Patent Application
20160060966
Flow control devices in tubular systems are employed for a multitude of purposes. One such purpose, as employed in the hydrocarbon recovery industry, is to equalize production flow across a length of wellbore to more evenly and thoroughly empty multiple reservoirs distributed along the wellbore. Without the inflow control devices, portions of the formation having higher permeability and thus higher flow rates could become depleted of hydrocarbon sooner than other portions of the formation that have lower permeability. Once depleted of hydrocarbon those portions of the formation may begin producing water that needs to be separated from the hydrocarbon at a later time. This separation is a costly and time consuming operation. Although conventional flow control devices serve the purpose for which they were designed; they can create undesirable restrictions to flow in a direction opposite to that of the produced fluids. Such flow restrictions can slow flow rates of treating fluids being pumped therethrough and hinder proper formation treatment in the process. The industry is therefore always receptive to new devices and methods that alleviate such undesirable characteristics of conventional inflow control devices.
A flow device, includes a flow-through region comprising at least one stage and configured to create a first pressure drop across the flow-through region in response to flow through the flow-through region in a first direction and a second pressure drop in response to flow through the flow-through region in a second direction, the first pressure drop being less than the second pressure drop under the same flow rates, the flow device having no moving parts to create the difference in pressure drop between the first direction and the second direction.
A method of creating different pressure drops based on a direction of flow, includes flowing fluid at a set flow rate through a flow-through region of a flow device in a first direction through a first opening into a pocket and out of the pocket through a second opening and creating a first pressure drop in the process; and flowing fluid at the set flow rate through the flow-through region of the flow device in a second direction through the second opening into the pocket and out of the pocket through the first opening and creating a second pressure drop in the process, the first pressure drop being less than the second pressure drop with no part moving within the first opening, the second opening or the pocket to create the difference in pressure drop.
A method of creating different pressure drops based on a direction of flow, includes flowing fluid at a set flow rate through a flow-through region of a flow device in a first direction through a first opening into a pocket and out through a second opening; accelerating fluid as it flows through at least one of the first opening and the second opening with a decrease in a cross sectional flow area of the at least one first opening and second opening and creating a first pressure drop in the process; flowing fluid at the set flow rate through the flow-through region of the flow device in a second direction through the second opening into the pocket and out through the first opening; and decelerating fluid as it flows through at least one of the second opening and the first opening with an increase in a cross sectional flow area of the at least one second opening and first opening and creating a second pressure drop in the process, the first pressure drop being less than the second pressure drop.
The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
Referring to
The stage 18, illustrated in the Figures has a pocket 30. A first opening 34 and a second opening 38 fluidically connect the pocket 30 to other pockets 42 and serve as inlets and outlets to the pocket 30. A flow area through the pocket 30 is larger than a flow area through either of the first opening 34 or the second opening 38. Additionally, a flow area of both the first opening 34 and the second opening 38 varies in a direction of fluid flow therethrough. For example, walls 46 of the first opening 34 are tapered such that flow area of the first opening 34 decreases along the direction of arrows 22. Similarly, walls 50 of the second opening 38 are also tapered such that a flow area of the second opening 38 decreases along the direction of arrows 22. As such, the walls 46, 50 are tapered in a same direction relative to flow.
In one embodiment the pocket 30, the first opening 38 and the second opening 38 are positioned within an annular space 56 defined between a first tubular 60 and a second tubular 64. The walls 46, 50 can be formed in either the first tubular 60, the second tubular 64 or on a separate part positioned within the annular space 56. Flow enters and exits the annular space 56 through ports 68 in the first tubular 60 on one longitudinal end 72 and through a screen 76 on an opposing longitudinal end 80 of the annular space 56.
In one embodiment an included angle 54 between the walls 46 and 50 of the openings 34 and 38 respectively measure in a range of about 40 to 90 degrees. Evaluation of the embodiment predicts difference in pressure drop across the flow-through region 14 made of six of these stages 18 in series that is between about 55 and 60 percent less in the first direction than in the second direction, with all other parameters being equal. Some parameters employed during one particular evaluation included a flow rate of 200 barrels per day of oil (1.8 cP, 0.86 SG). It should be noted that by assembling a plurality of the stages 18 in series one can create even greater differences in pressure drop between flow in the first direction and flow in the second direction.
The flow-through region 14 creates the difference in pressure drop between the first direction and the second direction at least in part by accelerating (over a reducing area) and decelerating (over an expanding area) fluid flowing through the openings 34, 38 with the changes in flow area defined by the tapered walls 46, 50.
Referring to
The baffle 120 of one embodiment presents a straight surface 156 that is oriented perpendicular to flow entering the pocket 130 from the first opening 134. In the illustrated embodiment more than half of the baffle 120 overlaps with the first opening 134, although in other embodiments more or less overlap could be employed, as could angles of the baffle 120 relative to the first opening 134.
Referring to
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It should be appreciated that in other embodiments an alternate pad could be employed that is not attached to the surface 440 but instead leaves a small clearance therebetween. Similarly, other embodiments could have a pad that spans a thickness of the pocket 442 to essentially attach or abut with the surface 440 as well as a surface positioned opposite the surface 440 of the pocket 442. Alternatively, offset pad 420 may be offset a short distance from first opening 434 as opposed to being adjacent to first opening 434 and still achieve a desirable result.
Although the features of the stages 18, 118, 218, 318, 418 are shown separately, other embodiments can employ any two or more of the features disclosed herein that are compatible within a single embodiment. Analysis has shown that embodiments of the flow device 10 employing one or more of the features in the stages 18, 118, 218, 318, 418 can result in pressure drops in the first direction that are in a range of 40 to 60 percent of the pressure drop in the second direction.
In downhole applications, such as for hydrocarbon recovery for example, the flow device 10 allows and operator to use a plurality of just this one flow device 10 (possibly with some set at different levels of pressure drop differential than others) with no moving parts to inject fluids into an earth formation with very little restriction, while also having sufficient restriction to equalize production flow therethrough in the opposing direction.
While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
