Method and apparatus for controlling downhole water production

Abstract

An apparatus for controlling water production in a wellbore comprises a body in the form of a base pipe, the base pipe having an axial flow passage in the form of axial throughbore and a lateral flow passage in the form of radial port. A shroud is disposed around the base pipe and forms a housing of the apparatus. In use, the apparatus forms part of a completion string for location in the wellbore, the apparatus configured to direct production fluid into a production conduit for recovery to surface, perform a quantitative measurement of water content within the production fluid, and vary the fluid flow in the fluid flow path based on the quantitative measurement of water content within the production fluid to maintain water production at or below a predetermined threshold.

Claims

1. A method for controlling water production in a wellbore, comprising: directing flow of a production fluid into a production conduit via a fluid flow path; using a sensor arrangement to perform a quantitative measurement of water content within the production fluid at a sampling rate, wherein the sampling rate varies upon detection of water in the production fluid; logging the quantitative measurement of water content within the production fluid over time to provide cumulative water content values; and configuring the flow path between a fully open configuration, a fully closed configuration and at least one intermediate configuration to vary the fluid flow in the fluid flow path based on the cumulative water content values to maintain water production at or below a predetermined threshold.

2. The method of claim 1, comprising varying the fluid flow in the fluid flow path autonomously.

3. The method of claim 1, wherein varying the fluid flow in the fluid flow path comprises reducing the size of the fluid flow path, wherein reducing the size of the fluid flow path comprises reducing the size of the fluid flow path while maintaining flow in the fluid flow path.

4. The method of claim 1, wherein the predetermined threshold is non-zero.

5. The method of claim 1, wherein reducing the size of the fluid flow path comprises fully closing the fluid flow path.

6. The method of claim 1, wherein varying the fluid flow in the fluid flow path comprises increasing the size of the fluid flow path.

7. The method of claim 1, comprising maintaining the fluid flow path when the quantitative measurement of water content in the production fluid is at or below the predetermined threshold.

8. The method of claim 1, wherein the sensor arrangement is reconfigurable from a passive state to an active state when water is detected in the production fluid.

9. An apparatus for controlling water ingress into a production conduit within a wellbore, comprising: a body comprising an axial flow passage and a lateral flow passage configured to provide fluid communication with the axial flow passage, the apparatus defining a fluid flow passage for directing flow of a production fluid into the production conduit via a fluid flow path; a sensor arrangement configured to log quantitative measurement of water content within the production fluid over time to provide cumulative water content values at a sampling rate, wherein the sampling rate varies upon detection of water in the production fluid; and a valve arrangement configured to vary the fluid flow in the fluid flow path based on the cumulative water content values within the production fluid by configuring the flow path between a fully open configuration, a fully closed configuration and at least one intermediate configuration to maintain water production at or below a predetermined threshold.

10. The apparatus of claim 9, wherein the apparatus is configured to vary the fluid flow in fluid flow path autonomously.

11. The apparatus of claim 9, the valve arrangement comprises a choke valve.

12. The apparatus of claim 9, wherein the sensor arrangement comprises a sensor configured to detect one or more property of the production fluid indicative of water content within the production fluid.

13. The apparatus of claim 12, wherein the sensor arrangement comprises a sensor configured to detect the presence of water, wherein the sensor configured to detect the presence of water comprises an electrical conductivity sensor (EC).

14. The apparatus of claim 13, wherein the sensor configured to detect the presence of water comprise an electrical conductivity (EC) sensor.

15. The apparatus of claim 9, wherein the sensor arrangement comprises a sensor configured to determine the water content in the production fluid, wherein the sensor configured to determine the water content of the production fluid comprises an electromagnetic (EM) flow meter.

16. The apparatus of claim 9, wherein the sensor arrangement comprises a light emitting and receiving system.

17. The apparatus of claim 9, comprising a communication arrangement, the communication arrangement comprising at least one of: A wired communication arrangement; a wireless communication arrangement; and a static pressure communication arrangement.

18. The apparatus of claim 9, comprising a controller configured to actuate the valve arrangement in response to the output signal from the sensor arrangement.

19. The apparatus of claim 9, comprising a power supply, the power supply comprising at least one of: a downhole power supply; a downhole power generator; and a battery.

20. A system for downhole water ingress control, comprising the apparatus according to claim 9.

21. The system of claim 20, comprising a plurality of the apparatus, wherein the apparatus are actuable independently.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) These and other aspects will now be described, by way of example only, with reference to the accompanying drawings, in which:

(2) FIG. 1 is a perspective cut away view of an apparatus according to an embodiment of the present disclosure;

(3) FIG. 2 shows an enlarged view of part of the apparatus shown in FIG. 1;

(4) FIG. 3 shows a diagrammatic view of a control system of the apparatus shown in FIG. 1;

(5) FIGS. 4, 5 and 6 show control system diagrams of the apparatus shown in FIG. 1;

(6) FIG. 7 shows the apparatus shown in FIG. 1 in a first, fully open, configuration;

(7) FIG. 7A shows an enlarged view of part of the apparatus shown in FIG. 7;

(8) FIG. 8 shows the apparatus in a second, intermediate, configuration;

(9) FIG. 8A shows an enlarged view of part of the apparatus shown in FIG. 8;

(10) FIG. 9 shows the apparatus in a third, partially closed, configuration;

(11) FIG. 9A shows an enlarged view of part of the apparatus shown in FIG. 9;

(12) FIG. 10 shows the apparatus in a fourth, fully closed, configuration;

(13) FIG. 10A shows an enlarged view of part of the apparatus shown in FIG. 10;

(14) FIG. 11 shows the apparatus in a fifth, partially open, configuration;

(15) FIG. 11A shows an enlarged view of part of the apparatus shown in FIG. 11;

(16) FIG. 12 shows the apparatus in a sixth, partially open, configuration;

(17) FIG. 12A shows an enlarged view of part of the apparatus shown in FIG. 12;

(18) FIG. 13 shows the apparatus in a seventh, fully open, configuration;

(19) FIG. 13A shows an enlarged view of part of the apparatus shown in FIG. 13;

(20) FIG. 14 shows a completion system according to an embodiment of the present disclosure; and

(21) FIGS. 15A to 15H show a method of operation of the completion system shown in FIG. 14.

DETAILED DESCRIPTION OF THE DRAWINGS

(22) FIG. 1 of the accompanying drawings shows an apparatus 10 for controlling water production in a wellbore B (shown in FIGS. 7 to 13A), according to an embodiment of the present disclosure.

(23) In use, and as will be described further below with reference to FIGS. 14 to 15H, the apparatus 10 forms part of a completion string CS for location in the wellbore B, the apparatus 10 configured to direct production fluid into a production conduit P for recovery to surface S, perform a quantitative measurement of water content within the production fluid, and vary the fluid flow in the fluid flow path based on the quantitative measurement of water content within the production fluid to maintain water production below a predetermined threshold.

(24) As shown in FIG. 1, the apparatus 10 comprises a body in the form of a base pipe 12, the base pipe 12 having an axial flow passage in the form of axial throughbore 14 and a lateral flow passage in the form of radial port 16. In use, the axial throughbore 14 forms a conduit for receiving production fluid in the wellbore B and forms part of the production conduit C for directing the production fluid to surface. The radial port 16 is formed through the wall of the base pipe 12 and, in use, communicates the production fluid into the throughbore 14.

(25) A shroud 18 is disposed around the base pipe 12 and forms a housing of the apparatus 10. In the illustrated embodiment, the shroud 18 comprises a separate component to the base pipe 12 and is coupled to the base pipe 12 at end ring portion 20 via a threaded connection 22. It will be recognised, however, that the shroud 18 and base pipe 12 may be secured together by any suitable coupling arrangement, such as a welded connection, adhesive bond, quick connect, interference fit or the like, or may be integrally formed.

(26) In the illustrated embodiment, a screen in the form of sand screen 24 is disposed around the base pipe 12. Beneficially, the sand screen 24 prevents entrained sand or other particulate matter from being produced to surface S. Other embodiments of the apparatus 10 may, however, operate without a screen.

(27) As shown in FIG. 1, an annulus 26 is defined between the base pipe 12 and the shroud 18, the annulus 26 forming a fluid flow path for directing the production fluid to the radial port 16. A flow guide 28 is disposed within, or formed in, the shroud 18, the flow guide 28 operable to assist in directing the axially directed production fluid flow radially through the radial port 16.

(28) Referring now also to FIG. 2 of the accompanying drawings, an enlarged view of a part of the apparatus 10, it can be seen that the apparatus 10 further comprises a sensor arrangement 30, a valve arrangement 32 and a controller 34.

(29) The sensor arrangement 30 is disposed in the annulus 26 of the apparatus 10 and is configured to perform a quantitative measurement of water content within the production fluid.

(30) In the illustrated embodiment, the sensor arrangement 30 comprises a first sensor in the form of electrical conductivity (EC) sensor 36 and a second sensor in the form of an electromagnetic (EM) flow meter 38. The electrical conductivity sensor 36 is configured to provide an output signal indicating the presence of water in the production fluid passing through the annulus 26 while the electromagnetic (EM) flow meter 38 is configured to provide an output signal indicative of the quantity of water (that is percentage water content) within the production fluid.

(31) While the sensor arrangement 30 in the apparatus 10 comprises two sensors 36,38 in some embodiments the valve arrangement 32 may actuate directly in response to the output signal from the electrical conductivity (EC) sensor 36, or may comprise additional sensors such as a sensor configured to indicate the condition of the valve arrangement 32.

(32) The valve arrangement 32 is operatively associated with the radial port 16 and is configured to vary the fluid flow through the radial port 16 based on the quantitative measurement of water within the production fluid observed by the sensor arrangement 30. In the illustrated embodiment, the valve arrangement 32 takes the form of a choke valve comprising a valve actuator in the form of linear actuator 40 and a valve member in the form of choke trim 42. In the illustrated embodiment, the linear actuator 40 comprises an electromagnetic linear actuator. Beneficially, and as described further below, the linear actuator 40 is configured to permit the choke trim 42 to be moved in increments; permitting a high degree of control over the degree to which fluid flow through the radial port 16 is occluded. In the illustrated embodiment, the choke trim 42 is provided with a weep port 44 (shown in FIG. 2).

(33) Referring now also to FIG. 3 of the accompanying drawings, in the illustrated embodiment the controller 34 comprises a programmable logic controller (PLC) 46. The PLC 46 is operatively associated with the sensor arrangement 30 and the valve arrangement 32, the PLC 46 configured to operate the choke trim 42 of the valve arrangement 32 in response to the output signal(s) received from the sensor arrangement 30.

(34) As shown in FIG. 3, the PLC 46 comprises amongst other things a CPU 48, and an internal clock 50. The PLC 46 may also comprise memory 52 for logging the quantitative measurement of water content within the production fluid over time. Beneficially, the apparatus 10 is thus capable of controlling water ingress, and thereby controlling water production, based on cumulative water content values rather than in response to instantaneous flow conditions.

(35) The apparatus 10 further comprises a power supply for supplying power to at least one of the sensor arrangement 30, valve arrangement 32 and PLC 46. In the illustrated embodiment, the power supply takes the form of a Lithium ion battery 54 housed within the shroud 18. In other embodiments, power to the apparatus 10 may be supplied via a wired connection to surface, or from a downhole power generator.

(36) Operation of the apparatus 10 will now be described with reference to FIGS. 1 to 3 and also FIGS. 4 to 13 of the accompanying drawings, of which FIGS. 4, 5 and 6 illustrate control system diagrams for the apparatus 10, and FIGS. 7 to 13A show the apparatus 10 in different configurations.

(37) The apparatus 10 is initially configured as shown in FIGS. 7 and 7A, with the choke trim 42 in a retracted configuration relative to the shroud 18, such that the radial port 16 is fully open. In use, production fluid entering through the sand screen 24 is directed into and along the annulus 26 of the apparatus 10, through the sensor arrangement 30 and into the throughbore 14 via radial port 16.

(38) As shown in FIG. 4, the sensor arrangement 30 is maintained in a dormant condition until the internal clock 50 within the PLC 46 reaches a predetermined time DT, at which predetermined time DT the sensor arrangement 30 is operated to sample and provide an output signal CWC indicating the water content in the production fluid flow through the apparatus 10.

(39) If the sampled water content is greater than a predetermined threshold value WC+, the PLC 46 signals the valve actuator 40 to extend the choke trim 42 one step, thereby moving the apparatus 10 from the first, fully open, configuration shown in FIGS. 7 and 7A to the second, partially closed, configuration shown in FIGS. 8 and 8A. The sensor arrangement 30 is then again operated to sample and provide an output signal indicating the water content in the production fluid flow through the apparatus 10.

(40) If the sampled water content CWC remains above the predetermined threshold value CW+, the PLC 46 signals the valve actuator 40 to extend the choke trim 42 another step, thereby moving the apparatus 10 from the configuration shown in FIGS. 8 and 8A to the configuration shown in FIGS. 9 and 9A.

(41) This process is repeated until the predetermined threshold value CW+is reached or the valve arrangement 32 is fully closed and the apparatus 10 defines the configuration shown in FIGS. 10 and 10A.

(42) In this way, fluid flow through the radial port 16 is variably choked, permitting a greater degree of control over water ingress into the throughbore 14, and water production to surface S; this being achieved autonomously and mitigating the demands on surface separation equipment.

(43) As described above, an apparatus 10 according to embodiments of the present disclosure also provides the ability to increase fluid flow where the sampled water content CWC is below the predetermined threshold.

(44) As shown in FIG. 4, if the sampled water content CWC is not above, or is no longer above, the predetermined threshold value WC+, the controller 34 determines whether the sampled water content CWC is below a lower threshold valve WC-.

(45) If the sampled water content CWC is below the threshold valve WC+but above the lower threshold valve WC-, the controller 34 maintains the position of the valve arrangement 32.

(46) If, however, the sampled water content CWC is below the threshold valve WC+and below the lower threshold valve WC-, the controller 34 signals the valve actuator 40 to retract the choke trim 42 one step, moving the apparatus 10 from the configuration shown in FIGS. 10 and 10A to the configuration shown in FIGS. 11 and 11A or FIGS. 12 and 12A. This process is repeated until the predetermined threshold value is reached or the valve arrangement 32 is fully opened and the apparatus 10 defines the configuration shown in FIGS. 13 and 13A.

(47) As shown in FIG. 5, which illustrates in more detail the control system diagram for the step of sampling the water content shown in FIG. 4, the apparatus 10 is capable—using the sensor 36—of determining and outputting a signal indicative of the presence of water in the production fluid and using the sensor 38 determining and outputting a signal indicative of the percentage of water in the production fluid. As shown in FIG. 5, where the sensor 36 initially detects the presence of water, the sampling rate at which the percentage of water in the production fluid is increased; extending battery life.

(48) FIG. 6 shows a control system diagram for the valve arrangement. In the illustrated embodiment, it can be seen that the valve actuator 40 is capable to 16 increments between fully open and fully closed configurations. However, it will be recognised that the valve actuator 40 may comprise more or less increments as required and in some embodiments may be configured to move directly between open and closed configurations.

(49) It will be recognised that the apparatus 10 provides the ability to control water production in the wellbore B. This can be achieved autonomously. Moreover, the apparatus 10 provides the ability not only to close and/or choke fluid flow through the radial port 16 but also to open or re-open the radial port 16 and thereby increase fluid flow through the radial port 16.

(50) As described above, and referring now also to FIGS. 14 to 15H of the accompanying drawings, the apparatus 10 forms part of a completion system S. In the illustrated embodiment shown in FIG. 14, the completion system S comprises a plurality of the apparatus 10 (four apparatus 10 are shown), each apparatus 10 operatively associated with a given formation zone and isolated by packers P.

(51) As shown in FIGS. 15A and 15B, where water coning occurs the apparatus 10 of the completion string S are capable of choking and then closing off fluid flow into the production conduit C, in order to limit the amount of water produced to surface. Where the water level subsides, for example due to the reduction in flow resulting from the apparatus 10 being choked or closed, the apparatus 10 are capable of re-opening to again produce, as shown in FIG. 15C.

(52) As shown in FIGS. 15D to 15H, this process may be repeated, reducing or optimising the amount of produced water while also increasing or optimising the extraction of hydrocarbons from the reservoir.

(53) It should be understood that the embodiments described herein are merely exemplary and that various modifications may be made thereto without departing from the scope of the invention.