Patent Application
20250129688
The present disclosure generally relates to flow control systems, and more specifically to a rotationally movable flow trim for a flow control valve of a downhole control system.
A downhole control system provides zonal control of multiple valves within a wellbore. The downhole control system, via controls provided on the surface, may actuate multiple downhole flow control devices, such as interval control devices (ICVs), in multiple zones. An ICV may regulate fluid flow of a corresponding formation section. For instance, multiple ICVs may be placed in different isolated sections within production tubing to control fluid flow within the tubing section, and to commingle various fluids within the common production tubing interior. As a result, ICVs are able to reduce water cut and gas cut, minimize well interventions, and maximize well productivity. Typically, ICV actuation is accomplished using electrical and hydraulic lines that can be used to control ICV positioning, without the need for reentry to the wellbore. Further, ICVs can include ports for opening or choking fluid flow from different positions of the ICV.
Illustrative embodiments of the present disclosure are described in detail below with reference to the attached drawing figures, which are incorporated by reference herein, and wherein:
The illustrated figures are only exemplary and are not intended to assert or imply any limitation with regard to the environment, architecture, design, or process in which different embodiments may be implemented.
In the following detailed description of the illustrative embodiments, reference is made to the accompanying drawings that form a part hereof. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is understood that other embodiments may be utilized and that logical structural, mechanical, electrical, and chemical changes may be made without departing from the spirit or scope of the invention. To avoid detail not necessary to enable those skilled in the art to practice the embodiments described herein, the description may omit certain information known to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the illustrative embodiments is defined only by the appended claims.
Flow control valves, such as interval control valves (ICVs), are used to precisely control fluid flow at specific intervals. An ICV generally comprises a flow closure member, such as a cylindrical sliding sleeve, that can be moved axially to either open or close flow ports placed on a flow trim thereof. The flow trims, typically formed of carbide, are used to provide production and injection at various choking positions via the flow ports, which may be selectively and adjustably open or closed with the sliding sleeve. It is desirable to have flexibility in ICV choking positions to allow operators better control over various parameters such as flow rate, flow assurance, high pressure drop management, and the like. However, design considerations must also ensure that such conditions are not adversely affected by any additions or modifications to the choking positions.
Typically, the design of the flow trim of an ICV is such that the flow ports have a substantially 90 degree spacing between one another, e.g., along the radial of the flow trim at a longitudinal cross-section. Control valve bypass lines are generally routed between these flow ports (e.g., at substantially 45 degrees radially relative to the ports) along the exterior of the ICV. However, at the flow trim itself, this portion between the flow ports along the same circumference is generally unused.
Embodiments presented herein disclose a flow control valve, such as an ICV, that has a rotationally alternating flow trim port scheme. More specifically, embodiments provide a rotatable flow trim defining a flow port placement at angular offsets along a radial, e.g., at 90 degree placements between each other, thereon and also having one or more additional flow ports placed within the portions in between the 90 degree port placements. For example, assume a first set of flow ports are placed in a 90 degree spacing configuration along a radial of the flow trim. In an embodiment, a second set of flow ports may be placed at the 45 degree marks of the flow trim along the radial. In such a case, the flow trim can then be rotated along its axis to switch between the first set of flow ports or the second set of flow ports to align with flow openings on the exterior of the flow control valve, in which the second set of flow ports is occluded when the first set of flow ports is aligned with the flow openings, and in which the first set of flow ports is occluded when the second set of flow ports is aligned with the flow openings.
Advantageously, providing multiple sets of rotationally alignable flow ports potentially increases the amount of choking positions in the flow trim of the ICV. More particularly, the flow trim can be rotated to a particular alignment at smaller angle increments, e.g., at 45 degree increments, to reach a given position. Further, embodiments of the present disclosure allow an operator, e.g., from a controller console on the surface, to rotate the flow trim to align ports to a desired configuration based on conditions associated with the downhole environment, based on a well plan specifications, based on flow and specified pressure parameters, etc. The operator may conduct such rotation alignment before deployment of a downhole control system to provide an opportunity to determine how the flow trim ports should be configured or aligned in advance. Further, the operator can also rotationally align the flow trim after the downhole control system has deployed to reach all available positions after deployment.
Referring now to
The downhole control system 100 also includes flow control valves 126 and 132. In an embodiment, the flow control valves 126 and 214 may be embodied as an interval control valve (ICV). The flow control valves 126 are 132 are remotely operable. For instance, the flow control valves 126 and 132 can be hydraulically actuated ICVs. As another example, the flow control valves 126 and 132 can be operated with an electric actuator(s) and/or electro-hydraulic actuator(s). In this example, the flow control valve 126 controls flow incoming from the perforation 108. The flow control valve 132 controls flow incoming from the perforation 114. The flow control valve 126 and 132 can be set to one of multiple opening positions for controlling the differential pressure between the formation 116 and the wellbore 120 and/or the flow rate of the inflow from the perforations 108 and 114.
Each of the flow control valves 126 and 132 may comprise a flow trim and flow closure member that is actuatable and otherwise movable between a closed position, in which fluid flow through the flow trims and openings is prevented, and an open position, in which fluid flow through the flow trim and openings is allowed.
In addition to the flow control valves 126 and 132, a downhole gauge and a packer are installed in each zone. As shown,
The controller 150 may determine a flow port setting for the flow control valves 126 and 132 based on downhole conditions and formation attributes in the zones 110 and 112 to be achieved. Flow port settings may be adjusted for example to achieve a certain differential pressure based on open flow openings of the flow control valves 126 and 132. Flow port settings may also be determined to achieve a certain flow rate based on adjusting the opening position of the flow control valves 126 and 132. Further, the flow ports may be adjusted to facilitate inflow or outflow adjustments, such as a “dump flood,” in which one of the zones 110 or 112 has a high pressure of gas, oil, and/or water injecting into the other zone. The flow trim can be adjusted to direct injection of fluid from the zone 110 into the zone 112.
Referring now to
The feed-through packer 220 may isolate adjacent zones (e.g., zones 110 and 112) within the well while allowing for bypass of multiple electrical and/or hydraulic control lines. In an embodiment, the feed-through packer 220 may be representative of the packers 122 and 128 of
The valve control system 224 incorporates one or more modules to enable choking and selective flow control to and from multiple zones (e.g., zones 110 and 112) with a minimum number of surface control lines. The valve control system 224 may be coupled with the controller 150 on the surface, e.g., via control lines running down thereto. The valve control system 224 may receive control signals used to control a sliding sleeve mechanism to restrict or allow flow in the ICV 226. As further described herein, in an embodiment, the valve control system 225 may also receive control signals to axially rotate a flow trim of the ICV 226 to align flow ports with flow openings of the ICV.
In an embodiment, the ICV 226 controls fluid flow to and from a given zone in the downhole environment. The ICV 226 generally includes a valve body, which is a housing that includes a sliding sleeve and other internal components. When actuated, e.g., via the controller 150 on the surface, the sliding sleeve moves to a desired position. The sliding sleeve moves along the length of the valve body such that when positioned over a flow port and/or opening of the valve body, fluid is able to flow through the port and/or opening. The ICV 226 may also include one or more communication ports to allow for monitoring and control of the position and operation thereof.
The sliding sleeve 304 is movably disposed within the central flow passage 300. The sliding sleeve 304 is axially movable within the body 302 between a first or “closed” position (i.e., the minimal flow condition of the ICV 226) and a second or “open” position (i.e., the maximal flow condition of the ICV 226). In commencing production or injection operations using the downhole control system 100, the sliding sleeve 304 may be actuated to initiate movement from the closed position to the open position. In other embodiments, the sliding sleeve 304 may be actuated in the opposite direction to move the sliding sleeve 304 to the open position.
In other embodiments, a rotating sleeve, a sliding plug, a rotating ball, an oscillating vane, an opening pocket, an opening window, or a valve capable of actuating the ICV 226 between the maximal and minimal conditions may be used as a flow closure member in place of the sliding sleeve 304. The sliding sleeve 304 may be selectively actuated between the first and second positions (and any position therebetween) using any suitable actuation device. In some embodiments, for example, the sliding sleeve 304 may be axially moved within the body 302 using a hydraulic actuation device. In other embodiments, the sliding sleeve 304 may be actuated with a mechanical, electromechanical, or pneumatic actuation device. The sliding sleeve 304 may further be selectively actuated from a remote location, such as the surface, e.g., via the controller 150.
The ICV 226 may further include an upper seal 303a and lower seal 303b positioned within the central flow passage 300 on opposing axial ends of openings exposed by the exterior of the body 302. The upper seal 303a interposes the body 302 and the sliding sleeve 304 when the ICV 226 is in a fully closed position. When in radial contact with the sliding sleeve, the upper and lower seals 303a,b operate to sealingly engage the sliding sleeve 304 such that fluid migration past the upper and lower seals 303a,b in either axial direction is substantially prevented.
In an embodiment, the flow trim 306 is positioned within the central flow passage 300. The illustrative flow trim 306 may be made of an erosion-resistant material such as, but not limited to, a carbide grade (e.g., tungsten, titanium, tantalum, vanadium, etc.), a carbide embedded in a matrix of cobalt or nickel by sintering, a ceramic, a surface hardened metal (e.g., nitride metals, heat-treated metals, carburized metals, etc.), a surface coated metal, a cermet-based material, a metal matrix composite, a nanocrystalline metallic alloy, an amorphous alloy, a hard metallic alloy, diamond, or any combination thereof. In an embodiment, a pin or similar object (or series thereof) may engage with the flow trim 306 to lock the flow trim 306 in place relative to the body 302 to prevent rotational movement of the flow trim 306 during injection or production operations.
In an embodiment, the flow trim 306, as described relative to
In an embodiment, each flow port 406, 412, and 414 may comprise a slot that is defined along a radial portion of a longitudinal cross-section of the flow trim 306 (e.g., about the circumference of the body 302). Although
When the flow trim 306 is installed in the ICV 226, at least a portion of the flow ports 406, 412, and/or 414 may generally coincide and otherwise align with the openings 301 and thus enable fluid flow through the ICV either into or out of the downhole control system 100, while other flow ports remain occluded and block flow through that port. In an embodiment, the flow trim 306 is rotatable along its axis to align the first set of flow ports 406 and 412 or second set of flow ports 414 with the openings 301. For example, prior to deployment of the flow control system 100, an operator may evaluate the formation from the surface to identify an optimal flow port alignment configuration in the flow trim 306 and subsequently rotate the flow trim 306 according to that alignment configuration. As another example, following deployment of the flow control system 100, the operator may also rotate the flow trim 306 (e.g., via the controller 150) to obtain a more suitable alignment with the openings 301 after having observed conditions in real-time. To accomplish this, the flow trim 306 may be coupled with one or more control lines from the surface. The valve control system 224 may receive and process control signals from the controller 150 via the control lines and cause the flow trim 306 to rotate to the specified configuration. For example, the signals may cause locking pins to disengage from the flow trim 306, rotate the flow trim 306 to the specified configuration, and reengage the flow trim 306 with the body 302 using the locking pins. In other embodiments, the flow trim 306 may be rotated by other implements, such as a mechanical push rod or an electrical signal to an electromechanical adjuster mechanism.
Advantageously, the rotational scheme for a flow trim having alternative port configurations at different angle increments allows for greater flexibility for an operator in terms of advanced planning for the well completion given the time traditionally required to custom design a flow trim in light of observed wellbore conditions and operational requirements. Embodiments of the present disclosure allow an operator to selectively alternate between different flow port configurations (and thus flow trim configurations) in considerably less time before and after deployment. In addition, the operator may select alternate configurations over the course of the well completion, e.g., selecting a flow port configuration in which flow ports 406 and 412 are exposed (and flow ports 414 occluded) during an early life phase and subsequently selecting a configuration in which flow ports 414 are exposed (and flow ports 412 occluded) during a late life phase.
Referring now to
In block 504, the controller 150 selects a flow port alignment configuration for the ICV 226 based on the identified initial downhole conditions, formation attributes, and operational specifications. For example, the controller 150 may receive, via a user interface, control commands from the user specifying the flow port alignment, e.g., by selecting one from a number of possible alignment configurations provided by the user interface. In an embodiment, the controller 150 may apply one or more predefined rules for selecting one from a number of possible alignment configurations based on the downhole conditions and formation attributes. Specifications on which the alignment configuration could be based include, differential pressure settings, flow rate, adjustments to inflow or outflow, and so on.
In block 506, the controller 150 rotates the flow trim 306 according to the selected flow port alignment configuration such that the flow ports associated with the configuration are in alignment with the lateral flow openings of the valve exterior. To do so, the controller 150 may transmit a signal via a control line coupled with the ICV 226 to cause the flow trim to rotate according to the selected flow port configuration. In an embodiment, an operator may manually rotate the flow trim 306 via a function on the user interface. Flow sensors coupled with the ICV 226 may determine whether a certain set of flow ports is currently in alignment with the lateral flow openings of the exterior of the valve.
The above-disclosed embodiments have been presented for purposes of illustration and to enable one of ordinary skill in the art to practice the disclosure, but the disclosure is not intended to be exhaustive or limited to the forms disclosed. Many insubstantial modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. For instance, although the flowcharts depict a serial process, some of the steps/processes may be performed in parallel or out of sequence, or combined into a single step/process. The scope of the claims is intended to broadly cover the disclosed embodiments and any such modification. Further, the following clauses represent additional embodiments of the disclosure and should be considered within the scope of the disclosure.
Clause 1 includes a flow control valve, comprising a body defining a central flow passage and one or more lateral flow openings for fluid communication between the central flow passage and an exterior of the body; and a flow trim positioned within the central flow passage and defining at least a first and a second plurality of flow ports, the first plurality of flow ports each defined along a radial portion of a longitudinal cross-section of the flow trim, and the second plurality of flow ports each defined along the radial portion and between a respective pair of the first plurality of flow ports, wherein the flow trim is rotationally movable to align one of the first plurality of flow ports or the second plurality of flow ports with the one or more lateral flow openings.
Clause 2 includes the subject matter of Clause 1, and wherein each of the first plurality of flow ports is defined at an angle offset between one another.
Clause 3 includes the subject matter of any of Clauses 1 and 2, and wherein the angle offset defining the first plurality of flow ports is a substantially 90 degree offset.
Clause 4 includes the subject matter of any of Clauses 1-3, and wherein each of the second plurality of flow ports is defined at an angle offset between one another.
Clause 5 includes the subject matter of any of Clauses 1-4, and wherein each of the second plurality of flow ports is defined at a 45 degree offset between the respective pair of the first plurality of flow ports.
Clause 6 includes the subject matter of any of Clauses 1-5, and further including a control line to receive control signals for rotating the flow trim to align the one of the first plurality of flow ports or the second plurality of flow ports with the one or more lateral flow openings.
Clause 7 includes the subject matter of any of Clauses 1-6, and further including a flow closure member positioned within the central flow passage and movable between a closed position, wherein the one or more lateral flow openings and the first and second plurality of flow ports are occluded to prevent fluid flow through the one or more lateral flow openings, and an open position, wherein the one or more lateral flow openings and the first or second plurality of flow ports are at least partially exposed to facilitate fluid flow through the one or more lateral flow openings.
Clause 8 includes the subject matter of any of Clauses 1-7, and wherein the flow closure member is one of a sliding sleeve or a rotating sleeve.
Clause 9 includes the subject matter of any of Clauses 1-8, and wherein the flow control trim comprises an annular wall.
Clause 10 includes the subject matter of any of Clauses 1-9, and wherein the flow control valve comprises an interval control valve (ICV).
Clause 11 includes the subject matter of any of Clauses 1-10, and wherein the second plurality of flow ports is occluded when the first plurality of flow ports is aligned with the one or more lateral flow openings, and wherein the first plurality of flow ports is occluded when the second plurality of flow ports is aligned with the one or more lateral flow openings.
Clause 12 includes a flow control system comprising a flow control valve comprising a body defining a central flow passage and one or more lateral flow openings for fluid communication between the central flow passage and an exterior of the body; and a flow trim positioned within the central flow passage and defining at least a first and a second plurality of flow ports, the first plurality of flow ports each defined along a radial portion of a longitudinal cross-section of the flow trim, and the second plurality of flow ports each defined along the radial portion and between a respective pair of the first plurality of flow ports, wherein the flow trim is rotationally movable to align one of the first plurality of flow ports or the second plurality of flow ports with the one or more lateral flow openings; and a controller configured to transmit control signals to the flow control valve to rotate the flow trim to align the one of the first plurality of flow ports or the second plurality of flow ports with the one or more lateral flow openings.
Clause 13 includes the subject matter of Clause 12, and wherein each of the first plurality of flow ports is defined at an angle offset between one another.
Clause 14 includes the subject matter of any of Clauses 12 and 13, and wherein the angle offset defining the first plurality of flow ports is a substantially 90 degree offset.
Clause 15 includes the subject matter of any of Clauses 12-14, and wherein each of the second plurality of flow ports is defined at an angle offset between one another.
Clause 16 includes the subject matter of any of Clauses 12-15, and wherein each of the second plurality of flow ports is defined at a 45 degree offset between the respective pair of the first plurality of flow ports.
Clause 17 includes the subject matter of any of Clauses 12-16, and further including a control line coupled with the flow control valve to receive, from the controller, control signals for rotating the flow trim to align the one of the first plurality of flow ports or the second plurality of flow ports with the one or more lateral flow openings.
Clause 18 includes the subject matter of any of Clauses 12-17, and further including a flow closure member positioned within the central flow passage and movable between a closed position, wherein the one or more lateral flow openings and the first and second plurality of flow ports are occluded to prevent fluid flow through the one or more lateral flow openings, and an open position, wherein the one or more lateral flow openings and the first or second plurality of flow ports are at least partially exposed to facilitate fluid flow through the one or more lateral flow openings, and wherein the flow closure member is one of a sliding sleeve or a rotating sleeve.
Clause 19 includes the subject matter of any of Clauses 12-18, and wherein the flow control valve comprises an interval control valve (ICV).
Clause 20 includes the subject matter of any of Clauses 12-19, and wherein the second plurality of flow ports is occluded when the first plurality of flow ports is aligned with the one or more lateral flow openings, and wherein the first plurality of flow ports is occluded when the second plurality of flow ports is aligned with the one or more lateral flow openings.
As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprise” and/or “comprising,” when used in this specification and/or in the claims, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. In addition, the steps and components described in the above embodiments and figures are merely illustrative and do not imply that any particular step or component is a requirement of a claimed embodiment.
