US20220170352A1 - System and method for wireless control of well bore equipment - Google Patents
System and method for wireless control of well bore equipment Download PDFInfo
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- US20220170352A1 US20220170352A1 US17/675,776 US202217675776A US2022170352A1 US 20220170352 A1 US20220170352 A1 US 20220170352A1 US 202217675776 A US202217675776 A US 202217675776A US 2022170352 A1 US2022170352 A1 US 2022170352A1
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Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/12—Methods or apparatus for controlling the flow of the obtained fluid to or in wells
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B47/00—Survey of boreholes or wells
- E21B47/12—Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling
- E21B47/14—Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling using acoustic waves
- E21B47/18—Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling using acoustic waves through the well fluid, e.g. mud pressure pulse telemetry
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B2200/00—Special features related to earth drilling for obtaining oil, gas or water
- E21B2200/06—Sleeve valves
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B34/00—Valve arrangements for boreholes or wells
- E21B34/06—Valve arrangements for boreholes or wells in wells
- E21B34/08—Valve arrangements for boreholes or wells in wells responsive to flow or pressure of the fluid obtained
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B34/00—Valve arrangements for boreholes or wells
- E21B34/06—Valve arrangements for boreholes or wells in wells
- E21B34/10—Valve arrangements for boreholes or wells in wells operated by control fluid supplied from outside the borehole
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B47/00—Survey of boreholes or wells
- E21B47/06—Measuring temperature or pressure
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- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Mining & Mineral Resources (AREA)
- Geology (AREA)
- Physics & Mathematics (AREA)
- Environmental & Geological Engineering (AREA)
- Fluid Mechanics (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Geophysics (AREA)
- Remote Sensing (AREA)
- Acoustics & Sound (AREA)
- Flow Control (AREA)
- Fluid-Pressure Circuits (AREA)
Abstract
There is provided an apparatus for controlling flow in a wellbore, comprising: a housing defining a fluid passage; a flow control device sealing an outlet of said fluid passage; an actuator for manipulating said flow control device to an open condition to permit fluid flow through said outlet; a controller for selectively activating said actuator; an acoustic receiver in communication with said controller, said acoustic receiver configured to receive acoustic signals comprising programming instructions for said controller.
Description
- This application is a continuation of U.S. patent application Ser. No. 16/485,485, which is a 371 of PCT/CA2018/050160 filed Feb. 13, 2018, and claims the benefit of and priority to U.S. Provisional Patent Application No. 62/458,194, filed Feb. 13, 2017, the contents of which are incorporated herein by reference.
- The present disclosure relates to hydraulic fracturing and, in particular, to control of downhole components in hydraulic fracturing.
- The number of stages accessible for hydraulic fracturing is generally limited due to mechanical limitations of existing technologies. Challenges exist with providing reliable isolation of previously fractured stages. Multistage fracturing of, and subsequent production from, horizontal wells requires the ability to control flow communication between the wellbore and the reservoir at multiple locations along the wellbore. Valving systems are incorporated within well completions to enable such control flow communication. Controllable actuation of such valving systems is a challenge, by virtue of the difficulty in physically accessing such valving system within deep horizontal wells.
- Mechanical shifting tools, deployable within wellbores using workstrings, have been developed to enable such actuation. However, significant costs are associated with their repeated deployment in order to perform multiple open-close operations.
- Remote signalling is also being developed as an alternative means for actuating downhole valving systems. In order to be useful, however, signals must be reliably transmitted downhole and addressable to the valve intended to be controlled.
- In one aspect, there is provided an apparatus for controlling flow in a wellbore, comprising: a housing defining a fluid passage; a flow control device sealing an outlet of said fluid passage; an actuator for manipulating said flow control device to an open condition to permit fluid flow through said outlet; a controller for selectively activating said actuator; an acoustic receiver in communication with said controller, said acoustic receiver configured to receive acoustic signals comprising programming instructions for said controller.
- In another aspect, there is provided a method of operating a flow control device in a wellbore string, comprising: encoding a control message for opening said flow control device as a sequence of digits; transmitting said control message by relieving pressure from a fluid in said wellbore string in a sequence of stages, wherein said relieving pressure comprises modulating a rate of change of fluid pressure to one of a plurality of threshold values in each stage, each said threshold value corresponding to a possible one of said digits.
- In another aspect, there is provided a method of operating a flow control device in a wellbore string, comprising: at said flow control device, periodically measuring a rate of pressure change and a rate of temperature change of fluid in said wellbore string; incrementing a counter if said rate of pressure change and said rate of temperature change are within respective value ranges; closing said flow control device in response to said counter reaching a threshold value.
- According to one example aspect is a method of remotely operating a flow control device in a wellbore string. The method includes encoding a control message as a sequence of digits for actuating said flow control device and transmitting said control message by relieving pressure from a fluid in said wellbore string in a sequence of stages, wherein said relieving pressure comprises modulating a rate of change of fluid pressure over the sequence of stages to encode the sequence of digits.
- According to another example aspect a control system is disclosed for remotely operating a flow control device in a wellbore string. The control system includes: an actuator for opening and closing a valve to selectively release pressure from a fluid in the wellbore string; and a wellhead controller configured to cause the actuator to open and close the valve to modulate a control message onto the fluid for the flow control device by selectively releasing pressure from the fluid in stages, wherein each stage corresponds to a digit of the control message.
- According to a further example aspect is a method of operating a flow control apparatus in a wellbore string, the flow control apparatus comprising a housing defining a fluid passage, a flow control device sealing an outlet of said fluid passage, an actuator for manipulating said flow control device to an open condition to permit fluid flow through said outlet, a controller for selectively activating said actuator, and a pressure sensor for sensing pressure in the fluid passage. The method includes: periodically sampling a pressure in the fluid passage using the pressure sensor; analyzing the samples, by the controller, to determine if a control message has been pressure modulated onto a fluid in the fluid passage, and if so, decoding the control message based on the samples and determining if the decoded control message includes an instruction for the controller to activate said actuator; and activating the actuator, if the control message includes an instruction for the controller to activate said actuator, to manipulate said flow control device to the open condition.
- According to a further example embodiment, a flow control apparatus for use in a wellbore string is disclosed, including: a housing defining a fluid passage; a flow control device sealing an outlet of said fluid passage; an actuator for manipulating said flow control device to an open condition to permit fluid flow through said outlet; and a pressure sensor for sensing pressure in the fluid passage. The apparatus includes a controller configured to: receive periodic pressure samples for fluid in the fluid passage from the pressure sensor; analyze the pressure samples to determine if a control message has been pressure modulated onto a fluid in the fluid passage, and if so, decode the control message based on the pressure samples and determine if the decoded control message includes an instruction for the controller to activate said actuator; and activate the actuator, if the control message includes an instruction for the controller to activate said actuator, to manipulate said flow control device to the open condition.
- According to a further example embodiment is an apparatus for controlling flow in a wellbore. The apparatus includes a housing defining a fluid passage; a flow control device sealing an outlet of said fluid passage; an actuator for manipulating said flow control device to an open condition to permit fluid flow through said outlet; a controller for selectively activating said actuator; and an acoustic receiver in communication with said controller, said acoustic receiver configured to receive acoustic signals comprising programming instructions for said controller.
- According to a further example aspect is a method of programming a flow control apparatus. The flow control apparatus includes: a housing defining a fluid passage; a flow control device sealing an outlet of said fluid passage; an actuator for manipulating said flow control device to an open condition to permit fluid flow through said outlet; a controller for selectively activating said actuator; an acoustic receiver in communication with said controller, said acoustic receiver configured to receive acoustic signals comprising programming instructions for said controller The method includes pre-programming the controller prior to installing the flow control apparatus in a downhole well-bore string by receiving acoustic signals through the acoustic receiver and decoding the acoustic signals to recover the programming instructions for said controller.
- According to another example aspect is an apparatus for controlling flow in a wellbore, including: a housing defining an internal fluid passage; a flow control device sealing an outlet of said fluid passage; an actuator for manipulating said flow control device to an open condition to permit fluid flow through said outlet; a controller for selectively activating said actuator; and an optical sensor configured to receive optical signals from a location external to said housing, the optical signals comprising programming instructions for said controller.
- According to a further example embodiment is a method of programming a flow control apparatus comprising: pre-programming a controller of the flow control apparatus prior to installing the flow control apparatus in a downhole well-bore string by receiving optical signals through an optical sensor and decoding the optical signals to recover the programming instructions for said controller.
- According to another example aspect is method of operating a flow control device in a wellbore string, comprising: at said flow control device, periodically measuring a rate of pressure change and a rate of temperature change of fluid in said wellbore string; incrementing a counter if said rate of pressure change and said rate of temperature change are within respective value ranges; and closing said flow control device in response to said counter reaching a threshold value.
- According to another example aspect is a flow control apparatus comprising: a housing including a housing passage; a flow communicator extending through the housing; a flow control member displaceable relative to the flow communicator for controlling flow communication, via the flow communicator, between the housing passage and an environment external to the housing; a sensor configured for sensing an actuating condition, wherein the actuating condition includes a characteristic within the wellbore that is produced in response to a movement of the flow control member relative to the flow communicator; a timer configured to start a countdown timer in response to the sensing of the actuating condition by the sensor. The sensor, the timer, and the flow control member are co-operatively configured such that, in response to the sensing of an actuating condition, the timer starts a countdown timer, and, in response to the expiry of the countdown timer, displacement of the flow control member, relative to the flow communicator, is effected.
- According to a further example aspect is a process for producing hydrocarbon material from a reservoir via a wellbore, comprising: (a) effecting stimulation of the reservoir, including: within the wellbore, displacing a flow control member, relative to a flow communicator, such that opening of the flow communicator is effected; while the flow communication is established between the wellbore and the reservoir via the flow communicator, injecting treatment material into the reservoir via the flow communicator for effecting stimulation of the reservoir; and after the injecting of treatment material, within the wellbore, displacing the flow control member, relative to the flow communicator, with effect that closing of the flow communicator is effected, such that the stimulation is completed; and (b) effecting production of hydrocarbon material from the reservoir, including: after the completion of the stimulation, starting a countdown timer; and in response to the expiry of the countdown timer, within the wellbore, displacing the flow control member, relative to the flow communicator, such that opening of the flow communicator is effected.
- According to a further example embodiment is a process for controlling fluid flow between a wellbore and a subterranean formation via a flow communicator using a flow control member that is disposed within the wellbore, comprising: moving the flow control member relative to the flow communicator; sensing the movement of the flow control member relative to the flow communicator; in response to the sensed movement, starting a countdown timer; and in response to the expiry of the countdown timer, displacing the flow control member relative to the flow communicator.
- The preferred embodiments will now be described with the following accompanying drawings, in which:
-
FIG. 1 is a schematic illustration of a system for effecting fluid communication between the surface and a subterranean formation via a wellbore; -
FIG. 2 is a side sectional view of an embodiment of a flow control apparatus for use in the system illustrated inFIG. 1 , illustrating the ports in the closed condition; -
FIG. 3 is a side sectional view of the flow control apparatus illustrated inFIG. 2 , illustrating the ports in the opened condition; -
FIG. 4 is a sectional view of a portion of an embodiment of the flow control apparatus illustrated inFIG. 2 , showing one configuration for effecting displacement of the flow control member by establishing fluid communication between a fluid responsive surface of the flow control member and the housing passage, with an actuatable valve effecting sealing, or substantial sealing of the fluid communication, and with the flow control member disposed in the closed position; -
FIG. 5 is a sectional view of the portion illustrated inFIG. 4 , with the actuatable valve having become displaced and thereby effecting fluid communication between the fluid responsive surface and the housing passage; -
FIG. 6 is a sectional view of a larger portion of the embodiment of the flow control apparatus illustrated inFIG. 3 , with the flow control member having been displaced to the open position, in response to the urging of fluid pressure acting on the fluid responsive surface; -
FIG. 7 is a sectional view of a portion of another embodiment of the flow control apparatus illustrated inFIG. 2 , showing one configuration for effecting displacement of the flow control member by establishing fluid communication between a fluid responsive surface of the flow control member and the housing passage, with an exploding bolt effecting sealing, or substantial sealing of the fluid communication; -
FIG. 8 is a sectional view of the portion the flow control apparatus illustrated inFIG. 7 , illustrated after fracturing of the bolt; -
FIG. 9 is an isometric view of a flow control member, with a controller assembly; -
FIG. 10 is a plan view of the controller assembly ofFIG. 9 ; -
FIGS. 11A, 11B are schematic views of hardware components of the controllers of the controller assembly ofFIG. 9 ; -
FIG. 12 is a block diagram of software at the controllers ofFIGS. 11A-11B ; -
FIG. 13 is a plot of a pressure profile representative of a modulation scheme for signaling a controller; -
FIG. 14A is a schematic diagram of modes of operation of a controller; -
FIG. 14B is a flow chart depicting processes taken at a wellhead controller and a flow control apparatus controller according to an example embodiment; -
FIG. 15 is a schematic illustration of a system for effecting fluid communication between the surface and a subterranean formation via a wellbore, with flow control apparatus having controllers at multiple locations; -
FIG. 16 is a flow chart depicting a process of operating the system ofFIG. 15 ; -
FIG. 17 is a flow chart depicting a process of closing a flow control apparatus of the system ofFIG. 15 ; -
FIG. 18 is a schematic illustration of some of the hardware components of an embodiment of a flow control apparatus; and -
FIG. 19 is a flow chart depicting a process of opening a flow control apparatus ofFIG. 18 . - Referring to
FIG. 1 , there is provided a wellborematerial transfer system 104 for conducting material from thesurface 10 to asubterranean formation 100 via awellbore 102, from thesubterranean formation 100 to thesurface 10 via thewellbore 102, or between thesurface 10 and thesubterranean formation 100 via thewellbore 102. In some embodiments, for example, thesubterranean formation 100 is a hydrocarbon material-containing reservoir. - In some embodiments, for example, the conducting (such as, for example, by flowing) material to the
subterranean formation 100 via thewellbore 102 is for effecting selective stimulation of a hydrocarbon material-containing reservoir. The stimulation is effected by supplying treatment material to the hydrocarbon material-containing reservoir. In some embodiments, for example, the treatment material is a liquid including water. In some embodiments, for example, the liquid includes water and chemical additives. In other embodiments, for example, the treatment material is a slurry including water, proppant, and chemical additives. Exemplary chemical additives include acids, sodium chloride, polyacrylamide, ethylene glycol, borate salts, sodium and potassium carbonates, glutaraldehyde, guar gum and other water soluble gels, citric acid, and isopropanol. In some embodiments, for example, the treatment material is supplied to effect hydraulic fracturing of the reservoir. In some embodiments, for example, the treatment material includes water, and is supplied to effect waterflooding of the reservoir. In some examples the treatment material may include a gas. - In some embodiments, for example, the conducting (such as, for example, by flowing) material from the
subterranean formation 100 to thesurface 10 via thewellbore 102 is for effecting production of hydrocarbon material from the hydrocarbon material-containing reservoir. In some of these embodiments, for example, the hydrocarbon material-containing reservoir, whose hydrocarbon material is being produced by the conducting via thewellbore 102, has been, prior to the producing, stimulated by the supplying of treatment material to the hydrocarbon material-containing reservoir. - In some embodiments, for example, the conducting to the
subterranean formation 100 from thesurface 10 via thewellbore 102, or from thesubterranean formation 100 to thesurface 10 via thewellbore 102, is effected via one or moreflow communication stations 115 that are disposed at the interface between thesubterranean formation 100 and thewellbore 102. In some embodiments, for example, theflow communication stations 115 are integrated within awellbore string 116 that is deployed within thewellbore 102. Integration may be effected, for example, by way of threading or welding. - A
wellhead 117 may be provided at the surface for communication of fluid into or out ofwellbore 102 andwellbore string 116.Wellhead 117 may be connected to a production conduit for receiving fluid produced via thewellbore 102.Wellhead 117 may further be connected to an injection conduit for communicating fluid intowellbore 102 andwellbore string 116.Wellhead 117 may have one ormore valves 123, operable to selectively permit or restrict flow fromwellbore string 116 to production conduit and from injection conduit to wellborestring 116. The one ormore valves 123 may be operable to open in discrete or continuously variable stages, such that the flow rate fromwellbore string 116 to production conduit 121 a and from injection conduit to wellborestring 116 is adjustable. In an example, at least some ofvalves 123 are proportional valves. The one ormore valves 123 may further be operable to selectively ventwellbore string 116 to atmosphere. - The
wellbore string 116 includes one or more of pipe, casing, and liner, and may also include various forms of tubular segments, such as theflow control apparatuses 115A described herein. Thewellbore string 116 defines awellbore string passage 119 for effecting conduction of fluids between thesurface 10 and thesubterranean formation 100. In some embodiments, for example, theflow communication station 115 is integratable within thewellbore string 116 by a threaded connection. - Successive
flow communication stations 115 may be spaced from each other along thewellbore string 116 such that eachflow communication stations 115 is positioned adjacent a zone or interval of thesubterranean formation 100 for effecting flow communication between thewellbore 102 and the zone (or interval). - For effecting the flow communication, the
flow communication station 115 includes aflow control apparatus 115A. Referring toFIGS. 2 to 6 , theflow control apparatus 115A includes one ormore ports 118 through which the conducting of the material is effected. Theports 118 are disposed within a sub that has been integrated within thewellbore string 116, and are pre-existing, in that theports 118 exist before the sub, along with thewellbore string 116, has been installed downhole within thewellbore string 116. - The
flow control apparatus 115A includes aflow control member 114 for controlling the conducting of material by theflow control apparatus 115A via the one ormore ports 118. Theflow control member 114 is displaceable, relative to the one ormore ports 118, for effecting opening of the one ormore ports 118. In some embodiments, for example, theflow control member 114 is also displaceable, relative to the one ormore ports 118, for effecting closing of the one ormore ports 118. In this respect, theflow control member 114 is displaceable from a closed position (seeFIG. 2 ) to an open position (seeFIG. 3 ). The open position of theflow control member 114 corresponds to an open condition of the one ormore ports 118. The closed position of theflow control member 114 corresponds to a closed condition of the one ormore ports 118. - In some embodiments, for example, the
flow control member 114 is displaceable mechanically, such as, for example, with a shifting tool. In some embodiments, for example, theflow control member 114 is displaceable hydraulically, such as, for example, by communicating pressurized fluid via the wellbore to urge the displacement of theflow control member 14. In some embodiments, for example, theflow control member 114 is integrated within a flow control apparatus which includes an actuator for effecting displacement of theflow control member 114 hydraulically in response to receiving of a signal transmitted from thesurface 10. - In some embodiments, for example, in the closed position (see
FIG. 2 ), the one ormore ports 118 are covered by theflow control member 114, and the displacement of theflow control member 114 to the open position (seeFIG. 3 ) effects at least a partial uncovering of the one ormore ports 118 such that the one ormore ports 118 become disposed in the open condition. In some embodiments, for example, in the closed position, theflow control member 114 is disposed, relative to the one ormore ports 118, such that a sealed interface is disposed between thewellbore string 116 and thesubterranean formation 100, and the disposition of the sealed interface is such that the conduction of material between thewellbore string 116 and thesubterranean formation 100, via theflow communication station 115 is prevented, or substantially prevented, and displacement of theflow control member 114 to the open position effects flow communication, via the one ormore ports 118, between thewellbore string 116 and thesubterranean formation 100, such that the conducting of material between thewellbore string 116 and thesubterranean formation 100, via the flow communication station, is enabled. In some embodiments, for example, the sealed interface is established by sealing engagement between theflow control member 114 and thewellbore string 116. In some embodiments, for example, theflow control member 114 includes a sleeve. The sleeve is slideably disposed within thewellbore string passage 119. - In some embodiments, for example, the
flow control apparatus 115A includes ahousing 120. Thehousing 120 includes one or more sealing surfaces configured for sealing engagement with aflow control member 114, wherein the sealing engagement defines the sealed interface described above. In this respect, sealingsurfaces housing 120 for sealing engagement with theflow control member 114. In some embodiments, for example, each one of the sealing surfaces 124, 126 is defined by a respective sealing member. In some embodiments, for example, each one of the sealing members, independently, includes an o-ring. In some embodiments, for example, the o-ring is housed within a recess formed within thehousing 120. In some embodiments, for example, the sealing member includes a molded sealing member (i.e. a sealing member that is fitted within, and/or bonded to, a groove formed within the sub that receives the sealing member). In some embodiments, for example, the one ormore ports 118 extend through thehousing 120, and are disposed between the sealingsurfaces - The
housing 120 includes ahousing passage 125 which forms a portion of thewellbore string passage 119 for effecting material transfer between thesurface 10 and thesubterranean formation 100. In this respect, material transfer between thehousing passage 125 and thesubterranean formation 100 is effected via the one ormore ports 118. Thehousing 120 includes aninlet 120A and anoutlet 120B. Theinlet 120A fluidly communicates with theoutlet 120B via thehousing passage 125. - The
flow control member 114 co-operates with the sealingmembers 122, 124 to effect opening and closing of the one ormore ports 118. When the one ormore ports 118 is disposed in the closed condition, theflow control member 114 is sealingly engaged to both of the sealingmembers 122, 124, thereby preventing, or substantially preventing, treatment material, being supplied through the wellbore string passage 119 (including the housing passage 125) from being injected into thesubterranean formation 100 via the one ormore ports 118. When the one ormore ports 118 is disposed in the open condition, theflow control member 114 is spaced apart or retracted from at least one of the sealing members thereby providing a passage for treatment material, being supplied through thewellbore string passage 119, to be injected into thesubterranean formation 100 via the one ormore ports 118. - Each one of the opening force and the closing force may be, independently, applied to the
flow control member 114 mechanically, hydraulically, or a combination thereof. In some embodiments, for example, theflow control member 114 is integrated within aflow control apparatus 115A which includes an actuator for effecting displacement of theflow control member 114 hydraulically in response to sensing of a signal transmitted from thesurface 10 by a sensor 150 (see below). - In some embodiments, for example, while the
flow control apparatus 115A is being deployed downhole with thewellbore string 116, theflow control member 114 is disposed in the closed position by one or more shear pins, and is thereby restricted from displacement relative to the one ormore ports 118 such that opening of the one ormore ports 118 is effected. The one or more shear pins are provided to secure theflow control member 114 to the wellbore string 116 (including while the wellbore string is being installed downhole) so that thepassage 119 is maintained fluidically isolated from theformation 100 until it is desired to treat theformation 100 with treatment material. To effect the initial displacement of theflow control member 114 from the closed position to the open position, sufficient force must first be applied to the one or more shear pins such that the one or more shear pins become sheared, resulting in theflow control member 114 becoming moveable relative to the one ormore ports 118. In some operational implementations, the force that effects the shearing is applied by a workstring. Alternatively, in some embodiments, for example, theflow control member 114 is restricted from displacement relative to the one or more ports 118 (such that opening of the one ormore ports 118 is effected), while being deployed downhole with the workstring, by being disposed in press fit engagement with thehousing 120. - In some embodiments, for example, the
flow control member 114 includes a sliding sleeve. - Referring to
FIGS. 4 to 6 , in some embodiments, for example, the displacement of theflow control member 114 from the closed position to the open position is effectible in response to urging by fluid pressure that is communicated from thehousing passage 125 to a fluidresponsive surface 140. The fluid communication between thehousing passage 125 and the fluidresponsive surface 140 is establishable, directly or indirectly, in response to sensing, by thesensor 150, of a signal that is communicated downhole. The fluid communication may be selectively permitted by an opening actuation system, a first example embodiment of which is shown in depicted inFIGS. 4 to 6 , and a second example embodiment of which is shown inFIGS. 7 and 8 . - In this respect, in some embodiments, for example, and referring to
FIG. 3 and the first embodiment ofFIGS. 4 to 6 , theflow control apparatus 115A includes afluid communication actuator 302 and a sealinginterface 304. The sealinginterface 304 effects sealing, or substantial sealing, of the fluidresponsive surface 140 from thehousing passage 125. Thefluid communication actuator 302 is configured for defeating the sealinginterface 304. In this respect, theactuator 302 is responsive to sensing a control signal that is addressed to theflow control apparatus 115A. In one example, the control signal is a sealing interface-defeating (“SID”) signal, sensed by thesensor 150 offlow control apparatus 115A, for defeating the sealinginterface 304 such that establishment of fluid communication between thehousing passage 125 and the fluidresponsive surface 140 is effected. - In some embodiments, for example, the SID signal is transmitted through the
wellbore 102. In some of these embodiments, for example, the SID signal is transmitted via fluid disposed within thewellbore 102. - In some examples,
sensor 150 is enabled to take measurements that will allowcontroller 500 to determine a rate of flow change in a pressurised fluid in the wellbore string passage. For example, in some embodiments, thesensor 150 is a pressure sensor, and the actuating signal is one or more pressure pulses. Various suitable sensors may be employed, depending on the nature of the signal being used for the actuating signal. An exemplary pressure sensor is a Kellar Pressure Transducer. Additional or other suitable sensors include a Hall effect sensor, a radio frequency identification (“RFID”) sensor, or a sensor that can detect a change in chemistry (such as, for example, pH), or radiation levels, or ultrasonic waves. - As described in further detail below, in some embodiments, the SID signal is sent by introducing modulated pressure changes within
wellbore passage 119. Specifically, pressure changes may be created withinwellbore 119 in a sequence of stages, with each stage having a particular rate of pressure change. The rate of pressure change corresponds to a digit or symbol in a number system, e.g. a binary or quaternary number system. In some embodiments, for example, thesensor 150 is disposed in communication within thewellbore 102, and the SID signal is being transmitted within thewellbore 102, such that thesensor 150 is disposed for sensing the SID signal being transmitted within thewellbore 102. In some embodiments, for example, thesensor 150 is disposed within thewellbore 102. In this respect, in some embodiments, for example, thesensor 150 is mounted to thehousing 120 within a hole that extends to thewellbore 102, and is held in by a backing plate that is configured to resist the force generated by pressure acting on thesensor 150. - In some alternative embodiments, for example, the
sensor 150 is configured to receive a signal generated by a seismic source. In some embodiments, for example, the seismic source includes a seismic vibrator unit. In some of these embodiments, for example, the seismic vibration unit is disposed at thesurface 10. - In some embodiments, for example, the
flow control apparatus 115 further includes avalve member 308, and the sealinginterface 304 is defined by a sealing, or substantially sealing, engagement between thevalve member 308 and thehousing 120. In some embodiments, for example, the sealinginterface 304 is defined by sealing members (such as, for example, o-rings) carried by thevalve member 308. In this respect, the change in condition of the sealinginterface 304 is effected by a change in condition of thevalve member 308. Also in this respect, theactuator 302 is configured to effect a change in condition of the valve member 308 (in response to the sensing of the SID signal by the sensor 150) such that there is a loss of the sealing, or substantially sealing, engagement between thevalve member 308 and thehousing 120, such that the sealinginterface 304 is defeated, and such that fluid communication between thehousing passage 125 and the fluidresponsive surface 140 is established. - In some embodiments, for example, the
valve member 308 is displaceable, and the change in condition of thevalve member 308, which theactuator 302 is configured to effect in response to the sensing of a SID signal by thesensor 150, includes displacement of thevalve member 308. In this respect, theactuator 302 is configured to effect displacement of thevalve member 308 such that the sealinginterface 304 is defeated and such that fluid communication between thehousing passage 125 and the fluidresponsive surface 140 is established. - In some embodiments, for example, the
flow control apparatus 115A further includes apassageway 310. Thevalve member 308 and thepassageway 310 are co-operatively disposed such that fluid communication between thehousing passage 125 and the fluidresponsive surface 140 is established in response to the displacement of thevalve member 308, which is effected in response to the sensing of the SID signal by thesensor 150. In this respect, the establishing of the fluid communication between thehousing passage 125 and the fluidresponsive surface 140 is controlled by the positioning of thevalve member 308 within thepassageway 310. In this respect, thevalve member 308 is configured for displacement relative to thepassageway 310. In some embodiments, for example, thevalve member 308 includes a piston. The displacement of thevalve member 308 is from a closed position (seeFIG. 4 ) to an open position (seeFIG. 5 ). In some embodiments, for example, when disposed in the closed position, thevalve member 308 is occluding thepassageway 310. In some embodiments, for example, when thevalve member 308 is disposed in the closed position, sealing, or substantial sealing, of fluid communication, between thehousing passage 125 and the fluidresponsive surface 140 is effected. When thevalve member 308 is disposed in the open position, fluid communication is effected between thehousing passage 125 and the fluidresponsive surface 140. - In some embodiments, for example, the
passageway 310 extends through theflow control member 114, and thevalve member 308 is disposed in a space within theflow control member 114, such that the displacement of thevalve member 308 is also relative to theflow control member 114. - In some embodiments, for example, the
actuator 302 includes an electro-mechanical trigger, such as an energetic device. The energetic device is configured to, in response to the signal received by thesensor 150, effect generation of an explosion. In some embodiments, for example, the energetic device is mounted within the body such that the generated explosion effects the displacement of thevalve member 308. An example of an energetic device is a squib. Anothersuitable actuator 302 is a fuse-able link or a piston pusher. - In some embodiments, for example, the
flow control apparatus 115A further includes first andsecond chambers first chamber 312 is disposed in fluid communication with the fluidresponsive surface 140 for receiving pressurized fluid from thehousing passage 125, and thesecond chamber 314 is configured for containing a fluid and disposed relative to theflow control member 114 such that fluid contained within thesecond chamber 314 opposes the displacement of theflow control apparatus 115A that is being urged by pressurized fluid within thefirst chamber 312, and the displacement of theflow control member 114 is effected when the force imparted to theflow control member 114 by the pressurized fluid within thefirst chamber 312 exceeds the force imparted to the flow control member by the fluid within thesecond chamber 314. In some embodiments, for example, the displacement of theflow control member 114 is effected when the pressure imparted to theflow control member 114 by the pressurized fluid within thefirst chamber 312 exceeds the pressure imparted to theflow control member 114 by the fluid within thesecond chamber 314. - In some embodiments, for example, both of the first and
second chambers housing 120 and theflow control member 114, and achamber sealing member 316 is also included for effecting a sealing interface between thechambers flow control member 114 is being displaced to effect the opening of the one ormore ports 118. - In some embodiments, for example, to mitigate versus inadvertent opening, the
valve member 308 may, initially, be detachably secured to thehousing 120, in the closed position. In this respect, in some embodiments, for example, the detachable securing is effected by a shear pin configured for becoming sheared, in response to application of sufficient shearing force, such that thevalve member 308 becomes movable from the closed position to the open position. In some embodiments, for example, the shearing force is effected by theactuator 302. - In some embodiments, for example, to prevent the inadvertent opening of the
valve member 308, thevalve member 308 may be biased to the closed position, such as by, for example, a resilient member such as a spring. In this respect, theactuator 302 used for effecting opening of thevalve member 308 must exert sufficient force to at least overcome the biasing force being applied to thevalve member 308 that is maintaining thevalve member 308 in the closed position. - In some embodiments, for example, to prevent the inadvertent opening of the
valve member 308, thevalve member 308 may be pressure balanced such that thevalve member 308 is disposed in the closed position. - In some embodiments, for example, the
flow control apparatus 115A further includes a control assembly, as described in greater detail below. The control assembly includes a controller that is configured to decode (recognize) a sensor-transmitted signal from thesensor 150 when thesensor 150 senses the SID signal and, in response to the received sensor-transmitted signal from thesensor 150, the controller will transmit an actuation command to theactuator 302. The controller may poll thesensor 150 to receive the sensor-transmitted signal or thesensor 150 may be configured to push the sensor-transmitted signal to the controller without being polled. In some embodiments, for example, the controller and thesensor 150 are powered by a battery that is disposed on-board within theflow control apparatus 115A. Passages for wiring for electrically interconnecting the battery, the sensor, the controller and the trigger are also provided within theapparatus 115A. - As noted above,
FIGS. 7 and 8 illustrate an alternative embodiment of an opening actuation system that can be used in theflow control apparatus 115A ofFIGS. 2 and 3 . Differences between the embodiment ofFIGS. 4 to 6 and the embodiment ofFIGS. 7 and 8 are as follows. In the embodiment ofFIGS. 7 and 8 , theflow control apparatus 115A also includes a sealinginterface 406 that effects sealing, or substantial sealing, of fluid communication between the fluid pressureresponsive surface 140 and thehousing passage 125. Theflow control apparatus 115A ofFIGS. 7 and 8 includes a sealing interface-conditioning actuator 402 configured for effecting a change in condition of the sealinginterface 406 from a non-defeatable condition to a defeatable condition. While the sealinginterface 406 is disposed in the defeatable condition, defeating of the sealinginterface 406 is effectible in response to communication of a pressurized fluid. After the defeating of the sealinginterface 406, fluid communication becomes effectible between thehousing passage 125 and the fluid responsive surface 140 (not shown) of theflow control member 114. In this respect, theflow control member 114 becomes displaceable from the closed position to the open position in response to the communication of fluid pressure from thehousing passage 125 to the fluidresponsive surface 140. - The
actuator 402 is configured to effect a change in condition of the sealinginterface 406 from a non-defeatable condition to a defeatable condition in response to sensing bysensor 150 of a control signal that is addressed to theflow control apparatus 115A. In the example ofFIGS. 7 and 8 , the control signal is a sealing interface actuation (“SIA”) signal, detected by thesensor 150. In this context, “non-defeatable” does not mean that the sealinginterface 406 cannot be defeated for all purposes, but under normal operating conditions, the sealing interface is not defeatable, and, at minimum, the sensing of the SIA signal by thesensor 150 effects a change in condition such that the sealing interface transitions to a relatively more defeatable condition, and defeatable upon application of fluid pressure during normal operating conditions). In some embodiments, for example, the SIA signal is transmitted through thewellbore 102. In some of these embodiments, for example, the SIA signal is transmitted via fluid disposed within thewellbore 102. - As noted above on respect of SID signal, in some embodiments, for example, the SIA signal can also be implemented as one or more pressure pulses. In some embodiments, for example, the SIA signal is defined by a pressure pulse characterized by at least a magnitude. In some embodiments, for example, the pressure pulse is further characterized by at least a duration. In some embodiments, for example, the SIA signal is defined by a pressure pulse characterized by at least a duration.
- In some embodiments, for example, the control signal (e.g. SID signal in the embodiment of
FIGS. 4 to 6 and SIA signal in the embodiment ofFIGS. 7, 8 ) is defined by a plurality of pressure pulses. In some embodiments, for example, the control signal is defined by a plurality of pressure pulses, each one of the pressure pulses characterized by at least a magnitude. In some embodiments, for example, the control signal is defined by a plurality of pressure pulses, each one of the pressure pulses characterized by at least a magnitude and a duration. In some embodiments, for example, the control signal is defined by a plurality of pressure pulses, each one of the pressure pulses characterized by at least a duration. In some embodiments, for example, each one of pressure pulses is characterized by time intervals between the pulses. - In the embodiment of
FIGS. 7, 8 , in some examples, theflow control apparatus 115A includes avalve member 408, and the sealinginterface 406 is defined by sealing, or substantially sealing, engagement between thevalve member 408 and thehousing 120. In this respect, the change in condition of the sealinginterface 406 is effected by a change in condition of thevalve member 408. Also in this respect, theactuator 402 is configured to effect a change in condition of the valve member 408 (in response to the sensing of the SIA signal by the sensor 150) such that the sealinginterface 406 becomes disposed in the defeatable condition. In this respect, while the sealing interface 406 (defined by the sealing, or substantially sealing, engagement between thevalve member 408 and the housing 120) is disposed in the defeatable condition (the defeatable condition having been effected in response to the change in condition of thevalve member 408, as above-described), in response to receiving communication of a pressurized fluid, there is a loss of the sealing, or substantially sealing, engagement between thevalve member 408 and thehousing 120. As a result, there is a loss of sealing, or substantially sealing, engagement between thevalve member 408 and thehousing 120, such that the sealinginterface 406 is defeated, and such that fluid communication is established between thehousing passage 125 and the fluidresponsive surface 140. - In some embodiments, for example, the
valve member 408 includes avalve sealing surface 408A configured for effecting the sealing, or substantially sealing, engagement between thevalve member 408 and thehousing 120. In this respect, the sealing, or substantially sealing, engagement between thevalve member 408 and thehousing 120 is effected by the sealing, or substantially sealing, engagement between thevalve sealing surface 408A and ahousing sealing surface 2202. Also in this respect, the change in condition of thevalve member 408 is such that thevalve sealing surface 408A becomes displaceable relative to thehousing sealing surface 2202 for effecting a loss of the sealing, or substantially sealing, engagement between thevalve sealing surface 408A and thehousing sealing surface 2202, such that the sealinginterface 404 is defeated and such that fluid communication is established between thehousing passage 125 and the fluidresponsive surface 140. Also in this respect, the loss of the sealing, or substantially sealing, engagement between thevalve member 408 and thehousing 120, that is effected in response to receiving communication of a pressurized fluid while thevalve member 408 is disposed such that thevalve sealing surface 408A is displaceable relative to thehousing sealing surface 2202, includes the loss of the sealing, or substantially sealing, engagement between thevalve sealing surface 408A and thehousing sealing surface 2202. - In some embodiments, for example, the
flow control apparatus 115A further includes a passageway 4270, and the passageway 410 extends between thehousing passage 125 and the fluidresponsive surface 140. Thevalve member 408 and thepassageway 427 are co-operatively disposed such that the fluid communication between thehousing passage 125 and the fluidresponsive surface 140 is established in response to the displacement of thevalve member 408 relative to thepassageway 427, effected in response to the sensing of the SIA by thesensor 150. Sealing, or substantial sealing, of thepassageway 427 is effected by the sealing or substantially sealing, engagement between thevalve member 408 and the housing 120 (and, in some embodiments, for example, thevalve sealing surface 408A and the housing sealing surface 2202). Also in this respect, sealing, or substantially sealing, of fluid communication between thehousing passage 125 and the fluidresponsive surface 140 is effected by the sealing or substantially sealing, engagement between thevalve member 408 and the housing 120 (and, in some embodiments, for example, thevalve sealing surface 408A and the housing sealing surface 2202). - In some embodiments, for example, the
actuator 402 includes a squib, and the change in condition of the sealing interface 406 (and also, in some embodiments, for example, the valve member 408) is effected by an explosion generated by the squib in response to sensing of the SIA signal through thesensor 150. In some embodiments, for example, the squib is suitably mounted within thehousing 120 to apply the necessary force to thevalve member 408. Anothersuitable valve actuator 402 is a fuse-able link or a piston pusher. - In some embodiments, for example, the change in condition of the
valve member 408 includes a fracturing of thevalve member 408. In the embodiment illustrated inFIG. 8 , the fracture is identified byreference numeral 412. In some embodiments, for example, while thevalve member 408 is disposed in a fractured condition, in response to receiving communication of a pressurized fluid, a loss of the sealing, or substantially sealing, engagement between thevalve member 408 and thehousing 120 is effected, such that there is an absence of sealing, or substantially sealing, engagement between thevalve member 408 and thehousing 120, and such that the sealinginterface 406 is defeated and such that fluid communication is established between thehousing passage 125 and the fluidresponsive surface 140. - In those embodiments where the change in condition of the
valve member 408 includes a fracturing of thevalve member 408, in some of these embodiments, for example, thevalve member 408 includes acoupler 408B that effects coupling of thevalve member 408 to thehousing 120 while the change in condition is effected. In some embodiments, for example, thecoupler 408B is threaded to thehousing 120. In those embodiments where thevalve member 408 includes acoupler 408B, in some of these embodiments, for example, thevalve member 408 and theactuator 402 are defined by an explodingbolt 414, such that the explodingbolt 414 is threaded to thehousing 120. In some embodiments, for example, the squib is integrated into thebolt 414. - In some embodiments, for example, the
flow control apparatus 115A further includes first and second chambers (only thefirst chamber 416 is shown). Thefirst chamber 416 is disposed in fluid communication with the fluidresponsive surface 140 for receiving pressurized fluid from thehousing passage 125, and the second chamber is configured for containing a fluid and disposed relative to theflow control member 114 such that fluid contained within the second chamber opposes the displacement of theflow control apparatus 115A that is being urged by pressurized fluid within thefirst chamber 416, and the displacement of theflow control member 114 is effected when the force imparted to theflow control member 114 by the pressurized fluid within the first chamber 434 exceeds the force imparted to the flow control member by the fluid within the second chamber. In some embodiments, for example, the displacement of theflow control member 114 is effected when the pressure imparted to theflow control member 114 by the pressurized fluid within thefirst chamber 416 exceeds the pressure imparted to the flow control member by the fluid within the second chamber. In some embodiments, for example, the fluid within the second chamber is disposed at atmospheric pressure. - In some embodiments, for example, both of the first and second chambers are defined by respective spaces interposed between the
housing 120 and theflow control member 114, and a chamber sealing member is also included for effecting a sealing interface between the first and second chambers while theflow control member 114 is being displaced to effect the opening of the one ormore ports 118. - As noted above in respect of the actuation system of the embodiment shown in
FIGS. 4 to 6 , embodiments of the actuation system of theflow control apparatus 115A ofFIGS. 7, 8 also include control assembly. The control assembly includes a controller configured to receive a sensor-transmitted signal from thesensor 150 upon the sensing of the SIA signal and, in response to the received sensor-transmitted signal, supply a transmitted signal to theactuator 402. In some embodiments, for example, the controller and thesensor 150 are powered by a battery that is disposed on-board within theflow control apparatus 115A. Passages for wiring for electrically interconnecting the battery, thesensor 150, the controller and theactuator 402 are also provided within theapparatus 115A. - In some embodiments,
flow control member 114 may also be displaceable from the open position to the closed position. For example, flowcontrol apparatus 115A may include a closing actuation system configured to causeflow control member 114 to be urged toward the closed position. The closing actuation system may be substantially similar to the opening actuation systems depicted inFIGS. 4 to 6 and 7,8 , except with a fluid responsive surface oriented in the opposite direction, so that pressure acting on the fluid responsive surface urgesflow control member 114 in the opposite direction. - As described above, urging of
flow control member 114 between its respective positions may be caused by pressurized fluid withinpassage 125. Alternatively, in some embodiments,flow control member 114 may be urged between its respective positions by pressurized fluid generated by a pressurized fluid generator, such as a squib. Examples of such configurations are disclosed in co-pending U.S. patent application Ser. No. 15/151,799, published as US patent application publication no. US 2016/0333679, the entire contents of which are incorporated herein by reference. - A control assembly and a process implemented by the control assembly to program and control an actuating system such as those described above in respect of
FIGS. 4 to 6 and 7, 8 will now be described with reference toFIGS. 9 through 17 .FIG. 9 depicts an exampleflow control member 114 with acontrol assembly 499 including afirst controller 500, and asecond controller 501.FIG. 10 depicts a plan view of thecontrol assembly 499.First controller 500 is electrically connected with a power source 502 (e.g. one or more batteries) and is connected in data communication withsensor 150 that is configured to detect a downhole control signal such as SID or SIA signal (sensor 150) not shown inFIGS. 9-10 ).Second controller 501 is also electrically connected withpower source 502 and is further connected in data communication with at least one additional sensor or transceiver, referred to astransceiver 504 that is configured to receive signals for programming/addressing the control assembly.Transceiver 504 may be of the same or different type assensor 150 and bothsensor 150 andtransceiver 504 may include multiple sensors of different types. For example,sensor 150 andtransceiver 504 may each include acoustic sensors such as microphones; piezoelectric sensors capable of detecting seismic vibrations; ultrasound sensors; electromagnetic sensors; pressure sensors; RFID sensors; or a combination thereof. - In the depicted embodiment,
power source 502 includes a plurality ofbatteries 503 and a bank ofcapacitors 507.Capacitors 507 electrically communicate withbatteries 503, which maintaincapacitors 507 in a charged state.First controller 500 may selectively causecapacitors 507 to discharge, providing an output trigger current to actuator 302/402.Capacitors 507 are capable of discharging more quickly thanbatteries 503. Thus,capacitors 507 are capable of providing brief power surge sufficient to ignite an explosive device such as a squib. -
Controllers power source 502 are received in a recess withinflow control member 114.Controllers power source 502 may be mounted on acarrier 505, e.g. a printed circuit board within the recess. In the depicted embodiment, the recess is an external annular recess onflow control member 114 andcarrier 505 extends aroundflow control member 114 in the recess.Carrier 505 may be sufficiently flexible to wrap aroundflow control member 114. -
Sensor 150 may be mounted to and communicate withfirst controller 500 by way ofcarrier 505.Sensor 150 may be received in a through hole inflow control member 114, such that it is exposed to fluid inwellbore string passage 119. - In other embodiments, one or more of first and
second controllers power source 502 may each be received in different recesses. -
First controller 500 communicates with an actuator system that is used to effect opening and or closing offlow control member 114, e.g. by a wired or wireless connection. For simplicity,controller 500 is described herein with reference to interactions withactuator 402 of the actuator system ofFIG. 7, 8 . However,controller 500 may additionally or alternatively be used in devices withfluid communication actuators 302 of the actuator system ofFIGS. 4 to 6 , or other types of actuators, and therefore references to actuator 402 should be understood to refer to other suitable types of actuators. -
Second controller 501 communicates withfirst controller 500. For example, as described in further detail below, in some embodiments,second controller 501 receives programming instructions and communicates withfirst controller 500 to causefirst controller 500 to operate according to the programming instructions. -
FIG. 11A is a block diagram of example components offirst controller 500. The components shown inFIG. 11A may be part of one or more semiconductor chips. As shown,first controller 500 includes aprocessor 506,memory 508,storage 510, and one or more input/output (I/O) devices 512. The components may communicate with one another, e.g. by way of abus 513. In the depicted embodiment, the I/O devices 512 includesensor 150. -
FIG. 11B is a block diagram of example components ofsecond controller 501. The components shown inFIG. 11B may be part of one or more semiconductor chips. As shown,second controller 501 includes aprocessor 506,memory 508,storage 510, and at least onetransceiver 504. The components may communicate with one another, e.g. by way of abus 513. In the depicted embodiment, the I/O devices include atransceiver 504. -
FIG. 12 is a block diagram of logical modules atcontrollers storage 510 for execution byprocessor 506. Alternatively, one or more logical modules may be implemented in specialized hardware circuits on one or more semiconductor chips. - As shown in
FIG. 12 ,controllers signal decoder module 514, aninstruction processing module 516, and atrigger module 518.Signal decoder module 514 converts signals received bysensor 150,transceiver 504 into instructions readable byinstruction processing module 516.Instruction processing module 516 parses the instructions and determines if the actuator should be activated.Trigger module 518 selectively causes transmitter 512-2 to output a signal for activatingactuator 402. - In an example embodiment,
transceiver 504 include anacoustic transceiver 504 a, capable of receiving and producing an output indicative of vibrations at frequencies in the sonic range (e.g. 500 Hz to 2 kHz) or the ultrasound range (e.g. over 20 kHz), and of generating vibrations at frequencies in the sonic range or the ultrasound range.Sensor 150 is a pressure transducer capable of detecting and producing an output indicative of changes in fluid pressure inwellbore string passage 119. - Control signals may be passed to first controller 500 (and in some examples, second controller 501) through
wellbore string passage 119 by inducing fluid pressure changes inwellbore string passage 119. For example, pressure changes may be introduced inwellbore string passage 119, by openingvalve 123 ofwellhead 117 and control messages may be encoded in the pressure changes, such as the magnitude and rate of the pressure change. In example embodiments,valve 123 is opened and closed by awellhead controller 640.Wellhead controller 640 may be implemented as a programmable logic controller, PC or other similar control device that controls a valve actuator ofvalve 123 to generate and transmit the control messages. As described in greater detail below, the control messages may be encoded as packetized messages (referred to herein as Downhole Data Units (DDUs)) that each comprise multiple symbols that are each encoded as a respective pressure change rate. - In an example, the
first controller 500 of eachflow control apparatus 115A may be assigned a unique identification value, which may be an 8-bit numerical value, e.g. from 0 to 255. A master transmitter at the surface may transmit a control signal downwellbore string passage 119, instructing a specific one offlow control apparatuses 115A to open. The signal may be the numerical identification value of the correspondingfirst controller 500. Eachfirst controller 500 is programmed with a unique identification value, which may also be referred to as an address. Programming of the unique identification value may be done prior to insertion ofcontroller 500 in a recess withinflow control member 114. As noted, in some embodiments,transceiver 504 includes anacoustic transceiver 504 a that is capable of detecting acoustic vibrations, including acoustic vibrations in the sonic range (e.g. 500 Hz to 2 kHz) or the ultrasound frequency range (e.g. over 20 kHz).Second controller 501 may be programmed using acoustic (e.g. sonic or ultrasound) vibrations. Specifically, vibrations may be transmitted to flowcontrol apparatus 115A and received bytransceiver 504 andcontroller 501. Instructions may be encoded in the vibrations, and decoded bysignal decoding module 514 andinstruction processing module 516 ofcontroller 501.Second controller 501 may then pass instructions tofirst controller 500 to programfirst controller 500. In some examples, the instructions sent via acoustic (e.g. sonic or ultrasound) vibrations received bytransceiver 504 ofsecond controller 501 include assignment of an identification value or address forfirst controller 500. - Conveniently, while
housing 120 may attenuate electromagnetic and certain other types of signals, sonic or ultrasound vibrations may pass relatively easily throughhousing 120. Accordingly, programming may be performed withcontroller 501 andtransceiver 504 fully enclosed byhousing 120. Conversely, programming by wired connection or by sending electromagnetic signals may require physical access tocontroller transceiver 504. - Sonic or ultrasound vibrations may be transmitted to a
acoustic transceiver 504 a throughhousing 120 using a programming apparatus including a suitable sonic or ultrasound transducer under control of a programmable logic controller, PC or other similar control device. For example, vibrations may be delivered using a piezoelectric or capacitive transducer positioned against a surface ofhousing 120. Alternatively, vibrations may be generated remotely, e.g. by vibration of a diaphragm and transmitted through a medium such as air tohousing 120.Transceiver 504 may include a speaker and a microphone. - In some embodiments, messages may be sent by sonic or ultrasound vibrations. Numerical values, such as hexadecimal values may be encoded as pairs of frequencies, which are transmitted. On receipt of a signal by
transceiver 504,signal decoding module 516 ofcontroller 501 converts the signal into the corresponding numerical value, e.g. using a lookup table. - Instructions may be sent to
controller 501 as packetized messages. Such messages are passed toinstruction processing module 518 ofcontroller 501 and parsed into computer-readable instructions. Instructions may include assignment of an address. In some embodiments,controller 501 andtransceiver 504 are capable of generating reply messages, such that full duplex communication can occur betweencontroller 501 and an external programming device via sonic or ultrasound vibrations. In such embodiments, instructions sent tocontroller 501 may include queries, such as battery or operating condition queries, and replies may include data such as battery charge, temperature, charge cycles and the like, and any error messages stored atcontroller 501. - Conveniently,
controllers flow control apparatus 115A in the wellbore. Thus,controllers 500 may be addressed sequentially in an order corresponding to their insertion order (and thus, to their respective positions along the wellbore). For example, address values may be incremented for eachflow control apparatus 115A inserted in the wellbore, such that thecontroller 500 with the lowest address value is inserted first and becomes positioned at the treatment zone closest to the well toe, and such that thesubsequent controllers 500 in the uphole direction define a sequence of address values. - In some alternative examples, assigning an address to a
controller 500 may comprise reading a unique identifier from the flow control apparatus 115(A) (using an RFID reader, for example) that has been pre-assigned to thecontroller 500 and mapping that unique identifier to a sequential address value. In such a configuration,wellhead controller 640 could be programmed to map a sequential address that is assigned during downhole installation to acontroller 500 to the controller's pre-assigned unique identifier. During operation, thewellhead controller 640 can use a lookup table to translate the sequential address to its mapped unique identifier that is then used in the DDU payload to signal thecontroller 500. Such a mapping procedure may reduce the programming required forcontrollers flow control apparatuses 115A. - In some example embodiments, instead of or in addition to an
acoustic transceiver 504 a, thetransceiver 504 ofsecond controller 501 includes an optical sensor or interface 504 b (FIG. 111B ) that is aligned with an optical port 552 (seeFIG. 10 ) that provide a line of sight from an outside of the controller assembly to the optical interface 504 b. The optical interface 504 b can be used as an interface for providing pre-installation instructions to controller 501 (including assignment of a unique address for controller 500) in the same manner as described above in respect ofacoustic transducer 504 a. For example, a suitable optical transducer under control of a programmable logic controller, PC or other similar control device could be aligned with theoptical port 552 to send encoded light messages to the optical interface 504 b for decoding bycontroller 501. In some examples the optical medium may be one or more of infrared light, visible light or ultraviolet light. In some examplesoptical port 552 may be a sight glass. The use of a non-contact line of sight programming system may be beneficial in some applications. - Once inserted in the wellbore, control signals (such as sealing interface-defeating (SID) signals or sealing interface actuation (SIA) signals) may be encoded in one or more DDUs and transmitted to the
first controller 500 of eachflow control apparatus 115A. The control signals may be encoded and transmitted by manipulation of fluid pressure withinwellbore string 116. In particular, withwellbore string passage 119 filled with fluid, the fluid pressurized, and the pressure then relieved by opening avalve 123 inwellhead 117, e.g. to vent air to atmosphere or to route fluid fromwellbore string passage 119 to a reservoir or production conduit. Release of pressure in this manner gradually reduces the pressure of fluid remaining inwellbore string 116 and thereby produces a pressure curve. As noted, opening ofvalve 123 is variable, such that the rate of pressure relief is likewise variable. Thus, the shape of the pressure curve can be modulated to encode instructions forfirst controller 500. For example, opening ofvalve 123 may be controlled to produce a rate of pressure change in any of a set of discrete predetermined values. The resulting pressure curve is monitored byfirst controller 500 and messages in the pressure curve are decoded bycontroller 500. - Specifically,
signal decoder module 514 offirst controller 500 periodically obtains measurements of fluid pressure inwellbore passage 119 fromsensor 150. Measurements may be obtained, for example, bypolling sensor 150 at a particular frequency, maintained e.g. by a clock signal. Based on the periodic pressure measurements,signal decoder module 514 determines a rate of pressure change inwellbore passage 119 and decodes the measured rate of pressure change to a corresponding numerical value. -
FIG. 13 depicts an example modulatedpressure curve 520. As depicted, pressure inwellbore string 116 is initially approximately constant, at pressure P0. In some examples, pressure P0 is approximately 2500 psi. Pressure is relieved in a sequence of stages by operation ofvalve 123. That is, at each stage,valve 123 is opened or closed to a specific opening state. In some examples,valve 123 may be opened to any of four possible states, e.g., 25% open, 50% open, 75% open and 100% open. As will be apparent, the amount of opening ofvalve 123 controls the rate at which pressure is relieved fromwellbore string passage 119—a large opening, such as 100% open will relieve pressure at a faster rate than a small opening, such as 25%. Thus, each of the four discrete opening states produces a corresponding rate of pressure relief. - As shown in
FIG. 13 , pressure inwellbore string passage 119 is relieved in 14 stages, ending at times T1 through T14, respectively. During each stage,valve 123 is set to one of four opening states and creates a pressure curve at one of four possible slopes (rates of pressure change) m1, m2, m3 and m4. For example, during the first stage, from T0 to T1,valve 123 is 100% open and produces a slope of m4. During the second stage, from T1 to T2,valve 123 is 25% open and produces a slope of m1. During the thirteenth stage, from T12 to T13,valve 123 is 75% open and produces a slope of m3. During the fourteenth stage, from T13 to T14,valve 123 is 50% open and produces a slope of m2. - As noted above,
first controller 500 measures pressure inwellbore string passage 119 usingsensor 150. For example,controller 500 may periodically pollsensor 150 for measured pressure values. Based on the polling frequency and reported pressure values,controller 500 can determine changes in pressure over time, e.g. by constructing a log of pressure measurements. - In an example,
controller 500 is configured to determine an average rate of pressure change over a time interval T of predetermined length. For example, as depicted inFIG. 13 , the time interval between each of T1, T2 . . . T14 is seven seconds. However, in other embodiments, the time interval may be shorter or longer. -
Controller 500 is configured to compare the pressure measured at the beginning and end of each time interval in order to determine the rate of pressure change during the interval. For example, the rate of change between T1 and T2 may be determined by dividing the difference between P2 and P1 by the time elapsed between T1 and T2. The resulting value may be matched to one of m1, m2, m3 or m4. Such matching may be done, for example, by measuring the actual slope ofcurve 520 during a time interval, and determining the closest one of slopes m1, m2, m3 and m4 to the actual slope. Alternatively, for a constant time interval, the rate of pressure change may be classified based on the measured pressure change during the interval. That is, pressure may be measured at the beginning and the end of each time interval, and the difference compared to threshold values, without explicitly calculating a rate of change. In such embodiments, slopes m1, m2, m3 and m4 may be replaced with pressure values rather than rates of change. - Thus, the rate of pressure change may be modulated to encode signals. In the embodiment of
FIG. 13 ,valve 123 is configured to open in one of four discrete stages, andcontroller 500 is configured to differentiate between four discrete rates of pressure change. Accordingly, signals may be encoded into base-four numbers, such that each value encoded as a rate of pressure change is between zero and four, i.e. two binary bits. As depicted, slope m1 is assigned a value of zero, or binary 00; slope m2 is assigned a value of 1, or binary 01; slope m3 is assigned a value of 2, or binary 10; and slope m4 is assigned a value of 3 orbinary 11. The term “symbol” is used herein to refer to a digit in a particular number system, e.g. a binary 0 or 1 or base-4 0, 1, 2 or 3. - Other configurations are possible. For example,
controller 500 could be configured to differentiate between two possible rates of pressure change, rather than four and signals could be encoded and transmitted as binary, rather than quaternary numbers. In other embodiments, systems greater than base-four may be used, subject to the ability ofvalve 123 to produce different rates of pressure change and the ability ofcontroller 500 andsensor 150 to resolve pressure change into discrete levels. - Messages transmitted through
wellbore passage 119 may include, for example, instructions forcontroller 500 of one or moreflow control apparatus 115A. Messages may further include training and synchronization signals and error correction information. - As shown,
curve 520 has fourteen stages, corresponding to a sequence of fourteen quaternary (base-four) numbers. Accordingly,curve 520 represents a downhole data unit (DDU) that consists of 14 symbols (S1 to S14), with each symbol representing one of four possible values. Table 1 shows the sequence of intervals, slopes and corresponding base-four numbers for thecurve 520 ofFIG. 13 , which represents an DDU that encodes the following sequence of 14 values (3, 0, 0, 3, 0, 3, 0, 0, 3, 2, 2, 3, 1, 1). -
TABLE 1 Downhole data unit (DDU) Interval (Symbol) Ending number time Slope Encoded value 1 T1 m4 S1 = 3 2 T2 m1 S2 = 0 3 T3 m1 S3 = 0 4 T4 m4 S4 = 3 5 T5 m1 S5 = 0 6 T6 m4 S6 = 3 7 T7 m1 S7 = 0 8 T8 m1 S8 = 0 9 T9 m4 S9 = 3 10 T10 m3 S10 = 2 11 T11 m3 S11 = 2 12 T12 m4 S12 = 3 13 T13 m3 S13 = 2 14 T14 m2 S14 = 1 - Values assigned to each of slopes m1 through m4 may for example be stored in a look up table maintained in memory 508 (
FIG. 11A ) bycontroller 500. - In some embodiments, messages transmitted through
wellbore passage 119 are encoded using error correction methods designed to correct for substitution of symbols in the received message. For example, in the embodiment ofFIG. 13 , the message transmitted in the 14 symbol DDU represented bypressure curve 520 includes an address or identification number between 0 and 255 that unique identifies aflow control apparatus 115A. A number between 0 and 255 can be represented as 8 binary bits or 4 quaternary (base-four) symbols. For example, thedecimal number 125 may be encoded as a base-four number 1331. - However,
curve 520 includes 14 stages, corresponding to 14 quaternary symbols. As will be explained in further detail, the first four symbols (S1 to S4) are preamble symbols used for synchronization and training ofcontroller 500. The remaining ten symbols (S5 to S14) form a 10 symbol payload word used for error-tolerant encoding of the address. - Address values may be converted into code words using a forward error-correction algorithm. In some embodiments, such algorithms may be allow for correction of up to 3 incorrectly-received symbols (i.e. three incorrectly-measured slopes) in each 10-symbol word.
- Generally, the amount of error tolerance of a message encoded with an error-correction algorithm depends on the length of the encoded data word. Specifically, longer encoded data words are often tolerant to a greater number of errors. However, longer words may take longer to transmit. Moreover, the number of symbols that can be transmitted through
wellbore passage 119 as described above is limited by the amount of pressure that can be relieved fromwellbore passage 119. In some examples, error tolerance up to three substituted symbols provides adequate performance, and encoding using binary Golay codes provides adequate transmission performance. However, in some embodiments, a greater or smaller degree of error correction may be desired. - As noted, some symbols transmitted via
wellbore passage 119 may be used for synchronization and training ofcontroller 500. For example, as shown inFIG. 13 , the first four symbols (S1 to S3) are used for synchronization and training. The synchronization and training signals may be a pre-set sequence of symbols, which may be programmed intofirst controller 500 prior to installation. - In some embodiments,
first controller 500 may have multiple modes, e.g. a low-power listening mode and a higher-power measuring mode.Controller 500 may obtain pressure measurements (e.g. by polling sensor 150) at different frequencies in the listening and measuring modes. While in the listening mode,controller 500 may pollsensor 150 at a low frequency (for example 1 Hz). While in the measuring mode,controller 500 may pollsensor 150 at a higher frequency (for example 10 Hz). Obtaining pressure measurements at higher frequency may improve accuracy, but may consume battery power at a greater rate.Controller 500 may generally operate in the listening mode in order to conserve battery power and may switch to the measuring mode only in response to an instruction, e.g. an instruction signal send viawellbore passage 119. -
Controller 500 may be configured to transition from the listening (low-power) mode to the measuring (higher power) mode upon detecting a transition signal viasensor 150. The signal may be one or more pre-programmed symbols sent by way of a pressure change inwellbore passage 119. For example, as depicted,controller 500 is configured to transition to the measuring (higher power) mode upon detection of the predetermined symbol sequence of base-4symbols 3, 0. Accordingly, in example embodiments, the first two symbols S1, S2 in a DDU are used to signalcontroller 500 to transition from low power listening mode to high power measuring mode. That is,controller 500 transitions from low power mode to the measuring mode upon detecting a pressure change that corresponds to a predetermined symbol sequence, namely a pressure change at a rate equivalent to slope M3, followed by pressure change at a rate equivalent to slope M0. Additionally, the first two symbols S1, S2 in a DDU are used as synchronization symbols, such that upon detection of the pre-programmed symbols,controller 500 may begin timing. As noted, signals are send by modulation of pressure changes through specific time intervals that each represent one symbol such that each DDU has a duration of 14 time intervals. In order to accurately measure pressure changes, measurement of time intervals atcontroller 500 must be synchronized with operation ofvalve 123. Thus, upon initial detection of the predetermined combination ofsymbols 3, 0,controller 500 may sync its internal clock with the timing of the received symbols. - Signals transmitted via
wellbore passage 119 may also include training signals for calibratingcontroller 500 andsensor 150, and in example embodiment, symbols S3 and S4 of the DDU are assigned as training symbols. - Based on characteristics of
wellhead 117,valve 123,wellbore passage 119 and other factors, estimated values of slopes m1, m2, m3, m4 (i.e. the expected rate of pressure change withvalve 123 25%, 50%, 75% and 100% open) may be determined (e.g. by numerical analysis or empirical testing) and programmed intocontroller 500. However, the actual rates of pressure change may vary during operation, for example due to changes invalve 123 orwellbore passage 119 over time. Therefore, calibration may be performed to correct the pre-programmed values based on actual operating conditions. - In the depicted example, training signals (symbols S3, S4) are sent following the synchronization signals (symbols S1 and S2). Thus, the training signals are sent during the third and fourth intervals of the transmission, i.e. between t2 and t3 and between t3 and t4. The training signals are signals of a known level, e.g. the symbols S1 and S2 have values that are known to the
controller 500. As shown, the rate of pressure change between t2 and t3 is m1 (representing a value 0) and the rate of pressure change between t3 and t4 is m4 (representing a value of 3). In other words, in the first training interval (symbol S3),valve 123 is operated to produce the smallest possible rate of pressure change. In the second training interval (symbol S4),valve 123 is operated to produce the largest rate of pressure change used for signalling purposes. -
Controller 500, usingsensor 150, measures and determines the pressure change during each time interval and determines the actual maximum and minimum rates of change created whenvalve 123 is 100% and 25% open, respectively. The measured rates may differ from pre-programmed rates, in which case corrected values may be stored, e.g. in a look up table. Intermediate rates of change m2 and m3 may be determined based on the measured values of m1 and m4. For example, rates of change m2 and m3 may be interpolated between the measured values of m1 and m4, such that the four discrete thresholds are evenly spaced. - Rates of change m1, m2, m3 and m4, as corrected based on measured values, may be stored by
controller 500, for example in a look up table instorage 508. Accordingly, training symbols S2 and S3 of DDU have predetermined values, allowingcontroller 500 to calibrate the measured pressure values to symbol values to allow accurate decoding of the subsequent payload symbols S5 to S14 of the DDU -
Controller 500 may be operated in a plurality of modes corresponding to programming, and opening and closing offlow control member 114. Operation ofcontroller 500 may in some embodiments be characterized as a state machine, for example, as shown inFIG. 14 . For example, as shown,controller 500 may be operated in aprogramming mode 600; anopening standby mode 602 and aclosing standby mode 604. -
Controller 500 may be directed to enter the programming mode by an instruction from a programming apparatus,e.g. controller 501. In some embodiments,controller 500 may be configured to respond to an instruction to enter theprogramming mode 600 while in any mode of operation. - On receipt of an instruction to enter
programming mode 600,instruction processing module 516 may cause an acknowledgement message to be sent.Instruction processing module 516 may listen for a further message defining an address value. Once the next message is received, the message may be parsed (i.e. converted or decoded to an address value) and the address value may be stored instorage 510 for later use.Instruction processing module 516 may then cause a further acknowledgement to be sent using transceiver 512 and may then enter an opening standby mode. - In the opening standby mode,
controller 500polls sensor 150 in its low-power listening mode, e.g. at a low frequency . . . Pressure changes inwellbore passage 119 are detected andsignal decoding module 514 checks for values encoded in pressure changes. In the event a pre-programmed synchronization signal (in the embodiment ofFIG. 13 , encoded symbol values 3, 0) is detected,controller 500 enters a measuring (higher-power) mode, in whichsensor 150 is polled at an increased frequency. -
Controller 500 then continues to pollsensor 150 to monitor pressure changes inwellbore passage 119. In some examples, training symbols S3, S4 are used to calibrate pressure change levels to symbol values. Sensed pressure changes over the remainder of the signal are decoded bysignal decoding module 514 to recover payload symbols S5 to S14. Error correction coding is applied to recover an address, and the decoded address message is provided toinstruction processing module 516.Instruction processing module 516 checks the received message against the stored address value. If a received message matches the stored address,instruction processing module 516 causes triggermodule 518 to produce a signal for activatingactuator 402 to effect movement offlow control member 114 to its open position. The signal may be a voltage provided fromcapacitors 507 by way of a wired connection. - Once
flow control member 114 is opened, fluid may be injected intoformation 100 by way of theflow control apparatus 115A for treatment of the formation to stimulate production. Injection may continue for a period of time, after which it may be desired to closeflow control apparatus 115A prior to injection through anotherflow control apparatus 115A. Such closing may be prompted by a control signal sent from the surface. Therefore, after opening,controller 500 may therefore transition to aclosing standby mode 602. The control signal may comprise an acoustic signal intended for thetransceiver 504 ofsecond controller 501, one or more pressure pulses inwellbore string passage 119 intended forpressure sensor 150 offirst controller 500, or both. In some embodiments, an acoustic closing signal may be sent, having frequency in the ultrasound range (e.g. >20 kHz) or in a lower range (e.g. 500 Hz to 2 kHz). - In some embodiments, the closing signal may be a standard signal common to all
controllers 500 and/or 501, such that when a closing signal is sent, allcontrollers 500 receiving the signal (either directly or indirectly from controller 501) cause the associatedflow control members 114 to move to their closed positions. - In other embodiments, closing signals may be specific to each
controller 500. For example, the closing signals may correspond to each controller's unique address value, or may be based on such value. - Acoustic closing signals, including acoustic signals in the sonic range or the ultrasound frequency range, may be received by
transceiver 504, decoded and provided to signalprocessing module 516 ofcontroller 501 and transmitted tocontroller 500 to act on. Closing signals may alternatively or additionally be sent using pressure pulses, which may be received bysensor 150 ofcontroller 500 directly, decoded and provided to signalprocessing module 516 ofcontroller 500. -
Signal processing module 516 ofcontroller 500 checks the decoded signals, and if a signal matches a stored closing instruction,signal processing module 516 causes triggermodule 518 to activate a closing actuator to effect movement offlow control member 114 to its closed position. - In some embodiments, in the closing standby mode,
signal decoding module 514 andsignal processing module 516 ofcontrollers formation 100 may be noisy due to operation of pumps, flowing of fluids and entrained particles and the like. Moreover, pressure withinwellbore string passage 119 may be elevated. Accordingly, during such time,transceiver 504 may receive vibrations associated with such noise and produce an output signal indicative of such noise, andsensor 150 may produce an output indicative of elevated pressure. In certain conditions, such as equipment failure, pumping may be stopped, leading to a reduction in noise level and pressure. During such conditions, it may be desired to effect movement offlow control member 114 to its closed position to prevent outflow of fluid intoformation 100. Accordingly,controller 500 may be programmed, in a closing standby mode, to monitor for drops in one or more of measured sound level and measured pressure. In the event of such a drop,signal processing module 516 may causetrigger module 518 to generate a signal to effect movement offlow control member 114 to its closed position by activation of a closing actuator. In some embodiments, a closing actuator may be activated in this manner only if both the measured sound level and measured pressure drop at approximately the same time. - In the example described above in respect of
FIG. 13 , the DDU has a set of specified parameters including: the number of possible values represented by each symbol (e.g. modulation levels M=4), the duration of each symbol (e.g. Ts=7 seconds), the number of symbols in each DDU (e.g. N=14), the allocation of these symbols between preamble (e.g. 2 synchronization symbols and 2 training symbols) and payload symbols (e.g. 10 symbols containing address information or other data or instructions), and the type of forward error correction (FEC) coding applied (e.g. Gray coding). As suggested above, in different example embodiments, one or more of these parameters can be changed to achieve different performance criteria. For example, reducing the number of possible values that can be encoded into a symbol and increasing the symbol duration may result in more robust signalling system that is simpler to modulate at the well head and less susceptible to noise as thesignal decoding module 514 will not have to distinguish between as many pressure rate change slopes and will have a longer period over which to assess pressure changes. The increased accuracy comes at the cost of reduced downhole data communication capacity per DDU, but in many applications this trade-off may be justified. In at least some examples the parameters will be influenced by characteristics of the installation such as the length of the borehole string, the number of flow stations in the borehole string, and sources of noise that could adversely affect the pressure sensing done at downhole stations. - In this regard, in an alternative example embodiment the number M of possible values encoded in each symbol is reduced to two (M=2), such that each of the N symbols S1 to S14 is a binary symbol. In the example case where binary symbols are used,
signal decoding module 514 is configured to associate a first rate of pressure change (slope m1) over a symbol duration Ts with one binary value (for example a logic 1) and a second rate of pressure change (slope m2) with a second binary value (for example a logic 0). In one example,valve 123 is switched between a predefined open position (for example 100% open) and a closed position to generate the two slopes m1 and m2, such that slope m1 is the rate of pressure change associated withvalve 123 being in an open position for at least a portion of a symbol duration and slope m2 corresponds tovalve 123 being in a closed position for a symbol duration. In example embodiments,valve 123 is opened and closed by awellhead controller 640, which is implemented by a digital computer configured to control a valve actuator ofvalve 123. In at least some examples,wellhead controller 640 may include similar components arranged in a configuration similar to that shown inFIGS. 11A and 11B in respect of first andsecond controllers valve 123. -
FIG. 14B illustrates a further example of transmitting and receiving control signals through theborehole string passage 119. In particular,FIG. 14B shows an example of aprocess 630 atwellhead controller 640 to encode and transmit a DDU, and aprocess 632 at acontroller 500 of aflow control apparatus 115A to receive and decode the DDU. As indicated bystep 650,process 630 begins with pressurization of thewellbore string passage 119 through the addition of fluid to a predetermined initial static pressure level (for example, P0≈2500 psi). Wellbore stringpassage pressurization step 650 may be controlled by a separate controller thanwellhead controller 640.Wellhead controller 640 monitors or is notified of the pressure conditions in thewellbore passage 119. - At some point after well passage pressurization,
wellhead controller 640 determines (for example, through operated initiated instructions) that a control message needs to be transmitted to a specifiedflow control apparatus 115A in the wellbore string. The control message may for example be an instruction for theflow control apparatus 115 to change from its current flow control state (for example closed) to a different state (for example open). As indicated atstep 651, the wellhead controller generates the control message by assembling a multi-symbol DDU that, in at least some example includes apreamble 634 and apayload 636. In the example of a binary symbol DDU, each symbol will have one of two values (for example a “1” or a “0”). As noted above, an initial group of the symbols of the DDU can be used aspreamble 634 for encoding a predefined synchronization and training symbol sequence that is known to thecontrollers 500 of theflow control apparatuses 115A. For example, in one embodiment the first four symbols of a DDU are used for thepreamble 634. In one such example, theDDU preamble 634 may be assigned the predetermined sequence of (S1=1, S2=0, S3=0, S4=1). In one example, theDDU payload 636 consists of a fixed length of 10 symbols appended to thepreamble 634, such that DDU has a length of 14 binary symbols. In example embodiments, the control message that is encoded into theDDU payload 636 consists of the unique identifier or address of thecontroller 500 of the targetflow control apparatus 115A that is to be controlled. As noted above, FEC coding may be applied by thewellhead controller 640 to the contents of the control message included inpayload 636 to allow the message to be recovered at the flowcontrol apparatus controller 500 based on only a sub-set of the payload symbols. - Once the DDU is assembled, the
wellhead controller 640 transmits the DDU downhole by pressure modulating the fluid contained in thewellbore string passage 119. As described above, and indicated instep 652,wellhead controller 640 modulates the wellbore fluid by actuating thewellhead valve 123. In example embodiments, each DDU symbol has a defined symbol duration Ts that is known to both thewellhead controller 640 and the flowcontrol apparatus controller 500, and each DDU has a defined number of symbols N, such that each DDU has a defined DDU duration of (Ts×N). In the presently described example embodiment,wellhead controller 640 modulates a binary “1” by causing a valve actuator to openwellhead valve 123 by a predefined amount at the start of a symbol duration Ts, and then subsequently close thevalve 123 at a time prior to the end of the symbol duration Ts. In at least some applications, movement of thevalve 123 between its defined open and closed positions is not instantaneous and the resulting pressure rate change for each interval will not have a linear slope, contrary to the slopes shown inFIG. 13 . In some embodiments, when modulating a “1” symbol,valve 123 is open to release pressure for only part of the symbol duration Ts—for example, less than 75% of the symbol duration Ts. In some examples,valve 123 is open for only approximately the first half of the symbol duration Ts. By way of illustrative example, in the case of symbol S1=1,wellhead controller 640 causesvalve 123 to move to its predefined open position at time T0=0, and then, midway through the symbol duration Ts at time=(T1−T0)/2wellhead controller 640 causesvalve 123 to move to its closed position. Thus, the pressure curve profile during the symbol duration Ts will be steeper over the first half of the symbol duration than the second half of the symbol duration. - In some alternative examples, rather than being strictly time based, wellhead controller may be configured to open
valve 123 at the start of symbol duration and then close it within the symbol duration as soon as a predetermined pressure drop has occurred, for example to closevalve 123 when the fluid pressure inwellbore passage 119 is measured a having dropped by a threshold psi since the valve was opened. In some examples, valve closing could be triggered once a predetermined volume of fluid has been released throughvalve 123. - In an example embodiment,
wellhead controller 640 causes wellhead valve to stay closed for the entire duration Ts to modulate a binary “0” symbol. Instep 652, thewellhead controller 640 causes thevalve 123 to be opened and closed as required to modulate all of the successive symbols S1 to S14 of the DDU as pressure rate changes in the fluid ofwellbore string passage 119. - In some examples, the amount of time that valve is open during a symbol duration may be varied to apply a higher modulation level than binary.
- On the DDU receiving side, in an example embodiment,
controller 500 of eachflow control apparatus 115A in thewellbore string 116 performsprocess 632 to detect and decode DDUs transmitted through thewellbore string passage 119. In example embodiments thecontroller 500 is pre-informed of the DDU parameters that have been used at the wellhead for encoding, including symbol duration Ts, number N of symbols in a DDU, the number and content of the symbols (e.g. S1 to S4) that make of preamble sequence 638, the level of encoding used (e.g. M=2 in the case of binary), and the target pressure drop per non-zero symbol duration (for example 100 PSI). Thecontroller 500 is unaware of exactly when to expect a DDU, and in this regard in some examples thesignal decoding module 514 ofcontroller 500 is configured to repeatedly perform steps of sampling (step 670), filtering and storing the samples (step 672) and analyzing the samples for preamble symbols (step 674). - Regarding
sampling step 670,controller 500 is configured to monitorsensor 150 to sample fluid pressure inwellbore string passage 119 at a predetermined sampling rate (SR). As noted above, an example of a sampling rate is 1 Hz. Thus the number of samples per symbol (NSS) will be symbol duration Ts divided by sampling rate SR. In example embodiments, thesignal decoding module 514 is configured to implement a low pass filter 520 (seeFIG. 12 ) to remove noise from samples collected atstep 670. In particular, in an example wherevalve 123 is repeatedly actuated between open and closed positions to pressure modulate the wellbore fluid, an unwanted effect can be the creation of a pressure pulses due to a fluid hammer effect (commonly called a water hammer) caused by the valve movement. The repeated opening and closing of valve during modulation of a DDU can further worsen the fluid hammer effect progressively over the transmission time for a DDU. Typically, however, noise modulated onto the wellbore fluid as a result of the fluid hammer effect will have a higher frequency than the DDU modulation frequency. - Accordingly, as indicated in
step 672, in example embodiments the measured pressure samples are filtered using a low pass filter with a predefined cut-off frequency. The cut-off frequency may in at least some examples be preconfigured to be lower than noise caused by the fluid hammer effect and higher than the symbol modulation frequency. The frequency of noise caused by the fluid hammer effect may be dependent on factors specific to an particular wellbore string installation, such as wellbore string length, and thus in some embodiments the cut-off frequency ofLPF 520 is one of the parameters ofcontroller 500 that can be configured on site when the controller is in itsprogramming mode 600. - As indicated in
step 672, the filtered samples are stored for analysis by thecontroller 500 incontroller memory 508 and/orstorage 510. The analysis performed bycontroller 500 to recover symbols is a comparative process in which data derived from successive groups of samples is compared against reference thresholds. In at least some examples, accuracy can be improved by storing a large number of samples for analysis, and accordingly in example embodiments thecontroller 500 is configured to maintain the stored samples in a table of samples for a duration that exceeds a DDU duration. - As indicated in
step 674, in an example embodiments thecontroller 500 is configured to analyze the filtered stored samples to determine if thepreamble 634 of a DDU has been received. In example embodiments, thecontroller 500 may do this by calculating an average pressure drop across successive sample sets that correspond to a symbol duration (for example sets that each include NSS samples) and determining a pressure drop over each set until a pressure drop profile is detected that matches the leading symbols ofDDU preamble 634. For example, in the case of preamble bits S1=1,S2=0,controller 500 can scan the table to locate a pattern of successive samples that include: samples that show a reasonably consistent static pressure (for example 2500 psi), followed by a group of NSS samples (corresponding to symbol duration Ts at a sampling rate SR) that show a cumulative pressure drop across the that exceeds a predefined threshold, followed by a subsequent group of NSS samples that shows a pressure drop across the group that is below a predefined threshold. In such examples, the predefined threshold may be set with a wide tolerance for the preamble symbols, for example the predefined threshold for predicting a “1” may be a pressure drop in excess of Y psi in the case where the actual drop at the wellhead was 2Ypsi) and the predefined threshold for predicting “0” may be a pressure drop of less than Y psi. In some example, the thresholds could be different for predicting “1” or a “0”. In some example embodiments, upon determining that a match has been found for in the table of data samples for preamble bits S1=1,S2=0, the controller will then determine the pressure drops across the next two successive 15 sample groups to confirm if they correspond to the next two preamble bits (e.g. S3=0,S4=1). In example embodiments, if a match for the preamble symbols of the DDU is located by thecontroller 500 in its table of stored samples, the controller concludes that a DDU has been received and that the following samples in the table correspond to the symbols of theDDU payload 636. Accordingly, at the successful conclusion ofstep 674 thecontroller 500 can reasonable predict that a DDU has been located, and has synchronized the symbols S1 to S14 of the DDU with respective groups of corresponding samples stored in the sample table. - Referring to step 678, in some examples, prior to decoding the payload symbols (e.g. S5 to S14) from the data samples, the
controller 500 is configured to determine more accurate thresholds for classifying the symbols. As noted above, in at least some examples threshold training can be done based on the pressure drops calculated across some of the preamble symbols (for example S3 and S4 can be used as training symbols for this purpose). However, in at least some measurements the controller is configured to further refine the classification thresholds based on the data samples stored in its data table for the entire DDU payload. Accordingly, in an example embodiment, instep 678 thecontroller 500 determines a refined classification threshold by: (a) based on the stored data samples, calculating a respective pressure drop across each of the symbol durations that correspond to respective payload symbols S5 to S14; (b) doing a preliminary symbol classification by comparing the calculated pressure drops across each symbol duration to a preliminary threshold (for example the same threshold used to predict the preamble bits or a threshold determined based on preamble training bits), to predict how many of the payload symbols S5 to S14 are “1”s and how many are “0”s; (c) calculate the total pressure drop across all of the symbols (S5 to S14) of theDDU payload 636; and (d) divide the total pressure drop by the number of payload symbols S5 to S14 that preliminarily classified as ones to calculate an average threshold to use as the refined classification threshold. In some examples, the preamble symbols can also be included when determining the average threshold to use as the refined classification threshold. - In at least some examples, the refined classification threshold is stored by
controller 500 to use as the starting threshold value for detecting preamble symbols in future DDUs received by thecontroller 500. - As indicated in
step 680, thesignal decoding module 514 ofcontroller 500 applies the refined classification threshold to classify each of the payload symbols (S5 to S14) as a “1” or “0” to recover the symbols ofDDU payload 636, and FEC decoding is carried out to recover the bits of the original control message. Atstep 682, the recovered control message is parsed by theinstruction processing module 516 ofcontroller 500 to determine if it is an instruction for that particular controller 500 (for example, is it the unique address of the controller 500). If not, thecontroller 500 ignores the message. However, if theinstruction processing module 516 determines thatcontroller 500 is the addressed recipient of the message,trigger module 518 is instructed to take the appropriate actuation action. - An example of a process for stimulating production of hydrocarbon material from a
subterranean formation 100 via a wellborematerial transfer system 104 including three or moreflow communication stations FIG. 15 ) will now be described. The description which follows is with reference to embodiments where the number of flow communication stations is three (3), and is defined by a firstflow communication station 1115, a secondflow communication station 2115, and a thirdflow communication station 3115. It is understood that the number offlow communication stations 115 is not limited to three (2) and may be any number offlow communication stations 115. - Each of
flow communication stations controller assembly 499 havingcontrollers FIG. 16 depicts an example method of stimulating production from a system such as that shown inFIG. 15 . - At
block 702, theflow control apparatus 115A of firstflow communication station 1115 is prepared for installation in the wellbore. As part of such preparation, messages are sent tocontroller 501 by way oftransceiver 504 for programming the flow control apparatus, namely, forprogramming controllers flow control apparatus 115A. - A programming device with an acoustic (e.g. sonic or ultrasound) transmitter or transceiver is placed in proximity to flow
control apparatus 115A. In some embodiments, the transmitter or transceiver may be placed in physical contract with theflow control apparatus 115A. Instructions are then encoded as sequences of acoustic (e.g. sonic or ultrasonic) vibrations. For example, as described above, the instructions may be sent as a series of hexadecimal values encoded and transmitted using DTMF signals. The instructions include an assignment of an identification value or address to theflow control apparatus 115A. In some embodiments, the address is a numerical value, which may be sequentially assigned based on the installed position of the flow control apparatus. That is, values may be assigned sequentially in a downhole-to-uphole direction or in an uphole-to-downhole direction. In an example, the values are 8-bit values, i.e. decimal 0 to 255 and flowcontrol apparatus 115A of firstflow communication station 1115 is assigned value 00000000 (decimal 0). -
Transceiver 504 receives the instructions as acoustic vibrations.Signal decoding module 514 de-modulates the received signals into instructions readable bycontroller 501 and passes the instructions toinstruction processing module 516. The instructions are then provided fromcontroller 501 tocontroller 500 for storage and for configuration ofcontroller 500. - Optionally, other instructions may also be provided to
controllers controllers transceiver 504. - At
block 704, flowcommunication station 1115, includingflow control apparatus 115A, is added towellbore string 116 and inserted in the wellbore. As subsequent components are added towellbore string 116, flowcommunication station 115 is advanced downhole toward its installed position. - At block 706, if more
flow control apparatus 115A of other flow communication stations are to be installed, the process returns to block 702 for programming of the nextflow control apparatus 115A. As noted, thecontroller 500 of the nextflow control apparatus 115A may be programmed with a unique identifier that sequentially precedes or follows the previousflow control apparatus 115A. - Notably, flow
control apparatuses 115A may be identical to one another prior to programming with an identification value. Thus, a set of flow control apparatuses may be provided for installation and individual ones of those flow control apparatuses may be selected in an arbitrary order to be programmed and then added towellbore string 116. As will be apparent, this may ease installation, relative to pre-programmed flow control apparatuses of which individual ones need to be selected and installed in a specific order. - If no more flow communication stations and associated
flow control apparatus 115A need to be installed,wellbore string 116 is completed. Atblock 708, the first fracturing stage is initiated by sending a signal for opening of the firstflow control member 115A. As described above, the signal may be a series of quaternary (base 4) symbols, encoded in a modulated pressure profile created by operation ofvalve 123 ofwellhead 117. The signal may include a first preset sequence of symbols for activating a measurement mode and synchronizingcontroller 500 with the signal, and a second preset sequence of symbols for calibratingcontroller 500. The signal may be received by acontroller 500 of eachflow control station 115A withinwellbore string 116. - Each
controller 500 may be calibrated based on the received preset sequence of symbols. Specifically, the preset sequence of symbols may include a maximum rate of pressure change, caused by operation ofvalve 123 in a fully-open state, and a minimum rate of pressure change, caused by operation ofvalve 123 in a minimally-open state. The minimum and maximum rates of pressure change may be stored as threshold values. Additional intermediate threshold values may further be stored, e.g. by interpolation between the minimum and maximum values. - The signal may further include an instruction for opening of the
flow control apparatus 115A of one of the flow communication stations inwellbore string 116. For example, the instruction may be an identification value for aparticular controller 500 of a particularflow control apparatus 115A. - As noted, the identification value may be transmitted after encoding according to an error-correction algorithm, so that the value can be successfully received even if one or more symbols is received incorrectly.
- Each
controller 500 decodes the received message and compares the identification value stored therein against its own value, obtained fromcontroller 501 via an acoustic programming device atblock 702. If the received identification value matches the value stored by anyspecific controller 500, the controller causes triggering ofactuator 402. - In the depicted embodiment, at
block 708, a first signal (for example a DDU) is communicated downhole containing a unique identification value ofcontroller 500 offlow communication station 1115. - In response to an activation signal from triggering
module 518 ofcontroller 500,actuator 402 is activated, allowing theflow control member 114 of the firstflow communication station 1115 to be displaced uphole, effecting opening of the one ormore ports 118 associated with the firstflow communication station 1115. Atblock 710, treatment of the formation is performed. That is, stimulation fluid is supplied from the surface, conducted through thewellbore string 116 and into the subterranean formation via the opened one ormore ports 118 associated with the firstflow communication station 1115, thereby effecting stimulation of a first stage. - At
block 710, after triggering ofactuator 402,controller 500 transitions to closingstandby mode 604 and awaits a closing condition.FIG. 17 depicts an example process of detecting a closing condition. - At
block 800,controller 500 waits for a period following activation ofactuator 402. - At
block 802,controller 500 confirms that the treatment is being successfully carried out. Specifically, thecontroller 500 obtains a measurement of pressure inwellbore passage 119 usingsensor 150 and a measurement of temperature inwellbore passage 119. The wait time atblock 800 may be chosen so that the measurements are taken while the treatment operation is expected to be in progress. Pressure and temperature are expected to be within a particular range. For example, if the treatment is a hydraulic fracturing operation, pressure and temperature inwellbore passage 119 are expected to drop after opening offlow control apparatus 115A. If either or both of the measured pressure and temperature is determined to be outside the expected range, an error may have occurred. For example, pressure may be higher than expected if theflow control member 114 is not moved to the open position. In such event,flow control apparatus 115A may be immediately closed by activation of a closing actuator for movingflow control member 114 from its open position to its closed position. - At
block 804,controller 500 rests for a second period, selected to permit completion of the treatment stage. In some embodiments, such as for some hydraulic fracturing operations, the wait period may be approximately 15 minutes. - At
block 806,controller 500 periodicallypolls sensor 150 and a temperature sensor for measurements of temperature and pressure inwellbore passage 119. Using measurements over time intervals of a preset length, rates of pressure and temperature change are calculated and classified as increasing, decreasing or static. In some examples, pressure increase of greater than 30 psi per minute is classified as increasing; pressure decrease of more than −30 psi per minute is classified as decreasing, and pressure change of between −30 psi and 30 psi per minute is classified as static. Temperature increase of more than 1° C. per minute is classified as increasing, temperature decrease of more than 1° C. per minute is classified as decreasing, and temperature change between 1° C. per minute and −1° C. per minute is classified as static. - Increasing pressure or static pressure is associated with injection of treatment fluid. Conversely, decreasing pressure indicates the end of a treatment stage, due to pumping being stopped. Likewise, decreasing or static temperature is associated with an in-progress treatment stage and increasing temperature is associated with the conclusion of a treatment stage.
- If pressure is falling and temperature and temperature is increasing or static, and if pressure is static and temperature is increasing,
controller 500 determines that a closing condition may exist and proceeds to block 808, at whichcontroller 500 checks the pressure change and the temperature change measured atblock 806 against respective threshold values. If both are below the respective threshold values,controller 500 increments a counter atblock 810 and proceeds to block 812. If not,controller 500 resets the counter atblock 814 and returns to block 806. - At
block 812,controller 500 checks if the counter is equal to or above a threshold number, e.g. 5. If so, atblock 816,controller 500 triggers a closing actuator of the closing actuation system to closeflow control apparatus 115A by movingflow control member 114 to its closed position. If not,controller 500 returns to block 806. - The threshold checks performed at
blocks block 808 tests the cumulative changes over a period of time to ensure that transient pressure and temperature readings do not create a false positive reading atblock 806. Similarly, the use of a counter and checking of the counter level atblock 812 ensures that closing offlow control apparatus 115A is not triggered unless multiple consecutive measurements are indicative of closing conditions at bothblocks block 808,controller 500 checks if the pressure change is less than 3.4 MPa and the temperature change is less than 2° C. In some examples, atblock 812,controller 500 checks if the counter is 5 or greater. - Moreover, the counter check at
block 812 provides an opportunity to cancel a closuring condition. That is, the counter check introduces a delay between the first detection of a closing condition and triggering of closing. During the delay period, closing may be cancelled by eliminating the closing condition, e.g. by activating a pump. - In some embodiments, measurements at any of
blocks transceiver 504. Sound levels above a particular threshold may be associated with an ongoing treatment operation. Sound levels below the threshold may indicate the completion of the operation. For example, sound levels may drop significantly in the event of stopping of a treatment pump or failure of a treatment pump. In some embodiments, the sound threshold is added as a further check at one or both ofblocks flow control apparatus 115A or reduce the pre-set threshold values for pressure and temperature change, or change or eliminate the counter threshold check atblock 812. In some embodiments, automatic triggering based on low sound level may be overridden by pressure or temperature measurements consistent with ongoing treatment operations. For example, triggering based on low sound levels may be overridden by measurement of increasing pressure. - In some embodiments, automatic closing based on monitoring of wellbore passage conditions may be performed without performing the checks at
blocks block 806 of pressure and temperature change rates associated with the end of a treatment operation. Such configurations may increase the risk of closing aflow control apparatus 115A based on false detection of a closing condition. - Referring again to
FIG. 15 , after the treatment throughflow communication station 1115 and closing of its flow control apparatus is completed, a signal is sent tocontroller 500 offlow communication station 2115.Controller 500 decodes the message as described above and triggers actuator 402 to cause theflow control member 114 of the secondflow communication station 2115 to be displaced uphole, effecting opening of the one ormore ports 118 associated with the secondflow communication station 2115. The act of displacement effects the deformation of theflow control member 114 associated with the secondflow communication station 2115 from the passive condition to the interference body-receiving condition. Stimulation fluid is supplied from the surface, conducted through thewellbore string 116 and into the subterranean formation via the opened one or more openedports 118 associated with the secondflow communication station 2115, thereby effecting stimulation of a second stage. - Described above are embodiments in which flow
control apparatuses 115A are provided with asingle actuator 402 for effecting opening, and in which flowcontrol apparatuses 115A are provided with two actuators for effecting opening and then closing. Such embodiments may be referred to as one-stage and two-stage, respectively. Other embodiments may have any number of actuators, for opening and closing in any number of stages. For example, flowcontrol apparatuses 115A may be configured for any number of alternating open and close stages, controlled as described above. Alternatively, messages sent tocontroller 500 by modulation of the rate of pressure change inwellbore passage 119 may include additional information, such as a stage number, in order to identify a specific actuator to be activated. - As described above, two
separate controllers sensor 150 andtransceiver 504, respectively. However, in some embodiments,controllers controllers sensor 150 andtransceiver 504. - As described above with reference to
FIG. 13 , signals are encoded in a pressure profile produced by relieving pressure in a sequence of stages of predetermined length, and the slope of the pressure curve during each stage represents a value. Alternatively, stages may be defined by an amount of pressure drop, and values may be encoded in the amount of time elapsed during each stage. For example, each stage may correspond to a 100 psi pressure drop inwellbore passage 119. The length of time required for a 100 psi drop to occur will depend on the rate of pressure change. Thus, for example, four different degrees of opening ofvalve 123 may produce stages of four corresponding lengths.Controller 500 may therefore measure the amount of time for a defined pressure drop to occur, and each length may correspond to a different encoded value. - In some embodiments, for example, the
flow control member 114 is displaceable, relative to the one ormore ports 118, in response to an applied mechanical force, such as, for example, a force applied by a shifting tool of a workstring. In some embodiments, for example, the shifting tool is integrated within a bottom hole assembly that includes other functionalities. Suitable workstrings include tubing string, wireline, cable, or other suitable suspension or carriage systems. Suitable tubing strings include jointed pipe, concentric tubing, or coiled tubing. In some embodiments, for example, the workstring includes a passage, extending from the surface, and disposed in, or configured to assume, fluid communication with the fluid conducting structure of the tool. The workstring is coupled to the shifting tool such that forces applied to the workstring are transmitted to the shifting tool to actuate displacement of theflow control member 114 relative to the one ormore ports 118. In some embodiments, for example, a suitable shifting tool is the Shift-Frac-Close™ tool available from NCS Multistage Inc. In some embodiments, for example, a suitable shifting tool is described in U.S. Patent Publication No. 20160251939A1. In this respect, in some embodiments, for example, theflow control member 114 is configured for gripping engagement by a shifting tool for translation with the shifting tool. In some embodiments, for example, the translation with the shifting tool is effected while the shifting tool is being moved within thewellbore 102 in response to an applied fluid pressure differential. - In some embodiments, for example, for each one of the
flow communication stations flow control member 114, relative to the one ormore ports 118, for effecting opening and closing of the one ormore ports 118, for effecting stimulation of the hydrocarbon material-containing reservoir, is effected by a shifting tool, and re-opening of the one ormore ports 118, for establishing flow communication with the reservoir such that hydrocarbon material is conducted to the surface, via thewellbore 102, and thereby produced via thewellbore 102, is effected by a displacement of theflow control member 114, relative to the one ormore ports 118, that is actuated in response to the expiry of a countdown timer. In some embodiments, for example, the countdown timer is started in response to the sensing of an actuating condition. - In this respect, and referring to
FIG. 18 , in some embodiments, for example, theflow control apparatus 115A includes atimer 152 coupled to thesensor 150 and configured to start a countdown timer in response to the sensing of an actuating condition by thesensor 150. Theflow control apparatus 115A further includes acontroller 154 and anactuator 156, wherein thecontroller 154, theactuator 156, thetimer 152, and thesensor 150 are co-operatively configured such that, in response to the sensing of an actuating condition, thetimer 152 starts a countdown timer, and, in response to the expiry of the countdown timer, thecontroller 154 effects displacement of theflow control member 114, relative to the one ormore ports 118, via theactuator 156, such that theflow control member 114 is displaced, relative to the one ormore ports 118. In some embodiments, for example, the displacement of the flow control member effects opening of the one ormore ports 118. In some embodiments, for example, the displacement of the flow control member effect closing of the one ormore ports 118. In some embodiments, for example, the actuator includes any one of the actuators described above. In this respect, in some embodiments, for example, the displacement of the flow control member, relative to the one ormore ports 118, for effecting the opening of the one ormore ports 118, is effected using any one of the actuation systems above-described and illustrated inFIGS. 2 to 8 . - In some embodiments, for example, the actuating condition includes a characteristic within the wellbore that is produced in response to a movement of the flow control member relative to the one or
more ports 118. In this respect, in some embodiments, for example, the sensed movement includes movement that effects opening of the one ormore ports 118. In some embodiments, for example, the sensed movement includes movement that effects closing of the one ormore ports 118. In some embodiments, for example, the sensed movement includes movement that effects, in sequence, opening and closing of the one ormore ports 118. In some embodiments, for example, the sensed movement includes movement that effects, in sequence, closing and opening of the one ormore ports 118. - In some embodiments, for example, a magnet is coupled to the
flow control member 114 such that the magnet is translatable with theflow control member 114, and thesensor 150 includes a Hall effect sensor. In this respect, theflow control member 114 and thesensor 150 are co-operatively configured such that a movement of the flow control member is sensed by the Hall effect sensor. - In some embodiments, for example, the
sensor 150 includes an accelerometer for sensing the movement of theflow control member 114. - In some embodiments, for example, for each one of the flow communication stations, independently, associated with the opening and closing of the one or
more ports 118 by theflow control member 114 is the sound generated in response to the collision of theflow control member 114 with a stop (e.g. shoulder) disposed within theflow control apparatus 115A while a force is being applied to the flow control member 114 (such as, for example, by a shifting tool) for effecting the displacement of theflow control member 114, relative to the one ormore ports 118. In the case of the opening of the one ormore ports 118, this displacement is the displacement of theflow control member 114 from the closed position to the open position. In the case of the opening of the one ormore ports 118, this displacement is the displacement of theflow control member 114 from the open position to the closed position. In this respect, in some of these embodiments, for example, thesensor 150 includes a transceiver for sensing these sounds associated with the movement of theflow control member 114. In this respect, and referring toFIG. 19 , in some embodiments, for example, atblock 900, thecontroller 500 periodicallypolls sensor 150 for measurements of sound level within the wellbore 102 (e.g. with a transceiver). Sound level above a particular threshold may be associated with the opening or closing of the one ormore ports 118. If the sound level exceeds a predetermined threshold, thecontroller 154 increments a counter atblock 902 and proceeds to block 904. Atblock 904, thecontroller 154 checks if the counter is equal to the number two (2). If so, atblock 906, thecontroller 154 triggers the countdown timer of thetimer 152. When the counter is equal to the number (2), this is representative of two collisions between theflow control member 114 and stops of theflow control apparatus 115A, and the fact that there have been the two collisions is representative of theflow control member 114 having been displaced to open the one ormore ports 118 to provide for the flow communication to enable the injection of treatment material into the reservoir, and then to close the one ormore ports 118 after the injection, with effect the simulation of the reservoir zone associated with the flow communication station is completed. Atblock 908, upon the expiration of the countdown timer, theflow control member 114 is actuated into displacement, relative to the one ormore ports 118, from the closed position to the open position, and thereby effecting opening of the one ormore ports 118 to enable production of hydrocarbon material from the reservoir via the one or more ports. - A similar protocol would be used for those embodiments whose
sensor 150 includes an accelerometer, with exception that the counter is incremented in response to sensed acceleration (or deceleration) exceeding a particular threshold. - If Hall effect sensors are used to sense the above-described opening and the closing of the one or
more ports 118 during the stimulation operation, a first Hall effect sensor (secured for example to flow control member 114) would be used to sense the opening of the one ormore ports 118 by theflow control member 114, by sensing of a first magnet (secured for example to the housing 120), becoming disposed in sufficient proximity of the first Hall effect sensor while the first Hall effect sensor translates with theflow control member 114 to the open position, and a second Hall effect sensor (also secured for example to flow control member 114) would be used to sense the closing of the one ormore ports 118 by theflow control member 114, by sensing of a second magnet (secured for example to the housing 120) becoming disposed in sufficient proximity of the second Hall effect sensor while the second Hall effect sensor translates with theflow control member 114 to the open position. In some examples, the locations of the Hall effect sensors and the magnets could be reversed. - In some embodiments, for example, stimulation of the reservoir is effected, and the stimulation of the reservoir includes, for each one of the
flow communication stations flow control member 114, relative to the one ormore ports 118, with a shifting tool, from the closed position to the open position, such that the one ormore ports 118 become disposed in the open condition (i.e. opening of the one ormore ports 118 is effected), and, while the one ormore ports 118 of the flow communication station (1115, 2115, or 3115) are opened, injecting treatment material into the reservoir via the opened one ormore ports 118 for effecting stimulation of the reservoir via the flow communication station (e.g. 1115, 2115, or 3115), and after the injecting of treatment material, displacing theflow control member 114, relative to the one ormore ports 118, with a shifting tool, from the open position to the closed position, such that the one ormore ports 118 become disposed in a closed condition (i.e. closing of the one ormore ports 118 is effected), such that the stimulation, via the flow communication station (1115, 2115, or 3115), is completed. - In some embodiments, for example, subsets of the plurality of flow communication stations (e.g. 1115, 2115, or 3115) are stimulated in sequence, wherein each one of the subsets, independently, is at least one flow communication station. In this respect, in some embodiments, for example, while a stimulated one of the subsets is being stimulated, the flow control members of the other ones of the subsets are disposed in the closed position such that treatment fluid being injected into the
wellbore 102 is directed into a zone of the reservoir via the stimulated one of the subsets, while bypassing, or substantially bypassing, zones of the reservoir that are aligned with the flow communication stations of the other ones of the subsets, with effect that there is an absence of stimulation of such zones via the flow communication stations of the other ones of the subsets. Also, in this respect, stimulation of another one of the subsets is not commenced until the simulation of the stimulated one of the subsets is completed. In some of these embodiments, for example, each one of the plurality of flow communication stations, independently, is stimulated in sequence. - After completion of the stimulation via the
flow communication stations flow communication stations flow communication stations flow control member 114, relative to the one ormore ports 118, for effecting closing of the one ormore ports 118 following the stimulation through the flow communication station (1115, 2115, or 3115), starting a countdown timer, and, in response to the expiry of the countdown timer, displacing theflow control member 114, relative to the one ormore ports 118, with an actuator (such as, for example, any one of the actuators described above), such that theflow control member 114 is displaced from the closed position to the open position, thereby effecting opening of the one ormore ports 118. The starting and expiration of the countdown timers of all of theflow communication stations more ports 118 of any one of the flow communication stations, in response to the expiry of the respective countdown timer, is only effectible after the stimulation via all of the flow communication stations has been completed. In some embodiments, for example, this displacement of theflow control member 114, relative to the one ormore ports 118, for effecting the opening of the one ormore ports 118, and thereby enabling the production of the hydrocarbon material from the reservoir, is effected using any one of the actuation systems above-described and illustrated inFIGS. 2 to 8 . As described above, in some embodiments, for example, the countdown timer is started in response to the sensing of the actuating condition. In some embodiments, for example, the actuating condition is the completion of the stimulation via the flow communication station, as represented by the sequential opening and closing of the one ormore ports 118 by theflow control member 114, and such actuating condition could be sensed by Hall effect sensors, an accelerometer, or a transceiver, or any combination thereof. - After the opening of the one or
more ports 118, hydrocarbon material is conducted from the stimulated reservoir to thewellbore 102 via the one ormore ports 118, and then to the surface via thewellbore 102. In some embodiments, for example the expiration of the countdown timers of all of the flow communication stations is co-ordinated such that the expiration is simultaneous, or substantially simultaneous, with effect that production is commenced simultaneously or substantially simultaneously. In some embodiments, for example, the expiration of the countdown timers of all of the flow communication stations is co-ordinated such that, for each one of a plurality of flow communication subsets (each one of the subsets, independently, is at least one flow communication station), the expiration is staggered. In some embodiments, for example, each one of the plurality of flow communication stations, independently, the expiration of the countdown timer is staggered. - In the above description, for purposes of explanation, numerous details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be apparent to one skilled in the art that these specific details are not required in order to practice the present disclosure. Although certain dimensions and materials are described for implementing the disclosed example embodiments, other suitable dimensions and/or materials may be used within the scope of this disclosure. All such modifications and variations, including all suitable current and future changes in technology, are believed to be within the sphere and scope of the present disclosure. All references mentioned are hereby incorporated by reference in their entirety.
Claims (20)
1. A process for controlling fluid flow between a wellbore and a subterranean formation via a flow communicator using a flow control member that is disposed within the wellbore, comprising:
moving the flow control member relative to the flow communicator;
sensing the movement of the flow control member relative to the flow communicator;
in response to the sensed movement, starting a countdown timer; and
in response to the expiry of the countdown timer, displacing the flow control member relative to the flow communicator.
2. The process as claimed in claim 1 wherein the displacement of the flow control member, that is effected in response to the expiry of the countdown timer, is a displacement that effects opening of the flow communicator.
3. The process as claimed in claim 1 wherein the displacement of the flow control member, that is effected in response to the expiry of the countdown timer, is a displacement that effects closing of the flow communicator.
4. The process as claimed in claim 1 wherein the sensed movement includes movement that effects opening of the flow control member.
5. The process as claimed in claim 1 wherein the sensed movement includes movement that effects closing of the flow control member.
6. The process as claimed in claim 1 wherein the sensed movement includes movement that effects, in sequence, opening and closing of the flow communicator.
7. The process as claimed in claim 1 wherein the sensed movement includes movement that effects, in sequence, closing and opening of the flow communicator.
8. The process as claimed in claim 1 wherein sensing of the sensed movement includes sensing by at least one of a Hall effect sensor, an accelerometer, or a transceiver.
9. The process as claimed in claim 1 , wherein the subterranean formation corresponds to a reservoir, the process further comprising:
prior to moving the flow control member relative to the flow communicator, (i) initially displacing the flow control member, relative to the flow communicator, such that opening of the flow communicator is effected to establish flow communication between the wellbore and the reservoir via the flow communicator, and (ii) injecting treatment material into the reservoir via the flow communicator for effecting stimulation of the reservoir;
wherein moving the flow control member relative to the flow communicator is performed after the injecting of the treatment material, and comprises displacing the flow control member, relative to the flow communicator, with effect that closing of the flow communicator is effected, such that the stimulation is completed;
and wherein displacing the flow control member relative to the flow communicator in response to the expiry of the countdown timer comprises displacing the flow control member, relative to the flow communicator, such that opening of the flow communicator is effected, enabling a hydrocarbon material from the reservoir to enter the wellbore.
10. The process as claimed in claim 9 wherein:
the expiry of the countdown timer effects generation of an explosion by an energetic device; and
the defeating of a sealed interface is effected in response to the generated explosion.
11. A method of operating a flow control device in a wellbore string, comprising:
at said flow control device, periodically measuring a rate of pressure change and a rate of temperature change of fluid in said wellbore string;
incrementing a counter if said rate of pressure change and said rate of temperature change are within respective value ranges;
closing said flow control device in response to said counter reaching a threshold value.
12. The method of claim 11 , comprising, at said flow control device, periodically measuring a sound level.
13. The method of claim 11 , comprising adjusting at least one of said respective value ranges and said threshold value based on said sound level.
14. An apparatus for controlling flow in a wellbore, comprising:
a housing defining a fluid passage;
a flow control device sealing an outlet of said fluid passage;
an actuator for manipulating said flow control device to an open condition to permit fluid flow through said outlet;
a controller for selectively activating said actuator; and
a sensor in communication with the controller, the sensor configured to receive, from a location external to the housing, a wireless programming signal carrying programming instructions for said controller.
15. The apparatus of claim 14 in combination with a programming device configured to provide the wireless programming signal from the location external to the housing.
16. The apparatus of claim 15 , wherein the sensor comprises an acoustic receiver located within the housing and configured to a receive, through a wall of the housing, an acoustic signal as the wireless programming signal, and the programming device comprises an acoustic transceiver configured for temporary placement on an external surface of the housing to provide the acoustic signal prior to deployment of the apparatus in the wellbore.
17. The apparatus of claim 15 wherein the wireless programming signal assigns a unique identifier to the controller, the apparatus further comprising a wireless receiver in communication with said controller, said wireless receiver configured to receive a wireless control message addressed to the controller using the unique identifier when the apparatus is deployed in the wellbore, wherein said controller is operable to selectively activate said actuator based on said wirelessly received control message.
18. The apparatus of claim 15 wherein said controller and the sensor are enclosed within a recess in a wall of the housing.
19. The apparatus of claim 15 , wherein the sensor comprises an optical receiver located within the housing and configured to a receive, through a wall of the housing, an optical signal as the wireless programming signal, and the programming device comprises an optical transceiver configured for providing the optical signal by temporarily positioning the optical transceiver in a line of sight of the optical receiver prior to deployment of the apparatus in the wellbore.
20. The apparatus of claim 19 wherein said optical sensor receives the wireless programming signal through an optical port of the housing, the optical port providing a line of sight from the optical sensor to the location external to said housing.
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US17/675,776 US20220170352A1 (en) | 2017-02-13 | 2022-02-18 | System and method for wireless control of well bore equipment |
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PCT/CA2018/050160 WO2018145215A1 (en) | 2017-02-13 | 2018-02-13 | System and method for wireless control of well bore equipment |
US201916485485A | 2019-10-08 | 2019-10-08 | |
US17/675,776 US20220170352A1 (en) | 2017-02-13 | 2022-02-18 | System and method for wireless control of well bore equipment |
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PCT/CA2018/050160 Continuation WO2018145215A1 (en) | 2017-02-13 | 2018-02-13 | System and method for wireless control of well bore equipment |
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US20210115767A1 (en) | 2021-04-22 |
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US11255169B2 (en) | 2022-02-22 |
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