Downhole fluid control system
11319774 · 2022-05-03
Assignee
Inventors
Cpc classification
F16K31/1221
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
E21B43/32
FIXED CONSTRUCTIONS
Y10T137/86734
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
E21B34/08
FIXED CONSTRUCTIONS
E21B34/14
FIXED CONSTRUCTIONS
Y10T137/2562
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
E21B43/12
FIXED CONSTRUCTIONS
Y10T137/0379
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y10T137/3421
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y10T137/7851
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y10T137/86718
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y10T137/7839
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
E21B34/08
FIXED CONSTRUCTIONS
E21B43/12
FIXED CONSTRUCTIONS
E21B43/32
FIXED CONSTRUCTIONS
F16K31/122
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
E21B34/14
FIXED CONSTRUCTIONS
Abstract
A fluid flow control device serving as an inflow port from a fluid reservoir (R) to the interior of a production pipe (S) is in the form of a housing (3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 3j, 3k, 3l). The housing has a primary flow path (18) and a secondary flow path (19). The secondary flow path is in fluid communication with a chamber (B) in which is arranged an actuator (5) for a valve device (4), the valve device arranged to open and close the primary flow path. At least one flow restrictor (1,2) is arranged in the secondary flow path, the flow restrictor arranged to provide a pressure to chamber (B) sufficient to actuate the valve to an open position when the fluid flowing through the secondary flow path is oil, and a pressure sufficient to actuate the valve to a closed position when the fluid has a viscosity and/or density less than oil.
Claims
1. A downhole fluid flow control system comprising: a fluid control module having an upstream side and a downstream side, the fluid control module including a main fluid pathway in parallel with a secondary fluid pathway each extending between the upstream and downstream sides; a valve element disposed within the fluid control module, the valve element operable between an open position wherein fluid flow through the main fluid pathway is allowed and a closed position wherein fluid flow through the main fluid pathway is prevented; a viscosity discriminator disposed within the fluid control module, the viscosity discriminator having a viscosity sensitive channel that forms at least a portion of the secondary fluid pathway; and a differential pressure switch operable to shift the valve element between the open and closed positions, the differential pressure switch including a first pressure signal from the upstream side, a second pressure signal from the downstream side and a third pressure signal from the secondary fluid pathway, the first and second pressure signals biasing the valve element toward the open position, the third pressure signal biasing the valve element toward the closed position; wherein, a magnitude of the third pressure signal is dependent upon the viscosity of a fluid flowing through the secondary fluid pathway; and wherein, the differential pressure switch is operated responsive to changes in the viscosity of the fluid, thereby controlling fluid flow through the main fluid pathway, whereby the valve element is caused to move to the closed position when an undesired fluid with an undesired viscosity passes through the viscosity discriminator.
2. The flow control system as recited in claim 1 wherein the valve element has first, second and third areas and wherein the first pressure signal acts on the first area, the second pressure signal acts on the second area and the third pressure signal acts on the third area such that the differential pressure switch is operated responsive to a difference between the first pressure signal times the first area plus the second pressure signal times the second area and the third pressure signal times the third area.
3. The flow control system as recited in claim 1 wherein the viscosity discriminator further comprises a viscosity discriminator disk.
4. The flow control system as recited in claim 3 wherein the viscosity sensitive channel further comprises a tortuous path of the viscosity discriminator.
5. The flow control system as recited in claim 4 wherein the tortuous path is formed on a surface of the viscosity discriminator.
6. The flow control system as recited in claim 4, wherein the tortuous path further comprises at least one circumferential path.
7. The flow control system as recited in claim 4, wherein the tortuous path further comprises at least one reversal of direction path.
8. The flow control system as recited in claim 1, wherein the third pressure signal is from a location downstream of the viscosity sensitive channel and wherein the third pressure signal is a total pressure signal.
9. The flow control system as recited in claim 1, wherein the magnitude of the third pressure signal increases with decreasing viscosity of the fluid flowing through the secondary fluid pathway.
10. The flow control system as recited in claim 1, wherein the magnitude of the third pressure signal created by the flow of a desired fluid through the secondary fluid path shifts the valve element to the open position and wherein the magnitude of the third pressure signal created by the flow of a undesired fluid through the secondary fluid path shifts the valve element to the closed position.
11. A downhole fluid control method comprising: positioning a fluid flow control system at a target location downhole, the fluid flow control system including a fluid control module having an upstream side and a downstream, a viscosity discriminator and a differential pressure switch, the fluid control module including a main fluid pathway in parallel with a secondary fluid pathway each extending between the upstream and downstream sides, the viscosity discriminator having a viscosity sensitive channel that forms at least a portion of the secondary fluid pathway; producing a desired fluid from the upstream side to the downstream side through the fluid control module; operating the differential pressure switch to shift the valve element to the open position responsive to producing the desired fluid by applying a first pressure signal from the upstream side to a first area of the valve element, a second pressure signal from the downstream side to a second area of the valve element and a third pressure signal from the secondary fluid pathway to a third area of the valve element; producing an undesired fluid from the upstream side to the downstream side through the fluid control module; and operating the differential pressure switch to shift the valve element to the closed position responsive to producing the undesired fluid by applying the first pressure signal to the first area of the valve element, the second pressure signal to the second area of the valve element and the third pressure signal to the third area of the valve element; wherein, a magnitude of the third pressure signal is dependent upon the viscosity of a fluid flowing through the secondary fluid pathway such that the viscosity of the fluid operates the differential pressure switch, thereby controlling fluid flow through the main fluid pathway.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) These and other characteristics of the invention will be clear from the following description of embodiments, given as non-restrictive examples, with reference to the attached sectional sketches and drawings wherein:
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DETAILED DESCRIPTION OF EMBODIMENTS
(17)
(18) In
(19) In general, the flow characteristics through a porous medium may be described using Darcy's law (i.e. laminar flow), expressed as:
(20)
(21) Thus, when flowing through the porous element 1, the fluid will undergo a pressure drop ΔP (from p.sub.1 to p.sub.2 in
(22) The flow characteristics in a fluid flowing through an orifice or another restrictor (i.e. turbulent flow), may be expressed as:
(23)
(24) Thus, when flowing through the orifice 2, the fluid experiences a pressure drop (ΔP) (from p.sub.2 to p.sub.3) which may be described by equation 2. The change in fluid pressure across the orifice is almost independent of viscosity, but proportional to the density and the orifice coefficient, and to the fluid velocity squared.
(25) Therefore, referring to
(26) Although the invention is explained hereinafter with reference to fluids flowing through a porous element and an orifice, and utilizing the change in viscosity, it should be understood that the invention applies to any combination of fluid flow restrictors where the first provides turbulent flow (completely or substantially) and the other provides laminar flow (completely or substantially), or vice versa.
(27) In general, the present invention utilizes the change in pressure (ΔP.sub.2) that occurs between two different flow restrictors when subjected to fluids of different properties, e.g. oil and water. These properties may be viscosity, as described above, but also density, as is evident from Equation 2. The two flow restrictors are configured to impose different flow characteristics on the fluids. In the example discussed above, the first flow restrictor 1 generates a substantially laminar flow and the second flow restrictor 2 generates a substantially turbulent flow.
(28)
(29)
(30) Another embodiment of the invented flow control device is schematically illustrated in
(31) In use, a fluid flow F (e.g. oil from a subterranean reservoir) enters the housing 3c through the inlet 7. Inside the housing 3c, the major portion F.sub.0 of the fluid F follows a primary conduit 18c before it exits the housing 3c through the outlet 8 and flows into the production pipe S. The remaining portion f of the fluid F flows through the porous member 1 in the body 4b and into a secondary conduit 19c defined by the chamber B before it exits the chamber B through the orifice 2, and flows into the production pipe S. If water and/or gas enters the flow F, causing the overall viscosity μ to drop, the resulting difference in values for p.sub.2 (ΔP.sub.2, see
(32)
(33) This embodiment of the flow control device further comprises a fluid restrictor element 32, here in the form of a face which serves to progressively choke the flow out of the orifice 2 as the movable piston 4d is moved towards the sealing surface 14.
(34) In use, a fluid flow F (e.g. oil from a subterranean reservoir) enters the housing 3d through the inlet 7. Inside the housing 3d, the major portion F.sub.0 of the fluid F follows a primary conduit 18d before it exits the housing 3d through the outlets 8. A portion f of the fluid F flows through the porous member 1 in the piston 4d and into the chamber B before it exits the chamber though the orifice 2, and is mixed with the flow from the primary conduit. In this embodiment of the control device, the difference in values for p.sub.2 (ΔP.sub.2) as the fluid viscosity μ changes, is serving to exert a pressure against a piston surface 5d. This change in pressure, acting on the piston surface 5d, generates a motive force which serves to close the piston 4d against the inlet 7. The sealing surfaces 14 and 15 are brought together, thus substantially preventing fluid from entering the housing 3d.
(35)
(36) In use, a fluid flow F (e.g. oil from a subterranean reservoir) enters the housing 3e through the inlet 7. Inside the housing 3e, the major portion F.sub.0 of the fluid F follows a primary conduit 18e before it exits the housing 3e through the outlets 8. A portion f of the fluid F flows through the porous member 1 in the movable member 4e and into the chamber B before it exits the chamber B though the orifice 2. In this embodiment of the control device, the difference in values for p.sub.2 (ΔP.sub.2, see
(37)
(38) In use, a fluid flow F (e.g. oil from a subterranean reservoir) enters the housing 3f through the inlet 7. Inside the housing 3f, the major portion F.sub.0 of the fluid F follows a primary conduit 18f before it exits the housing 3f through the outlets 8. A minor portion f of the fluid F flows through the porous member 1 in the movable member 4f and into the chamber B before it exits the chamber B though the orifice 2b located in the movable member 4f and/or the orifice 2c located in the lower part 12f. Also in the embodiment of the control device shown in
(39)
(40) In use, a fluid flow F (e.g. oil from a subterranean reservoir) enters the housing 3g through the inlet 7. Inside the housing 3g, the major portion F.sub.0 of the fluid F follows a primary conduit 18g before it exits the housing 3g through the outlet(s) 8. A portion f of the fluid F flows through the porous member 1 arranged in the movable member 4g and into the chamber B before it exits the chamber B through the orifice 2b located on the upper part 4gu of movable member 4g and/or the orifice 2c located on the lower part 4g1 of the movable member 4g. Also in this embodiment of the control device, the difference in values for p.sub.2 (ΔP.sub.2, see
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(42) In use, a fluid flow F (e.g. oil from a subterranean reservoir) enters the housing 3h through the tangential inlet 7. Inside the housing 3h the fluid F follows a primary conduit 18h before it exits through the outlet 8, inducing a high pressure area with whirls. A minor portion f of the fluid F may flow into the conduit(s) 24, optionally through any porous member(s) 1, further into the chamber B and out though the orifice(s) 2 in member 4h. Also in this embodiment of the invention, the difference in values for P.sub.2 (ΔP.sub.2, see
(43)
(44) In use, a fluid flow F enters the housing 3i through the inlet/orifice 7,1. If the viscosity of the flowing fluid is sufficiently high, such as oil, a translationally moving member/actuator 4i comprising a piston 24 and spring 25 attached by appropriate seals 16i inside a second chamber 26, is in an open position, i.e. a valve member 27 enabling blocking of the outlet 8 has been lifted by the actuator 4i. This is a consequence of the corresponding high pressure (p.sub.2) formed inside the chamber B due to the high resistance set up by the second fluid restrictor at the outlet 8, which again causes the upward movement of the piston 24.
(45) Likewise, fluids with sufficiently low viscosity such as water or gas would not create sufficient pressure in chamber B to maintain the piston 24 in a raised position, thereby causing a closure of the outlet 8. An upper chamber 28 shown above the piston 24 is set in fluid communication with the outside of housing 3i via an upper conduit 29, thus ensuring a constant downward force of the actuator 4i which corresponds to the prevailing exterior pressure (p.sub.1).
(46)
(47) In use, a minor portion f of the fluid flow F enters the housing 3j through the upper conduit 29 and the porous material 1, and further through the channel/nozzle 30 into the output area 31. At the same time a major portion F.sub.0 of the fluid flow F flows through inlet 7 into the flow path 18j. The porous material 1 and the channel/nozzle 30 are thus acting as the first flow restrictor 1 and the second flow restrictor 2, respectively, while the upper chamber 28 has the same function as chamber B in
(48)
(49) In use, a fluid flow F enters a primary conduit 18k through a primary inlet 7. This fluid flow is then divided into a major portion F.sub.0 of the flow F going around the chamber 28 and a minor portion f of the flow F entering the pressure chamber B through porous material 1.
(50) The minor portion f further into the actuator chamber 28, subsequently through the channel(s)/nozzle(s) 30 and finally through the outlet 8 together with the major portion F.sub.0 of the flow F. The porous material 1 and the channel(s)/nozzle(s) 30 are thus acting as the first flow restrictor 1 and the second flow restrictor 2, respectively, and the pressure chamber B has the same function as chamber B in
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(52) In use, a fluid flow F (e.g. oil from a subterranean reservoir) enters the housing 3l through the inlet 7. Inside the housing 3l, the major portion F.sub.0 of the fluid F follows the primary conduit 18l before it exits the housing 3l through the outlet(s) 8. A portion f of the fluid F flows through the porous member 1 into the secondary conduit 19l, via the chamber B beneath the member 4l and finally exits the chamber B through the orifice 2. In this embodiment of the control device, the difference in values for p.sub.2 (ΔP.sub.2, see
(53) Note that for all the above embodiments the invention is not limited to specific material such as porous member for the first or second fluid restrictors or a specific geometry such as an orifice for the other fluid restrictor. In fact, any choice of material and/or geometry is possible as long as one of the restrictors creates a mainly laminar flow and the other restrictor creates a mainly turbulent flow during use. Also, even if directional words such as up, down, below, above, sideways, etc. are used with reference to the drawings, in should be understood that these words are used only for clarity and should not be interpreted as limiting the directional position of the inventive control device.
(54) All of the embodiments of the inventive flow control device described above are autonomous in that they move (to close or open a fluid inlet) based on a changing property (e.g. viscosity μ) of the fluid. The porous member 1, the orifice 2 and the internal dimensions of the housing 3a-k may be designed to suit various applications.
(55) As a first example, reference is made to
(56) For a second example, reference is made to
(57) These examples are intended to illustrate the function of the inventive inflow control device. It should be understood that the fluid flow restrictors 1,2 may be arranged and configured differently, for example essentially reversed in the flow path, if the device is intended to be used in a gas reservoir and it is desirable to prevent water from entering the production.
(58) It should be understood that the inventive flow control device may also be arranged and configured to control and prevent the inflow of other fluids, such as CO.sub.2 (which has been injected into the reservoir) and steam (injected in connection with e.g. so-called Steam-Assisted Gravity Drainage (SAGD) of heavy oil), and water in gas-producing wells.
(59) Although the invention has been described with reference to the control of well fluids (such as oil, gas, water) from a subterranean reservoir, the skilled person will understand that the invented device and method is useful in any application where the objective is to control fluid flow based on the properties (e.g. viscosity, density) of the various fluids in the flow in order to prevent unwanted fluids from entering a fluid flow. Examples of such applications are injection wells, separation processes and steam traps.