Patent Grant
9133697
This invention relates to resource production, and more particularly to resource production using heated fluid injection into a subterranean zone.
Fluids in hydrocarbon formations may be accessed via wellbores that extend down into the ground toward the targeted formations. In some cases, fluids in the hydrocarbon formations may have a low enough viscosity that crude oil flows from the formation, through production tubing, and toward the production equipment at the ground surface. Some hydrocarbon formations comprise fluids having a higher viscosity, which may not freely flow from the formation and through the production tubing. These high viscosity fluids in the hydrocarbon formations are occasionally referred to as “heavy oil deposits.” In the past, the high viscosity fluids in the hydrocarbon formations remained untapped due to an inability to economically recover them. More recently, as the demand for crude oil has increased, commercial operations have expanded to the recovery of such heavy oil deposits.
In some circumstances, the application of heated treatment fluids (e.g., steam and/or solvents) to the hydrocarbon formation may reduce the viscosity of the fluids in the formation so as to permit the extraction of crude oil and other liquids from the formation. The design of systems to deliver the steam to the hydrocarbon formations may be affected by a number of factors.
Systems and methods of producing fluids from a subterranean zone can include downhole fluid heaters (including steam generators) alone or in conjunction with artificial lift systems such as pumps (e.g., electric submersible, progressive cavity, and others), gas lift systems, and other devices. Supplying heated fluid from the downhole fluid heater(s) to a target subterranean zone such as a hydrocarbon-bearing formation or cavity can reduce the viscosity of oil and/or other fluids in the target formation.
Configuring systems such that loss of surface, wellbore, or supply (e.g., treatment fluid supply) pressure causes control valves in downhole fluid heater supply lines (e.g., treatment fluid, fuel, and/or oxidant lines) to close can reduce the possibility that downhole combustion will continue after a system failure. Control valves that are disposed downhole (rather than at the surface) can reduce the amount of fluids (e.g., treatment fluid, fuel, and/or oxidant) that flows out of the supply lines. In some instances, the control valves can be passive control valves biased towards a closed position and opened by application of specified pressure. Pressure changes due to, for example, failure of a well casing can cause the valve to close without relying signals from the surface. In some instances, hydraulically or electrically operated valves can be operated by local (e.g., downhole) or remote (e.g., surface) control systems in response to readings from downhole pressure sensors.
In one aspect, systems include: a downhole fluid heater having a treatment fluid inlet, an oxidant inlet and a fuel inlet; and a downhole control valve in communication with one of the treatment fluid inlet, oxidant inlet or fuel inlet of the downhole fluid heater, the downhole control valve responsive to change flow to the inlet based at least on pressure in the wellbore.
Such systems can include one or more of the following features.
In some embodiments, systems also include a seal disposed between the downhole fluid heater and the control valve, the seal adapted to contact a wall of the wellbore and hydraulically isolate a portion of the wellbore above the seal from a portion of the wellbore below the seal. In some cases, systems also include a second seal opposite the control valve from the first mentioned seal, the second seal adapted to contact the wall of the wellbore and hydraulically isolate a portion of the wellbore above the second seal from a portion of the wellbore below the second seal; and a conduit in communication with a space between the first mentioned seal and the second mentioned seal and adapted to provide pressure to the wellbore between the first mentioned seal and the second mentioned seal. The conduit can be in communication with a treatment fluid supply adapted to provide treatment fluid to the downhole fluid heater.
In some embodiments, the downhole control valve further comprises a moveable member movable to change the flow to the inlet at least in part by a pressure differential between the flow to the inlet and pressure in the wellbore.
In some embodiments, the downhole control valve is in communication with the fuel inlet; and the system also includes a second downhole control valve in communication with one of the treatment fluid inlet or oxidant inlet of the downhole fluid heater.
In some embodiments, the downhole control valve is in communication with one of the oxidant inlet or fuel inlet of the downhole fluid heater, and the downhole control valve is responsive to change the fuel and oxidant ratio based at least on pressure in the wellbore.
In some embodiments, the downhole control valve is proximate the downhole fluid heater.
In some embodiments, the control valve is a control valve responsive to cease flow to the inlet based on a loss of pressure in the wellbore.
In some embodiments, the downhole fluid heater comprises a downhole steam generator.
In one aspect, systems include: a downhole fluid heater installed in a wellbore; treatment fluid, oxidant, and fuel conduits connecting fuel, oxidant and treatment fluid sources to the downhole fluid heater; and a downhole fuel control valve in communication with the fuel conduit configured to change flow to the downhole fluid heater in response to a changes of pressure in a portion of the wellbore.
Such systems can include one or more of the following features.
In some embodiments, systems also include a seal disposed between the downhole fluid heater and the fuel shutoff valve, the seal sealing against axial flow in the wellbore, and wherein the downhole fuel control valve is configured to change flow to the downhole fluid heater in response to a loss of pressure above the seal. In some cases, systems also include a second seal disposed uphole of the fuel shutoff valve, the second seal sealing against axial flow in the wellbore, and wherein the treatment fluid conduit is hydraulically connected to a portion of the wellbore defined in part between the first mentioned seal and the second seal.
In some embodiments, the downhole fuel shutoff valve comprises a moveable member movable at least in part by pressure in the wellbore to change flow through the fuel conduit.
In some embodiments, systems also include a second downhole control valve in communication with the treatment fluid or the oxidant conduit and responsive to pressure in the portion of the wellbore.
In some embodiments, the downhole fluid heater comprises a downhole steam generator.
In one aspect, methods include: receiving, at downhole fluid heater in a wellbore, flows of treatment fluid, oxidant, and fuel; and with a downhole valve responsive to wellbore annulus pressure, changing the flow of at least one of the treatment fluid, oxidant or fuel.
Such methods can include one or more of the following features.
In some embodiments, changing the flow comprises changing the flow in response to a loss of pressure in the wellbore annulus. In some cases, changing the flow comprises ceasing the flow.
In some embodiments, methods also include applying pressure to a portion of the wellbore proximate the downhole valve, and wherein changing the flow comprises changing the flow in response to a loss of pressure in the wellbore proximate the downhole valve.
In some embodiments, changing the flow comprises changing the flow of at least one of the oxidant or the fuel to change a ratio of oxidant to fuel supplied to the downhole fluid heater.
In some cases, the downhole fluid heater comprises a downhole steam generator.
Systems and methods based on downhole fluid heating can improve the efficiencies of heavy oil recovery relative to conventional, surface based, fluid heating by reducing the energy or heat loss during transit of the heated fluid to the target subterranean zones. Some instances, this can reduce the fuel consumption required for heated fluid generation.
In some instances, downhole fluid heater systems (e.g., steam generator systems) include automatic control valves in the proximity of the downhole fluid heater for controlling the flow rate of water, fuel and oxidant to the downhole fluid heater. These systems can be configured such that loss of surface, wellbore or supply pressure integrity will cause closure of the downhole safety valves and rapidly discontinue the flow of fuel, treatment fluid, and/or oxidant to the downhole fluid heater to provide failsafe downhole combustion or other power release.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
Like reference symbols in the various drawings indicate like elements.
Systems and methods of treating a subterranean zone can include use of downhole fluid heaters to apply heated treatment fluid to the subterranean zone. One type of downhole fluid heater is a downhole steam generator that generates heated steam or steam and heated liquid. Although “steam” typically refers to vaporized water, a downhole steam generator can operate to heat and/or vaporize other liquids in addition to, or as an alternative to, water. Supplying heated treatment fluid from the downhole fluid heater(s) to a target subterranean zone, such as one or more hydrocarbon-bearing formations or a portion or portions thereof, can reduce the viscosity of oil and/or other fluids in the target subterranean zone. In some instances, downhole fluid heater systems include automatic control valves in the proximity of the downhole fluid heater for controlling the flow rate of water, fuel and oxidant to the downhole fluid heater. These systems can be configured such that loss of surface, wellbore or supply pressure integrity will cause closure of the downhole safety valves and rapidly discontinue the flow of fuel, water, and/or oxidant to the downhole fluid heater to provide failsafe downhole combustion or other power release.
Referring to
Supply lines 124a, 124b, and 124c carry fluids from the surface 116 to corresponding inlets 121a, 121b, 121c of the downhole fluid heater 120. For example, in some embodiments, the supply lines 124a, 124b, and 124c are a treatment fluid supply line 124a, an oxidant supply line 124b, and a fuel supply line 124c. In some embodiments, the treatment fluid supply line 124a is used to carry water to the downhole fluid heater 120. The treatment fluid supply line 124a can be used to carry other fluids (e.g., synthetic chemical solvents or other treatment fluid) instead of or in addition to water. In this embodiment, fuel, oxidant, and water are pumped at high pressure from the surface to the downhole fluid heater 120.
Each supply line 124a, 124b, 124c has a downhole control valve 126a, 126b, 126c. In some situations (e.g., if the casing system in the well fails), it is desirable to rapidly discontinue the flow of fuel, oxidant and/or treatment fluid to the downhole fluid heater 120. A valve in the supply lines 124a, 124b, 124c deep in the well, for example in the proximity of the fluid heater, can prevent residual fuel and/or oxidant in the supply lines 124a, 124b, 124c from flowing to the fluid heater, preventing further combustion/heat generation, and can limit (e.g., prevent) discharge of the reactants in the downhole supply lines 124a, 124b, 124c into the wellbore. The downhole control valves 126a, 126b, 126c are configured to control and/or shut off flow through the supply lines 124a, 124b, 124c, respectively, in specified circumstances. Although three downhole control valves 126a, 126b, 126c are depicted, fewer or more control valves could be provided.
A seal 122 (e.g., a packer) is disposed between the downhole fluid heater 120 and control valves 126a, 126b, 126c. The seal 122 may be carried by treatment injection string 112. The seal 122 may be selectively actuable to substantially seal and/or seal against the wall of the wellbore 114 to seal and/or substantially seal the annulus between the wellbore 114 and the treatment injection string 112 and hydraulically isolate a portion of the wellbore 114 uphole of the seal 122 from a portion of the wellbore 114 downhole of the seal 122.
In this embodiment, treatment control valve 126a, fuel control valve 126c and oxidant control valve 126b are deployed at the bottom of the delivery supply lines just above the packer 122. The control valves 126a, 126b, 126c will close unless a minimum pressure is maintained on the wellbore annulus above the packer 122. The annulus of between treatment injection string 112 and the walls (e.g., casing) of wellbore 114 is generally filled with a liquid (e.g., water or a working fluid). As described in greater detail below, the annulus pressure at the valves 126a, 126b, 126c (e.g., the pressure in the annulus at the surface combined with a hydrostatic pressure component) acts on the control valves 126a, 126b, 126c and maintains them in the open position. Thus, a loss in pressure in the annulus will cause the control valves 126a, 126b, 126c to close. The minimum pressure can be selected to allow for minor fluctuations in pressure to prevent accidental actuation of the control valves.
If the required surface pressure is removed, intentionally or unintentionally, the control valves 126a, 126b, 126c will automatically close, shutting off the flow of reactants and water downhole. In an emergency shut-down event, the surface annulus pressure source can be intentionally disconnected to disrupt reactant flow downhole. This particular embodiment requires no additional communication, power source etc. to be connected to the downhole valves in order for them to close.
Additionally, if hydrostatic pressure is lost, the control valves 126a, 126b, 126c will close thereby interrupting the flow of reactants downhole. Loss of working fluid from the annulus due to casing, supply tubing or packer leaks could cause this situation to occur.
A well head 117 may be disposed proximal to the surface 116. The well head 117 may be coupled to a casing 115 that extends a substantial portion of the length of the wellbore 114 from about the surface 116 towards the subterranean zone 110 (e.g., the subterranean interval being treated). The subterranean zone 110 can include part of a formation, a formation, or multiple formations. In some instances, the casing 115 may terminate at or above the subterranean zone 110 leaving the wellbore 114 un-cased through the subterranean zone 110 (i.e., open hole). In other instances, the casing 115 may extend through the subterranean zone and may include apertures 119 formed prior to installation of the casing 115 or by downhole perforating to allow fluid communication between the interior of the wellbore 114 and the subterranean zone. Some, all or none of the casing 115 may be affixed to the adjacent ground material with a cement jacket or the like. In some instances, the seal 122 or an associated device can grip and operate in supporting the downhole fluid heater 120. In other instances, an additional locating or pack-off device such as a liner hanger (not shown) can be provided to support the downhole fluid heater 120. In each instance, the downhole fluid heater 120 outputs heated fluid into the subterranean zone 110.
In the illustrated embodiment, wellbore 114 is a substantially vertical wellbore extending from ground surface 116 to subterranean zone 110. However, the systems and methods described herein can also be used with other wellbore configurations (e.g., slanted wellbores, horizontal wellbores, multilateral wellbores and other configurations).
The downhole fluid heater 120 is disposed in the wellbore 114 below the seal 122. The downhole fluid heater 120 may be a device adapted to receive and heat a treatment fluid. In one instance, the treatment fluid includes water and may be heated to generate steam. The recovery fluid can include other different fluids, in addition to or in lieu of water, and the treatment fluid need not be heated to a vapor state (e.g. steam) of 100% quality, or even to produce vapor. The downhole fluid heater 120 includes inputs to receive the treatment fluid and other fluids (e.g., air, fuel such as natural gas, or both) and may have one of a number of configurations to deliver heated treatment fluids to the subterranean zone 110. The downhole fluid heater 120 may use fluids, such as air and natural gas, in a combustion or catalyzing process to heat the treatment fluid (e.g., heat water into steam) that is applied to the subterranean zone 110. In some circumstances, the subterranean zone 110 may include high viscosity fluids, such as, for example, heavy oil deposits. The downhole fluid heater 120 may supply steam or another heated treatment fluid to the subterranean zone 110, which may penetrate into the subterranean zone 110, for example, through fractures and/or other porosity in the subterranean zone 110. The application of a heated treatment fluid to the subterranean zone 110 tends to reduce the viscosity of the fluids in the subterranean zone 110 and facilitate recovery to the surface 116.
In this embodiment, the downhole fluid heater is a steam generator 120. Supply lines 124a, 124b, 124c convey gas, water, and air to the steam generator 120. In certain embodiments, the supply lines 124a, 124b, 124c extend through seal 122. In the embodiment of
In some cases, a downhole fluid lift system (not shown), operable to lift fluids towards the ground surface 116, is at least partially disposed in the wellbore 114 and may be integrated into, coupled to or otherwise associated with a production tubing string (not shown). To accomplish this process of combining artificial lift systems with downhole fluid heaters, a downhole cooling system can be deployed for cooling the artificial lift system and other components of a completion system. Such systems are discussed in more detail, for example, in U.S. Pat. App. Pub. No. 2008/0083536 .
Supply lines 124a, 124b, 124c can be integral parts of the production tubing string (not shown), can be attached to the production tubing string, or can be separate lines run through wellbore annulus 128. Although depicted as three separate, parallel flow lines, one or more of supply lines 124a, 124b, 124c could be concentrically arranged within another and/or fewer or more than three supply lines could be provided. One exemplary tube system for use in delivery of fluids to a downhole fluid heater includes concentric tubes defining at least two annular passages that cooperate with the interior bore of a tube to communicate air, fuel and treatment fluid to the downhole heated fluid generator.
Referring to
The moveable member 318 includes an uphole portion 324, a downhole portion 326, and a central portion 328 that has a larger maximum dimension (e.g., diameter) than the uphole portion 324 or the downhole portion 326. The uphole portion 324 of the moveable member 318 is received within and seals against interior surfaces of a narrow portion of the valve body 310 that extends uphole from shoulder 322. The downhole portion 326 of the moveable member 318 is received within and seals against interior surfaces of inner surfaces of downhole connector 316. The moveable member 318 and the valve body 310 together define an annular first cavity 330 on the uphole side of the central portion 328 of the moveable member 318 and an annular second cavity 332 on the downhole side of the central portion 328 of the moveable member 318.
Ports 334 extending through the moveable member 318 provide a hydraulic connection between an interior bore 336 of the moveable member 318 and the second cavity 332. Ports 338 extending through valve body 310 provide a hydraulic connection between the first cavity 330 and the region outside the valve body (e.g., a wellbore in which the valve 300 is disposed).
Ports 335 extending through the uphole portion 324 of the moveable member 318 provide a hydraulic connection between the interior bore 335 of the moveable member 318 and the interior bore 312 of valve body when the valve 300 is in its open position. In use, this hydraulic connection, allows fluids to flow through the valve 300. When the valve is in its closed position, ports 335 are aligned with a wall portion of the valve body and flow is substantially sealed against flowing through ports 335. Sealing members 340 (e.g., o-rings) are received in recesses in the outer surfaces of movable member 318 to sealingly engage the inner surfaces of valve body 310. Closure of the valve 300 substantially limits both uphole and downhole flow through the valve 300. For example, closure of the valve 300 in response to a casing rupture can limit (e.g., prevent) discharge of the reactants in the downhole supply lines 124a, 124b, 124c into the wellbore. In another example, closure of the valve 300 can limit (e.g., prevent) wellbore pressure from causing fluids to flow up the supply lines when annulus pressure is not present.
The net axial pressure forces from wellbore annulus pressure in the first cavity 330 bias the moveable member 318 in a downhole direction (i.e., toward the open position), and the net pressure forces from interior bore pressure in the second cavity bias the moveable member 318 in an uphole direction (i.e., toward the closed position). The resilient member 320 biases moveable member 318 in an uphole direction (i.e., towards the closed position). The area on which wellbore annulus pressure forces are acting on the moveable member 318 in first cavity 330, the area on which internal bore pressure forces are acting on the moveable member 318 in the second cavity 332, and the force exerted by the resilient member 320 on the moveable member 318 are selected to bias the moveable member 318 in a downhole direction (i.e., toward the open position) at a specified pressure differential between the wellbore annulus pressure and the internal bore pressure. In certain instances, the specified pressure differential can be selected based on normal operating conditions of the well system and downhole fluid heater 120, such that if the wellbore annulus pressure drops below normal operating conditions (i.e., a loss in wellbore pressure), the exemplary control valve 300 closes.
Referring to
Although generally similar to that discussed above with reference to
Referring now to
The downhole fluid heater 120 can be activated, receiving treatment fluid, oxidant, and fuel to combust the oxidant and fuel, thus heating treatment fluid (e.g., steam) in the wellbore (step 220). The heated fluid can reduce the viscosity of fluids already present in the target subterranean zone 110 by increasing the temperature of such fluids and/or by acting as a solvent. After a sufficient reduction in viscosity has been achieved, fluids (e.g., oil) are produced from the subterranean zone 110 to the ground surface 116 through the production tubing string (not shown). In some instances, surface, wellbore or supply pressure integrity is lost due, for example, to system failure or the wellbore pressure is changed to change the flow of treatment fluid, oxidant and/or fuel (e.g., to change the ratio of oxidant and fuel). The loss of surface, wellbore or supply pressure integrity allows closure of the downhole safety valves and rapidly discontinue the flow of fuel, treatment fluid, and/or oxidant to the downhole fluid heater to provide failsafe downhole combustion or other power release (step 230).
A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention.
For example, the system can be implemented with a variable flow treatment fluid control valve, variable oxidant fuel control valve and/or variable flow fuel control valve as supply control valves 126a, 126b, 126c. A variable flow control valve is a valve configured to change the amount of restriction through its internal bore in response to specified pressure conditions in the wellbore annulus. For example, the variable flow control valve may be responsive to cycling of pressure up and back down or down and back up in the wellbore annulus, responsive to a specified pressure differential between the valve's internal bore and the wellbore annulus, and/or responsive to other specified pressure conditions. In certain instances, the variable flow control valve can have a full open position (with the least internal restriction) a full closed position (ceasing or substantially ceasing against flow) and one or more intermediate positions of different restriction that can be cycled through in response to the specified pressure conditions.
In some instances, the variable flow control valves are adjusted remotely to change the reactant (fuel and oxidant) mixtures in response to specified pressure conditions in the wellbore annulus. For example, the variable flow control valves can be adjustable using wellbore annulus pressure cycling, pressure differential between the valve's internal bore and the wellbore annulus pressure, and/or other specified pressure conditions to adjust the flow restriction to the fuel inlet and/or the oxidant inlet remotely. In an embodiment using wellbore annulus pressure cycling, the variable flow control valves are adjusted to change the ratio of fuel to oxidant each time the annulus pressure is cycled in a specified manner (e.g., by momentarily raising or lowing the wellbore annulus pressure to a specified pressure). The ratio will remain at a particular setting after the last annulus pressure cycle is finished. A ratchet inside the valve causes incremental changes in the fuel/oxidant for each ratchet position, and the final ratchet position allows the ratio to return to an initial ratio. For example, the initial ratio may correspond to a minimum fuel/oxidant ratio, cycling the wellbore annulus pressure causes the valve to incrementally change ratchet positions and increase the fuel/oxidant ratio in one or more increments, and the final ratchet position returns the ratio from the maximum fuel/oxidant ratio to the minimum fuel/oxidant ratio. Subsequent applications of annulus pressure cycles will incrementally change the fuel oxidant ratio in incremental amounts until the maximum ratio is again reached and then reset back to the minimum ratio. In this way the ratio can be set to any desired level repeatedly. The ratchet technology described above is described in U.S. Pat. No. 4,429,748. Adjusting the fuel/oxidant ratio can be achieved by providing a variable flow fuel control valve as valve 126c and/or a variable flow oxidant control valve as valve 126b. Similar control of the treatment fluid can be achieved by providing a variable flow treatment fluid control valve as valve 126a.
In some embodiments, the fuel, oxidant and treatment fluid supply lines could have both shut off control valves and variable flow control valves, or both variable flow and shut-off positions and control could be incorporated into the same valves. Using a combination of the features of the exemplary embodiments described above and illustrated in Figures primary and secondary valve operation assures safe and effective operation of the downhole combustion and steam generation system under a wide variety of potential downhole and surface conditions.
Accordingly, other embodiments are within the scope of the following claims.
This application is a National Stage application of, and claims the benefit of priority to, PCT/US2008/068816, filed Jun. 30, 2008, which claims the benefit of priority to U.S. Provisional Patent Application No. 60/948,346 filed Jul. 6, 2007, the entirety of both are incorporated by reference herein.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/US2008/068816 | 6/30/2008 | WO | 00 | 11/3/2010 |
| Publishing Document | Publishing Date | Country | Kind |
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| WO2009/009336 | 1/15/2009 | WO | A |
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| Number | Date | Country | |
|---|---|---|---|
| 20110036575 A1 | Feb 2011 | US |
| Number | Date | Country | |
|---|---|---|---|
| 60948346 | Jul 2007 | US |
