This invention relates, in general, to equipment utilized in conjunction with operations performed in subterranean wells and, in particular, to a flow control screen assembly that is operable to control the inflow of formation fluids and selectively operable to prevent reverse flow of fluids into the formation.
Without limiting the scope of the present invention, its background will be described with reference to producing fluid from a hydrocarbon bearing subterranean formation, as an example.
During the completion of a well that traverses a hydrocarbon bearing subterranean formation, production tubing and various completion equipment are installed in the well to enable safe and efficient production of the formation fluids. For example, to prevent the production of particulate material from an unconsolidated or loosely consolidated subterranean formation, certain completions include one or more sand control screens positioned proximate the desired production intervals. In other completions, to control the flow rate of production fluids into the production tubing, it is common practice to install one or more flow control devices within the tubing string.
Attempts have been made to utilize fluid flow control devices within completions requiring sand control. For example, in certain sand control screens, after production fluids flows through the filter medium, the fluids are directed into a flow control section. The flow control section may include one or more flow restrictors such as flow tubes, nozzles, labyrinths or the like. Typically, the production rate through these flow control screens is fixed prior to installation by individually adjusting the flow restrictors of the flow control screens.
It has been found, however, that the during the completion process, it may be desirable to pressure up the completion string to operate or set certain tools, such as packers. Current flow control screens require the running of a separate work string into the completion string to achieve this result or require that one or more permanent check valves be incorporated into each of the flow control screens. In addition, it has been found, that it may desirable to allow reverse flow from the completion string into the formation in certain completions requiring fluid flow control, sand control and tools setting capabilities.
Accordingly, a need has arisen for a flow control screen that is operable to control the inflow of formation fluids in a completion requiring sand control. A need has also arisen for such a flow control screen that is operable to be pressured up during the completion process. Further, a need has arisen for such a flow control screen that is operable to selectively allow reverse flow from the completion string into the formation.
The present invention disclosed herein comprises a flow control screen for controlling the inflow of formation fluids in completions requiring sand control. In addition, the flow control screen of the present invention is operable to be pressured up during the completion process. Further, the flow control screen of the present invention is operable to selectively allow reverse flow from the completion string into the formation.
In one aspect, the present invention is directed to a flow control screen having a fluid flow path between a perforated section of a base pipe and a filter medium positioned around a blank pipe section of the base pipe. The flow control screen comprises at least one valve assembly disposed within the fluid flow path. The valve assembly includes a piston body and a valve plug. The piston body has an internal seat and a collet assembly that is radially outwardly constrained in a first operating position of the piston body to retain the valve plug therein and radially outwardly unconstrained in a second operating position of the piston body. Reverse flow is initially prevented as an internal differential pressure seats the valve plug on the internal seat and causes the piston body to shift from the first operating position to the second operating position upon reaching a predetermined internal differential pressure. Thereafter, an external differential pressure causes the valve plug to be expelled through the collet assembly, thereby no longer preventing reverse flow.
In one embodiment, the valve assembly further includes a retainer sleeve that radially outwardly constrains the collet assembly in the first operating position of the piston body. In this embodiment, the piston assembly may be slidably positioned within an axial opening of a housing member of the flow control screen. Also, in this embodiment, the piston assembly and the housing member may be initially secured together with a retainer pin that prevents movement of the piston body from the first operating position to the second operating position until the predetermined internal differential pressure acts on the valve plug.
In another embodiment, the valve assembly further includes a cylinder assembly that radially outwardly constrains the collet assembly in the first operating position of the piston body but does not radially outwardly constrain the collet assembly in the second operating position of the piston body. In this embodiment, the piston assembly may be slidably positioned within the cylinder assembly. Also, in this embodiment, the piston assembly and the cylinder assembly may be initially secured together with a retainer pin that prevents movement of the piston body from the first operating position to the second operating position until the predetermined internal differential pressure acts on the valve plug.
In one embodiment, the valve plug may be in the form of a spherical blocking member. In another embodiment, the collet assembly may include a plurality of collet fingers having radially inwardly projecting lips. In a further embodiment, the collet assembly may include a plurality of collet fingers having radially outwardly projecting lips. In yet another embodiment, the flow control screen may include a fluid flow control section in the fluid flow path that causes a pressure drop in fluids traveling therethrough. In an additional embodiment, the flow control screen may include at least one reentry barrier in the fluid flow path operable to prevent reentry of the valve plug into the piston body.
In another aspect, the present invention is directed to a flow control screen having a fluid flow path between a perforated section of a base pipe and a filter medium positioned around a blank pipe section of the base pipe. The flow control screen comprises a plurality of circumferentially distributed valve assemblies disposed within the fluid flow path. Each valve assembly includes a piston body and a valve plug. Each piston body has an internal seat and a collet assembly that is radially outwardly constrained in a first operating position of the piston body to retain the valve plug therein and radially outwardly unconstrained in a second operating position of the piston body. Reverse flow is initially prevented as an internal differential pressure seats the valve plugs on the internal seats and causes the piston bodies to shift from the first operating position to the second operating position upon reaching a predetermined internal differential pressure. Thereafter, an external differential pressure causes the valve plugs to be expelled through the collet assemblies, thereby no longer preventing reverse flow.
In a further aspect, the present invention is directed to a method for operating a flow control screen. The method includes disposing at least one valve assembly within a fluid flow path between a perforated section of a base pipe and a filter medium positioned around a blank pipe section of the base pipe; retaining a valve plug within a piston body of the valve assembly by radially outwardly constraining a collet assembly in a first operating position of the piston body; applying an internal differential pressure to seat the valve plug on an internal seat of the piston body to prevent reverse flow; applying a predetermined internal differential pressure on the valve plugs to shift the piston body from the first operating position to a second operating position while continuing to prevent reverse flow; and applying an external differential pressure to expel the valve plug through the collet assembly, thereby no longer preventing reverse flow.
The method may also include using a retainer sleeve to radially outwardly constrain the collet assembly in a first operating position of the piston body, using a cylinder assembly to radially outwardly constrain the collet assembly in a first operating position of the piston body, shearing a retainer pin responsive to application of the predetermined internal differential pressure to shift the piston body from the first operating position to the second operating position or preventing reentry of the valve plug into the piston body with at least one reentry barrier disposing within the fluid flow path between the perforated section of the base pipe and the at least one valve assembly.
For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:
While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the present invention.
Referring initially to
Positioned within wellbore 12 and extending from the surface is a tubing string 22. Tubing string 22 provides a conduit for formation fluids to travel from formation 20 to the surface. At its lower end, tubing string 22 is coupled to a completions string that has been installed in wellbore 12 and divides the completion interval into various production intervals adjacent to formation 20. The completion string includes a plurality of flow control screens 24, each of which is positioned between a pair of packers 26 that provides a fluid seal between the completion string 22 and wellbore 12, thereby defining the production intervals.
Flow control screens 24 serve the primary functions of filtering particulate matter out of the production fluid stream and controlling the flow rate of the production fluid stream. In addition, as discussed in greater detail below, flow control screens 24 are operable to be pressured up during installation of the completion string. For example, when the completion string is positioned in the desired location in wellbore 12, internal pressure may be used to set packers 26 to divide the completion interval into the desired number of production intervals. During this setting process, flow control screens 24 are in their running configuration in which they are operable to hold pressure for repeated cycles as long as the pressure remains below a predetermined threshold pressure. Once all pressure operated completion components are set or during the setting of the final pressure operated completion component, the internal pressure may be raised above the predetermined threshold pressure to operate flow control screens 24 into their sheared configuration. In this configuration, flow control screens continue to hold pressure, however, when the internal pressure is released and the differential pressure across flow control screens 24 is positive between the outside and inside of flow control screens 24, flow control screens 24 are operated to their production configuration.
Even though
Referring next to
Positioned in the annular region between housing sleeve 118 and base pipe 102 is a split ring spacer 126. Positioned within a plurality of axial openings 128 in flow tube housing 120 are flow tubes 130 that form a fluid flow control section of flow control screen 100. As best seen in
Positioned within a plurality of axial openings 146 in intermediate housing 122 are valve assemblies 136 that form a reverse fluid flow control section of flow control screen 100. As best seen in
Valve plugs 140 are depicted as spherical blocking members and are initially allowed to move within piston body 148 between shoulder 160 and lips 158, as best seen in
When it is desired to operate flow control screens 100 from the running configuration to the sheared configuration, the internal differential pressure may be raised to a predetermined threshold pressure above the shear pressure of retainer pins 142 causing retainer pins 142 to shear, as best seen in
Referring now to
Valve plug 240 is depicted as a substantially cylindrical blocking member that is initially allowed to move within piston body 248 between shoulder 260 and a predetermined location within collet assembly 256, as best seen in
When it is desired to operate flow control screens 200 from the running configuration to the sheared configuration, the internal differential pressure may be raised above the shear pressure of retainer pins 242 causing retainer pins 242 to shear, as best seen in
Referring now to
Valve plugs 340 are depicted as spherical blocking members. Initially, uphole travel of each valve plug 340 is limited by shoulder 360 and downhole travel of valve plug 340 is limited by lips 358 as radially outward movement of collet fingers 354 is disallowed by retainer sleeve 344. Axial movement of piston assembly 338 is initially prevented by retainer pin 342, which frangibly secures piston assembly 338 to intermediate housing 322. A seal, depicted as o-ring 362, prevents fluid travel around piston assembly 338 through opening 346. In the illustrated embodiment, a reentry barrier 366 is secured between intermediate housing 322 and production port housing 324. Reentry barrier 366 is positioned proximate the discharge ends 368 of retainer sleeves 344 and is axially disposed within intermediate housing extensions 370. As best seen in
When it is desired to operate flow control screens 300 from the running configuration to the sheared configuration, the internal differential pressure may be raised above the shear pressure of retainer pins 342 causing retainer pins 342 to shear. In this configuration, valve assemblies 336 continue to hold pressure and prevent reverse fluid flow through flow control screens 300 from the production ports to the filter medium. Once the internal differential pressure is released and an external differential pressure is applied across flow control screen 300, valve plugs 340 are expelled from piston assemblies 338 as radially outward movement of collet fingers 354 is no longer disallowed by retainer sleeve 344. Valve plugs 340 then pass through retainer sleeve 344, pass by flexible arms 372 and enter annular region 364. Once discharged, reentry of a valve plug 340 into a piston assembly 338 is disallowed by arms 372 of reentry barrier 366 such that valve assemblies 336 no longer prevent reverse fluid flow placing flow control screen 300 in its production configuration.
Referring now to
Valve plugs 440 are depicted as spherical blocking members. Initially, uphole travel of each valve plug 440 is limited by shoulder 460 and downhole travel of valve plug 440 is limited by lips 458 as radially outward movement of collet fingers 454 is disallowed by retainer sleeve 444. Axial movement of piston assembly 438 is initially prevented by retainer pin 442, which frangibly secures piston assembly 438 to intermediate housing 422. A seal, depicted as o-ring 462, prevents fluid travel around piston assembly 438 through opening 446. In the illustrated embodiment, a plurality of reentry barriers 466, only one being pictured in
When it is desired to operate flow control screens 400 from the running configuration to the sheared configuration, the internal differential pressure may be raised above the shear pressure of retainer pins 442 causing retainer pins 442 to shear. In this configuration, valve assemblies 436 continue to hold pressure and prevent reverse fluid flow through flow control screens 400 from the production ports to the filter medium. Once the internal differential pressure is released and an external differential pressure is applied across flow control screen 400, valve plugs 440 are expelled from piston assemblies 438 as radially outward movement of collet fingers 454 is no longer disallowed by retainer sleeve 444. Valve plugs 440 then pass through retainer sleeve 444, pass by rod members 472 and enter annular region 464. Once discharged, reentry of a valve plug 440 into a piston assembly 438 is disallowed by rod members 472 such that valve assemblies 436 no longer prevent reverse fluid flow placing flow control screen 400 in its production configuration.
While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.
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