The disclosure relates generally to systems and methods for performing completion and production activities in a wellbore.
Hydrocarbons such as oil and gas are recovered from a subterranean formation using a wellbore drilled into the formation. Such wells are typically completed by placing a casing along the wellbore length and perforating the casing adjacent each such production zone to extract the formation fluids (such as hydrocarbons) into the wellbore. These production zones are sometimes separated from each other by installing a packer between the production zones. Fluid from each production zone entering the wellbore is drawn into a tubing that runs to the surface. Sometimes it is desirable to treat the formation in some manner in order to improve production. One type of treatment is a “frac” operation. It is also desirable to control drainage along the production zone or zones to reduce undesirable conditions such as an invasive gas cone, water cone, and/or harmful flow patterns.
The present disclosure addresses these and other needs of the prior art.
In aspects, the present disclosure provides an apparatus for controlling a flow of a fluid between a wellbore tubular and a formation. The apparatus may include a frac tool having at least one port in selective fluid communication with the formation, and an inflow control device having a flow control path configured to provide a predetermined pressure drop for a flowing fluid. The inflow control device may have a flow coupler configured to provide selective fluid communication with the at least one port.
It should be understood that examples of the more important features of the disclosure have been summarized rather broadly in order that detailed description thereof that follows may be better understood, and in order that the contributions to the art may be appreciated. There are, of course, additional features of the disclosure that will be described hereinafter and which will form the subject of the claims appended hereto.
The advantages and further aspects of the disclosure will be readily appreciated by those of ordinary skill in the art as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference characters designate like or similar elements throughout the several figures of the drawing and wherein:
Each production device 34 is used to govern one or more aspects of a flow of one or more fluids into or out of the production string 20. As used herein, the term “fluid” or “fluids” includes liquids, gases, hydrocarbons, multi-phase fluids, mixtures of two of more fluids, water, brine, engineered fluids such as drilling mud, fluids injected from the surface such as water, and naturally occurring fluids such as oil and gas.
The wellbore 11 is “open hole,” meaning the wellbore arrangement 11 has an uncased borehole that is directly open to the formation 16. Production fluids, therefore, flow directly from the formation, 16, and into the annulus 30 or production nipples that is defined between the production string 21 and the wall of the wellbore 11.
Referring now to
The frac tool 110 may be used to hydraulically fracture an adjacent formation to enhance fluid mobility. In one embodiment, the frac tool 110 has ports 114 that provide fluid communication between the flow bore 38 and the formation or the annular space 30 (
The ports 114, which may include an array of telescoping members 120, are circumferentially distributed around an outer surface of the housing 102. The array may have any number or size of ports 114 as needed for the expected flow rates for fracturing or subsequent production. The telescoping members 120 are shown in the retracted position in
The inflow control device 150 may be positioned axially adjacent to the frac tool 110. In one embodiment, the inflow control device 150 control one or more characteristics of fluid flow between a formation and the flow bore 38. The in-flow control device 150 may include a mandrel 152 that slides axially inside the housing 102. The mandrel may include a flow control passage 154, a latching section 156, and a flow coupler 158. The flow coupler 158 may be a sleeve-like member that has an outer circumferential surface separated by an annular gap 160 from an inner surface of the housing 102. The flow coupler 158 may include one or more sealing elements that prevent fluid communication between the gap 160 and the flow bore 38.
The flow control passage 154 is configured to impose one or more flow characteristics (e.g., controlled pressure drops) on the fluid flow through the inflow control device 150. For example, the flow control passage 154 may include helical passage ways that wind along an outer surface of the mandrel 152. The helical passage, which may include two or more parallel passages, may generate a pressure drop using frictional forces resisting flow along this circuitous flow path. When the flow coupler 158 is coupled to the ports 114, fluid flow between the interior and the exterior of the tool 100 occurs only through the ports 114, the flow coupler 158, and the flow control passage 154. The fluid, in some embodiments, may also flow through the openings 162 in the mandrel 152.
The latching section 156 may be used to axially shift the mandrel 152 and move the flow coupler 158 into fluid contact with the ports 114. In embodiments, the latching section 156 may include collets, profiles, locking dogs, or other elements device that connect to complementary features on a running tool (not shown). As shown, the latching section 156 may include a locking dog 157 that locks the mandrel 152 to the housing 102 until shifted by the running tool (not shown). Alternatively, the shifting could be accomplished electronically.
An illustrative use of the well tool 100 will be described with reference to
After the frac operation has been completed, a conventional shifting tool (not shown) may be conveyed into flow bore 38 using coiled tubing or other tool carrier. The shifting tool (not shown) may be manipulated as needed to mechanically engage the latching section 156. Once so connected, the shifting tool (not shown) is axially displaced, which causes the mandrel 152 to also slide until the flow coupler 158 is radially aligned with and coupled to the ports 114. Thereafter, the shifting tool (not shown) is disconnected from the mandrel 152 and retrieved to the surface. Alternatively, this same procedure could be accomplished electronically using wire or wireless transmission. The inflow control device 150 is now in the position shown in
This process may be repeated for every well device 100 in the wellbore. To prepare for production or injection operations, a milling operation may be performed by drilling out the seats 126 and other obstructions along the flow bore 38.
The teachings of the present disclosure are not limited to any particular well configuration or any particular design for the frac tool or inflow control device. For example, while a single horizontal leg is shown in
While
Likewise, while the Figures show the inflow control device 150 using helical passages for generating a pressure drop, other configurations may be used to control flow rate, velocity, and pressure drops. In one embodiment, the flow control passage 154 may be a labyrinth-type passage that has a non-helical tortuous flow path. The tortousity of the passage may be obtained by using circular, diagonal, or curved passage way. These passage ways may wind around the other surface of the mandrel 152 to form a flow path that generates a gradual pressure drop using primarily frictional flow resistance. In other embodiments, a relatively sharp pressure drop may be generated using openings formed as orifices. Additionally, the flow control passage 154 may include two or more parallel fluid paths that are hydraulically isolated from one and other. These hydraulically isolated paths may each be configured to generate a different flow condition (e.g., different pressure drops). In such a hydraulically parallel arrangements, a user can select which of the paths may be open or closed in order to generate a desired pressure drop, flow rate, or other flow characteristic.
Moreover, the flow control passage may incorporate one or more features that control friction factors, flow path surface properties, and flow path geometry and dimensions. The flow control passages may also include hydrophilic or hydrophobic materials. These features, separately or in combination, may cause flow characteristics to vary as fluid with different fluid properties (e.g., density and viscosity) flow through the inflow device 150.
In still other embodiments, the flow path 152 may include a permeable media that is formulated, structured, or otherwise configured to generate a desired pressure drop. Illustrative permeable media include, but are not limited to, packed ball bearings, beads, or pellets, or fibrous elements, a packed body of ion exchange resin beads, and swellable media. The beads may be formed as balls having little or no permeability. The permeable media may be responsive to the amount of water in a fluid; e.g., the permeable media may increase resistance to inflow as water cut increases.
The well tools of the present disclosure may be distributed along a section of a production well to provide fluid control at multiple locations. This can be useful, for example, to impose a desired drainage or production influx pattern. By appropriately configuring these well tools, a well owner can increase the likelihood that an oil or gas bearing reservoir will drain efficiently. This drainage pattern may include equal drainage from all zones or individualized and different drainage rates for one or more production zones. During injection operations, wherein a fluid such as water or steam is directed into the reservoir, the well tools may be used to distribute the injected fluid in a desired manner. It should be understood that the teachings of the present disclosure may readily be applied to other situations such as geothermal wells, water producing wells, etc. ICD's of the present disclosure may improve the influx (bpd/ft) since additional pressure drops across the frac sleeve may promote uniform flow coming to the base pipe. The pressure drops may also be used to mitigate cross flow in some of the fractures. Such cross flow may reduce the flow rate per unit time since flow is re-injected through the fractures. ICD's may also enable the establishing of “rule of thumb” for the optimum stages number given the average perm—to mitigate flow interference.
The influx (bpd/fx) is affected by: the pressure drop in the base pipe, the reservoir heterogeneities, the mobility ratio and variations of reservoir pressure along the wellbore. If one of those factors are present along the wellbore the amount of fluid coming into the base pipe will be uneven.
If variations of the reservoir pressure along the wellbore are greater than pressure drop in the base pipe, then cross-flow between fractures could occur. The cross-flow between fractures is an operational condition. To identify this condition in frac point operations, a production logging tool may be run. Space for this tool may be provided by milling the ball seat or using dissolved material. If cross-flow occurs, the flow rate could improve over time, but profitability would improve if cross-flow is immediately addressed. The ICD solution may assist to address others issues as mobility control (water or gas production), uneven fluid and cross-flow.
An ICD generally requires additional pressure drop through the completion to deliver equal or approximately equal amount of fluid coming into the base pipe. Low reservoir pressure and low permeability may or may not be able to accommodate such a pressure drop. In most cases, the ICD pressure drop should be greater than the reservoir pressure minus the pressure drop through the porous media (reservoir). If the pressure drop is less, the ICD pressure drop will be transparent to the reservoir and there will not be enough pressure to control the flow.
The basepipe diameter reduction may be optimized in low viscosity fluid condition since the pressure drop (in the production mode) in the base pipe will not affect the influx. The maximum flow rate to not exceed erosion limits may be the constraint. However, in the pumping direction that could be a restriction to pump high proppant concentration at high flow rate.
The ICD geometry will play a role to not exceed the erosion limits and no plugging issues (in fracturing condition that is not the case). That is, the pressure drop required to balance the flow could be due to changes of flow area (orifice ICD) or others pressure drop mechanism (friction or tortuosity, or combination of both).
For the sake of clarity and brevity, descriptions of most threaded connections between tubular elements, elastomeric seals, such as o-rings, and other well-understood techniques are omitted in the above description. Further, terms such as “slot,” “passages,” and “channels” are used in their broadest meaning and are not limited to any particular type or configuration. The foregoing description is directed to particular embodiments of the present disclosure for the purpose of illustration and explanation. It will be apparent, however, to one skilled in the art that many modifications and changes to the embodiment set forth above are possible without departing from the scope of the disclosure.
This applications claims priority from U.S. Provisional Application Ser. No. 61/762,221, filed Feb. 7, 2013, the disclosure of which is incorporated herein by reference in its entirety.
Number | Name | Date | Kind |
---|---|---|---|
5896928 | Coon | Apr 1999 | A |
6112817 | Voll et al. | Sep 2000 | A |
6494265 | Wilson et al. | Dec 2002 | B2 |
7409999 | Henriksen et al. | Aug 2008 | B2 |
7591312 | Johnson et al. | Sep 2009 | B2 |
7757761 | Augustine | Jul 2010 | B2 |
7775283 | Coronado et al. | Aug 2010 | B2 |
7823645 | Henriksen et al. | Nov 2010 | B2 |
7909088 | O'Malley et al. | Mar 2011 | B2 |
7913765 | Crow et al. | Mar 2011 | B2 |
7954546 | Kim et al. | Jun 2011 | B2 |
7980265 | Holmes et al. | Jul 2011 | B2 |
7992637 | Garcia | Aug 2011 | B2 |
8069921 | Garcia et al. | Dec 2011 | B2 |
8096351 | Peterson et al. | Jan 2012 | B2 |
8104538 | Richard et al. | Jan 2012 | B2 |
8151881 | Johnson et al. | Apr 2012 | B2 |
8210258 | O'Malley et al. | Jul 2012 | B2 |
8312931 | Xu et al. | Nov 2012 | B2 |
8342245 | Richard et al. | Jan 2013 | B2 |
8403038 | Russell et al. | Mar 2013 | B2 |
8403061 | Russell et al. | Mar 2013 | B2 |
8424609 | Duphorne et al. | Apr 2013 | B2 |
8443888 | Coronado | May 2013 | B2 |
8443892 | Richard et al. | May 2013 | B2 |
8469105 | O'Malley et al. | Jun 2013 | B2 |
8469107 | O'Malley et al. | Jun 2013 | B2 |
8527100 | Russell et al. | Sep 2013 | B2 |
8544548 | Coronado et al. | Oct 2013 | B2 |
8550166 | Xu et al. | Oct 2013 | B2 |
8646535 | Xu et al. | Feb 2014 | B2 |
8678350 | Coull | Mar 2014 | B2 |
9080421 | Holderman | Jul 2015 | B2 |
20060278399 | Dwivedi et al. | Dec 2006 | A1 |
20080006413 | Le Gloahec | Jan 2008 | A1 |
20080041588 | Richards | Feb 2008 | A1 |
20090065199 | Patel | Mar 2009 | A1 |
20090084553 | Rytlewski | Apr 2009 | A1 |
20110030969 | Richards | Feb 2011 | A1 |
20120048559 | Ganguly | Mar 2012 | A1 |
20120168164 | Sun et al. | Jul 2012 | A1 |
20130319664 | McNamee | Dec 2013 | A1 |
Number | Date | Country |
---|---|---|
2012037645 | Mar 2012 | WO |
Entry |
---|
PCT/US2014/015288—International Search Report dated Nov. 20, 2014. |
Number | Date | Country | |
---|---|---|---|
20140216754 A1 | Aug 2014 | US |
Number | Date | Country | |
---|---|---|---|
61762221 | Feb 2013 | US |