U.S. patent application number 14/705817 was filed with the patent office on 2015-09-10 for apparatus and method to remotely control fluid flow in tubular strings and wellbore annulus.
This patent application is currently assigned to MIT Innovation Sdn Bhd. The applicant listed for this patent is MIT Innovation Sdn Bhd, Petroliam Nasional Berhad (PETRONAS). Invention is credited to Mohammed Abdulmalek Aldheeb, Karam J. Jawamir, Raed Ismail Kafafy, Abdul Mushawwir Khalil, Ahmed Moustafa Tahoun.
Application Number | 20150252651 14/705817 |
Document ID | / |
Family ID | 49324049 |
Filed Date | 2015-09-10 |
United States Patent
Application |
20150252651 |
Kind Code |
A1 |
Tahoun; Ahmed Moustafa ; et
al. |
September 10, 2015 |
Apparatus and Method to Remotely Control Fluid Flow in Tubular
Strings and Wellbore Annulus
Abstract
A method and apparatus is disclosed for remotely and selectively
controlling fluid flow through tubular string disposed within a
wellbore and further control fluid flow between the tubular string
inner flow passage and the annular flow passage. The present
invention further discloses a method of selectively and remotely
receiving and interpreting a for of command or information at a
desired apparatus within the wellbore caused by the operator on
earth surface.
Inventors: |
Tahoun; Ahmed Moustafa;
(Agawam, MA) ; Kafafy; Raed Ismail; (Setapak,
MY) ; Jawamir; Karam J.; (KL, MY) ; Aldheeb;
Mohammed Abdulmalek; (KL, MY) ; Khalil; Abdul
Mushawwir; (KL, MY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MIT Innovation Sdn Bhd
Petroliam Nasional Berhad (PETRONAS) |
Kuala Lumpur
Kuala Lumpur |
|
MY
MY |
|
|
Assignee: |
; MIT Innovation Sdn Bhd
Kuala Lumpur
MY
Petroliam Nasional Berhad (PETRONAS)
Kuala Lumpur
MY
|
Family ID: |
49324049 |
Appl. No.: |
14/705817 |
Filed: |
May 6, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13861255 |
Apr 11, 2013 |
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14705817 |
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13846946 |
Mar 18, 2013 |
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13861255 |
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61710887 |
Oct 8, 2012 |
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61710823 |
Oct 8, 2012 |
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61622572 |
Apr 11, 2012 |
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61710887 |
Oct 8, 2012 |
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61710823 |
Oct 8, 2012 |
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61622572 |
Apr 11, 2012 |
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61648575 |
May 17, 2012 |
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Current U.S.
Class: |
166/250.01 ;
166/53 |
Current CPC
Class: |
E21B 21/103 20130101;
E21B 41/0085 20130101; E21B 47/00 20130101; E21B 23/006 20130101;
E21B 34/102 20130101; E21B 2200/04 20200501; E21B 34/06 20130101;
E21B 34/066 20130101 |
International
Class: |
E21B 34/06 20060101
E21B034/06; E21B 21/10 20060101 E21B021/10; E21B 47/00 20060101
E21B047/00; E21B 41/00 20060101 E21B041/00 |
Claims
1. An apparatus for remotely controlling fluid flow in a wellbore
based on changing the environment in the wellbore, the apparatus
disposed on a tubular string in the wellbore, the apparatus
comprising: a body, an inner passage through the body, an orifice
to the inner passage disposed on a lateral side of the body, a
valve having a movable element, the valve disposed in fluid
communication with the inner passage and the orifice, a means for
actuating the valve element, a means for powering the means for
actuating the valve element, a means for disabling movement of the
valve element, a means for detecting at least one change in the
environment in the wellbore, a means for decoding the at least one
change in the environment, and wherein the means for disabling
movement of the valve element is responsive to the means for
decoding, and wherein the means for actuating the valve element is
responsive to the means for decoding.
2. The apparatus of claim 1 wherein the moveable element is
rotatable to a plurality of predetermined positions.
3. The apparatus of claim 2 wherein the plurality of predetermined
positions comprise at least two predetermined positions selected
from the set of predetermined positions including: restricted fluid
flow through the inner flow passage and restricted flow between the
inner flow passage and a wellbore annulus through the orifice;
fluid flow communication through the inner flow passage and
restricted fluid flow between the inner flow passage and a annular
flow passage through the orifice; fluid flow communication between
a first end of the body and an annular flow passage and restricted
flow between a second end of the body and the annular flow passage;
and fluid flow communication between the first end of the body and
an annular flow passage and fluid flow communication between the
second end of the body and the annular flow passage.
4. The apparatus of claim 2 wherein the rotatable element comprises
at least one surface of spherical shape and at least two ports and
one cavity.
5. The apparatus of claim 1 wherein the detecting means comprises a
sensor.
6. The apparatus of claim 5 wherein the sensor is positioned and
arranged in the wellbore environment and configured to sense at
least one physical property of the environment.
7. The apparatus of claim 1 wherein the apparatus comprises: at
least one means for detecting a plurality of intended changes in at
least one physical property of the environment resulting in a
detectable signal within the apparatus for processing the
signal.
8. The apparatus of claim 1 wherein the means for powering
comprises an electric generator.
9. The apparatus of claim 8 wherein the electric generator is an
electric generator positioned and arranged to receive hydraulic
energy from fluid in the tubular string and is configured to
provide electrical energy to the means for actuating.
10. The apparatus of claim 8 wherein the electric generator is an
electric generator positioned and arranged to receive hydraulic
energy from a fluid pressure difference between the inner fluid
passage and the annular fluid passage.
11. The apparatus of claim 1 wherein the means for powering
comprises a means for transforming hydraulic energy from fluid in
the wellbore.
12. The apparatus of claim 1 wherein the means for powering
comprises an energized resilient element.
13. The apparatus of claim 1 wherein the means for actuating
comprises an electric motor.
14. A method of remotely and selectively controlling an apparatus
disposed in a tubular string within a wellbore, the method
including: disposing in a wellbore a tubular string including an
apparatus, the apparatus comprising: a body defining boundaries
between an inner flow passage through the said apparatus and an
annular flow passage within the wellbore annulus and having two
suitable end connections; at least one controllable element
operable in plurality of desired states; an activator disposed
within the body capable of selectively changing the apparatus into
either one of two modes: a disabled mode wherein the at least one
controllable element is not operable, and an enabled mode wherein
the at least one controllable element is operable to a desired
state, comprising a sensor capable of detecting an intended change
in a physical property of an environment; and an actuator suitable
for changing the at least one controllable element into a desired
state; causing a change in a physical property of the environment
in certain sequence within a specified period of time resulting in
a detectable pattern at the sensor, the change in a physical
property comprising a sequence of a plurality of signal variations
within a suitable period of time; comparing the said detectable
pattern with a command pattern to determine if the controllable
element state is desired to be changed to a different desired state
and then causing the activator to change the apparatus mode into
the suitable mode; and causing the actuator to convert a suitably
available energy source, causing the at least one controllable
element into the different desired state.
15. The method of claim 14 wherein the change in a physical
property of the environment is a mechanical movement of the
apparatus by means of moving the tubular string, causing the
apparatus to move within the wellbore in at least one direction
detectable by the said sensor.
16. The method of claim 14 wherein the change in a physical
property of the environment is a change of property of fluid
introduced from surface into the wellbore detectable by the
sensor.
17. The method of claim 14 wherein the change of physical property
includes a change in one or more of the following fluid properties:
pressure, temperature, flow rate, density, viscosity, color, and
composition, detectable by the sensor.
18. The method of claim 14 wherein the change in a physical
property of the environment is a change of electromagnetic field
detectable by the said sensor,
19. The method of claim 14 wherein the change in a physical
property of the environment is a change of electric field
detectable by the said sensor,
20. The method of claim 14 wherein the at least one controllable
element is a valve.
21. A method for remotely and selectively controlling fluid flow in
a tubular string and wellbore annulus, the method comprising:
disposing a tubular string into a wellbore comprising at least one
flow control apparatus, the apparatus comprising: a body defining
boundaries between an inner flow passage through the said apparatus
and an annular flow passage within the wellbore annulus and having
two suitable end connections and at least one lateral hole suitable
for connecting the inner flow passage and the annular flow passage;
a controllable valve operable in a plurality of desired states
altering the fluid flow pattern within the wellbore, wherein the
valve includes at least one rotatable element having plurality of
surfaces, wherein the rotatable element is rotatable to a plurality
of desired positions, wherein the valve further divides the inner
flow passage into an upstream section and a downstream section,
wherein the upstream section is the portion of the inner flow
passage from the valve and through one end connection of the body
and the downstream section is the portion of the inner flow passage
from the valve and through the other end connection of the body; an
activator disposed within the body capable of selectively changing
the apparatus into either one of two modes: a disabled mode, where
the valve is not operable, and an enabled mode, where the valve is
operable to a desired state, comprising a means responsive to an
intended change in the environment; and an actuator capable of
changing the position of the rotatable element to cause the valve
into a desired state, comprising a means for transforming a
suitably available energy source into a mechanical movement;
causing a plurality of changes in one or more physical property of
the environment within a specified period of time resulting in a
detectable pattern at the sensor comprising a plurality of signal
variations within a suitable period of time; comparing the
detectable pattern with a command pattern to determine if the valve
state is desired to be changed to a different desired state and
then causing the activator to cause the apparatus mode into the
desired mode; and causing the actuator to change the rotatable
element position to cause the valve into a different state
resulting in a change of the fluid flow pattern by the desired
apparatus into a desired flow pattern.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/710,887, filed Oct. 8, 2012.
[0002] This application claims the benefit of U.S. Provisional
Application No. 61/622,572, filed Apr. 11, 2012.
[0003] This application claims the benefit of U.S. Provisional
Application No. 61/710,823, filed Oct. 8, 2012.
BACKGROUND OF INVENTION
[0004] 1. Technical Field
[0005] This invention is related to tools and methods that are
used, for example, in oil and gas drilling and completion. The
present invention is related, for example, to a device or apparatus
for controlling fluid flow within a tubular string. In a particular
example, the device or apparatus is used in the control of fluid
flow between a tubular string inner flow passage and its annular
flow passage in the wellbore by selectively and remotely sending a
command to the apparatus disposed within wellbore.
[0006] 2. Discussion of Background
[0007] U.S. Patent Application Publication US20120255741A1
published on Oct. 11, 2012 for ANNULAR CIRCULATION VALVE AND
METHODS OF USING THE SAME, by A. Stewart, and is herein
incorporated by reference.
[0008] U.S. Patent Application Publication US20110088914A1
published on Apr. 21, 2011 for METHOD OF ACTIVATING A DOWNHOLE TOOL
ASSEMBLY, by M. Howell, et al. and is herein incorporated by
reference.
[0009] U.S. Patent Application Publication US20110048723A1
published on Mar. 03, 2011 for MULTI-ACTING CIRCULATING VALVE by J.
Edwards, and is herein incorporated by reference.
[0010] U.S. Patent Application Publication US20110088906A1
published on Apr. 21, 2011 for PRESSURE EQUALIZING A BALL VALVE
THROUGH AN UPPER SEAL BYPASS, by T. Myerley, and is herein
incorporated by reference.
[0011] U.S. Pat. No. 8,327,954B2 issued on Dec. 11, 2012 for
OPTIMIZED REAMING SYSTEM BASED UPON WEIGHT ON TOOL, by P. Desai,
and is herein incorporated by reference.
[0012] U.S. Pat. No. 7,905,292B2 issued on Mar. 15, 2011 for
PRESSURE EQUALIZATION DEVICE FOR DOWNHOLE TOOLS, by C. Bean, et al.
and is herein incorporated by reference.
[0013] U.S. Pat. No. 7,533,728B2 issued on May 19, 2009 for BALL
OPERATED BACK PRESSURE VALVE, by D. Winslow, et al and is herein
incorporated by reference.
[0014] U.S. Pat. No. 7,520,336B2, issued on Apr. 21, 2009 for
MULTIPLE DART DROP CIRCULATING TOOL, by M. Modelli, and is herein
incorporated by reference.
[0015] U.S. Pat. No. 7,347,289B2 issued on Mar. 25, 2008 for
DART-OPERATED BIG BORE BY-PASS VALVE, by P. Lee, and is herein
incorporated by reference.
[0016] U.S. Pat. No. 7,347,288B2 issued on Mar. 25, 2008 for BALL
OPERATED BY-PASS TOOL FOR USE IN DRILLSTRING, by P. Lee, and is
herein incorporated by reference.
[0017] U.S. Pat. No. 7,334,650B2 issued on Feb. 26, 2008 for
APPARATUS AND METHODS FOR DRILLING A WELLBORE USING CASING, by R.
Giroux, et al. and is herein incorporated by reference.
[0018] U.S. Pat. No. 6,923,255B2 issued on Aug. 2, 2005 for
ACTIVATING BALL ASSEMBLY FOR USE WITH A BY-PASS TOOL IN A
DRILLSTRING, by P. Lee, and is herein incorporated by
reference.
[0019] U.S. Pat. No. 6,328,109B1 issued on Dec. 11, 2001 for
DOWNHOLE VALVE, by R. Pringle, et al. and is herein incorporated by
reference.
[0020] U.S. Pat. No. 6,289,999B1 issued on Sep. 18, 2001 for FLUID
FLOW CONTROL DEVICES AND METHODS FOR SELECTIVE ACTUATION OF VALVES
AND HYDRAULIC DRILLING TOOLS, by C. Dewey, et al. and is herein
incorporated by reference.
[0021] U.S. Pat. No. 6,148,664 issued on Nov. 21, 2000 for METHOD
AND APPARATUS FOR SHUTTING IN A WELL WHILE LEAVING DRILL STEM IN
THE BOREHOLE, by J. Baird, and is herein incorporated by
reference.
[0022] U.S. Pat. No. 5,499,687 issued on Mar. 19, 1996 for DOWNHOLE
VALVE FOR OIL/GAS WELL, by P. Lee, and is herein incorporated by
reference.
[0023] U.S. Pat. No. 5,437,308 issued on Aug. 1, 1995 for DEVICE
FOR REMOTELY ACTUATING EQUIPMENT COMPRISING A BEAN-NEEDLE SYSTEM,
by P. Morin, et al. and is herein incorporated by reference.
[0024] U.S. Pat. No. 5,318,138 issued on Jun. 7, 1994 for
ADJUSTABLE STABILIZER, by C. Dewey, et al. and is herein
incorporated by reference.
[0025] U.S. Pat. No. 5,048,611 issued on Sep. 17, 1991 for PRESSURE
OPERATED CIRCULATING VALVE, by C. Cochran, and is herein
incorporated by reference.
[0026] U.S. Pat. No. 4,889,199 issued on Dec. 26, 1999 for DOWNHOLE
VALVE FOR USE WHEN DRILLING AN OIL AND GAS WELL, by P. Lee, and is
herein incorporated by reference.
[0027] U.S. Pat. No. 4,655,289 issued on Apr. 7, 1987 for REMOTE
CONTROL SELECTOR VALVE, by W. Schoeffler, and is herein
incorporated by reference.
[0028] U.S. Pat. No. 4,574,894 issued on Mar. 11, 1986 for BALL
ACTUATED DUMP VALVE, by R. Jadwin, and is herein incorporated by
reference.
[0029] U.S. Pat. No. 4,576,233 issued on Mar. 18, 1986 for
DIFFERENTIAL PRESSURE ACTUATED VENT ASSEMBLY, by F. George, and is
herein incorporated by reference.
[0030] U.S. Pat. No. 4,452,313 issued on Jun. 5, 1984 for
CIRCULATION VALVE, by M. McMahan, and is herein incorporated by
reference.
[0031] U.S. Pat. No. 4,445,571 issued on May 1, 1984 for
CIRCULATION VALVE, by D. Hushbeck, and is herein incorporated by
reference.
[0032] U.S. Pat. No. 4,072,166 issued on Feb. 7, 1978 for VALVE
APPARATUS FOR DEEP DRILLING, by W. Tiraspolsky, et al. and is
herein incorporated by reference.
[0033] U.S. Pat. No. 3,552,412 issued on Jan. 05, 1971 for DRILL
STRING DUMP VALVE, by D. Hagar, et al. and is herein incorporated
by reference.
[0034] U.S. Pat. No. 4,058,165 issued on Aug. 30, 1938 for TESTING
CIRCULATING VALVE, by J. Holden, and is herein incorporated by
reference.
[0035] U.S. Pat. No. 2,128,352, issued on Oct. 20, 1936 for METHOD
AND APPARATUS FOR RELEASING FLUID FROM DRILL PIPE, by T. Creighton,
and is herein incorporated by reference.
[0036] U.S. Pat. No. 163,161 issued on May 11, 1875 for IMPROVEMENT
IN MAINSPRINGS FOR WATCHES, by JOHN A. DAWSON, and is herein
incorporated by reference.
[0037] One example of the current invention is to introduce a
method and apparatus tier selectively and remotely controlling
fluid flow through a tubular string and its surrounding wellbore
annulus and, thus, changing the fluid flow profile within wellbore.
In one example, a fraction or all of the fluid is diverted from
within the inner fluid flow passage of the tubular string and the
apparatus to the wellbore annulus. In one example, the current
invention makes it possible to control the fluid flow profile in
the wellbore and tubular string and, accordingly, significantly
reduce risks and operating cost associated with cutting beds. Risks
associated with fluid-losses are caused by various reasons, some of
which were explained by way of examples: risks associated with
accumulation of suspended cuttings, among other operating risks,
where change of fluid flow profile within the wellbore is desired.
In another example of the current invention, a method is introduced
for remotely operating a downhole apparatus selectively into a
desired state without limiting other operations, such as flow rate
or flow pressure, during periods when it is not desired to change
fluid flow pattern.
[0038] U.S. Pat. No. 4,889,199 to Lee discloses a plastic, i.e.,
deformable ball used to block a flow opening in the sleeve for
positioning the sleeve and aligning flow ports. This form of flow
control apparatus is operated using what is called drop ball. A
ball is inserted into the string at the surface and pumped down the
inner flow passage of the tubular string to engage the sleeve
profile. Such drop ball-operated apparatus often introduces
limitations to the drilling practices, causing increase in
operating cost. For example, the drop ball introduces restrictions
within the inner flow passage and imposes limitations on running
services using wireline to access, for example, to run free point
services or interact with logging while drilling equipment located
beneath the drop ball operated apparatus.
[0039] Another form of flow control apparatus, sometimes called
bypass tool or called circulation apparatus, defines ports in the
apparatus body which are initially closed by an axially movable
sleeve.
[0040] Other downhole remotely-operated apparatus, such as those in
sited references, induce limitation in the operating practice since
fluid flow properties such as flow rate or pressure must to be kept
within certain levels to maintain the apparatus in the
corresponding state. This limitation causes the drilling operation
efficiency to suffer as it may be desirable to operate the drilling
fluid, for example, with a different flow profile, such as at a
different flow rate or pressure that my undesirably cause the
apparatus to change mode.
[0041] What is needed is a way to selectively turn on or off the
flow control device, locking it in a particular desired fluid flow
profile (or "state") when in an "oft" or disabled mode along with a
way to selectively turn "on" the flow control device (into an
"enabled" mode) and thereby be enabled to change to another desired
fluid flow profile (change to another "state"). To further satisfy
this need, what is needed is a way to communicate the desired mode
and desired state to the flow control device using deliberate
changes to the environment surrounding the flow control device,
such as altering the pressure of the fluid in the tubular or
wellbore in a predetermined sequence, or using a combination of
sensors to discern the communicated command. What is further needed
is a way to power the actuation of the flow control device between
the various fluid flow states and power to set the enabled or
disabled mode.
SUMMARY OF SOME EXAMPLES OF THE INVENTION
[0042] In one example, disclosed is an apparatus for remotely
controlling fluid flow in a wellbore based on changing the
environment in the wellbore, the apparatus disposed on a tubular
string in the wellbore, the apparatus including: a body, an inner
passage through the body, an orifice to the inner passage disposed
on a lateral side of the body, a valve having a movable element,
the valve disposed in fluid communication with the inner passage
and the orifice, a. means for actuating the valve element, a means
for powering the means for actuating the valve element, a means for
disabling movement of the valve element, a means for detecting at
least one change in the environment in the wellbore, a means for
decoding the at least one change in the environment, wherein the
means for disabling movement of the valve element is responsive to
the means for decoding, and wherein the means for actuating the
valve element is responsive to the means for decoding.
[0043] In one example, the moveable element is rotatable to a
plurality of predetermined positions.
[0044] In one example, the plurality of predetermined positions
comprises at least two predetermined positions selected from the
set of predetermined positions including: restricted fluid flow
through the inner flow passage and restricted flow between the
inner flow passage and a wellbore annulus through the orifice;
fluid how through the inner flow passage and restricted fluid flow
between the inner flow passage and a wellbore annulus through the
orifice; fluid flow communication between a first end of the body
and a wellbore annulus and restricted flow between a second end of
the body and the wellbore annulus; and fluid flow communication
between the first end of the body and a wellbore annulus and fluid
flow communication between the second end of the body and the
wellbore annulus.
[0045] In one example, the rotatable element comprises at east one
surface of spherical shape and at least two ports and one
cavity.
[0046] In one example, the detecting means comprises a sensor. In
one example, the sensor is positioned and arranged in the wellbore
environment and configured to sense at least one physical property
of the environment.
[0047] In one example, the apparatus comprises: at least one means
for detecting a plurality of intended changes in at least one
physical property of the environment resulting in a detectable
signal within the apparatus for processing the signal.
[0048] In one example, the means for powering comprises an electric
generator.
[0049] In one example, the electric generator is an electric
generator positioned and arranged to receive hydraulic energy from
fluid in the tubular string and is configured to provide electrical
energy to the means for actuating.
[0050] In one example, the electric generator is an electric
generator positioned and arranged to receive hydraulic energy from
a fluid pressure difference between the inner fluid passage and the
annular fluid passage.
[0051] In one example, the means for powering comprises a means for
transforming hydraulic energy from fluid in the wellbore.
[0052] In one example, the means fir powering comprises an
energized resilient element,
[0053] In one example, the means for actuating comprises an
electric motor.
[0054] In one set of examples, disclosed is an apparatus for
remotely controlling fluid flow in a tubular string 110 and a
wellbore annulus 156, the apparatus including: a body 200 defining
the boundaries between an inner flow passage 152 through the
apparatus and an annular flow passage 154 within the wellbore
annulus 156, the body including: a first end disposed at one end of
the body, a second end disposed at another end of the body, and at
least one lateral hole 210 disposed in a side of the body for
connecting the inner flow passage 152 and the annular flow passage
154; a controllable valve 220 disposed in the inner flow passage
152, the controllable valve 220 comprising at least one moveable
element, and where the element is movable to a plurality of
predetermined positions, positioned and arranged to alter fluid
flow between the first end, the second end, and the at least one
lateral hole, and where a predetermined position of movable element
determines a desired altered fluid flow state of controllable valve
220; a means for actuating the moveable element into at least one
of the plurality of predetermined positions; a means for powering
the means for actuating the moveable element; a means for disabling
movement of the moveable element; a means for detecting at least
one change in at least one physical property in an environmental
condition within the wellbore; a means for decoding at least one
instruction from the at least one detected change in the
environmental condition; and where the means for disabling movement
of the valve element is responsive to an instruction of the at
least one decoded instruction; and where the means for actuating
the valve element into the at least one of the plurality of
predetermined positions is responsive to an instruction of the at
least one decoded instruction.
[0055] In one example, the moveable element is rotatable to a
plurality of predetermined positions.
[0056] In one example, the plurality of predetermined positions
comprise at least two predetermined positions selected from the set
of predetermined positions including: restricted fluid flow through
the inner flow passage and restricted flow between the inner flow
passage and the wellbore annulus through the orifice, fluid flow
through the inner flow passage and restricted fluid flow between
the inner flow passage and the wellbore annulus through the
orifice; fluid flow communication between the first end of the body
and the annular flow passage and restricted flow between the second
end of the body and the annular flow passage; and fluid flow
communication between the first end of the body and the annular
flow passage and fluid flow communication between the second end of
the body and the annular flow passage.
[0057] In one example, the moveable element is suitably positioned
to cause the valve into a at least one state such that the flow
pattern will be in one of the following patterns: (a) no flow
pattern wherein the flow passage between the upstream and the
downstream is restricted and the flow passage between the inner
flow passage and the annular flow passage is also restricted; (b)
through flow pattern wherein the passage between the upstream and
the downstream of the inner flow passage is not restricted whereas
the passage between the inner flow passage and the annular flow
passages is restricted; (c) diverted flow pattern wherein the flow
passage between the upstream and the said annular flow passage is
not restricted whereas the flow passage to the downstream is
restricted; and (d) full flow pattern wherein the flow passage
between the upstream and the downstream of the inner flow passage
is not restricted and the flow passage between the said inner flow
passage and the annular flow passages is not restricted.
[0058] In one example, the means for actuating the moveable element
into at least one of the plurality of predetermined positions
includes an actuation mandrel 246 connected to actuation linkage
242 attached to push-pull point 308 causing the movable element to
rotate and change its position. In one example, the means for
actuating the moveable element into at least one of the plurality
of predetermined positions includes a pinion 420 connected to the
movable element and at least one rack 410 connected to an actuation
mandrel 246, the rack 410 and the pinion 420 engaged to move rack
410 in ascertain direction as the pinion 420 rotates around a pivot
307. In one example, the means for actuating the moveable element
into at least one of the plurality of predetermined positions
includes an electric motor mechanically connected to the moveable
le element.
[0059] In one example, the means for powering the means for
actuating the moveable element includes an actuation mandrel 246
attached to a resilient element. In one example, the resilient
element is a spring. In one example, the means for powering
includes an energized spring connected to a pinion through a worm
gear. In one example, the means for powering the means for
actuating the moveable element includes an inertia element 510
disposed within the actuation mandrel 246 having a mass capable of
storing kinetic energy. In one example, the means for powering
includes an electrical energy source one example, the electrical
energy source is a battery. In one example, the electrical energy
source is a wireline from the surface. In one example, the
electrical energy source is a fluid powered electric generator. In
one example, the means for powering includes a turbine transforming
hydraulic fluid flowing through the wellbore. In one example, the
means for powering is disposed in the tubular string. In one
example, the means for powering is disposed in a bottom hole
assembly.
[0060] In one example, the means for disabling movement of the
moveable element includes a locking means. In one example, the
means for disabling includes a lock 277 element engageable with a
locking groove 278 connected to an actuation mandrel 246. In one
example, the means for disabling includes a lock driver 720 driving
a lock 277. In one example, lock driver 720 is a motor. In one
example, lock driver 720 is a solenoid. In one example, the means
for disabling includes means for disconnecting electric energy from
an electric motor or solenoid. In one example, the means for
disabling includes a controller disconnecting electric energy from
an electric motor or solenoid.
[0061] In one example, the means tier detecting at least one change
in at least one physical property in an environmental condition
within the wellbore includes a sensor. In one example, the means
tier detecting includes a pressure sensor 272 configured to sense
pressure variation within the wellbore. In one example, the means
for detecting includes a flow sensor 272 configure to sense
variation of fluid flow rate within the wellbore. In one example,
the means for detecting includes an electrode to sense a change in
voltage or current with respect to the tubular string 110. In one
example, the means for detecting includes an electrode to sense a
change in voltage or current from an induced electric signal into
the formation. In one example, the means for detecting includes an
accelerometer affected by change of tubular string 110 movement. In
examples, the accelerometer is configured to sense movement in one
or more directions. In one example, the means for detecting
includes a sensor configured to sense magnetic field changes. In
one example, the means for detecting includes a chemical
sensor.
[0062] In one example, the means for decoding at least one
instruction from the at least one detected change in the
environmental condition includes a barrel cam track and cam
follower. In one example, the barrel cam track is disposed on a
barrel cam, the barrel cam connected to an actuation mandrel. In
one example, the means for decoding at least one instruction from
the at least one detected change in the environmental condition
includes a controller configured to compare a detected signal
pattern to a predetermined command pattern. In one example, the
controller is an electronic controller. In one example, the
controller is an electronic computational device.
[0063] In one set of examples, disclosed is an apparatus for
remotely controlling fluid flow in tubular strings and wellbore
annulus, including: (a) a body defining the boundaries between an
inner flow passage through the said apparatus and an annular flow
passage within the wellbore annulus and having two suitable end
connections and at least one lateral hole suitable for connecting
the inner flow passage and the annular flow passage; (b) a
controllable valve operable in plurality of desired states altering
fluid flow pattern within a wellbore, wherein the valve is having
at least one rotatable element having plurality of surfaces, where
the rotatable element is rotatable to a plurality of desired
positions wherein the valve further divides the inner flow passage
into upstream section and downstream, wherein the upstream section
is the portion of the inner flow passage from the valve and through
one end connection of the body and the downstream section is the
portion of the inner flow passage from the valve and through the
other end connection of the body; (c) an activator disposed within
the body capable of selectively changing the apparatus into either
one of two modes: a disabled mode, wherein the said valve is not
operable, and an enabled mode, wherein the said valve is operable
to a desired state, comprising a means responsive to an intended
change in an environment; and (d) an actuator capable of changing
the position of the said rotatable element to cause the valve into
a desired state comprising a means for transforming a suitably
available energy source into a mechanical movement.
[0064] In one example, the rotatable element is suitably positioned
to cause the valve into a at least one state such that the flow
pattern will be in one of the following patterns: (a) no flow
pattern wherein the flow passage between the upstream and the
downstream is restricted and the flow passage between the inner
flow passage and the annular flow passage is also restricted; (b)
through flow pattern wherein the passage between the upstream and
the downstream of the inner flow passage is not restricted whereas
the passage between the inner flow passage and the annular flow
passages is restricted; (c) diverted flow pattern wherein the flow
passage between the upstream and the said annular flow passage is
not restricted whereas the flow passage to the downstream is
restricted; and (d) full flow pattern wherein the flow passage
between the upstream and the downstream of the inner flow passage
is not restricted and the flow passage between the said inner flow
passage and the annular flow passages is not restricted.
[0065] In one example, the rotatable element includes at least one
surface of spherical shape and at least two ports and one
cavity.
[0066] In one example, the rotatable element includes at least one
cavity.
[0067] In one example, the detecting means comprises a sensor. In
one example, the sensor is positioned and arranged in the wellbore
environment and configured to sense at least one physical property
of the environment.
[0068] In one example, the apparatus includes: at least one means
for detecting a plurality of intended changes in at least one
physical property of the environment resulting in a detectable
signal within the apparatus suitable for processing the signal.
[0069] In one example, the activator includes a suitable controller
disposed within the said apparatus suitable for processing the
signal. In one example, the suitable controller is positioned and
arranged to receive at least one signal from at least one detecting
means and configured to interpret the one or more signals and
configured to provide at least one control instruction to the
actuator. In one example, the suitable controller compares the at
least one signal from at least one detecting means with a
predetermined pattern to determine if the controllable element
state is desired to be changed to a different desired state. In one
example, the suitable controller signals the actuator to actuate
the controllable valve based on the comparison of the at least one
signal from at least one detecting means with the predetermined
pattern.
[0070] In one example, the activator further includes a suitable
means for restricting the change of the valve state when the said
apparatus is in the disabled mode, a means for disabling. In one
example, the suitable means includes controlling power to the
actuator. In one example, the suitable means includes providing an
instruction to actuate a lock.
[0071] In one example, the activator includes a means for
restricting the movement of the rotatable element when in the said
apparatus is in the disabled mode.
[0072] In one example, the actuator includes a means for
transforming a hydraulic energy from fluid disposed within the
wellbore into another form of energy suitable for changing position
of the rotatable element. In one example, said another form of
energy suitable for changing position of the rotatable element is
electricity.
[0073] In one example the actuator includes a means for
transforming a mechanical energy from tubular string movement
within the wellbore into another form of energy suitable for
changing position of the rotatable element. In one example, said
another form of energy suitable for changing position of the
rotatable element is electricity.
[0074] In one example, the actuator includes a means for
transforming an electrical energy from source on surface through
the wellbore into another form of energy suitable for changing
position of the rotatable element. In one example, said another
form of energy suitable for changing position of the rotatable
element is mechanical energy.
[0075] In one example, the actuator includes a means for
transforming an electrical energy source disposed within the
apparatus into another form of energy suitable for changing
position of the rotatable element. In one example, said another
form of energy suitable for changing position of the rotatable
element is mechanical energy.
[0076] In one example, the electrical energy source is a
battery.
[0077] In one example, the electrical energy source is a suitable
electric generator. In one example, a suitable electric generator
is an electric generator positioned and arranged to receive
mechanical energy from the tubular string and is configured to
provide electrical energy to the actuator.
[0078] In one example, the electrical energy source is a suitable
electric generator. In one example, a suitable electric generator
is an electric generator positioned and arranged to receive
hydraulic energy from fluid in the tubular string and is configured
to provide electrical energy to the actuator. In one example, a
suitable electric generator is an electric generator positioned and
arranged to receive hydraulic energy from a fluid pressure
difference between the inner fluid passage and the annular fluid
passage.
[0079] In one example, the means for powering includes a means for
transforming hydraulic energy from fluid in the wellbore.
[0080] In an example, the actuator includes a means for
transforming a mechanical energy source disposed within the
apparatus into another form of energy suitable for changing
position of rotatable element.
[0081] In an example, the mechanical energy source is an energized
resilient element.
[0082] In all example, the actuator includes an electric motor.
[0083] In one set of examples, disclosed is a method of remotely
and selectively controlling an apparatus disposed in a tubular
string within a wellbore, the method including: disposing in a
wellbore a tubular string including an apparatus, the apparatus
including: a body defining boundaries between an inner flow passage
through the said apparatus and an annular flow passage within the
wellbore annulus and having two suitable end connections; at least
one controllable element operable in plurality of desired states;
an activator disposed within the body capable of selectively
changing the apparatus into either one of two modes: a disabled
mode wherein the at least one controllable element is not operable,
and an enabled mode wherein the at least one controllable element
is operable to a desired state, including a sensor capable of
detecting an intended change in a physical property of an
environment; and an actuator suitable for changing the at least one
controllable element into a desired state; causing a change in a
physical property of the environment in certain sequence within a
specified period of time resulting in a detectable pattern at the
sensor, the change in a physical property comprising a sequence of
a plurality of signal variations within a suitable period of time;
comparing the said detectable pattern with a command pattern to
determine if the controllable element state is desired to be
changed to a different desired state and then causing the activator
to change the apparatus mode into the suitable mode; and causing
the actuator to convert a suitably available energy source, causing
the at least one controllable element into the different desired
state.
[0084] In an example, the change in a physical property of the
environment is a mechanical movement of the apparatus by means of
moving the tubular string causing the apparatus to move within the
wellbore in at least one direction detectable by the said
sensor.
[0085] In an example, the change in a physical property of the
environment is a change of property of fluid introduced from
surface into the wellbore detectable by the said sensor.
[0086] In an example, the change of physical property includes a
change in one or more of the following fluid property: pressure,
temperature, flow rate, density, viscosity, color, composition or
another physical change detectable by the said sensor.
[0087] In an example, the change in a physical property of the
environment is a change of electromagnetic field detectable by the
said sensor.
[0088] In an example, the change in a physical property of the
environment is a change of electric field detectable by the said
sensor.
[0089] In an example, the controllable element is a valve.
[0090] In a set of examples, disclosed is a method for remotely and
selectively control fluid flow in a tubular string and wellbore
annulus, the method including: disposing a tubular string into a
wellbore comprising at least one flow control apparatus, the
apparatus including: a body defining boundaries between an inner
flow passage through the said apparatus and an annular flow passage
within the wellbore annulus and having two suitable end connections
and at least one lateral hole suitable for connecting the inner
flow passage and the annular flow passage; a controllable valve
operable in a plurality of desired states altering the fluid flow
pattern within the wellbore, where the valve includes at least one
rotatable element having plurality of surfaces, where the rotatable
element is rotatable to a plurality of desired positions, where the
valve further divides the inner flow passage into an upstream
section and a downstream section, where the upstream section is the
portion of the inner flow passage from the valve and through one
end connection of the body and the downstream section is the
portion of the inner flow passage from the valve and through the
other end connection of the body; an activator disposed within the
body capable of selectively changing the apparatus into either one
of two modes: a disabled mode, where the valve is not operable, and
an enabled mode, where the valve is operable to a desired state,
including a means responsive to an intended change in the
environment; and an actuator capable of changing the position of
the rotatable element to cause the valve into a desired state,
including a means for transforming a suitably available energy
source into a mechanical movement; causing a plurality of changes
in one or more physical property of the environment within a
specified period of time resulting in a detectable pattern at the
sensor comprising a plurality of signal variations within a
suitable period of time; comparing the detectable pattern with a
command pattern to determine if the valve state is desired to be
changed to a different desired state and then causing the activator
to cause the apparatus mode into the desired mode; causing the
actuator to change the rotatable element position to cause the
valve into a different state resulting in a change of the fluid
flow pattern by the desired apparatus into a desired flow
pattern.
[0091] In one example, disclosed is method for remotely and
selectively controlling fluid flow in a tubular string and wellbore
annulus, the method including: disposing a tubular string into a
wellbore comprising at least one flow control apparatus, the
apparatus including: a body, an inner passage through the body, an
orifice disposed on a lateral side of the body, a valve having a
movable element, the valve disposed in fluid communication with the
inner passage and the orifice; changing at least one physical
property in the environment in the wellbore; sensing the change in
the at least one physical property in the environment; disabling
movement of the valve element in response to a predetermined sensed
change; enabling movement of the valve element in response to a
predetermined sensed change; actuating the valve in response to a
predetermined sensed change when movement of the valve is
enabled.
[0092] In one example, the movable element is positioned and
arranged upon actuation of the valve into a predetermined position
selected form the set of positions including: restricted fluid flow
through the inner flow passage and restricted flow between the
inner flow passage and the annular flow passage through the
orifice, fluid flow communication through the inner flow passage
and restricted fluid flow between the inner flow passage and the
annular flow passage through the orifice; fluid flow communication
between the first end of the body and the annular flow passage and
restricted flow between the second end of the body and the annular
flow passage; and fluid flow communication between the first end of
the body and the annular flow passage and flow communication
between the second end of the body and the annular flow passage
[0093] In one example, disclosed is a method for remotely and
selectively controlling fluid flow in a tubular string and wellbore
annulus, the method including: disposing a tubular string into a
wellbore comprising at least one flow control apparatus, the
apparatus including: a body, an inner flow passage through the
body, an orifice disposed on a lateral side of the body, a valve
having a movable element, the element movable to a plurality of
predetermined positions, the valve disposed in fluid communication
with the annular passage and the orifice; actuating the moveable
element into at least one of the plurality of predetermined
positions; disabling movement of the moveable element; detecting at
least one change in at least one physical property in an
environmental condition within the wellbore; decoding at least one
instruction from the at least one detected change in the
environmental condition; where the disabling movement of the
moveable element is responsive to a decoded instruction of the at
least one decoded instruction; and where the actuating the valve
element into the at least one of the plurality of predetermined
positions is responsive to a decoded instruction of the at least
one decoded instruction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0094] A complete understanding of the present invention may be
obtained by reference to the accompanying drawings, when considered
in conjunction with the subsequent, detailed description, in
which:
[0095] FIG. 1 is a section view of an example of a wellbore
drilling system wherein a plurality of the fluid flow control
apparatus are disposed within drilling tubular string;
[0096] FIG. 2 is a section view of a preferred example of the flow
control apparatus;
[0097] FIGS. 3A-3D are detail views of examples of a rotatable
moveable element 300;
[0098] FIG. 4 is a perspective cutaway view of an example of an
actuator in a form of rack and pinion;
[0099] FIG. 5 is a detail of an example of an actuator linkage and
mechanical energy source;
[0100] FIG. 6 is a section view of an example of an actuator and
energy source disposed within the flow control apparatus body;
[0101] FIGS. 7A1 through 7D1 and 7A2 through 7D2 and 7E are detail
views of an example of a flow passage caused by having an example
rotatable element disposed in different possible positions within
the valve body, the example rotatable element having a curved outer
surface;
[0102] FIGS. 8A1 through 8C1 and 8A2 through 8C2 are detail views
of an example of a flow passage caused by having an example
rotatable element disposed in different possible positions within
the valve body, the example rotatable element is a form of a two
ports rotatable element comprising a spherical surface and having
two ports and one cavity connecting the two ports;
[0103] FIGS. 9A1 through 9C1 and 9A2 through 9C2 are detail views
of an example of a flow passage caused by having an example
rotatable element disposed in different possible positions within
the valve body, the example rotatable element is a form of a
cylindrical shaped rotatable element having two ports and one
cavity connecting the two ports;
[0104] FIGS. 10A1 through 10C1 and 10A2 through 10C2 and 10A3
through 10C3 are detail views of an example of a flow passage
caused by having an example rotatable element disposed in different
possible positions within the valve body, the example rotatable
element is a form of a three ports rotatable element comprising a
spherical surface and having three ports and one cavity connecting
the three ports;
[0105] FIGS. 11A, 11B, 11C are section views of an example of the
activator when the flow control apparatus is in disabled mode (FIG.
11A), and in enabled mode (FIG. 11B and FIG. 11C);
[0106] FIGS. 12A, 12B, 12C are barrel cam views from different
angles of respective Figs, 12A, 12B, 12C, showing an example cam
track profile;
[0107] FIG. 13 is a detail view of an example of barrel cam track
with a plurality of track passages and a plurality of movement
levels;
[0108] FIG. 14 is a flowchart of the disclosed method describing,
in one example, the steps suitable for remotely and selectively
controlling an apparatus disposed in a wellbore;
[0109] FIG. 15 is a flowchart of the disclosed method describing,
in one example, the steps for selectively and remotely controlling
a flow passage causing desired flow pattern within a wellbore;
[0110] FIG. 16 is a diagram of an example form of signal pattern
comprising a sequence of signal variations over a period of
time;
[0111] FIG. 17 is a diagram of an example form of reference (or
command) pattern comprising a predetermined set of signal
variations within a specific period of time;
[0112] FIG. 18 is a diagram of an example form of signal variations
within a suitable period of time acceptable as matching with the
reference/command pattern;
[0113] FIG. 19 is a diagram of an example form of detectable
pattern of signal variations within a suitable period of time
having an example form of matching pattern to the reference/command
pattern;
[0114] FIGS. 20A, 20B, 20C are detailed perspective cutaway views
of an example embodiment of a means for transforming hydraulic
energy from fluid in the wellbore into electric energy source
suitable for operating the valve, or, in an example, a mechanical
movement directly into making a suitable movement of the rotatable
element. FIG. 20A is a view of the apparatus during no circulation,
FIG. 20B is a view of the apparatus during transition between no
circulation and mud circulation. FIG. 20C is a view of the
apparatus during mud circulation;
[0115] FIG. 21 is a section view of another preferred example of
the flow control apparatus 150 comprising plurality of valves;
and
[0116] FIG. 22 is another section view of another preferred example
of the flow control apparatus 150 comprising plurality of
valves.
[0117] For purposes of clarity and brevity, like elements and
components will bear the same designations and numbering throughout
the Figures.
DETAILED DESCRIPTION
[0118] U.S. Provisional Application No. 61/710,887, filed Oct. 8,
2012 for METHOD AND APPARATUS TO CONTROL THE MUD FLOW IN DRILL
STRINGS AND WELLBORE ANNULUS, by Ahmed TAHOUN, Raed Kafafy, Karam
Jawamir, Mohamed Aldheeb, Abdul Mushawwir Mohamad Khalil is herein
incorporated by reference in its entirety.
[0119] U.S. Provisional Application No. 61/622,572, filed Apr. 11,
2012 for METHOD AND APPARATUS OF CONTROL DRILLING FLUID LOSSES AND
IMPROVED HOLE CLEANING IN OIL & GAS SUBTERRANEAN DRILLING
OPERATIONS, by Ahmed Moustafa Tahoun is herein incorporated by
reference in its entirety.
[0120] U.S. Provisional Application No. 61/710,823, filed Oct. 8,
2012 for METHOD AND APPARATUS TO HARVEST ENERGY INSIDE WELLBORE
FROM CHANGE OF FLUID FLOW RATE, by Ahmed M. Tahoun, Raed I. Kafafy,
Karam Jawamir, Mohamed A. Aldheeb, Abdul M. Khalil is herein
incorporated by reference in its entirety.
[0121] FIG. 1 is a section view of an example of a wellbore 100
drilling system wherein a plurality of the fluid flow control
apparatus 150 are disposed within drilling tubular string 110
during well forming operation. Majority of drilling systems used in
current days include a tabular string 110 composed of a drill bit
120 having a plurality of perforations 125 located through the
drill bit 120 to allow fluid flow there through. A heavy tubular
with bigger outer diameter among other equipment such as mud motors
or logging while drilling equipment or directional drilling control
systems, or any combination thereof that is frequently called
bottom hole assembly 130 connected to the drill bit 120 from one
end. Bottom hole assembly 130 is normally connected by form of
thread from the other end to other tubular conduit such as drill
pipe 140 connecting the bottom hole assembly 130 to surface. The
drill pipe 140 outer diameter is commonly known to be smaller when
compared to the bottom hole assembly 130, therefore the annular
volume surrounding the drill pipe 140 within the wellbore 100 over
any particular length is larger than the annular volume surrounding
the bottom hole assembly 130 of equivalent length within the
wellbore 100. Plurality of fluid flow control apparatus 150
disposed within the wellbore 100 are connected to a portion of the
tubular string 110 by a suitable means normally a form of thread on
each end connection 155 of the flow control apparatus 150. The
wellbore 100 formed into the earth may have a deviated section 180
where the wellbore 100 is not vertical. A cased hole 185 section is
the portion of the wellbore 100 having a tubular of large diameter
called casing lining the inner side of the wellbore 100 to protect
wellbore 100 from damage. While drilling a deeper section into
earth formations an open hole 188 section of the wellbore 100 is
formed. A surface mud pumping system 190 is disposed with most
drilling operations and includes a drilling fluid tank 194 to store
drilling fluid and a pump 192 to force fluid into the inner flow
passage 152 defined as the inner space within the tubular string
110. Cuttings 170 generated from hole making are carried out
through the annular flow passage 154. An annular flow passage 154
is defined as the space between the inner wall of the wellbore 100
and the outer wall of the tubular string 110. Cutting beds 175 are
sometimes formed by accumulation of cuttings 170 deposited normally
at the lower side of wellbore 100 particularly in deviated section
180 of open hole 188 or cased hole 185 of wellbore 100. Plurality
of fractures 160 connected to wellbore 100 may naturally exist or
formed during the drilling operations. When fractures 160 exist in
a wellbore 100, they may act as a passage causing a portion of
drilling fluid to flow into earth formation causing what is
commonly known as losses. When losses are encountered, well control
is compromised and drilling operation risks and costs are
increased. The flow control apparatus 150 comprises a valve 220,
the said valve 220 further divides the inner flow passage 152 into
upstream 157 section and downstream 159 section where upstream 157
section is defined as the portion of the inner flow passage 152
from the valve 220 and through the upstream 157 end connection 155
of the flow control apparatus 150 and the downstream 159 section as
defined as the portion of the inner flow passage 152 from the valve
220 and through the downstream 159 end connection 155 of the flow
control apparatus 150.
[0122] FIG. 2 is a section view of a preferred example of the flow
control apparatus 150 comprising a body 200 defining the boundaries
between an inner flow passage 152 through the said apparatus and
the annular flow passage 154 within the wellbore annulus 156 and
having a suitable connecting means such as a form of thread to
connect the apparatus body 200 to a portion of the tubular string
110 through an end connection 155 disposed on each end connection
155 of the said body 200. One of the end connections is the
upstream 157 end connection 1 and the other end connection 155 is
the downstream 159 end connection 155. The said body 200 further
comprises one or more lateral hole 210 suitable for connecting the
inner flow passage 152 to the annular flow passage 154. The flow
control apparatus 150 further comprises a valve 220. The valve 220
is the element of the flow control apparatus 150 which allows or
restricts the flow connectivity between the upstream 157 section,
the downstream 159 section, the inner flow passage 152 and the
lateral hole 210 connecting to the annular flow passage 154. In one
example, valve 220 is composed of a valve housing 225 and a
plurality of rotatable elements. In one example, valve housing 225
is an integral part of the body 200. In another example, valve
housing 225 is a separate member element inserted into an inner
space of the body 200. In one example, a rotatable element 300 is
disposed in valve housing 225. The rotatable element 300 is
suitable to be rotated into a plurality of positions. Each position
taken by the rotatable element 300 causes the valve 220 to be in a
state suitable to connect the said flow passages to establish a
particular flow pattern within the flow control apparatus 150,
hence wellbore 100 as will be explained later when describing FIGS.
7, 8, 9 and 10.
[0123] In one example, flow control apparatus 150 further comprises
an actuator 240 capable of transforming a suitably available energy
into a mechanical energy suitable for rotating the rotatable
element 300 into a desired position. By way of example, the
actuator 240 in this figure is composed of an actuation mandrel 246
disposed within the body 200 and movable with respect to the body
200. The said actuation mandrel 246 is having an inner surface that
is forming part of the inner flow passage 152 and is having a flow
orifice 280 profile suitable to be affected by the fluid flowing
through the inner flow passage 152. When a fluid flows through the
actuation mandrel 246 the hydraulic energy from the said fluid flow
exerts a suitable force on the flow orifice 280 causing the
actuation mandrel 246 to move with respect to the body 200 and
exert a suitable force on the actuation linkage 242 suitably
attached to the rotatable element 300 push-pull point 308 causing
the rotatable element 300 to rotate and change its position.
[0124] In one example, the actuation mandrel 246 is suitably
attached to a resilient element such as a spring 244. When the
actuation mandrel 246 moves by effect of hydraulic energy from
fluid flow, it pushes the resilient element in a suitable direction
that causes it to deform and build strain energy which is stored
within the said resilient element. When the resilient element is
allowed to relax and deform back to the previous shape, it will
release the said stored strain energy into a mechanical movement
that is suitable for the actuation mandrel 246 to utilize to
perform the desired actuation. The above is a demonstration of the
actuator 240 causing a transformation of hydraulic energy from
fluid flowing through the wellbore 100 inner flow passage 152 to a
mechanical energy in the form of actuation mandrel 246 movement.
The above is a further demonstration of the actuator 240 causing a
transformation of mechanical energy originating from actuation
mandrel 246 movement into another form of energy such as strain
energy stored within a suitable resilient element located within
the apparatus. The spring 244 form of the resilient element is held
on the other end by a spring retainer 254 suitably maintained in
its position by a suitable fastener such as a spring retainer bolt
256 connecting the spring retainer 254 to the body 200. The spring
244 form of a resilient element is located within the apparatus to
keep the actuation mandrel 246 biased in certain direction.
[0125] In one example, the flow control apparatus 150 further
comprises an activator 270. The activator 270 includes a means of
detecting a physical change in the environment using one or more
sensor 272, in one example, disposed within the said apparatus. The
said sensor 272 is capable of being affected by intended change in
one or more physical property of the environment caused by action
initiated on surface by the operator.
[0126] In one example, activator 270 further comprises a locking
means to put the flow control apparatus 150 into either enabled
mode or disabled mode. In the enabled mode, the actuator 240 within
the said flow control apparatus 150 will be operable, whereas in
the disabled mode, the actuator 240 within the said flow control
apparatus 150 is inoperable. In one example, the locking means
comprises a lock 277 element such that when engaged with a suitable
locking groove 278 suitably connected to the actuation mandrel 246,
it will restrict the movement of one or more of the actuator 240
elements such as the actuation mandrel 246 and cause the flow
control apparatus 150 to be in a disabled mode. When the apparatus
is in disabled mode, the valve 220 is not operable to change its
state. When the lock 277 is disengaged from the locking groove 278,
the actuator 240 disposed within the flow control apparatus 150
will not be restricted. by the lock 277 element and the flow
control apparatus 150 will be in enabled mode and the valve 220
will be operable into a different state.
[0127] In one example, the activator 270 further comprises a
controller 274 suitable to analyze the signal output of the sensor
272 and compare it to a command pattern 899 to determine the
desired mode then cause suitable changes within the activator 270,
thus providing a means for decoding signals from one or more
sensors. In one example, controller 274 is an electronic
computational device having interface electronics to the sensor(s)
and memory to store command pattern 899 and computational
instructions to perform the comparison. In one example, command
pattern is programmable. The said controller 274 comprises a
movement limiting means to limit the actuation linkage 242 movement
and cause it to stop after a desired displacement. In one example,
the movement limiting means of movement control comprises a barrel
cam 248 disposed within the body 200 and suitably connected to the
actuation mandrel 246. The said barrel cam 248 comprises a cam
track 740 with a profile suitable for a cam follower 250 disposed
within the body 200 to limit the movement of the barrel cam 248
travel between specific predetermined two or more track point such
as those explained in FIG. 13. Any of the said track point
restricts the barrel cam 248 displacement from movement in one or
more direction. As the barrel cam 248 is suitably connected to the
actuation mandrel 246, when the flow control apparatus 150 is in
enabled mode, the movement of the barrel cam 248 as determined by
the cam follower 250 travelling the cam track 740 causes the
actuation mandrel 246 movement to be restricted between specific
desired positions.
[0128] FIGS. 3A-3D are detail views of examples of a rotatable
moveable element 300.
[0129] FIG. 3A is a view of a two ports rotatable element 310
having at least one spherically formed surface and having one port
305 on its surface and another port 305 on its surface wherein both
ports are suitably connected through a cavity within the rotatable
element 300.
[0130] FIG. 3B is a view of a cylindrical rotatable element 320
having at least one surface curved in a cylindrical form, and
having one port 305 on its surface and another port 305 on its
surface wherein both ports are suitably connected through a cavity
within the rotatable element 300.
[0131] FIG. 3C is a view of a three ports rotatable element 330
having at least one form of a spherical surface and having at least
three ports on its surfaces wherein each port 305 is suitably
connected to another port 305 through a cavity within the rotatable
element 300.
[0132] FIG. 3D is a view of a general form of a possible embodiment
of a rotatable element 300 having at least one outer surface 340
suitable to engage with one or more fluid flow passage such as the
inner flow passage 152, upstream 157 section, downstream 159
section and a lateral hole 210 connecting to the annular flow
passage 154.
[0133] FIG. 4 is a perspective cutaway view of an example of an
actuator in a form of rack and pinion. Actuation linkage 242 causes
rotatable element 300 to change position using a rack 410 and a
pinion 420, where at least one pinion 420 is suitably connected to
the rotatable element 300 and at least one rack 410 is connected to
the actuation mandrel 246 and both the rack 410 and the pinion 420
are suitably engaged so that when the rack 410 moves in certain
direction the pinion 420 rotates around a suitably located pivot
307. Engagement between rack 410 and pinion 420 is commonly formed
by way of a matching thread however other forms are also possible,
such as by way of example, a friction surface or a magnetic
coupling. In this FIG. the valve 220 is composed of a valve housing
225 located inside the body 200 and the rotatable element 300 is in
the form of three ports rotatable element 330 explained
earlier.
[0134] FIG. 5 is a detail view of an example of an actuator linkage
and mechanical energy source. Actuation linkage 242 is configured,
positioned, and arranged to cause rotatable element 300 to change
position. In this figure, movement of the actuation mandrel 246 in
a suitable direction causes the actuation linkage 242 to exert a
suitable force on a push-pull point 308 causing the rotatable
element 300 to change position. An inertia element 510 is disposed
within the actuation mandrel 246 having a suitable mass capable of
storing kinetic energy in proportion to its mass and speed of
movement.
[0135] When the tubular string 110 moves in certain direction, such
as when moved along the wellbore 100 axis by pulling in the
direction out of wellbore 100 to earth surface or lowering it
deeper into earth through the wellbore 100, the flow control
apparatus 150 follows the same movement as it is rigidly connected
at its end connection 155 through a form of thread to a portion of
the tubular string 110 and causing elements disposed within the
flow control apparatus 150 to follow the same movement as the
tubular string 110. The inertia element 510 will store kinetic
energy in proportion to its mass and to its movement speed and
accordingly to the movement speed of the tubular string 110. When
tubular string 110 movement changes, the inertia element 510 will
lag the change of movement in time before it follows the new
movement of the tubular string 110, due to its stored kinetic
energy. When the flow control apparatus 150 is in enabled mode, the
change of energy stored in inertia element 510 due to change in
tubular string 110 movement can cause movement of the actuation
mandrel 246 in a suitable direction, causing the rotatable element
300 to change position. In one example, in the case when the
tubular string 110 is lowered into earth formation and then stops,
a change of movement occurs. The kinetic energy stored within the
inertia element 510 will cause inertia element 510 to continue
movement in the original direction if the flow control apparatus
150 is in enabled mode. In one example, this movement is
transformed into a mechanical movement to cause the change of
rotatable element 300 position. In one example, inertia element 510
represents an energy source disposed within the actuator 240 having
a means of transforming mechanical energy from tubular string 110
movement within the wellbore 100 into mechanical energy capable of
operating the said valve 220.
[0136] FIG. 6 is a section view of an example of an actuator and
energy source disposed within the flow control apparatus body. In
this example, actuator 240 includes an electric motor 620 as means
of transforming a suitably available electrical energy source into
a mechanical energy capable of changing the position of the
rotatable element 300 by means of linkage in the form of a suitable
gear engagement such as worm gear 610 and pinion 420. When the
suitable electric energy source is connected to the electric motor
620, electric motor 620 causes the worm gear 610, connected to the
electric motor 620 output, to adequately rotate the pinion 420 that
is suitably connected to the rotatable element 300 around the pivot
307, as a result changing the rotatable element 300 position. In
this figure, in one example, an alternative energy source is
disposed within the said apparatus in a form of an energized
resilient element as means of mechanical energy source disposed
within the apparatus. An energized spring 630, in one example, such
as a strained coiled spring 244 or other form of strained resilient
element, is suitably connected to the pinion 420 by means of a
suitable linkage such as a worm gear 610.
[0137] When the flow control apparatus 150 is enabled, stored
mechanical energy disposed within the energized spring 630 that is
allowed to relax to a less strained state by releasing strain
energy into mechanical movement, causing the worm gear 610 to
adequately move the pinion 420 that is suitably connected to the
rotatable element 300 around the pivot 307 and, as a result,
changing the rotatable element 300 position. The example explained
above of strain energy stored in a resilient element is similar to
the energy stored in a watch winding spring explained by Dawson in
U.S. Pat. No. 163,161, issued May 11, 1875.
[0138] In one example, a means of transforming mechanical energy
source disposed within the said apparatus in a form of and
energized resilient element is explained. In one example, a means
of transforming electrical energy source disposed within the said
apparatus is a form of electric motor. The electric motor 620 is
suitable for transforming an electrical energy from a suitable
electrical energy source disposed within the flow control apparatus
150 in a form of suitable battery 276 or an electric generator.
[0139] In one example, an electric generator is in the form of a
turbine, transforming hydraulic fluid flowing through the wellbore
100 into electrical power as a source to be used directly or stored
in a form of electrical storage such as rechargeable battery 276 or
a capacitor. In one example, the electrical energy source is
disposed within the tubular string 110 or, in another example, in
the bottom hole assembly 130. In one example, the electrical energy
source is on surface in a form of battery 276 or, in another
example, from an electric line from domestic energy source or, in
another example, from a drilling system electric generator. In one
example, electrical energy sources not disposed within the flow
control apparatus 150 are connected to the said apparatus actuator
240 by a connecting means such as wireline cable commonly used for
wireline services in the oil well, made by companies such as
Schlumberger or Halliburton, and other electric wireline service
providers.
[0140] FIGS. 7A1 through 7D1 and 7A2 through 7D2 and 7E are detail
views of an example of a flow passage caused by having an example
rotatable element disposed in different possible positions within
the valve body, the example rotatable element having a curved outer
surface. In this example, valve 220 is presented in different
states by way of presenting the rotatable element 300 in different
positions. The valve 220 is capable of forming one of more possible
flow passage 700.
[0141] FIG. 7A1 is a section view and FIG. 7A2 is a perspective
cutaway view of the valve 220 in one state where the rotatable
element 300 is in a position such that it restricts flow passage
between the inner flow passage 152 and the annular flow passage 154
by way of aligning the outer surface 340 to obstruct flow passage
between the inner flow passage 152 and the lateral hole 210. The
rotatable element 300 in this position further restrict flow
passage within the inner flow passage 152 between the upstream 157
section and downstream 159 section passages by way of aligning the
outer surface 340 to obstruct the inner flow passage 152 between
the upstream 157 section and downstream 159 section. These figures
demonstrate the "no flow" pattern wherein the flow passage between
the upstream 157 section and the downstream 159 section is
restricted and the flow passage between the inner flow passage 152
and the annular flow passage 154 is also restricted.
[0142] FIG. 7B1 is a section view and FIG. 7B2 is a perspective
cutaway view of the valve 220 in one state where the rotatable
element 300 is in a position such that it restricts flow passage
between the inner flow passage 152 and the annular flow passage 154
by way of aligning the outer surface 340 to obstruct the flow
passage between the inner flow passage 152 and the lateral hole
210. The rotatable element 300 in this position does not restrict
flow passage within the inner flow passage 152 between the upstream
157 section and downstream 159 section by way of aligning the outer
surface 340 such that the inner flow passage 152 between the
upstream 157 section and downstream 159 section is not obstructed.
These figures demonstrate the "through flow" pattern 705 wherein
the passage between the upstream 157 section and the downstream 159
section of the inner flow passage 152 is not restricted whereas the
passage between the inner flow passage 152 and the annular flow
passages is restricted.
[0143] FIG. 7C1 is a section view and FIG. 7C2 is a perspective
cutaway view of the valve 220 in one state where the rotatable
element 300 is in a position such that one portion of the inner
flow passage 152 is connected with the annular flow passage 154 by
way of aligning the outer surface 340 such that it does not
obstruct flow passage between one portion of the inner flow passage
152 and the annular flow passage 154 through the lateral hole 210.
The rotatable element 300 in this position further restricts flow
passage within the inner flow passage 152 between the upstream 157
section and downstream 159 section passages by way of aligning the
outer surface 340 such that the inner flow passage 1152 between the
upstream 157 section and downstream 159 section is obstructed.
These figures demonstrate the diverted flow pattern 710 wherein the
flow passage between the upstream 157 section and the annular flow
passage 154 is not restricted whereas the flow passage to the
downstream 159 section is restricted.
[0144] FIG. 7D1 is a section view and FIG. 7D2 is a perspective
cutaway view of the valve 220 in one state where the rotatable
element 300 is in a position such that the inner flow passage 152
is connected with the annular flow passage 154 through the lateral
hole 210 by way of aligning the rotatable element 300 outer surface
340 such that it does not obstruct flow passage between the inner
flow passage 152 and the lateral hole 210. The rotatable element
300 in this position further does not restrict flow passage within
the inner flow passage 152 between the upstream 157 section and
downstream 159 section by way of aligning the outer surface 340
such that the inner flow passage 152 between the upstream 157
section and downstream 159 section is not obstructed. These figures
demonstrate the full flow pattern 715 wherein the flow passage
between the upstream 157 section and the downstream 159 section of
the inner flow passage 152 is not restricted and the flow passage
between the inner flow passage 152 and the annular flow passages is
also not restricted.
[0145] FIG. 7E shows a perspective view of an example of rotatable
element 300 having a crescent-moon shape about an intended axis of
rotation, forming a three-dimensional prism body in the
longitudinal direction along this intended axis of rotation. In one
example, a portion of the element having a cylindrical surface is
sufficient.
[0146] FIGS. 8A1 through 8C1 and 8A2 through 8C2 are detail views
of an example of a flow passage caused by having an example
rotatable element disposed in different possible positions within
the valve body, the example rotatable element is a form of a two
ports rotatable element comprising a spherical surface and having
two ports and one cavity connecting the two ports. In this example,
valve 220 is presented in different states by way of showing the
rotatable element 300 in different positions. In these figures, the
rotatable element 300 is in the form of two ports rotatable element
310.
[0147] FIG. 8A1 is a section view and FIG. 8A2 is a perspective
cutaway view of the valve 220 in one state where the rotatable
element 300 is in a position such that it restricts flow passage
between the inner flow passage 152 and the annular flow passage 154
by way of aligning the outer surface 340 to obstruct the flow
passage between the inner flow passage 152 and the lateral hole
210. The rotatable element 300 in this position does not restrict
flow passage within the inner flow passage 152 between the upstream
157 section and downstream 159 section by way of aligning the outer
surface 340 such that the inner flow passage 152 between the
upstream 157 section and downstream 159 section is not obstructed.
This figure demonstrate the through flow pattern 705 wherein the
passage between the upstream 157 section and the downstream 159
section of the inner flow passage 152 is not restricted whereas the
passage between the inner flow passage 152 and the annular flow
passages is restricted.
[0148] FIG. 8B1 is a section view and FIG. 8B2 is a perspective
cutaway view of the valve 220 in one state where the rotatable
element 300 is in a position such that one portion of the inner
flow passage 152 is connected with the annular flow passage 154 by
way of aligning the outer surface 340 such that it does not
obstruct flow passage between one portion of the inner flow passage
152 and the annular flow passage 1154 through the lateral hole 210.
The rotatable element 300 in this position further restrict flow
passage within the inner flow passage 152 between the upstream 157
section and downstream 159 section passages by way of aligning the
outer surface 340 to such that the inner flow passage 152 between
the upstream 157 section and downstream 1159 section is obstructed.
These figures demonstrate the diverted flow pattern 7110 wherein
the flow passage between the upstream 157 section and the annular
flow passage 154 is not restricted whereas the flow passage to the
downstream 159 section is restricted.
[0149] FIG. 8C1 is a section view and FIG. 8C2 is a perspective
cutaway view of the valve 220 in one state where the rotatable
element 300 is in a position such that the inner flow passage 152
is connected with the annular flow passage 154 through the lateral
hole 210 by way of aligning the rotatable element 300 outer surface
340 such that it does not obstruct flow passage between the inner
flow passage 152 and the lateral hole 210. The rotatable element
300 in this position further does not restrict flow passage within
the inner flow passage 152 between the upstream 157 section and
downstream 159 section passages by way of aligning the outer
surface 340 such that the inner flow passage 152 between the
upstream 157 section and downstream 159 section is not obstructed.
These figures demonstrate the full flow pattern 715 wherein the
flow passage between the upstream 157 section and the downstream
159 section of the inner flow passage 152 is not restricted and the
flow passage between the inner flow passage 152 and the annular
flow passages is not restricted.
[0150] FIGS. 9A1 through 9C1 and 9A2 through 9C2 are detail views
of an example of a flow passage caused by having an example
rotatable element disposed in different possible positions within
the valve body, the example rotatable element is a form of a
cylindrical shaped rotatable element having two ports and one
cavity connecting the two ports. In this example, valve 220 is
presented in different states by way of showing the rotatable
element 300 in different positions. In these figures, the rotatable
element 300 is in the form of a cylindrical shaped rotatable
element 300.
[0151] FIG. 9A1 is a section view and FIG. 9A2 is a perspective
cutaway view of the valve 220 in one state where the rotatable
element 300 is in a position such that it restricts flow passage
between the inner flow passage 152 and the annular flow passage 154
by way of aligning the outer surface 340 to obstruct the flow
passage between the inner flow passage 152 and the lateral hole
210. The rotatable element 300 in this position does not restrict
flow passage within the inner flow passage 152 between the upstream
157 section and downstream 159 section by way of aligning the outer
surface 340 such that the inner flow passage 152 between the
upstream 157 section and downstream 159 section is not obstructed.
These figures demonstrate the "through flow" pattern 705 wherein
the passage between the upstream 157 section and the downstream 159
section of the inner flow passage 152 is not restricted whereas the
passage between the inner flow passage 152 and the annular flow
passages is restricted.
[0152] FIG. 9B1 is a section view and FIG. 9B2 is a perspective
cutaway view of the valve 220 in one state where the rotatable
element 300 is in a position such that one portion of the inner
flow passage 152 is connected with the annular flow passage 154 by
way of aligning the outer surface 340 such that it does not
obstruct flow passage between one portion of the inner flow passage
152 and the annular flow passage 154 through the lateral hole 210.
The rotatable element 300 in this position further restrict flow
passage within the inner flow passage 152 between the upstream 157
section and downstream 159 section passages by way of aligning the
outer surface 340 to such that the inner flow passage 152 between
the upstream 157 section and downstream 159 section is obstructed.
These figures demonstrate the "diverted flow" pattern 710 wherein
the flow passage between the upstream 157 section and the annular
flow passage 154 is not restricted whereas the flow passage to the
downstream 159 section is restricted.
[0153] FIG. 9C1 is a section view and FIG. 9C2 is a perspective
cutaway view of the valve 220 in one state where the rotatable
element 300 is in a position such that the inner flow passage 152
is connected with the annular flow passage 154 through the lateral
hole 210 by way of aligning the rotatable element 300 outer surface
340 such that it does not obstruct flow passage between the inner
flow passage 152 and the lateral hole 210. The rotatable element
300 in this position further does not restrict flow passage within
the inner flow passage 152 between the upstream 157 section and
downstream 159 section passages by way of aligning the outer
surface 340 such that the inner flow passage 152 between the
upstream 157 section and downstream 159 section is not obstructed.
These figures demonstrate the "full flow" pattern 715 wherein the
flow passage between the upstream 1157 section and the downstream
159 section of the inner flow passage 152 is not restricted and the
flow passage between the inner flow passage 152 and the annular
flow passages is not restricted.
[0154] FIGS. 10A1 through 10C1 and 10A2 through 10C2 and 10A3
through 10C3 are detail views of an example of a flow passage
caused by having an example rotatable element disposed in different
possible positions within the valve body, the example rotatable
element is a form of a three ports rotatable element comprising a
spherical surface and having three ports and one cavity connecting
the three ports. In this example, valve 220 is presented in
different states by way of showing the rotatable element 300 in
different positions. In these figures, the rotatable element 300 is
in the form of a three ports rotatable element 330.
[0155] FIG. 10A1 is a section view and FIG. 10A2 is a perspective
cutaway view and FIG. 10A3 is an exploded view of the valve 220 in
one state where the rotatable element 300 is in a position such
that it restricts flow passage between the inner flow passage 152
and the annular flow passage 154 by way of aligning the outer
surface 340 to obstruct the flow passage between the inner flow
passage 152 and the lateral hole 210. The rotatable element 300 in
this position does not restrict flow passage within the inner flow
passage 152 between the upstream 157 section and downstream 159
section by way of aligning the outer surface 340 such that the
inner flow passage 152 between the upstream 157 section and
downstream 159 section is not obstructed. These figures demonstrate
the through flow pattern 705 wherein the passage between the
upstream 157 section and the downstream 159 section of the inner
flow passage 152 is not restricted whereas the passage between the
inner flow passage 152 and the annular flow passages is
restricted.
[0156] FIG. 10B1 is a section view and FIG. 10B2 is a perspective
cutaway view and FIG. 10B3 is an exploded view of the valve 220 in
one state where the rotatable element 300 is in a position such
that one portion of the inner flow passage 1152 is connected with
the annular flow passage 154 by way of aligning the outer surface
340 such that it does not obstruct flow passage between one portion
of the inner flow passage 152 and the annular flow passage 154
through the lateral hole 210. The rotatable element 300 in this
position further restrict flow passage within the inner flow
passage 152 between the upstream 157 section and downstream 159
section passages by way of aligning the outer surface 340 to such
that the inner flow passage 152 between the upstream 157 section
and downstream 159 section is obstructed. These figures demonstrate
the diverted flow pattern 710 wherein the flow passage between the
upstream 157 section and the annular flow passage 154 is not
restricted whereas the flow passage to the downstream 159 section
is restricted.
[0157] FIG. 10C1 is a section view and FIG. 10C2 is a perspective
cutaway view and FIG. 10C3 is an exploded view of the valve 220 in
one state where the rotatable element 300 is in a position such
that the inner flow passage 1152 is connected with the annular flow
passage 154 through the lateral hole 210 by way of aligning the
rotatable element 300 outer surface 340 such that it does not
obstruct flow passage between the inner flow passage 152 and the
lateral hole 210. The rotatable element 300 in this position
further does not restrict flow passage within the inner flow
passage 152 between the upstream 157 section and downstream 159
section passages by way of aligning the outer surface 340 such that
the inner flow passage 152 between the upstream 157 section and
downstream 159 section is not obstructed. These figures demonstrate
the full flow pattern 715 wherein the flow passage between the
upstream 157 section and the downstream 159 section of the inner
flow passage 152 is not restricted and the flow passage between the
inner flow passage 152 and the annular flow passages is not
restricted.
[0158] FIGS. 11A, 11B, 11C are section views of an example of the
activator when the flow control apparatus is in disabled mode (FIG.
11A), and in enabled mode (FIG. 11B and FIG. 11C). In this example,
a locking means causes flow control apparatus 150 into enabled mode
or disabled mode. The locking means provides an example of a means
for disabling movement of the moveable element 300. By way of
example, the locking means comprises at least two elements. One
element is a lock 277 element and the other element is a locking
profile such as a locking groove 278. One of the elements is
disposed in a suitable location within the body 200 and the other
element is disposed within a suitable location within an actuator
240 element. The lock 277 is further movable between at least two
positions by means of a lock driver 720 suitable to change the lock
277 position from one position to another.
[0159] FIG. 11A is a section view of the lock 277 engaged with the
locking groove 278.
[0160] FIG. 11B is a view of the lock 277 disengaged from the
locking groove 278, and
[0161] FIG. 11C is a view of the lock 277 disengaged from the
locking groove 278 and the actuation mandrel 246 moved to a
different position. The lock 277 viewed in these figures is caused
to change position by a suitable lock driver 720. The lock driver
720, in one example, is a suitable solenoid. In another example,
the lock 277 viewed these figures is driven by lock driver 720 in a
form of a suitable motor. It is understood that the lock 277 can be
driven by other suitable lock driver 720 to cause it to move
between at least two positions such that, in one position the lock
277 is disengaged from the locking groove 278, and in another
position the lock 277 is suitably engaged the locking groove
278.
[0162] In one example, when a suitable electric charge is connected
to the solenoid, the solenoid becomes energized causing the lock
277 to retract into the body 200 and the lock 277 is caused to
disengage away from the locking groove 278 causing the flow control
apparatus 150 into enabled mode. The solenoid is operable such that
when energized with a different charge the lock 277 is caused to
extend into the inner wall of the body 200 and is caused to be
suitably engaged with the locking groove 278 causing the flow
control apparatus 150 into a disabled mode.
[0163] In one example, the same function made by the solenoid means
of lock driver 720 is achieved by a suitable motor or, in another
example, by another suitable means, to cause the lock 277 to change
position. When the lock 277 is engaged with the suitable locking
groove 278 disposed within the actuation mandrel 246, it restricts
the movement of the actuation mandrel 246, therefore restricting
the movement of the actuation linkage 242. The movement of the
rotatable element 300 is therefore restricted and the valve 220 is
restricted from changing its state and is not operable into a
different state.
[0164] The flow control apparatus 150 is said to be in disabled
mode when the valve 220 is not operable to a different state. When
the lock 277 is disengaged from the locking groove 278, the
actuator 240 mandrel disposed within the flow control apparatus 150
will not be restricted by the lock 277 element and the flow control
apparatus 150 will be in enabled mode and the valve 220 will be
operable into a different state. The flow control apparatus 150 is
said to be in enabled mode when the valve 220 is operable to a
different state. The locking means explained is by way of
example.
[0165] In another example of the lock 277 means is explained; in a
different example of the actuator 240 such as the example shown in
FIG. 6, where the actuator 240 comprises a suitable electric motor
620 is achieved by disconnecting the electric source form the
electric motor 620 causing the electric motor 620 to be inoperable
and accordingly the rotatable element 300 is restricted from
changing position by means of the gear arrangement where the worm
engaged with the pinion 420 act as a break when the worm gear 610
is not rotatable, and the flow control apparatus 150 is then said
to be in the disabled mode. When the electric motor 620 is
connected to the suitable electric energy source, it rotates in
certain direction causing the worm gear 610 to rotate and resulting
in a change of the rotatable element 300 position and the valve 220
is operable into a different state and the flow control apparatus
150 is said to be in enabled mode.
[0166] FIGS. 12A, 12B, 12C are barrel cam views from different
angles of respective FIGS. 11A, 11B, 11C, showing an example cam
track profile. In one example, barrel cam 248 (originally shown in
FIG. 2) viewed from different angles in details (FIGS. 11A, 11B,
11C), shows an example cam track 740 profile. The barrel earn 248
comprises a suitable cam track 740 disposed on a curved surface
having plurality of stop points. A cam follower 250 suitably
disposed within the apparatus such that the cam follower 250 and
the barrel cam 248 are movable to each other wherein either the cam
follower 250 or the barrel cam 248 is restricted from moving in at
least one direction with respect to the body 200.
[0167] In one example, the cam follower 250 in FIG. 2 is not
movable with respect to the body 200 main axis that is parallel to
the wellbore 100 axis, while the barrel cam 248 in FIG. 2 is
movable with respect to the can follower 250 when the actuation
mandrel 246 moves within the body 200. The cam track 740 comprises
at least one stop point 794 such that when the cam follower 250
traverses the cam track 740 in a traverse direction 725 and passes
a stop point 794, the cam follower 250 will be restricted from
traversing the cam track 740 in the opposite direction by
restriction means such as a step within the cam track 740. In this
example, while the barrel cam 248 is moving relative to the body
200, the cam follower 250 traverse the track in the traverse
direction 725 from track point 1 (755) to track point 2 (760) then
to track point 3 (765) then to track point 4 (770) and then
continue traversing the cam track 740 to reach the starting track
point 1 (755). Throughout the barrel cam 248 movement is controlled
by the cam track 740 profile and the cam follower 250, the axial
and rotational movement of the barrel cam 248 suitably mounted on
the actuation mandrel 246 result in a controlled movement of the
actuation mandrel 246.
[0168] FIG. 13 is a detail view of an example of a barrel cam track
with a plurality of track passages and a plurality of movement
levels In this example, cam track 740 is shown as having multiple
paths, in this example, showing an upper track 750 and a lower
track 752. In one example, each of the upper track 750 and the
lower track 752 has at least one stop point 794 suitably located
onto the cam track 740 to cause the cam follower 250 traversing the
cam track 740 to have a plurality of possible combinations of
sequence of stop points. Continuing with this example, in one path,
the cam follower 250 traverses the upper track 750 starting from
track point 1 (755) then track point 2 (760) followed by track
point 3 (765) and track point 4 (770) then to track point 1 (755)
when the cam follower 250 fully travers the upper track 750. The
cam follower 250 is also suitably controlled to traverse the lower
track 752, starting from track point 1 (755) then track point 5
(780) followed by track point 6 (785) then track point 7 (790) then
track point 8 (795) then track point 4 (770) and then back to the
starting point at track point 1 (755) where the cam follower 250
completes the traverse of the lower track 752. It is understood
that this figure demonstrates by way of one example a possible
combination of stop points in a cam track 740 where the cam
follower 250 traversing the upper track 750 in this example passes
by a total of four (4) track stop points, while traversing the
lower track 752, the cam follower 250 passes pass by six (6) track
stop points before completing the lower track 752 to the starting
point. This form of multi cam track 740 is advantageous and
desirable in control systems. It is understood that plurality of
tracks and plurality of track stop points are possible using this
concept.
[0169] In one example, the plurality of cam track is a means for
decoding the command pattern as explained herein. A change in the
environment will cause the cam follower to traverse the cam track
for example as the force generated from the hydraulic fluid flowing
through the inner flow passage exert force on the actuator, and
with the cam mounted on the inner mandrel such that it is movable
with the mandrel movement in an axial direction. When cam follower
traverse the cam track from track point 1 755 for a particular
distance between track point 1 755 and track point 4 770 the cam
follower will engage and traverse the upper track 750 following the
track points explained earlier. When cam follower traverse the cam
track for a different distance between track point 1 755 and track
point 4 it will traverse the lower cam track 752. The distance
traversed between track point 1 755 and track point 4 770 caused by
the movement of the actuator mandrel due to a specific change of
the at least one change of the environment will determine the track
passage that the cam follower will traverse. Specific change of the
environment will control the track traversed by the cam follower
and the cam explained in FIG. 13 is an example of a means for
decoding the at least one change in the environment.
[0170] FIG. 14 is a flowchart of the disclosed method describing,
in one example, the steps suitable for remotely and selectively
controlling an apparatus disposed in a wellbore. In one example, an
apparatus is disposed within a wellbore 100 and includes the step
1410 of disposing in a wellbore 100 a tubular string 110 containing
a plurality of an apparatus comprising a body 200, a plurality of
controllable element, an activator 270 and an actuator 240. The
method also includes the step 1420 of causing a change in at least
one physical property of the environment in certain sequence within
a specified period of time resulting in a detectable pattern of
signal variations within the apparatus comprising plurality of
signal variations within a suitable period of time. The method also
includes the step 1430 of comparing the detectable pattern with a
predetermined pattern called a command pattern 899 to determine
whether a controllable element state within the apparatus is
desired to be changed and then cause the activator 270 to change
the apparatus mode into enabled mode. The method also includes the
step 1440 of causing the actuator 240 to transform a suitably
available energy source to cause the controllable element into the
different desired state.
[0171] FIG. 15 is a flowchart of the disclosed method describing,
in one example, the steps for selectively and remotely controlling
a flow passage causing desired flow pattern within a wellbore. In
one example, the method for selectively and remotely controlling a
flow passage causing desired flow pattern within a wellbore 100
includes the step 1510 of disposing a tubular string 110 containing
a plurality of an apparatus comprising a body 200, a plurality of
controllable valve 220, an activator 270 and an actuator 240. The
method also includes the step 1520 of causing a change in at least
one physical property of the environment in certain sequence within
a specified period of time resulting in a detectable pattern of
signal variations within the apparatus comprising plurality of
signal variations within a suitable period of time. The method also
includes the step 1530 of comparing the detectable pattern with a
predetermine pattern called a command pattern 899 to determine
whether a controllable valve 220 state within the apparatus is
desired to be changed and then cause the activator 270 to change
the apparatus mode into enabled mode. The method also includes the
step 1540 of causing the actuator 240 to transform a suitably
available energy source to cause the controllable valve 220 into
the different state suitable for changing the flow pattern into the
desired flow pattern. As a result, the flow pattern will take any
of the flowing patterns, no flow, full flow, a diverted flow and a
through flow as explained in FIGS. 7, 8, 9, and 10.
[0172] FIG. 16 is a diagram of an example form of signal pattern
comprising a sequence of signal variations over a period of time.
This diagram is also aimed to aid understanding the terms used in
the description in this disclosure. In one example, a signal level
point 805 is any possible value of a signal. A signal level zone
806 is defined as any signal value within suitable two signal
points, defining the signal level zone 806 boundaries. A time
period is referenced as the period of time between any two time
points. A time zone 546 is defined as the time period when the
signal value stays within a signal level zone 806. When a signal
value is changed to a different signal level zone 806, a different
time zone 546 is defined. A signal is said to have a possible
reference pattern 864 if its value stays within a particular signal
level zone 806 for a specific time zone 546. In one example, a
sequence of reference patterns is, or is used as, or is referred to
as, a command pattern.
[0173] FIG. 17 is a diagram of an example form of reference pattern
864 comprising a predetermined set of signal variations within a
specific period of time. For example, a reference pattern A (865)
is defined for the signal value within signal level zone 1 (809)
and for a time zone A (825), and a reference pattern B (870) is
defined for the signal value within signal level zone 2 (811) and
for a time zone B (830). Similarly, a reference pattern C (875) is
defined for the signal value within signal level zone 3 (816) and
for a time zone C (835).
[0174] FIG. 18 is a diagram of an example form of signal variations
within a suitable period of time acceptable as matching with the
reference pattern. In this example, the sequence of a reference
pattern A (865), a reference pattern B (870), and a reference
pattern C (875). A signal is said to have other pattern 880 if it
stays within a particular signal level zone 806 for other time zone
840 not matching those defined by reference pattern A (865), or
reference pattern B (870) or reference pattern C (875).
[0175] FIG. 19 is a diagram of an example form of detectable
pattern of signal variations within a suitable period of time
having an example form of matching pattern to the
reference/pattern. In chronological order the activator 270
processor will interpret the sensor 272 signal by referring to
reference pattern A (865), reference pattern B (870), reference
pattern C (875), and other pattern 880 as follows: a reference
pattern C (875), then a reference pattern B (870), then a reference
pattern A (865), then a reference pattern B (870), then a reference
pattern A (865) then other pattern 880 then a reference pattern A
(865), then a reference pattern B (870), then a reference pattern C
(875), then other pattern 880.
[0176] FIGS. 20A, 20B, 20C are detailed perspective cutaway views
of an example embodiment of a means fir transforming hydraulic
energy from fluid in the wellbore into electric energy source
suitable for operating the valve, or, in an example, a mechanical
movement directly into making a suitable movement of the rotatable
element. FIG. 20A is a view of the apparatus during no circulation.
FIG. 20B is a view of the apparatus during transition between no
circulation and mud circulation. FIG. 20C is a view of the
apparatus during mud circulation.
[0177] In one example, an actuator 240 includes a means for
transforming hydraulic energy from fluid in the wellbore 100 into
electric energy source. An actuation mandrel 246 is disposed within
the body 200 inner space having a flow orifice 280 and inner
surface and outer surface 340. A mud compartment 905 defined as the
space between the inner body 200 surface and the actuation mandrel
246 outer surface 340 is having a suitably diameter at one end
larger than the diameter on the other end and having at least one
generator port 900 suitable for connecting fluid within the mud
compartment 905 to fluid in the annular passage. The different
inner diameter of the mud compartment 905 is such that when the
actuation mandrel 246 moves in certain direction will cause the
volume of mud compartment 905 to change. A suitable seal element is
disposed within the mandrel and body 200 to restrict hydraulic
communication between inner flow passage 152 and mud compartment
905. A suitable form of resilient element is disposed within the
mud compartment 905 such as a coil spring 244 wherein the movement
of the actuation mandrel 246 in certain direction will cause a
change in the strain of the said spring 244 and the move of the
actuation mandrel 246 in a different direction will cause another
change in the strain of the said spring. One or more electric coil
885 is disposed within the present invention and one or more magnet
is further disposed within the present invention such that movement
of the actuation mandrel 246 within the body 200 will cause the
relative location between the magnet and the electric coil 885. In
this figure, different forms of magnets are presented by way of
example such as stud magnet 895 and ring magnet 890. An example of
different form of a suitable electric coil 885 is also presented
having different shapes as in figure.
[0178] FIG. 20A is a view of the apparatus during no circulation.
FIG. 20C is a view of the apparatus during mud circulation. FIG.
20B is a view of the apparatus during transition between no
circulation and mud circulation by way of referring to wellbore 100
operation, and tubular string 110 disposed within a wellbore 100
comprising a drill bit 120, a bottom hole assembly 130, a plurality
of flow control apparatus 150 and drill pipe 140.
[0179] FIG. 21 is a section view of another preferred example of
the flow control apparatus 150 comprising plurality of valves. One
valve 220 comprises a moveable element, sliding sleeve 390,
comprising a connecting hole. The sliding sleeve 390 is movable
within the body 200 by the actuation mandrel movement by the
actuator 240, causing the connecting hole to be in position such
that it is aligned in communication with the lateral hole 210 and
fluid is in communication between the annular flow passage 154 and
inner flow passage 152. When the sliding sleeve 390 is moved by the
actuation mandrel to another position, communication hole 920 is
not in fluid communication with the lateral hole 210 and resulting
in the fluid flow between the annular flow passage 154 to be not in
communication with the inner flow passage 152 through the
communication hole. The body 200 further comprises a pressure
compensation hole to connect the annular fluid pressure to an
internal compartment of the apparatus for compensating the pressure
between the inner mandrel and the pressure of the annular flow
passage. The apparatus in FIGS. 21 and 22 comprises another valve
220 such as those described in FIG. 2 in addition to the valve 220
with sliding sleeve 390 element.
[0180] FIG. 22 is another section view of another preferred example
of the flow control apparatus 150 comprising plurality of valves.
One valve 22.0 comprises a sliding sleeve 390 comprising a
connecting hole. The sliding sleeve 390 is movable within the body
200 by the actuation mandrel movement by the actuator 240, causing
the connecting hole to be in position such that it is aligned in
communication with the lateral hole 210 and fluid is in
communication between the annular flow passage 154 and inner flow
passage 152. When the sliding sleeve 390 is moved by the actuation
mandrel to another position, communication hole 920 is not in fluid
communication with the lateral hole 210 and resulting in the fluid
flow between the annular flow passage 154 to be not in
communication with the inner flow passage 152 through the
communication hole. Within the body 200 is further disposed a means
for interpreting the signal in a form of electronic controller 274.
In one example, the electronic controller 274 has a processor, a
memory and a suitable wiring to connect the signal from the sensor
272 to the processor, and a suitable wiring to connect the power to
an actuator 240 means such as the electric motor 620 or solenoid in
order to move the movable element 380 or to unlock the lock 277
disposed within the apparatus. The apparatus further includes a
sensor 272 responsive to chemical composition of the fluid within
the wellbore 100 or, in one example, within the tubular string. In
one example, changes in fluid chemical composition generate a
suitable signal and a type of sensors sensitive to fluid chemical
composition is used, allowing interpretation or analysis to
identify or otherwise decode a command pattern 899.
[0181] In one example, the apparatus in FIGS. 21 and 22 includes
another valve 220 having a movable element 380 in the form of
sliding sleeve 390 element.
[0182] Drilling risks encountered during wellbore 100 operations
include by way of examples having cutting beds 175, having
suspended cuttings 170 in the well bore or having fluid losses into
porous formation or fractures 160. It is desirable to change
annular flow velocity at certain points within the wellbore 100 to
improve hole cleaning by way of causing the cutting beds 175 and
suspended cuttings 170 to move up the wellbore 100 annular passage
to surface. It is further desirable to dispose certain fluid
composition such as materials and chemicals to treat formation
damage and reduce fluid losses. It is further desirable to
introduce cement composition in a suitable form for treating a
wellbore 100 fracture through the wellbore 100 to plug the
formation fractures 160 without flowing the cement through the
bottom hole assembly 130 components. It is further desirable to
control flow pattern within the wellbore 100 and between inner flow
passage 152 and annular passage at different points within the
tubular string 110 to deal with one or more of the drilling
operations risks encountered. During customary drilling operation
such as when the drill bit 120 cuts and removes new formation at
the bottom of the well and enlarging the wellbore 100, it is
further desirable to have continuous mechanical access through the
inner flow passage 152 to enable running wireline services such as
gyro survey to evaluate the well directional information. It is
further desirable to dispose a drop ball activated equipment such
as under reamers within the same tubular string 110. It is further
desirable to enable the operator to use optimized drilling
parameters such as varying flow rate or drilling with high pressure
without undesirably causing the flow control apparatus 150 into a
different mode. It is further desirable to dispose plurality of
flow control apparatus 150 within the same tubular string 110 at
various points and operate each one individually and selectively.
It is further desirable to operate the flow control apparatus 150
to cause plurality of fluid flow pattern including one or more of
the following flow patterns: through flow, lateral flow, full flow
or no flow. It is further desirable to dispose the flow control
apparatus 150 within the tubular string 110 such that mechanical
restrictions within the inner flow passage 152 caused by other
components of the tubular string 110 disposed between the flow
control apparatus 150 and surface does not restrict the operation
of the flow control apparatus 150. It is further desirable to
operate the flow control apparatus 150 efficiently independent of
the depth or the deviation of the point where the flow control
apparatus 150 is disposed with respect to the tubular string 110.
The present invention introduces an apparatus and method to address
some or all of the above desirables without the need to pull the
tubular string 110 out of the wellbore 100 and resulting in a
substantial savings of operation time and reduce operating
cost.
[0183] Therefore, in one example, the apparatus for remotely and
selectively control fluid flow in tubular strings and wellbore
annulus 156 has: [0184] a. body 200 defining the boundaries between
an inner flow passage 152 through the said apparatus and an annular
flow passage 154 within the wellbore annulus 156 and having two
suitable end connections and at least one lateral hole 210 suitable
for connecting the inner flow passage 152 and the annular flow
passage 154; [0185] b. a controllable valve 220 operable in
plurality of desired states altering the fluid flow pattern within
the wellbore 100 wherein the said valve 220 is having at least one
rotatable element 300 wherein the said element is rotatable to
plurality of desired positions. The valve 220 further divides the
inner flow passage 152 into upstream 157 section and downstream 159
section wherein upstream 157 section is defined as the portion of
the inner flow passage 152 from the valve 220 and through the
upstream 1.57 end connection 155 of the flow control apparatus 150
and the downstream 159 section as defined as the portion of the
inner flow passage 152 from the valve 220 and through the
downstream 159 end connection 155 of the body 200; [0186] c. an
activator 270 disposed within the body 200 capable of selectively
change the apparatus in either one of two modes: a disabled mode
wherein the said valve 220 is not operable, and an enabled mode
wherein the said valve 220 is operable to a different state,
comprising a means for detecting an intended change in the
environment; and [0187] d. an actuator 240 capable of changing the
rotatable element 300 position to cause the valve 220 into a
desired state comprising a means for transforming a suitably
available energy source into a mechanical movement.
[0188] In one example, the rotatable element 300 is suitably
selected to cause the valve 220 into a suitable state and to cause
a change of the flow pattern into one or more of the following
patterns: [0189] i. no flow pattern wherein the flow passage
between the upstream 157 section and the downstream 159 section is
restricted and the flow passage between the inner flow passage 152
and the annular flow passage 154 is also restricted and the valve
220 is in no flow state; [0190] ii. through flow pattern 705
wherein the passage between the upstream 157 section and the
downstream 159 section of the inner flow passage 152 is not
restricted whereas the passage between the inner flow passage 152
and the annular flow passages is restricted and the valve 220 is in
through flow state; [0191] iii. diverted flow pattern 710 wherein
the flow passage between the upstream 157 section and the said
annular flow passage 154 is not restricted whereas the flow passage
to the downstream 159 section is restricted and the valve 220 is in
diverted flow state; and [0192] iv. full flow pattern 715 wherein
the flow passage between the upstream 157 section and the
downstream 159 section of the inner flow passage 152 is not
restricted and the flow passage between the said inner flow passage
152 and the annular flow passages is not restricted and the valve
220 is in full flow state.
[0193] In one example, rotatable element 300 has a suitable
embodiment explained by way of example in FIG. 3.
[0194] In one example, the activator 270 further comprises a
plurality of suitable sensor 272 means for detecting an intended
change in at least one physical property of the environment
resulting in a signal within the apparatus suitable for processing.
By way of example, in one example of the apparatus, the sensor 272
means is a form of pressure sensor 272 suitable to be affected by
pressure variation within the wellbore 100 caused by way of example
by a change of depth or change of fluid flow pressure. In another
example, the sensor 272 means is a flow sensor 272 suitable to be
affected by variation of flow property such as fluid flow rate
within the wellbore 100. In another example, the sensor 272 means
is a form of an electrode suitable for detecting an electrical
signal such as a change of the potential voltage or electric
current of the said electrode with respect to the tubular string
110 caused by an induced electric signal into the formation. In
another example, the sensor 272 means is a form of an accelerometer
affected by change of tubular string 110 movement in one or more
direction such as the rotation speed or axial movement speed or any
combination thereof In another example, the sensor 272 means is a
form of magnetometer affected by magnetic field changes due to
change of surrounding magnetic conductivity of the environment at
the apparatus caused by change of the detected signal of earth
magnetic field in certain pattern caused induced by a change of the
apparatus location in earth by way of moving the tubular string
110. It is understood that the sensor 272 means could take any
other form suitable for detecting at least one change of the
environment at the apparatus.
[0195] In one example, the activator 270 further comprises a
controller 274 means disposed within the flow control apparatus 150
in a form suitable for processing the signal generated by the
sensor 272 means explained above.
[0196] In one example, controller 274 means is capable of comparing
the detected signal pattern to a predetermined command pattern 899.
When a command pattern 899 is detected, the controller 274 means
causes the suitable change within the apparatus to cause the desire
change of the apparatus mode then to cause the change of the
controller 274 to make the suitable changes within the apparatus to
change the controllable valve 220 into the desired state. The
controller 274 further comprises a movement limiting means to limit
the actuation linkage 242 movement and cause it to stop at a
desired displacement. By a way of example, movement limiting means
of movement control include a barrel cam 248 disposed within the
body 200 and suitably connected to the actuation mandrel 246. The
said barrel cam 248 comprises a cam track 740 with a profile
suitable for the cam follower 250 disposed within the body 200 to
limit the movement of the barrel cam 248 travel between specific
predetermined two or more track point such as those explained in
FIG. 12 and FIG. 14. Any of the said track point restricts the
barrel cam 248 displacement from movement in one or more direction.
As the barrel cam 248 is suitably connected with the actuation
mandrel 246, when the flow control apparatus 150 is in enabled
mode, the movement of the barrel cam 248 as determined by the cam
follower 250 traversing the cam track 740 causing the actuation
mandrel 246 movement to be restricted to move to a specific
position.
[0197] In one example, the activator 270 further comprises a
locking means suitable for selectively change the apparatus mode
when it is desired to change the apparatus mode to an enabled mode
or to a disabled mode. By way of example, the locking means
comprises a lock 277 element such that when engaged with a suitable
locking groove 278 suitably connected with the actuation mandrel
246, restricts the movement of one or more of the actuator 240
elements such as the actuation mandrel 246 and cause the flow
control apparatus 150 to be in a disabled mode. When the apparatus
is in disabled mode, the valve 220 is not operable to change its
state. When the lock 277 is disengaged from the locking groove 278,
the actuator 240 disposed within the flow control apparatus 150
will not be restricted by the lock 277 element and the flow control
apparatus 150 will be in enabled mode and the valve 220 will be
operable into a different state.
[0198] In an example as described in FIG. 11, the lock 277 is
caused to change position by a suitable lock driver 720. The lock
driver 720 in one example is a suitable solenoid. In another
example, the lock 277 viewed in FIG. 11 is driven by lock driver
720 in a form of a suitable motor. It is understood that the lock
277 can be driven by other suitable lock driver 720 to cause it to
move between at least two positions such that, in one position lock
277 is disengaged from the locking groove 278, and in another
position the lock 277 is suitably engaging the locking groove 278.
In one example where the lock driver 720 is a solenoid, for
example, when a suitable electric charge is connected to the
solenoid, the solenoid becomes energized causing the lock 277 to
retract into the body 200 and the lock 277 is caused to disengage
away from the locking groove 278 causing the flow control apparatus
150 into enabled mode.
[0199] In one example, the solenoid is further operable such that
when energized with a different suitable charge the lock 277 is
caused to extend through the inner wall of the body 200 and is
caused to be suitably engaged with the locking groove 278 causing
the flow control apparatus 150 into a disabled mode. The same
function made by the solenoid means of lock driver 720 is be
achieved by a suitable motor in another example. It is understood
that the locking means by way of example and does not limit the
apparatus locking to these mentioned examples. When the lock 277 is
engaged with the suitable locking groove 278 disposed within the
actuation mandrel 246, it restricts the movement of the actuation
mandrel 246 therefore restricting the movement of the actuation
linkage 242 and therefore the movement of the rotatable element 300
is restricted and the valve 220 is restricted from changing its
state and not operable into a different state. The flow control
apparatus 150 is said to be in disabled mode when the valve 220 is
not operable to a different state. When the lock 277 is disengaged
from the locking groove 278, the actuator 240 mandrel disposed
within the flow control apparatus 150 will not be restricted by the
lock 277 element and the flow control apparatus 150 will be in
enabled mode and the valve 220 will be operable into a different
state. The flow control apparatus 150 is said to be in enabled mode
when the valve 220 is operable to a different state. The locking
means explained is by way of example. Another example of the
locking means is explained; in a different example of the actuator
240 such as the example in FIG. 6 where the actuator 240 comprises
a suitable electric motor 620, the locking means is achieved by
disconnecting the electric energy source form the electric motor
620 causing the electric motor 620 to be inoperable and accordingly
the rotatable element 300 to be restricted from changing position
by means of the gear arrangement where the worm engaged with the
pinion 420 act as a break when the worm gear 610 is not rotatable,
and the flow control apparatus 150 is then said to be in the
disabled mode. When the electric motor 620 is connected to the
suitable electric energy source, it rotates in a suitable direction
causing the worm gear 610 to rotate causing the pinion 420 to
rotate in a suitable direction and resulting in a change of the
rotatable element 300 position and the valve 220 is operable into a
different state and the flow control apparatus 150 is said to be in
enabled mode during when the electric energy source is connected to
the said motor.
[0200] In one example, flow control apparatus 150 further comprises
an actuator 240 capable of changing the rotatable element 300
position to cause the valve 220 into a desired state therefore
causing a change in flow pattern comprising a means for
transforming a suitably available energy source into a mechanical
movement. In one example, the actuator 240 comprises a form of an
electric motor 620 powered by a suitable battery 276 or a suitable
generator or capacitor or other suitable electric energy source
disposed within the apparatus or available on a different location
within the tubular string 110 or on surface and connected to the
apparatus by connecting means such as wireline cable introduced
tarn surface to the apparatus through wellbore 100. In this example
of actuator 240 having an electric motor 620 means of transforming
a suitably available electrical energy source into a mechanical
energy is capable of changing the position of the rotatable element
300 by means of linkage in the form of a suitable gear engagement
such as worm gear 610 and pinion 420. When the said electric energy
source is connected to the electric motor 620 causing the worm gear
610 connected to the electric motor 620 output to adequately rotate
the pinion 420 that is suitably connected to the rotatable element
300 around the pivot 307 and will cause a change of the rotatable
element 300 position and accordingly a change of the controllable
valve 220 state and a suitable change of the flow pattern.
[0201] In another example, the actuator 240 transforms an energy
source in the form of an energized resilient element such as a
spring 244. The resilient element stores energy when caused to
change its state from relaxed state to a strained state
alternatively called an energized state by means of causing a
strain to the resilient element such as by means of coiling,
compressing or stretching the resilient element from a less
strained state. The said resilient element in such a strained state
when suitably connected to the rotatable element 300 and when the
apparatus is in enabled mode will cause the rotatable element 300
into a different position. In another example, the form of
resilient element energy source is pre-energized before disposing
the flow control apparatus 150 into the wellbore 100. In a further
other example, the resilient element energy source is energized
while within the wellbore 100 by another energy source such as
hydraulic flow as explained in the embodiment viewed in FIG.
20.
[0202] In an example, the actuator 240 comprises a means suitable
to transform a form of mechanical energy source caused by an
inertia mass element disposed within the flow control apparatus 150
into a mechanical movement suitable for changing the rotatable
element 300 position. When the flow control apparatus 150 is in
enabled mode, and when the inertia element 510 is suitably
energized by way of momentum or inertia for example through
movement of tubular string 110, the inertia element 510, suitably
connected to the rotatable element 300 as explained earlier, will
cause a change of the rotatable element 300 position and
accordingly cause a change in the valve 220 state.
[0203] In an example, the actuator 240 is suitable for transforming
a hydraulic energy of the fluid flowing through the inner flow
passage 152 or annular flow passage 154 or any combination thereof
to generate a suitable mechanical energy causing the rotatable
element 300 to change position explained herein. The practice of
introducing drilling fluid composition into the tubular string 110
inner flow passage 152 will cause the fluid in the inner flow
passage 152 to have higher pressure than the fluid in the annular
flow passage 154 at the same depth, and the fluid is called to be
circulated through the inner flow passage 152 and the operation is
commonly called mud circulation. When no fluid is introduced into
the tubular string 110 inner flow passage 152, the fluid pressure
in the inner flow passage 152 will be similar to the fluid pressure
in the annular flow passage 154 at the same depth and the operation
is commonly called no circulation.
[0204] In an example, the apparatus actuator 240 described in FIG.
20 harvests energy from the change of pressure between the inner
flow passage 152 and the annular flow passage 154 at the apparatus
depth during the mud circulation and stores it through deforming a
resilient element such as the spring 244 shown in figure. The mud
compartment 905 defined as the space between the inner body 200
surface and the actuating mandrel outer surface 340 is having a
suitably varying diameter so that fluid pressure exerted on the
flow orifice 280 during mud circulation that is higher than the
fluid pressure in the mud compartment 905 causing the actuation
mandrel 246 to move in the direction suitable to compress the
spring 244. During no circulation the pressure in the mud
compartment 905 is the same as the pressure in the inner flow
passage 152 and the force exerted by the compressed spring 244 will
be released causing the actuation mandrel 246 to move to the
opposite direction. The actuator 240 is further having an
arrangement of electric coils and magnets such as stud magnet 895
or ring magnet 890 or any combination thereof. When the actuation
mandrel 246 moves with the effect of mud circulation in one
direction and moves again at no circulation in the opposite
direction it will cause a change of magnetic field detected by the
electric coil 885 caused by the change of relative position of the
electric coil 885 and the magnet element causing electric charges
observed in the electric coil 885. In a further example of the
present invention, the said electric charges is utilized to move
the electric motor 620 and in a further example, the said electric
charges is utilized to charge a suitable means of storing electric
charge such as capacitor or rechargeable battery 276. A method of
energy harvesting is now explained where electric energy is
harvested from hydraulic energy within the wellbore 100, and a
mechanical energy is harvested from hydraulic energy within the
wellbore 100. It is understood that the energy sources explained
herein are made by way of example and not exhaustive. The same
function is possible to be achieved by other means of energy
sources suitably available within the apparatus.
[0205] In one example, the actuator 240 comprises an actuation
mandrel 246 having a suitable flow orifice 280 profile that is
affected by fluid flowing through the inner flow passage 152. When
fluid flows through the actuation mandrel 246 the hydraulic energy
from the said fluid flow exerts a suitable force on the flow
orifice 280 causing the actuation mandrel 246 to move with respect
to the body 200 and exerting a suitable force on the actuation
linkage 242 suitably attached to the rotatable element 300
push-pull point 308 causing the rotatable element 300 to move and
causing the rotatable element 300 to change its position.
[0206] In one example, the flow control apparatus 150 explained
herein is normally disposed in the wellbore 100 while in initial
valve 220 state of through flow state. Customary drilling operation
may take place by including the steps of drilling, flowing drilling
fluid into the tubular inner flow passage 152, lowering the tubular
string 110 deeper into the earth and extending deeper into the
earth by way of removing layer of earth through drilling process by
means of drill bit 120 operation. With reference to the preferred
example explained in FIG. 2, when the valve 220 state is through
flow state as in detail A of FIG. 10, there is no restriction
within the inner flow passage 152. When desired, it is possible in
this state to run a suitable wireline services such as gyro survey
through the tool inner flow passage 152. It is further possible to
operate a drop ball operated device disposed within the tubular
string 110 by means of introducing a suitable drop ball through the
tubular string 110 inner flow passage 152 including the inner flow
passage 152 portion through the flow control apparatus 150. When it
is desired to change the flow pattern of a particular flow control
apparatus 150 disposed within the tubular string 110, a suitable
change in the environment is made causing a signal pattern to be
detected within the apparatus. A command pattern 899 is suitably
formed sequence of signal pattern predetermined and stored within
each tool and for each desired command. By way of example, a
possible command pattern 899 to change a particular valve 220
disposed within a particular flow control apparatus 150 from one
flow state to another flow state comprises the following sequence
in order, reference pattern A 865 followed by reference pattern B
870 then followed by reference pattern C 875. A controller 274
disposed within the flow control apparatus 150 processing the
signal detected within the apparatus will observe the said command.
pattern 899 at command time point 910. At command time point 910,
the activator 270 will cause the desired change within the
apparatus to cause it into the desired mode. The activator 270
further will cause the actuator 240 to cause the controllable valve
220 into the desired state by changing the rotatable element 300
into the desired position by means of transforming a suitably
available energy source as explained earlier into a mechanical
movement. It is to note that a suitable command pattern 899 is
predetermined for each flow control apparatus 150 disposed within
the tubular string 110. This is another desired advantage of the
present invention allowing a user to dispose a plurality of flow
control apparatus 150 within the same tubular string 110 and cause
each one individually and selectively into a possible independent
valve 220 state and accordingly a suitable flow pattern. It is
further to note that the command pattern 899 is suitably
predetermined such that change of the environment caused during
customary operations will not cause the flow control apparatus 150
to change its mode or flow pattern to change, this is another
desirable advantage of the present invention such that optimal
operating parameters is possible to be deployed without the risk of
undesirably causing the flow control apparatus 150 to change its
mode or flow pattern.
[0207] In further example, it is possible to extend and apply the
same method of selectively controlling a flow control apparatus 150
using command pattern 899 to any other apparatus disposed within a
tubular string 110 suitably equipped to detect such a command
pattern 899 and cause the desired actuation to selectively take
place. The example explained in FIG. 19 and detailed above for the
flow control apparatus 150 may be implemented on any other suitably
equipped apparatus having a device means suitable for any desired
action such as a valve 220. The command pattern 899 explained and
disclosed herein is another desirable advantage of the present
invention as it provide extra flexibility of disposing plurality of
apparatus each could have a different device means to perform a
different function. Such a command pattern 899 provides an
advantage means to enable the operator to selectively and remotely
operate plurality of apparatus disposed within a wellbore 100 into
a desired mode or a desired state independently.
[0208] Furthermore, and with reference to the flow control
apparatus 150, when it is desirable to dispose a particular fluid
composition to treat formation damage such as cement composition to
treat formation fractures 160, it would be desirable to operate a
flow control apparatus 150 dispose within the tubular string 110
between the bottom hole assembly 130 and surface and cause its
valve 220 into bypass state. When in bypass state such as the state
explained in FIG. 10 detail (B1), (B2) and (B3). It is to note that
fluid composition will all exit the lateral hole 210 into the
annular passage to reach the damage formation it is to note that
the inner flow passage 152 downstream 159 section of the valve 220
is obstructed in such a way that safeguard bottom hole assembly 130
components disposed between the drill bit 120 and the said flow
control apparatus 150 from having such a cement composition
undesirably flowing into the said bottom hole assembly 130
components. It is a further advantage that the preferred example
explained in FIG. 2 utilizing the valve 220 detailed in FIG. 10
will allow the user to displace all treatment composition fluid
within the inner flow passage 152 with another composition fluid
without leaving any tangible volume of the treatment composition
fluid within the inner flow passage 152. This is another advantage
of the present invention whereas when it is desired to change the
valve 220 state into through flow state after performing the said
disposition of treatment composition fluid into the annular
passage, there will be no significant treatment composition fluid
within the inner flow passage 152 that would enter the bottom hole
assembly 130 inner flow passage 152 and will not be a source of
risk to the bottom hole assembly 130 components.
[0209] In one example, as the flow control apparatus 150 is rigidly
attached to the tubular string 110 through the end connection 155
and the inner flow passage 152 is hydraulically connected to
surface and the drilling fluid commonly used in drilling operations
is relatively incompressible, causing any change on the surface by
means of moving the tubular string 110 in any direction or causing
the fluid flow to change in any particular pattern will cause a
suitable change in the environment reasonably detectable by sensor
272 disposed within the flow control apparatus 150 nearly at the
same time. This is another advantage of the present invention will
save significant operating time when compared to a drop ball
activated devices where the drop ball has to consume a significant
time traversing the inner flow passage 152 from surface to reach
its corresponding apparatus. It is a further advantage of the
present invention to be operated by causing a command pattern 899
within a similar time independent of the depth or location of the
flow control apparatus 150, and independent of the well deviation
anywhere in the wellbore 100 where the present invention is
disposed of particularly when compared to drop ball activated
apparatus where the drop ball will take different time to reach the
corresponding apparatus depending on that apparatus depth, and well
deviation. It is a further advantage that the present invention
command pattern 899 does not demand a physical access within the
inner flow passage 152 allowing the operator to dispose the flow
control apparatus 150 within the tubular string 110 below other
devices that may have mechanical restriction within the inner flow
passage 152 such a drop ball activated apparatus disposed between
the flow control apparatus 150 and surface within the same tubular
string 110 is another further advantage that the present invention
is operable in unlimited number of times and does not suffer from
the limited number of operable cycles that is associated with drop
ball activated apparatus imposed by what is called a ball capture
means used commonly with apparatus using drop ball system. It is
another further advantage that the present invention is operable in
one or more of the following flow states: through flow, diverted
flow, full flow, and no flow explained earlier providing a far more
flexibility to the operator. The through flow is commonly used in
customary drilling operation. The diverted flow is of an advantage
for composition fluid particularly when the said composition is not
suitable to pass through equipment disposed downstream 159 of the
flow control apparatus 150, as by the way of example the
disposition of cement composition to treat fractures 160 when
equipment downstream 159 of the flow control apparatus 150 is a
bottom hole assembly 130 component. The full flow pattern 715 is a
useful pattern to suitably control or increase the annular fluid
velocity aiding to improve hole cleaning and reduce cutting beds
175 and reduce suspended cuttings 170 within the wellbore annulus
156 while at the same time allow for portion of the circulated
fluid to flow through the inner flow passage 152 and possibly
through the bit perforations 125 to maintain well control at all
times. The no flow mode is another important mode suitable for
securing the well as a form of sub surface safety valve 220 and
could be used in emergency cases where it is desired not to allow
flow within the bottom of the well and the inner flow passage 152
such as situations when well control is compromised for example
during what is call well kick or early warning of blow out.
[0210] While this invention has been described with respect to a
limited number of embodiments, those skilled in the art, having
benefit of this disclosure, will appreciate that other embodiments
can be devised which do not depart from the scope of the invention
disclose.
[0211] While the invention has been illustrated and described in
detail in the drawings and foregoing description, such illustration
and description are to be considered illustrative or exemplary and
not restrictive and it is not intended to limit the invention to
the disclosed embodiments. The mere fact that certain measures are
recited in mutually different dependent claims does not indicate
that a combination of these measures cannot be used
advantageously.
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