Patent Application
20220356779
The present disclosure generally relates to systems and methods for flow control valves, such as intelligent flow control valves used in oil and gas wells, and more specifically to indexers and indexing methods for flow control valves.
Valves are employed in a variety of applications to control flow of a fluid. Depending on the valve configuration, the valve may be actuated between two or more positions that correspond with two or more flow configurations. Generally, the valve is coupled with an actuation system, e.g. an electronic, hydraulic, or mechanical actuation system, which may be selectively operated to shift the valve between the flow configurations. The valve is shifted between positions by, for example, moving a valve element contained within the valve.
An indexer for an intelligent flow control valve can cycle from closed to open to gradually decreasing choke sizes.
In some configurations, a mechanical indexer for an intelligent flow control valve comprising a plurality of choke positions is provided. The indexer can cycle from a full closed position, to a full open position, to gradually decreasing choke sizes. The indexer can cycle from a full closed position, to a full open position, to gradually decreasing choke sizes alternating with the full open position. The indexer can cycle from a full closed position, to a full open position, to a full closed position, to a full open position, to gradually decreasing choke sizes alternating with a full open position. The indexer can cycle from a full closed position, to a full open position, to a full closed position, to a full open position, to gradually decreasing choke sizes.
In some configurations, the mechanical indexer includes a first indexer member comprising a plurality of interconnected slots forming a track; and a second indexer member comprising a detent disposed within the track, wherein the second indexer member is configured to move relative to the first indexer member such that the detent travels along the track, and wherein a position of the detent relative to the track determines the choke position. The first indexer member can include or be formed as a sleeve, with the track formed in an outer surface of the sleeve. The second indexer member can include or be formed as a hollow ring having a bore therethrough, with the detent protruding into the bore from an inner surface of the ring. A flow control valve can include the mechanical indexer.
In some configurations, a choke system for use in a well includes: a valve comprising an orifice through which well fluid flow can be choked; an actuator configured to position the valve at one or more positions including a full open position, a full closed position, and a plurality of incremental positions having varying choke sizes between the full open position and the full closed position; and an indexing mechanism coupled to the actuator, the indexing mechanism configured to shift movement of the actuator to move the valve through the one or more positions from the full closed position, to the full open position, and through the plurality of incremental positions in an order corresponding to gradually decreasing choke sizes.
The indexing mechanism can include a first indexer member comprising a plurality of interconnected slots forming a track; and a second indexer member comprising a detent disposed within the track, wherein the second indexer member is configured to move relative to the first indexer member such that the detent travels along the track, and wherein a position of the detent relative to the track determines the choke position. The first indexer member can include or be formed as a sleeve, with the track formed in an outer surface of the sleeve. The second indexer member can include or be formed as a hollow ring having a bore therethrough, with the detent protruding into the bore from an inner surface of the ring. A flow control valve can include the mechanical indexer.
The indexing mechanism can be configured to shift the actuator to move the valve to the full open position between each of the incremental positions. The indexing mechanism can be configured to shift the actuator to move the valve from the full closed position, to the full open position, to the full closed position, to the full open position, and then through the plurality of incremental positions in an order corresponding to gradually decreasing choke sizes. The indexing mechanism can be configured to shift the actuator to move the valve to the full open position between each of the incremental positions.
In some configurations, a method of controlling flow of well fluid through a valve including an indexer includes: starting the indexer in a position corresponding to a full close position of the valve; transitioning the indexer to a position corresponding to a full open position of the valve; and cycling the indexer from the full open position through a series of incremental positions corresponding to decreasing choke sizes of the valve.
The indexer can include a first indexer member comprising a plurality of interconnected slots forming a track; and a second indexer member comprising a detent disposed within the track, wherein the second indexer member is configured to move relative to the first indexer member such that the detent travels along the track, and wherein a position of the detent relative to the track determines the choke position. Cycling the indexer through the series of incremental positions can include moving the second indexer member relative to the first indexer member such that the detent moves along the track. Cycling the indexer through the series of incremental positions can include moving the indexer to the position corresponding to the full open position of the valve between each of the series of incremental positions.
Certain embodiments, features, aspects, and advantages of the disclosure will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements. It should be understood that the accompanying figures illustrate the various implementations described herein and are not meant to limit the scope of various technologies described herein.
In the following description, numerous details are set forth to provide an understanding of some embodiments of the present disclosure. It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the disclosure. These are, of course, merely examples and are not intended to be limiting. However, it will be understood by those of ordinary skill in the art that the system and/or methodology may be practiced without these details and that numerous variations or modifications from the described embodiments are possible. This description is not to be taken in a limiting sense, but rather made merely for the purpose of describing general principles of the implementations. The scope of the described implementations should be ascertained with reference to the issued claims.
As used herein, the terms “connect”, “connection”, “connected”, “in connection with”, and “connecting” are used to mean “in direct connection with” or “in connection with via one or more elements”; and the term “set” is used to mean “one element” or “more than one element”. Further, the terms “couple”, “coupling”, “coupled”, “coupled together”, and “coupled with” are used to mean “directly coupled together” or “coupled together via one or more elements”. As used herein, the terms “up” and “down”; “upper” and “lower”; “top” and “bottom”; and other like terms indicating relative positions to a given point or element are utilized to more clearly describe some elements. Commonly, these terms relate to a reference point at the surface from which drilling operations are initiated as being the top point and the total depth being the lowest point, wherein the well (e.g., wellbore, borehole) is vertical, horizontal or slanted relative to the surface.
The present disclosure generally relates to systems and methods for controlling valve position and fluid flow. Such systems and methods can be used in oil and gas wells. A valve, such as a flow control valve, can be actuated among a plurality of fluid flow positions via an indexer. In some configurations, the present disclosure provides a choke system or valve adapted to choke the flow through one or more orifices of the valve. A valve actuator operably attached to the valve is able to position the valve at one or more incremental positions between an open position and a closed position. The valve actuator can define a predefined shifting sequence to provide the incremental positions of the valve. The change in flow area as the valve is actuated through the incremental positions varies so that predetermined changes in flow condition can be provided. As used here, flow condition may refer to pressure drop across the valve and/or flow rate through an orifice in the valve.
An indexing mechanism is connected to the actuator and/or choke to restrict motion of the valve actuator to provide the incremental positions between the open and closed choke positions. The indexing mechanism can be a mechanical indexer, such as a J-slot indexer. In some configurations, the indexing mechanism includes a first indexer member defining a plurality of elongated, spaced, interconnected slots and a second indexer member having an indexer detent pin. The indexer detent is adapted to mate with and move within the plurality of slots. The first and second indexer members are adapted for movement relative to one another, with the plurality of slots and the indexer detent adapted to cooperatively restrict the relative movement of the first and second indexer members.
The indexer and/or choke positions of typical Intelligent Flow Control Valves (FCV) available in the market are configured to transition from a full closed (FC) position to gradually opening or incrementally increasing positions to a full open (FO) position. Generally, the FCV is placed in the full open position at the beginning of production or injection. However, the FCV is first placed in the closed position and then gradually opened to incrementally larger choke sizes to reach the full open position. Therefore, the production or injection must be shut in first, and then production or injection is started. This may have an adverse effect on the reservoir. Additionally, the FCV could fail to cycle during changing of the choke position. To go to, for example, choke position four, the FCV must first cycle through choke positions 1, 2, and 3. The production or injection will be severely choked if the FCV fails at, for example, position 1.
The present disclosure provides various indexer designs, e.g., mechanical indexer designs, for FCV. In some configurations, the indexer has reverse choke positions or a reverse indexer and/or choke pattern or sequence. In other words, in some configurations, the indexer cycles from closed to full open to gradually smaller choke sizes, rather than closed to gradually larger choke sizes as in previously available valves. Designs according to the present disclosure can advantageously help prevent or reduce the likelihood of adverse effects due to FCV failure.
Referring to
The choke or valve includes one or more orifices. For example, the valve can include a plurality of orifices, each corresponding to one of the positions of the indexer 100, or an orifice having a series of segments or increment areas, each segment or increment area corresponding to one of the positions of the indexer 100. The position of the detent 122 relative to the slots 112 determines the choke position. For example, when the detent 122 is positioned relative to the slots 112 such that the indexer 100 is in the full open (FO) position, all of the plurality of orifices, or the entirety of an orifice having multiple segments or increment areas, can be uncovered and/or open. When the detent 122 is positioned relative to the slots 112 such that the indexer 100 is in the full close (FC) position, all of the plurality of orifices, or the entirety of an orifice having multiple segments or increment areas, can be covered and/or closed. When the detent 122 is positioned relative to the slots 112 such that the indexer 100 is in an incremental position between FO and FC, a subset of the orifices, or a portion of the orifice, can be uncovered and/or open.
Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and/or within less than 0.01% of the stated amount. As another example, in certain embodiments, the terms “generally parallel” and “substantially parallel” or “generally perpendicular” and “substantially perpendicular” refer to a value, amount, or characteristic that departs from exactly parallel or perpendicular, respectively, by less than or equal to 15 degrees, 10 degrees, 5 degrees, 3 degrees, 1 degree, or 0.1 degree.
Although a few embodiments of the disclosure 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 disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments described may be made and still fall within the scope of the disclosure. It should be understood that various features and aspects of the disclosed embodiments can be combined with, or substituted for, one another in order to form varying modes of the embodiments of the disclosure. Thus, it is intended that the scope of the disclosure herein should not be limited by the particular embodiments described above.
Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 CFR 1.57. The present application claims priority benefit of U.S. Provisional Application No. 62/930,979, filed Nov. 5, 2019, the entirety of which is incorporated by reference herein and should be considered part of this specification.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2020/059073 | 11/5/2020 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 62930979 | Nov 2019 | US |
