U.S. patent application number 13/170366 was filed with the patent office on 2011-10-20 for system and method for controlling flow in a wellbore.
This patent application is currently assigned to SCHLUMBERGER TECHNOLOGY CORPORATION. Invention is credited to David James Biddick, Paul Gordon Goughnour, Russell Alan Johnston, Dwayne May, David McCalvin.
Application Number | 20110253392 13/170366 |
Document ID | / |
Family ID | 41213855 |
Filed Date | 2011-10-20 |
United States Patent
Application |
20110253392 |
Kind Code |
A1 |
May; Dwayne ; et
al. |
October 20, 2011 |
SYSTEM AND METHOD FOR CONTROLLING FLOW IN A WELLBORE
Abstract
A technique enables control over flow in a wellbore with a flow
control system. The flow control system combines a flow reduction
mechanism with a flow control device, such as a valve. The flow
reduction mechanism comprises a closure member which can be
selectively moved between an unactuated and actuated position,
allowing relatively greater flow through the flow control device in
the unactuated position. The flow reduction mechanism actuates
prior to or in conjunction with the flow control device to reduce
flow and thus reduce the loading forces that would otherwise act
against the flow control mechanism upon closure of the flow control
device.
Inventors: |
May; Dwayne; (Humble,
TX) ; McCalvin; David; (Missouri City, TX) ;
Goughnour; Paul Gordon; (Fresno, TX) ; Biddick; David
James; (Missouri City, TX) ; Johnston; Russell
Alan; (Alvin, TX) |
Assignee: |
SCHLUMBERGER TECHNOLOGY
CORPORATION
SUGAR LAND
TX
|
Family ID: |
41213855 |
Appl. No.: |
13/170366 |
Filed: |
June 28, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12108151 |
Apr 23, 2008 |
8002040 |
|
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13170366 |
|
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Current U.S.
Class: |
166/386 ;
166/332.1; 166/332.3; 166/332.8 |
Current CPC
Class: |
E21B 34/10 20130101;
E21B 2200/05 20200501; E21B 2200/04 20200501; Y10T 137/7847
20150401 |
Class at
Publication: |
166/386 ;
166/332.3; 166/332.8; 166/332.1 |
International
Class: |
E21B 34/10 20060101
E21B034/10 |
Claims
1. A method for use in a wellbore that provides a reduction of a
flow and a corresponding reduction of flow induced forces on one or
more related primary flow controlling members comprising: providing
a flow reduction device in a well equipment string; positioning the
flow reduction device on an uphole side of at least one related
primary flow controlling member, wherein at least one of the
related primary flow controlling members comprises one or more ball
closure mechanisms; actuating the flow reduction device to limit an
uphole flow to a restricted uphole flow prior to or in conjunction
with closure of the related primary flow controlling member; and
actuating the related primary flow controlling member.
2. The method of claim 1 wherein the flow reduction device is
coupled with the related primary flow controlling member.
3. The method as recited in claim 1 wherein the related primary
flow controlling member is a subsurface safety valve.
4. The method as recited in claim 1 wherein the related primary
flow controlling member is a formation isolation valve.
5. The method as recited in claim 1 wherein the related primary
flow controlling member is an injection valve.
6. The method as recited in claim 1 wherein the related primary
flow controlling member is an on/off or multiple position downhole
production/injection flow control valve.
7. The method as recited in claim 1 wherein the flow reduction
device comprises one or more flapper mechanisms.
8. The method as recited in claim 1 wherein the flow reduction
device comprises one or more ball mechanisms.
9. The method as recited in claim 1 wherein the flow reduction
device comprises at least one sleeve closure mechanism.
10. A system for use in a well, comprising: a primary flow control
device positioned to control flow through a completion; and a flow
reduction mechanism which is positionable in a flow path routed
through a primary flow control device of a well equipment string,
the flow reduction mechanism comprising a ball valve configured to
provide one or more orifices in a closed position to form a
restricted flow opening sized to reduce a flow of fluid in the
well.
11. The system of claim 10 wherein the primary flow control device
is a flapper valve.
12. The system of claim 10 wherein the flow reduction mechanism is
downstream of the primary flow control device when fluid is flowing
uphole.
13. The system of claim 10 wherein the flow reduction mechanism and
the primary flow control device are independently actuated.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a Divisional which claims priority to
U.S. application Ser. No. 12/108,151 filed Apr. 23, 2008, entitled
"System And Method For Controlling Flow In A Wellbore" which is
incorporated herein by reference.
BACKGROUND
[0002] In many well related operations, appropriate well equipment
is moved downhole to control fluid flow. For example, various
completions are used to facilitate and control the flow of fluid in
both production operations and injection operations. Valves are
sometimes used to choke or otherwise control flow of fluid through
the well equipment.
[0003] In some applications, detrimental reverse flow can be a
problem and valves have been used to prevent flow in the
undesirable direction. Flapper valves, for example, have been used
to enable flow through tubing in one direction while blocking flow
in the opposite direction. However, flapper valves offer limited
ability for adjustment to accommodate various procedures during a
production and/or injection operation.
[0004] For example, many subsurface safety valves utilize a flapper
as a closure mechanism fitted within a body or housing member to
enable control over fluid flow through a primary longitudinal bore
upon an appropriate signal from a control system. The signal
typically is a rapid reduction of the hydraulic operating pressure
that holds the valve open, thereby facilitating shut-in of the
production or injection flow. The closure mechanism typically is
movable between the full closed and full open positions by movement
of a tubular device, often called a flow tube. The flow tube can be
moved to the open position or operated by the valve actuator which
is motivated by hydraulics, pressure, electronics, or other
external signal and power sources. The shifting of the flow tube to
a closed position typically is performed by a mechanical power
spring and/or a pressurized accumulator that applies a required
load to move the flow tube to the closed position upon interruption
of the "opening" signal. As a result, the valve may occasionally be
required to close against a moving flow stream in the performance
of its designed function. However, this action can subject the
valve to substantial loading forces.
SUMMARY
[0005] In general, the present invention provides a system and
method for controlling flow in a wellbore. A flow control system
combines a flow reduction mechanism with a flow control device,
such as a valve. The flow reduction mechanism comprises a closure
member, such as a flapper type device having one or more flapper
elements pivotally mounted in the flow reduction mechanism. The
flow reduction mechanism actuates prior to or in conjunction with
the flow control device to reduce flow and thus reduce the loading
forces that would otherwise act against the flow control device
upon closure of the flow control device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Certain embodiments of the invention will hereafter be
described with reference to the accompanying drawings, wherein like
reference numerals denote like elements, and:
[0007] FIG. 1 is a front elevation view of a well assembly having a
flow control system deployed in a wellbore, according to an
embodiment of the present invention;
[0008] FIG. 2 is a schematic illustration of a flow reduction
mechanism used with the flow control system of FIG. 1, according to
an embodiment of the present invention;
[0009] FIG. 3 is a cross-sectional view taken generally along the
axis of one example of the flow reduction mechanism illustrated in
FIG. 2, according to an embodiment of the present invention;
[0010] FIG. 4 is another cross-sectional view taken generally along
the axis of the flow reduction mechanism while in a closed
configuration, according to another embodiment of the present
invention;
[0011] FIG. 5 is a cross-sectional view similar to that of FIG. 4,
but showing the flow reduction mechanism shifted to an enclosed,
open configuration, according to an embodiment of the present
invention;
[0012] FIG. 6 is a cross-sectional view of another example of a
flow reduction mechanism while in a closed configuration, according
to an embodiment of the present invention;
[0013] FIG. 7 is a perspective view of the flow reduction mechanism
similar to that of FIG. 6 while in a closed configuration,
according to another embodiment of the present invention;
[0014] FIGS. 8A and 8B are perspective views of a single and
multiple orifice flapper valve according to another embodiment of a
component of the present invention; and
[0015] FIG. 9 is a perspective view of a dual element flapper valve
according to another embodiment of a component of the present
invention.
DETAILED DESCRIPTION
[0016] In the following description, numerous details are set forth
to provide an understanding of the present invention. However, it
will be understood by those of ordinary skill in the art that the
present invention may be practiced without these details and that
numerous variations or modifications from the described embodiments
may be possible.
[0017] The present invention generally relates to a flow control
system used to control flow in a wellbore. For example, the flow
control system comprises a flow control device combined with a flow
reduction mechanism for use in a variety of well related
operations. The flow control system can be used in production
and/or injection operations.
[0018] Generally, combining the flow restricting or flow reduction
mechanism with the flow control device reduces potential loads
acting on the flow control device which enhances the ability of the
flow control device to close and seal effectively. In production
applications, this allows higher production rates without adverse
impact on the reliability of the flow control device. In many
applications, the flow reduction mechanism is designed to actuate
prior to closure of the flow control device to reduce flow through
the closure device. The flow reduction mechanism can actuate
separately or in concert with the flow control device. In some
embodiments, the flow reduction mechanism can be disposed in a body
of the flow control device and also utilize certain common
actuation components.
[0019] The flow reduction mechanism reduces the flow rate through
the flow control device, e.g. valve, which thereby reduces the
loading forces applied to the actuation mechanism components during
performance of a primary function of the flow control device, i.e.
shutting off flow during an uncontrolled flow event. In a producing
well, for example, the production flow is shut off during an
uncontrolled event. The flow reduction device does not normally
affect the nominal flow area of the flow control device, which
allows the nominal flow area to remain unobstructed during normal
flow periods although in some situations the nominal flow area may
be slightly reduced. However, the ability to reduce flow enables
higher initial flow rates through the flow control device because
the closure rate and flow induced loadings are reduced by the flow
reduction mechanism prior to exposing the flow control device to
full dynamic closure loading.
[0020] As a result, the flow reduction device is useful in
conjunction with a variety of flow control devices, including
subsurface safety valves and other valves used in oil or gas
production and injection well completions, to prevent uncontrolled
well flows for example. The flow reduction method and system also
enables higher flow rates and provides protection in wells having
flow rates that can be potentially damaging to flow control devices
during emergency closures, or slam closures for example. Use of the
flow reduction device within the flow control system results in a
reduction of the flow related loading caused by the rapid closures
of the primary valve system, thereby allowing the application of
valve systems of high durability within dimensional and flow rate
limits that are otherwise impractical. The flow reduction device
can be used as part of or in cooperation with many types of flow
control devices having flapper mechanisms and other types of
closure mechanisms. Additionally, the flow reduction device may be
mounted with a variety of methods such as casing mounted, tubing
mounted, or wireline mounted for example. However, the flow
reduction device is not to be limited for use with safety valves or
to prevent uncontrolled well flows, any application requiring a
reduced flow rate in either direction though a well bore may
incorporate a flow reduction device.
[0021] Referring generally to FIG. 1, one embodiment of a well
system is illustrated as utilizing a flow control system that
comprises a flow reduction mechanism to reduce loading on the
corresponding flow control device. In this embodiment, a well
system 30 comprises a well equipment string, such as a completion
string 32, deployed in a wellbore 34 via a conveyance 36. The
wellbore 34 is drilled into a subsurface formation 38 that may
contain desirable production fluids, such as petroleum. In the
example illustrated, wellbore 34 is lined with a casing 40. The
casing 40 typically is perforated to form a plurality of
perforations 42 through which fluid can flow from formation 38 into
wellbore 34 during production or from wellbore 34 into formation 38
during an injection operation.
[0022] In the embodiment illustrated, completion 32 and conveyance
36 comprise an internal fluid flow passage along which fluid
potentially can flow downhole and/or uphole, depending and the
operation being conducted. In most applications, completion 32 is
formed as a tubular and may comprise a variety of components 44
depending on the specific operation or operations that will be
performed in wellbore 34. A flow control system 46 is positioned to
enable control over flow through completion 32 or along other fluid
flow paths routed through a variety of wellbore tubulars or other
fluid conducting components. In the embodiment illustrated, flow
control system 46 may be coupled to components 44 of completion 32.
Additionally, flow control system 46 comprises a primary flow
control device 47, such as a valve, and a flow reduction mechanism
48. Flow control device 47 may comprise a subsurface safety valve
or a variety of other valves or flow control devices. Generally,
flow control device 47 comprises a barrier mechanism 49, such as a
flapper, that can be used to shut off flow through completion 32.
Barrier mechanism 49, however, also may comprise ball valves and
other types of barrier devices that can move between open and
closed positions. Completion 32 also may utilize one or more
packers 50 positioned and operated to selectively seal off one or
more well zones along wellbore 34 to facilitate production and/or
injection operations.
[0023] Flow reduction mechanism 48 provides flow control device 47,
e.g. a subsurface safety valve or other downhole flow controlling
device, with the capability of actuation against production flow
rates where proper actuation would otherwise be unattainable. The
flow reduction mechanism is positioned in the flow path (or area of
flow) through flow control device 47 and is selectively actuatable
to reduce flow through device 47 to a portion of its full flow
capacity. Actuation of the flow reduction mechanism 48 may be
separate or in conjunction with actuation of flow control device 47
and may include, but not be limited by, one of the following
methods: mechanical, hydraulic, electrical, magnetic, electronic,
pressure, thermal, and chemical, among others. Flow reduction
mechanism 48 also can be utilized with other downhole valves and
devices that benefit from restricting flow through the device prior
to activation of the device closure system.
[0024] As illustrated, wellbore 34 is a generally vertical wellbore
extending downwardly from a wellhead 51 disposed at a surface
location 52. However, flow control system 30 can be utilized in a
variety of vertical and deviated, e.g. horizontal, wellbores to
control flow along tubulars positioned in those wellbores.
Additionally, the wellbore 34 can be drilled in a variety of
environments, including subsea environments. Regardless of the
environment, flow control system 46 is used to provide greater
control over flow and to enable fail safe operation.
[0025] Referring generally to FIG. 2, one example of flow reduction
mechanism 48 is illustrated schematically as deployed in a tubular
structure 54 that may be part of completion 32. Tubular structure
54 also may be the longitudinal region of the flow area of flow
control device 47 (see FIG. 1). In this embodiment, flow reduction
mechanism 48 comprises a flow restriction assembly 56 that may
include a variety of flow reducing members, such as a flapper
assembly having one or more flapper elements 58. In other
embodiments, however, flow restriction assembly 56 may comprise
collets, slidable segmented plates, or other devices that are
readily movable between open and closed positions. By way of
further example, flapper element 58 may comprise a single flapper
element with an opening 59. In other embodiments, opening 59 may be
formed by a plurality of flapper elements 58 that close in a manner
that forms opening 59 to restrict flow while allowing a desired
amount of flow.
[0026] In the embodiment illustrated, flapper element 58 is
pivotally mounted in flow reduction mechanism 48 via a pivot
connection 60. When flow reduction mechanism 48 is positioned as
illustrated, flapper element 58 restricts flow moving along a flow
path 62. In one example, flapper element 58 can be designed to
pivot to an open position under the influence of fluid flowing in a
downhole direction. However, when flow moves in an opposite, e.g.
uphole, direction flapper element 58 is automatically pivoted to a
flow restricting position.
[0027] Flow reduction mechanism 48 further comprises an actuation
assembly 64, a stored energy assembly 66, and an isolation assembly
68. The actuation assembly 64 is designed to force the flow
reduction mechanism 48 to a position in which flapper element or
elements 58 are held in an open position when provided with an
appropriate signal/input. The signal may be provided via, for
example, a control line 70 that extends to a surface location. The
stored energy assembly 66 acts against the actuation assembly 64 to
bias the flow reduction mechanism 48 toward a configuration in
which flapper elements 58 can pivot to a closed position. Actuation
assembly 64 is selectively operable to shift flow reduction
mechanism 48 from this latter configuration by moving an isolation
assembly 68 to a position that holds mechanism 48 in an open flow
configuration. For example, actuation assembly 64 can be operated
to move isolation assembly 68 in a manner that forces flapper
element 58 to an open position. When the input to actuation
assembly 64 is changed, stored energy assembly 66 is able to return
isolation assembly 68 to its initial position, thus allowing free
operation of valve assembly 56, e.g. free pivoting motion of
flapper element 58 to the closed position.
[0028] The components of flow reduction mechanism 48 can be
designed in a variety of configurations. For example, actuation
assembly 64 may comprise a hydraulic piston, an electro-mechanical
device, a gas-piston coupled with a hydraulic system, or other
devices that may be selectively actuated to move isolation assembly
68. The actuation assembly 64 also can be designed to operate under
the influence of flow directed downhole. Depending on the design of
actuation assembly 64, control line 70 may comprise a hydraulic
control line, an electric control line, an optical control line, a
wireless signal receiver, or other suitable devices for providing
the appropriate signal to actuation assembly 64. Additionally,
stored energy assembly 66 may comprise a variety of devices, such
as one or more springs. By way of example, stored energy assembly
66 may comprise one or more coil springs, gas springs, wave
springs, power springs or other suitable springs able to store
energy upon movement of isolation assembly 68 via actuation
assembly 64. Depending on the requirements of a given application,
the orientation of the stored energy assembly 66 can be selected to
hold the device in a normally closed or normally open position. In
alternative embodiments, stored energy assembly 66 could be
replaced with a second control line, e.g. a second hydraulic line,
to cause movement of isolation assembly 68 back to its previous
position.
[0029] The isolation assembly 68 is designed to cooperate with flow
restriction assembly 56 in a manner that enables selective shifting
of the restriction assembly 56 to an open position. For example,
when flow restriction assembly 56 comprises flapper element 58,
isolation assembly 68 can comprise a tubular member 72 positioned
to move into flapper element 58 and to pivot flapper element 58 to
an open position. In some applications, tubular member 72 is the
same flow tube used to actuate the primary flow control device 47
(see FIG. 1) from one operational position to another. It should be
noted that isolation assembly 68 can be designed in a variety of
configurations. In an alternate embodiment, the illustrated
isolation assembly can even be replaced with levers or other
mechanisms able to open and close the flappers 58 or other closure
elements. In still other embodiments, isolation assembly 68 can be
actuated by fluid velocity.
[0030] In fact, flow control device 47 (see FIG. 1) and flow
reduction mechanism 48 can be designed and positioned in a variety
of cooperative configurations. For example, flow control device 47
may comprise a valve, e.g. a subsurface safety valve, having a
variety of primary motivators or operators that can be positioned
to actuate both the valve and the flow reduction mechanism 48. For
example, tubular member 72 may be formed as part of the primary
motivator for actuating the valve-type flow control device 47. In
other embodiments, alternate mechanisms can be used to actuate the
flow reduction mechanism 48 and the flow control device 47. The use
of alternate mechanisms facilitates positioning of the flow
reduction mechanism 48 and flow control device 47 in adjacent
housings or in separate subs. Regardless, the flow reduction
mechanism 48 is designed to selectively reduce the available flow
rate which, in turn, reduces impact loading during slam closures of
the primary sealing mechanism, e.g. flapper element 49, of the flow
control device 47.
[0031] A specific example of a flow reduction mechanism 48 is
illustrated in FIGS. 3-5. In this embodiment, flow reduction
mechanism 48 comprises flapper element 58 and specifically a
plurality of flapper elements 58 that form opening 59 when closed.
The flapper elements 58 are pivotally mounted to enable full bore
flow of fluid, illustrated by arrows 74, when the flow control
device is in the position illustrated in FIG. 3. When fluid is
flowed through flow restriction assembly 56 in the direction of
arrows 74, flapper elements 58 can freely pivot to an open position
to enable flow along the fluid flow path 62. However, fluid flow in
an opposite, e.g. uphole, direction is reduced/restricted to
facilitate actuation of flow control device 47 (see FIG. 1).
[0032] In this embodiment, actuation assembly 64 comprises a
hydraulic actuation assembly having a hydraulic piston assembly 76
coupled to a hydraulic control line 70. Pressurized hydraulic fluid
can be selectively applied via control line 70 to shift hydraulic
piston assembly 76 along wellbore tubular 54. The hydraulic piston
assembly 76 is operatively connected to both isolation assembly 68
and stored energy assembly 66. For example, hydraulic piston
assembly 76 may be positioned to act against a shoulder 78 of a
tubular isolation assembly 68 in a first direction, and stored
energy assembly 66 may be positioned to act against an opposing
shoulder 80 of tubular isolation assembly 68 in an opposing
direction, as further illustrated in FIG. 4. In this embodiment,
isolation assembly 68 comprises tubular member 72, and stored
energy assembly 66 is in the form of a coil spring 82 disposed over
tubular member 72 and between tubular member 72 and the surrounding
wellbore tubular 54.
[0033] When an appropriate hydraulic input is provided to actuation
assembly 64, the hydraulic piston assembly 76 is shifted or moved
along wellbore tubular 54. The movement of hydraulic piston
assembly 76 forces tubular member 72 of isolation assembly 68 to
slide along wellbore tubular 54 compressing coil spring 82. The
continued movement of isolation assembly 68 forces tubular member
72 through flapper elements 58, as illustrated in FIG. 5. Movement
of tubular member 72 effectively forces flow restriction assembly
56 and flapper elements 58 to an open configuration in which fluid
can freely flow along the fluid flow path, as represented by arrow
84. In the embodiment illustrated, tubular member 72 encloses
flapper elements 58 in a cavity 86 formed between tubular member 72
and wellbore tubular 54. The enclosed flapper elements 58 are
completely isolated from the flow of fluid through flow control
device 47 (see FIG. 1) and flow reduction mechanism 48. In fact,
tubular member 72 of the isolation assembly 68 can be positioned to
abut a corresponding step 88 of tubular member 54 to create a
smooth transition 90 that does not obstruct fluid flow along fluid
flow path 62. In at least some applications, tubular member 72 and
the input, e.g. hydraulic input, used to shift tubular member 72
can be used to actuate both flow reduction mechanism 48 and flow
control device 47 to a desired operational configuration.
[0034] Stored energy assembly 66, in the form of coil spring 82,
maintains a biasing force against isolation assembly 68 while the
flow reduction mechanism 48 is maintained in its open configuration
illustrated in FIG. 5. Upon further actuation of assembly 64, e.g.
upon release of hydraulic pressure acting on hydraulic piston
assembly 76, the stored energy assembly 66 is allowed to move
isolation assembly 68 back to its previous position in which
flapper elements 58 are able to pivot to the closed, flow
restricting configuration.
[0035] Modifications in the various assemblies of flow control
system 46 (see FIG. 1) can be adopted according to overall system
design requirements and environmental factors. For example,
individual or multiple flapper elements 58 can be utilized in a
variety of shapes and sizes, and the flapper elements can be
deployed at single or multiple locations along the wellbore
tubular. Additionally, the stored energy systems and isolation
systems can be changed according to the overall design of the flow
control system 46, completion 32, and/or well system 30.
Furthermore, control signals can be supplied to actuation assembly
64 from a surface location or from a variety of other locations at
or away from the well site. The control signals can be carried by a
variety of wired or wireless control lines as required by the
actuator assembly to enable selective shifting of the flow
reduction mechanism 48 and flow control device 47 (see FIG. 1) from
one configuration to another.
[0036] Another specific example of a flow reduction mechanism 48 is
illustrated in FIGS. 6-7. In this embodiment, flow reduction
mechanism 48 comprises a ball valve element 98 that forms an
opening 99 when closed. When fluid is flowed through flow
restriction assembly 56 comprising the ball valve element 98 in the
direction of arrows 74, fluid flow is reduced/restricted by the
opening 99 to facilitate actuation of flow control device 47 (see
FIG. 1). However, when the ball valve element 99 is pivoted to an
open configuration (not shown), the flow restriction assembly 56 is
configured to enable full bore flow of fluid. It should be noted
that the flow reduction mechanism 48 can be designed and actuated
in a variety of configurations.
[0037] Referring generally back to FIG. 1, various features and
components can be integrated into or used in conjunction with the
flow control system 46. For example, the flow control device can
incorporate internal self-equalizing components to equalize
pressures above and below barrier element 49. The flow control
device 47 also may comprise an internal profile with sealing
capability to enable acceptance of through-tubing accessories, such
as plugs, flow measurement tools, lock mandrels, and other
accessories. In some embodiments, the flow control system 46 may
incorporate a locking mechanism that can be actuated to either
temporarily or permanently lock the flow control system in an open
state to facilitate removal of components, installation of
components, and other service operations.
[0038] Other examples of components that can be used with the flow
control system include dynamic or static mechanisms positioned to
prevent debris from entering portions of the flow control device 47
or flow reduction mechanism 48 that would interfere with the
function of their respective closure members. In some applications,
the flow control system 46 may be constructed with a body having an
eccentric design to optimize the inside diameter to outside
diameter relationship. A variety of chemical injection systems also
can be incorporated with the flow control system to enable
selective injection of chemicals during service operations or other
downhole operations. The flow control device 47 and/or flow
reduction mechanism 48 can further incorporate mechanisms that
enable selective mechanical actuation of the system if
necessary.
[0039] Referring now to FIGS. 8A-8B, another embodiment of a
component used with a flow control system may include a flapper
valve with a flapper mechanism containing an orifice. In FIG. 8A, a
flapper mechanism 200 may contain a single orifice 210 or in some
cases, as shown in FIG. 8B, a flapper mechanism 300 may contain
multiple orifices 210. Although a circular orifice 210 is shown in
both figures, embodiments of the present invention may not be
limited to any particular geometry. Also, only the flapper
mechanism 200, 300 is shown in these figures. A person of skill in
the art would recognize other components (not shown) such as, for
example, a spring to bias the flapper mechanisms 200, 300 in a
closing direction, a tube or other device to open the flapper
mechanism 200, 300, and a valve seat for abutting against the
flapper mechanism 200, 300 when closed. In some embodiments, a
series of flapper valves may be used in an incremental fashion
prior to actuation of the flow control device 47.
[0040] Yet another exemplary embodiment of a component used in a
flow control system is illustrated in FIG. 9. In this embodiment, a
flapper valve comprising a first flapper mechanism 410 and a second
flapper mechanism 420 may be used. The first and second flapper
mechanisms 410, 420 may contain one or more orifices 210 similar to
flapper valves 200, 300. In addition or alternatively, the first
and second flapper mechanisms 410, 420 may close to form orifices.
As shown, the first flapper mechanism 410 may contain a
semi-circular groove 225 and the second flapper mechanism 420 may
contain a corresponding semi-circular groove 225. When the first
and second flapper mechanisms 410, 420 are actuated, the
corresponding semi-circular grooves 225 may form an orifice
configured to reduce the flow of a fluid through a well bore.
Although identical grooves 225 are shown in the first and second
flapper mechanisms 410, 420, this is only to simplify the detailed
description and not to limit the range and location of flow
reducing devices. As with the flapper mechanisms 200 and 300, other
components used to implement the flapper valve are not shown but
are within the knowledge of a person of skill in the art.
[0041] In some embodiments, activation, positions of the flow
control device 47 and/or the flow reduction mechanism 48, and
operation may be measured and/or monitored using sensor technology.
The sensor technology may be provided within the flow control
device 47 and/or the flow reduction mechanism 48 to measure the
well fluid flows, temperatures, pressures, and stresses within the
system, among other parameters. The sensor technology may be used
to identify the location of the flow control device 47 and the flow
reduction mechanism 48 within multiple zones of a multi-zone
formation.
[0042] Accordingly, although only a few embodiments of the present
invention have been described in detail above, those of ordinary
skill in the art will readily appreciate that many modifications
are possible without materially departing from the teachings of
this invention. Such modifications are intended to be included
within the scope of this invention as defined in the claims.
Additionally, the use of the word closed or opened should be
interpreted with their broadest meanings. For example, closed or a
derivative of closed should include but not be limited in
interpretation to mean actuated, shifted, etc., while opened or a
derivative of open should likewise include unrestricted, un
actuated, etc.
* * * * *