DOWNHOLE CONTROL ARRANGEMENT, VALVE ARRANGEMENT, SIDE POCKET MANDREL, AND METHOD FOR OPERATING A DOWNHOLE VALVE ARRANGEMENT

Abstract

A downhole control arrangement for installation in hydrocarbon well and for controlling the operation of a downhole valve arrangement comprises an electrically controlled control valve, wherein the control arrangement comprises a control system and an electric power supply source configured for supplying electric power to the control system. A downhole valve arrangement for controlling the flow of an injection fluid into a production tubing of a hydrocarbon well comprises a control arrangement, and a side pocket mandrel for installation in a production tubing for use in a hydrocarbon well, wherein the side pocket mandrel comprises an interior pocket space and a valve arrangement.

Claims

1. A downhole control arrangement for installation in hydrocarbon well and for controlling an operation of a downhole valve arrangement comprising an electrically controlled control valve, wherein the downhole control arrangement comprises a control system and an electric power supply source configured to supply electric power to the control system.

2. The downhole control arrangement according to claim 1, wherein the electric power supply source comprises a downhole induction coil arrangement.

3. The downhole control arrangement according to claim 2, wherein the downhole induction coil arrangement is configured to transmit signals from a topside controller to the control system and vice versa.

4. The downhole control arrangement according to claim 3, wherein the control system comprises a control unit and an actuator, wherein the downhole induction coil arrangement is configured to transmit signals from the topside controller to the control unit and vice versa, wherein the control unit is configured to send signals to the actuator, and the actuator is configured to move a control valve of the valve arrangement between an open position and a closed position based on the signals.

5. The downhole control arrangement according to claim 4, wherein the actuator is configured to send signals to the control unit with information about an open/closed status of the control valve.

6. The downhole control arrangement according to claim 4, wherein the control system comprises a sensor configured to determine an open/closed status of the control valve and to send information about the open/closed status to the control unit.

7. The downhole control arrangement according to claim 2, wherein the downhole induction coil arrangement is configured to supply the electric power from the topside controller to an actuator .

8. The downhole control arrangement according to claim 4, further comprising an electric power storage device connected to the downhole induction coil arrangement, and the electric power storage device is connected to supply the electric power to the actuator.

9. The downhole control arrangement according to claim 8, wherein the electric power storage device is chargeable by means of transmitting the electric power from the downhole induction coil arrangement.

10. The downhole control arrangement according to claim 2, wherein the downhole induction coil arrangement comprises a first induction coil electrically connectable to a topside controller, located externally of the well, and a second induction coil connected to the control system.

11. A downhole valve arrangement for controlling a flow of an injection fluid into a production tubing of a hydrocarbon well, the downhole valve arrangement comprising: a valve housing having an interior space and with at least one flow inlet for infeed of an injection fluid, and at least one flow outlet for delivering injection fluid to the well tubing, an electrically controlled control valve located in the valve housing, and the electrically controlled control valve being configured to open or close a fluid communication path between the inlet and the outlet, the downhole control arrangement in accordance with claim 1, which controls the operation of the downhole valve arrangement including the opening and closing of the electrically controlled control valve.

12. A side pocket mandrel for installation in a production tubing for use in a hydrocarbon well, wherein the side pocket mandrel comprises: an interior pocket space; a valve arrangement located in the interior pocket space for controlling the flow of an injection fluid from an external injection fluid source into the production tubing; and an induction coil arrangement connected to a topside controller and connected to the valve arrangement for transmission of signals from the topside controller to the valve arrangement or vice versa and/or for transfer of electric power from the topside controller to the valve arrangement.

13. The side pocket mandrel according to claim 12, wherein the induction coil arrangement comprises a first induction coil located at least partly along an interior wall part of the interior pocket space and a second induction coil located along an exterior part of the valve arrangement, and the second induction coil is located inside the first induction coil in a concentric manner.

14. The side pocket mandrel according to claim 12, further comprising a recess provided in an external wall part of the first side wall), and the recess reaches down into a first compartment , and the recess is configured to receive a first induction coil of the induction coil arrangement for insertion into the first compartment.

15. The side pocket mandrel according to claim 14, further comprising a lid configured to cover the recess.

16. The side pocket mandrel according to claim 12, further comprising: a first seal member located between an internal wall of the pocket space and the valve arrangement at a first location and a second seal member located between the internal wall of the pocket space and the valve arrangement at a second location, whereby a first compartment is obtained in the pocket space between the first seal member and the second seal member.

17. The side pocket mandrel according to claim 12, wherein the induction coil arrangement is located in a first compartment.

18. The side pocket mandrel according to claim 16, further comprising: an inlet port for injection fluid provided in a first side wall of the side pocket mandrel, wherein the first side wall is located between the first seal member and the second seal member, wherein the inlet port is connectable to the external injection fluid source, and wherein the valve arrangement comprises a flow inlet located in the first compartment, an outlet port for injection fluid provided in a second side wall of the side pocket mandrel, wherein the second side wall is located in a second compartment of the pocket space, wherein the second compartment is separated from the first compartment by one of the first and second seal members, wherein the outlet port connects the second compartment with a well tubing, and wherein the valve arrangement comprises a flow outlet located in the second compartment.

19. The side pocket mandrel according to claim 12, wherein the valve arrangement is the valve arrangement as defined in claim 11, wherein the induction coil arrangement is connected to the valve arrangement via the control system.

20. A side pocket mandrel for installation in a production tubing of a hydrocarbon well, wherein the side pocket mandrel comprises an interior pocket space and the valve arrangement as defined in claim 11, located in the pocket space for controlling the flow of an injection fluid from an external injection fluid source into the production tubing.

21. A method for operating a downhole valve arrangement, installed in a side pocket mandrel forming part of a production tubing of a hydrocarbon well, the downhole valve arrangement comprising an electrically controlled control valve for controlling a flow of an injection fluid from an external injection fluid source into the production tubing, and wherein the downhole valve arrangement is connected to a downhole control arrangement comprising an induction coil arrangement comprising two induction coils, the method comprising : sending a signal from a topside controller, via cabling provided in an annulus, to a first induction coil functioning as a transmitter coil, transmitting a signal by induction to the second induction coil functioning as a receiver coil, transmitting a signal via cabling to a control unit, sending a signal from the control unit to an actuator to open the electrically controlled control valve, or alternatively to close the electrically controlled control valve.

22. The method of claim 21, comprising; sending a valve status signal from the actuator to the control unit confirming that the electrically controlled control valve is open or closed, or using a sensor to check if the electrically controlled control valve is open or closed and send a valve status signal to the control unit, sending the valve status signal from the control unit to the second induction coil now functioning as the transmitter coil, transmitting the valve status signal by induction to the first induction coil now functioning as the receiver coil, transmitting the valve status signal via cabling to the topside controller.

23. A method for supplying electric power to a downhole valve arrangement, installed in a side pocket mandrel forming part of a production tubing-of a hydrocarbon well, the downhole valve arrangement comprising an electrically controlled control valve for controlling a flow of an injection fluid from an external injection fluid source into the production tubing, and wherein the downhole valve arrangement is connected to a downhole control arrangement comprising an induction coil arrangement comprising a first induction coil and a second induction coil, the method comprising , transmitting electric power from a topside controller connected to an electric power source, via cabling provided in an annulus, to the first induction coil functioning as a transmitter coil, transmittingthe electric power by induction to the second induction coil -functioning as a receiver coil, transmitting of the electric power via cabling to a control unit that controls an actuator to open the electrically controlled control valve, or alternatively to close the valve.

24. The method according to claim 23, comprising using the electric power to charge a power storage device that supplies the electric power to the actuator.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0055] The present disclosure will now be described in more detail, with reference being made to the enclosed schematic drawings illustrating different aspects and embodiments of the present disclosure, given as examples only, and in which:

[0056] FIG. 1 is a diagram showing a downhole control arrangement,

[0057] FIG. 2 shows an example of a side pocket mandrel,

[0058] FIG. 3 shows an example of a valve arrangement,

[0059] FIG. 4 shows an enlargement of part of the side pocket mandrel in FIG. 2,

[0060] FIG. 5 shows a cross section of part of the side pocket mandrel in FIG. 4, along A-A,

[0061] FIG. 6 is a schematic diagram illustrating steps of a first method, and

[0062] FIG. 7 is a schematic diagram illustrating steps of a second method.

[0063] Elements that are the same or represent corresponding or equivalent elements have been given the same reference numbers in the different figures.

DETAILED DESCRIPTION

[0064] In FIG. 1 is shown an example of a downhole control arrangement 60 for installation in a hydrocarbon well and for controlling the operation of a downhole valve arrangement 10 comprising an electrically controlled control valve. As an example, the downhole valve arrangement 10 may be such as the one shown in FIG. 2, but also other types of valve arrangements are possible. The control arrangement 60 comprises a control system 70 and an electric power supply source configured for supplying electric power to the control system 70.

[0065] In the illustrated example, the electric power supply source comprises a downhole induction coil arrangement 80. The induction coil arrangement is connected to an external electric power supply and can supply electric power to the control system 70 by wireless power transfer. By varying the frequency or amplitude of an alternating current that is fed to the induction coils, a digital signal can be superimposed on top of the power signal. In FIG. 1, the lines with the arrows indicate that power is transferred or signals are transferred or both power and a signal are transferred. Arrows with dotted lines indicate optional variations. The transfer may be by cabling or possible other means. Transfer across the induction coils will be by induction. Transfer from the actuator to the valve arrangement will be by mechanical connection. In the cases where there are two lines between two components, e.g. 40, 41 and 42, 43, with arrows in opposing directions, this indicates that signals/power can be transferred in both directions. However, in reality there could be one cable. In some examples, it would be possible to have additional signal connections than the ones illustrated, e.g. signals could be sent in any direction where there exists electric connection. By means of the induction arrangement can thus be communicated different data, commands, etc.

[0066] The induction coil arrangement 80 may be configured for transmitting signals from a topside controller 90 to the control system 70 and vice versa. The topside controller would be connected to an electric power supply. The top side controller 90 could be any type of control apparatus that is arranged above ground. It could be manually operated e.g. by a person pressing a button to open or close the valve or perform other operations, or it could be automatic. The top side controller may e.g. also contain a display device that can indicate e.g. the open or closed status of the valve, the status of a power storage device that is also part of the control arrangement, or other information that may be obtained.

[0067] In the illustrated example, the control system comprises a control unit 100 and an actuator 110. The induction coil arrangement 80 is configured for transmitting signals 40, 42; 41, 43 from the topside controller 90 to the control unit and vice versa, wherein the control unit is configured to send signals 45 to the actuator, and the actuator is configured to mechanically move 47 a control valve of the valve arrangement 10 between an open position and a closed position based on said signals. The actuator can comprise e.g. a motor, a gearbox, a solenoid or other electrically powered actuator that can move a valve member to open the control valve. The actuator may be powered directly from the induction coil arrangement, but usually it would be powered from the power storage device 120. The actuator can alternatively be regarded as being part of the valve arrangement, e.g. as an electrically controlled valve, but in the present context it is described as being part of the control system.

[0068] The actuator 110 may be configured to send signals 51 to the control unit 100 with information about the open/closed status of the control valve.

[0069] As an option, the control system 70 may comprise a sensor 130 configured to obtain 53 information and determine the open/closed status of the control valve and to send information 52 about the status to the control unit 100. The sensor may e.g. be a position sensor for the control valve or a pressure sensor that registers the pressure inside the control valve.

[0070] The induction coil arrangement 80 may also be configured for supplying electric power from the topside controller 90 to the actuator 110. This may e.g. be done by supplying power by cabling 48 directly from the induction coil arrangement 80 to the actuator. According to an alternative, there may be provided an electric power storage device 120 connected 49 to the induction coil arrangement 80, and the electric power storage device is connected 46 to supply electric power to the actuator. The electric power storage device 120 may be a chargeable device that is chargeable by means of transmitting 49 electric power from the induction coil arrangement. It may e.g. comprise a battery or a capacitor. According to another alternative, the electric power storage device is chargeable via the control unit 100, which receives 42 electric power from the induction coil arrangement and is configured to transmit 44 the electric power to the power storage device. There may also be provisions for the power storage device 120 to send 50 information to the control unit about the charge status and for the control unit to obtain such information and send it to the topside controller.

[0071] The induction coil arrangement 80 comprises a first induction coil 81 electrically connectable to a topside controller 90, located externally of the well, and a second induction coil 82 connected to the control system 70. The second induction coil is also optionally electrically connected to the actuator 110 and/or the power storage device 120. Depending on the direction of the signal, the first induction coil functions as a transmitter and the second induction coil functions as a receiver, or vice versa.

[0072] In FIG. 3 is shown a schematic example of a downhole valve arrangement 10 for controlling the flow of an injection fluid into a production tubing of a hydrocarbon well. The valve arrangement comprises a valve housing 11 having an interior space 12 and with at least one flow inlet 13 for infeed of injection fluid, and at least one flow outlet 14 for delivering injection fluid to the well tubing. It also comprises an electrically controlled control valve 15 located in the housing, and the control valve is configured to open or close a fluid communication path between the inlet 13 and the outlet 14. The valve arrangement further comprises a downhole control arrangement 60 as described above, which controls the operation of the downhole valve arrangement 10 including the opening and closing of the control valve 15. However only the induction coil 82 closest to the valve arrangement is shown in FIG. 3. The actuator of the control device would thus work to move the control valve such that injection fluid fed via the inlets 13 will enter into the interior space 12 of the valve housing. In the illustrated example there is also a check valve 16 arranged between the control valve and the outlet 14. This check valve will prevent backflow from the tubing into the valve housing. It is optional. When the control valve opens and fluid enters the interior space of the valve arrangement, the check valve will automatically move down and free the outlets 14 such that a free fluid communication path will exist between the inlet 13 and the outlet 14.

[0073] An example of a side pocket mandrel 1 is shown in FIG. 2. FIG. 2 illustrates a side pocket mandrel for installation in a production tubing 3 for use in a hydrocarbon well. The side pocket mandrel comprises an interior pocket space 6 and a valve arrangement 10 located in the pocket space for controlling the flow of an injection fluid from an external injection fluid source into the production tubing. The side pocket mandrel 1 also comprises an induction coil arrangement 80 connected to a topside controller 90 and connected to the valve arrangement 10 for transmission of signals from the topside controller to the valve arrangement or vice versa and/or for transfer of electric power from topside controller to the valve arrangement. The connection to the topside controller can be made by cabling 40/41 as schematically illustrated.

[0074] The valve arrangement 10 comprises an electrically controlled control valve. The valve arrangement can for example be of the type previously described with reference to FIG. 3.

[0075] According to an example, the induction coil arrangement 80 comprises a first induction coil 81 located at least partly along an interior wall part 33 of the pocket space 6 and a second induction coil 82 located along an exterior part of the valve arrangement 10, and the second induction coil is located inside the first induction coil in a concentric manner. See FIG. 4 and FIG. 5.

[0076] In the following is given a general description of a side pocket mandrel 1 and its functions, in order to facilitate the understanding of the following description. Even though the details of the enclosed patent claims are illustrated in connection with the example of a side pocket mandrel shown in FIG. 2 and FIG. 4, the enclosed patent claims should not be interpreted as limited to this example and all its details, but only to the details in the claims. The side pocket mandrel comprises an interior pocket space 6 and a valve arrangement 10, located in the pocket space, for controlling the flow of an injection fluid from an external injection fluid source into the production tubing 3. An inlet port 22 for injection fluid is provided in a first side wall 20 of the side pocket mandrel. The injection fluid can be supplied by a injection line connected at one end to the inlet port and at the other end to the external injection fluid source, which may be located at ground level. This may e.g. the case when the injection fluid is a chemical liquid. Alternatively, the inlet port may simply just provide a fluid connection between the valve arrangement 10 and the annulus 5, as shown in the FIG. 2. The well annulus 5 is the space between the outer protective casing 4 and the production tubing 3. An outlet port 26 for injection fluid is provided in a second side wall 24 of the side pocket mandrel 1 and the outlet port provides a fluid connection between the tubing 3 and the valve arrangement 10. By opening the valve arrangement, injection fluid will flow from the annulus 5, or from a connected injection line, via the valve arrangement 10 and into the tubing 3. A casing string in a well can comprise a number of side pocket mandrels at various locations along the tubing.

[0077] According to an example, the side pocket mandrel 1 comprises a recess 23 provided in an external wall part 21 of the first side wall 20, and the recess reaches down into the first compartment 32. The external wall part is facing the annulus 5. The recess is configured to receive the first induction coil 81 of the induction coil arrangement for insertion into the first compartment 32. It may be mentioned that preferably the first induction coil 81 is put in place in the first compartment 32 before the valve arrangement 10, on which the second induction coil 82 is pre-installed, is inserted into the interior pocket space in the side pocket mandrel. As shown in FIG. 5 there may be a small gap 83 between the induction coils. A lid 25 is provided that is configured to cover the recess 23. The lid also covers the induction coil arrangement located in the recess. The lid would normally be mounted after the first, outer, induction coil 81 has been installed. This would occur when the side pocket mandrel is still on the ground, before it is mounted to the tubing. In the illustrated example, the lid 23 is mounted over the recess by means of screws. However, also other mounting means are of course possible. As mentioned before, the induction coil arrangement can supply electric power to the control system 70, and thereby to the valve arrangement, and also to the power storage device 120 by wireless power transfer between the two induction coils. By varying the frequency or amplitude of an alternating current that is fed to the induction coils, a digital signal can be superimposed on top of the power signal. In relation to FIG. 2 has been mentioned that external electric power to the first induction coil 81 can be supplied via cabling 40/41 connected to a power source. In FIG. 5 is shown an example with an electrical junction box 85 to which the cabling can be connected. The junction box is attached to the outside of the side pocket mandrel. A connection cable 86, leading from the junction box 85 to the first, outer induction coil 81, can be installed in a channel 86 provided in the wall of the side pocket mandrel for this purpose.

[0078] In the case when the valve arrangement is used for injection of a chemical liquid delivered by an injection line from surface, the area where the transmitter and receiver are located may have a different pressure to the annulus. In such a case the lid as well as the junction box will need to seal against the side pocket mandrel in order to make a pressure barrier and to prevent any fluid connection between the annulus 5 and the first compartment 32.

[0079] As shown in FIG. 2, the pocket space 6 of the side pocket mandrel has an opening 35 through which the valve arrangement 10 can be inserted into the pocket space 6. Many existing side pocket mandrels also has a so called plug hole in its end wall opposite the opening 35. This hole may be used for installing the first, outer, induction coil 81 in the side pocket mandrel, as an alternative to providing a recess and a lid. If there is no such hole, it may also be provided for the purpose of installing the first induction coil.

[0080] The side pocket mandrel 1 may further comprise a first seal member 28 located between an internal wall 29 of the pocket space and the valve arrangement, at a first location, and a second seal member 30 located between the internal wall 29 of the pocket space and the valve arrangement at a second location. By this is obtained a first compartment 32 in the pocket space between the first seal member 28 and the second seal member 30.

[0081] According to the shown example, the induction coil arrangement 80 is located in the first compartment 32.

[0082] The side pocket mandrel may comprise an inlet port 22 for injection fluid provided in a first side wall 20 of the side pocket mandrel, which first side wall 20 is located between the first seal member 28 and the second seal member 30. The inlet port 22 is connectable to the external injection fluid source. The valve arrangement 10 comprises a flow inlet 13 located in the first compartment 32.

[0083] The side pocket mandrel may further comprise an outlet port 26 for injection fluid provided in a second side wall 24 of the side pocket mandrel, which second side wall 24 is located in a second compartment 34 of the pocket space 6. The second compartment 34 is separated from the first compartment 32 by one of the seal members 30, and outlet port 26 connects the second compartment 32 with the interior of the well tubing 3. The valve arrangement 10 comprises a flow outlet 14 located in the second compartment 34.

[0084] As previously mentioned, the valve arrangement may be a valve arrangement as previously described in relation to FIG. 3, and which is connected to the second induction coil 82 via the control system 70. But also other types of valves are conceivable. The second, inner, induction coil 82 may actually be made part of the valve arrangement. In any case it would be mounted on the valve arrangement before the valve arrangement including the control system, power storage etc., is mounted in the side pocket mandrel. During this mounting, the valve arrangement, including the second, inner, induction coil 82, will be inserted so that the forward part of it will pass through the first, outer, induction coil 81, until the two induction coils are in their respective correct locations in relation to each other. As mentioned, they are located in a concentric manner relative each other. The small gap 83 will facilitate the insertion. The entire valve arrangement, including the second induction coil, can be retrievable from the side pocket mandrel when downhole, such that it would be replaceable by another valve arrangement.

[0085] In FIG. 6 is illustrated an example of a first method. The method is a method for operating a downhole valve arrangement 10, installed in a side pocket mandrel 1 forming part of a production tubing 3 of a hydrocarbon well, the valve arrangement comprising an electrically controlled control valve 15 for controlling the flow of an injection fluid from an external injection fluid source into the production tubing 3, and wherein the valve arrangement is connected to a downhole control arrangement 60 comprising an induction coil arrangement 80 comprising two induction coils, comprising steps of [0086] sending a signal 40 from a topside controller 90, via cabling provided in the annulus, to a first induction coil 81 functioning as a transmitter coil, (200) [0087] transfer of signal by induction to the second induction coil 82 functioning as a receiver coil, (210) [0088] transmission of signal 42 via cabling to a control unit 100, (220) [0089] sending a signal 45 from the control unit to an actuator to open the control valve, or alternatively to close the valve. (230)

[0090] The method may also comprise sending a valve status signal 51 from the actuator 110 to the control unit 100 confirming that the control valve is open alternatively closed, or using a sensor 130 to check 53 if the control valve is open or closed and send a valve status signal 52 to the control unit, (240) further comprising [0091] sending 43 the valve status signal from the control unit 100 to the second induction coil 82 now functioning as a transmitter coil, (250) [0092] transfer of valve status signal by induction to the first induction coil 81 now functioning as a receiver coil, (260) [0093] transmission of valve status signal via cabling 41 to topside controller 90. (270)

[0094] In FIG. 7 is illustrated an example of a second method. The method is a method for supplying electric power to a downhole valve arrangement 10, installed in a side pocket mandrel 1 forming part of a production tubing 3 of a hydrocarbon well, the valve arrangement comprising an electrically controlled control valve 15 for controlling the flow of an injection fluid from an external injection fluid source into the production tubing, and wherein the valve arrangement is connected to a downhole control arrangement 60 comprising an induction coil arrangement 80 comprising two induction coils, comprising steps of [0095] transmitting electric power 40 from a topside controller connected to an electric power source, via cabling provided in the annulus, to a first induction coil functioning as a transmitter coil, (300) [0096] transfer of electric power by induction to the second induction coil functioning as a receiver coil, (310) [0097] transmission 42 of electric power via cabling to a control unit 100 that controls an actuator 110 to open 47 the control valve, or alternatively to close the valve. (320)

[0098] The control actuator 110 can be supplied with electric power either directly from the induction coil arrangement 80, via cabling 48, or from a power storage device 120 via cabling 46. The control unit 100 may send a signal 44 to the power storage device 120 to supply electric power to the actuator 110.

[0099] The method may also comprise using the electric power to charge a power storage device 120 that supplies electric power to the actuator 110. (330) This can be done either directly from the induction coil arrangement 80 via cabling 49 or via the control unit 100.

[0100] The control unit will typically comprise signal transmitter, signal receiver, and logical circuitry to provide the different functions. It may e.g. comprise a field programmable gate array, a processor or similar.

[0101] The present disclosure shall not be considered limited to the illustrated embodiments, but can be modified and altered in many ways, as realised by a person skilled in the art, without departing from the scope defined in the appended claims.