Patent Grant
12116872
Production tubing and other equipment can be installed in a wellbore of a well system (e.g., an oil or gas well) for communicating fluid in the wellbore to the well surface. The resulting fluid at the well surface is referred to as production fluid. Production fluid can include a mix of different fluid components, such as oil, water, and gas, and the ratio of the fluid components in the production fluid can change over time. This can make it challenging for a well operator to control which types of fluid components are produced from the wellbore. For example, it can be challenging for a well operator to produce mostly oil from the wellbore, while reducing or eliminating the production of gas or water from the wellbore.
These drawings illustrate certain aspects of some of the embodiments of the present disclosure and should not be used to limit or define the method.
A downhole flow control device is disclosed for controlling the production of formation fluids while using flow of the formation fluids to drive a turbine in a turbine chamber. Flow through the turbine chamber is optimized using a chamber insert. The chamber insert and the housing cooperatively define a reduced chamber volume for optimizing flow about the turbine. A housing of the flow control device defines a first arcuate portion of the reduced chamber volume. A baffle of the chamber insert defines a second arcuate portion contiguous with the first arcuate portion to fully encircle the turbine and to cordon off a cavity in the turbine housing radially outward of the reduced chamber volume. The baffle is perforated to allow some flow to the cavity leading to a bypass port. An overhead portion of the baffle defines a ceiling extending in parallel to a top of the turbine, which cordons off an arched portion defined by the housing over the turbine.
The reduced chamber volume defined in part by the first arcuate portion of the housing, the second arcuate portion of the baffle, and the ceiling defined by the overhead portion, together define a substantially cylindrical chamber volume about the turbine. This arrangement improves flow dynamics about the turbine to improve turbine performance and efficiency. The turbine may be used for any of a variety of applications, such as an inflow control device or electrical power generation. Non-limiting example configurations are provided below with reference to the following figures.
A tubing string 112 extends from an above ground location (i.e., a surface of the well site) along the wellbore 102, defining an annulus 103 between the tubing string 112 and the wellbore 102 along the open hole portions and with the casing 108 along the cased portions. The tubing string 112 may be included with an upper completion that can provide a conduit for fluid (e.g., production fluid) to travel from the substantially horizontal section 106 to the well's surface. The tubing string 112 can include any number of production tubular sections 116, examples of which are individually indicated at 116a-116d, at various production intervals adjacent to the subterranean formation 110. A corresponding number of packers 118, individually indicated at 118a-118e, can be positioned on opposing sides of production tubular sections to define production intervals (e.g., production interval 122) and provide fluid seals between the tubing string 112 and the wall of the wellbore 102.
Any number of inflow control devices (ICDs) 120, individually indicated at 120a-120d, may be included for production of formation fluids into the tubular sections 116. The inflow control devices 120 are examples of downhole flow control devices that can be included with the flow control system 140 and which can utilize a turbine as further disclosed below. Generally, inflow control devices are used to control the flow of formation fluid from a production interval into a production tubular section. Generally, an ICD may create a pressure drop, which may be used, for example, to help balance the influx of production fluids from a length of a horizontal section to reduce heel-toe effects, or to slow the flow from a highly permeable zone in an effort delay water or gas breakthrough. Although not required, some ICDs may be autonomous ICDs (i.e., AICDs) that are additionally capable of autonomously restricting undesired fluid or fluid components to a greater extent. ICDs 120 may be used individually to restrict the flow of certain fluid components, thereby collectively increasing a proportion of desired fluid components. For example, the production interval 122 may produce formation fluid having more than one type of fluid component, such as oil, water, carbon dioxide, and natural gas. Each inflow control device 120 uses the properties of different fluid components such as density and/or viscosity to reduce or restrict the flow of fluid of less desirable fluid components (e.g., water and CO2) into the production tubular section 116 while collectively producing a higher proportion of a more desirable fluid components, such as oil. In some examples, the inflow control devices 120 can be autonomous inflow control devices (AICDs) that can allow or restrict fluid flow into the production tubular sections 116 based on fluid properties such as density, viscosity, etc., without requiring signals from the well's surface by the well operator.
For ease of illustration,
Formation fluids enter the housing 202 and pass through the turbine chamber 204 of the flow control device 200 before entering a production conduit (e.g., production tubing string). In particular, an inlet port 206 to the turbine chamber 204 is in fluid communication with the annulus 103 about the housing 202. One or more outlet port (discussed below and shown in subsequent figures) provides fluid communication between the turbine chamber 204 and a production conduit, such as the production tubular sections 116 of
A variety of configurations generally known in the art apart from the specific teachings of this disclosure may be used to provide the higher pressure drop at one outlet port and a lower pressure drop at another outlet port. For example, the higher pressure drop may be achieved by directing flow through the bypass port along a more tortuous path before reaching the production conduit. Likewise, flow through the central outlet port 209 may have a more direct path to the production conduit.
In a formation that produces significant quantities of both oil and water, the ICD 300 may be configured to restrict flow in relation to how much water is being produced. Thus, with multiple ICDs 300 placed in different production intervals, the ICDs 300 will collectively produce more oil than if formation fluids were produced at full capacity without discriminating between oil and water. In a similar respect, zones that are producing more oil than water will contribute more to the overall production of formation fluid than zones that are producing more water than oil.
One or more radial flow path (in this case, a plurality of radial flow paths) 270 extend from a periphery 264 of the turbine 260 toward its center.
The closure 452 is moveable with respect to the housing 442 for controlling flow through the housing 442 along one or more flow paths through the housing 442. The actuator 466 is used to drive the closure 452 in order to control flow of formation fluids at that location. The electronics package 460 and the actuator 466 are examples of downhole components that require electrical power. In an example configuration, the electronics package 460 may be modular. The modular electronics package 460 may be preconfigured with components selected specific to a particular system or desired tool configuration. The modular electronics package may be removably securable such as by inserting laterally in an exterior side pocket 461 of the housing 442, wherein the housing 442 may comprise a mandrel having the side pocket 461. Upon insertion into the side pocket 461, the modular electronics package 460 may automatically physically couple to the flow control body (e.g., by snapping in) and/or electrically connect to a portion of an electrical power grid within a larger smart node well system. The actuator 466 may also be modular and similarly secured to a respective side pocket 463.
The housing 442 is fluidly coupled to a production conduit 470, defining an annulus 103 between the housing 442 and the wellbore 102. Formation fluid 28 flows from the formation 17 into the annulus 103 and from the annulus 103 into the production conduit 470 through the flow control system 440. The production conduit 470 may comprise production tubing 424 and/or other tubular members for conveying formation fluid 28 to surface. A portion of the production conduit 470 may also be defined by the housing 442 and other components fluidly coupled to the housing 442, such as a base pipe of a sand control assembly. The housing 442 may be generally round or tubular to conform with the wellbore 102 and to position around or otherwise in-line with production tubing 424.
The housing 442 defines at least one primary flow path 444 extending from an exterior 43 of the housing 442 to an interior 45 of the housing 442 for producing formation fluids 28 into the production conduit 470. The primary flow path 444 shown may be one of a plurality of primary flow paths circumferentially spaced for entry of the formation fluids 28 into the production conduit 470. A portion of the flow through the housing 442 is also directed through the generator 450. In this example, the flow through the generator 450 is directed through the housing 442 along one or more secondary flow path 446 spaced from the primary flow path 444. Alternatively, the primary flow path 444 could be diverted inside the flow control system 440 along one or more secondary flow path to the generator 450. In either case, flow through the generator 450 may be expelled into the production conduit 470 along with other produced formation fluids. The closure 452 is operable using the actuator 466 to adjust the flow of the formation fluids 28 through the primary and secondary flow paths 444, 446 of the housing 442.
The disclosed apparatuses enable a number of methods involving the use of a turbine in a flow control device in a well. In one example, a method of producing formation fluid in a well comprises positioning a chamber insert in a turbine chamber to form a reduced chamber volume. Flow of the formation fluid is directed through the reduced chamber volume in the turbine chamber and to a production conduit of the well. The flow through the reduced chamber volume is used to rotate a turbine rotatably disposed in the turbine chamber. More particularly, the flow in the reduced chamber volume may be directed along a cylindrical surface cooperatively defined by a first arcuate wall portion of the housing and a second arcuate wall portion of the chamber insert. The chamber insert may comprise one or both of a ceiling over the turbine and a perforated baffle radially outward of the turbine. Again, a perforated baffle portion or other permeable member may be omitted in some cases, as discussed above. The method may include directing a portion of the flow in the turbine chamber through an outlet port to the production conduit, and directing another portion of the flow through perforations in the baffle to a bypass port.
The turbine rotation may be used in a variety of applications. In one example, flow may be directed through the turbine to an outlet port or around the turbine to a bypass port. A proportion of the flow through the outlet port and the bypass port may be controlled in relation to a density of one or more fluid components of the flow. Controlling the proportion of the flow through the outlet port and the bypass port may include directing some of the flow along a radial flow path from a periphery of the turbine toward a center of the turbine. A float component within the radial flow path may be moved in relation to the density of the one or more fluid components to move the float component between an open position that enables fluid flow along the radial flow path to the outlet port and a closed position that restricts fluid flow along the radial flow path to the outlet port. Another method may use rotation of the turbine to generate electrical power in response to the rotation of the turbine.
Various examples of a downhole flow control device have been provided, wherein flow through a turbine chamber is optimized using a chamber insert. The disclosed principles may be applied to any of a variety of downhole applications. The examples discussed above include inflow control devices and downhole electrical power generators for on-board components. Other configurations may combine applications. For example, a flow control device according to this disclosure may be configured so that a turbine is used both as an ICD and for electrical power generation. The various systems, apparatus, methods, and other constructs may include any suitable combination of the features disclosed herein, including one or more of the following examples.
Example 1. A flow control device for a well, comprising: a housing positionable in a well, the housing having a turbine chamber with an inlet port and an outlet port for fluid communication with a production conduit; a turbine rotatably disposed in the turbine chamber with the inlet port directed toward the turbine; and a chamber insert removably securable in the turbine chamber to cooperatively define a reduced chamber volume with the turbine chamber.
Example 2. The flow control device of Example 1, wherein the reduced chamber volume is a cylindrical chamber volume about the turbine.
Example 3. The flow control device of Example 2, wherein the cylindrical chamber volume comprises a first arcuate wall portion defined by the housing and a second arcuate wall portion defined by the chamber insert.
Example 4. The flow control device of any of Examples 1 to 3, wherein the chamber insert comprises an overhead portion defining a ceiling over the turbine and a perforated baffle defining a portion of the reduced chamber volume.
Example 5. The flow control device of Example 4, wherein the ceiling has a generally flat structure that traverses the turbine chamber parallel to a top face of a turbine.
Example 6. The flow control device of Example 4 or 5, further comprising:
one or more arcuate vanes extending from the ceiling to guide flow through the turbine chamber.
Example 7. The flow control device of any of Examples 4 to 6, further comprising a bypass port in the turbine chamber outward of the reduced chamber volume, wherein perforations of the perforated baffle are in fluid communication with the bypass port.
Example 8. The flow control device of any of Examples 4 to 7, wherein the turbine is rotatably mounted about a turbine axis transverse to a housing axis, wherein the turbine chamber comprises an arched portion defined by the housing over the turbine, and wherein the ceiling of the chamber insert traverses the arched portion perpendicular to a turbine axis.
Example 9. The flow control device of any of Examples 1 to 8, further comprising: an inflow control device for directing flow through different outlet ports based on a density of fluid components.
Example 10. The flow control device of Example 9, wherein the different outlet ports comprise a central outlet port and the turbine comprises a plurality of radial flow paths in fluid communication with the central outlet port.
Example 11. The flow control device of Example 9 or 10, wherein the different outlet ports comprise a bypass port radially outward of the reduced chamber volume, wherein flow exiting the turbine chamber through the central outlet port experiences a lower pressure drop than flow exiting the turbine chamber through the bypass port.
Example 12. The flow control device of any of Examples 1 to 11, further comprising an electrical generator that generates electrical power in response to the rotation of the turbine.
Example 13. The flow control device of Example 1, wherein rotation of the turbine selectively restricts the flow of lower density fluid components while simultaneously generating electrical power downhole.
Example 14. A method of controlling flow of formation fluid produced by a well, the method comprising: positioning a chamber insert in a turbine chamber to cooperatively define a reduced chamber volume about a turbine; directing a flow of the formation fluid through the reduced chamber volume to a production conduit of the well; and using the flow through the reduced chamber volume to rotate a turbine rotatably secured in the turbine chamber.
Example 15. The method of Example 14, wherein cooperatively defining the reduced chamber volume about the turbine comprises forming a cylindrical chamber by positioning a second arcuate wall portion defined by a baffle of the chamber insert contiguous with a first arcuate wall portion defined by a housing.
Example 16. The method of Example 15, wherein cooperatively defining the reduced chamber volume comprises traversing an arched portion of the housing with an overhead portion of the chamber insert to define a ceiling over the turbine and positioning a perforated baffle radially outward of the turbine.
Example 17. The method of Example 16, further comprising directing a portion of the flow along radial flow paths in the turbine to a central outlet port, and directing another portion of the flow through perforations in the baffle to a bypass port.
Example 18. The method of Example 17, further comprising controlling a proportion of the flow to the central outlet port and a proportion of the flow to the bypass port in relation to a density of one or more fluid components of the flow.
Example 19. The method of any of Examples 14 to 18, further comprising: generating electrical power in response to the rotation of the turbine.
Example 20. The method of any of Examples 14 to 19, further comprising: using rotation of the turbine to control a proportion of the flow along radial flow paths in the turbine to a central outlet port and to a bypass port in relation to a density of the flow; and simultaneously generating electrical power in response to the rotation of the turbine.
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