1. Field of the Invention
The invention relates generally to systems and methods for selective control of fluid flow into a wellbore.
2. Description of the Related Art
Hydrocarbons such as oil and gas are recovered from a subterranean formation using a wellbore drilled into the formation. Such wells are typically completed by placing a casing along the wellbore length and perforating the casing adjacent each such production zone to extract the formation fluids (such as hydrocarbons) into the wellbore. These production zones are sometimes separated from each other by installing a packer between the production zones. Fluid from each production zone entering the wellbore is drawn into a tubing that runs to the surface. It is desirable to have substantially even drainage along the production zone. Uneven drainage may result in undesirable conditions such as an invasive gas cone or water cone. In the instance of an oil-producing well, for example, a gas cone may cause an inflow of gas into the wellbore that could significantly reduce oil production. In like fashion, a water cone may cause an inflow of water into the oil production flow that reduces the amount and quality of the produced oil. Accordingly, it is desired to provide even drainage across a production zone and/or the ability to selectively close off or reduce inflow within production zones experiencing an undesirable influx of water and/or gas.
The present disclosure addresses these and other needs of the prior art.
In aspects, the present disclosure provides an apparatus for controlling fluid flow into a wellbore tubular. In one embodiment, the apparatus includes a reactive element configured to react when exposed to a fluid and a flow control device configured to control a flow of the fluid. The flow control device may be actuated by a reaction of the reactive element to the fluid, which may be water, a hydrocarbon, an engineered fluid, and/or a naturally occurring fluid.
In embodiments, the reactive element reacts by exhibiting a change in a mechanical material property, a modulus, a storage modulus, a shear strength, a glass transition temperature, ductility, hardness and/or density. In embodiments, the reaction of the reactive element may a deformation, a bending, an expansion, contraction, and/or a twisting. In aspects, the reactive element may be configured to have a chemical reaction to the fluid, and/or a molecular reaction to the fluid. In aspects, the reaction of the reactive element is reversible. In some embodiments, the reactive element may be a shape memory polymer.
In embodiments, the flow control device may be a valve, an orifice, and/or a tortuous path. Depending on the configuration of the flow control device, the flow control device may be actuated by a compression applied by the reactive element, and/or a tension applied by the reactive element. In some arrangements, the flow control device includes an actuating element operably coupled to the reactive element. The reaction of the reactive element to a given fluid, such as water, releases the actuating element to actuate the flow control device.
In aspects, the present disclosure provides a method for producing fluid from a subterranean formation. The method may include positioning a reactive element downhole in a wellbore, and actuating a flow control device in response to a reaction of the reactive element to a given fluid. The fluid may be water, a hydrocarbon, an engineered fluid, and/or a naturally occurring fluid. In some embodiments, the reactive element may be a shape memory polymer.
In aspects, the present disclosure provides a system for controlling flow of one or more fluids into a wellbore intersecting a subterranean formation. The system may include a wellbore tubular conveying the one or more fluids to a surface location, and a plurality of flow control devices distributed along a section of the wellbore tubular. Each flow control device may include a reactive element configured to react when exposed to a fluid. Each of the flow control device may be actuated by a reaction of the reactive element to the fluid to control a flow of the fluid into the wellbore tubular. In some embodiments, the reactive element may be a shape memory polymer.
It should be understood that examples of the more important features of the disclosure have been summarized rather broadly in order that detailed description thereof that follows may be better understood, and in order that the contributions to the art may be appreciated. There are, of course, additional features of the disclosure that will be described hereinafter and which will form the subject of the claims appended hereto.
The advantages and further aspects of the disclosure will be readily appreciated by those of ordinary skill in the art as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference characters designate like or similar elements throughout the several figures of the drawing and wherein:
The present disclosure relates to devices and methods for controlling production of a hydrocarbon producing well. The present disclosure is susceptible to embodiments of different forms. There are shown in the drawings, and herein will be described in detail, specific embodiments of the present disclosure with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure, and is not intended to limit the disclosure to that illustrated and described herein. Further, while embodiments may be described as having one or more features or a combination of two or more features, such a feature or a combination of features should not be construed as essential unless expressly stated as essential.
Referring initially to
Each production device 34 features a production control device 38 that is used to govern one or more aspects of a flow of one or more fluids into the production assembly 20. As used herein, the term “fluid” or “fluids” includes liquids, gases, hydrocarbons, multi-phase fluids, mixtures of two of more fluids, water, brine, engineered fluids such as drilling mud, fluids injected from the surface such as water, and naturally occurring fluids such as oil and gas. Additionally, references to water should be construed to also include water-based fluids; e.g., brine or salt water. In accordance with embodiments of the present disclosure, the production control device 38 may have a number of alternative constructions that ensure selective operation and controlled fluid flow therethrough.
Referring now to
In one embodiment, the production control device 100 includes a particulate control device 110 for reducing the amount and size of particulates entrained in the fluids, an in-flow control device 120 that controls overall drainage rate from the formation, and a flow control device 130 that controls in-flow area based upon the composition of a flowing fluid. The particulate control device 110 can include known devices such as sand screens and associated gravel packs and the in-flow control device 120 can utilize devices employing tortuous fluid paths designed to control inflow rate by created pressure drops.
An exemplary flow control device 130 may be configured to control fluid flow into a flow bore 102 based upon one or more characteristics (e.g., water content) of the in-flowing fluid. In embodiments, the flow control device 130 is actuated by a reactive element 132 that reacts with a specified fluid in the vicinity of the flow control device 130. By react or reaction, it is meant that the reactive element 132 undergoes a change in one or more characteristics or properties upon exposure to the specified fluid. The characteristic or property may include, but is not limited to, a mechanical property, an electrical property, and a material composition. Moreover, the change may be reversible in some arrangements. That is, the reactive element 132 may revert to an original condition once the specified fluid has dissipated or is no longer present. Also, the reactive element 132 may revert to an original condition upon exposure to another specified fluid. Illustrative reactive elements are described below.
Referring now to
Referring now to
During the “null” activation, the reactive element 202 is sized to orient the lever 208 such that the flow restriction element 204 is not engaged with or seated on the orifice 206. Because the reactive element 202 is relatively stiff in the “null” activation, the lever 208 and flow restriction element 204 are generally static and remain in this position. A counter weight lobe 212 may also be positioned on the lever 208 to assist the reactive element 202 in applying the necessary force on the lever 208 to keep the flow restriction element 204 unseated. When a sufficient amount of water surrounds the reactive element 202, the reactive element 202 undergoes a transformation that causes a drop in the value of Tg. Because the new Tg is below the ambient downhole temperature, the reactive element 202 becomes flexible and loses its capacity to apply a counter force on the lever 208. As the weight of the flow restriction element 204 overcomes the force applied by the reactive element 202, the flow restriction element 204 rotates into a seating engagement with the orifice 206. Thus, the flow control device 200 is actuated by the reaction of the reactive element 202 when exposed to water. This reaction may be characterized as a change in material property in one aspect, a change in shape in another aspect or a change in Tg in still another aspect.
If water no longer surrounds the reactive element 202, the value of Tg returns to that for “null” activation. Thus, the reactive element 202 reverts to its shape and/or size during “null” activation, which causes the flow restriction element 202 to rotate out of engagement with the orifice 206. Thus, the reaction of the reactive element 204 may be considered reversible.
In some embodiments, the
Referring now to
The electrical circuit 244 includes a switch 254 that selectively energizes an electromagnetic circuit 256. In some embodiments, the switch 254 may be a switch that is activated using an applied magnetic field, such as a Reed switch. For example, the switch 254 may be moved between an energized and non-energized position by a magnetic trigger 258. The magnetic trigger 258 includes a magnetic element 260 that may slide or shift between two positions. In a first position, the magnetic field generated by the magnetic element 260 is distant from and does not affect the switch 254. In a second position, the magnetic field generated by the magnetic element 260 is proximate to and does affect the switch 254. The switch 254 may be configured to energize the electromagnetic circuit 256 when the magnetic trigger 258 is in the first position and de-energize the electromagnetic circuit 256 when the magnetic trigger 258 is in the second position. It should be understood that, in addition to magnetic fields, the switch 254 may also be activated by mechanical co-action, an electrical signal, a hydraulic or pneumatic arrangement, a chemical or additive, or other suitable activation systems.
Movement of the magnetic trigger 258 between the first position and the second position is controlled by the reactive element 242 and a biasing element 262. In the “null” activation, the reactive element 242 has a size and stiffness than maintains the biasing element 262 in a compressed state and the magnetic trigger 258 in the first position. When a sufficient amount of water surrounds the reactive element 242, the reactive element 242 loses its capacity to resist the biasing force applied by the biasing element 262. As the biasing element 262 overcomes the resistive force of the reactive element 242, the biasing element 262 slides the magnetic trigger 260 into the second position. When magnetic elements 262 of the magnetic trigger 260 are sufficiently close to the switch 254, the switch 254 opens or breaks the electromagnetic circuit 256 and thereby de-activates the magnetic field generated by the electromagnetic circuit 256. Thereafter, gravity or some other force urges the flow restriction element 246 to rotate into engagement with the orifice 248.
If water no longer surrounds the reactive element 242, the value of Tg returns to that for “null” activation. Thus, the reactive element 242 reverts to shape and/or size during “null” activation, which compresses the spring 262 and causes the magnetic trigger 260 to return to the first position. Because the magnetic elements 260 no longer affect the switch 254, the switch 254 re-energizes the electromagnetic circuit 244 and the generated magnetic field causes the flow restriction element 244 to rotate out of engagement with the orifice 248. Thus, again, the reaction of the reactive element 242 may be considered reversible.
In some embodiments, the
Referring now to
It should be understood that the above arrangements are merely illustrative of flow devices according to the present disclosure. For example, in some variants, a reactive element may be formed to have a non-reversible reaction with a fluid. For instance, the reactive element may use a material that reacts to a specified fluid by disintegrating. Exemplary types of disintegration include, but are not limited to, oxidizing, dissolving, melting, and fracturing. Referring to
In other variants, a reactive element may be configured to react with fluids other than water. For example, a reactive element may be configured to utilize an oil-activated SMP material. Referring now to
In still other variants, an SMP material may be configured to use activation thresholds based on parameters other than temperature, such as pressure or downhole compositions. Moreover, the activation parameter may also be varied to provide an additional layer of control over the flow control devices. For instance, the threshold value may be selected such that human intervention may be used to complete an actuation of the flow control device. In one scenario, the “null” activation Tg and the transformed value for Tg may both be selected to be higher than the ambient wellbore temperature. Thus, a second step of raising the ambient wellbore temperature may be used to complete the actuation process for the flow control device.
In still other variants, forces other than gravity may be used to move flow restriction elements between an open position and a closed position. For example, biasing members, such as springs, may be used to apply a force that either keeps a flow restriction element in an open or closed position. The reactive element may be configured to counteract or restrain the force applied by such a biasing element. Additionally, while
It should be understood that
For the sake of clarity and brevity, descriptions of most threaded connections between tubular elements, elastomeric seals, such as o-rings, and other well-understood techniques are omitted in the above description. The foregoing description is directed to particular embodiments of the present disclosure for the purpose of illustration and explanation. It will be apparent, however, to one skilled in the art that many modifications and changes to the embodiment set forth above are possible without departing from the scope of the disclosure.