SA111320776B1 - System and Method for Controlling Flow in a Wellbore - Google Patents

Abstract

System and Method for Controlling Flow in a Wellbore Abstract The present invention relates to a technique for controlling flow in a wellbore. One or more flow control valve assemblies may be designed to pair with an existing downhole. Each flow control valve assembly includes a flow control valve in conjunction with a control module. The control module includes several electrically controlled valves positioned to control the flow of actuating fluid to the flow control valve. Each flow control valve assembly also includes a hydraulic override system to allow hydraulic actuation of the flow control valve to a predetermined position when, for example, no electrical power is available for the unit's electrically controlled valves. control module. Figure 1.

Description

System and method for controlling flow in a wellbore Full description

Invention background

Hydrocarbon fluids are obtained; For example; oil

Natural gas ¢ from a subterranean geologic formation

ly to lish repository; By drilling a well it penetrates the bearing formation

| el Once a borehole has been drilled; can. hydrocarbon-bearing formation of hydrocarbon 0

Various images of completion components ll to control and enhance production efficiency

Fluids from the warehouse. Judi is a piece of equipment that can be attached to a valve to control the flow of water

Ghat flow. Flow control valve: Flow control valves allow a variety of

Lad positions are between fully open and fully closed. To achieve this, a z0 control module can be used to shift a choke toroid in the shape of an Alfie that is set to control the production or

0 injection of reservoir fluids

In this area, previous attempts to achieve an effective flow control system based on Ade have failed, and in particular the document dng. 70046050777 in creating an effective and reliable flow control system

,. Aliyah 101

creamy

general description of the invention in general; The present invention provides a technique for controlling flow in a drilled hole. One or more flow control valve assemblies may be designed to couple with an existing downhole. Each flow control valve assembly© includes a flow control valve that cooperates with a control module. The control module includes several electrically controlled LED valves positioned to control the flow of actuating fluid to the flow control valve. Each flow control valve assembly also includes a hydraulic override system to allow Yo to hydraulic actuation of the flow control valve to a predetermined position when eg; No electrical power available for electrically controlled valves of the control module (ala, control module) the previous technical field with a different type and input than the hydraulic bypass for the use of a hydraulically actuated valve tends to be the usual In the open position as mentioned in the Ve elements of protection for the present application Previous attempts in the relevant field to achieve an effective and reliable flow control system and in particular dag Ea 7004005073332 have failed to create an effective and reliable flow control system. The hydraulic override, which includes a hydraulically operated valve, is in the usual open position, and the hydraulically operated valve is made in a closed position by pressure used through the first hydraulic line, Yo, until a hydraulic override is obtained. Desirable Not found in field technology

the previous.

_p _ C pi abbreviation for drawings Certain embodiments of the invention will be described hereinafter with reference to the accompanying drawings; where similar reference numbers refer to similar items; F: A Jig Figure 1: A schematic diagram of a well system deployed in a borehole and comprising several “flow control valve assemblies” according to an embodiment of the present invention; FIGURE 1: A schematic example of a type of squirt system comprising several flow control valve assemblies i, » flow control valve assemblies of an embodiment of the present invention; Jia shape? For example: a schematic example of a control module; 0 electro-hydraulic control module coupled with a flow control valve i, » flow control valve of an embodiment of the present invention; form full; : a schematic diagram of the control module in Fig. ? but in another operational design Ga, of an embodiment of the present invention; Figure ©: is a schematic diagram of the control module in Fig. “ but in another operational design; 0 according to an embodiment of the present invention; Figure + : is a schematic diagram of the controller module in Fig. 7 but in another operational design Ga, of an embodiment of the present invention;

a J -

Figure 7: A schematic diagram of the modular control unit in Fig. * but in an AT operational design

Ga, of an embodiment of the present invention; And

Jig Figure A : Diagram of the DAT model from the control module; Gy for an alternative form of

the current invention.

In the following description; Several details are described to provide a sense of the present invention. in spite of

So that those of ordinary skill in the art may realize that the present invention may be applied

Without these details, many changes or modifications can be made from the specification models.

The disclosure described herein generally relates to a system and methodology for controlling fluid flow in a wellbore. For example; maybe

The system and methodology generally relates to well completion systems and components including drill strings consisting of

Tubing strings include one or more flow control valve assemblies

control valve. in some applications; Many flow control valve assemblies are used

To control flow to or from specific wellbore bands along a long wellbore. VO Each of the flow control valve assemblies includes a flow control valve coupled to a modular control unit

electro-hydraulic control; Such as: an electro-hydraulic control module

The amodule is used to control the opening and closing of the flow control valve. On some applications

least The control module is used to control the variable operating mode of the control valve

Flow to selectively control the flow rate through the flow control valve.

+ - in some models; For example; The module control module is used to shift the piston or actuator of the AT incrementally; For example; choke In a corresponding flow control valve, corresponding flow control valve. The displacement of the actuator increases or decreases the injection or flow production rates of fluids into or out of a surrounding reservoir© using various flow control valve assemblies; The fluid flow rate into or out of several well zones can be controlled independently. For example; A control module can be controlled using several eg; Two hydraulic control lines and an electrical line. in some embodiments; electrical line es ball comprises individual wires 1001710021 0 by applying a current greater than the current limit value to a given subset of the wires; Solenoid valves or other individually electrically actuated valves can be actuated by Jada type modular control units. Jal actuating a type valve with a solenoid that controls the flow of actuating fluid to the actuator “eg; Piston ¢ for the flow control valve. 0 The actuator moves in a certain direction when Jef pressure is applied from the limit value of pressure 40 through a first hydraulic line. The actuator stops moving if the current is reduced below the limit value for the current on that particular subset of wires regardless of the amount of hydraulic pressure applied to the first hydraulic control line.

a -

The flow control valve actuator can be made to move in an opposite direction if

Use a current greater than the limiting value of the current on another subset of wire to actuate the valve

a second electrically operated; For example, “JEN is a solenoid valve. Actuation of the electrically actuated second valve causes the flow control valve actuator to be moved by conditioned fluid

© Fluid pressurized pressure in the first hydraulic line at a pressure level

higher than a given limit value for the pressure in the first hydraulic line. Modules included

control modules | also has a hydraulic override system that allows the operation of

The corresponding flow control valve or valves when there is no electrical power available at the control module. For example, Jad can apply:

class or control module on a hydraulic pressure module 0 0

Control at a pressure greater than the pressure limit value of a second for a second hydraulic line

line to cause desirable movement of the actuator within the flow control valve or valves

scenery or contrast. When sufficient pressure is used on the second hydraulic line ¢ do not be there

The need for a current to be present on the wires in the electrical line.

NO Generally referring to Fig. 1; a model of a 01 well system is shown to control the flow of

YY controlling flow of fluid in a wellbore in this model; includes

Bleeding System 01 on a Y¢ pipeline component drill string comprises a tubing string that can

Includes a variety of downhole equipment. 71 downhole includes line post

YE tubing string and equipment below Blister 77 additionally on many

Ye flow control valve assemblies 78. Each assembly includes a

The flow YA flow control valve assembly contains a Yo flow control valve coupled to a control unit

Ym - A corresponding control module “FY” such as: an electro-hydraulic control module that worked as a function. Say (Say) Use YA flow control valve assemblies to control the inflow of reservoir fluid or the outflow of injection fluid with respect to several 74 well zones in the YU surrounding reservoir © Note that equipment Existing 71 downhole ill Jind can include a variety of gaskets and other equipment designed to isolate various well zones 4 along the wellbore YY along the wellbore: also with reference to Figure oF a diagram is provided for one sample display For well 01 system using several YA hydraulic lines and electrical line 0 560. YA hydraulic lines and electric line £0 are coupled to several VY control modules In a manner designed to allow individual control over the corresponding flow control valves +¥.In this (ala)JE) each YY control module is an electro-hydraulic module electro-hydraulic module coupled coupled to two of the 0 YA hydraulic lines and to electrical line 560. eg each control module 77 is actuated to selectively control the control valve In the flow Yoo kL flow control valve through the flow ale hydraulic actuation flowing through the hydraulic lines YA hydraulic lines for example (JE) the hydraulic operating fluid can flow from a first hydraulic line line Play YA Yo is the first VY module design to operate a flow control valve 0 to the closed position. Und can move the control module 37 to a second design that allows the operating fluid

And -

Hydraulic flow from the first hydraulic line YA to the VO flow control valve such that the VO flow control valve is actuated to the open position. Each TY controller is already controlled to allow the desired incremental actuation of the corresponding flow control valve© between the two modes

Opening and closing. © in the form shown; Each Yoo Flow Control Valve includes a sensor ?; Monitors the operating position of the flow control valve. For example; Sensors £Y sensors can include position sensors that track the position of the actuator inside each flow control valve y Each sensor can be paired ?? Corresponding electronics ¢£ which in turn is coupled to the electrical line we count 506 electrical or another DL 0 line. The £5 electronics communicate data from the EY sensors to a CE Dla control system ie: a processor-based control system. The £7 control system can be used to provide appropriate inputs to each of the YY electro-hydraulic module coupled so that desired operation of a corresponding corresponding flow control valve (eg 01) is ensured. “Jbl 7 control system can be set; at a superficial position. 0 though; Other models can fully or partially place the fT control system; Inside electronics 44 and/or at other locations below the downhole. As explained, Lah above; YY control modules can be individually controlled by applying a current greater than a current limit value to a particular subset of wires in electrical line 0 to cause single actuation of the solenoid valves (or Other valves 0 electrically actuated) within specific modular control units. As shown in Figure 9 though; The electrical line can be Gia 56 electrical line with electronics units

and 1 electronics modules 4 associated with the electro- YY hydraulic module coupled and each electronics module ¢€ can be coupled to the corresponding module 37 through communication line 57. The control signals are sent through the electrical count 50 to the electronics ££(© in turn providing the appropriate signals to the relevant module HY

In Figure oF an example of one of the control modules 7 is shown schematically as being coupled to its corresponding control valve LF the control module PY is also coupled to the YA hydraulic lines and to the electrical line electrical line 56 by electronics LE for illustration purposes; One of the 0 hydraulic lines and our YA hydraulic line is classified as a first hydraulic line 58 while the other YA hydraulic line is classified as a second hydraulic line 0. It should be noted that two hydraulic lines; However, Ame forms can be used

.additional hydraulic lines as shown; The $A first hydraulic line and the Vo second hydraulic line © are connected to several Giles actuated valves eg Jaks 06 OF (JU) valves MCU YY control module eg » Many electrically actuated valves 57 06 may include solenoid valves 40 . The particular form shown uses electrically actuated valves of (lil) although additional electrically actuated valves or other combinations of yo-values can be used to achieve the same or similar function. Electrically actuated valves are paired oF 54 by electrical line 56 by electronics £4 and receiver

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Control signals via electrical line ©0; electronics ;; To allow ne dal of valves©07; to desirable operational designs. If the valves le 54 oF are solenoid valves; For example, the supply of current through the electrical line 0 and the electronics ;; To supply or remove power to the appropriate solenoid. line can be

© first hydraulic line 58 and second hydraulic line 0 also coupled to valve ila) 01 eg: hydraulically actuated valve; Cooperates with electrically actuated valves 57; 06 to control the operation of the flow control valve 70 and to allow hydraulic bypass as described in more detail above. The MCU valve 57 is in the normally open position; As shown in Figure .0

¥Y control module Depending on the specific application; Each controller module 0 can include a variety of attributes and other components. For example; Line and valve © 4 oF can be coupled to electrically actuated valves €A first hydraulic line second hydraulic similarly; Second hydraulic line LOA Auxiliary 576 can be coupled via filter Can Ne and to auxiliary valve 0 via filter 08 oY to electrically actuated valves 0 Tine

15 Place additional TY filters in the hydraulic fluid flow path between a control module Valves of oY #1 and the flow control valve 01. Other distinguishing features can include one or more SST flow restriction device 66 and one or more TT non-return valves suitably positioned along the path to the second hydraulic line +0. :

0 in the form shown; A YY control module is also configured with component format providing a WTA hydraulic override system A hydraulic override system allows

Turn on the corresponding flow control valve 1 without Ales being able to

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for example; When there is no electrical power available to the control module”. For example, hydraulic pressure can be applied to the control module YY through the second hydraulic line 50 at a pressure greater than the pressure limit value pressure threshold of the second hydraulic line to cause desired operation © of the flow control valve Ty on some embodiments; the flow control valve 01 can be operated to an open flow position by the hydraulic bypass system override

system Gk In Figure oF the flow control valve Vo is shown as incorporating a Ve actuator that can be moved between an open flow position and a closed flow position to achieve a desired fluid flow rate 0 to or from a range of jill landscapes corresponding well zone 4 . For example Jad the actuator can have a piston a flow control valve 77. In some embodiments the £Y position sensor can be mounted at least on the Ve actuator eg; on a VY piston to use the TY control module to operate flow control valve 0 for example; To move the piston of the “VY flow control valve” hydraulic pressure Salou 0 is initially applied to the first hydraulic line LEA The pressure condition of the electro-hydraulic control module is indicated YY hydraulic control module After applying pressure to the first hydraulic line EA in Figure of Once sufficient hydraulic pressure has been applied to the first hydraulic ball EA the normally open valve is shifted © 7 to a closed position; As shown. when Ye closes it; Valve 01 prevents pressure contact between the first port Mie VE and a second port 16 of the control module valve 07. Additionally; Pressure is held back at the special VA pressure ports

DC - with both electrically actuated valves oF and 54; dB each of the solenoid valves. To move the Ve actuator of a Ve flow control valve in the open direction; The Gil eS actuated valve 4 is energized by applying current through an electrical ball line © 56 and corresponding corresponding electronics 44. In some applications; The il may be provided for a special electrically actuated valve on a subset AL of the wires in electrical line 60 5. The pressure Ala of the control module FY module is indicated while the valve which is Electrically operated of the power in Figure 0 a hydraulic pressure from the first hydraulic line 0 58 is connected to the side opening port Av of the flow control valve Yo through Flow through the VA port and out through the AY port of the electrically actuated valve 54. The flow of hydraulic fluid drives the pressure conditioned sufficiently through the valve module 08 and to the flow control valve 01 flow control valve actuator Ve to move in the direction of open. Lovie 0 Ve player moves towards increased openness; The volume of hydraulic fluid Sis us acts upon the closing ils of the Ve flow control valve actuator to the second hydraulic lill 50 second hydraulic line through the AY port Mie and port port 4/ of the electrically operated valve the other 7©. After passing through the valve module (oY) the vented hydraulic fluid also flows through the non-return valve 7 and the flow restrictor 14.

- 10 piston for example; The piston of the “Vo flow control valve Jide of” continues to move toward the fully open position as long as the electrically actuated valve (VY

Vo remains empowered. As soon as the power is removed from valve module 0, the actuator stops moving and the pressure condition returns to the pressure state shown in the figure; No matter how much to actuate the control valve actuator in the .48 first hydraulic line the pressure in the first hydraulic line © is powered by oF in the closed direction; Electrically actuated valve supplied 71 Flow condition shown LEE and electronics 50 electrical line applied current through electric line Valve operated supplied Laan YY control module pressure control module From hydraulic pressure to power in Fig. 1 hydraulic pressure of Gil eS is connected to its operation 0 €A first hydraulic line to port Mie closure sla 7 of flow control valve 30 By flowing through the VA port and out through the AY port of the electrically actuated valve OF the flow drives hydraulic fluid through the valve module 0F and to the flow control valve 71 flow control valve actuator Vo to move in the close direction. volume of in the direction of closure; A hydraulic fluid volume Ve behaves when the actuator 1 flow control valve moves on the opening side of the hydraulic fluid actuator and the AY port through port 0 second hydraulic line to the second hydraulic line Ve of the other electrically actuated valve 54. After passing through an 84 port unit of vented hydraulic fluid had the hydraulic fluid of modular valve Yo | flow also flow through the flow restrictor 14. flow restrictor continues The actuator of the flow control valve 001 to move towards the closed position as long as the electrically actuated valve

And 1 - OY remains powered. However; Once the valve OY module has been depowered, the Ve actuator stops moving and the electro-hydraulic “©” control module returns to the pressure condition shown in Figure 4. As discussed above, each Lad module includes YY control module based on a hydraulic override TA system that allows the V+ flow control valve actuator to be moved to a desired operating position when no electrical power is available.For example a 1A hydraulic override system can be designed To allow the hydraulic actuation of the piston Sel hydraulic actuation the flow control valve? in one direction into an open flow position, as shown in Figure 7. The second bypass shown in Figure 7 is performed using the second hydraulic line 0 first hydraulic ball © hydraulic line

EA line The pressure-conditioned hydraulic fluid is connected in the second +0 hydraulic line to the opening/Av port side of the flow control valve 1 through the Af Vo port and out through the EA port AY is for electrically actuated valve?5. This flow of hydraulic fluid through valve module 54 causes the flow control valve actuator 0 to move and thus the flow control valve Yee is actuated in the open direction. in this form; The non-return valve 676 forms part of the VA hydraulic override system and prevents the pressure-conditioned operating fluid in the +0 second hydraulic line from communicating with the diaphragm / eas 01 of flow control valve 30. The auxiliary valve AT also functions port Yo

11 - - from the hydraulic bypass system TA to allow hydraulic fluid to drain. For example; When the hydraulic bypass system TA is used to actuate the piston (Sf 77 piston other actuator) in the asl direction a volume of hydraulic fluid on the closing side of the flow control valve 01 is drained to first ¢A hydraulic line© by auxiliary valve “© which is in its own normally open position; As shown in the figure. Normally open valve 07 is indicated as a hydraulically actuated valve; However; Other types of valves may be used to control the desired discharge of hydraulic fluid to the $A first hydraulic line when valve 01 Se Me includes a hydraulically actuated valve flow restrictor 1¢ assists valve 07 in the process Closure. For example; Without flow restriction TE the first hydraulic ball pressure conditioning EA can cause the pressure-conditioned hydraulic fluid_ to connect to the 50 second hydraulic line through the electrically actuated valve OF and the non-return valve med The flow restriction device 14 creates a differential pressure between the first hydraulic line Ve £A and the second hydraulic line 0©; Allows normally open valve 01 to move to the closed position. It should be noted though that the flow restriction 64 can be located elsewhere and still serve the same purpose. Examples of components and component formats for each YY control module are shown to demonstrate the ability to provide individual control of flow control valves Tr in; For example; Ye is a multi-shift implementation of Sh. However; Special types of valves can be changed OFF

11 - - 0%( 07 Non-return valves 11 flow restrictor 14; and other components and/or rearranged to fit other applications. In Figure A for example, the flow restrictor 714 and valve have been replaced Non-return 766 with AA relief valve A variety of relief valves are accommodated for the desired differential pressure© configuration lad between first hydraulic line Lally ¢A first hydraulic line second hydraulic line© to ensure proper operation of normally open valve Normal 076. Unf Relief valve 88 allows hydraulic bypass with the TA hydraulic override system When electricity is unavailable to solenoid valves or other types of electrically actuated valves OF OF Gall is prevented 0 backflow of the hydraulic fluid through the valve electrically actuated OFF by the AA relief valve which performs a similar function to the check valves 17 in the previous model. YY control module in addition to components of the flow control valve assemblies 78 and the entire 010 blister system to accommodate 10 variety of structural variables; operational and/or environmental. For example Jl various combinations of solenoid valves and auxiliary valves can be used in conjunction with two or more hydraulic lines to provide the desired control on individual flow control valves while Wad is provided bypass function in If the electrical pull is lost. additionally; The number and format of the YA 00 flow control valve assemblies can vary greatly from one well application to another. Flow control valve assemblies can be used

11 - - In both lateral and vertical well drilling to achieve the desired fluid flow from the surrounding well ull zones and | or to surrounding well zones idl domains. The relatively simple approach of providing control of individual flow control valves while maintaining bypass capability makes the Gp system suitable for use in multi© displacement completion assemblies. YY control modules allow individual flow control at many locations” eg 01 JB or more locations; Through many flow control valve assemblies. Although only a few embodiments of the present invention have been described in detail Lad above; Those skilled in the art will already realize that many modifications can be made without departing 0 materially from the principles of this invention. plug on it; Such modifications are intended to be included within the scope of this invention as specified in the claims.

Claims (1)

1 - - Elements of protection 1-1 system for controlling flow in a wellbore; 1 includes: ¥ - pipeline component comprises a tubing string comprising several assemblies £ flow control valve; Each flow control valve assembly © includes a flow control valve and a control module; The control module is associated with a first hydraulic line 1 » second hydraulic line ¢ and an electrical line A - The JS includes a control module containing several solenoid 4 valves that respond to electrical signals sent along electrical line 0 to control the opening and closing of the check control valve. flow control valve through 1) the fluid passing through the first and second hydraulic lines; The control module 1 additionally provides a hydraulic bypass to allow displacement of the flow control valve without WY requiring electrical power to be supplied to the control module; Whereas, the 04 hydraulic bypass 0©:108 hydraulic that includes a hydraulically operated valve is in the usual open position 0, and the hydraulically operated valve is made in a closed position by means of a pressure of 4 used by means of a first hydraulic line until A desirable VY 760106 hydraulic bypass is obtained. 1 ?- The system mentioned in Clause 0, wherein each flow control valve includes a ¥ piston of the flow control valve and a sensor to monitor the position of ¥ piston of the control valve 0 flow control valve Nor - 1 ?- the system mentioned in protection no. ALC where the hydraulic bypass allows the displacement of the alas piston “flow control valve” to an open flow position. 1 ©- the system mentioned in protection no. 1 where the fluid flows to activate the flow control valve Y through several solenoid valves 1#- System Gy of protection 0 where it operates Many valves have “solenoids in association with a non-return valve and a flow restrictive device coupled in the line” – the second hydraulic line ¢ the non-return valve ensures that the flow opens £ the flow control valve during Hydraulic override. ball ¥ first hydraulic line and second hydraulic line .second hydraulic line £ 1 #- System as stated in claim 0 incorporating several solenoid valves On two solenoid valves. 1 + system as in claim 0 where * solenoids 0 valves are controlled by special electrical signals transmitted through electrical line 0 to allow selective 1 control of control valve assemblies in flow control yy - -; valve assemblies )4058 placed at certain iy ranges. 1 4- The system is according to what is mentioned in protection element No. A, where one of the two “solenoid” valves controls the fluid flow to move the piston of the flow control valve V towards Open position The other of the two solenoid valves, the solenoid, controls the fluid flow to move the piston of the flow control valve © towards a closed position.