WO2016065233A1

WO2016065233A1 - Eutectic flow control devices

Info

Publication number: WO2016065233A1
Application number: PCT/US2015/057068
Authority: WO
Inventors: Mariano Ruben SANCHEZ
Original assignee: Schlumberger Canada Limited; Services Petroliers Schlumberger; Schlumberger Holdings Limited; Schlumberger Technology B.V.; Prad Research And Development Limited; Schlumberger Technology Corporation
Priority date: 2014-10-24
Filing date: 2015-10-23
Publication date: 2016-04-28

Abstract

A flow control device includes a body forming a port therethrough and an eutectic material disposed in the port in an initial state to block fluid flow through the port or to limit fluid flow to one direction through the port.

Description

EUTECTIC FLOW CONTROL DEVICES

RELATED APPLICATIONS

[0001] This application claims priority to provisional application Serial No. 62/068,107 filed on October 24, 2014, which is incorporated herein by reference in its entirety.

BACKGROUND

[0002] This section provides background information to facilitate a better understanding of the various aspects of the disclosure. It should be understood that the statements in this section of this document are to be read in this light, and not as admissions of prior art.

[0003] Exploring, drilling and completing hydrocarbon and other wells are generally complicated, time consuming, and ultimately very expensive endeavors. As a result, over the years, a significant amount of added emphasis has been placed on maximizing hydrocarbon recovery for every well drilled. Along these lines, well monitoring and maintenance have become critical to effective well management throughout the life of the well. In many circumstances this may include accounting for low or changing downhole pressure in a well in terms of production. For example, a well may access a reservoir but be limited in terms of available pressure to drive hydrocarbon production from the well. Such low pressure may be present at the outset of operations or develop over the course of the life of the well. [0004] In order to maximize recovery from such low pressure wells, hardware supporting gas lift techniques may be installed in the well during initial well completions. For example, a gas lift mandrel may be centrally installed which is capable of supporting hydrocarbon production therethrough. In this way, pressure from the oilfield surface may be imparted at the annulus of the well to encourage reservoir fluids through the mandrel toward the oilfield surface.

[0005] While production through the gas lift mandrel as described above may be effective, it may not always be desirable. For example, during installation of the mandrel or while running an intervention it may be desirable to ensure that production through the mandrel is closed off. For that matter, gas lift assisted production may not be desired at the outset of operations if the pressure in the well is sufficiently high. Thus, the mandrel may be equipped with an inflow control device or valve that may initially close off a window or ports to the mandrel and later opened when production through the mandrel is sought.

[0006] Unfortunately, operating an inflow control device may often be difficult. For example, the mandrel may be disposed of downhole for an extended period and at great depths before manipulation of a valve is attempted (e.g. based on changing well conditions). However, due to factors such as prolonged exposure to the well environment, sophisticated moving parts and the depths involved, physical manipulation of the valve with a surface deployed tool or otherwise, for sake of opening or closing may pose a significant challenge.

SUMMARY

[0007] A flow control device includes a body forming a port therethrough and an eutectic material disposed in the port in an initial state to block fluid flow through the port or to limit fluid flow to one direction through the port. A well system including a tubular string having a central passageway disposed in a wellbore and a flow control device having an eutectic material disposed in a port in an initial state to block fluid flow through the port or to limit fluid flow to one direction through the port.

[0008] This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The disclosure is best understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of various features may be arbitrarily increased or reduced for clarity of discussion.

[0010] Figure 1 illustrates a well system incorporating flow control device according to one or more aspects of the disclosure.

[0011] Figure 2 illustrates a flow control device in the form of a gas lift mandrel according to one or more aspects of the disclosure.

[0012] Figures 3 and 4 illustrate flow control devices located with a screen assembly according to one or more aspects of the disclosure.

[0013] Figures 5 to 9 illustrate non-limiting examples of eutectic flow control devices according to one or more aspects of the disclosure.

[0014] Figure 10 illustrates an example of operating an eutectic flow control device in a well system according to one or more aspects of the disclosure.

DETAILED DESCRIPTION

[0015] It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

[0016] As used herein, the terms connect, connection, connected, in connection with, and connecting may be used to mean in direct connection with or in connection with via one or more elements. Similarly, the terms couple, coupling, coupled, coupled together, and coupled with may be used to mean directly coupled together or coupled together via one or more elements. Terms such as up, down, top and bottom and other like terms indicating relative positions to a given point or element are may be utilized to more clearly describe some elements. Commonly, these terms relate to a reference point such as the surface from which drilling operations are initiated.

[0017] Figure 1 illustrates a well system 10 incorporating flow control devices 20. Well system 20 has wellbore 12 which may include for example a vertical section 11 and a deviated or lateral wellbore section 13 that extends through one or more formations. The vertical section is illustrated as being cased and the lateral section is depicted in Figure 1 as being uncased. Moreover, the wellbore may be part of a subterranean or subsea well, depending on the particular embodiment of the invention.

[0018] As depicted in Figure 1, a tubular string 14, e.g., completion string, extends into the wellbore 12 and includes one or more ports, described herein as inflow control devices (ICD) 20, to selectively control production and/or injection across the ICD 20. As further described, the ICDs 20 may be initially deployed in a closed position, plugged with an eutectic material, such that the ICD 20 can be activated to an operable state at a later time by removing melting and thereby removing the eutectic plug. As used herein, the term "eutectic" is meant to refer to any material or composition which may be provided in a solid form and controllably heated to effectively liquefy and remove. This may include conventional soldering alloys suitable for downhole use. However, this may also include non-alloy compositions. The eutectic material may contain for example bismuth, lead, tin, cadmium, or indium. The eutectic material may expand when it is cooled and solidifies. The eutectic material may be melted for example by heating via various mechanisms, including without limitation heat delivery lines (e.g., electric lines), pyrotechnic devices and chemical reactions, for example thermite. The heating element or device may be disposed with the tubular string for activation when desired or run into the central passage when it is desired to liquefy an eutectic plug.

[0019] For example, in Figure 1 tubular string 14 is illustrated as including ICDs 20 arranged for example in gas lift mandrels 16 and within screen assemblies 18. The ICDs can either regulate the injection of fluid from the central passageway 22 of the string 14 into the annulus 24 or regulate the production of produced well fluid from the annulus 24 into the central passageway 22 of the string 14. The tubular string 14 may include packers 26 (shown in Figure 1 their unset, or radially contracted states), which are radially expanded, or set, for purposes of sealing off the annulus to define the isolated zones. For the following discussion, it is assumed that the string 14 receives produced well fluid, although the concepts, systems and techniques that are disclosed herein may likewise be used for purposes of injection, in accordance with other embodiments of the invention.

[0020] Each completion screen assembly 18 includes a sand screen 28, which is constructed for example to support a surrounding filtering gravel substrate and allow produced well fluid to flow into the central passageway of the string 14 for purposes of allowing the produced fluid to be communicated to the surface of the well. Before being used for purposes of production, however, the tubular completion string 14 and its completion screen assemblies 18 are used in connection with at least one downhole completion operation, such as a gravel packing operation to deposit the gravel substrate in annular regions that surround the sand screens 28.

[0021] Figure 1 illustrates a control line 54 disposed with the tubular string and operationally connected to heating devices 56 disposed next to each of ICDs, or ports, containing eutectic plugs to selectively heat and liquefy the plugs when desired. As will be understood by those skilled in the art with benefit of this disclosure, other means and mechanisms for heating and melting the eutectic plugs may be utilized.

[0022] Figure 2 illustrates an example of an ICD 20 arranged for example as a gas lift mandrel 16 forming a central bore coaxial with central bore or passage 22 of the tubular string and a side passage 30 formed by a body 32 portion of the tubular mandrel 16. In this example, a port 34 is formed through the tubular mandrel 16 (e.g., tubular string) such that port 34 can provide fluid communication between the central passage 22 and the exterior, e.g., annulus 24. In this example, ports 36 in the side body 32 provide direct communication between the annulus 24 and the side passage 30. A valve 38, referred to herein as a gas lift valve, is depicted illustrated as disposed in the side passage 30 to selectively control fluid flow between ports 36 and 34. Valve 38 may be an injection pressure operated valve that is responsive to annulus 24 pressure or a production pressure operated valve that is responsive to the pressure in central passage 22. As further described below the port 34 may initially be plugged with an eutectic material, i.e. eutectic plug, to be removed when desired at a later date.

[0023] Figure 3 illustrates an example of an inflow control device 20 incorporated in a screen assembly 18. With reference also to Figure 1, screen assembly 18 includes a base pipe 40 which may be concentrically formed about longitudinal axis 42 and in use forms a portion of tubular string 14. The screen 28 circumscribes the base pipe 40 to form an annular receiving region 44 between the exterior of the surface of the base pipe and the interior surface of the screen. Openings 46 are formed through the through the screen 28. An ICD 20 is provided having a port 34 formed through the base pipe 40 to provide fluid communication between the central passage 22 and the exterior, i.e., annulus 24 when it is open. In the embodiment of a screen assembly the ICD 20 is located radially under the screen 28. The port 34 may be sized and/or formed to control or be responsive to a pressure differential.

[0024] In Figure 3 an eutectic plug 48 is disposed in the port 34 placing the ICD in an initial closed position. For example, the tubular string may be run into the wellbore with the port 34 in the initial closed position with the eutectic plug in place. In this manner the radial fluid communication is blocked for example while other operations are performed. Additionally, the eutectic plugs provide a means for selectively opening ports at a later date for radial production and/or injection. For example, it may be desired to produce fluid from the lowest most zone and so the eutectic plug in the lower most zone is melted by heating leaving the upper zone(s) closed and isolated from the central passage. Heat may be applied in various manners to liquefy the eutectic plug such as providing an electrical current through a line disposed with the tubular string to energize a heating element adjacent to the eutectic plug. In another example, a heat generating element (e.g., electrical heating device, propellant material, etc.) may be run into the central passage to be activated when adjacent to the eutectic plug to be liquefied.

[0025] Figure 4 illustrates another example of a screen assembly 18 including an ICD 20. In this embodiment, the screen assembly includes a sleeve valve 50 for example for depositing the gravel substrate in annular region 44. The depicted sleeve valve 50 includes sleeve member 52 that is slidably disposed with the base pipe 40 to open and close a port 51 formed through the base pipe 40. Sleeve member 52 may include one or more radial ports 53 which are moved into alignment with port 51 when the sleeve valve is in the open position. In operation, ICD 20 may be in the closed state with eutectic plug 48 in place in port 34. Sleeve valve 50 may be opened, for example with a shifting tool, region 44 then gravel packed, and sleeve valve again closed. Eutectic plug 48 may then be heated and liquefied to open port 34 and ICD 20.

[0026] Refer now to Figure 5 to 9 illustrating non-limiting embodiments of inflow control devices 20 in accordance to aspects of this disclosure. Figure 5 illustrates an ICD 20 disposed with a tubular string 14, i.e. a base pipe. ICD 20 includes a body 58 located with the tubular string 14. Body 58 may be formed by the base pipe or be a housing disposed with the base pipe. ICD 20 includes a port 34 formed through the body and providing a radial opening through the base pipe. Eutectic plug 48 is disposed in its solidified form in port 34 sealing the opening.

[0027] Figure 6 depicts an ICD 20 with a port having a restricted orifice or nozzle 60 for the purpose of regulating production or injection through the ICD 20 and a larger diameter chamber section 62. ICD 20 is in the blocked position with the eutectic plug 20 blocking fluid flow through the port 34.

[0028] Figure 7 illustrates an ICD 20 that is arranged to act as a check valve, or one-way flow valve, in the initial state with the eutectic plug in place. In this embodiment, the eutectic material plug 48 is configured as a flow plate 68 having openings 64 to permit fluid flow. A valve member 66, e.g., ball, is disposed in the chamber 62 to seal the nozzle 60 when fluid is flowing in the direction shown by the arrow. If and when it is desired to allow fluid flow in both directions through the ICD, the eutectic flow plate 48 is melted and the valve member 66 is released from the ICD.

[0029] Figure 8 illustrated another example of a check valve type of ICD 20. In this embodiment fluid flow is blocked in both directions when the ICD is in the initial state or position with the eutectic material 48 in place. In this example the flow plate 68 is constructed of a base pipe material. The eutectic material 48 is disposed in the chamber 62 positioning valve member 66 in the closed position blocking flow in both directions. When the eutectic material 48 is melted it will flow through ports 64 and or nozzle 60 freeing valve member 66 to move in response to fluid flow.

[0030] Figure 9 illustrates another example of a check valve type ICD 20 having a nozzle 60. In this example, the constricted nozzle 60 portion of port 34 is formed by eutectic material 48 when in the initial state as illustrated. When the eutectic material 48 is melted the diameter of the constructed nozzle 60 is expanded such that valve member 66 no longer seals the port 34 allowing fluid flow in both directions. In some embodiments the nozzle 60 may expand sufficient to allow the valve member 66 to pass through the port.

[0031] Figure 10 illustrates another an example of selectively actuating the ICDs 20 disposed in a well system from an initial state to a second state. In this example, a heating device or element 56 is conveyed into the tubular sting 14 on a conveyance 70 (e.g., wire line, slick line, coil tubing). Heating device 56 may be a single use device, such as a propellant charge, or a multiple use device. In the depicted example the lower most ICD 20 is in the second state with the eutectic material melted and thus removed from port 34. The upper two ICDs 20 are illustrated in the initial state with the eutectic material 48 disposed so as to block or otherwise limit fluid flow through the ICD. The lower most ICD 20 was operated by positioning heating device 56 adjacent to it and then activated the heating device 56. Additional ICDs may be operated to the second state in a single operation or in operations performed at a later date.

[0032] The foregoing outlines features of several embodiments so that those skilled in the art may better understand the aspects of the disclosure. Those skilled in the art should appreciate that they may readily use the disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the disclosure, and that they may make various changes, substitutions and alterations herein without departing from the spirit and scope of the disclosure. The scope of the invention should be determined only by the language of the claims that follow. The term "comprising" within the claims is intended to mean "including at least" such that the recited listing of elements in a claim are an open group. The terms "a," "an" and other singular terms are intended to include the plural forms thereof unless specifically excluded.

Claims

WHAT IS CLAIMED IS:

1. A flow control device, comprising:

a body forming a port therethrough; and

an eutectic material disposed in the port in an initial state to block fluid flow through the port or to limit fluid flow to one direction through the port.

2. The flow control device of claim 1, wherein the port comprises a constricted nozzle section.

3. The flow control device of claim 1, wherein the eutectic material forms a constricted nozzle portion of the port such that fluid flow is allowed in both directions through the port upon melting the eutectic material.

4. The flow control device of claim 1, comprising a valve member allowing one-way flow through the port when in the initial state, wherein the eutectic material comprises an opening to allow fluid flow through the eutectic material.

5. The flow control device of claim 1, wherein the body is disposed in a gas lift mandrel.

6. The flow control device of claim 5, wherein the port extends between a central

passageway and a side passage of the gas lift mandrel.

7. The flow control device of claim 1 , wherein the body is disposed in a tubular string.

8. The flow control device of claim 1, wherein the body is disposed in a screen assembly for connecting within a well system.

9. The flow control device of claim 8, wherein the screen assembly comprises a base pipe having a central passageway and a screen circumscribing the base pipe; the port formed through the base pipe between the central passageway and the screen.

10. A well system, the system comprising:

a tubular string having a central passageway disposed in a wellbore; and

a flow control device having a port formed through the tubular string and an eutectic material disposed in the port in an initial state to block fluid flow through the port or to limit fluid flow to one direction through the port.

11. The system of claim 10, wherein the flow control device is disposed with a gas lift

mandrel connected within the tubular string, the port extending between the central passageway and a side passage of the gas lift mandrel.

12. The system of claim 10, comprising a screen circumscribing a portion of the tubular string through which the port is formed.

13. A method comprising disposing a tubular string in a wellbore, the tubular string comprising a flow control device formed through the tubular string and configured in an initial state with an eutectic material disposed in a port blocking fluid flow through the port or limiting fluid flow to one direction through the port.

14. The method of claim 13, comprising melting the eutectic material.

15. The method of claim 13, comprising melting the eutectic material in response to heating an element disposed adjacent to the flow control device.

16. The method of claim 13, wherein the flow control device is located with a gas lift

mandrel and the port extending between a central passageway of the tubular string and a side passage of the gas lift mandrel.

17. The method of claim 16, wherein in the initial state the eutectic material blocks fluid flow through the port; and

melting the eutectic material thereby configuring the flow control device in a second state such that fluid flow is permitted through the port.

18. The method of claim 13, comprising a screen circumscribing a portion of the tubular string through which the port is formed; and melting the eutectic material thereby configuring the flow control device in a second state.

The method of claim 18, wherein in the second state fluid flow is restricted to a one-way flow.

The method of claim 18, wherein in the initial state the eutectic material blocks fluid flow through the port; and