In hydrocarbon production wells, it may be beneficial to regulate the flow of formation fluids from a subterranean formation into a wellbore penetrating the same. A variety of reasons or purposes may necessitate such regulation including, for example, prevention of water and/or gas coning, minimizing water and/or gas production, minimizing sand production, maximizing oil production, balancing production from various subterranean zones, equalizing pressure among various subterranean zones, and/or the like.
A number of devices are available for regulating the flow of formation fluids. Some of these devices may be non-discriminating for different types of formation fluids and may simply function as a “gatekeeper” for regulating access to the interior of a wellbore pipe, such as a well string. Such gatekeeper devices may be simple on/off valves or they may be metered to regulate fluid flow over a continuum of flow rates. Other types of devices for regulating the flow of formation fluids may achieve at least some degree of discrimination between different types of formation fluids. Such devices may include, for example, tubular flow restrictors, nozzle-type flow restrictors, autonomous inflow control devices, non-autonomous inflow control devices, ports, tortuous paths, combinations thereof, and the like.
Autonomous flow control devices may be particularly advantageous in subterranean operations, since they are able to automatically regulate fluid flow without the need for operator control due to their design. In this regard, autonomous flow control devices may be designed such that they provide a greater resistance to the flow of undesired fluids (e.g., gas and/or water) than they do desired fluids (e.g., oil), particularly as the percentage of the undesired fluids increases.
While autonomous flow control devices may operate in a passive fashion, it may be desirable to limit the flow of an undesired fluid into the interior of a production tubing string. For example, oftentimes, the ratio of oil-to-water in a stimulated fluid may be less than optimal.
These drawings illustrate certain aspects of some examples of the present disclosure and should not be used to limit or define the disclosure.
Provided are systems and methods for controlling the fluid flow into an interior of a production tubing string from the surrounding formations. As discussed below, design features may include the addition of a shuttle valve between the autonomous flow control device and the production tubing string. In examples, the shuttle valve may selectively restrict any fluid flow through the outlet flow ports of the autonomous flow control device into the production tubing string.
As depicted, a plurality of well screens 114, flow control devices 116, and packers 118 may be interconnected along production tubing 112, such as along portions of the production tubing 112 in horizontal section 106 of wellbore 102. Packers 118 may be configured to seal off an annulus 120 defined between production tubing 112 and the walls of wellbore 102. As a result, fluids 122 may be produced from multiple intervals of the surrounding subterranean formation 108 via isolated portions of annulus 120 between adjacent pairs of packers 118.
As illustrated, in some examples, a well screen 114 and a flow control device 116 may be interconnected in production tubing 112 and positioned between a pair of packers 118. Without limitation, well screens 114 may be swell screens, wire wrap screens, mesh screens, sintered screens, expandable screens, pre-packed screens, treating screens, or other known screen types. In operation, well screen 114 may be configured to filter fluids 122 flowing into production tubing 112 from annulus 120. Flow control device 116 may be configured to restrict or otherwise regulate the flow of fluids 122 into production tubing 112, based on certain physical characteristics of the fluids. In examples, flow control device 116 may be a centrifugal fluid selector, wherein a portion of the centrifugal fluid selector may be actuated to rotate by the flow of fluids 122.
Without limitation, flow control device 116 may be an autonomous flow control device. The autonomous flow control device may utilize fluid dynamics and delay the flow of unwanted fluids such as water and/or gas into the interior of production tubing 112. The autonomous flow control device may operate as a passive flow control device, not requiring moving components and/or electronics. The autonomous flow control device may be any suitable shape. Without limitation, a suitable shape may include, but is not limited to, cross-sectional shapes that are circular, elliptical, triangular, rectangular, square, hexagonal, and/or combinations thereof The autonomous flow control device may be made from any suitable material. Suitable materials may include, but are not limited to, metals, nonmetals, polymers, ceramics, and/or combinations thereof. Without limitation, the autonomous flow control device may be made from tungsten carbide and/or steel.
It will be appreciated that well system 100 is merely one example of a wide variety of well systems in which the principles of this disclosure may be utilized. Accordingly, it should be understood that the principles of this disclosure are not necessarily limited to any of the details of the depicted well system 100, or the various components thereof, depicted in the drawings or otherwise described herein. For example, it is not necessary in keeping with the principles of this disclosure for wellbore 102 to include a generally vertical section 104 or a generally horizontal section 106. Moreover, it is not necessary for fluids 122 to be only produced from subterranean formation 108 since, in other examples, fluids may be injected into subterranean formation 108, or fluids 122 may be both injected into and produced from subterranean formation 108, without departing from the scope of the disclosure.
Furthermore, it is not necessary that at least one well screen 114 and flow control device 116 be positioned between a pair of packers 118. Nor is it necessary for a single flow control device 116 to be used in conjunction with a single well screen 114. Rather, any number, arrangement and/or combination of such components may be used, without departing from the scope of the disclosure. In some applications, it is not necessary for flow control device 116 to be used with a corresponding well screen 114. For example, in injection operations, the injected fluid could be flowed through flow control device 116, without also flowing through well screen 114.
Those skilled in the art will readily recognize the advantages of being able to regulate the flow of fluids 122 into production tubing 112 from each zone of subterranean formation 108, for example, to prevent water coning 124 or gas coning 126 in subterranean formation 108. Other uses for flow regulation in a well may include, but are not limited to, balancing production from (or injection into) multiple zones, minimizing production or injection of undesired fluids, maximizing production or injection of desired fluids, etc.
In examples, housing 202 may be any suitable size, height, and/or shape. Without limitation, a suitable shape may include, but is not limited to, cross-sectional shapes that are circular, elliptical, triangular, rectangular, square, hexagonal, and/or combinations thereof. In certain examples, housing 202 may be circular. Housing 202 may encase the internal components of flow control device 116. In examples, housing 202 may protect the internal components of flow control device 116 from an external environment. In certain examples, housing 202 may include protrusions 204.
Protrusions 204 may be extensions of material from the diameter of housing 202. In examples, protrusions 204 may be any suitable size, height, and/or shape. Without limitation, a suitable shape may include, but is not limited to, cross-sectional shapes that are circular, elliptical, triangular, rectangular, square, hexagonal, and/or combinations thereof. In certain examples, protrusions 204 may visually appear and physically operate similarly to teeth on a mechanical gear.
In alternate examples, protrusions 204 may be extensions of material from a ring of material that is coupled to housing 202. In these examples, the inner diameter of the ring of material may be equal to or larger than the diameter of housing 202. Depending on the inner diameter of the ring of material, there may or may not be an annulus between the ring of material and housing 202. During operations of flow control device 116, a portion of flow control device 116 may be disposed within a flow path of fluids 122 (i.e., referring to
In examples, there may be an opening 208 between protrusions 204 that allows access to an internal chamber 210 of housing 202. There may be a plurality of openings 208 that allow fluids 122 to flow from the flow path, between a set of protrusions 204, and into internal chamber 210. In examples, internal chamber 210 may be any suitable size, height, and/or shape. Without limitation, a suitable shape may include, but is not limited to, cross-sectional shapes that are circular, elliptical, triangular, rectangular, square, hexagonal, and/or combinations thereof. Internal chamber 210 may include various structures and/or supports that guide the flow of fluids 122 towards outlet 206.
In examples, outlet 206 may be disposed within internal chamber 210 of housing 202. Outlet 206 may be an opening that allows fluids 122 to exit flow control device 116. Outlet 206 may be coupled to a control line (discussed further below), wherein fluids 122 may flow through the control line and engage a shuttle valve (discussed further below). In examples, fluids 122 that flowed through the control line may enter the interior of production tubing 112 (i.e., referring to
Floats 200 may block a potential flow path of fluids 122 while in an initial position. Floats 200 may be structures designed to float when disposed in a particular fluid due to having a lower density than said fluid. Floats 200 may be made from any suitable material. Suitable materials may include, but are not limited to, metals, nonmetals, polymers, ceramics, and/or combinations thereof. Without limitations, floats 200 may be made from any material that is less dense than water and/or denser than oil. In examples, floats 200 may be any suitable size, height, and/or shape. Without limitation, a suitable shape may include, but is not limited to, cross-sectional shapes that are circular, elliptical, triangular, rectangular, square, hexagonal, and/or combinations thereof. With reference to
In examples, as best seen on
In alternate examples, floats 200 may slide along a wall. Referring to
In examples, a portion of flow control device 116 may be disposed within the flow of fluids 122. The flow of fluids 122 may be in a feedback loop 610. In examples, fluid restrictor 604 and injection valve 606 may be disposed within feedback loop 610. Without limitations, fluid restrictor 604 and injection valve 606 may be the same or similar valve in that both fluid restrictor 604 and injection valve 606 allow fluids 122 to flow in one direction. The flow of fluids 122 from subterranean formation 108 may travel through and/or past with flow control device 116 and/or fluid restrictor 604. However, the flow of fluids 122 from subterranean formation 108 may be inhibited by injection valve 606.
The flow of fluids 122 may cause flow control device 116 to rotate. In examples, fluids 122 may enter flow control device 116 as flow control device 116 rotates. If fluids 122 mostly includes of oil, then fluids 122 may exit flow control device 116 and flow through control line 608. Control line 608 may be coupled to regulatory valve 602.
Without limitations, regulatory valve 602 may be a shuttle valve, a ball valve, a diaphragm shuttle valve, a bellows valve, a pilot-operated valve, a pilot-operated check valve, and/or the like. In examples, regulatory valve 602 may include a biasing spring. In certain examples, regulatory valve 602 may be an inverse shuttle valve. If regulatory valve 602 is a type of shuttle valve, the shuttle may be a ball shuttle. In examples, the pressure supplied from control line 608 may be greater than a secondary pressure. The pressure supplied from control line 608 may be equal to the pressure of fluids 122 that are flowing from subterranean formation 108. If the pressure supplied from control line 608 is greater than a secondary pressure, then regulatory valve 602 may actuate to allow fluids 122 to enter the interior of production tubing 112 (i.e., referring to
If fluids 122 mostly includes of water, then there may be little flow of fluids 122 through control line 608. In this example, a balance line 612 may equalize the secondary pressure in regulatory valve 602 with the pressure from control line 608. There may be a weep line 614 that adjusts the pressure supplied by control line 608 to be less than the secondary pressure within regulatory valve 602. In examples, weep line 614 may be a connecting line from control line 608 to the interior of production tubing 112. If the pressure supplied by control line 608 is less than the secondary pressure within regulatory valve 602, then regulatory valve 602 may be actuated to close and restrict the flow of fluids 122 into the interior of production tubing 112.
In certain examples, a complete seal may not be needed when restricting regulatory valve 602. A complete seal may prevent flow control device 116 from rotating. Therefore, there may be a flow line 616 that connects the interior of production tubing 112 to the secondary pressure within regulatory valve 602. In examples, flow line 616 may be a leak around the valve seat or a bypass around the valve seat within regulatory valve 602. Flow line 616 may allow the circulation of the flow of fluids 122 supplied by subterranean formation 108 to continue, thus ensuring the rotation of flow control device 116.
Any of the above described flow control devices 116 may be used to move shuttle valve 700 (e.g., referring to
Concerning the present examples, regulatory valve 602 may be a pilot operated shuttle valve. Without limitations, the pilot operated shuttle valve may be a valve which allows fluids 122 to flow through from one of two sources. Additionally, the pilot operated shuttle valve may include a shuttle valve 700, wherein shuttle valve 700 is configured to displace when actuated upon by an external pressure. Shuttle valve 700 may be any suitable size, height, and/or shape. As illustrated, shuttle valve 700 may include a first end piece 702 coupled to a second end piece 704 by a connecting rod 706. In examples, first end piece 702 may prevent the flow of fluids 122 from subterranean formation 108 into regulatory valve 602 to be in fluid communication with the flow of fluids 122 from injection valve 606. Further, second end piece 704 may prevent the flow of fluids 122 from subterranean formation 108 into regulatory valve 602 to be in fluid communication with the flow of fluids 122 from offset line 609. Connecting rod 706 may serve to affix first end piece 702 to second end piece 704 so that first end piece 702 may displace accordingly with second end piece 704 when one of the two is actuated upon by fluid pressure supplied by injection valve 606 and/or offset line 609.
It should be noted that each float 200 may have a different density. Additionally, each float 200 placed in flow control device 116 may be different from each other by about 5%, about 10%, about 15%, about 20% , about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95%. The density of each float 200 may be between about 0.5 SG to about 1.5 SG. Specific examples may be 0.8 SG, 1 SG, 1.2 SG, or 1.5 SG.
Additionally, each D-AICD may be configured to flow at different flow rates when fully open. For example, following the example above the second D-AICD may be designed to allow double the flow rate of the first and third when all are fully open thus changing the flow percentages at each stage. It should also be noted that a D-AICD may operate without regulatory valve 602 (e.g., referring to
Referring back to
When the water cut reaches a predetermined value, a first float 1202 may close reducing the flow and pressure at P2 and cause shuttle valve 700 to move closer to a closed position, which may restrict the flow of fluid through regulatory valve 602 (e.g., referring to
As discussed above, control system 600 may function and operate off of density within a fluid instead of viscosity. Currently, flow control systems use viscosity to allow and/or restrict the flow of fluid through a regulatory valve. Control system 600 may utilize artificial gravity with floats 200 to allow control system 600 to operate independently. Therefore, control system 600 may be able to toggle back and forth from high restriction to low restriction as the property of a fluid changes downhole.
Statement 1. A fluid control system may comprise a flow control device including one or more floats attached within the flow control device, an outlet within the flow control device that is connected to the one or more floats, a regulatory valve that is fluidly connected to the flow control device, and a blocking element placed within the regulatory valve.
Statement 2. The fluid control system of statement 1, wherein the one or more floats allow for a first oil and water mixture to pass through the outlet.
Statement 3. The fluid control system of statements 1 or 2, further including a fluid restrictor and an injection valve.
Statement 4. The fluid control system of statements 1-3, further including a balance line, a weep line, and a flow line which balance a pressure differential between fluids from a subterranean formation and an interior of a production string.
Statement 5. The fluid control system of statements 1-4, wherein the regulatory valve is a shuttle valve, a ball valve, a diaphragm shuttle valve, a bellows valve, a pilot-operated valve, or a pilot-operated check valve.
Statement 6. The fluid control system of statements 1-5, further including one or more fluid restrictors fluidly attached to the flow control device.
Statement 7. The fluid control system of statement 6, wherein the one or more fluid restrictors are a nozzle, a vortex, a change in a diameter an offset line, or a fluid diode.
Statement 8. The fluid control system of statements 1-6, wherein the one or more floats have a specific gravity of about 0.8 to about 1.5.
Statement 9. An autonomous flow control system may comprise a first flow control device attached to a production tubing at a first location in a wellbore, a second flow control device attached to the production tubing at a second location in the wellbore, a first set of floats attached within the first flow control device, and a second set of floats attached within the second flow control device.
Statement 10. The autonomous flow control system of statement 9, wherein the first set of floats allow for a first oil and water mixture to pass through a first outlet attached to the first flow control device.
Statement 11. The autonomous flow control system of statements 9 or 10, wherein the second set of floats allow for a second oil and water mixture to pass through a second outlet attached to the second flow control device.
Statement 12. The autonomous flow control system of statements 9-11, further including a first regulatory valve fluidly attached to the first flow control device.
Statement 13. The autonomous flow control system of statement 12, wherein the first regulatory valve is a shuttle valve, a ball valve, a diaphragm shuttle valve, a bellows valve, a pilot-operated valve, or a pilot-operated check valve.
Statement 14. The autonomous flow control system of statements 9-12, further including a second regulatory valve fluidly attached to the second flow control device.
Statement 15. The autonomous flow control system of statement 14, wherein the second regulatory valve is a shuttle valve, a ball valve, a diaphragm shuttle valve, a bellows valve, a pilot-operated valve, or a pilot-operated check valve.
Statement 16. The autonomous flow control system of statements 9-12 or 14, wherein the first flow control device and the second flow control device further including a fluid restrictor and an injection valve.
Statement 17. The autonomous flow control system of statement 9-12, 14, or 16, wherein the first flow control device and the second flow control device further including a balance line, a weep line, and a flow line which balance a pressure differential between fluids from a subterranean formation and an interior of the production tubing.
Statement 18. The autonomous flow control system of statement 9-12, 14, 16, or 17, further including one or more fluid restrictors fluidly attached to the first flow control device and the second flow control device.
Statement 19. The autonomous flow control system of statement 18, wherein the one or more fluid restrictors are a nozzle, a vortex, a change in a diameter an offset line, or a fluid diode.
Statement 20. The autonomous flow control system of statement 9-12, 14, or 16-18, wherein the first set of floats and the second set of floats have a specific gravity of about 0.8 to about 1.5.
The preceding description provides various examples of the systems and methods of use disclosed herein which may contain different method steps and alternative combinations of components. It should be understood that, although individual examples may be discussed herein, the present disclosure covers all combinations of the disclosed examples, including, without limitation, the different component combinations, method step combinations, and properties of the system. It should be understood that the compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the elements that it introduces.
For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.
Therefore, the present examples are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular examples disclosed above are illustrative only and may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual examples are discussed, the disclosure covers all combinations of all of the examples. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. It is therefore evident that the particular illustrative examples disclosed above may be altered or modified and all such variations are considered within the scope and spirit of those examples. If there is any conflict in the usages of a word or term in this specification and one or more patent(s) or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.
Number | Date | Country | |
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62721829 | Aug 2018 | US |