comprises a valve element having a fluid flow
passageway with a cross sectional area that is reduced in response
to contact between the material and the undesired fluid.
19. The flow control apparatus as recited in claim 11 wherein the
actuator further comprises a biasing member that biases a valve
element in a first direction and wherein the material prevents
movement of the valve element in the first direction until the
material is contacted by the undesired fluid.
20. The flow control apparatus as recited in claim 11 wherein the
material remains in a swelled state as long as the material stays
in contact with the undesired fluid and returns to an unswelled
state if contact with the undesired fluid ceases.
21. A sand control completion for installation in a wellbore, the
completion comprising: first and second seal assemblies that define
a production zone in the wellbore; and a sand control screen
operably positioned between the first and second seal assemblies,
the sand control screen comprising a base pipe having at least one
opening that allows fluid flow between an exterior of the base pipe
and an interior flow path of the base pipe, a filter medium
positioned exteriorly of the base pipe, the filter medium
selectively allowing fluid flow therethrough and preventing
particulate flow of a predetermined size therethrough and a flow
restricting device operably positioned in a fluid flow path between
the filter medium and the at least one opening, the flow
restricting device including a valve and an actuator, the actuator
including a material that swells in response to contact with an
undesired fluid such that the flow restricting device is operable
to autonomously reduce the fluid flow through from the production
zone in response to contact between the material and the undesired
fluid.
22. A multizone sand control completion for installation in a
wellbore, the completion comprising: at least two sets of first and
second seal assemblies that define at least two production zones in
the wellbore; and a sand control screen positioned between each of
the first and second seal assemblies, each of the sand control
screens comprising a base pipe having at least one opening that
allows fluid flow between an exterior of the base pipe and an
interior flow path of the base pipe, a filter medium positioned
exteriorly of the base pipe, the filter medium selectively allowing
fluid flow therethrough and preventing particulate flow of a
predetermined size therethrough and a flow restricting device
operably positioned in a fluid flow path between the filter medium
and the at least one opening, the flow restricting device including
a valve and an actuator, the actuator including a material that
swells in response to contact with an undesired fluid such that
each of the flow restricting devices is operable to autonomously
reduce the fluid flow from a respective production zone in response
to contact between the material and the undesired fluid.
Description
TECHNICAL FIELD OF THE INVENTION
[0001] This invention relates, in general, to controlling the
production of fluids from a well that traverses a hydrocarbon
bearing subterranean formation and, in particular, to an apparatus
for autonomously controlling the inflow of production fluids from
the subterranean well in response to contact with an undesired
fluid.
BACKGROUND OF THE INVENTION
[0002] 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.
[0003] During the completion of a well that traverses a hydrocarbon
bearing subterranean formation, production tubing and various
equipment are installed in the well to enable safe and efficient
production of the formation fluids. For example, to prevent the
production of particulate material from an unconsolidated or
loosely consolidated subterranean formation, certain completions
include one or more sand control screens positioned proximate the
desired production intervals. In other completions, to control the
flow rate of production fluids into the production tubing, it is
common practice to install one or more flow control devices within
the tubing string.
[0004] Recently, attempts have been made to utilize fluid flow
control devices within completions requiring sand control. For
example, in one such device, after production fluids flows through
the filter media of the sand control screen, the fluids are
directed into a flow control 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 sand control screen. The fluid leaving the labyrinth
passes to the tubing string for carrying to the surface. While
certain benefits have been achieved through the use of such
devices, many of these devices are complicated to operate, have
suffered from poor reliability and require certain intervention for
operation.
[0005] 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 and
does not require intervention to control inflow.
SUMMARY OF THE INVENTION
[0006] The present invention disclosed herein comprises a flow
control apparatus for controlling the inflow of formation fluids.
The flow control apparatus of the present invention is not
difficult or expensive to manufacture. In addition, the flow
control apparatus of the present invention is reliable in a variety
of flow conditions and does not require intervention to control
inflow.
[0007] In one aspect, the present invention is directed to a flow
control apparatus for controlling the inflow of production fluids
from a subterranean well that includes a tubular member having at
least one opening that allows fluid flow between an exterior of the
tubular member and an interior flow path of the tubular member and
a flow restricting device operably positioned in a fluid flow path
between a fluid source and the at least one opening. The flow
restricting device includes a valve and an actuator. The actuator
includes a material that swells in response to contact with an
undesired fluid, such as water or gas. The flow restricting device
is operable to autonomously reduce the fluid flow through the flow
control apparatus in response to contact between the material and
the undesired fluid.
[0008] In one embodiment of the flow control apparatus, fluid flow
through the flow control apparatus is increasingly restricted in
response to contact between the material and the undesired fluid.
In another embodiment, fluid flow through the flow control
apparatus is substantially completely restricted in response to
contact between the material and the undesired fluid.
[0009] In certain embodiments of the flow control apparatus, the
valve includes a sliding sleeve that is operated from the open
position to a choking or closed position by the actuator. In other
embodiments, the valve includes a longitudinally shiftable valve
element that is operated from the open position to a choking or
closed position by the actuator. In still other embodiments, the
valve includes a valve element having a fluid flow passageway with
a cross sectional area that is reduced in response to contact
between the material and the undesired fluid. In yet another
embodiment, the actuator includes a biasing member that biases a
valve element in a first direction. In this embodiment, the
material prevents movement of the valve element in the first
direction until the material is contacted by the undesired
fluid.
[0010] In one embodiment of the flow control apparatus, once the
material contacts the undesired fluid, the material permanently
remains in a swelled state. In another embodiment of the flow
control apparatus, once the material contacts the undesired fluid,
the material remains in a swelled state as long as the material
stays in contact with the undesired fluid but returns to an
unswelled state if contact with the undesired fluid ceases.
[0011] In another aspect, the present invention is directed to a
sand control screen that is positionable within a wellbore. The
sand control screen includes a base pipe having at least one
opening that allows fluid flow between an exterior of the base pipe
and an interior flow path of the base pipe and a filter medium
positioned exteriorly of the base pipe. The filter medium
selectively allows fluid flow therethrough and prevents particulate
flow of a predetermined size therethrough. A flow restricting
device is operably positioned in a fluid flow path between the
filter medium and the at least one opening. The flow restricting
device including a valve and an actuator. The actuator includes a
material that swells in response to contact with an undesired fluid
such that the flow restricting device is operable to autonomously
reduce the fluid flow through the screen in response to contact
between the material and the undesired fluid.
[0012] In a further aspect, the present invention is directed to a
sand control completion for installation in a wellbore. The
completion includes first and second seal assemblies that define a
production zone in the wellbore and a sand control screen operably
positioned between the first and second seal assemblies. The sand
control screen includes a base pipe having at least one opening
that allows fluid flow between an exterior of the base pipe and an
interior flow path of the base pipe, a filter medium positioned
exteriorly of the base pipe, the filter medium selectively allowing
fluid flow therethrough and preventing particulate flow of a
predetermined size therethrough and a flow restricting device
operably positioned in a fluid flow path between the filter medium
and the at least one opening. The flow restricting device includes
a valve and an actuator. The actuator includes a material that
swells in response to contact with an undesired fluid such that the
flow restricting device is operable to autonomously reduce the
fluid flow from the production zone in response to contact between
the material and the undesired fluid.
[0013] In yet another aspect, the present invention is directed to
a multizone sand control completion for installation in a wellbore.
The completion includes at least two sets of first and second seal
assemblies that define at least two production zones in the
wellbore and a sand control screen positioned between each of the
first and second seal assemblies. Each of the sand control screens
includes a base pipe having at least one opening that allows fluid
flow between an exterior of the base pipe and an interior flow path
of the base pipe, a filter medium positioned exteriorly of the base
pipe, the filter medium selectively allowing fluid flow
therethrough and preventing particulate flow of a predetermined
size therethrough and a flow restricting device operably positioned
in a fluid flow path between the filter medium and the at least one
opening. Each flow restricting device includes a valve and an
actuator. The actuators include a material that swells in response
to contact with an undesired fluid such that each of the flow
restricting devices is operable to autonomously reduce the fluid
flow from the respective production zones in response to contact
between the material and the undesired fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] 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:
[0015] FIG. 1 is a schematic illustration of a well system
operating a plurality of fluid flow control devices according to
the present invention;
[0016] FIG. 2A is side view partially in quarter section of a fluid
flow control device according to the present invention in its least
restricting configuration;
[0017] FIG. 2B is side view partially in quarter section of a fluid
flow control device according to the present invention in its most
restricting configuration;
[0018] FIG. 3A is side view partially in quarter section of a fluid
flow control device according to the present invention in its least
restricting configuration;
[0019] FIG. 3B is side view partially in quarter section of a fluid
flow control device according to the present invention in its most
restricting configuration;
[0020] FIG. 4A is side view partially in quarter section of a fluid
flow control device according to the present invention in its least
restricting configuration;
[0021] FIG. 4B is side view partially in quarter section of a fluid
flow control device according to the present invention in its most
restricting configuration;
[0022] FIG. 5A is side view partially in quarter section of a fluid
flow control device according to the present invention in its least
restricting configuration;
[0023] FIG. 5B is side view partially in quarter section of a fluid
flow control device according to the present invention in its most
restricting configuration;
[0024] FIG. 6A is side view partially in quarter section of a fluid
flow control device according to the present invention in its least
restricting configuration;
[0025] FIG. 6B is side view partially in quarter section of a fluid
flow control device according to the present invention in its most
restricting configuration;
[0026] FIG. 7A is side view partially in quarter section of a fluid
flow control device according to the present invention in its least
restricting configuration;
[0027] FIG. 7B is side view partially in quarter section of a fluid
flow control device according to the present invention in its most
restricting configuration;
[0028] FIG. 8A is side view partially in quarter section of a fluid
flow control device according to the present invention in its least
restricting configuration; and
[0029] FIG. 8B is side view partially in quarter section of a fluid
flow control device according to the present invention in its most
restricting configuration.
DETAILED DESCRIPTION OF THE INVENTION
[0030] 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.
[0031] Referring initially to FIG. 1, therein is depicted a well
system including a plurality of fluid flow control devices
embodying principles of the present invention that is schematically
illustrated and generally designated 10. In the illustrated
embodiment, a wellbore 12 extends through the various earth strata.
Wellbore 12 has a substantially vertical section 14, the upper
portion of which has installed therein a casing string 16. Wellbore
12 also has a substantially horizontal section 18 that extends
through a hydrocarbon bearing subterranean formation 20. As
illustrated, substantially horizontal section 18 of wellbore 12 is
open hole.
[0032] Positioned within wellbore 12 and extending from the surface
is a tubing string 22. Tubing string 22 provides a conduit for
formation fluids to travel from formation 20 to the surface.
Positioned within tubing string 22 are a plurality of seal
assemblies 24, 26, 28, 30, 32, 34 and a plurality of fluid flow
control devices 36, 38, 40, 42, 44. Each of the seal assemblies 24,
26, 28, 30, 32, 34 provides a fluid seal between tubing string 22
and the wall of wellbore 12. Each pair of seal assemblies defines a
production interval. As illustrated, seal assemblies 24, 26 define
production interval 46, seal assemblies 26, 28 define production
interval 48, seal assemblies 28, 30 define production interval 50,
seal assemblies 30, 32 define production interval 52 and seal
assemblies 32, 34 define production interval 54.
[0033] Through use of the fluid flow control devices 36, 38, 40,
42, 44 of the present invention and by providing numerous
production intervals 46, 48, 50, 52, 54, precise control over the
volume and composition of the produced fluids is enabled. For
example, in an oil production operation if an undesired fluid
component, such as water or gas, is entering one of the production
intervals, the fluid flow control device in that interval will
autonomously restrict the production of that undesired fluid
component and in some cases the entire fluid stream from that
production interval. Accordingly, when a production interval
corresponding to a particular one of the fluid flow control devices
produces a greater proportion of an undesired fluid, the fluid flow
control device in that interval will increasingly or entirely
restrict flow from that interval. Thus, the other production
intervals which are producing a greater proportion of desired
fluid, in this case oil, will contribute more to the production
stream entering tubing string 22. In particular, there will be a
greater pressure drop from formation 20 to tubing string 22,
resulting in a greater production of the desired fluid, due to the
increased restriction to flow from the production interval that
would otherwise be producing a greater proportion of the undesired
fluid.
[0034] In the illustrated embodiment, each of the fluid flow
control devices 36, 38, 40, 42, 44 provides not only fluid flow
control capability but also sand control capability. The sand
control screen elements or filter media associated with fluid flow
control devices 36, 38, 40, 42, 44 are designed to allow fluids to
flow therethrough but prevent particulate matter of sufficient size
from flowing therethrough. The exact design of the screen element
associated with fluid flow control devices 36, 38, 40, 42, 44 is
not critical to the present invention as long as it is suitably
designed for the characteristics of the formation fluids and any
treatment operations to be performed. For example, the sand control
screen may utilize a nonperforated base pipe having a wire wrapped
around a plurality of ribs positioned circumferentially around the
base pipe that provide stand off between the base pipe and the wire
wrap. Alternatively, a fluid-porous, particulate restricting, metal
material such as a plurality of layers of a wire mesh that are
sintered together to form a fluid porous wire mesh screen could be
used as the filter medium. As illustrated, a protective outer
shroud having a plurality of perforations therethrough may be
positioned around the exterior of the filter medium.
[0035] Even though FIG. 1 depicts the fluid flow control devices of
the present invention in an open hole environment, 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
cased wells. Also, even though FIG. 1 depicts one fluid flow
control device in each production interval, it should be understood
by those skilled in the art that any number of fluid flow control
devices of the present invention may be deployed within a
production interval without departing from the principles of the
present invention.
[0036] In addition, even though FIG. 1 depicts the fluid flow
control devices of the present invention in a horizontal section of
the wellbore, 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 deviated or vertical wellbores.
Accordingly, it should be understood by those skilled in the art
that the use of directional terms such as above, below, upper,
lower, upward, downward and the like are used in relation to the
illustrative embodiments as they are depicted in the figures, the
upward direction being toward the top of the corresponding figure
and the downward direction being toward the bottom of the
corresponding figure. Further, even though FIG. 1 depicts the fluid
flow control devices of the present invention as including sand
control screen elements, 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 completions that do
not require sand control.
[0037] Referring next to FIGS. 2A-2B, therein is depicted a fluid
flow control device according to the present invention that is
representatively illustrated and generally designated 100. Fluid
flow control device 100 may be suitably coupled to other similar
fluid flow control devices, seal assemblies, production tubulars or
other downhole tools to form a tubing string as described above.
Fluid flow control device 100 includes a sand control screen
section 102 and a flow restrictor section 104. Sand control screen
section 102 includes a suitable sand control screen element or
filter medium, such as a wire wrap screen, a woven wire mesh screen
or the like, designed to allow fluids to flow therethrough but
prevent particulate matter of sufficient size from flowing
therethrough. In the illustrated embodiment, a protective outer
shroud 106 having a plurality of perforations 108 is positioned
around the exterior of the filter medium.
[0038] Flow restrictor section 104 is configured in series with
sand control screen section 102 such that fluid must pass through
sand control screen section 102 prior to entering flow restrictor
section 104. Flow restrictor section 104 includes an outer housing
110. Outer housing 110 defines an annular chamber 112, an annular
chamber 114 and an annular chamber 116 with base pipe 118. Disposed
between annular chamber 112 and annular chamber 114 and partially
within annular chamber 114 is a valve assembly 120. Valve assembly
120 includes a tubular fluid passageway 122, a support member 124,
an actuator 126 and a sliding sleeve 128. Disposed between annular
chamber 114 and annular chamber 116 is a support member 130 having
a tubular fluid passageway 132.
[0039] As best seen in FIG. 2A, tubular fluid passageway 122 serves
as a first stage flow restrictor to control fluid flow through
fluid flow control device 100 when a desired fluid, such as oil,
depicted as arrows 134, is being produced. As illustrated, once
desired fluid 134 enters flow restrictor section 104, desired fluid
134 passes through annular chamber 112 and encounters tubular fluid
passageway 122 which restricts the flow of desired fluid 134. After
passing through tubular fluid passageway 122, desired fluid 134
enters annular chamber 114 before passing into the interior flow
path of base pipe 118 via openings 136, which are depicted in the
form of slots. Once inside the interior flow path of base pipe 118,
desired fluid 134 flows to the surface within the tubing string. In
addition, a portion of desired fluid 134 (not pictured) also passes
through tubular fluid passageway 132, that serves as a second stage
flow restrictor, before passing into base pipe 118 via openings
138. As tubular fluid passageway 132 provides a greater restriction
to flow than openings 136, the majority of desired fluid 134 enters
base pipe 118 via openings 136.
[0040] As best seen in FIG. 2B, when an undesired fluid, such as
water, depicted as arrows 140, is produced, valve assembly 120 is
actuated to its closed or choking position. In the illustrated
embodiment, this actuation is achieved by longitudinally shifting
sliding sleeve 128 into contact with support member 130 in response
to the expansion of actuator 126. Once sliding sleeve 128 contacts
support member 130 all or a majority of the undesired fluid 140
must now pass through tubular fluid passageway 132 before entering
base pipe 118 via openings 138. As tubular fluid passageway 132
provides a greater restriction to flow than tubular fluid
passageway 122, the production of undesired fluid 140 through fluid
flow control device 100 is reduced as compared to the production of
desired fluid 134 in FIG. 2A. The increased pressure drop caused by
tubular fluid passageway 132 not only reduces the production of
undesired fluid 140 from the production interval corresponding to
fluid flow control device 100 but may also tend to increase
production from other production intervals which are producing a
desired fluid. Specifically, as there will be a greater pressure
drop from the formation to the tubing string for all fluids, with a
greater restriction to flow only being applied to undesired fluids,
a greater production of fluids from intervals not producing the
undesired fluid will occur.
[0041] As noted above, the actuation of valve assembly 120 is
achieved in response to the expansion of actuator 126. More
specifically, actuator 126 is formed from a material that expands
when it comes in contact with an activating agent. For example, the
material of actuator 126 may be a polymer that swells multiple
times its initial size upon activation by an activating agent that
stimulates the polymer chains to expand both radial and axially. In
an autonomous implementation of fluid flow control device 100, the
undesired fluid serves as the activating agent. For example, when
the undesired fluid is water, the material of actuator 126 may be a
water-swellable polymer such as a water-swellable elastomer or
water-swellable rubber. More specifically, the material of actuator
126 may be a water-swellable hydrophobic polymer or water-swellable
hydrophobic copolymer and preferably a water-swellable hydrophobic
porous copolymer. As another example, the material of actuator 126
may be a salt polymer such as polyacrylamide or modified
crosslinked poly(meth)acrylate that has the tendency to attract
water from salt water through osmosis wherein water flows from an
area of low salt concentration, the formation water, to an area of
high salt concentration, the salt polymer, across a semi permeable
membrane, the interface between the polymer and the production
fluids, that allows water molecules to pass therethrough but
prevents the passage of dissolved salts therethrough. Other
embodiments of actuator 126 may employ different types of swelling
polymers or materials that are activated by other activating
agents. For example, in certain implementations, it may be
desirable to have the material of actuator 126 swell upon
activation by a hydrocarbon gas component of the production
fluids.
[0042] As best seen in FIG. 2B, once actuator 126 is exposed to the
activating agent, actuator 126 swells to longitudinally shift
sliding sleeve 128 into contact with support member 130. Once this
operation is complete, actuator 126 retains the activating fluid
therein. As a result, after actuator 126 has transformed from its
unswelled state (FIG. 2A) to its swelled state (FIG. 2B), actuator
126 retains its expanded size. If required, full access through
fluid flow control device 100 can be reestablished via removal of
plug 142. For example, plug 142 may be mechanically removed from
base pipe 118 or chemically attacked such that a fluid flow path is
created upstream of valve assembly 120. It should be noted that the
use of plug 142 or other similar removeable device in this and the
other embodiments of the present invention is an additional feature
which may be included or excluded optionally. Alternatively, in
certain embodiments, actuator 126 may be deactivated upon removal
of the activating agent from contact with actuator 126. This
implementation is useful in the scenario in which an oil producing
production zone temporarily produces the unwanted fluid of water
that acts as the activating agent for actuator 126, then later
reverts back to oil production. In this case, actuator 126 is
transitioned back from its swelled state to its unswelled state due
to the removal of the activating agent.
[0043] Depended upon the specific composition of actuator 126, the
swelling process may take place over a relatively short period of
time, several minutes, or a relatively long period of time, several
days or weeks. As flow control device 100 is typically installed in
a well that contains drilling fluids, which may include the
activating agent of actuator 126, a composition for the material of
actuator 126 with a relatively long swelling process may be
desirable to enable the installation of actuator 126 without
immediate actuation of flow control device 100, thus enabling the
drilling fluid to be removed from contact with actuator 126 before
actuation takes place. The removal of the drilling fluids could be
done by displacing the drilling fluids with other fluids form the
surface of by flowing reservoir fluids through flow control device
100. Additionally or alternatively, an outer skin may be applied to
actuator 126 prior to installation that protects actuator 126 from
any activation agent in the drilling fluids. For example, the skin
may be relatively impermeable to the activating agent such that
contact between the activating agent and actuator 126 is initially
limited or the skin may entirely prevent contact between the
activating agent and actuator 126 until such skin is removed, for
example, due to the passage of time or a treatment used to remove
the skin from actuator 126.
[0044] Even though fluid flow control device 100 has been described
as having one valve assembly 120, it should be understood by those
skilled in the art that a fluid flow control device of the present
invention could alternatively have more than one valve assembly
positioned in the flow restrictor section thereof. The number of
valve assemblies and the exact location and circumferential
distribution of the valve assemblies will be determined based upon
a number of factors including the volume of desired fluid to be
produced through fluid flow control device 100, the types or types
of fluid that comprise the desired fluid and undesired fluid, the
mechanical space requirements within fluid flow control device 100
and the like. In addition, even though the fluid passageways 122,
132 have been described as being tubular, it should be understood
by those skilled in the art that the passageways or nozzles that
restrict fluid flow through fluid flow control device 100 could
alternatively have different configurations including different
cross sectional shapes and different directional pathways such as
labyrinth type pathways, without departing from the principles of
the present invention.
[0045] Referring next to FIGS. 3A-3B, therein is depicted a fluid
flow control device according to the present invention that is
representatively illustrated and generally designated 200. Fluid
flow control device 200 includes a sand control screen section 202
and a flow restrictor section 204. Sand control screen section 202
includes a suitable sand control screen element or filter medium.
In the illustrated embodiment, a protective outer shroud 206 having
a plurality of perforations 208 is positioned around the exterior
of the filter medium.
[0046] Flow restrictor section 204 is configured in series with
sand control screen section 202 such that fluid must pass through
sand control screen section 202 prior to entering flow restrictor
section 204. Flow restrictor section 204 includes an outer housing
210. Outer housing 210 defines an annular chamber 212 and an
annular chamber 214 with base pipe 218. Disposed at least partially
within annular chamber 214 is a valve assembly 220. Valve assembly
220 includes a tubular fluid passageway 222, a support member 224,
an actuator 226, a sliding sleeve 228 and a support member 230.
[0047] As best seen in FIG. 3A, tubular fluid passageway 222 serves
as a flow restrictor to control fluid flow through fluid flow
control device 200 when a desired fluid 234 is being produced. As
illustrated, once desired fluid 234 enters flow restrictor section
204, desired fluid 234 passes through annular chamber 212 and
encounters tubular fluid passageway 222 which restricts the flow of
desired fluid 234. After passing through tubular fluid passageway
222, desired fluid 234 enters the interior of sliding sleeve 228,
passes through openings 232 into annular chamber 214 before passing
into base pipe 218 via openings 236 for transport to the
surface.
[0048] As best seen in FIG. 3B, when an undesired fluid 240 is
produced, valve assembly 220 is actuated to its closed or choking
position. In the illustrated embodiment, this actuation is achieved
by longitudinally shifting sliding sleeve 228 such that openings
232 are blocked by the outer surface of the tubular including
tubular fluid passageway 222. Depending upon the sealing
therebetween, this may result in a complete shut off of flow
through fluid flow control device 200. In some instances a complete
closedown of production is not wanted. In the illustrated
embodiment an incomplete seal is created between sliding sleeve 228
and tubular fluid passageway 222. In this manner, the actuation of
actuator 226 creates an increased restriction to flow, without
completely preventing flow. Thus, some of unwanted fluid 240 is
permitted to flow through openings 236 into base pipe 218.
[0049] Actuator 226 is formed from a material that expands when it
comes in contact with an activating agent. In an autonomous
implementation of fluid flow control device 200, undesired fluid
240 serves as the activating agent. As best seen in FIG. 3B, once
actuator 226 is exposed to the activating agent, actuator 226
swells to longitudinally shift sliding sleeve 228. Once this
operation is complete, actuator 226 retains the activating fluid
therein. As a result, after actuator 226 has transformed from its
unswelled state (FIG. 3A) to its swelled state (FIG. 3B), actuator
226 retains its expanded size. If required, full access through
fluid flow control device 200 can be reestablished via removal of
plug 242. Alternatively, in certain embodiments, actuator 226 may
be deactivated upon removal of the activating agent from contact
with actuator 226. Alternatively or additionally, an outer skin may
be applied to actuator 226 prior to installation that protects
actuator 226 from premature actuation.
[0050] Referring next to FIGS. 4A-4B, therein is depicted a fluid
flow control device according to the present invention that is
representatively illustrated and generally designated 300. Fluid
flow control device 300 includes a sand control screen section 302
and a flow restrictor section 304. Sand control screen section 302
includes a suitable sand control screen element or filter medium.
In the illustrated embodiment, a protective outer shroud 306 having
a plurality of perforations 308 is positioned around the exterior
of the filter medium.
[0051] Flow restrictor section 304 is configured in series with
sand control screen section 302 such that fluid must pass through
sand control screen section 302 prior to entering flow restrictor
section 304. Flow restrictor section 304 includes an outer housing
310. Outer housing 310 defines an annular chamber 312 and an
annular chamber 314 with base pipe 318. Disposed at least partially
within annular chamber 314 is a valve assembly 320. Valve assembly
320 includes a tubular fluid passageway 322, a support member 324,
an actuator 326 and a support member 330.
[0052] As best seen in FIG. 4A, tubular fluid passageway 322 serves
as a flow restrictor to control fluid flow through fluid flow
control device 300 when a desired fluid 334 is being produced. As
illustrated, once desired fluid 334 enters flow restrictor section
304, desired fluid 334 passes through annular chamber 312 and
encounters tubular fluid passageway 322 which restricts the flow of
desired fluid 334. After passing through tubular fluid passageway
322, desired fluid 334 enters annular chamber 314 before passing
into base pipe 318 via openings 336 for transport to the
surface.
[0053] As best seen in FIG. 4B, when an undesired fluid 340 is
produced, valve assembly 320 is actuated to its closed or choking
position. In the illustrated embodiment, this actuation is achieved
by longitudinally shifting the tubular that defines tubular fluid
passageway 222 such that it comes in contact with support member
330. Depending upon the sealing therebetween, this may result in a
complete shut off of flow through fluid flow control device 300. In
some instances a complete closedown of production is not wanted. In
the illustrated embodiment an incomplete seal is created between
the tubular and support member 330. In this manner, the actuation
of actuator 326 creates an increased restriction to flow, without
completely preventing flow. Thus, some of unwanted fluid 340 is
permitted to flow through openings 336 into base pipe 318.
[0054] Actuator 326 is formed from a material that expands when it
comes in contact with an activating agent. In an autonomous
implementation of fluid flow control device 300, undesired fluid
340 serves as the activating agent. As best seen in FIG. 4B, once
actuator 326 is exposed to the activating agent, actuator 326
swells to longitudinally shift the tubular. Once this operation is
complete, actuator 326 retains the activating fluid therein. As a
result, after actuator 326 has transformed from its unswelled state
(FIG. 4A) to its swelled state (FIG. 4B), actuator 326 retains its
expanded size. If required, full access through fluid flow control
device 300 can be reestablished via removal of plug 342.
Alternatively, in certain embodiments, actuator 326 may be
deactivated upon removal of the activating agent from contact with
actuator 326. Alternatively or additionally, an outer skin may be
applied to actuator 326 prior to installation that protects
actuator 326 from premature actuation.
[0055] Referring next to FIGS. 5A-5B, therein is depicted a fluid
flow control device according to the present invention that is
representatively illustrated and generally designated 400. Fluid
flow control device 400 includes a sand control screen section 402
and a flow restrictor section 404. Sand control screen section 402
includes a suitable sand control screen element or filter medium.
In the illustrated embodiment, a protective outer shroud 406 having
a plurality of perforations 408 is positioned around the exterior
of the filter medium.
[0056] Flow restrictor section 404 is configured in series with
sand control screen section 402 such that fluid must pass through
sand control screen section 402 prior to entering flow restrictor
section 404. Flow restrictor section 404 includes an outer housing
410. Outer housing 410 defines an annular chamber 412 and an
annular chamber 414 with base pipe 418. Disposed at least partially
within annular chamber 414 is a valve assembly 420. Valve assembly
420 includes a tubular fluid passageway 422, a support member 424,
an actuator 426, a plunger 428 and a support member 430.
[0057] As best seen in FIG. 5A, tubular fluid passageway 422 serves
as a flow restrictor to control fluid flow through fluid flow
control device 400 when a desired fluid 434 is being produced. As
illustrated, once desired fluid 434 enters flow restrictor section
404, desired fluid 434 passes through annular chamber 412 and
encounters tubular fluid passageway 422 which restricts the flow of
desired fluid 434. After passing through tubular fluid passageway
422, desired fluid 434 enters annular chamber 414 before passing
into base pipe 418 via openings 436 for transport to the
surface.
[0058] As best seen in FIG. 5B, when an undesired fluid 440 is
produced, valve assembly 420 is actuated to its closed or choking
position. In the illustrated embodiment, this actuation is achieved
by longitudinally shifting plunger 428 such that it comes in
contact with a seat in support member 424. Depending upon the
sealing therebetween, this may result in a complete shut off of
flow through fluid flow control device 400, as illustrated, or may
result in an incomplete seal creating only an increased restriction
to flow without completely preventing flow.
[0059] Actuator 426 is formed from a material that expands when it
comes in contact with an activating agent. In an autonomous
implementation of fluid flow control device 400, undesired fluid
440 serves as the activating agent. As best seen in FIG. 5B, once
actuator 426 is exposed to the activating agent, actuator 426
swells to longitudinally shift plunger 428. Once this operation is
complete, actuator 426 retains the activating fluid therein. As a
result, after actuator 426 has transformed from its unswelled state
(FIG. 5A) to its swelled state (FIG. 5B), actuator 426 retains its
expanded size. If required, full access through fluid flow control
device 400 can be reestablished via removal of plug 442.
Alternatively, in certain embodiments, actuator 426 may be
deactivated upon removal of the activating agent from contact with
actuator 426. Alternatively or additionally, an outer skin may be
applied to actuator 426 prior to installation that protects
actuator 426 from premature actuation.
[0060] Depended upon the specific composition of the actuator, the
swelling of the actuator may be related to the proportion of the
undesired fluid in the production fluid stream. For example, using
certain embodiments of the fluid flow control device of the present
invention enables the progressive restriction of flow through the
fluid flow control device as the proportion of water production
increases. While the water cut is small, the material of the
actuator may only swell a little such that the increase in the
restriction to flow is only slight. As the water cut increase, the
material of the actuator may increasingly swell, thereby creating a
greater restriction to flow. Once the water proportion reaches a
predetermined level, the material of actuator 426 swells to
longitudinally shift plunger 428 such that it comes in contact with
a seat in support member 424, as described above.
[0061] Referring next to FIGS. 6A-6B, therein is depicted a fluid
flow control device according to the present invention that is
representatively illustrated and generally designated 500. Fluid
flow control device 500 includes a sand control screen section 502
and a flow restrictor section 504. Sand control screen section 502
includes a suitable sand control screen element or filter medium.
In the illustrated embodiment, a protective outer shroud 506 having
a plurality of perforations 508 is positioned around the exterior
of the filter medium.
[0062] Flow restrictor section 504 is configured in series with
sand control screen section 502 such that fluid must pass through
sand control screen section 502 prior to entering flow restrictor
section 504. Flow restrictor section 504 includes an outer housing
510. Outer housing 510 defines an annular chamber 512, an annular
chamber 514 and an annular chamber 516 with base pipe 518. Disposed
between annular chamber 512 and annular chamber 514 is a valve
assembly 520. Valve assembly 520 includes a support member 524 and
an actuator 526. Disposed between annular chamber 514 and annular
chamber 516 is a tubular fluid passageway 522 and a support member
528.
[0063] As best seen in FIG. 6A, tubular fluid passageway 522 serves
as a flow restrictor to control fluid flow through fluid flow
control device 500 when a desired fluid 534 is being produced. As
illustrated, once desired fluid 534 enters flow restrictor section
504, desired fluid 534 passes through annular chamber 512, valve
assembly 520 and annular chamber 514 then encounters tubular fluid
passageway 522 which restricts the flow of desired fluid 534. After
passing through tubular fluid passageway 522, desired fluid 534
enters annular chamber 516 before passing into base pipe 518 via
openings 536 for transport to the surface.
[0064] As best seen in FIG. 6B, when an undesired fluid 540 is
produced, valve assembly 520 is actuated to its closed or choking
position. In the illustrated embodiment, this actuation is achieved
by radial expansion of actuator 526 which reduces the area of the
flow path through valve assembly 520. Depending upon the extent of
the radial expansion of actuator 526, this may result in a complete
shut off of flow through fluid flow control device 500. In some
instances a complete closedown of production is not wanted. In the
illustrated embodiment, a relative small passageway exists within
valve assembly 520. In this manner, the actuation of actuator 526
creates an increased restriction to flow, without completely
preventing flow. Thus, some of unwanted fluid 540 is permitted to
flow through valve assembly 520, annular chamber 514, tubular fluid
passageway 522, annular chamber 516 and openings 536 into base pipe
518.
[0065] Actuator 526 is formed from a material that expands when it
comes in contact with an activating agent. In an autonomous
implementation of fluid flow control device 500, undesired fluid
540 serves as the activating agent. As best seen in FIG. 6B, once
actuator 526 is exposed to the activating agent, actuator 526
swells to create a flow restriction. Once this operation is
complete, actuator 526 retains the activating fluid therein. As a
result, after actuator 526 has transformed from its unswelled state
(FIG. 6A) to its swelled state (FIG. 6B), actuator 526 retains its
expanded size. If required, full access through fluid flow control
device 500 can be reestablished via removal of plug 542.
Alternatively, in certain embodiments, actuator 526 may be
deactivated upon removal of the activating agent from contact with
actuator 526. Alternatively or additionally, an outer skin may be
applied to actuator 526 prior to installation that protects
actuator 526 from premature actuation.
[0066] As noted above, the fluid flow control devices of the
present invention may have more that one valve assembly positioned
in the flow restrictor section thereof. In the illustrated
embodiment of FIGS. 6A-6B, it is particularly desirable to have
multiple valve assemblies 520 as the valve assemblies can operate
as fluid discriminators. Specifically, in certain flow conditions
wherein the fluid being produced includes both the desired fluid
and undesired fluid and wherein these component are stratified
within fluid flow control device 500, valve assemblies 520 can
operate independently of one another to preferentially reduce the
production of the undesired fluid relative to the desired fluid. In
the case of a production fluid containing both oil and water,
stratification of this production fluid may result in the oil
component being above the water component within annular chamber
512. As the water component is the activating agent to actuate
valve members 520, only the valve members being exposed to the
water, those to the bottom of fluid flow control device 500, will
be actuated. This results in a preferential production of oil
through the unactuated valve assemblies 520. Likewise, in the case
of a production fluid containing both oil and gas, stratification
of this production fluid results in the gas component being above
the oil component within annular chamber 512. If the gas component
is the activating agent to actuate valve members 520, only the
valve members being exposed to the gas, those to the top of fluid
flow control device 500, will be actuated. This results in a
preferential production of oil through the unactuated valve
assemblies 520.
[0067] Referring next to FIGS. 7A-7B, therein is depicted a fluid
flow control device according to the present invention that is
representatively illustrated and generally designated 600. Fluid
flow control device 600 includes a sand control screen section 602
and a flow restrictor section 604. Sand control screen section 602
includes a suitable sand control screen element or filter medium.
In the illustrated embodiment, a protective outer shroud 606 having
a plurality of perforations 608 is positioned around the exterior
of the filter medium.
[0068] Flow restrictor section 604 is configured in series with
sand control screen section 602 such that fluid must pass through
sand control screen section 602 prior to entering flow restrictor
section 604. Flow restrictor section 604 includes an outer housing
610. Outer housing 610 defines an annular chamber 612 and an
annular chamber 614 with base pipe 618. Disposed between annular
chamber 612 and annular chamber 614 is a valve assembly 620. Valve
assembly 620 includes a tubular fluid passageway 622, a support
member 624 and an actuator 626.
[0069] As best seen in FIG. 7A, tubular fluid passageway 622 serves
as a flow restrictor to control fluid flow through fluid flow
control device 600 when a desired fluid 634 is being produced. As
illustrated, once desired fluid 634 enters flow restrictor section
604, desired fluid 634 passes through tubular fluid passageway 622
which restricts the flow of desired fluid 634. After passing
through tubular fluid passageway 622, desired fluid 634 enters
annular chamber 614 before passing into base pipe 618 via openings
636 for transport to the surface.
[0070] As best seen in FIG. 7B, when an undesired fluid 640 is
produced, valve assembly 620 is actuated to its closed or choking
position. In the illustrated embodiment, this actuation is achieved
by radial expansion of actuator 626 which radially compresses
tubular fluid passageway 622 and reduces the area of the flow path
through tubular fluid passageway 622. Depending upon the extent of
the radial expansion of actuator 626, this may result in a complete
shut off of flow through fluid flow control device 600. In some
instances a complete closedown of production is not wanted. In the
illustrated embodiment a relatively small passageway exists through
tubular fluid passageway 622. In this manner, the actuation of
actuator 626 creates an increased restriction to flow, without
completely preventing flow. Thus, some of unwanted fluid 640 is
permitted to flow through tubular fluid passageway 622 into annular
chamber 614 through openings 636 into base pipe 618.
[0071] Actuator 626 is formed from a material that expands when it
comes in contact with an activating agent. In an autonomous
implementation of fluid flow control device 600, undesired fluid
640 serves as the activating agent. As best seen in FIG. 7B, once
actuator 626 is exposed to the activating agent, actuator 626
swells to increase the flow restriction of tubular fluid passageway
622. Once this operation is complete, actuator 626 retains the
activating fluid therein. As a result, after actuator 626 has
transformed from its unswelled state (FIG. 7A) to its swelled state
(FIG. 7B), actuator 626 retains its expanded size. If required,
full access through fluid flow control device 600 can be
reestablished via removal of plug 642. Alternatively, in certain
embodiments, actuator 626 may be deactivated upon removal of the
activating agent from contact with actuator 626. Alternatively or
additionally, an outer skin may be applied to actuator 626 prior to
installation that protects actuator 626 from premature
actuation.
[0072] Referring next to FIGS. 8A-8B, therein is depicted a fluid
flow control device according to the present invention that is
representatively illustrated and generally designated 700. Fluid
flow control device 700 includes a sand control screen section 702
and a flow restrictor section 704. Sand control screen section 702
includes a suitable sand control screen element or filter medium.
In the illustrated embodiment, a protective outer shroud 706 having
a plurality of perforations 708 is positioned around the exterior
of the filter medium.
[0073] Flow restrictor section 704 is configured in series with
sand control screen section 702 such that fluid must pass through
sand control screen section 702 prior to entering flow restrictor
section 704. Flow restrictor section 704 includes an outer housing
710. Outer housing 710 defines an annular chamber 712 and an
annular chamber 714 with base pipe 718. Disposed at least partially
within annular chamber 714 is a valve assembly 720. Valve assembly
720 includes a tubular fluid passageway 722, a support member 724,
a sliding sleeve 728 and a support member 730. Valve assembly 720
also includes an actuation system including actuator 726 and
biasing member 732.
[0074] As best seen in FIG. 8A, tubular fluid passageway 722 serves
as a flow restrictor to control fluid flow through fluid flow
control device 700 when a desired fluid 734 is being produced. As
illustrated, once desired fluid 734 enters flow restrictor section
704, desired fluid 734 passes through annular chamber 712 and
encounters tubular fluid passageway 722 which restricts the flow of
desired fluid 734. After passing through tubular fluid passageway
722, desired fluid 734 enters the interior of sliding sleeve 728,
passes through openings 736 into annular chamber 714 before passing
into base pipe 718 via openings 738 for transport to the
surface.
[0075] As best seen in FIG. 8B, when an undesired fluid 740 is
produced, valve assembly 720 is actuated to its closed or choking
position. In the illustrated embodiment, this actuation is achieved
by longitudinally shifting sliding sleeve 728 such that openings
736 are blocked by the outer surface of the tubular including
tubular fluid passageway 722. Depending upon the sealing
therebetween, this may result in a complete shut off of flow
through fluid flow control device 700. In some instances a complete
closedown of production is not wanted. In the illustrated
embodiment an incomplete seal is created between sliding sleeve 728
and tubular fluid passageway 722. In this manner, the actuation of
actuator 726 creates an increased restriction to flow, without
completely preventing flow. Thus, some of unwanted fluid 740 is
permitted to flow through openings 738 into base pipe 718.
[0076] Actuator 726 is formed from a composite material that
includes a plurality of pellets of a material that expands when it
comes in contact with an activating agent in an epoxy matrix. In an
autonomous implementation of fluid flow control device 700,
undesired fluid 740 serves as the activating agent. As best seen in
FIG. 8B, once actuator 726 is exposed to the activating agent, the
swellable pellets of actuator 726 swell and break the epoxy matrix
which allows the biasing force of biasing member 732 to
longitudinally shift sliding sleeve 728. Once this operation is
complete, full access through fluid flow control device 700 can be
reestablished via removal of plug 742.
[0077] 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.
* * * * *