Information
-
Patent Grant
-
6298916
-
Patent Number
6,298,916
-
Date Filed
Friday, December 17, 199924 years ago
-
Date Issued
Tuesday, October 9, 200122 years ago
-
Inventors
-
Original Assignees
-
Examiners
Agents
-
CPC
-
US Classifications
Field of Search
US
- 166 386
- 166 278
- 166 129
- 166 142
- 166 145
- 166 149
- 166 183
-
International Classifications
-
Abstract
A completion string for use in a wellbore includes a main conduit, such as a production tubing, and one or more alternate path conduits, such as shunt tubes, that extend generally in parallel with the main conduit. A flow control device is positioned in each alternate path conduit to control flow through the alternate path conduit. The one or more alternate path conduits may be adapted to carry gravel slurry to perform gravel packing operations. The one or more flow control devices in the one or more alternate path conduits may be actuated to the open position to allow communication of the gravel slurry to multiple zones in the wellbore. Once the gravel packing operation is completed, the one or more flow control devices may be actuated to the closed position to block fluid flow communication between multiple zones through the alternate path conduits during operation of the well. Other types of fluids may be communicated through the one or more alternate path conduits, such as fracturing fluids.
Description
BACKGROUND
The invention relates to controlling fluid flow in conduits such as shunt tubes or other types of alternate conduits.
To complete a well, one or more formation zones adjacent the wellbore are perforated to allow fluid from the formation zones to flow into the well for production to the surface. Perforations are typically created by perforating gun strings that are lowered to desired intervals in the wellbore. When fired, perforating guns extend perforations into the surrounding formation.
In producing fluids from a formation, particulate materials such as sand may be produced with the formation fluids. Such particulates may damage the well and significantly reduce production and life of the well. Formation fluids containing particulates may act as an abrasive that wears and erodes downhole components, such as tubing. In addition, production of particulates such as sand may create voids in the formation behind the casing which may result in buckling of or other damage to the casing. The flow of the production fluids may be insufficient to lift the particulates from the well, which may result in buildup of the particulates in the well. In addition, particulates produced to the surface are waste products requiring disposal, which may be costly.
Various methods and devices for reducing or eliminating sand and other particulate production have been developed. Gravel packing of the formation is a popular method for controlling sand production. However, other sand control mechanisms may also be used. Although there are variations, gravel packing essentially involves placing a sand screen around the section of the production string containing the production inlets. This section of the production string is aligned with the perforations. A slurry of gravel in a viscous transport fluid is pumped into the annulus between the sand screen and the casing. The deposited gravel blocks the formation particulates, such as sand, from flowing into the production tubing. However, formation fluids are allowed to enter the production string for flow to the well surface.
A major issue associated with gravel packing is obtaining substantially uniform distribution of the gravel over the entire interval to be completed. Poor distribution of gravel is often caused by the loss of liquid from the gravel slurry into the more permeable portions of the formation, which causes creation of gravel “bridges” in the annulus before all of the gravel has been placed. These bridges block further flow of the slurry through the annulus to prevent or reduce distribution of gravel past the bridge.
To alleviate the problem of bridging in gravel packing, shunt tubes have been used as alternate paths through which the gravel slurry can flow. Thus, if a sand bridge forms in the annulus, the slurry is still free to flow through the shunt tubes and out into the annulus through ports in the shunt tubes to complete the filling of the annulus past the sand bridge.
The shunt tubes may extend through a plurality of completion zones. As the annular region in each of the zones fill up with gravel, a point of “sand out” is reached in which further injection of gravel is prevented. At this point, any excess sand or other particulates in the production string may be circulated to the well surface. The well is then ready for production. However, the shunt tubes may remain in communication with multiple zones, which may cause commingling of formation fluids between zones. Such commingling of formation fluids is undesirable. Thus, a need exists for a method and apparatus to block communication of fluids between different zones through shunt tubes or other alternate conduits during production.
SUMMARY
In general, according to one embodiment, an apparatus for use in a wellbore includes a main conduit, a second conduit, and a flow control device positioned in the second conduit to control flow through the second conduit.
Other features and embodiments will become apparent from the following description, from the drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
illustrates an embodiment of completion equipment positioned in a wellbore having a plurality of completion zones.
FIGS. 2A-2C
,
3
A-
3
C, and
4
A-
4
C are cross-sectional views of a packer assembly in accordance with one embodiment in three different positions, the packer assembly including a side conduit and a flow control device in the side conduit.
FIGS. 5A-5C
are a side view of the packer assembly of
FIGS. 2A-2C
with a portion of the outer housing cut out to show a portion of a flow control device actuator.
FIGS. 6 and 7
illustrate the flow control device actuator of
FIGS. 5A-5C
in an actuated position.
FIG. 8
illustrates the flow control device actuator of
FIGS. 5A-5C
in a recocked or relaxed position.
FIGS. 9-11
are cross-sectional views of a barrel valve in three different positions in the flow control device of
FIGS. 2A-2C
,
3
A-
3
C, and
4
A-
4
C.
FIGS. 12-13
are cross-sectional views of a ratchet mechanism coupling an actuating member to the barrel valve of
FIGS. 9-11
.
FIGS. 14-16
illustrate a lock mechanism that holds the barrel valve in position.
DETAILED DESCRIPTION
In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled 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.
As used here, the terms “up” and “down”; “upper” and “lower”; “upwardly” and downwardly”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly described some embodiments of the invention. However, when applied to equipment and methods for use in wells that are deviated or horizontal, such terms may refer to a left to right, right to left, or other relationship as appropriate.
Referring to
FIG. 1
, completion equipment including casing
14
, a production tubing
12
, and other components are positioned in a wellbore
10
having a plurality of zones
16
,
18
, and
20
. In further embodiments, a larger or a smaller number of zones may be present in the wellbore
10
. Sand control devices
22
,
24
and
26
may be positioned in the proximity of the zones
16
,
18
and
20
, respectively, to control production of sand and other particulates into the tubing
12
through perforations
28
,
30
and
32
in the zones
16
,
18
and
20
, respectively. Each of the sand control assemblies
22
,
24
and
26
includes a screen having perforations through which well fluids may flow. Gravel packs
34
,
36
and
38
may be formed in annular regions in the proximity of the zones
16
,
18
and
20
, respectively.
To form the gravel packs, a gravel slurry may be pumped down an upper annular region
42
between the outside of the production tubing
12
and the inner wall of the casing
14
above a packer assembly
40
. A crossover device
48
may be part of the packer assembly
40
to allow the gravel slurry to flow past the packer assembly
40
into a first annular region
50
adjacent the first zone
16
. One or more shunt tubes
44
may be present in the annular region
50
. The shunt tubes
44
start near the upper part of the annular region
50
and extend down the completion string to the lower annular regions
52
and
54
that are adjacent zones
18
and
20
, respectively. The shunt tubes
44
include ports
46
placed at intervals along the length of the shunt tubes
44
to allow communication between the inside and the outside of the shunt tubes
44
.
A packer assembly
56
, which may include a cup packer or other type of packer, is positioned between the first annular region
50
and the second annular region
52
. A second packer assembly
58
is positioned between the second annular region
52
and the third annular region
54
. The packer assemblies
56
and
58
provide the isolation between the three zones
16
,
18
, and
20
.
The shunt tubes
44
are attached to the packer assemblies
56
and
58
. Each of the packer assemblies
56
and
58
includes internal side or alternative conduits
60
and
62
, respectively, that are attached to and in fluid communication with the shunt tubes
44
. The shunt tubes
44
and the conduits
60
and
62
in the packer assemblies
56
and
58
are adapted to receive gravel slurry that is injected or pumped into the wellbore
10
. Each of the packer assemblies
56
and
58
also includes a main conduit
57
or
59
that is in communication with the production tubing
12
. As used here, the term “alternate path conduit” is intended to cover any fluid flow path that is separate from a main production or injection conduit
13
. The alternate path conduit may refer to a conduit in one or more completion components, such as the packer assembly
56
or
58
; a conduit run outside completion equipment, such as a shunt tube; or a combination of conduits that are outside and inside completion components.
In accordance with some embodiments of the invention, flow control devices
70
are placed in the side conduits
60
of the packer assembly
56
, and flow control devices
72
are placed in the side conduits
62
of the packer assembly
58
. Although plural shunt tubes
44
and conduits
60
and
62
are illustrated, further embodiments may include only a single shunt tube
44
and a single conduit
60
or
62
.
In one embodiment, to actuate the flow control devices
70
and
72
, a service tool
80
may be used. The service tool
80
may have been positioned initially in the tubing
12
below the third zone
20
. The service tool
80
includes seals
82
to seal the lower portion of the production tubing
12
so that fluid does not flow up the tubing
12
from below the service tool
80
. In accordance with some embodiments, the service tool
80
includes a latch profile
84
adapted to engage flow control device actuators
86
and
88
in the packer assemblies
56
and
58
, respectively. In one embodiment, activation of the actuator
86
or
88
may be performed by upward movement of the service tool
80
after gravel packing has been completed. In the illustrated embodiment, the operator to actuate the flow control device
70
and
72
is part of the service tool
80
. In other embodiments, the flow control device operator may be in another tool.
In operation, gravel slurry is pumped down the upper annular region
42
and communicated through conduits
49
in the crossover device
48
to the first annular region
50
. In the example given, the first, second, and third annular regions
50
,
52
, and
54
are filled in that order. However, in other examples, the order in filling up the several regions may be varied. As the annular region
50
fills up or is blocked by bridging, further flow of gravel slurry is provided through the shunt tubes
44
to exit through ports
46
to lower portions of the annular region
50
. Once the annular region
50
is filled, the gravel slurry flows through the side conduits
60
in the packer assembly
56
to the shunt tube portions
44
in the second annular region
52
. The gravel slurry enters the annular region
52
through exit ports
46
of the shunt tubes
44
to fill the annular region
52
with gravel. Next, the gravel slurry flows further down the shunt tubes
44
and through the side conduits
62
into the third annular region
54
to fill the region
54
with gravel. Once the annular regions
50
,
52
and
54
have completely filled with gravel, a condition referred to as “sand out” occurs, in which further pumping of gravel slurry into the annular regions is not possible. This condition is determined by the well operator based on a reduced injection rate of the gravel slurry, a comparison of the volume of gravel slurry pumped into the well and the expected volume based on tests of the formation, and a pressure increase.
In some arrangements, the shunt tubes or other alternate conduits may also be used to flow fracturing fluid to perform fracturing operations. Fracturing of a formation is performed to stimulate the formation to improve production of fluids. Generally, fracturing involves the injection of fluid under high pressure into the perforated formation to create or extend fractures in the hydrocarbon bearing formation. Typically, fracturing is performed before gravel packing operations.
To prevent commingling of fluids after sand out has occurred, flow control devices
70
and
72
may be actuated from an open position to a closed position. In the described example, the flow control devices are assumed to be both initially open. However, in other examples, one or more flow control devices in shunt tubes may be initially closed and opened at a later time. As used here, a closed position does not necessarily mean complete blockage of fluid flow. Rather, some acceptable fluid leakage may occur through the flow control devices
70
and
72
even though they are in the closed position. For example, such leakage may be about six percent or less of the fluid flow when the flow control devices
70
and
72
are fully open. When actuated to the closed positions, further flow in the shunt tubes
44
are blocked, thus preventing commingling of fluids between annular regions
50
,
52
and
54
. If desired, the flow control devices
70
and
72
may be actuated open again from the closed position.
Commingling of fluids between zones may have various undesirable effects. Introduction of contaminants from one zone to another may occur. Mixing some types of contaminants may produce chemical reactions that may produce solids to plug a formation. Also, with inter-zone communication through the shunt tubes, separate testing of each zone may not be possible.
After sand out occurs, any accumulated sand or other particulates in the production string are circulated to the well surface. Next, the service tool
80
may be raised to engage the lower flow control device actuator
88
in the packer assembly
58
to close the flow control device
72
. After the flow control device
72
has been closed, the service tool
80
can be raised further to engage the flow control device actuator
86
in the packer assembly
56
. Upward movement of the service tool
80
closes the flow control device
70
. With both flow control devices
70
and
72
in the closed position, commingling of fluids through the shunt tubes
44
is eliminated or reduced.
After the flow control devices
70
and
72
are closed, the service tool
80
can be retrieved to the surface. Other types of flow control device operators may also be used. In another embodiment, instead of using a mechanical actuating mechanism that is part of the service tool
80
to actuate the flow control devices
70
and
72
, hydraulic control lines may be run from the surface to each of the packer assemblies
56
and
58
. Pistons may be provided in the actuators
86
and
88
to allow hydraulic actuation of the flow control devices
70
and
72
.
In another embodiment, electrical activation of the actuators
86
and
88
may be possible. Electrical lines may be run through control lines to the packer assemblies
56
and
58
. Power and signaling can then be provided down the electrical lines to control activation of the actuators
86
and
88
. In yet another embodiment, instead of using electrical lines, inductive couplers may be used to activate the actuators
86
and
88
. If inductive coupling is used, a first inductive coupler portion may be positioned in each packer assembly
56
or
58
and a second inductive coupler portion may be located inside a tool that may be run into the production tubing
12
. For example, the second inductive coupler portion may be located in the service tool
80
. To activate the actuator
86
or
88
using the inductive coupler mechanism, the service tool
80
(or some other tool run in the tubing
12
) may be moved into proximal relation with the first inductive coupler portion in the packer assembly
56
or
58
. An electrical signal can then be transmitted down electrical wires, such as wires inside a wireline, to the service tool
80
, with the electrical energy coupled from the second inductive coupler portion to the first inductive coupler portion to activate the actuator
86
or
88
. Other mechanisms for activating the actuators
86
and
88
may also be possible in further embodiments.
Referring to
FIGS. 2A-2C
and
5
A-
5
C, the packer assembly
56
or
58
according to one embodiment is illustrated in greater detail. The packer assembly
56
or
58
includes an inner bore
100
that is in communication with the inner bore of the production tubing
12
. A coupling adapter
102
connects a mandrel
104
in the packer assembly to the production tubing
12
above the packer assembly
56
or
58
. The mandrel
104
divides the inner bore
100
from the alternate or side conduits
60
or
62
in the packer assembly
56
or
58
, respectively. A shunt locator mechanism
106
connects the shunt tubes
44
to the side conduit
60
or
62
. Thus, as indicated by the arrows, the flow of gravel slurry in the shunt tube
44
flows into the side conduit
60
or
62
. As illustrated in
FIG. 5A
, a plurality of shunt tubes
44
are provided in one embodiment, with each shunt tube
44
in communication with a corresponding side conduit
60
or
62
. Casing cup packers
108
and
112
are attached to a cup support housing
110
. The casing cups
108
and
112
are in contact with the inner wall of the casing
14
to provide a seal around the outside of the cup packer assembly
56
or
58
. In another embodiment, other types of packers may be employed.
The lower ends of the cup support housing
110
and mandrel
104
are connected to a valve housing
114
(FIGS.
2
B and
5
B). As shown in
FIG. 2B
, the valve housing houses a barrel valve
118
that is part of the flow control device
70
or
72
. In
FIG. 2B
, the barrel valve
118
is shown in its open position. The barrel valve
118
includes an inner conduit
120
that when open is aligned with the side conduit
60
or
62
.
A shunt
128
and another housing section
132
are connected below the valve housing
114
. A sub
134
is attached to the lower end of the shunt
128
. Each side conduit
60
or
62
extends through bores in the shunt
128
and the sub
134
.
In addition, an actuator sleeve
122
is arranged inside the valve housing
114
, shunt
128
, and sub
134
. The actuator sleeve
122
is adapted to move longitudinally or axially in the inner bore
100
of the packer assembly
56
or
58
. The actuator sleeve
122
is shown in its initial, un-actuated position. The actuator sleeve
122
can move upwardly until an upper end
126
of the sleeve
122
abuts a shoulder
124
formed in the inner wall of the valve housing
114
. An engagement profile
136
is provided in the inner wall of the actuator sleeve
122
to engage a valve operator (e.g., such as one in the service tool
80
), to move the actuator sleeve
122
up and down to actuate the barrel valve
118
. An outer sleeve
138
surrounding the sub
134
is connected to the sub
134
. In one embodiment, a portion
139
of the outer sleeve
138
may be in the form of a screen.
In FIG. SB, an outer section of the valve housing
114
is cut out to show a further portion of the actuator
86
or
88
that is at a different phase with respect to the portion shown in
FIG. 2B. A
rotatable actuating ring
142
is coupled to the barrel valve
118
by a ratchet mechanism, shown in
FIGS. 12 and 13
. The actuating ring
142
is rotatable by a control arm
140
having an end in abutment with an upper surface of a rod member
148
. The control arm
140
when actuated upwardly comes in contact with a lower surface of a control rod
144
. The rod member
148
is moveable longitudinally by the actuator sleeve
122
to push upwardly against the control arm
140
to rotate the actuating ring
142
. Movement of the control arm
140
pushes the control rod
144
up against a spring
146
. If the rod member
148
is moved upwardly to rotate the actuating ring
142
, the barrel valve
118
is rotated to the next position (that is, from open to closed or closed to open).
Another spring
150
is arranged around a lower part of the rod member
148
. The spring
150
sits on an extension
153
of the actuator sleeve
122
. The extension
153
is attached to the rod member
148
by a nut
152
. Upward movement of the rod member
148
by the actuator sleeve
122
also compresses the spring
150
.
As shown in
FIG. 2C
, the lower end of the sub
134
is connected to a lower support housing
166
and a lower mandrel
164
. The side conduit
60
or
62
continues to extend through the space between the lower support housing
166
and the lower mandrel
164
. Casing cup packers
160
and
162
are attached to the lower support housing
166
. The casing cup packers
160
and
162
are adapted to contact the inner wall of the casing
14
to provide a seal. A lower shunt locator mechanism
168
connects the side conduit
60
or
62
to the shunt tube
44
below the packer assembly
56
or
58
. The lower end of the mandrel
164
is threadably connected to the next portion of the production tubing
12
.
Referring to
FIGS. 3A-3C
,
6
, and
7
, the barrel valve
118
has been actuated to the closed position. As shown in
FIGS. 3B and 7
, the actuator sleeve
122
has been moved upwardly to its actuated position. The upward movement of the actuator sleeve
122
moves the rod member
148
and the control arm
140
to rotate the actuating ring
142
in the clockwise direction. Upward movements of the control rod
144
and rod member
148
compress respective spring
146
and spring
150
. The rotation of the actuating ring
142
in the clockwise direction rotates the barrel valve
118
to its closed position, as illustrated in FIG.
3
B.
FIG. 6
shows another portion of the flow control device actuator
86
or
88
in a phase different from that of the portion shown in
FIG. 7. A
stop rod
154
is provided to stop further upward movement of the rod member
148
to prevent overload on the control arm pin
156
from force applied by the rod member
148
.
Referring to
FIGS. 4A-4C
and
8
, after the barrel valve
118
has been actuated to its closed position, the actuating ring
142
is allowed to rotate back in the counterclockwise direction to its initial “recocked” or relaxed position, as shown in FIG.
8
. The force applied by the springs
146
and
150
returns the control rod
144
and rod member
148
to their respective relaxed positions after the flow control device operator has disengaged the profile
136
of the actuator sleeve
122
. The movement of the control rod
144
to its relaxed position pushes the control arm
140
downwardly, which in turn rotates the actuating ring
142
back to its initial position. A ratchet mechanism between the actuating ring
142
and the barrel valve
118
allows the valve to remain in its closed position even though the actuating ring
142
is rotating in the counterclockwise direction to its relaxed position. Thereafter, the actuator sleeve
122
may be re-actuated to open the barrel sleeve
118
, using the same procedure discussed above.
Referring to
FIGS. 9
,
10
and
11
, the barrel valve
118
and actuating ring
142
are shown in three different positions, corresponding to the positions illustrated in
FIGS. 2B
,
5
B;
3
B,
7
; and
4
B,
8
. In
FIG. 9
, the barrel valve
118
is in its open position. The actuating ring
142
is attached to the barrel valve
118
by a control arm screw
145
. A spring
202
is held by the screw
145
to press the actuating ring
142
against a side of the barrel valve
118
. Seals
204
and
206
, which may be O-ring seals, are provided around portions of the barrel valve
118
to seal fluids passing through the conduit
120
of the barrel valve
118
.
A ratchet mechanism
210
is positioned between the inner surface of the actuating ring
142
and a side of the barrel valve
118
. The ratchet mechanism
210
allows the actuating ring
142
to engage the barrel valve
118
when the actuating ring
142
rotates in a first direction (e.g., clockwise). However, when the actuating ring
142
rotates in the opposite direction (e.g., counterclockwise), the ratchet mechanism
210
provides a path of lower resistance to allow the barrel valve
118
to remain in position even though the actuating ring
142
is rotating.
In
FIG. 10
, the barrel valve
118
has been rotated to its closed position by the actuating ring
142
. In
FIG. 11
, the actuating ring
142
rotates back to its relaxed or recocked position in the counterclockwise direction without rotating the barrel valve
118
.
Referring to
FIGS. 12 and 13
, the ratchet mechanism
210
between the actuating ring
142
and the barrel valve
118
includes a first gear profile
208
on one side of the barrel valve
118
and a second gear profile
209
on the inside of the actuating ring
142
. The gear profiles
208
and
209
are adapted to engage when the actuating ring rotates in the clockwise position but to not engage when the actuating ring
142
rotates back in the counterclockwise direction.
Referring to
FIGS. 14
,
15
and
16
, a valve locking mechanism is illustrated that includes a ball
250
that is pushed against the surface of the barrel valve
118
by a spring
252
. Grooves
254
are formed in the outer surface of the barrel valve
118
to receive the locking ball
250
. The force applied by the spring
252
against the locking ball
250
allows the barrel valve
118
to remain in position while the ratchet mechanism
210
is ratcheting back to its relaxed or recocked position. In the illustrated embodiment, four locking grooves
254
are provided that are about 90° apart. Each locking groove
254
corresponds to a position (open or closed) of the barrel valve
118
.
In
FIG. 14
, the barrel valve
118
is in a first position. When the barrel valve
118
is rotated by the actuating ring
142
to the next position, the locking ball
250
is pushed away from the groove
254
onto the outer surface of the barrel valve
118
, as illustrated in FIG.
15
. The barrel valve
118
is rotated by about 90 degrees to its next position, where the locking ball
250
is received by the next locking groove
254
in the barrel valve
118
.
A pressure release mechanism
258
is provided adjacent the spring
252
to release pressure in case of pressure buildup in the space in which the spring
252
is located. This prevents high pressure from locking the barrel valve
118
in either an open position or a closed position.
In operation, according to one example, the packer assemblies
56
and
58
may be run in with respective barrel valves
118
in the open position. After the packer assemblies are set at desired intervals, gravel slurry may be pumped into the wellbore to perform gravel packing. The gravel slurry enters the shunt tubes
44
and is passed through each packer assembly
56
or
58
through the side conduits
60
or
62
, respectively, as the annular region
50
,
52
, and
54
fill up with gravel. Communication through the side conduits
60
or
62
is possible while the barrel valve
118
remains in its opened position. After the gravel packing operation has completed, a flow control device operator, which may be located in the service tool
80
, is moved upwardly to engage, in each packer assembly
56
or
58
, the profile
136
(
FIG. 2B
) of the actuator sleeve
122
to move the actuator sleeve
122
upwardly. This causes the barrel valve
118
to close, as illustrated in FIG.
3
B. As a result, further fluid communication through each side conduit
60
or
62
between different zones is shut off. When the flow control device operator is further moved upwardly, the operator is disengaged from the latch profile
136
of the actuator sleeve
122
, which allows springs
146
and
150
to push the control rod
144
and actuating ring
142
back to their initial, relaxed positions. This allows re-actuation of the barrel valve
118
if desired.
In accordance to further embodiments, other arrangements of the flow control devices may be used. For example, flow control devices may be placed at strategic locations along each alternate path conduit to control fluid communication between various portions of a wellbore. Some of the flow control devices may be run into the wellbore in the open position, while others are run into the wellbore in the closed position. After predetermined tasks are performed, some of the flow control devices may be actuated open while others closed. In further embodiments, a flow control device actuator may be operatively coupled to more than one flow control device so that the actuator can actuate multiple flow control devices at the same time.
In other embodiments, different forms of actuators may be used to operate the barrel valves. For example, a hydraulic or electrical actuating system may be used. Further, different types of valves may be used in the side conduits, such as ball valves, sleeve valves, flapper valves, and so forth.
A completion string has been described that includes a main conduit, such as production tubing, and one or more alternate path conduits, such as shunt tubes and side conduits in packer assemblies. Flow control devices are placed in each alternate path conduit to control fluid flow. The flow control devices may be adjustable between at least an open position and a closed position. If desired, each flow control device may also be adjusted to an intermediate choke position. In one application, the alternate path conduits are used to carry gravel slurry during gravel packing operations. After desired portions of the well have been packed with gravel, the flow control devices may be actuated from the open position to the closed position to block fluid communication through the alternate path conduits. This avoids or reduces commingling of fluids between different portions or zones in the well.
While the invention has been disclosed with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of the invention.
Claims
- 1. An apparatus for use in a wellbore, comprising:a main conduit; a plurality of shunt conduits; and a plurality of flow control devices positioned in corresponding shunt conduits to control flow through the shunt conduits.
- 2. The apparatus of claim 1, wherein each shunt conduit includes a shunt tube.
- 3. An apparatus for use in a wellbore, comprising:a main conduit; a shunt conduit; a flow control device positioned in the shunt conduit to control flow through the shunt conduit, wherein the shunt conduit extends between at least two zones in the wellbore, the flow control device adapted to be actuated to a closed position to block fluid communication between the two zones through the shunt conduit, and wherein the shunt conduit includes a shunt tube having at least one side port in fluid communication with at least one of the zones.
- 4. The apparatus of claim 3, wherein the shunt tube is adapted to carry gravel slurry to each of the at least two zones.
- 5. The apparatus of claim 3 further comprising a packer assembly including the main conduit and the shunt conduit.
- 6. The apparatus of claim 3, wherein the flow control device includes a valve actuatable between at least an open position and a closed position.
- 7. The apparatus of claim 6, wherein the valve includes a barrel valve.
- 8. The apparatus of claim 3, wherein the main conduit includes a production tubing.
- 9. Add The apparatus of claim 8, wherein the shunt conduit is attached to the production tubing.
- 10. The apparatus of claim 3, further comprising at least one other shunt tube.
- 11. The apparatus of claim 3, wherein the shunt tube has a plurality of ports in communication with at least one of the zones.
- 12. The apparatus of claim 3, wherein the shunt tube is adapted to extend to a location above the at least two zones.
- 13. The apparatus of claim 3, wherein the shunt tube is adapted to carry fluid from above the at least two zones to the at least two zones if the flow control device is open.
- 14. A method of controlling fluid communication in a wellbore, comprising:providing a main conduit and a shunt conduit, the shunt conduit having ports to plural zones in the wellbore; providing a flow control device in the shunt conduit; actuating the flow control device between at least an open and a closed position to control fluid flow in the shunt conduit; opening the flow control device to enable communication of fluid through the shunt conduit and out the ports to the zones; and closing the flow control device to prevent communication between zones.
- 15. The method of claim 14, further comprising providing at least one other shunt conduit and one other flow control device.
- 16. The method of claim 14, further comprising flowing production fluid through the main conduit and flowing another type of fluid through the shunt conduit.
- 17. The method of claim 16, wherein flowing the other type of fluid includes flowing a fluid containing gravel slurry.
- 18. The method of claim 16, wherein flowing the other type of fluid includes flowing a fracturing fluid.
- 19. The method of claim 14, wherein actuating the flow control device includes actuating a barrel valve.
- 20. The method of claim 14, wherein providing the shunt conduit comprises extending the shunt conduit from above the plural zones to each of the plural zones.
- 21. A completion string for use in a wellbore, comprising:a tubing; a packer attached to the tubing to divide the wellbore into a first zone and a second zone; a shunt conduit next to the tubing, the shunt conduit having at least a first side port to communicate with the first zone and at least a second side port to communicate with the second zone, the shunt tube adapted to carry fluid for communication through the first and second side ports to respective first and second zones; and a flow control device in the shunt conduit to control flow through the shunt conduit, the flow control device adapted to be opened to communicate the fluid to the first and second zones from the shunt conduit, and the flow control device adapted to be closed to prevent communication between the zones.
- 22. The completion string of claim 21, further comprising at least another shunt conduit.
- 23. The completion string of claim 21, wherein the shunt conduit includes a shunt tube.
- 24. The completion string of claim 21, wherein the shunt conduit is adapted to extend from above the first and second zones to each of the first and second zones.
- 25. The completion string of claim 21, wherein the packer includes a first conduit in communication with the tubing and a second conduit in communication with the shunt conduit.
- 26. The completion string of claim 21, further comprising at least one other packer attached to the tubing and isolating a third zone, wherein the shunt conduit extends to the first, second, and third zones.
- 27. The completion string of claim 26, further comprising at least another flow control device to control flow through the shunt conduit between the second and third zones.
- 28. The completion string of claim 21, wherein the shunt conduit is adapted to carry gravel slurry to gravel pack the first and second zones.
- 29. The completion string of claim 21, wherein the shunt conduit is adapted to carry fracturing fluid to fracture formation proximal the first and second zones.
- 30. An apparatus for use in a wellbore, comprising:a production tubing; a plurality of shunt conduits; and a packer assembly including a first conduit in communication with the production tubing and a plurality of second conduits in communication with the shunt conduits, the packer assembly further including flow control devices in corresponding shunt conduits, each flow control device actuatable between at least an open position and a closed position.
- 31. The apparatus of claim 30, wherein the shunt conduits comprise shunt tubes.
- 32. The apparatus of claim 30, wherein each shunt conduit has at least one port communicating with a respective one of the plural zones isolated by the packer assembly.
- 33. The apparatus of claim 32, wherein each shunt conduit is adapted to carry one of gravel slurry and fracturing fluid to communicate through the ports to the zones.
- 34. An apparatus for use in a wellbore, comprising:a main conduit; a shunt tube; and a flow control device in the shunt tube to control flow through the shunt tube.
- 35. The apparatus of claim 34, further comprising at least one other shunt tube and one other flow control device in the one other shunt tube.
- 36. The apparatus of claim 34, wherein the shunt tube has an inlet and at least one side port.
- 37. The apparatus of claim 36, wherein the shunt tube has a plurality of side ports.
- 38. The apparatus of claim 37, wherein the wellbore has plural zones, and wherein the plurality of side ports are adapted to communicate with the plural zones.
- 39. An apparatus for use in a wellbore having plural zones, comprising:a main conduit; an alternate path conduit, the alternate path conduit having plural side ports to communicate fluid from the alternate path conduit to at least two of the plural zones; and a flow control device in the alternate path conduit to control fluid flow in the alternate path conduit.
- 40. The apparatus of claim 39, wherein the alternate path conduit has an inlet to receive gravel slurry, the alternate path conduit adapted to deliver the gravel slurry through the side ports to the at least two of the plural zones.
- 41. A method of gravel packing a zone in a wellbore, comprising:providing a shunt conduit extending beside a main conduit, the shunt conduit extending to the zone; injecting a gravel slurry into the shunt conduit; and actuating a flow control device in the shunt conduit to control flow of the gravel slurry through the shunt conduit to the zone.
- 42. The method of claim 41, wherein providing the shunt conduit comprises providing a shunt tube.
- 43. The method of claim 41, further comprising the shunt conduit to at least one other zone in the wellbore to flow gravel slurry to the one other zone.
- 44. The method of claim 43, further comprising providing plural side ports to communicate the gravel slurry from inside the shunt conduit to the plural zones.
- 45. An apparatus for use in a wellbore, comprising:a main conduit; a shunt conduit; a flow control device positioned in the shunt conduit to control flow through the shunt conduit, wherein the flow control device includes a barrel valve actuatable between at least an open position and a closed position; and an actuating member and a ratchet mechanism coupling the actuating member to the barrel valve.
- 46. The apparatus of claim 45, wherein the actuating member engages the barrel valve when moving in a first direction.
- 47. The apparatus of claim 46, wherein the ratchet mechanism allows the actuating member to return to a second position without moving the barrel valve.
US Referenced Citations (12)