U.S. patent application number 15/515592 was filed with the patent office on 2017-10-19 for flow distribution assemblies with shunt tubes and erosion-resistant shunt nozzles.
The applicant listed for this patent is Halliburton Energy Services, Inc.. Invention is credited to Liam Andrew AITKEN, Matthew Ryan GOMMEL.
Application Number | 20170298711 15/515592 |
Document ID | / |
Family ID | 55858176 |
Filed Date | 2017-10-19 |
United States Patent
Application |
20170298711 |
Kind Code |
A1 |
AITKEN; Liam Andrew ; et
al. |
October 19, 2017 |
FLOW DISTRIBUTION ASSEMBLIES WITH SHUNT TUBES AND EROSION-RESISTANT
SHUNT NOZZLES
Abstract
A shunt tube assembly includes a shunt tube having an inner flow
path for a fluid and defining an opening in a sidewall of the shunt
tube. A shunt nozzle is coupled to the sidewall and has an elongate
slot defined therethrough and is aligned with the opening to
provide fluid communication between the inner flow path and an
exterior of the shunt tube. The elongate slot has a length and a
height, and the length is greater than the height.
Inventors: |
AITKEN; Liam Andrew;
(Bedford, TX) ; GOMMEL; Matthew Ryan; (The Colony,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Halliburton Energy Services, Inc. |
Houston |
TX |
US |
|
|
Family ID: |
55858176 |
Appl. No.: |
15/515592 |
Filed: |
October 15, 2015 |
PCT Filed: |
October 15, 2015 |
PCT NO: |
PCT/US2015/055703 |
371 Date: |
March 29, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62073240 |
Oct 31, 2014 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 10/61 20130101;
E21B 43/11 20130101; E21B 41/0078 20130101; E21B 43/04 20130101;
E21B 17/1007 20130101 |
International
Class: |
E21B 41/00 20060101
E21B041/00; E21B 17/10 20060101 E21B017/10 |
Claims
1. A shunt tube assembly, comprising: a shunt tube having an inner
flow path for a fluid and defining an opening in a sidewall of the
shunt tube; and a shunt nozzle coupled to the sidewall and having
an elongate slot defined the ethrough and aligned with the opening
to provide fluid communication between the inner flow path and an
exterior of the shunt tube, wherein the elongate slot has a length
and a height, and the length is dissimilar to the height.
2. The shunt tube assembly of claim 1, wherein the shunt tube is
rectangular and the length is a horizontal measurement of the
elongate slot generally parallel to the shunt tube, and the height
is a vertical measurement of the elongate slot generally orthogonal
to the shunt tube.
3. The shunt tube assembly of claim 2, wherein the length is
greater than the height.
4. The shunt tube assembly of claim 1, wherein the shunt nozzle is
a six-sided block comprising: a first end and a second end opposite
the first end; a top and a bottom opposite the top; and a first
side and a second side opposite the first side, wherein the
elongate slot extends between the first and second sides.
5. The shunt tube assembly of claim 4, wherein the length of the
elongate slot is constant between the first and second sides.
6. The shunt tube assembly of claim 4, wherein the length of the
elongate slot varies between the first and second sides.
7. The shunt tube assembly of claim 1, wherein the height of the
elongate slot is constant across the length of the elongate
slot.
8. The shunt tube assembly of claim 1, wherein the height of the
elongate slot varies across the length of the elongate slot.
9. The shunt tube assembly of claim 8, wherein the elongate slot
defines a channel where the height is increased as compared to
remaining portions of the elongate slot.
10. The shunt tube assembly of claim 9, wherein the channel
exhibits a cross-sectional shape selected from the group consisting
of circular, oval, ovoid, polygonal, and any combination
thereof.
11. The shunt tube assembly of claim 1, wherein the shunt nozzle is
coupled to the sidewall by at least one of welding, brazing, an
adhesive, a mechanical fastener, and any combination thereof.
12. The shunt tube assembly of claim 1, wherein the elongate slot
extends from the shunt tube at an angle ranging between 1.degree.
and 179.degree. with respect to the shunt tube.
13. The shunt tube assembly of claim 1, wherein the shunt nozzle
comprises a material selected from the group consisting of a
carbide, a carbide embedded in a matrix of cobalt or nickel by
sintering, a cobalt alloy, a ceramic, a surface-hardened metal, a
steel alloy, a chromium alloy, a nickel alloy, a cermet-based
material, a metal matrix composite, a nanocrystalline metallic
alloy, an amorphous alloy, a hard metallic alloy, or any
combination thereof.
14. The shunt tube assembly of claim 1, wherein an inner surface of
the shunt nozzle is clad with an erosion-resistant material
selected from the group consisting of a carbide, a cobalt alloy,
and a ceramic.
15. A method, comprising: introducing a flow distribution assembly
into a wellbore on a work string, the flow distribution assembly
including at least one shunt tube extending along an exterior of
the work string and having an inner flow path for a fluid and
defining an opening in a sidewall of the shunt tube; conveying the
fluid into the inner flow path from an annulus defined between the
work string and the wellbore; and discharging at least a portion of
the fluid from the at least one shunt tube at a shunt nozzle
coupled to the sidewall and having an elongate slot defined
therethrough and aligned with the opening to provide fluid
communication between the inner flow path and the annulus, wherein
the elongate slot has a length and a height, and the length is
dissimilar to the height.
16. The method of claim 15, further comprising preventing erosion
of the shunt fitting, wherein the shunt nozzle comprises an
erosion-resistant material selected from the group consisting of a
carbide, a ceramic, a cobalt alloy, a surface-hardened metal,
stainless steel, a nickel-chromium alloy, a molybdenum alloy, and a
chromium steel.
17. The method of claim 15, further comprising preventing erosion
of an inner surface of the shunt nozzle, wherein the inner surface
of the shunt nozzle is clad with an erosion-resistant material
selected from the group consisting of a carbide, a cobalt alloy,
and a ceramic.
18. The method of claim 15, further comprising preventing erosion
of the at least one shunt tube, wherein the at least one shunt tube
comprises an erosion-resistant material selected from the group
consisting of a carbide, a ceramic, a cobalt alloy, a
surface-hardened metal, and a composite.
19. The method of claim 15, wherein the elongate slot defines a
channel where the height is increased along the length as compared
to remaining portions of the elongate slot.
20. The method of claim 15, wherein the shunt tube is rectangular
and the length is a horizontal measurement of the elongate slot
generally parallel to the shunt tube and the height is a vertical
measurement of the elongate slot generally orthogonal to the shunt
tube, and wherein the length is greater than the height.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of priority under
35 U.S.C. .sctn.371 as a national phase of International Patent
Application Serial No. PCT/U52015/055703 entitled "Flow
Distribution Assemblies with Shunt Tubes and Erosion-Resistant
Shunt Nozzles," and filed on Oct. 15, 2015, which claims the
benefit of priority under 35 U.S.C. .sctn.119 as a nonprovisional
of U.S. Provisional Patent Application Ser. No. 62/073,240 entitled
"Flow Distribution Assemblies with Shunt Tubes and
Erosion-Resistant Fittings," and filed on Oct. 31, 2014, the
disclosures of which are hereby incorporated by reference in their
entirety for all purposes.
BACKGROUND
[0002] In the course of completing wellbores traversing
hydrocarbon-bearing subterranean formations, it is oftentimes
desirable to inject various types of fluids into the wellbore for a
number of purposes. For example, steam is often injected into
surrounding formations to stimulate the production of
high-viscosity hydrocarbons, and treatment fluids, such as
hydrochloric acid, are often injected into a wellbore to react with
acid-soluble materials present within the formation and thereby
enlarge pore spaces in the formation. In other applications, water
or a gas may be injected into the surrounding formations to
maintain formation pressures so that a producing well can continue
production. In yet other applications, a gravel slurry is deposited
in spaced intervals surrounding well screens during gravel-packing
operations.
[0003] Such fluid injection operations are typically carried out by
placing an injection string at a desired location within a
wellbore. The injection string oftentimes includes a wellbore
screen assembly that includes one or more sand screens arranged
about perforated production tubing. The annulus between the sand
screens and the wellbore wall is generally gravel-packed to
mitigate the influx of formation sands derived from the surrounding
subterranean formations. Packers are customarily set above and
below sand screen assemblies to seal off the annulus in the zone
where production fluids flow into the production tubing. The
annulus around the sand screens is then packed with a gravel
slurry, which comprises relatively coarse sand or gravel suspended
within water or a gel and acts as a filter to reduce the amount of
fine formation sand reaching the screens.
[0004] During the gravel packing process, annular sand bridges can
form around the sand screen assembly that may prevent the complete
circumscribing of the screen structure with gravel in the completed
well. This incomplete screen structure coverage by the gravel may
leave an axial portion of the sand screen exposed to the fine
formation sand, thereby undesirably lowering the overall filtering
efficiency of the sand screen structure.
[0005] One approach to avoiding the creation of annulus sand
bridges has been to incorporate shunt tubes that longitudinally
extend across the sand screens. The shunt tubes provide flow paths
that allow the inflowing gravel slurry to bypass any sand bridges
that may be formed and otherwise permit the gravel slurry to enter
the annulus between the sand screens and the wellbore beneath sand
bridges, thereby forming the desired gravel pack beneath it.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The following figures are included to illustrate certain
aspects of the present disclosure, and should not be viewed as
exclusive embodiments. The subject matter disclosed is capable of
considerable modifications, alterations, combinations, and
equivalents in form and function, without departing from the scope
of this disclosure.
[0007] FIG. 1 depicts a well system that can employ one or more
principles of the present disclosure.
[0008] FIGS. 2A and 2B depict isometric and cross-sectional side
views, respectively, of an exemplary shunt tube assembly.
[0009] FIGS. 3A and 3B depict isometric and cross-sectional side
views, respectively, of another exemplary shunt tube assembly.
[0010] FIGS. 4A-4C depict views of yet another exemplary shunt tube
assembly.
[0011] FIGS. 5A-5B depict views of another exemplary shunt tube
assembly.
[0012] FIGS. 6A-6B depict views of another exemplary shunt tube
assembly.
DETAILED DESCRIPTION
[0013] The present disclosure generally relates to downhole fluid
flow control and, more particularly, to flow distribution
assemblies used to distribute fluid flow into surrounding
subterranean formations.
[0014] The presently disclosed embodiments enable relatively high
rates of fluid flow through a flow distribution assembly during
gravel packing and/or formation fracture packing operations. The
exemplary flow distribution assemblies described herein include
shunt tubes that extend along the exterior of a work string to
allow for fluid communication. In some embodiments, the shunt tubes
include one or more shunt nozzles coupled to a sidewall of the
shunt tube and have an elongate slot defined therethrough. The
elongate slot may be aligned with an opening defined in the
sidewall to provide fluid communication between the inner flow path
of the shunt tube and an exterior thereof. The geometry (shape) of
the elongate slot may allow for the same or greater cross-sectional
flow area as would be provided by a shunt nozzle having a circular
hole, but does not require the circular footprint. As a result, the
shape of the elongate slot may help reduce erosion of the shunt
nozzle by increasing the flow area, which has a direct correlation
to reduction in velocity for similar flow rates.
[0015] Referring to FIG. 1, illustrated is an exemplary well system
100 that can employ one or more principles of the present
disclosure, according to one or more embodiments. As depicted, the
well system 100 includes a wellbore 102 that extends through
various earth strata and may have a substantially vertical section
104 that may transition into a substantially horizontal section
106. The upper portion of the vertical section 104 may have a liner
or casing string 108 secured therein with, for example, cement 110.
The horizontal section 106 may extend through a hydrocarbon bearing
subterranean formation 112. As illustrated, the horizontal section
106 may be arranged within or otherwise extend through an open hole
section of the wellbore 102. In other embodiments, however, the
horizontal section 106 of the wellbore 102 may also be completed
using casing 108 or the like, without departing from the scope of
the disclosure.
[0016] A work string 114 may be positioned within the wellbore 102
and extend from the surface (not shown). The work string 114
provides a conduit for fluids to be conveyed either to or from the
formation 112. Accordingly, the work string 114 may be
characterized as an injection string in embodiments where fluids
are introduced or otherwise conveyed to the formation 112, but may
alternatively be characterized as production tubing in embodiments
where fluids are extracted from the formation 112 to be conveyed to
the surface.
[0017] At its lower end, the work string 114 may be coupled to or
otherwise form part of a completion assembly 116 generally arranged
within the horizontal section 106. As depicted, the completion
assembly 116 may include a plurality of flow distribution
assemblies 118 axially offset from each other along portions of the
completion assembly 116. Each flow distribution assembly 118 may
include one or more sand screens 120 disposed about the outer
surface of the work string 114. The sand screens 120 may comprise
fluid-porous, particulate restricting devices made from a plurality
of layers of a wire mesh that are diffusion bonded or sintered
together to form a fluid porous wire mesh screen. In other
embodiments, however, the sand screens 120 may have multiple layers
of a woven wire metal mesh material having a uniform pore structure
and a controlled pore size that is determined based upon the
properties of the formation 112. For example, suitable woven wire
mesh screens may include, but are not limited to, a plain Dutch
weave, a twilled Dutch weave, a reverse Dutch weave, combinations
thereof, or the like. In other embodiments, however, the sand
screens 120 may include a single layer of wire mesh, multiple
layers of wire mesh that are not bonded together, a single layer of
wire wrap, multiple layers of wire wrap or the like, that may or
may not operate with a drainage layer. Those skilled in the art
will readily recognize that several other sand screen 120 designs
are equally suitable, without departing from the scope of the
disclosure.
[0018] Each flow distribution assembly 118 may further include one
or more shunt tubes 122 that extend along the exterior of the work
string 114 and the sand screens 120 and otherwise within an annulus
124 defined between the flow distribution assemblies 118 and the
wall of the wellbore 102. The shunt tubes 122 may be configured to
convey fluids to various fluid flow points along the axial length
of the completion assembly 116 so that the fluid can be evenly
distributed within an annulus 124 defined between the flow
distribution assemblies 118 and the wall of the wellbore 102.
Accordingly, the completion assembly 116 may prove useful in
various wellbore operations, such as gravel-packing operations,
fracture packing operations, and the like. In such wellbore
operations, the fluids that may be conveyed by the shunt tubes 122
may include, but are not limited to, a fracturing fluid, a proppant
slurry, a gravel slurry, and any combination thereof.
[0019] The shunt tubes 122 may include at least one transport tube
that extends along all or substantially all of the completion
assembly 116 and may further include one or more packing tubes that
extend from the transport tube(s). The transport tube(s) may be
open to the annulus 124 at its uphole end to receive the fluid
therein to flow along the entire axial length of the transport
tube(s). The fluid may enter the annulus 124 via a crossover sub
(not shown), or the like, positioned within the work string 114
above the uppermost flow distribution assembly 118. The crossover
sub discharges the fluid into the annulus 124 from the interior of
the work string 114, and a portion of the fluid is received by the
transport tube(s). As the fluid flows down (within) the transport
tube(s), a portion of the fluid is able to flow into the packing
tubes, which split off the transport tube(s) and run substantially
parallel thereto along all or a portion of each flow distribution
assembly 118. Each packing tube may include one or more openings or
outlets that are able to discharge the fluid into the annulus 124
at predetermined locations. In other embodiments, the transport
tube(s) may also include one or more openings or outlets that are
able to discharge the fluid into the annulus 124 at predetermined
locations.
[0020] The fluids discharged into the annulus 124 may contain solid
particulates, such as gravel, proppant, and other solid debris
that, over time, may tend to erode certain surfaces of the shunt
tubes 122, such as the openings or outlets facilitate fluid
discharge into the annulus 124. As such openings erode and enlarge,
usually those near the upper end of the shunt tubes 122, more and
more of the fluid (e.g., a gravel slurry) will exit through the
enlarged openings with less and less of the fluid will reach the
lower, smaller openings in the shunt tubes 122. This increased flow
through the larger, eroded openings can cause "sand bridges" (i.e.,
the accumulation of particulates) to form in the shunt tubes 122,
which may block any further substantial downward flow in the
affected shunt tubes 122. Once this occurs, no further fluid can be
delivered through the affected shunt tube 122 to the downhole
portions of the wellbore 102. Another effect of having enlarged or
eroded openings due to erosion is a loss of control in the
direction of the flow. If the flow is redirected towards the sand
screens 120, damage could ensue and thereby cause a loss in
filtering capability.
[0021] According to the present disclosure, the fluid flow points
provided in the shunt tubes 122 may each include a shunt fitting
and/or a shunt nozzle. The shunt fittings and the shunt nozzles
associated with the shunt tubes 122 may be made of
erosion-resistant materials and thereby provide an
erosion-resistant exit pathway for fluids to exit the shunt tubes
122 into the annulus 124.
[0022] It should be noted that even though FIG. 1 depicts the flow
distribution assemblies 118 as being arranged in an open hole
portion of the wellbore 102, alternative embodiments are
contemplated herein where one or more of the flow distribution
assemblies 118 is arranged within a cased portion of the wellbore
102. Further, even though FIG. 1 depicts the flow distribution
assemblies 118 as being arranged in the horizontal section 106 of
the wellbore 102, those skilled in the art will readily recognize
that the principles of the present disclosure are equally well
suited for use in vertical wells, deviated wellbores, slanted
wells, multilateral wells, combinations thereof, and the like. As
used herein, directional terms such as above, below, upper, lower,
upward, downward, left, right, uphole, downhole and the like are
used in relation to the illustrative embodiments as they are
depicted in the figures, the upward direction being toward the top
of the corresponding figure and the downward direction being toward
the bottom of the corresponding figure, the uphole direction being
toward the surface of the well and the downhole direction being
toward the toe of the well.
[0023] Referring now to FIGS. 2A and 2B, with continued reference
to FIG. 1, illustrated are isometric and cross-sectional side
views, respectively, of an exemplary shunt tube assembly 200,
according to one or more embodiments. The shunt tube assembly 200
(hereafter the "assembly 200") may be used in the exemplary well
system 100 of FIG. 1. More particularly, the assembly 200 may be
positioned or otherwise arranged at various points within one or
more of the shunt tubes 122 of the flow distribution assemblies 118
of FIG. 1. As illustrated, the assembly 200 may include a shunt
tube 202 and an associated shunt fitting 204. The shunt tube 202
may be the same as or similar to any of the shunt tubes 122 of FIG.
1. Accordingly, the shunt tube 202 may be a transport tube or a
packing tube, as described above, and may be configured to convey
fluids from the annulus 124 (FIG. 1) to various fluid flow points
along the axial length of the completion assembly 116 (FIG. 1).
[0024] At least one of the fluid flow points may correspond to the
location of the shunt fitting 204. As illustrated, the shunt
fitting 204 may be positioned inline in the shunt tube 202. More
particularly, the shunt fitting 204 may interpose a first or upper
portion 206a of the shunt tube 202 and a second or lower portion
206b of the shunt tube 202. The shunt fitting 204 may be attached
to the upper and lower portions 206a,b of the shunt tube 202 at
corresponding attachment locations 207a and 207b, respectively, via
a variety of attachment means including, but not limited to,
welding, brazing, adhesives, mechanical fastening (e.g., screws,
bolts, pins, snap rings, etc.), shrink fitting, interference
fitting, or any combination thereof. While only one shunt fitting
204 is shown as positioned inline in the shunt tube 202, it will be
appreciated that multiple shunt fittings 204 may be connected
inline in the shunt tube 202 to provide a corresponding multiple
number of fluid flow point locations.
[0025] The shunt tube 202 may be generally tubular or, in other
words, in the general shape of a tube or a conduit. As best seen in
FIG. 2B, the shunt tube 202 may provide a fluid conduit or inner
flow path 208 for the flow of a fluid, as shown by the arrows A.
The fluid A may be any of the fluids mentioned above including, but
not limited to, a fracturing fluid, a gravel slurry, and any
combination thereof. In the illustrated embodiment, the shunt tube
202 and the shunt fitting 204 are depicted as having a generally
rectangular cross-sectional shape. In other embodiments, however,
the shunt tube 202 and the shunt fitting 204 may alternatively
exhibit a circular cross-section or any other polygonal
cross-section, such as triangular, square, trapezoidal, or any
other polygonal shape. In yet other embodiments, the shunt tube 202
and the shunt fitting 204 may exhibit a cross-sectional shape that
is substantially oval or kidney shaped, without departing from the
scope of the disclosure.
[0026] As illustrated, the shunt fitting 204 may include an outlet
210 that fluidly communicates with the inner flow path 208. The
outlet 210 may provide an opening or exit port for at least a
portion of the fluid A to be discharged from the assembly 200. In
some embodiments, the outlet 210 may comprise a hole that is flush
with the body of the shunt fitting 204. In other embodiments, as
illustrated, the outlet 210 may comprise a nozzle feature that
extends from the body of the shunt fitting 204 at an angle 212
(FIG. 2B) with respect to the longitudinal axis of the shunt tube
202. The angle 212 may be any angle ranging between 1.degree. and
179.degree. with respect to the shunt tube 202. In the illustrated
embodiment, the angle 212 is about 25.degree. offset from the shunt
tube 202 (i.e., its longitudinal axis), but could alternatively be
greater or smaller than 25.degree., without departing from the
scope of the disclosure.
[0027] In order to prevent or otherwise reduce erosion resulting
from the circulating fluid A during operation, the shunt fitting
204 may be made of an erosion-resistant material. The
erosion-resistant material may be, but is not limited to, a carbide
(e.g., tungsten, titanium, tantalum, or vanadium), a carbide
embedded in a matrix of cobalt or nickel by sintering, a cobalt
alloy, a ceramic, a surface hardened metal (e.g., nitrided metals,
heat-treated metals, carburized metals, hardened steel, etc.), a
steel alloy (e.g. a nickel-chromium alloy, a molybdenum alloy,
etc.), a cermet-based material, a metal matrix composite, a
nanocrystalline metallic alloy, an amorphous alloy, a hard metallic
alloy, or any combination thereof.
[0028] In other embodiments, or in addition thereto, the interior
or inner walls of the shunt fitting 204 may be clad or coated with
an erosion-resistant material, such as tungsten carbide, a cobalt
alloy, or ceramic. In such embodiments, the outlet 210 of the shunt
fitting 204 in particular may be clad or coated with the
erosion-resistant material. The interior or inner walls of the
shunt fitting 204 may be clad with the erosion-resistant material
via any suitable process including, but not limited to, weld
overlay, thermal spraying, laser beam cladding, electron beam
cladding, vapor deposition (chemical, physical, etc.), any
combination thereof, and the like.
[0029] In some embodiments, the shunt tube 202 may also be
configured to be erosion-resistant or otherwise comprise an
erosion-resistant material. For instance, the shunt tube 202 may be
made of a carbide or a ceramic. In other embodiments, the shunt
tube 202 may be made of a metal or other material that is
internally cladded with an erosion-resistant material such as, but
not limited to, tungsten carbide, a cobalt alloy, or ceramic. In
yet other embodiments, the shunt tube 202 may be made of a material
that has been surface hardened, such as surface hardened metals
(e.g., via nitriding), heat treated metals (e.g., using 13 chrome),
carburized metals, or the like. In even further embodiments, the
shunt tube 202, or a portion thereof, may be an Aramid-type fiber
tube, such as a Kevlar or other type of composite material.
[0030] Referring now to FIGS. 3A and 3B, illustrated are isometric
and cross-sectional side views, respectively, of another exemplary
shunt tube assembly 300, according to one or more embodiments. The
shunt tube assembly 300 (hereafter the "assembly 300") may be used
in the exemplary well system 100 of FIG. 1 and may be similar in
some respects to the assembly 200 of FIGS. 2A-2B and therefore may
be best understood with reference thereto, where like numerals
indicate like components not described again in detail. Similar to
the assembly 200, the assembly 300 may include the shunt tube 202,
including the upper and lower portions 206a,b thereof. The assembly
300 may also include the shunt fitting 204, including the outlet
210 that fluidly communicates with the inner flow path 208 to
provide an exit for at least a portion of the fluid A to be
discharged from the shunt tube 202. In some embodiments, as
illustrated, the outlet 210 may be a nozzle that extends from the
body of the shunt fitting 204 at the angle 212 (FIG. 3B).
[0031] Unlike the assembly 200 of FIGS. 2A-2B, however, the
assembly 300 may further include a first or upper coupling assembly
302a and a second or lower coupling assembly 302b. The upper
coupling assembly 302a may include an upper coupling 304a and the
lower coupling assembly 302b may include a lower coupling 304b. The
upper and lower couplings 304a,b may be configured to be coupled or
otherwise attached to opposing ends of the shunt fitting 204. More
particularly, a first or upper end 306a of the shunt fitting 204
may be coupled to the upper coupling 304a, and a second or lower
end 306b of the shunt fitting 204 may be coupled to the lower
coupling 304b. The upper and lower couplings 304a,b may be coupled
to the upper and lower ends 306a,b of the shunt fitting 204,
respectively, via a variety of attachment means including, but not
limited to, welding, brazing, adhesives, mechanical fastening
(e.g., screws, bolts, pins, snap rings, etc.), shrink fitting,
interference fitting, or any combination thereof.
[0032] In some embodiments, the upper and lower couplings 304a,b
may be directly coupled or otherwise attached to the upper and
lower portions 206a,b of the shunt tube 202, respectively, such as
via welding, brazing, adhesives, mechanical fastening (e.g.,
screws, bolts, pins, snap rings, etc.), shrink fitting,
interference fitting, or any combination thereof. In other
embodiments, however, one or both of the upper and lower coupling
assemblies 302a,b may include an extension, such as an upper
extension 308a and/or a lower extension 308b. The upper and lower
extensions 308a,b may be similar in cross-sectional shape to the
shunt tube 202. At one end, the upper and lower extensions 308a,b
may be coupled or otherwise attached to the upper and lower
couplings 304a,b, respectively, and at the other end, the upper and
lower extensions 308a,b may be coupled or otherwise attached to the
upper and lower portions 206a,b of the shunt tube 202,
respectively. Such coupling engagements of the upper and lower
extensions 308a,b with the upper and lower couplings 304a,b and the
upper and lower portions 206a,b of the shunt tube 202 may be
accomplished via any one of welding, brazing, adhesives, mechanical
fastening (e.g., screws, bolts, pins, snap rings, etc.), shrink
fitting, interference fitting, or any combination thereof.
[0033] Those skilled in the art will readily appreciate the
advantage that the assembly 300 may provide to a well operator. For
instance, the upper and lower coupling assemblies 302a,b may allow
the shunt fitting 204 to be coupled to the upper and lower
couplings 304a,b, and optionally the upper and lower extensions
308a,b, offsite prior to being delivered to a well site. This may
allow a manufacturer to properly braze the upper and lower
couplings 304a,b to the shunt fitting 204, which may be made of a
material that is difficult to weld, such as tungsten carbide. Once
on site, the upper and lower coupling assemblies 302a,b may be
coupled to the upper and lower portions 206a,b of the shunt tube
202, respectively, using common attachment means, such as welding
or brazing techniques, an adhesive, a mechanical fastener, shrink
fitting, interference fitting, and any combination thereof.
[0034] Referring now to FIGS. 4A-4C, illustrated are various views
of yet another exemplary shunt tube assembly 400, according to one
or more embodiments. More particularly, FIG. 4A depicts an
isometric view of the shunt tube assembly 400 (hereafter the
"assembly 400"), FIG. 4B depicts a cross-sectional side view of one
embodiment of the assembly 400, and FIG. 4C depicts a
cross-sectional side view of a second embodiment of the assembly
400. The assembly 400 may be used in the exemplary well system 100
of FIG. 1 and may be similar in some respects to the assemblies 200
and 300 of FIGS. 2A-2B and 3A-3B and therefore may be best
understood with reference thereto, where like numerals indicate
like components not described again.
[0035] Similar to the assemblies 200 and 300 of FIGS. 2A-2B and
3A-3B, the assembly 400 may include the shunt tube 202 for
conveying the fluid A therethrough. Unlike the assemblies 200 and
300, however, the assembly 400 may further include a shunt nozzle
402 that extends from the shunt tube 202 at an angle 404 (FIGS. 4B
and 4C) that provides an exit for at least a portion of the fluid A
to be discharged from the assembly 400. The angle 404 may be any
angle ranging between 1.degree. and 179.degree. with respect to the
shunt tube 202. In the illustrated embodiment, the angle 404 is
about 45.degree. offset from the shunt tube 202, but could
alternatively be greater or smaller than 45.degree., without
departing from the scope of the disclosure.
[0036] The shunt nozzle 402 may be a substantially tubular
structure that fluidly communicates with an opening 406 defined in
the shunt tube 202. The opening 406 may provide fluid communication
between the inner flow path 208 of the shunt tube 202 and an
exterior thereof. In some embodiments, as illustrated, the shunt
nozzle 402 may have a generally circular or cylindrical
cross-sectional shape. In other embodiments, however, the shunt
nozzle 402 may alternatively have a polygonal cross-sectional
shape, such as triangular, square, rectangular, trapezoidal, or any
other polygonal shape. In yet other embodiments, the shunt nozzle
402 may exhibit a cross-sectional shape that is substantially oval
or kidney shaped, without departing from the scope of the
disclosure.
[0037] Similar to the shunt fitting 204 of FIGS. 2A-2B and 3A-3B,
the shunt nozzle 402 may also be made of an erosion-resistant
material, such as those discussed above. In other embodiments, or
in addition thereto, the interior or inner surfaces of the shunt
nozzle 402 may be clad or coated with an erosion-resistant
material, such as tungsten carbide, a cobalt alloy, or ceramic. In
some embodiments, the erosion-resistant material may be applied to
the inner surfaces of the shunt nozzle 402 before the shunt nozzle
402 is coupled to the shunt tube 202. In other embodiments, the
erosion-resistant material may be applied to the inner surfaces of
the shunt nozzle 402 after the shunt nozzle 402 is coupled to the
shunt tube 202, without departing from the scope of the
disclosure.
[0038] In the embodiment shown in FIG. 4B, the shunt nozzle 402 is
depicted as being inserted into the opening 406 and otherwise
coupled to the shunt tube 202 as recessed into the opening 406. In
such embodiments, the shunt nozzle 402 may be coupled to the shunt
tube 202 within the opening 406 via a variety of attachment means
including, but not limited to, welding, brazing, adhesives,
mechanical fastening (e.g., screws, bolts, pins, snap rings, etc.),
shrink fitting, interference fitting, or any combination
thereof.
[0039] In the embodiment shown in FIG. 4C, the shunt nozzle 402 is
depicted as being aligned with the opening 406 and flush mounted to
the outer surface of the shunt tube 202. In such embodiments, the
shunt nozzle 402 may be coupled or otherwise attached to the outer
surface of the shunt tube 202 via one or more of welding, brazing,
adhesives, mechanical fastening (e.g., screws, bolts, pins, snap
rings, etc.), or any combination thereof.
[0040] FIGS. 5A and 5B illustrate isometric and cross-sectional
isometric views, respectively, of another exemplary shunt tube
assembly 500, according to one or more additional embodiments. The
shunt tube assembly 500 (hereafter the "assembly 500") may be used
in the exemplary well system 100 of FIG. 1 and may be similar in
some respects to the assemblies 200, 300, and 400 described above,
and therefore may be best understood with reference thereto, where
like numerals indicate like components not described again.
[0041] Similar to the assemblies 200, 300, 400, for example, the
assembly 500 may include a shunt tube 202 for conveying the fluid A
therethrough. The assembly 500 may further include a shunt nozzle
502 that extends from a sidewall of the shunt tube 202. The shunt
nozzle 502 may generally comprise a six-sided block having a first
end 504a, a second end 504b opposite the first end 504a, a top
506a, a bottom 506b opposite the top 506a, a first side 508a, and a
second side 508b opposite the first side 508a. In the illustrated
embodiment, the shunt nozzle 502 is formed in the general shape of
a rectangular block, but could alternatively comprise a square
block, without departing from the scope of the disclosure.
[0042] An elongate slot 510 is defined through the shunt nozzle 502
and extends between the opposing first and second sides 508a,b. As
shown in FIG. 5A, the elongate slot 510 has a length 512 and a
height 514. The length 512 comprises a horizontal measurement of
the elongate slot 510 generally parallel to the shunt tube 202 and
extending in the direction generally between the first and second
ends 504a,b. The height 514 comprises a vertical measurement of the
elongate slot 510 generally orthogonal to the shunt tube 202 and
extending in the direction generally between the top and bottom
506a,b. As seen in FIG. 5B, the elongate slot 510 also exhibits a
depth 516, which comprises a measurement extending between the
first and second sides 508a,b.
[0043] As used herein, the term "elongate slot" refers to an
opening defined in the shunt nozzle 502 where magnitudes or
measurements of the length 512 and the height 514 of the opening
are dissimilar. In the illustrated embodiment, for instance, the
length 512 of the opening is greater than the height 514. In other
embodiments, however, the height 514 of the opening may
alternatively be greater than the length 512, without departing
from the scope of the disclosure. The elongate slot 510 may exhibit
any cross-sectional shape where the length 512 of the opening is
greater than the height 514. In the illustrated embodiment, for
example, the cross-sectional shape of the elongate slot 510 is
generally rectangular with rounded ends or corners, but could
alternatively include sharp or squared off ends. In other
embodiments, however, the cross-sectional shape of the elongate
slot 510 may be oval, ovoid, kidney shaped, a parallelogram, or any
other polygonal cross-sectional shape where the length 512 is
greater than the height 514.
[0044] The geometry (shape) of the elongate slot 510 may prove
advantageous in creating a smoother transition for the fluid A to
exit the rectangular-shaped shunt tube 202, which may help reduce
erosion. More particularly, the flow of the fluid A through the
elongate slot 510 may be more laminar as compared to circular
nozzles, and thereby exhibiting more favorable flow
characteristics. Moreover, the geometry of the elongate slot 510
may allow for the same or greater cross-sectional flow area as
would be provided by a shunt nozzle having a circular hole, but
does not require the circular footprint, which may not physically
fit on the sidewall of the rectangular shunt tube 202. Accordingly,
the shape of the elongate slot 510 may help reduce the erosion of
the shunt nozzle 502 by increasing the flow area, which has a
direct correlation to the reduction in velocity for similar flow
rates.
[0045] In some embodiments, the length 512 of the elongate slot 510
may be constant along the depth 516 between the opposing first and
second sides 508a,b. In other embodiments, however, the magnitude
of the length 512 may vary along the depth 516, without departing
from the scope of the disclosure. In such embodiments, for example,
the length 512 may taper outward from the first side 508a to the
second side 508b along the depth 516, or alternatively taper inward
from the first side 508a to the second side 508b. In other
embodiments, the length 512 may vary (i.e., undulate) along the
depth 516 between the opposing first and second sides 508a,b,
without departing from the scope of the present disclosure.
[0046] Moreover, in some embodiments, the height 514 of the
elongate slot 510 may be constant across the length 512 of the
elongate slot 510, but may alternatively vary across the length
512. In the illustrated embodiment, for example, the elongate slot
510 may define a channel 518 that extends along the depth 516
between the opposing first and second sides 508a,b and exhibits a
height 520 that is greater than the height 514. Stated differently,
the channel 518 may comprise a portion of the elongate slot 510
where the height 514 increases as compared to remaining portions of
the elongate slot 510. In some embodiments, as illustrated, the
channel 518 may comprise a generally round conduit that extends
along the depth 516. In other embodiments, however, the channel 518
may exhibit other cross-sectional shapes, such as oval, ovoid,
polygonal, or any combination thereof, where the height 514 along
the length 512 is increased.
[0047] Similar to the assembly 400 of FIG. 4C, the shunt nozzle 502
may be aligned with the opening 406 and flush mounted to the outer
surface of the shunt tube 202. More particularly, the elongate slot
510 may be aligned with the opening 406, and the first side 508a of
the shunt nozzle 502 may be coupled or otherwise secured to the
outer surface of the shunt tube 202 via one or more of welding,
brazing, adhesives, mechanical fastening (e.g., screws, bolts,
pins, snap rings, etc.), or any combination thereof. The elongate
slot 510 provides fluid communication between the inner flow path
208 of the shunt tube 202 and the exterior and thereby provides an
exit for at least a portion of the fluid A to be discharged from
the assembly 500.
[0048] The elongate slot 510 may extend at an angle 522 (FIG. 5B)
with respect to the shunt tube 202. The angle 522 may be any angle
ranging between 1.degree. and 179.degree. with respect to the shunt
tube 202. In the illustrated embodiment, the angle 522 is about
75.degree. offset from the shunt tube 202, but could alternatively
be greater or smaller than 75.degree., without departing from the
scope of the disclosure.
[0049] In some embodiments, the shunt nozzle 502 may be made of a
block of erosion-resistant material, such as any of the
erosion-resistant materials listed herein. In other embodiments,
however, and since the geometry of the elongate slot 510 helps
reduce erosion of the shunt nozzle 502 by increasing the flow area
(i.e., larger cross-sectional area=lower fluid velocity=less
erosion), the shunt nozzle 502 may alternatively be made of more
common steels or less resilient metal alloys. Use of stainless
steels, such as chromium or nickel alloys having an SAE designation
3XX or harder or even less resilient alloys, reduces the complexity
in manufacturing as many erosion-resistant materials require more
elaborate and costly securing practices such as brazing.
Accordingly, the shunt nozzle 502 may alternatively be made with a
variety of heat-treated stainless steels such as, but not limited
to, 410SST, 135MY, or 30MY (SAE designations). As will be
appreciated, using such basic metallic materials may prove
advantageous in allowing simpler manufacturing construction, where
basic welding practices and other securing means can be used.
[0050] In yet other embodiments, or in addition to the foregoing
materials, the interior or inner surfaces of the shunt nozzle 502
may be clad or coated with an erosion-resistant material, such as
tungsten carbide, a cobalt alloy, or ceramic. In some embodiments,
the erosion-resistant material may be applied to the inner surfaces
of the shunt nozzle 502 before it is coupled to the shunt tube 202.
In other embodiments, the erosion-resistant material may be applied
to the inner surfaces of the shunt nozzle 502 after it is coupled
to the shunt tube 202, without departing from the scope of the
disclosure.
[0051] FIGS. 6A and 6B illustrate isometric and cross-sectional
isometric views, respectively, of another exemplary shunt tube
assembly 600, according to one or more additional embodiments. The
shunt tube assembly 600 (hereafter the "assembly 600") may be used
in the exemplary well system 100 of FIG. 1 and may be similar in
some respects to the assembly 500 of FIGS. 5A-5B and therefore may
be best understood with reference thereto, where like numerals
indicate like components not described again.
[0052] Similar to the assembly 500, for example, the assembly 600
may include a shunt tube 202 for conveying the fluid A
therethrough. The assembly 600 may further include the shunt nozzle
502, as generally described above. An elongate slot 602 is defined
through the shunt nozzle 502 and extends between the opposing first
and second sides 508a,b. As with the elongate slot 510 of FIGS.
5A-5B, the elongate slot 602 has the length 512, the height 514,
and the depth 516, where the length 512 and the height 514 of the
elongate slot 602 are dissimilar. In the illustrated embodiment,
the length 512 is depicted as greater than the height 514, but
could alternatively be smaller than the height 514, without
departing from the scope of the disclosure. The elongate slot 602
may exhibit any cross-sectional shape where the length 512 of the
opening is greater than the height 514. In the illustrated
embodiment, for example, the cross-sectional shape of the elongate
slot 602 is generally rectangular with rounded corners, but could
alternatively exhibit a cross-sectional shape that is oval, ovoid,
kidney shaped, a parallelogram, or any other polygonal
cross-sectional shape where the length 512 is greater than the
height 514.
[0053] Again, the shunt nozzle 502 and, more particularly, the
elongate slot 602 may be aligned with the opening 406 and flush
mounted to the outer surface of the shunt tube 202 via one or more
of welding, brazing, adhesives, mechanical fastening (e.g., screws,
bolts, pins, snap rings, etc.), or any combination thereof. The
elongate slot 602 provides fluid communication between the inner
flow path 208 of the shunt tube 202 and the exterior and thereby
provides an exit for at least a portion of the fluid A to be
discharged from the assembly 600. Moreover, the elongate slot 602
may extend at the angle 522 (FIG. 6B) with respect to the shunt
tube 202 and to inner flow path 208.
[0054] While the assemblies 200, 300, 400, 500, and 600 described
herein are generally described with reference to injection
operations, where a fluid A is injected into a surrounding
formation 112 (FIG. 1) via the shunt tubes 202 and associated shunt
fittings 204 or shunt nozzles 402, those skilled in the art will
readily appreciate that the assemblies 200, 300, 400, 500, and 600
may alternatively be used in production operations (e.g.,
reverse-flow operations), without departing from the scope of the
disclosure. For example, in other embodiments, the flow of another
fluid (not shown), such as a formation fluid, may instead be drawn
into the shunt tubes 202 via the shunt fittings 204 or shunt
nozzles 402, 502, or 602 and subsequently into the inner flow path
208 to be produced to the surface. Advantageously, the
erosion-resistant characteristics of the shunt tubes 202 and the
shunt fittings 204 and shunt nozzles 402, 502, or 602 allow the
fluids to be produced without causing detrimental eroding.
[0055] Embodiments disclosed herein include:
[0056] A. A shunt tube assembly that includes a shunt tube having
an inner flow path for a fluid and defining an opening in a
sidewall of the shunt tube, and a shunt nozzle coupled to the
sidewall and having an elongate slot defined therethrough and
aligned with the opening to provide fluid communication between the
inner flow path and an exterior of the shunt tube, wherein the
elongate slot has a length and a height, and the length is
dissimilar to the height.
[0057] B. A method that includes introducing a flow distribution
assembly into a wellbore on a work string, the flow distribution
assembly including at least one shunt tube extending along an
exterior of the work string and having an inner flow path for a
fluid and defining an opening in a sidewall of the shunt tube,
conveying the fluid into the inner flow path from an annulus
defined between the work string and the wellbore, and discharging
at least a portion of the fluid from the at least one shunt tube at
a shunt nozzle coupled to the sidewall and having an elongate slot
defined therethrough and aligned with the opening to provide fluid
communication between the inner flow path and the annulus, wherein
the elongate slot has a length and a height, and the length is
dissimilar to the height.
[0058] Each of embodiments A and B may have one or more of the
following additional elements in any combination: Element 1:
wherein the shunt tube is rectangular and the length is a
horizontal measurement of the elongate slot generally parallel to
the shunt tube, and the height is a vertical measurement of the
elongate slot generally orthogonal to the shunt tube. Element 2:
wherein the length is greater than the height. Element 3: wherein
the shunt nozzle is a six-sided block comprising a first end and a
second end opposite the first end, a top and a bottom opposite the
top, and a first side and a second side opposite the first side,
wherein the elongate slot extends between the first and second
sides. Element 4: wherein the length of the elongate slot is
constant between the first and second sides. Element 5: wherein the
length of the elongate slot varies between the first and second
sides. Element 6: wherein the height of the elongate slot is
constant across the length of the elongate slot. Element 7: wherein
the height of the elongate slot varies across the length of the
elongate slot. Element 8: wherein the elongate slot defines a
channel where the height is increased as compared to remaining
portions of the elongate slot. Element 9: wherein the channel
exhibits a cross-sectional shape selected from the group consisting
of circular, oval, ovoid, polygonal, and any combination thereof.
Element 10: wherein the shunt nozzle is coupled to the sidewall by
at least one of welding, brazing, an adhesive, a mechanical
fastener, and any combination thereof. Element 11: wherein the
elongate slot extends from the shunt tube at an angle ranging
between 1.degree. and 179.degree. with respect to the shunt tube.
Element 12: wherein the shunt nozzle comprises a material selected
from the group consisting of a carbide, a carbide embedded in a
matrix of cobalt or nickel by sintering, a cobalt alloy, a ceramic,
a surface-hardened metal, a steel alloy, a chromium alloy, a nickel
alloy, a cermet-based material, a metal matrix composite, a
nanocrystalline metallic alloy, an amorphous alloy, a hard metallic
alloy, or any combination thereof. Element 13: wherein an inner
surface of the shunt nozzle is clad with an erosion-resistant
material selected from the group consisting of a carbide, a cobalt
alloy, and a ceramic.
[0059] Element 14: further comprising preventing erosion of the
shunt fitting, wherein the shunt nozzle comprises an
erosion-resistant material selected from the group consisting of a
carbide, a ceramic, a cobalt alloy, a surface-hardened metal,
stainless steel, a nickel-chromium alloy, a molybdenum alloy, and a
chromium steel. Element 15: further comprising preventing erosion
of an inner surface of the shunt nozzle, wherein the inner surface
of the shunt nozzle is clad with an erosion-resistant material
selected from the group consisting of a carbide, a cobalt alloy,
and a ceramic. Element 16: further comprising preventing erosion of
the at least one shunt tube, wherein the at least one shunt tube
comprises an erosion-resistant material selected from the group
consisting of a carbide, a ceramic, a cobalt alloy, a
surface-hardened metal, and a composite. Element 17: wherein the
elongate slot defines a channel where the height is increased along
the length as compared to remaining portions of the elongate slot.
Element 18: wherein the shunt tube is rectangular and the length is
a horizontal measurement of the elongate slot generally parallel to
the shunt tube and the height is a vertical measurement of the
elongate slot generally orthogonal to the shunt tube, and wherein
the length is greater than the height.
[0060] By way of non-limiting example, exemplary combinations
applicable to A and B include: Element 3 with Element 4; Element 3
with Element 5; Element 7 with Element 8; and Element 8 with
Element 9.
[0061] Therefore, the disclosed systems and methods are well
adapted to attain the ends and advantages mentioned as well as
those that are inherent therein. The particular embodiments
disclosed above are illustrative only, as the teachings of the
present disclosure may be modified and practiced in different but
equivalent manners apparent to those skilled in the art having the
benefit of the teachings herein. Furthermore, no limitations are
intended to the details of construction or design herein shown,
other than as described in the claims below. It is therefore
evident that the particular illustrative embodiments disclosed
above may be altered, combined, or modified and all such variations
are considered within the scope of the present disclosure. The
systems and methods illustratively disclosed herein may suitably be
practiced in the absence of any element that is not specifically
disclosed herein and/or any optional element disclosed herein.
While compositions and methods are described in terms of
"comprising," "containing," or "including" various components or
steps, the compositions and methods can also "consist essentially
of" or "consist of" the various components and steps. All numbers
and ranges disclosed above may vary by some amount. Whenever a
numerical range with a lower limit and an upper limit is disclosed,
any number and any included range falling within the range is
specifically disclosed. In particular, every range of values (of
the form, "from about a to about b," or, equivalently, "from
approximately a to b," or, equivalently, "from approximately a-b")
disclosed herein is to be understood to set forth every number and
range encompassed within the broader range of values. Also, the
terms in the claims have their plain, ordinary meaning unless
otherwise explicitly and clearly defined by the patentee. Moreover,
the indefinite articles "a" or "an," as used in the claims, are
defined herein to mean one or more than one of the element that it
introduces. If there is any conflict in the usages of a word or
term in this specification and one or more patent or other
documents that may be incorporated herein by reference, the
definitions that are consistent with this specification should be
adopted.
[0062] As used herein, the phrase "at least one of" preceding a
series of items, with the terms "and" or "or" to separate any of
the items, modifies the list as a whole, rather than each member of
the list (i.e., each item). The phrase "at least one of" allows a
meaning that includes at least one of any one of the items, and/or
at least one of any combination of the items, and/or at least one
of each of the items. By way of example, the phrases "at least one
of A, B, and C" or "at least one of A, B, or C" each refer to only
A, only B, or only C; any combination of A, B, and C; and/or at
least one of each of A, B, and C.
* * * * *