Well completion equipment is used in a variety of well related applications involving, for example, the production of fluids. The completion equipment is deployed in a wellbore and often comprises one or more valves for controlling fluid flow in the well.
In some wells, it is desirable to control flow in several zones. Accordingly, downhole flow control valves are positioned in each of the zones and used, for example, to control the flow of fluid from the formation and surrounding wellbore into the completion.
Actuation of the valves is accomplished by several methods, including running multiple hydraulic control lines downhole and to each of the flow control valves. In other applications, hydraulic control lines can be combined with hydraulic multiplexers to direct hydraulic input to specific valves in specific zones. However, existing methods typically require several hydraulic control lines or a relatively high degree of complexity to control multiple valves in multiple well zones.
In general, the present invention provides a system and method for controlling multiple flow control valves, each with a plurality of choke positions. The flow control valve system comprises a flow control valve having a variable choke that can be adjusted to a plurality of positions based on input from a single hydraulic line and an electrical line.
Depending on the application, additional flow control valves can be added, and each additional flow control valve is adjustable via the electrical line and single hydraulic line.
Certain embodiments of the invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:
In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those of ordinary skill in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
The present invention relates to well systems utilizing well completion equipment, including downhole well tools, such as flow control valves and mechanisms for actuating flow control valves. The system provides a methodology to facilitate multi-dropping a plurality of well zones with a limited number of control lines. Generally, electrical inputs are used to control electromechanical devices which, in turn, are used to control hydraulic input provided by a single hydraulic control line for selectively actuating a plurality of the flow control valves.
Referring generally to
Completion 22 is located within the interior of casing 28 and comprises a tubing 44 and a plurality of completion components 46. For example, well completion 22 may comprise pumping components 48 and one or more packers 50 to separate wellbore 26 into different zones, e.g. zones corresponding with well zones 36, 38, 40 and/or 42. Additionally, well completion 22 comprises at least one flow control valve system 52 and often a plurality of flow control valve systems 52 deployed at different locations along wellbore 26. In many applications, well system 20 comprises a plurality of flow control valve systems 52, such as at least three flow control valve systems 52 deployed at different locations to control flow of fluid to or from different well zones, e.g. flow of production fluid into wellbore 26 and through or along well completion 22 and tubing 44. In the specific embodiment illustrated, well system 20 has four flow control systems 52.
Referring generally to
As illustrated, the flow control valve systems 52 are controlled by an electric line 54 and a single fluid control, e.g. hydraulic, line 56. Each flow control valve system 52 comprises a flow control valve 58 and an electro-mechanical device 60 that controls flow of fluid, e.g. hydraulic fluid, between the single control line 56 and the flow control valve 58. The electromechanical device 60 is operated based on electrical inputs via electric line 54.
In the illustrated embodiment, each flow control valve 58 comprises a variable choke 62 that may be adjusted to a closed position, an open position, and at least one intermediate position therebetween. For example, each variable choke 62 may comprise a plurality of intermediate positions, e.g. four intermediate positions, as illustrated. Each flow control valve 58 further comprises a position adjustment mechanism, such as an indexer 64, coupled to variable choke 62 to sequentially adjust the variable choke between its closed and open positions. Additionally, each flow control valve 58 comprises a dual line actuator 66 that is coupled to indexer 64 and designed to reciprocate in response to hydraulic input for adjustment of indexer 64 to desired indexer settings.
In this example, each electromechanical device 60 comprises an electro-hydraulic servo valve, such as a linear drive, four-ways, two-positions directional servo valve. Device 60 may be built into the corresponding flow control valve 58. Device 60 comprises a motive unit 68 and a driver 69 that respond to electrical input via electric line 54 to adjust device 60, in this case an electro-hydraulic servo valve, to a first flow position 70 or a second flow position 72. For purposes of explanation, the first flow position 70 can be referred to as a straight flow position, and the second flow position 72 can be referred to as a cross-over flow position. When in first flow position 70, fluid from hydraulic line 56 flows into a chamber 74 on one side of dual line actuator 66 while an opposite chamber 76 on the other side of dual line actuator 66 is open to a vent outlet 78 that allows the control fluid to be vented, for example, to the wellbore annulus. (See upper flow control valve system 52 of
Accordingly, in operation, electro-mechanical device 60 is controlled electrically from, for example, surface 32 and effectively pilots the dual line actuator 66 of flow control valve 58 by selectively switching the flow of control fluid to either chamber 74 or chamber 76. The selection of first flow position 70 or second flow position 72 is accomplished by electrically commanding specific servo valves via electrical inputs through electric line 54. In this embodiment, hydraulic pressure from control line 56 is applied only once the pressure ports of device 60 are fully opened with respect to flow from control line 56. This prevents any seals within electro-mechanical device 60 from being exposed to the relatively high pressure exerted through line 56.
By applying pressure from control line 56 to selected chambers of dual line actuator 66, actuator 66 is able to reciprocate indexer 64 which creates hard-stops at discrete locations that correspond to specific choke positions of variable choke 62. Once a sequential choke position is reached, hydraulic pressure in actuator 66 is bled off, and the position of device 60 remains the same until the next actuation. When it is desired to move variable choke 62 to the next position, servo valve 60 is electrically switched again, and hydraulic pressure is applied to operate actuator 66 and move indexer 64/variable choke 62 to the next sequential position, as described above. If a second zone needs to be addressed, the flow control valve system 52 associated with the second zone is actuated in a similar fashion. The electromechanical device 60 of the flow control valve system associated with the second zone is actuated by unique electrical inputs to the specific device 60, while the devices 60 corresponding to other well zones remain in their same position. Hydraulic inputs through the same hydraulic line 56 are used to move the corresponding dual line actuator 66, indexer 64 and a variable choke 62. It should be noted that when control line 56 is pressurized, the nonactivated flow control valve systems 52 may be exposed to the pressure, but the indexer 64 of each of those systems prevents the corresponding variable choke from changing position.
An example of adjusting individual flow control valve systems is illustrated graphically in
In functional diagram 80, the position of device 60, i.e. straight flow position 70 or cross-over flow position 72, is illustrated by a timeline 84, and the hydraulic signal, i.e. hydraulic line 56 pressurized or non-pressurized, is illustrated by timeline 86. Additionally, the corresponding choke position is provided by graph line 88. Functional diagram 82 has corresponding timelines 90 and 92 along with corresponding graph line 94 representing the choke position of the lower flow control valve 58.
Referring first to functional diagram 80, servo valve 60 is initially in a straight flow position 70. Subsequently, an electrical signal is input to the corresponding device 60 via electric line 54, causing motive unit 68 to shift servo valve 60 to the cross-over flow position 72. While in the cross-over flow position, control line 56 is pressurized, causing movement of dual line actuator 66 and indexer 64, thereby changing the choke position from position number 1 to position number 2. The pressure in control line 56 is then released, and subsequently an appropriate electrical signal is provided to servo valve 60 causing movement back to straight flow position 70. Pressure is then again applied via control line 56, thereby causing movement of actuator 66 in a reverse direction which transitions indexer 64 and variable choke 62 to choke position number 3, as illustrated. During the hydraulic and electrical inputs to the upper flow control valve system, servo valve 60 of the lower flow control valve system is set in cross-flow position 72. No further electrical inputs are provided to the lower servo valve to change its position, as illustrated by functional diagram 82. Accordingly, even though both flow control valve systems 52 are exposed to the same pressure signals (see timelines 86 and 92), the choke position of the lower indexer 64 and choke 62 remains at position number 4, as illustrated.
A variety of electromechanical devices 60 can be designed to control fluid flow between control line 56 and flow control valve 58. In
As illustrated, spool valve 110 comprises a spool 112 slidably mounted within a spool cavity 114. Spool cavity 114 is communicatively coupled with control line 56 via a port 116 and with actuator 66 via ports 118 and 120. Additionally, spool cavity 114 has a bleed port 122 through which internal fluid can be bled from spool cavity 114 to vent 78.
With additional reference to
Referring first to
Referring generally to
In this embodiment, each flow control valve system 52 again comprises the flow control valve 58 and the electro-mechanical device 60. Electro-mechanical device 60 controls flow of fluid between the single fluid control line 56 and the flow control valve 58 based on the electrical inputs via electric line 54. However, various components of both flow control valve 58 and electro-mechanical device 60 have been changed relative to the embodiment described with reference to
As illustrated, each flow control valve 58 comprises a choke 124 that is continuously or infinitely variable between a closed position and a fully open position. Each flow control valve 58 further comprises a position adjustment mechanism in the form of an electrical position transducer 126 coupled to the corresponding infinitely variable choke 124. The electrical position transducer 126 may comprise a position detector 128 able to provide continuous feedback to a control system regarding the actual position of infinitely variable choke 124. Thus, choke 124 can be accurately set at any position from closed to fully open. Additionally, each flow control valve 58 comprises dual line actuator 66 coupled to electric position transducer 126 and designed to move the position transducer 126 and choke 124 in response to hydraulic input, as described above with respect to the embodiment illustrated in
In this embodiment, each electromechanical device 60 may comprise a hydraulic servo valve in the form of a four-way, three-position servo valve. Again, device 60 may be a separate device or built into a corresponding flow control valve 58. Device 60 comprises a motive unit 130 that responds to an electrical input from electric line 54 sent through a controller/PID corrector 132. It should be noted that position detector 128 can be coupled to controller 132 to provide feedback to controller 132 regarding the position of choke 124. Motive unit 130 adjusts device 60, e.g. a servo valve, to one of three positions, namely a first flow position 134, a second flow position 136, and a third position which is a closed or no-flow position 138. When in the first, flow position 134, fluid from hydraulic line 56 flows into chamber 74 of dual line actuator 66 while the opposite chamber 76 is open to vent outlet 78. When motive unit 130 actuates device 60 to the second flow position 136, fluid from hydraulic line 56 flows into chamber 76 of dual line actuator 66, and chamber 74 is open to vent 78. When motive unit 130 actuates device 60 to the third, closed position 138, the volume of control fluid in chambers 74 and 76 is fixed or locked, preventing movement of dual line actuator 66 and choke 124.
By applying pressure from control line 56 to selected chambers 74 or 76 of dual line actuator 66, the actuator is able to move the electrical position transducer 126 and the infinitely variable choke 124 to any desired choke position. The electrical position transducer 126 is able to provide feedback as to the actual position of choke 124, thus enabling a well operator precise control over the positioning of each individual choke.
A schematic example of adjusting the individual flow control valve systems is illustrated in
In functional diagram 140, the position of electromechanical device 60 is illustrated by a timeline 144. The fluid, e.g. hydraulic, signal in control line 56 is illustrated by a timeline 146 as either pressurized or non-pressurized. Additionally, the corresponding position of choke 124 is provided by a graph line 148. Functional diagram 142 has corresponding timelines 150 and 152 along with corresponding graph line 154 representing the choke position of the lower flow control valve 58.
Referring to functional diagram 140, the servo valve device 60 is initially in a closed flow position 138, as indicated by segment 156 of timeline 144. While in this position, control line 56 is pressurized, as indicated by timeline 146. Subsequently, an electric signal is input to the corresponding device 60 via electric line 54, causing motive unit 130 to shift the servo valve 60 to the second flow position 136, as indicated by segment 158 of timeline 144. While in the second flow position, the pressure in control line 56 causes actuation of dual line actuator 66 and movement of electrical position transducer 126, thereby changing the opening of choke 124, as indicated by graph line 148. An electric signal to servo valve 60 then returns the servo valve to the closed position 138 until a subsequent electric signal once again moves device 60 to the second flow position 136, as indicated by segment 160 of timeline 144. During this time, pressure has been maintained in control line 56 which causes movement of dual line actuator 66 and electrical position transducer 126 to further change the opening of choke 124 in the same direction, as indicated by graph line 148. Subsequently, servo valve 60 is returned to the closed, no-flow position 138 to hold the choke position until further adjustment of the choke. By way of example, the choke 124 may be adjusted again through actuation of device 60 to the first flow position 134, as indicated by segment 162. In first flow position 134, the maintained pressure in control line 56 moves dual line actuator 66 and electrical position transducer 126 in an opposite direction until choke 124 arrives at a desired choke position, as again indicated by graph line 148. Position detector 128 provides feedback to enable the precise amount of opening or closing of choke 124 as desired by the well operator. Each time the choke 124 is moved to a desired choking position, the servo valve is moved back to its closed flow position 138 which isolates actuator 66 from both control line 56 and the formation environment, thus locking the choke at the desired position.
During the hydraulic and electrical inputs to the upper flow control valve system, the same hydraulic pressure is maintained with respect to the lower flow control system, as indicated by timeline 152. However, different electrical inputs can be provided to the servo valve 60 of the lower flow control system. In this example, the lower choke 124 is initially at a 90% position, and the lower servo valve 60 is in a closed, no-flow position 138 as indicated by segment 164 on timeline 150. Subsequently, an electrical input is provided to the lower device 60 shifting it to a second flow position, as indicated by segment 166 of timeline 150. The servo valve is maintained in this position a sufficient length of time such that the hydraulic pressure from control line 56 is able to move the lower dual line actuator 66 and electrical position transducer 126 until the lower choke 124 is opened the desired amount, as indicated by graph line 154. Thus, with electrical line 54 and a single hydraulic line 56, the chokes 124 can be independently controlled to infinitely variable positions.
In this embodiment, the electromechanical devices 60 can be designed as four-way, three-position servo valves, as illustrated in
As illustrated, spool valve 180 comprises a spool 182 slidably mounted within a spool cavity 184. The spool 182 may be mounted between spring members 186 which tend to bias the spool toward a centralized closed flow position. Spool cavity 184 is communicatively coupled with control line 56 via a port 188 and with actuator 66 via ports 190 and 192. Additionally, spool cavity 184 has a bleed port 194 through which an internal fluid can be bled from spool cavity 184 to vent 78. In
As illustrated in
When it is desired to move choke 124 in an opposite direction, an appropriate electrical signal is supplied to motive unit 130 via electric line 54 to shift the spool 182 in an opposite direction, as illustrated in
The ability to use electric input to control the flow of pressurized fluid through a control line provides the overall system with great flexibility for integration into a variety of well applications, including intelligent completion applications and reservoir modeling integration. The use of separate electric commands and fluid, e.g. hydraulic, commands via a single control line, enables a well operator to readily isolate and/or optimize flow rates from specific well zones at specific periods of time.
Accordingly, although only a few embodiments of the present invention have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this invention. Accordingly, such modifications are intended to be included within the scope of this invention as defined in the claims.