CA2963180A1 - Valve apparatus - Google Patents

Valve apparatus Download PDF

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Publication number
CA2963180A1
CA2963180A1 CA2963180A CA2963180A CA2963180A1 CA 2963180 A1 CA2963180 A1 CA 2963180A1 CA 2963180 A CA2963180 A CA 2963180A CA 2963180 A CA2963180 A CA 2963180A CA 2963180 A1 CA2963180 A1 CA 2963180A1
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CA
Canada
Prior art keywords
pressure
fluid
control valve
pump
flow passage
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
CA2963180A
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French (fr)
Inventor
Mark Joseph Denny
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BP Exploration Operating Co Ltd
Original Assignee
BP Exploration Operating Co Ltd
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Filing date
Publication date
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Publication of CA2963180A1 publication Critical patent/CA2963180A1/en
Abandoned legal-status Critical Current

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Classifications

    • EFIXED CONSTRUCTIONS
    • E21EARTH DRILLING; MINING
    • E21BEARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B34/00Valve arrangements for boreholes or wells
    • E21B34/06Valve arrangements for boreholes or wells in wells
    • E21B34/10Valve arrangements for boreholes or wells in wells operated by control fluid supplied from outside the borehole
    • EFIXED CONSTRUCTIONS
    • E21EARTH DRILLING; MINING
    • E21BEARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B34/00Valve arrangements for boreholes or wells
    • E21B34/06Valve arrangements for boreholes or wells in wells
    • E21B34/08Valve arrangements for boreholes or wells in wells responsive to flow or pressure of the fluid obtained
    • EFIXED CONSTRUCTIONS
    • E21EARTH DRILLING; MINING
    • E21BEARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/12Methods or apparatus for controlling the flow of the obtained fluid to or in wells
    • E21B43/121Lifting well fluids

Abstract

A subsurface flow control apparatus comprises: a fluid flow passage configured to engage a packer in a well bore, the fluid flow passage being capable of permitting fluids to flow through the packer, wherein the fluid flow passage comprises a pump intake coupling adapted to couple to an intake of a pump for drawing fluid from the fluid flow passage into said pump intake and out of a pump discharge of the pump; a control valve arranged to control the flow of fluid through the fluid flow passage; and a controller arranged to control the control valve based on the fluid pressure, P2, in the fluid flow passage between the control valve and the pump intake coupling, and based on the fluid pressure, P1, at said pump discharge.

Description

VALVE APPARATUS
The present invention relates to methods and apparatus for use in wells and fluid pipes, and to safety valves and apparatus, and in particular to apparatus comprising safety valves for use in wells and pipes, and still more particularly for wells used to obtain hydrocarbons.
Multiple stage centrifugal pumps driven by submersible electric motors are an established means of producing hydrocarbons from wells that have insufficient pressure in the hydrocarbon reservoir for the fluids to flow to surface naturally.
Traditionally electric submersible pumps (ESPs) have been deployed into wells attached to the end of a string of jointed pipe (production tubing) with the cable supplying power to the motor being clamped to the outside of the tubing string, whilst the hydrocarbon fluids discharged from the pump flow up the inside of the tubing string.
One disadvantage of these ESP systems is that the equipment will inevitably wear and degrade over time and eventually fail necessitating its replacement. In order to replace a failed ESP system the tubing must be recovered from the well to bring the failed equipment back to surface. The recovery of the tubing from a well requires the use of a rig which adds considerably to the time and cost involved in replacing the failed equipment.
Often the rig intervention costs are considerably higher than the cost of the actual failed pump equipment.
Unsurprisingly alternatives to this method of deploying ESPs have been sought, and two main alternative methods exist, namely coiled tubing deployed ESPs and cable deployed ESPs.
In coiled tubing deployed ESP systems, the pump is attached to the end of a continuous coil of small diameter tubing with the cable either housed inside the tubing or clamped to the outside in the same way as for jointed pipe deployed pumps.
Being a continuous length of pipe coiled tubing can be deployed and recovered directly onto a reel and so the time and cost required to replace an ESP may be reduced.
In cable deployed ESP systems, the pump is deployed into the well on a cable and variously latched into or onto a permanent supporting arrangement designed to receive it.
The cable may be an electromechanical cable that remains in the well during operation to supply power to the pump or a purely mechanical cable that is only used to deploy and recover the pump with a separate permanent electrical cable used to provide electrical
2 power.
Irrespective whether the pump is deployed using coiled tubing or cable (mechanical cable or electromechanical cable) the fact that the pump must pass through either the tubing or casing 1 to latch into or onto some receptacle precludes the provision of a conventional subsurface safety valve (SSV). Known safety valves complicate the otherwise simple process of deploying the ESP system, due to the need to form a reliable seal between the coil or cable deploying the pump and the valve.
It is possible to provide a retrievable SSV in the case of mechanical cable deployed pumps, by providing a profile in the casing 1 or tubing above the pump, into which the valve can be latched in a separate operation after the pump has been deployed.
However this adds to the number of operations and the time required replacing the pump system.
Aspects and examples of the disclosure address at least a part of the above described technical problem.
In an aspect of the disclosure there is provided a subsurface flow control apparatus comprising:
a fluid flow passage configured to engage a packer in a well bore, the fluid flow passage being capable of permitting fluids to flow through the packer, wherein the fluid flow passage comprises a pump intake coupling adapted to couple to an intake of a pump for drawing fluid from the fluid flow passage into said pump intake and out of a pump discharge of the pump;
a control valve arranged to control the flow of fluid through the fluid flow passage;
and a controller arranged to control the control valve based on the fluid pressure, P2, in the fluid flow passage between the control valve and the pump intake coupling, and based on the fluid pressure, Pl, at said pump discharge.
The controller can be arranged to receive a first pressure input corresponding to the fluid pressure, P2, in the fluid flow passage between the control valve and the pump intake coupling and a second pressure input corresponding to the fluid pressure, Pl, at said pump discharge.
The controller can be configured so that in the event that the fluid pressure, Pl, at said pump discharge is equal to the fluid pressure, P2, in the flow passage between the control valve and the pump intake coupling, the controller is arranged to inhibit fluid from
3 flowing through the control valve unless the pressure, P2, in the flow passage is greater than the pressure, P3, on the other side of the control valve from the pump intake coupling by more than a selected threshold pressure.
It can be seen that the present invention is arranged such that, in use, it can permit fluid to flow to the surface of a well only when a pump is operating.
The controller can comprise at least one pressure feedback, separate from the flow passage, adapted to communicate pressure at least partially across the packer for controlling the control valve.
The pressure feedback may comprise at least one of a fluid line or a rigid mechanical coupling. In an embodiment, the pressure feedback comprises at least one port arranged to communicate the fluid pressure, Pl, at said pump discharge to an actuator. The port may extend through a wall of the fluid flow passage.
In one embodiment, the apparatus may comprise a sealed bladder, filter, or labyrinth chamber coupled to the fluid line of the pressure feedback to inhibit solids from clogging the fluid line.
The controller may comprise a pressure driven actuator coupled to control the control valve based on the fluid pressure, P2, in the flow passage between the control valve and the pump intake coupling, and based on the fluid pressure, P1, at said pump discharge.
The control valve can be biased into a closed configuration. In an embodiment, the controller comprises a pressure chamber arranged so that the pressure in the chamber acts against the bias to open the control valve.
The pressure feedback can comprise a fluid line coupled to communicate the fluid pressure, P1, at said pump discharge to the chamber.
A pump may be provided which is couplable to the pump intake coupling for drawing fluid through the flow passage. With this arrangement, the controller is arranged to open the control valve in response to operation of the pump.
The controller is preferably arranged to open the control valve in the event that the pressure difference across the packer is greater than the selected threshold pressure. The threshold can be selected so that the difference between the intake pressure and discharge pressure of the pump is sufficient to open the control valve.
The pump may be one which allows fluid to be forced back through the pump from the discharge to the intake.
4 In an embodiment of the invention, the apparatus further includes an equalisation valve operable separately from the control valve to enable fluid to flow through the flow passage. This equalisation valve is typically biased closed. The equalisation valve is preferably arranged so that any pressure difference across the equalisation valve does not act against the bias to open the equalisation valve. Optionally, the equalisation valve comprises a sliding sleeve valve.
The apparatus may comprise a latch for engaging with a tool to enable the apparatus to be removed from a well bore wherein the equalisation valve is configured to be actuated by a tool engaged with the latch.
The control valve may comprise a sliding sleeve valve. In this case, the sliding sleeve valve can comprise a sleeve and a piston arranged inside the sleeve, and the side wall of the piston and the sidewall of the sleeve may each comprise a port arranged so that sliding the piston relative to the sleeve throttles the flow of fluid through the port to control the flow of fluid through the sliding sleeve valve.
According to a second aspect of the invention, a subsurface flow control apparatus comprises:
a fluid flow passage adapted to enable fluids to flow between a first pressure zone and a second pressure zone in a well;
an outflow control valve for controlling the flow of fluid from the first pressure zone, through the fluid flow passage to the second pressure zone, wherein the outflow control valve is configured to remain closed unless a pressure in the fluid flow passage (that is, the pressure in the fluid flow passage on the side of the control valve facing the second pressure zone) is less than the pressure in the second pressure zone by more than a first selected threshold pressure; and an inflow control valve operable to allow fluid to flow from the second pressure zone, through the fluid flow passage to the first pressure zone, when the pressure inside the fluid flow passage is greater than the pressure in the first pressure zone by more than a second selected threshold pressure. The first pressure zone is typically the section of wellbore below a packer and the second pressure zone is typically the section of wellbore above the packer.
Typically, a pump having a pump intake and a pump discharge is coupled to the fluid flow passage for drawing fluid from the fluid flow passage and pumping the fluid into the second pressure zone.
The first selected threshold pressure can be selected based on the pressure difference between the pump intake and the pump discharge so that operating the pump opens the outflow control valve.
5 A controller may be provided, which is adapted to control the outflow control valve based on said pressure difference between the pump intake and the pump discharge. The controller can comprise a pressure driven actuator comprising a pressure driven sleeve coupled to actuate the outflow control valve.
The inflow control valve can comprise a second pressure driven sleeve arranged so that, when the pressure in the first pressure zone is greater than the pressure in the fluid flow passage, the second pressure driven sleeve is driven to close the inflow control valve.
Generally, at least one of the inflow control valve and the outflow control valve is biased into a closed configuration that inhibits flow through said at least one valve. The biasing may be provided by a spring.
According to another aspect of the invention, a coiled tubing deployed electric submersible pump apparatus can comprise the subsurface flow control apparatus described in the above embodiments.
In a further aspect of the invention, a cable deployed electric submersible pump apparatus can comprise the subsurface flow control apparatus described in the above embodiments.
Embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:
Figure 1 shows a schematic illustration of an electric submersible pump assembly and a flow control valve apparatus in a well bore;
Figure 2 shows a schematic illustration of a section through a flow control valve apparatus according to an embodiment of the invention;
Figure 3 shows a schematic illustration of a section through a flow control valve apparatus according to another embodiment of the invention; and Figure 4 (comprising Figures 4a and 4b) shows a schematic illustration of a section through a flow control valve apparatus according to a further embodiment of the invention.
In general, embodiments of the disclosure provide a flow control apparatus for controlling fluid flow in a well bore. The apparatus comprises a control valve and is
6 coupled to a packer so that the control valve closes the tail pipe of a pump seated above the packer for pumping fluids out of the well. Packers are well known in the field of oil and gas production, and provide a seal between the interior surface of an outer conduit, such as the wellbore or well casing, and an exterior surface of an inner tubular, such as a section of production tubing.
A pressure feedback communicates the pump discharge pressure to the control valve, such that the differential pressure developed across the pump when it is operating is applied to control the control valve. The control valve is biased closed so that it operates as a deadman's switch. In the absence of a signal holding the control valve open, the control valve closes. Accordingly, when the pump fails, or the feedback line is broken or damaged, the control valve closes to provide a system that "fails safe closed". In this way, the control apparatus can operate as a subsurface safety valve.
Embodiments of the disclosure permit fluids to be forced, or "bullheaded", into a closed well through the control valve to displace hydrocarbons back into the formation, prior to a workover and further inhibit the unwanted production of fluids from the well.
Figure 1 shows an apparatus according to an embodiment of the invention inside the production casing 1 in a well bore. A packer 2 is disposed in the casing 1.
The packer 2 is annular in shape, and the outer edge of the annulus engages with the casing 1 to provide a seal so that fluid flow in the casing 1 flows through the annular packer 2.
The packer 2 has a first side, for facing into the well, and a second side for facing out of the well. A fluid flow passage 8 extends through the annular packer 2 from the first side to the second side to permit fluid to flow out of the well.
In the arrangement illustrated in Figure 1, a pump 10 is seated on the second side of the packer 2. The intake 20 of the pump 10 is in communication with the flow passage so that it can draw fluid through the flow passage 8. The pump discharge port 22 is positioned in the production casing above the packer 2 for pumping the fluid up the production casing, out of the well.
A control valve 4 is coupled to the fluid flow passage 8 and arranged to control the flow of fluid along the fluid flow passage 8 so that closing the control valve 4 closes the fluid flow passage 8 and shuts the pump intake 20 off from the well bore below the packer.
The control valve 4 is biased into a closed state, so that as a default it prevents fluid from flowing through the flow passage 8.
7 The packer 2 has a pressure feedback line 9 extending through it, separate from the flow passage 8. The pressure feedback line 9 communicates fluid pressure P1 above the packer 2 (e.g. the pressure on the second side of the packer 2) back through the packer 2 to the control valve 4 beneath the packer 2 (the first side of the packer 2).
The flow control apparatus comprises a coupling 36 to which the pressure feedback line 9 is coupled. The coupling 36 may include known means capable of connecting the pressure feedback line 9 to a port through a sidewall of the fluid flow passage 8. The port puts the pressure feedback line 9 in pressure communication with a chamber 34 (discussed below) which can control the actuation of the control valve 4.
The flow control apparatus is configured so that, if the differential pressure between the chamber 34 and the pump intake 20 is greater than a threshold pressure, the control valve 4 will open. In the example of Figure 1, where the apparatus comprises a pump 10, the biasing of the control valve 4 can be selected based on the difference between the pump discharge and pump intake pressures so that the pressure difference generated when the pump is turned on is sufficient to overcome the biasing and cause the control valve 4 to open.
In operation, in the event that the pump 10 is not pumping, and the pressure P3 in the wellbore beneath the packer 2 is greater than or equal to the pressure P1 in the wellbore above the packer 2, the control valve 4 is held in its default, closed, state.
In the event that the pressure P1 above the packer 2 is greater than the pressure P3 below the packer 2 by more than the threshold pressure of the control valve 4, the control valve 4 opens to permit fluid to flow back through the flow passage 8 into the well. This can permit "bullheading"
fluid into a well.
In the event that the pump 10 begins pumping, the operation of the pump 10 reduces the pressure P2 at the pump intake 20 and also therefore in the flow passage
8. The pump discharge pressure P1 above the packer 2 increases and is communicated back through the pressure feedback line 9 to the chamber 34 to open the control valve 4. Whilst the pump 10 is pumping, the pressure difference between the pump discharge 22 and the pump intake 20 is maintained and the control valve 4 is held open.
In the event that the pump 10 fails and stops pumping, the pump discharge pressure P1 reduces and the pressure difference across the pump is no longer sufficient to maintain the valve in the open position. Consequently, the control valve 4 closes and inhibits fluid flowing through the flow passage 8. The pump intake 20 is then sealed from the wellbore below the packer 2. The control valve 4 therefore prevents well fluids flowing up the well.
Figure 2 shows an example of one type of apparatus according to that illustrated in Figure 1.
Figure 2 shows a packer 2 and a flow passage 8 through the packer 2. A
pressure feedback line 9, which is separate from the flow passage 8, extends through the packer 2.
A pump 10 is arranged to draw fluid from a first side of the packer 2, and to discharge it to the second side of the packer 2.
A control valve 4 is arranged on a first side of the packer 2 to control the flow of fluid through the flow passage 8 of the packer 2 into the pump intake 20. The control valve 4 comprises a throttle 26,28 through which fluid can pass. A coupling 36 couples the pressure feedback line 9 to a chamber 34 which can actuate movement of the valve 4 so as to open and close the throttle based on the pressure applied to the chamber 34.
The control valve 4 illustrated in Figure 2 comprises a sleeve valve. In the example shown in Figure 2, the sleeve valve includes a hollow cylindrical piston 5 surrounded by a sleeve 7 so that the piston 5 can slide axially along the sleeve 7. A first end of the sleeve 7 is open to the wellbore below the packer 2, and the second end of the sleeve 7 is in fluid communication with the pump intake 20. The first end of the piston 5 is closed, and, inside the sleeve 7, the second end of the piston 5 is in fluid communication with the pump intake 20.
In this example, the sleeve 7 forms an integral part of the fluid flow passage 8.
Accordingly, the control valve 4 is located at one end of the fluid flow passage 8 and the other end of the fluid flow passage 8 is coupled to the pump intake 20.
Alternatively, rather than being integral, the sleeve 7 may be connected to a first end of the fluid flow passage 8 which passes through the packer 2.
In another example, the sleeve 7 may be connected directly to one side of the packer 2. In turn, the pump intake 20 can be connected directly to the other side of the packer 2.
Other mechanical constructions will be apparent to the skilled reader, for putting the control valve 4 in fluid communication with the intake 20 of the pump.
The piston 5 and the sleeve 7 both comprise throttle ports 26,28 in their sidewalls.
When the throttle ports are aligned, fluid can flow between the outside of the sleeve 7 and the pump intake 20 via the inside of the piston 5. When the throttle ports 26, 28 are not
9 aligned, the throttle port 28 on the piston 5 is closed by the sidewall of the sleeve 7 and vice versa, which closes the control valve 4. As described further below, the control valve 4 is biased closed, in which case the ports 26,28 are misaligned. When the piston 5 slides axially along the sleeve against this bias, the ports 26,28 can be brought into alignment.
The interior surface of the sleeve 7 comprises a waist 17 that is narrower in interior diameter than the rest of the sleeve 7. The second, open, end of the piston 5 fits through the waist 17 and comprises a flange 18 that extends radially outwards from the piston 5 to engage with the internal surface of the sleeve 7 above the waist 17. This provides an annular gap 21 between the exterior surface of the piston 5, and the interior surface of the sleeve 7. A coil spring 30 is disposed in this annular gap 21 surrounding the piston 5 so that one end of the spring 30 abuts the waist 17 of the sleeve 7 and the other end of the spring abuts the flange 18 of the piston 5. Thus, the spring lies between the sidewalls of the piston 5 and the sleeve 7, and can be compressed by pushing the flange towards the waist 17 to extend the piston 5 towards and/or out of the first, open, end of the sleeve 7 away from the packer 2. The fluid pressure inside the piston 5 is coupled to this annular gap by vents 32.
Towards the first, closed, end of the piston 5 there is a shoulder 19 that is wider than the waist 17 and lies on the other side of the waist 17 from the flange 18 so that the flange 18, waist 17 and shoulder 19 cooperate to limit the range of motion of the valve piston 5 and retain the piston 5 in the sleeve 7.
The space between the waist 17 of the sleeve 7 and the shoulder 19 of the piston 5 provides the chamber 34 that can be expanded by sliding the piston 5 to move the shoulder 19 away from the waist 17, compressing the spring. The feedback line 9 is coupled to provide fluid pressure to the chamber 34 by the coupling 36. It can be seen, therefore, that the valve can be actuated by movement of the piston 5 and that movement of the piston is controlled based on the difference in pressure between the pump discharge (which is communicated to the chamber 34) and the pump intake.
It will be appreciated that the following parameters contribute to the force on the control valve piston 5:
= the fluid pressure, P1, in the feedback line 9 and chamber 34;
= the fluid pressure, P2, inside the control valve piston 5;
= the exterior (bottomhole) fluid pressure, P3, acting on the piston 5;

= the geometry of the piston 5 and sleeve 7;
= the geometry of the chamber 34; and = the bias force exerted by the spring 30.
In the event that the exterior (bottomhole) fluid pressure, P3, acting on the piston 5 is 5 greater than the fluid pressure P2 inside the piston 5, the piston 5 is pushed into the sleeve 7 so that the piston's shoulder 19 moves towards the sleeve's waist 17. This causes the two throttle ports 26, 28 to be misaligned to close the control valve 4.
In the event that the bottomhole pressure, P3, is less than the pressure, P2, in the piston 5, the control valve 4 still remains closed until the pressure difference between the
10 pressure P2 in the piston 5 and the bottomhole pressure P3 exceeds a threshold pressure difference. This threshold pressure difference is determined by the geometry of the piston 5, sleeve 7 and chamber 34, and the bias force applied by the spring 30. This threshold pressure difference can be selected by choosing the geometry and spring constant so that the control valve 4 can be configured to support a specific threshold back pressure. For example, this threshold pressure difference might be selected to be large enough to support a hydrostatic head associated with the depth at which the control valve 4 is to be deployed.
This can enable the control valve 4 to inhibit the inadvertent flow of fluid and solids back down through the pump and into the well. The threshold pressure difference can also be selected to be small enough to enable the control valve 4 to be opened by pumping fluid back into the well to increase the pressure P1 above the packer 2 to overcome the threshold, for example as part of a "bullhead kill" process. When this pumping is stopped and the increased pressure above the packer 2 is relieved, the control valve 4 will close again under the bias of the spring 30, keeping the kill fluid in place above the control valve 4. Accordingly, in the absence of a pump, or when the pump 10 is inoperative, the apparatus operates as a sub-surface controlled safety control valve 4 which "fails safe closed" to close off the well.
When the pump 10 is operated, there is an increase in the pressure in the chamber 34 associated with the discharge pressure P1 of the pump 10, and a reduction in the pressure, P2, associated with the intake pressure of the pump 10. The parameters listed above are selected so that these pressure changes are sufficient to open the control valve 4. Once the control valve 4 is opened, the hydrostatic pressure on either side of the flow ports 26, 28 are equalised, and so the pressures above, P2, and below, P3, the control valve 4 are equal.
11 Accordingly, the spring constant of the spring 30 and the geometry of the chamber 34 can be selected for the pump 10 so that the differential pressure evolved by the pump 10 (the difference between its discharge pressure, P1, and its intake pressure, P2) is sufficient to hold the control valve 4 open whilst the pump 10 is operating.
It is possible that the pressure in the wellbore beneath the packer 2 (i.e.
bottomhole pressure, P3) may be so great that the pressure, Pl, generated by the pump 10 is insufficient to open the control valve 4. This may occur in the case of a well that is shut in, wherein the bottomhole pressure, P3, can increase during the shut-in period.
In this situation, before the pump is switched on, fluid can be pumped down into the well to increase the pressures P1 and P2 (since P1 is equal to P2 at this point) to balance out the high bottomhole pressure, P3. Then, when the pump is switched on, the pressure, Pl, generated by the pump 10 can overcome the bottomhole pressure, P3, and open the control valve 4. Similarly the flow out of the top of the well may be choked back to maintain P1 at a sufficiently high pressure to hold the valve open until the bottomhole pressure P3 reduces.
Figure 3 illustrates another sleeve valve suitable for use as a control valve 4 in the apparatus described with reference to Figure 1 and Figure 2.
In order to recover apparatus such as that shown in Figure 1 and Figure 2 from a well, it can be necessary to overcome significant forces exerted by the hydrostatic pressure above and below the apparatus. The flow control apparatus of Figure 3 comprises a pressure equalisation valve configured to be mechanically actuated by a pulling tool latching on to the valve to retrieve it.
The flow control apparatus of Figure 3 is similar to the apparatus of Figure 2, and in Figure 2 and Figure 3, like reference numerals are used to indicate like elements. As in the apparatus of Figure 2, the control valve 204 comprises a piston 205 disposed in a sleeve 7.
Also, the piston 205 comprises a shoulder 19, and a flange 18, and there is a waist 17 on the interior surface of the sleeve 7. Also as in the example shown in Figure 2, the flange 18 and waist 17 hold a spring 30 between them that surrounds the piston 5. In addition, the shoulder 19 and waist 17 cooperate to provide a chamber 34 that is couplable to a pressure feedback line 9 (not shown in Figure 3) by a coupling 36.
The flow control apparatus shown in Figure 3 further comprises an equalisation valve 206 that is operable to enable fluid to flow through the flow passage 8 even when the
12 throttle ports 26, 28 of the control valve 204 are closed. The equalisation valve 206 is arranged so that the difference between the pressure, P2, inside the piston 205, and the bottomhole pressure, P3, outside the piston 205, does not alter the force required to operate the equalisation valve 206. This enables the pressure in the well above the control valve 204, and the bottomhole pressure in the well beneath the control valve 204 to be equalised without the need to displace the piston 205 to open the throttle ports 26,28 of the control valve 204.
The equalisation valve 206 is biased closed, and arranged so that the pressure differential across the control valve 204 does not act to open it. Therefore, in the absence of a positive opening force the equalisation valve 206 remains closed.
In Figure 3, the equalisation valve is arranged in the closed end of the piston 5. The equalisation valve comprises a body 220, having a recess 222 facing into the valve piston 5. Seated in the recess is a cylinder 221 which can move axially within the recess 222, and behind the cylinder in the recess is a second spring 223.
The body 220 and the cylinder 221 comprise throttle ports 226, 228 which, when aligned, provide fluid communication between the outside of the control valve sleeve 7, and the inside of the control valve piston 205. The throttle ports 226,228 of the equalisation valve 206 can be opened by sliding the cylinder 221 axially with respect to the body 220 to align them, and closed by sliding the cylinder axially to misalign them. The second spring 223 is arranged to bias the cylinder 221 against detents or some other stop in the body (not shown). This holds the cylinder in a position in which the ports are misaligned and the equalisation valve is closed.
The throttle ports 226,228 in the body 220 of the equalisation valve 206 are also arranged so that fluid pressure in the ports acts only radially on the cylinder. Accordingly, this fluid pressure does not alter the force required to open or close the equalisation valve 206. The force required to open or close the equalisation valve 206 is which is determined by the second spring 223.
In operation, when it is desired to retrieve the apparatus from a well, a pulling tool can be lowered to engage the flow control apparatus, for example by coupling with a latch on the apparatus. The pulling tool can then push the cylinder 221 into the body 220 of the equalisation valve 206, against the force of the second spring 223 to open the equalisation valve, thereby enabling the flow control apparatus to be removed from the well.
13 The features of the embodiments described with reference to the drawings are merely exemplary, and many alternatives and variations will be apparent to the skilled addressee in the context of the present disclosure.
For example, although the control valve 4 has been described as a sliding sleeve valve, the same control may equally be applied to any type of controllable valve for example flapper valves, ball valves, needle valves and the like. For example, a ball valve may be substituted by simply allowing the sliding piston to bear upon a pin offset from the axis of rotation of the valve ball to allow the linear motion of the sleeve to rotate the ball.
Similarly, other valve types may be actuated with suitable mechanisms derived from an actuator controlled by either the differential pressure across the entire valve or the differential pressure across a pump 10 coupled to the control valve 4 as described with reference to Figure 1 and Figure 2.
As another example, the pressure feedback line 9 through the packer 2 need not comprise a fluid pipe, and may comprise a pressure sensor adjacent the pump discharge 22 which communicates a control signal through the packer 2.
It will also be seen that the chamber 34 in the control valve 4 need not be actuated simply by fluid pressure, and a transducer, such as an electromechanical, or auxiliary powered hydraulic actuator may be provided to operate the control valve 4 in response to a control signal, or in response to pressure communicated by the feedback line 9. Each of these two optional features may be used individually, or in combination.
Indeed, any kind of controller may be used to control the control valve 4 based on the fluid pressure, P2, in the flow passage 8 between the control valve 4 and the pump intake 20, and based on the fluid pressure, P1, at said pump discharge 22.
It will also be appreciated that the control valve 4 need not be disposed below the packer 2, and may be arranged inside it, or even above the packer. In either case, the control valve 4 is arranged such that the second end of the piston is in fluid communication with the pump intake 20, the first, closed end of the piston is exposed to the bottomhole pressure P3, and the throttle ports 26,28 can allow or prevent fluid flow between the wellbore below the packer and the pump intake 20 when they are aligned or misaligned respectively. This could be achieved, for example, by positioning the control valve inside an outer conduit which extends through the packer. A seal is provided around the control valve between the outside surface of the control valve and the inner surface of the conduit
14 to prevent fluid travelling along the conduit around the outside of the control valve. When the throttle ports 26,28 are aligned fluid can flow between the conduit below the control valve and the inside of the control valve.
Although the control valve 4 and the equalisation valve 206 have been described as being biased closed by springs, any mechanical, electrical, hydraulic or magnetic form of biasing may be used. In addition, the control valve 4 has been described as being opened initially by a change in pressure associated with starting the pump 10. It will be appreciated that other means of opening the valve to initiate flow may additionally be provided. For example, a hydraulic line to the surface, or an electromechanical mechanism may be used to open the control valve 4 to equalise the pressures P2 and P3.
It has been noted that when the pump 10 is inactive or absent, the valve may behave as a pressure relieving non-return valve. By applying an overpressure in the injection direction, the valve can be opened to allow fluid flow into the well. In an embodiment, this allows the well to be killed by displacing well fluids through the valve.
Given the valve actuating mechanism, it is possible to select the spring to ensure that the valve opens at a selected over pressure. This also ensures a defined overbalance pressure above the valve to act as a second barrier to flow. However this feature also means that if it is ever required to remove or replace the flow control apparatus, it could be difficult to remove it as the force created by the differential hydrostatic pressure would have to be overcome in order to unseat the apparatus. The equalisation valve described with reference to Figure 3 provides one way to address this issue.
Additionally, when the valve is closed, the fluid column above the valve can be monitored to confirm that the well is static (no flow is entering or leaving the fluid column above the valve).
Figure 4 (split over Figures 4a and 4b) shows another example of a flow control apparatus adapted to be disposed inside a well bore, in accordance with the present invention.
The assembly shown in Figure 4 comprises a packer 100 configured to be deployed in a well bore, and a fluid flow passage 110 arranged to enable fluids to flow through the packer and adapted to be coupled to a pump intake of a pump (not shown in Figure 4) for drawing fluid through the fluid flow passage 110. The apparatus comprises an inflow control valve 120 and an outflow control valve 130. The outflow control valve 130 is arranged in the flow passage 110 beneath the packer 100 to control the flow of fluid from beneath the packer into the fluid flow passage and to the pump intake. The inflow control valve 120 is coupled in the flow passage 110 between the packer 100 and the outflow control valve 130, and can permit fluid to flow from above the packer to below the packer, 5 for example for a "bullheading" operation.
The outflow control valve comprises a ball valve 130 which is controlled by a controller 140. The controller 140 comprises a first pressure driven sleeve 144 and a pressure driven actuator rod 142. A first end of the pressure driven actuator rod 142 is connected to the ball valve 130. The other end of the pressure driven actuator rod 142 is 10 connected to the first pressure driven sleeve 144. The actuator rod is arranged so that longitudinal movement of the first pressure driven sleeve 144 opens and closes the ball valve to permit or inhibit fluid flow out from the wellbore below the packer into the fluid flow passage 110. The first pressure driven sleeve 144 is located in the fluid flow passage between the pump intake and the packer 100 and is biased by a first spring 146. The bias
15 of the first spring acts to close the ball valve 130.
A supplementary pressure driven sleeve and supplementary pressure driven actuator rod (not shown) may be provided in series with the first pressure driven sleeve 144 and first pressure driven actuator rod 142. The supplementary sleeve and rod work in tandem with the first sleeve and rod to increase the force of the controller. The supplementary pressure driven sleeve and pressure driven actuator rod can be arranged between the first pressure driven sleeve 144 and pressure driven actuator rod 142 and the pump The fluid pressure at the pump discharge (i.e. above the packer 100) is communicated to the first pressure driven sleeve 144 through ports 148 in the sidewall of the fluid flow passage 110. An increase in pump discharge pressure acts, via the ports 148, against the bias of the first spring 146.
The inflow control valve 120 comprises a second pressure driven sleeve 122 and a second spring 126. The second spring 126 biases the second pressure driven sleeve 122 to cover vents 124 through the fluid flow passage 110. Accordingly, unless the force of the spring 126 is overcome by a difference in pressure between the inside of the fluid flow passage 110 and the annulus outside the fluid flow passage (i.e. the pump discharge pressure), the vents 124 remain closed.
In operation, the outflow control valve is controlled as follows. The controller 140 is
16 arranged to control the outflow control valve 130 based on the difference between the fluid pressure, Pl, in the annulus above the packer 100 and a pressure, P2, inside the fluid flow passage 110 at the pump intake. In the event that the fluid pressure, Pl, in the annulus (e.g.
at the pump discharge above the packer) is greater than the fluid pressure, P2, in the flow passage 110 by more than a first selected threshold pressure, the controller 140 is arranged to open the outflow control valve 130 to enable fluid to flow from the wellbore below the packer into the fluid flow passage 110 towards the pump intake. The threshold pressure is dictated by the spring.
In the event that the pump is not pumping, there is no pressure difference across the pump and so the outflow control valve 130 remains in its default, closed, state.
As with the apparatus illustrated in Figure 1, in the event that the pump begins pumping, the operation of the pump reduces the pressure at the pump intake in the fluid flow passage. The difference between the pump discharge pressure and the pump intake pressure causes the first pressure driven sleeve 144 to move against the first spring 146 and to move the actuator rod 142. This in turn causes the outflow control valve 130 to open.
Whilst the pump is pumping, the pressure difference between the pump intake and the pump discharge is maintained and the outflow control valve 130 is held open. In the event that the pump fails, and stops pumping, the controller 140 closes the outflow control valve 130 to inhibit fluid flowing out of the well through the flow passage.
As regards the inflow control valve 120, the second pressure driven sleeve 122 is arranged to open to permit fluid to flow back into the wellbore in the event that the pressure inside the fluid flow passage 110 is greater than the pressure in the annulus beneath the packer 100 by more than a second selected threshold pressure ¨
sufficient to overcome the biasing force of the second spring 126. Accordingly, in operation, fluid can be forced (e.g. "bullheaded") back into the wellbore through the inflow control valve 120 by applying sufficiently high back pressure in the wellbore above the valve.
In addition, the second pressure driven sleeve 122 is arranged so that, when the pressure in the annulus beneath the packer 100 is greater than the pressure in the fluid flow path, this pressure forces the sleeve to cover the vents 124. Accordingly, a build up of pressure beneath the packer helps to maintain the control valve closed.
It can be seen that, in contrast to the apparatus illustrated Figure 1, the apparatus illustrated in Figure 4 does not comprise a separate pressure feedback line through the
17 packer because the controller 140 comprises an actuator that is operated by the annulus pressure above the packer. In other respects, however, the mode of operation is unchanged.
Although the example of Figure 4 is illustrated as comprising a packer, the packer 100 need not be part of the apparatus. For example, the apparatus may be retrofitted to existing packers in place in a well bore, or it may be provided as a kit of parts with a separate packer. In Figure 4, the controller 140 comprises an actuator rod 142, and a first pressure driven sleeve 144 which operates to control the outflow valve mechanically.
However, such direct mechanical coupling is not necessary, and in some examples electrical and/or electromechanical actuators can be used to provide the same functionality.
In Figure 4, the outflow control valve 130 comprises a ball valve, however any appropriate valve such as a sleeve valve may also be used. Similarly, the inflow control valve 120 of Figure 4 comprises a sleeve valve, but in some examples other kinds of valve may be used for this purpose.
The first pressure driven sleeve 144 and the second pressure driven sleeve 122 are shown in Figure 4 as being biased by springs. However other means of biasing may be used, for example other mechanical biases, for example electromechanical biases, for example magnetic biases.
Other examples and variations will be apparent to the skilled addressee in the context of the present disclosure.

Claims (29)

CLAIMS:
1. A subsurface flow control apparatus comprising:
a fluid flow passage configured to engage a packer in a well bore, the fluid flow passage being capable of permitting fluids to flow through the packer, wherein the fluid flow passage comprises a pump intake coupling adapted to couple to an intake of a pump for drawing fluid from the fluid flow passage into said pump intake and out of a pump discharge of the pump;
a control valve arranged to control the flow of fluid through the fluid flow passage;
and a controller arranged to control the control valve based on the fluid pressure, P2, in the fluid flow passage between the control valve and the pump intake coupling, and based on the fluid pressure, P1, at said pump discharge.
2. The apparatus of claim 1 wherein the controller is configured so that in the event that the fluid pressure, P1, at said pump discharge is equal to the fluid pressure, P2, in the flow passage between the control valve and the pump intake coupling, the controller is arranged to inhibit fluid from flowing through the control valve unless the pressure, P2, in the flow passage is greater than the pressure, P3, on the other side of the control valve from the pump intake coupling by more than a selected threshold pressure.
3. The apparatus of claim 1 or 2 in which the controller comprises at least one pressure feedback, separate from the flow passage, adapted to communicate pressure at least partially across the packer for controlling the control valve.
4. The apparatus of claim 3 in which the pressure feedback comprises at least one of a fluid line and a rigid mechanical coupling.
5. The apparatus of claim 3 or 4 in which the pressure feedback comprises at least one port arranged to communicate the fluid pressure, P1, at said pump discharge to an actuator.
6. The apparatus of any preceding claim in which the controller comprises a pressure driven actuator coupled to control the control valve based on the fluid pressure, P2, in the flow passage between the control valve and the pump intake coupling, and based on the fluid pressure, P1, at said pump discharge.
7. The apparatus of any of claims 3 to 6 in which the control valve is biased into a closed configuration.
8. The apparatus of claim 7 in which the controller comprises a pressure chamber arranged so that the pressure in the chamber acts against the bias to open the control valve.
9. The apparatus of claim 8 in which the pressure feedback comprises a fluid line coupled to communicate the fluid pressure, P1, at said pump discharge to the chamber.
10. The apparatus of any preceding claim, further comprising said pump couplable to the pump intake coupling for drawing fluid through the flow passage.
11. The apparatus of claim 10 wherein the controller is arranged to open the control valve in response to operation of the pump.
12. The apparatus of claim 11 when dependent on claim 2, wherein the controller is arranged to open the control valve in the event that the pressure difference across the packer is greater than the selected threshold pressure, and the threshold is selected so that the difference between the intake pressure and discharge pressure of the pump is sufficient to open the control valve.
13. The apparatus of any of claims 10 to 12, wherein the pump is arranged to allow fluid to be forced back through the pump from the discharge to the intake.
14. The apparatus of any preceding claim comprising an equalisation valve operable separately from the control valve to enable fluid to flow through the flow passage.
15. The apparatus of claim 14 in which the equalisation valve is biased closed.
16. The apparatus of claim 15 wherein the equalisation valve is arranged so that any pressure difference across the equalisation valve does not act against the bias to open the equalisation valve.
17. The apparatus of any of claims 14 to 16 in which the equalisation valve comprises a sliding sleeve valve.
18. The apparatus of any preceding claim in which the control valve comprises a sliding sleeve valve.
19. The apparatus of claim 17 or claim 18 in which the sliding sleeve valve comprises a sleeve and a piston arranged inside the sleeve, and the side wall of the piston and the sidewall of the sleeve each comprises a port arranged so that sliding the piston relative to the sleeve throttles the flow of fluid through the port to control the flow of fluid through the sliding sleeve valve.
20. The apparatus of any preceding claim, comprising a latch for engaging with a tool to enable the apparatus to be removed from a well bore wherein the equalisation valve is configured to be actuated by a tool engaged with the latch.
21. A subsurface flow control apparatus comprising:
a fluid flow passage adapted to enable fluids to flow between a first pressure zone and a second pressure zone in a well;
an outflow control valve for controlling the flow of fluid from the first pressure zone, through the fluid flow passage to the second pressure zone, wherein the outflow control valve is configured to remain closed unless a pressure in the fluid flow passage is less than the pressure in the second pressure zone by more than a first selected threshold pressure;
an inflow control valve operable to allow fluid to flow from the second pressure zone, through the fluid flow passage to the first pressure zone, when the pressure inside the fluid flow passage is greater than the pressure in the first pressure zone by more than a second selected threshold pressure.
22. The apparatus of claim 21 comprising a pump having a pump intake coupled to the fluid flow passage for drawing fluid from the fluid flow passage, and a pump discharge capable of pumping fluid into the second pressure zone.
23. The apparatus of claim 22 wherein the first selected threshold pressure is selected based on the pressure difference between the pump intake and the pump discharge so that operating the pump opens the outflow control valve.
24. The apparatus of claim 23 comprising a controller adapted to control the outflow control valve based on said pressure difference between the pump intake and the pump discharge.
25. The apparatus of claim 24 wherein the controller comprises a pressure driven actuator comprising a pressure driven sleeve coupled to actuate the outflow control valve.
26. The apparatus of any of claims 21 to 25 wherein the inflow control valve comprises a second pressure driven sleeve arranged so that, when the pressure in the first pressure zone is greater than the pressure in the fluid flow passage, the second pressure driven sleeve is driven to close the inflow control valve.
27. The apparatus of any of claims 21 to 26 in which at least one of the inflow control valve and the outflow control valve is biased into a closed configuration that inhibits flow through said at least one valve.
28. A coiled tubing deployed electric submersible pump apparatus comprising the subsurface flow control apparatus of any preceding claim.
29. A cable deployed electric submersible pump apparatus comprising the subsurface flow control apparatus of any preceding claim.
CA2963180A 2014-10-01 2014-10-01 Valve apparatus Abandoned CA2963180A1 (en)

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PCT/EP2014/071105 WO2016050301A1 (en) 2014-10-01 2014-10-01 Valve apparatus

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