The present invention generally relates to wellbore flow control devices and, more specifically, to making on-site field adjustments to autonomous inflow control assemblies.
In hydrocarbon production wells, it is often beneficial to regulate the flow of formation fluids from a subterranean formation into a wellbore penetrating the same. A variety of reasons or purposes can necessitate such regulation including, for example, prevention of water and/or gas coning, minimizing water and/or gas production, minimizing sand production, maximizing oil production, balancing production from various subterranean zones, equalizing pressure among various subterranean zones, and/or the like.
A number of devices are available for regulating the flow of formation fluids. Some of these devices are non-discriminating for different types of formation fluids and can simply function as a “gatekeeper” for regulating access to the interior of a wellbore pipe, such as a well string. Such gatekeeper devices can be simple on/off valves or they can be metered to regulate fluid flow over a continuum of flow rates. Other types of devices for regulating the flow of formation fluids can achieve at least some degree of discrimination between different types of formation fluids. Such devices can include, for example, tubular flow restrictors, nozzle-type flow restrictors, autonomous inflow control devices, non-autonomous inflow control devices, ports, tortuous paths, combinations thereof, and the like.
Autonomous inflow control devices (AICD) can be particularly advantageous in subterranean operations, since they are able to automatically regulate fluid flow without the need for operator control due to their design. In this regard, AICDs can be designed such that they provide a greater resistance to the flow of undesired fluids (e.g., gas and/or water) than they do desired fluids (e.g., oil), particularly as the percentage of the undesired fluids increases.
Several AICDs are often combined into an AICD system that can be manufactured to particular specifications and/or designs requested by well operators based on production needs for particular well sites. Such design specifications may include the required flow rate of fluids through the AICD system for normal operation. Upon receiving the AICD system at a well site, however, production needs for the well operator or a well site may have changed. For instance, the well operator may learn new information about the well, which would necessitate an AICD system configured for different production capabilities.
Alternatively, the well operator may desire to use the manufactured AICD system at a different well site where the production needs and/or capabilities are different. Accordingly, it may prove advantageous to have an AICD system that is adjustable on-site by the well operator.
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.
The present invention generally relates to wellbore flow control devices and, more specifically, to making on-site field adjustments to autonomous inflow control assemblies.
Disclosed are various ways for a well operator to make on-site adjustments to autonomous inflow control device assemblies prior to deployment downhole in order to alter the fluid flow capacity of the autonomous inflow control device assemblies. As described herein below, a crimping tool may be used to crimp or otherwise plastically deform a shroud arranged about the autonomous inflow control device assembly such that the shroud isolates one or more autonomous inflow control devices associated with the assembly. In some cases, the crimping tool may have one or more axially extending fingers and each finger may have a profile defined on an inner surface thereof. A radial load may be applied to the fingers such that the profile is forced into engagement with the shroud and results in its plastic deformation. As a result, the well operator may have the ability to strategically adjust fluid flow capabilities of an autonomous inflow control device assembly in the field.
As used herein, the term “on-site” refers to a rig location or field location where an autonomous inflow control device (AICD) system or assembly may be delivered and otherwise following its discharge from a manufacturer's facility. The term may also refer to any location that the AICD system or assembly might encounter or otherwise be located prior to being deployed downhole for operation.
Referring to
One or more well screens 114, one or more flow control devices 116, and one or more packers 118 may be interconnected along the production tubular 112, such as along portions of the production tubular 112 in the horizontal section 106 of the wellbore 102. The packers 118 may be configured to seal off an annulus 120 defined between the production tubular 112 and the walls of the wellbore 102. As a result, fluids 122 may be produced from multiple intervals or “pay zones” of the surrounding subterranean formation 108 via isolated portions of the annulus 120 between adjacent pairs of the packers 118.
As illustrated, in some embodiments, a well screen 114 and a flow control device 116 may be interconnected in the production tubular 112 and positioned between a pair of packers 118. The well screens 114 may be swell screens, wire wrap screens, mesh screens, sintered screens, expandable screens, pre-packed screens, treating screens, or other known screen types. In operation, the well screen 114 may be configured to filter the fluids 122 flowing into the production tubular 112 from the annulus 120. The inflow control device 116 may be configured to restrict or otherwise regulate the flow of the fluids 122 into the production tubular 112, based on certain physical characteristics of the fluids.
It will be appreciated that the well system 100 of
Furthermore, it is not necessary that at least one well screen 114 and inflow control device 116 be positioned between a pair of packers 118. Nor is it necessary for a single inflow control device 116 to be used in conjunction with a single well screen 114. Rather, any number, arrangement and/or combination of such components may be used, without departing from the scope of the disclosure. In some applications, it is not necessary for a flow control device 116 to be used with a corresponding well screen 114. For example, in injection operations, the injected fluid could be flowed through a flow control device 116, without also flowing through a well screen 114.
It is not necessary for the well screens 114, flow control devices 116, packers 118 or any other components of the production tubular 112 to be positioned in uncased sections 104, 106 of the wellbore 102. Rather, any section of the wellbore 102 may be cased or uncased, and any portion of the production tubular 112 may be positioned in an uncased or cased section of the wellbore 102, without departing from the scope of the disclosure.
Those skilled in the art will readily recognize the advantages of being able to regulate the flow of fluids 122 into the production tubular 112 from each zone of the subterranean formation 108, for example, to prevent water coning 124 or gas coning 126 in the formation 108. Other uses for flow regulation in a well include, but are not limited to, balancing production from (or injection into) multiple zones, minimizing production or injection of undesired fluids, maximizing production or injection of desired fluids, etc. The exemplary flow control devices 116, as described in greater detail below, may provide such benefits by increasing resistance to flow if a fluid velocity increases beyond a selected level (e.g., to thereby balance flow among zones, prevent water coning 124 or gas coning 126, etc.), increasing resistance to flow if a fluid viscosity or density decreases below a selected level (e.g., to thereby restrict flow of an undesired fluid, such as water or gas, in an oil producing well), and/or increasing resistance to flow if a fluid viscosity or density increases above a selected level (e.g., to thereby minimize injection of water in a steam injection well).
Referring now to
The bottom plate 202b may define one or more fluid inlets 206 (two shown) that provide fluid access into the flow chamber 204. While two fluid inlets 206 are depicted in
The bottom plate 202b of the AICD 200 may further provide or otherwise define various internal structures 210 and an outlet 212. The AICD 200 may be configured to resist the flow of the fluid 208 therethrough based on one or more characteristics of the fluid 208, such as density, viscosity, and/or velocity of the fluid 208 or its various fluid components. More specifically, the internal structures 210 may be configured to induce spiraling of the flow of the fluid 208 about the outlet 212. As a result, the fluid 208 may be subjected to centrifugal or vortex forces that may cause various components of the fluid 208 that are more viscous to collect or otherwise congregate more rapidly at the outlet 212, while components of the fluid 208 that are less viscous to flow to the outlet 212 less rapidly. As a result, the AICD 200 may provide a greater resistance to the flow of undesired fluids (e.g., water, gas, etc.) than desired fluids (e.g., oils), particularly as the percentage of the undesired fluids increases.
Referring now to
The housing 302 may define or otherwise provide one or more fluid compartments 308 configured to receive and secure a combination of a buckle 304 and an AICD 306 therein. As best seen in
As best seen in
In yet other embodiments, the AICD 306 may be shrink-fitted, threaded, brazed, or welded into a corresponding buckle 304, without departing from the scope of the disclosure. More particularly, each buckle 304 may define or otherwise provide a main ridge member 320, a central cavity 322 interior to the main ridge member 320, and a trough 324 extending about the periphery of the main ridge member 320. The AICD 306 may be arranged within the central cavity 322 and the outlet 318 may extend at least partially through the central cavity 322 in order to place the AICD 306 in fluid communication with the interior 314 of the base pipe 312. Both the main ridge member 320 and the trough 324 may generally extend about the periphery of the AICD 306.
As shown in
In some embodiments, it may be desired by a well operator to make on-site fluid flow adjustments to the AICD assembly 300 prior to deployment downhole. More particularly, a well operator may desire to reduce or eliminate fluid flow to one or more of the AICDs 306, and thereby reduce the amount of fluid flow entering the interior 314 of the base pipe 312. According to the present disclosure, this may be done by crimping or otherwise plastically deforming the shroud 326 such that the shroud 326 provides a fluid barrier that restricts fluid flow to and from the AICDs 306. To accomplish this, the shroud 326 may be made of a rigid or semi-rigid material that allows the shroud 326 to plastically deform upon assuming a radial pressure or mechanical force. In some embodiments, for example, the shroud 326 may be made of a metal, such as stainless steel or aluminum.
Referring to
In the illustrated embodiment, the crimping tool 400 may have an annular body 402 and one or more fingers 404 (four shown) that extend longitudinally from the annular body 402. The annular body 402 and the fingers 404 may be sized and otherwise configured to extend about the outer diameter of the AICD assembly 300. In other words, the inner diameter of the annular body 402 and the fingers 404 (or only the fingers 404) may be slightly larger than the outer diameter of the AICD assembly 300 (i.e., the shroud 326) such that at least the fingers 404 of the crimping tool 400 may be able to freely translate along an axial length of the AICD assembly 300.
Each finger 404 may have or otherwise provide a head 406 at its distal end. The inner radial surface of each head 406 may provide or otherwise define a crimping profile 408 (best seen in
In the illustrated embodiment, four fingers 404 are depicted as being included in the crimping tool 400. Each finger 404 may be configured to align and interact with a corresponding one of the AICDs 306, such that the number of AICDs 306 in the AICD assembly 300 is generally equal to the number of fingers 404. In other embodiments, however, the crimping tool 400 may include more or less fingers 404 than the number of AICDs 306. For instance, in at least one embodiment, the crimping tool 400 may have only one or two fingers 404 configured to align and interact with more than two AICDs 306, without departing from the scope of the disclosure.
Referring now to
In order for a well operator to crimp the AICD assembly 300, and thereby undertake on-site fluid flow adjustments to the AICD assembly 300, the crimping tool 400 may be generally extended over the end of the AICD assembly 300. The crimping tool 400 may be advanced along the axial length of the AICD assembly 300 until at least one of the heads 406 of the fingers 404 aligns with a desired or predetermined location on the shroud 326. The predetermined location refers to a location on the AICD assembly 300 where the well operator desires to plastically deform the shroud 326 using the crimping tool 400. In some embodiments, the predetermined location may be marked or otherwise visibly designated on the shroud 326 and the well operator may be able to align the crimping tool 400 with the markings. As can be appreciated, aligning the crimping tool 400 at the predetermined location may require the crimping tool 400 to be axially and/or angularly moved with respect to the AICD assembly 300.
Once the crimping tool 400 is located at the predetermined location, a radial load may be applied to the head 406, as indicated by the arrows A. In some embodiments, the radial load A may be applied through a radial impact force, such as with a blunt instrument or object (e.g., sledge hammer, etc.). In other embodiments, the radial load A may result from the use of any suitable actuator or actuation device known to those skilled in the art. Suitable actuation devices may operate hydraulically, mechanically, electrically, electromechanically, pneumatically, or any combination thereof.
In yet other embodiments, the radial load A may result from the application of an axial load, as indicated by the arrows B, as applied to the head 406. More particularly, as illustrated, the outer radial surface of the head 406 may be beveled, angled, or otherwise tapered in an axial direction, thereby defining a beveled or angled surface. A ring or other annular cylindrical structure (not shown) may be extended partially over the head 406 and forced against the head 406 in the axial direction B. As a result of the beveled surface of the head 406, the axial load B against the head 406 translates into the radial load A required to force the head 406 into radial engagement with the shroud 326. Similar to the radial load A, the axial load B may be realized using any suitable actuator or actuation device known to those skilled in the art, and may operate hydraulically, mechanically, electrically, electromechanically, pneumatically, or any combination thereof.
Upon applying the radial load A, the profile 408 may be forced into radial engagement with the outer surface of the shroud 326. Continued and increased application of the radial load A may result in the shroud 326 being plastically deformed radially in the general shape or configuration of the profile 408. This is shown in
While the profiles 408 in the depicted embodiment are designed to match the general shape or design of the trough 324, those skilled in the art will readily appreciate that the design of the profiles 408 may be configured to plastically deform the shroud 326 in any shape or form capable of substantially isolating the AICD 306 from the influx of fluids. For instance, the profiles 408 may be designed or otherwise configured to match the general shape or design of the AICD 306 and thereby plastically deform the shroud 326 directly about the periphery of the AICD 306 and otherwise within the central cavity 322. The profile 408 may also be designed or otherwise configured to match the general shape of the fluid compartment 308 and thereby plastically deform the shroud 326 about the inner periphery of the fluid compartment 308. In further embodiments, the profile 408 may be designed or otherwise configured to plastically deform the shroud 326 within a portion of the fluid compartment 308 such that the flow conduits 310 (
Accordingly, a well operator may be able to make on-site fluid flow adjustments to the AICD assembly 300 prior to its deployment downhole. The well operator may be able to use the crimping tool 400 on-site to selectively crimp the shroud 326 about each of the AICDs or about a desired number of AICDs 306 and thereby selectively reduce the flow of fluid 208 into the interior 314 of the base pipe 312. Once the desired on-site fluid flow adjustments have been made, the AICD assembly 300 may then be deployed downhole for operation.
Embodiments disclosed herein include:
A. An autonomous inflow control device (AICD) assembly that includes a housing arranged about a base pipe that defines at least one flow port and an interior, the housing defining a fluid compartment in fluid communication with the at least one flow port, an AICD arranged in the fluid compartment and having at least one fluid inlet and an outlet in fluid communication with the at least one flow port, a shroud coupled to the housing and covering the fluid compartment, and a crimping tool arrangeable about the housing and the shroud and having a profile defined thereon, the profile being configured to engage and plastically deform the shroud in order to fluidly isolate the AICD.
B. A method that includes receiving an autonomous inflow control device (AICD) assembly subsequent to its manufacture, the AICD assembly including a housing arranged about a base pipe defining at least one flow port and the housing defining a fluid compartment in fluid communication with the at least one flow port, wherein the AICD assembly further includes an AICD arranged in the fluid compartment and a shroud coupled to the housing and covering the fluid compartment, arranging a crimping tool about the AICD assembly, the crimping tool having a profile defined thereon, applying a radial load on the crimping tool to force the profile into radial engagement with the shroud, plastically deforming the shroud with the crimping tool and thereby fluidly isolating the AICD within the housing, and deploying the AICD assembly into a wellbore and reducing an influx of fluid into the AICD with the shroud as plastically deformed.
Each of embodiments A and B may have one or more of the following additional elements in any combination: Element 1: wherein the shroud is made of at least one of stainless steel and aluminum. Element 2: wherein the profile exhibits a shape configured to plastically deform the shroud around the AICD. Element 3: further comprising one or more flow conduits defined in the housing and facilitating fluid communication between the fluid compartment and an exterior of the housing, wherein the profile exhibits a shape configured to plastically deform the shroud within the fluid compartment and occlude the one or more flow conduits. Element 4: wherein the crimping tool comprises an annular body, one or more fingers extending longitudinally from the annular body, and a head provided at a distal end of each finger, wherein the profile is defined on an inner radial surface of the head of each finger. Element 5: wherein a radial load is applied to the head in order to plastically deform the shroud. Element 6: wherein the head has a beveled outer radial surface and the radial load is applied through the application of an axial load applied on the beveled outer radial surface. Element 7: further comprising a buckle disposed within the fluid compartment, the buckle providing a main ridge member, a central cavity defined interior to the main ridge member, and a trough extending about the periphery of the main ridge member, wherein the AICD is arranged in the central cavity. Element 8: wherein the profile exhibits a shape corresponding to a shape of the trough such that the shroud is plastically deformed into the trough. Element 9: wherein the profile exhibits a shape configured to plastically deform the shroud within the central cavity and around a periphery of the AICD. Element 10: wherein the profile exhibits a shape configured to plastically deform the shroud around an inner periphery of the fluid compartment.
Element 11: wherein plastically deforming the shroud comprises plastically deforming the shroud around the AICD. Element 12: wherein the AICD assembly further includes one or more flow conduits defined in the housing and facilitating fluid communication between the fluid compartment and an exterior of the housing, and wherein plastically deforming the shroud comprises occluding the one or more flow conduits with the shroud. Element 13: wherein the crimping tool includes an annular body, one or more fingers extending longitudinally from the annular body, and a head provided at a distal end of each finger, and wherein applying the radial load on the crimping tool comprises applying the radial load to the head of at least one of the one or more fingers, wherein the profile is defined on an inner radial surface of the head of each finger, and plastically deforming the shroud as the profile is forced into radial engagement with the shroud. Element 14: wherein the head has a beveled outer radial surface, and wherein applying the radial load to the head comprises applying an axial load on the beveled outer radial surface, the axial load being translated into the radial load upon engaging the beveled outer radial surface. Element 15: wherein the AICD assembly further includes a buckle disposed within the fluid compartment and providing a main ridge member, a central cavity configured to receive the AICD, and a trough extending about the periphery of the main ridge member, and wherein plastically deforming the shroud comprises plastically deforming the shroud into the trough, the profile exhibiting a shape corresponding to a shape of the trough. Element 16: wherein the AICD assembly further includes a buckle disposed within the fluid compartment and providing a main ridge member, a central cavity configured to receive the AICD, and a trough extending about the periphery of the main ridge member, and wherein plastically deforming the shroud comprises plastically deforming the shroud within the central cavity and around a periphery of the AICD. Element 17: wherein the AICD assembly further includes a buckle disposed within the fluid compartment and providing a main ridge member, a central cavity configured to receive the AICD, and a trough extending about the periphery of the main ridge member, and wherein plastically deforming the shroud comprises plastically deforming the shroud around an inner periphery of the fluid compartment. Element 18: wherein arranging the crimping tool about the AICD assembly comprises advancing the crimping tool axially to a predetermined location on the shroud, and angularly adjusting the crimping tool with respect to the AICD assembly, if needed, in order to radially align the crimping tool at the predetermined location.
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.
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” does not require selection of at least one item; rather, the phrase 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.
Filing Document | Filing Date | Country | Kind |
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PCT/US13/75538 | 12/17/2013 | WO | 00 |