Systems and methods for producing hydrocarbon material from unconsolidated formations

A wellbore material transfer system is disclosed, and comprises a downhole fluid conductor defining a downhole-conducting fluid passage, an uphole fluid conductor defining an uphole-conducting fluid passage, a flow controller for opening and closing the uphole-conducting fluid passage, and a completion disposed within a wellbore and defining a wellbore interval between the completion and the wellbore, the completion including selectively openable first and second flow communicators. While the flow communicators are open and the uphole-conducting fluid passage is closed, a subterranean formation zone may be fractured, and flow communication is absent, via the second flow communicator and the uphole-conducting fluid passage, between the wellbore interval and the surface. While the flow communicators and the uphole-conducting fluid passage are open, the wellbore interval may be gravel packed, and a solids-depleted fluid is conductible, via the second flow communicator and the uphole-conducting fluid passage, from the wellbore interval to the surface.

FIELD

The present disclosure relates to systems and methods for producing hydrocarbon material from a subterranean formation, and, in particular, systems and methods for hydraulically fracturing a subterranean zone corresponding to a wellbore interval, gravel packing the wellbore interval, and producing, via the gravel pack, from the subterranean formation.

BACKGROUND

Production of hydrocarbon reservoirs is complicated by the presence of solid particulate matter that is entrained within the produced fluid. Such solid particulate matter includes naturally-occurring solids debris, such as sand. It also includes solids, such as proppant, which have been intentionally injected into the reservoir, in conjunction with treatment fluid, for improving the rate of hydrocarbon production from the reservoir. The entrained solids can complicate operations by causing erosion and interfering with fluid flow. To control sand production, screened frac sleeves are employed within wellbore completions. An exemplary technology including screened frac sleeves, and methods employing such technology, is disclosed in International Patent Publication No. WO2018161170A1.

SUMMARY

In one aspect, there is provided a wellbore material transfer system for transferring material between the surface and a subterranean formation, comprising: a downhole fluid conductor extending from the surface and into the subterranean formation, and defining a downhole-conducting fluid passage; an uphole fluid conductor extending from the surface and into the subterranean formation, and defining an uphole-conducting fluid passage; an uphole-conducting fluid flow controller for opening and closing the uphole-conducting fluid passage; a completion including a flow control apparatus that includes a selectively openable first flow communicator and a selectively openable second flow communicator; wherein: the completion is disposed within a wellbore such that a wellbore interval is defined between the completion and the wellbore; the first flow communicator is for effecting flow communication between the downhole-conducting fluid passage and the wellbore interval; the second flow communicator is defined by a flow communicating filtering medium; the second flow communicator is for effecting flow communication between wellbore interval and the downhole-conducting fluid passage; the flow control apparatus is configurable in a production-readying configuration; in the production-readying configuration, each one of the first flow communicator and the second flow communicator, independently, is disposed in an open condition; while the flow control apparatus is disposed in the production-readying configuration, and the uphole-conducting fluid passage is closed by the uphole-conducting fluid flow controller: stimulation material is conductible, via the downhole-conducting fluid passage and the first flow communicator, to the wellbore interval, with effect that hydraulic fracturing of a zone of the subterranean formation, corresponding to the wellbore interval, is effected; and there is an absence of flow communication, via the second flow communicator and the uphole-conducting fluid passage, between the wellbore interval and the surface; and while the flow control apparatus is disposed in the production-readying configuration, and the uphole-conducting fluid passage is disposed in an open condition: gravel slurry material is conductible, via the downhole-conducting fluid passage and the first flow communicator, to the wellbore interval, with effect that gravel packing of the wellbore interval is effected; and a solids-depleted fluid is conductible, via the second flow communicator and the uphole-conducting fluid passage, from the wellbore interval to the surface.

In another aspect, there is provided a wellbore material transfer system for transferring material between the surface and a subterranean formation, comprising: a wellbore string disposed within a wellbore, extending into the subterranean formation, such that an intermediate wellbore space is defined between the wellbore string and the wellbore; a completion continuous with the wellbore string, wherein the completion includes: a flow control apparatus including: a housing; an apparatus passage defined within the housing; a first flow communicator, extending through the housing, for effecting flow communication between the apparatus passage and an intermediate wellbore space interval portion of the intermediate wellbore space; and a second flow communicator, extending through the housing, for effecting flow communication between the apparatus passage and the intermediate wellbore space interval portion; wherein: the first flow communicator is disposed in flow communication with the second flow communicator via the intermediate wellbore space interval portion; and the second flow communicator is defined by a flow communicating filtering medium; an uphole fluid-conducting tool string disposed within a wellbore string space of the wellbore string such that a downhole-conducting fluid passage is defined between the uphole fluid conducting tool string and the wellbore string, wherein the uphole fluid-conducting tool string defines an uphole-conducting fluid passage; an uphole-conducting fluid flow controller for controlling flow through the uphole-conducting fluid passage; an uphole-disposed completion-defined sealed interface, established by an uphole-disposed completion portion of the completion, that is disposed uphole relative to the first flow communicator, for preventing material, disposed within the downhole-conducting fluid passage and uphole relative to the first flow communicator, from being conducted externally of the wellbore string; a downhole-conducting fluid passage sealed interface, established within the downhole-conducting fluid passage and downhole relative to the first flow communicator, for preventing material, disposed uphole relative to the downhole-conducting fluid passage sealed interface, from being conducted downhole, relative to the downhole-conducting fluid passage sealed interface, via the downhole-conducting fluid passage, and is also for preventing material, disposed downhole relative to the downhole-conducting fluid passage sealed interface, from being conducted uphole, relative to the downhole-conducting fluid passage sealed interface, via the downhole-conducting fluid passage; an uphole intermediate wellbore space sealed interface, established within the intermediate wellbore space and uphole relative to the first flow communicator, for preventing material, disposed within the intermediate wellbore space interval portion, from being conducted uphole, relative to the uphole intermediate wellbore space sealed interface, via the intermediate wellbore space; a downhole intermediate wellbore space sealed interface, established within the intermediate wellbore space and downhole relative to the second flow communicator, for preventing material disposed within the intermediate wellbore space interval portion from being conducted downhole, relative to the downhole intermediate wellbore space sealed interface, via the intermediate wellbore space; and a downhole-disposed completion-defined sealed interface, established by a downhole-disposed completion portion of the completion that is disposed downhole relative to the second flow communicator, for preventing material disposed within the wellbore string space, downhole relative to the second flow communicator, from being conducted externally of the wellbore string; wherein: the flow control apparatus is configurable in a production-readying configuration, wherein, in the production-readying configuration, each one of the first and second flow communicators independently, is disposed in an open condition; the completion, the uphole fluid conducting tool string, the downhole-conducting fluid passage sealed interface, the uphole intermediate wellbore space sealed interface, and the downhole intermediate wellbore space sealed interface are co-operatively configurable for disposition in a downhole material supplying configuration within the wellbore; in the downhole material-supplying configuration: (i) the flow control apparatus is disposed in the production-readying configuration, (ii) flow communication is established, via the first flow communicator, between the downhole-conducting fluid passage and the intermediate wellbore space interval portion, (iii) flow communication is established, via the second flow communicator, between the intermediate wellbore space interval portion and the uphole-conducting fluid passage, (iii) the portion of the completion, disposed uphole relative to the first flow communicator, defines an uphole-disposed completion-defined sealed interface for preventing material disposed within the downhole-conducting fluid passage, uphole relative to the first flow communicator, from being conducted externally of the wellbore string, (iv) the uphole-disposed completion-defined sealed interface and the downhole-conducting fluid passage sealed interface co-operate for preventing material, being conducted downhole via the downhole-conducting fluid passage, from bypassing the first flow communicator, (v) the uphole intermediate wellbore space sealed interface is disposed for preventing material, being conducted via the first flow communicator, from the downhole-conducting fluid passage and into the intermediate wellbore space interval portion, from being conducted uphole, relative to the uphole intermediate wellbore space sealed interface, via the intermediate wellbore space, (vi) the downhole intermediate wellbore space sealed interface is disposed for preventing material, being conducted via the first flow communicator, from the downhole-conducting fluid passage and into the intermediate wellbore space, from being conducted downhole, relative to the downhole intermediate wellbore space sealed interface, via the intermediate wellbore space, (vii) the portion of the completion, disposed downhole relative to the second flow communicator, defines a downhole-disposed completion-defined sealed interface for preventing material disposed within the wellbore string space, downhole relative to the second flow communicator, from being conducted externally of the wellbore string, (viii) the downhole-conducting fluid passage sealed interface and the downhole-disposed completion-defined sealed interface co-operate such that material being conducted, via the second flow communicator, from the intermediate wellbore space and into the apparatus passage, is prevented from bypassing the uphole-conducting fluid passage; while the completion, the uphole fluid conducting tool string, the downhole-conducting fluid passage sealed interface, the uphole intermediate wellbore space sealed interface, and the downhole intermediate wellbore space sealed interface are co-operatively disposed in the downhole material supplying configuration, and the uphole-conducting fluid flow controller is disposed in a closed condition, a stimulation material is injectable through the downhole-conducting fluid passage and into the intermediate wellbore space interval portion, via the first flow communicator, for effecting hydraulic fracturing of a corresponding zone of the subterranean formation; and while the completion, the uphole fluid conducting tool string, the downhole-conducting fluid passage sealed interface, the uphole intermediate wellbore space sealed interface, and the downhole intermediate wellbore space sealed interface are co-operatively disposed in the downhole material supplying configuration, and the uphole-conducting fluid flow controller is disposed in an open condition, a gravel pack slurry is injectable through the downhole-conducting fluid passage and into the intermediate wellbore space interval portion, via the first flow communicator, for effecting gravel packing of the intermediate wellbore space interval portion.

In another aspect, there is provided a method of at least conditioning a subterranean formation for production of hydrocarbon material, comprising: over a first time interval, while: (i) a wellbore interval is disposed in flow communication, via a first flow communicator of a downhole flow control apparatus, with a downhole-conducting fluid passage that extends from the surface and into the subterranean formation, and is also disposed in flow communication, via a second flow communicator of the downhole flow control apparatus, with an uphole-conducting fluid passage that extends from the surface and into the subterranean formation, and (ii) an uphole-conducting fluid flow controller is disposed in a closed condition such that the uphole-conducting fluid passage is closed, with effect that there is an absence of flow communication, via the uphole-conducting fluid passage, between the wellbore interval and the surface: supplying a stimulation material to the wellbore interval, via the downhole-conducting fluid passage and the first flow communicator, with effect that stimulation of a zone of the subterranean formation, corresponding to the wellbore interval, for hydrocarbon production is effected, such that a stimulation phase is defined; after the first time interval, and over a second time interval, and while: (i) a wellbore interval is disposed in flow communication, via a first flow communicator of a downhole flow control apparatus, with a downhole-conducting fluid passage that extends from the surface and into the subterranean formation, and is also disposed in flow communication, via a second flow communicator of the downhole flow control apparatus, with an uphole-conducting fluid passage that extends from the surface and into the subterranean formation, and (ii) the uphole-conducting fluid flow controller is disposed in an open condition such that the uphole-conducting fluid passage is open, with effect that flow communication, via the uphole-conducting fluid passage, between the wellbore interval and the surface is effected: supplying a slurry material to the wellbore interval, via the downhole-conducting fluid passage and the first flow communicator, with effect that gravel packing of the wellbore interval is effected, and a solids-depleted fluid is conducted to the surface via the second flow communicator and the open uphole-conducting fluid passage, such that a gravel packing phase is defined; wherein: the second flow communicator is defined by a flow communicating filter medium.

In another aspect, there is provided a method of at least conditioning a subterranean formation for production of hydrocarbon material, comprising: over a first time interval, and while: (i) a wellbore interval is disposed in flow communication, via a first flow communicator of a downhole flow control apparatus, with a downhole-conducting fluid passage that extends from the surface and into the subterranean formation, and is also disposed in flow communication, via a second flow communicator of the downhole flow control apparatus, with an uphole-conducting fluid passage that extends from the surface and into the subterranean formation, and (ii) an uphole-conducting fluid flow controller is disposed in an open condition such that the uphole-conducting fluid passage is open, with effect that flow communication, via the uphole-conducting fluid passage, between the wellbore interval and the surface is effected: supplying a slurry material to the wellbore interval, via the downhole-conducting fluid passage and the first flow communicator, with effect that gravel packing of the wellbore interval is effected, and a solids-depleted fluid is conducted to the surface via the second flow communicator and the open uphole-conducting fluid passage, such that a gravel packing phase is defined; over a second time interval, while: (i) a wellbore interval is disposed in flow communication, via a first flow communicator of a downhole flow control apparatus, with a downhole-conducting fluid passage that extends from the surface and into the subterranean formation, and is also disposed in flow communication, via a second flow communicator of the downhole flow control apparatus, with an uphole-conducting fluid passage that extends from the surface and into the subterranean formation, and (ii) an uphole-conducting fluid flow controller is disposed in a closed condition such that the uphole-conducting fluid passage is closed, with effect that there is an absence of flow communication, via the uphole-conducting fluid passage, between the wellbore interval and the surface: supplying a stimulation material to the wellbore interval, via the downhole-conducting fluid passage and the first flow communicator, with effect that stimulation of a zone of the subterranean formation, corresponding to the wellbore interval, for hydrocarbon production is effected, such that a stimulation phase is defined; wherein: the second flow communicator is defined by a flow communicating filter medium.

In another aspect, there is provided a wellbore completion component, defining a transition impeder, comprising: a housing; and a completion component feature configurable in a first configuration and a second configuration; wherein: the transition impeder includes: a transition-impeding fluid passage; and a fluid disposed for flow within the transition-impeding fluid passage; the flow of the fluid, through the transition-impeding fluid passage, is effected in response to the transitioning of the completion component feature from the first configuration to the second configuration; and the transition impeder and the completion component feature are co-operatively configured such that resistance to flow, of the fluid through the transition-impeding fluid passage, impedes the transitioning of the completion component feature from the first configuration to the second configuration.

In another aspect, there is provided a method of modulating a flow communication state of a downhole flow control apparatus, wherein: the downhole flow control apparatus includes a flow communicator and a flow controller for controlling flow communication via the flow communicator; the flow control apparatus is configurable in at least a first flow communication configuration, a second flow communication configuration, and a third flow communication configuration; transitioning from the first flow configuration to the second flow configuration is effected in response to displacement of the flow controller, relative to the flow communicator, in one of an uphole and downhole direction, with effect that modulation of flow communication, via the flow communicator, is effected; transitioning from the second flow configuration to the third flow configuration is effected in response to displacement of the flow controller, relative to the flow communicator, in the one of an uphole and downhole direction, with effect that modulation of flow communication, via the flow communicator, is effected; and the transitioning from the first configuration to the third configuration is effectible in the absence of a displacement of the flow controller, relative to the flow communicator, in the other one of an uphole and downhole direction.

In another aspect, there is provided a wellbore material transfer system for transferring material between the surface and a subterranean formation, comprising: a wellbore string disposed within a wellbore, extending into the subterranean formation, such that an intermediate wellbore space is defined between the wellbore string and the wellbore; a flow control apparatus, integrated within the wellbore string, and including: a housing; an apparatus passage defined within the housing; a first flow communicator, extending through the housing, for effecting flow communication between the apparatus passage and the intermediate wellbore space; and a second flow communicator, extending through the housing, for effecting flow communication between the apparatus passage and the intermediate wellbore space; wherein: the first flow communicator is disposed in flow communication with the second flow communicator via the intermediate wellbore space; and the second flow communicator is defined by a flow communicating filtering medium; and a flow controller for controlling the flow communication via the first and second flow communicators; a tool string, defining an uphole-conducting fluid passage, and configured for disposition within a wellbore string space of the wellbore string, wherein the tool string includes: a sealed interface effector; and a shifting tool; wherein: the flow control apparatus is configurable in a production-readying configuration, wherein, in the production-readying configuration, each one of the first and second flow communicators independently, is disposed in an open condition; the flow control apparatus is configurable in a production configuration, wherein, in the production configuration, the first flow communicator is closed by the flow controller; while the tool string is disposed within the wellbore string, the sealed interface effector is deployable to a sealing configuration for establishing a sealed interface between the tool string and the wellbore string; the flow control apparatus and the tool string are co-operatively configurable for disposition in a downhole material supplying configuration; in the downhole material-supplying configuration: (i) the tool string is disposed within the wellbore string such that a downhole-conducting fluid passage is defined between the tool string and the wellbore string; (ii) the sealed interface effector is deployed in the sealing configuration such that a sealed interface is established within the downhole-conducting fluid passage and downhole relative to the first flow communicator, for preventing material, being conducted downhole within the downhole-conducting fluid passage, from bypassing the first flow communicator, and also for preventing material, being conducted uphole within the apparatus, from bypassing the uphole-conducting fluid passage; (iii) the flow control apparatus is disposed in the production-readying configuration, (iv) flow communication is established, via the first flow communicator, between the downhole-conducting fluid passage and the intermediate wellbore space, (v) flow communication is established, via the second flow communicator, between the intermediate wellbore space and the apparatus passage; while the flow control apparatus and the tool string are co-operatively disposed in the downhole material supplying configuration, a stimulation material is injectable through the downhole-conducting fluid passage and into the intermediate wellbore space, via the first flow communicator, for effecting hydraulic fracturing of a corresponding zone of the subterranean formation; and while the flow control apparatus and the tool string are co-operatively disposed in the downhole material supplying configuration, a gravel pack slurry is injectable through the downhole-conducting fluid passage and into the intermediate wellbore space interval portion, via the first flow communicator, for effecting gravel packing of the intermediate wellbore space interval portion; and the flow control apparatus is transitionable from the production-readying configuration to the production configuration in response to displacement of the flow controller by the shifting tool.

Other aspects will be apparent from the description and drawings provided herein.

DETAILED DESCRIPTION

There is provided a method of: (i) stimulating a zone of a subterranean formation104via a wellbore interval, and (ii) gravel packing the wellbore interval.

In some of these embodiments, for example, these operations are facilitated by an fluid conducting tool string204(such as, for example, a coiled tubing string) that is deployable through a wellbore string200disposed within a wellbore100. The tool string204includes the shifting tool228, for effecting displacement of a flow controller222for effecting flow communication with a wellbore interval106disposed between the wellbore string200and the subterranean formation104, and which co-operates with a deployable sealed interface effector205for co-operatively diverting fluids during the stimulation and gravel packing operations.

In some of these embodiments, for example, the transitioning between the stimulating and the gravel packing corresponds to switching between closed and open conditions of a flow controller224disposed at the surface102.

Additionally, a flow control apparatus212is provided which, while transitioning from a first configuration, which facilitates both of stimulation and gravel packing, to a second configuration, which facilitates production, becomes disposed in an intermediate configuration that seals downhole flow communication via the flow control apparatus212. By providing such sealing of downhole flow communication, stimulation material and gravel slurry material can be directed to wellbore intervals corresponding to other zones of the subterranean formation for readying production of such zones. The establishing of the intermediate configuration is assisted by providing a transition impeder300for enabling detection, at the surface, of resistance to flow of a viscous fluid.

Referring toFIG.1, the wellbore material transfer system10is provided for conducting material, within the wellbore100, to and from the surface102.

The wellbore100extends from the surface102and into the subterranean formation104. In some embodiments, for example, the subterranean formation104includes a reservoir that contains hydrocarbon material.

The wellbore100can be straight, curved, or branched. The wellbore100can have various wellbore sections. A wellbore section is an axial length of the wellbore100. A wellbore section can be characterized as “vertical” or “horizontal” even though the actual axial orientation can vary from true vertical or true horizontal, and even though the axial path can tend to “corkscrew” or otherwise vary. The term “horizontal”, when used to describe a wellbore section, refers to a horizontal or highly deviated wellbore section as understood in the art, such as, for example, a wellbore section having a longitudinal axis that is between 70 and 110 degrees from vertical.

Referring toFIG.7, the system facilitates the conducting of stimulation material to the subterranean formation104via the wellbore100, for effecting selective stimulation of the subterranean formation104, such as a subterranean formation104including a hydrocarbon material-containing reservoir. The stimulation is effected by supplying the stimulation material to the subterranean formation104. In some embodiments, for example, the stimulation material includes a liquid, such as a liquid including water. In some embodiments, for example, the liquid includes water and chemical additives. In other embodiments, for example, the stimulation material is a slurry including water and solid particulate matter, such as proppant. In some embodiments, for example the stimulation material includes chemical additives. Exemplary chemical additives include acids, sodium chloride, polyacrylamide, ethylene glycol, borate salts, sodium and potassium carbonates, glutaraldehyde, guar gum and other water-soluble gels, citric acid, and isopropanol. In some embodiments, for example, the stimulation material is supplied for effecting hydraulic fracturing of the subterranean formation104.

Referring toFIG.12, the system also provides for the conducting of gravel slurry material to the subterranean formation104via the wellbore100is for gravel packing selective intervals of the wellbore100. The gravel packing prevents production of sand along with hydrocarbon material that is being received from the subterranean formation104. The gravel slurry material includes one or more of gravel, sand, and other solid particulate materials suspended in a fluid. In some embodiments, for example, the solid particulate material includes proppant.

The gravel packing results in deposition and accumulation, within the wellbore100, of solid particulate materials that have been separated from the gravel slurry material, such that a solids-depleted fluid has been obtained. In this respect, the system enables the conducting of the solids-depleted fluid for effecting the return of the solids-depleted fluid to the surface as a return fluid.

Referring toFIG.19, after the gravel packing, the system10also facilitates the conducting of hydrocarbon material, being produced from the subterranean formation, to the surface.

The conducting of fluids to and from the surface102is effected via a completion202of the wellbore string200. The completion202is provided at a downhole end of the wellbore string200for effecting flow communication between the surface102and the subterranean formation104. The completion202is deployable downhole with the wellbore string200. An intermediate wellbore space106is defined between the wellbore string200and the wellbore100and provides space for establishing the gravel pack, as will be further explained below.

The wellbore string200may include pipe, casing, or liner, and may also include various forms of tubular segments. The wellbore string200defines a wellbore string space200A. An fluid conducting tool string204is deployable within the wellbore string space200A and defines an tool string-defined fluid passage206, extending from the surface102, for conducting material uphole to the surface102. The disposition of the fluid conducting tool string204within the wellbore string space200A is such that an intermediate passage is defined between fluid conducting tool string204and the wellbore string200, and the intermediate passage functions as a annular fluid passage208, extending from the surface, for conducting material downhole from the surface102. In this respect, the wellbore string200is configured for conducting material, via the passages206,208defined therein, between the surface102and the completion202. In some embodiments, for example, the fluid conducting tool string204is a coiled tubing string.

In some embodiments, for example, flow through the tool string-defined fluid passage206is controllable via the uphole-conducting fluid flow controller224. In some embodiments, for example, the uphole-conducting fluid flow controller224is disposed at the surface102.

In some embodiments, for example, the wellbore100is completed open hole. In some embodiments, for example, the wellbore100is completed cased, and flow communication between the wellbore100and the subterranean formation104is effected via perforations, such as those formed by a plug and perf operation.

The completion202includes a plurality of flow control stations (three flow communication stations,210A,210B,210C, are illustrated) for effecting the conducting of material between the surface102and the subterranean formation104. Successive flow communication stations210A,210B,210C may be spaced from each other along the wellbore100(such as, for example, with blank pipe) such that each one of the flow communication stations210A,210B,210C, independently, is positioned adjacent a respective interval of the wellbore100, for effecting flow communication between the surface102and a selected interval of the wellbore100.

Each one of the flow communication stations210A,210B,210C, independently, includes a respective flow control apparatus212. In some embodiments, for example, the flow control apparatus212is in the form of a sub that is integratable within the wellbore string200, such as, for example, by threaded coupling.

Referring toFIG.2, the flow control apparatus212includes a housing214. An apparatus passage216is defined within the housing214for receiving the deployed fluid conducting tool string204. The apparatus passage216forms a portion of the wellbore string space200A.

The flow control apparatus212is respective to a corresponding intermediate wellbore space interval portion106A of the intermediate wellbore space106. The flow control apparatus212includes a first flow communicator218for effecting flow communication between the wellbore string space200A and the intermediate wellbore space interval portion106A. The flow control apparatus212also includes a second flow communicator220for effecting flow communication between the wellbore string space200A and the intermediate wellbore space interval portion106A. In this respect, the first flow communicator218is disposed in flow communication with the second flow communicator220via the intermediate wellbore space interval portion106A.

The intermediate wellbore space interval portion106A is defined between an uphole wellbore spaced sealed interface108A and a downhole intermediate wellbore space sealed interface110A.

The uphole intermediate wellbore space sealed interface108A is disposed within the intermediate wellbore space106, uphole relative to the first flow communicator218. The sealed interface108A is established by a sealed interface effector108. In some embodiments, for example, the sealed interface effector108includes a packer. The uphole wellbore space sealed interface108A is for preventing material, disposed within the intermediate wellbore space interval portion106A, from being conducted uphole, relative to the uphole intermediate wellbore space sealed interface108A, via the intermediate wellbore space106.

The downhole intermediate wellbore space sealed interface110A is disposed within the intermediate wellbore space106, downhole relative to the second flow communicator220. The sealed interface110A is established by a sealed interface effector110. In some embodiments, for example, the sealed interface effector110includes a packer. The downhole wellbore space sealed interface110A is for preventing material, disposed within the intermediate wellbore space interval portion106A, from being conducted downhole, relative to the downhole intermediate wellbore space sealed interface110A, via the intermediate wellbore space106.

The first flow communicator218extends through the housing214. In some embodiments, for example, the first flow communicator218is defined by a plurality of ports. In some embodiments, for example, the axes of the ports are disposed within the same cross-section of the flow control apparatus212. The first flow communicator218is provided for effecting flow communication between the apparatus passage216and the intermediate wellbore space interval portion106A. In this respect, the first flow communicator218functions to effect flow communication between the annular fluid passage208of the wellbore string200and the wellbore.

In this way, the first flow communicator218is configured for injecting solids-containing fluid material, delivered by the annular fluid passage208, into the intermediate wellbore space interval portion106A. An exemplary solids-containing fluid material being injected externally of the flow control apparatus212is the stimulation material for effecting hydraulic fracturing of the subterranean formation. Another exemplary solids-containing fluid material being injected externally of the flow control apparatus212is the gravel slurry material for gravel packing.

The second flow communicator220extends through the housing214and is disposed downhole relative to the first flow communicator218. In some embodiments, for example, the second flow communicator218is defined by a plurality of ports. In some embodiments, for example, the axes of the ports are disposed within the same cross-section of the flow control apparatus212. The second flow communicator220is provided for effecting flow communication between the apparatus passage216and a space that is external to the flow control apparatus212. In this respect, the second flow communicator220functions to effect flow communication between the tool string-defined fluid passage206and the intermediate wellbore space interval portion106A.

Unlike the first flow communicator218, the second flow communicator220is configured such that the maximum size of solid particulate matter, that is conductible through the second flow communicator220, is less than the maximum size of solid particulate matter conductible through the first flow communicator218.

In this way, the second flow communicator220is configured for conducting fluid material, without oversize solids, from the intermediate wellbore space106to the tool string-defined fluid passage206. An exemplary fluid receivable from the intermediate wellbore space106, and being conducted through the second flow communicator220, is the solids-depleted fluid obtained during gravel packing of an interval of the wellbore100. In some embodiments, for example, the solids-depleted fluid is that which is obtained while gravel packing is being effectuated in response to the supplying of the gravel slurry material to the intermediate wellbore passage106via the corresponding first flow communicator218. In this respect, during gravel packing, oversize solids, within the gravel slurry material, are prevented from passing through the second flow communicator220, from the intermediate wellbore space106to the tool string-defined fluid passage206, with effect that the oversize solids are filtered from the gravel slurry material, such that a residual solids-depleted fluid passed through the second flow communicator220, from the intermediate wellbore space106to the tool string-defined fluid passage206.

Another exemplary fluid receivable from the intermediate wellbore space interval portion106A is hydrocarbon material that is produced from the subterranean formation104.

In some embodiments, for example, the second flow communicator220is defined by a flow communicating filter medium221. The filter medium221is configured for preventing oversize solid particulate matter from being conducted from the intermediate wellbore space106and into the tool string-defined fluid passage206. In this respect, the filter medium221functions as a debris retention device. In some embodiments, for example, the filter medium is a screen (such as, for example, a wire wrap screen), and the flow communication is effected via apertures defined within the screen. In some embodiments, for example, the filter medium is defined by a sand screen221A that is wrapped around a perforated section (defined by ports221B) of a base pipe223(or perforated liner), the perforated section defining a plurality of apertures. In some embodiments, for example, the filter medium is in the form of a porous material that is integrated within an aperture of a base pipe. In some embodiments, for example, the second flow communicator220is configured for preventing passage of +100 mesh proppant from the intermediate wellbore space interval portion106A and into the tool string-defined fluid passage206. In some embodiments, for example, the first flow communicator218is configured for permitting passage of solid particulate matter (e.g. sand) that passes through a 3 mesh sieve. In some embodiments, for example, the first flow communicator218is configured for permitting passage of solid particulate matter that passes through a 3½ mesh sieve. In some embodiments, for example, the first flow communicator218is configured for permitting passage of passage of solid particulate matter that passes through a 4 mesh sieve. In some embodiments, for example, the first flow communicator218is defined by a plurality of ports and, for each one of the ports, independently, there is an absence of occlusion, of the port (such as, for example, an absence of occlusion by a filter medium). In some embodiments, for example, the second flow communicator220is defined by a screened frac sleeve.

The flow control apparatus212further includes a flow controller222. In some embodiments, for example, the flow controller222is in the form of a sliding sleeve that is displaceable, relative to the housing214, within the passage216. The displacing is for controlling flow communication via the flow communicators218,220. In some embodiments, for example, the displacing of the flow controller222is effected by a shifting tool228that translates with the uphole fluid conducting string204. In some embodiments, for example, the shifting tool228is in the form of mechanical slips.

Referring toFIGS.2to6, in some embodiments, for example, when the flow control apparatus212is initially installed, the flow controller222is releasably retained relative to the housing214such that both of the flow communicators218,220are disposed in the closed condition. In some embodiments, for example, the releasable retention is effected by one or more frangible members. A suitable applied force must be applied to the flow controller222to effect fracturing of the frangible members and thereby effect the release of the flow controller222from such retention.

In some embodiments, for example, the flow controller222is displaceable to various selected positions and, while disposed in these selected positions, the flow controller222is prevented from being inadvertently moved from these selected positions. In this respect, in some embodiments, for example, collet retainers are provided for preventing such inadvertent movement. An exemplary co-operative configuration of a flow controller and a collet retainer is described in U.S. patent application Ser. No. 14/830,507 which is incorporated by reference in its entirety herein.

The deployable sealed interface effector205is carried by the fluid conducting tool string204. The sealed interface effector205is deployable with effect that a sealed interface205A becomes established within the annular fluid passage208, downhole relative to the first flow communicator218. Such a sealed interface is provided for preventing material, disposed uphole relative to the downhole-conducting fluid passage sealed interface205A, from being conducted downhole, relative to the downhole-conducting fluid passage sealed interface205A, via the annular fluid passage208. Such a sealed interface is also provided for preventing material, disposed downhole relative to the downhole-conducting fluid passage sealed interface205A, from being conducted uphole, relative to the downhole-conducting fluid passage sealed interface205A, via the annular fluid passage208. In some embodiments, for example, the deployable sealed interface effector205includes a packer. In some embodiments, for example, the packer is swellable. In some embodiments, for example, the packer is mechanically actuatable. In some embodiments, for example, the sealed interface is established by sealing engagement of the sealed interface effector with the wellbore string200, such as, for example, by sealing engagement to the flow controller222of the flow control apparatus212that is integrated within the wellbore string200.

When it is desired to inject stimulation material into a zone of a subterranean formation104for effecting the hydraulic fracturing of such zone, and then subsequently gravel pack a corresponding interval of the wellbore100, the fluid conducting tool string204is deployed through the wellbore string200such that the shifting tool228becomes suitably positioned, within the apparatus passage216of the flow control apparatus212, for actuation into engagement with the flow controller222for displacing the flow controller222relative to the flow communicators218,200. Referring toFIG.2, while suitably positioned, the shifting tool228is actuated, and becomes engaged to the flow controller222. In parallel, the sealed interface effector205is deployed and becomes sealingly engaged to the flow controller222to define the sealed interface205A. While the shifting tool228is engaged to the flow controller222, a compressive force is applied to the fluid conducting tool string204, from the surface102, with effect that the flow controller222is released from retention (for example, the frangible members are fractured) and displaced a sufficient distance relative to the flow communicators218,220, in the downhole direction, such that the flow communicators218,220become disposed in the open condition. In some embodiments, for example, the displacing of the flow controller222is effected in response to application of fluid pressure to the flow controller222.

Referring toFIGS.8to10, while each one of the flow communicators218,220, independently, is disposed in an open condition, the flow control apparatus212is disposed in a production-readying configuration.

Referring toFIGS.7to10, the completion202, the fluid conducting tool string204, the downhole-conducting fluid passage sealed interface205A, the uphole intermediate wellbore space sealed interface108A, and the downhole intermediate wellbore space sealed interface110A are co-operatively configurable for disposition in a downhole material supplying configuration within the wellbore100. In the downhole material-supplying configuration: (i) the flow control apparatus212, of a one of the flow communication stations, is disposed in the production-readying configuration, (ii) flow communication is established, via the first flow communicator218, between the annular fluid passage208and the intermediate wellbore space interval portion106A, (iii) flow communication is established, via the second flow communicator220, between the intermediate wellbore space interval portion106A and the tool string-defined fluid passage206, (iii) the portion of the completion202, disposed uphole relative to the first flow communicator218of the flow control apparatus212, defines an uphole-disposed completion-defined sealed interface230for preventing material disposed within the annular fluid passage208, uphole relative to the first flow communicator218, from being conducted externally of the wellbore string200, (iv) the uphole-disposed completion-defined sealed interface230and the downhole-conducting fluid passage sealed interface205A are co-operating for preventing material, being conducted downhole via the annular fluid passage208, from bypassing the first flow communicator218, (v) the uphole intermediate wellbore space sealed interface108A is disposed for preventing material, being conducted via the first flow communicator218, from the annular fluid passage208and into the intermediate wellbore space interval portion106A, from being conducted uphole, relative to the uphole intermediate wellbore space sealed interface108A, via the intermediate wellbore space106, (vi) the downhole intermediate wellbore space sealed interface110A is disposed for preventing material, being conducted via the first flow communicator218, from the annular fluid passage208and into the intermediate wellbore space interval portion106A, from being conducted downhole, relative to the downhole intermediate wellbore space sealed interface110A, via the intermediate wellbore space106, (vii) the portion of the completion, disposed downhole relative to the second flow communicator220of the flow control apparatus212, defines a downhole-disposed completion-defined sealed interface232for preventing material disposed within the wellbore string space102A, downhole relative to the second flow communicator220, from being conducted externally of the wellbore string102, (viii) the downhole-conducting fluid passage sealed interface205A and the downhole-disposed completion-defined sealed interface232are co-operating such that material being conducted, via the second flow communicator220, from the intermediate wellbore space106and into the apparatus passage216, is prevented from bypassing the tool string-defined fluid passage206.

In some embodiments, for example, flow communication, via the second flow communicator220, between the intermediate wellbore space interval portion106A and the tool string-defined fluid passage206, is established in response to alignment between the second flow communicator220and throughbores222A defined within the flow controller222.

In some embodiments, for example, the uphole-disposed completion-defined sealed interface230(seeFIG.1) is established while the flow communicators218,220of the other ones of the flow control apparatuses212, disposed uphole relative to the flow control apparatus212(the flow control apparatus212that is already disposed in the production-readying configuration), are disposed in the closed condition. Because the flow communicators218,220of the other ones of the flow control apparatuses212are disposed in the closed condition, there is an absence of flow communication, via one or more of the flow communicators218,220of the other ones of the flow control apparatuses212, between the wellbore string space200A and the intermediate wellbore space interval portion106A.

In some embodiments, for example, the downhole-disposed completion-defined sealed interface232(seeFIG.1) is established while the flow communicators218,220of the other ones of the flow control apparatuses212, disposed downhole relative to the flow control apparatus212(the flow control apparatus212that is already disposed in the production-readying configuration), are disposed in the closed condition. Because the flow communicators218,220of the other ones of the flow control apparatuses212are disposed in the closed condition, there is an absence of flow communication, via one or more of the flow communicators218,220of the other ones of the flow control apparatuses212, between the wellbore string space200A and the intermediate wellbore space interval portion106A.

Referring toFIGS.7to11, while the completion202, the fluid conducting tool string204, the downhole-conducting fluid passage sealed interface205A, the uphole intermediate wellbore space sealed interface108A, and the downhole intermediate wellbore space sealed interface110A are co-operatively disposed in the downhole material supplying configuration within the wellbore100, and the uphole-conducting fluid flow controller224is disposed in a closed condition (such that there is an absence of flow communication between the intermediate wellbore space interval portion106A and the surface102, via the second flow communicator220and the tool string-defined fluid passage206), a stimulation material400is injectable through the annular fluid passage208and into the intermediate wellbore space interval portion106A, via the first flow communicator218, for effecting hydraulic fracturing of a corresponding zone of the subterranean formation104during a stimulation phase. The hydraulic fracturing produces fractures120. In this respect, because the uphole-conducting fluid flow controller224is closing the tool string-defined fluid passage206, there is an absence of flow of the stimulation material, which has been injected into the intermediate wellbore space interval portion106A, through the second flow communicator220. If the uphole-conducting fluid flow controller224was disposed in an open condition, flow communication would be established between the intermediate wellbore space interval portion106A and the surface102, via the second flow communicator220and the uphole-fluid conducting passage206. In such circumstances, because the injected stimulation material400contains solid particulate material and is being injected at a relatively higher flowrate, the filter medium221(e.g. screen) would be susceptible to erosion by the stimulation material being flowed therethrough. In this respect, because the uphole-conducting fluid flow controller224is disposed in a closed condition while the flow control apparatus212and the fluid conducting tool string204are co-operatively disposed in the production-readying configuration, erosion of the filter medium221, by stimulation material being injected through the flow communicator221, is mitigated.

Referring toFIGS.11to15, while the completion202, the fluid conducting tool string204, the downhole-conducting fluid passage sealed interface205A, the uphole intermediate wellbore space sealed interface108A, and the downhole intermediate wellbore space sealed interface110A are co-operatively disposed in the downhole material supplying configuration within the wellbore100, and the uphole-conducting fluid flow controller224is disposed in a closed condition (such that the system10is configured for effecting hydraulic fracturing of a zone of the subterranean formation104, as discussed above), the system10is re-configurable for effecting gravel packing of the intermediate wellbore space interval portion106A, corresponding to the zone of the subterranean formation104that has just been hydraulically fractured, by opening of the tool string-defined fluid passage206with the uphole-conducting fluid flow controller224. In response to the opening of the tool string-defined fluid passage206, flow communication is thereby established between the intermediate wellbore space interval portion106A and the surface102. Because flow communication is established between the intermediate wellbore space interval portion106A and the surface102, via the second flow communicator106and the tool string-defined fluid passage206, formation of a gravel pack404within the intermediate wellbore space106, immediately adjacent to the second flow communicator220, in response to injection of a gravel slurry material402into the intermediate wellbore space interval portion106A from the annular fluid passage208, is facilitated during a gravel packing phase. This is because the solids-depleted fluid406, obtained in response to separation of solid particulate materials from the injected gravel slurry material402(a necessary incident of the gravel packing), is conductible from the intermediate wellbore space interval portion106A to the surface102, via the second flow communicator220and the tool string-defined fluid passage206. In some embodiments, for example, the flowrate of the injected gravel slurry material402is lower relative to the flowrate of the injected stimulation material, and because the flowrate of the injected gravel slurry material402is lower relative to the flowrate of the injected stimulation material, damage to the filter medium221, by the injection of the gravel slurry material is not as concerning. In some embodiments, for example, the ratio of the flowrate of the injected stimulation material to the flowrate of the injected gravel slurry material is at least 1.1, such as, for example, at least 1.25, such as, for example, at least 1.5.

In some embodiments, for example, during the transitioning from the stimulation phase to the gravel packing phase, the supplying of the stimulation material is suspended. In some of these embodiments, for example, during the transitioning from the stimulation phase to the gravel packing phase, the opening of the uphole-conducting fluid flow controller224is effected.

In some embodiments, for example, the stimulation material400is the same material as the slurry material402, such that the stimulation material400is the slurry material402. In some embodiments, during the transitioning from the stimulation phase to the gravel packing phase, the slurry material402continues to be supplied to the wellbore interval106, such that the supplying of slurry material402to the wellbore interval106remains uninterrupted. In some of these embodiments, for example, during the transitioning from the stimulation phase to the gravel packing phase, the opening of the uphole-conducting fluid flow controller224is effected.

Referring toFIG.1A, in some embodiments, for example, the fluid flow resistance between the wellbore interval106A and the surface102, via the flow control apparatus212(including that through the flow communicator220) and the fluid conducting tool string204, is sufficiently significant such that the flow through the filter medium221is sufficiently slow such that erosion of the filter medium221(e.g. screen) during the stimulation phase is not a significant concern. In some of these embodiments, for example, it is unnecessary for the system10to include the uphole-conducting fluid flow controller224so as to prevent return flow, via the flow communicator220, to the surface102.

It is understood that the order of operations can be reversed. In this respect, in some embodiments, for example, gravel packing of the wellbore interval can be effected, and, after the gravel packing, stimulation material can be injected to effect hydraulic fracturing of the subterranean formation104can be effected. In those embodiments where the uphole-conducting fluid flow controller224is provided to mitigate erosion of the filter medium221, initially, the uphole-conducting fluid flow controller224can be disposed in the open condition for facilitating the gravel packing operation, and can then be closed during the stimulation phase.

Prior to producing the formation104, the tool string205is removed from the wellbore100. After the tool string205is removed the wellbore100, the produced hydrocarbon-comprising fluid material is produced at the surface102.

In some embodiments, for example, the actuation of the shifting tool228into the engagement with the flow controller222is a mechanical actuation, and the actuation of the sealed interface effector208, with effect that the sealed interface205A is established, is also a mechanical actuation.

In some embodiments, for example, the shifting tool228and the sealed interface effector208are deployed downhole as part of a bottomhole assembly500. In some embodiments, for example, the bottomhole assembly500defines a downhole end of the tool string205.

In some embodiments, for example, the bottomhole assembly500is similar to the bottomhole assembly described in U.S. patent application Ser. No. 14/830,507, which is incorporated by reference in its entirety herein, and the actuation of the shifting tool228(e.g. mechanical slips) and the sealed interface effector (e.g. packer) corresponds to that, of the corresponding shifting tool and sealed interface effector, described in U.S. patent application Ser. No. 14/830,507. In some of these embodiments, for example, the bottomhole assembly500includes an equalization valve for facilitating unsetting of the sealed interface effector208(e.g. packer), to enable movement of the tool string205to another interval for: (i) hydraulic fracturing of the corresponding zone of the another interval, and (ii) gravel packing of such interval.

To accommodate the requisite fluid flows during each one of hydraulic fracturing and gravel packing (as described above), while still facilitating circulation (e.g. for removal of solid particulate, that has deposited within the intermediate passage defined between fluid conducting tool string204and the wellbore string200, such as solid particulate that has deposited during the stimulation or gravel packing operations) and pressure equalization (e.g. for unsetting the packer), in some embodiments, for example, the equalization valve assembly is suitably modified. In some embodiments, for example, the equalization valve assembly of the bottomhole assembly described in U.S. patent application Ser. No. 14/830,507 is replaced with the crossover tool502illustrated inFIGS.26to29.

The crossover tool502includes an upper mandrel504and a lower mandrel506which co-operatively define a housing503. The upper mandrel504defines an upper mandrel passage508, and the lower mandrel defines a lower mandrel passage510. The upper and lower mandrel passages508,510co-operate to define a cross-over tool passage512, the cross-over tool passage512defining at least a portion of the tool string-defined fluid passage206. A pressure equalization flow communicator514(for example, defined by one or more ports) is defined through the housing for effecting flow communication between the annular fluid passage208and the cross-over tool passage512. The upper mandrel504and the lower mandrel506co-operate to define an equalization valve515for sealing flow communication, via the flow communicator514, between the annular fluid passage208and the cross-over tool passage512. In this respect, the upper mandrel504defines a plug516of the equalization valve515, and the lower mandrel506defines a seat518of the equalization valve515. The seat518is configured to receive the plug516such that, while the plug516is seated on the seat518, the equalization valve514is closed. The closure of the equalization valve515seals flow communication, via the flow communicator514, between the annular fluid passage208and the cross-over tool passage512.

Disposed within the upper mandrel passage508, uphole relative to the equalization valve515, is a tool passage flow-controlling check valve520. The tool passage flow-controlling check valve520is configured for: (i) opening in response to establishing of a sufficient fluid pressure differential, within the mandrel passage508, across the check valve520, wherein the sufficient fluid pressure differential is established by a fluid pressure, acting over the downhole surface of a valve member of the check valve520, sufficiently exceeding a fluid pressure acting over the uphole surface of the valve member of the check valve520, and (ii) preventing flow through the mandrel passage508in a downhole direction across the check valve520.

The cross-over tool further includes a flow circulation-controlling check valve522configured for: (i) opening in response to establishing of a sufficient fluid pressure differential, across the check valve522, wherein the sufficient fluid pressure differential is established by a fluid pressure within the mandrel passage508, acting over a tool passage-facing surface of a valve member of the check valve522, sufficiently exceeding a fluid pressure within the annular fluid passage208acting over annular fluid passage-facing surface of the valve member of the check valve522, and (ii) preventing flow, across the check valve522(via communication passage524), from the annular fluid passage208to the mandrel passage508.

FIG.26illustrates the cross-over tool502disposed in a pressure equalization mode for, amongst other things, facilitating the unsetting of the sealed interface effector208(e.g. packer). In this respect, flow communication is effected, via the pressure equalization flow communicator514, between the annular fluid passage208and the cross-over tool passage512, for dissipating fluid pressure within the annular fluid passage208, by evacuation of fluid from the annular fluid passage208in accordance with the flowpath526.

FIG.27illustrates the cross-over tool502disposed in a circulation mode for, amongst other things, removing solid particulate from the annular fluid passage208(such as, for example, after a gravel packing operation). In this respect, fluid is flowed from the surface102, downhole through the upper mandrel passage508, urges opening of the check valve522, with effect that the fluid is conducted to the annular fluid passage208via the communication passage524, and then recirculated to the surface102with entrained solid particulate that has been carried by the conducted fluid, in accordance with the flowpath528. Notably, flow of such fluid, through the upper mandrel passage508, downhole of the communication passage524is prevented by the check valve520, and the fluid within the annular fluid passage is prevented from re-entering the tool string-defined fluid passage206by the closed equalization valve515.

FIG.28illustrates the cross-over tool502disposed in a hydraulic fracturing mode for stimulating the subterranean formation100via hydraulic fracturing. As illustrated, the stimulation material is conducted downhole through the annular fluid passage208, externally of the cross-over tool502, in accordance with the flowpath530. Notably, the check valve522and the closed equalization valve515prevent the stimulation material from being flowed into the tool string-defined fluid passage206. Return flow is prevented, in the uphole direction through the tool string-defined fluid passage206, by the closed flow controller224.

FIG.29illustrates the cross-over tool502disposed in a gravel packing mode. In the gravel packing mode, gravel slurry material is conducted downhole through the annular fluid passage208, externally of the cross-over tool502, in accordance with the flowpath532. Notably, the check valve522and the closed equalization valve515prevent the gravel slurry material, being conducted downhole, from being flowed into the tool string-defined fluid passage206. The return fluid is conducted in an uphole direction through the tool string-defined fluid passage206(including the cross-over tool passage512) to the surface102in accordance with flowpath534. The return fluid flows past the closed equalization valve515, being prevented from being discharged into the annular fluid passage208by the closed equalization valve515, urges opening of the check valve520, and flows through the check valve520. While the return fluid is flowing past the check valve522, the check valve522remains closed. This is because the pressure, of the gravel slurry material being conducted downhole through the annular fluid passage208, being communicated to the annular fluid passage-facing surface of the valve member of the check valve522via the communication passage524, exceeds the pressure of the return fluid on the opposite side of the valve member of the check valve522.

Referring toFIGS.15to18, after completion of the hydraulic fracturing and gravel packing, the flow controller222is then displaced (such as, for example, in the uphole direction), relative to the housing214, for effecting closing of the flow communicators218,220. In this respect, while both of the flow communicators218,220are disposed in the closed condition, the flow control apparatus212is disposed in an intermediate closed configuration. In some embodiments, for example, the displacing of the flow controller222, resulting in the transitioning of the flow control apparatus212from the production-readying mode to the intermediate closed configuration, is effected by the shifting tool228, and in response to a pulling up force applied to the tool string204. While the flow control apparatus212is disposed in the intermediate closed configuration, hydraulic fracturing and/or gravel packing, of other intervals of the wellbore100and corresponding zones of the subterranean formation100, can be effectuated.

After these other operations at the other flow control stations are completed, the tool string204, or another tool string, is returned to manipulate the flow control apparatus212, such that the flow control apparatus212is transitioned from the intermediate closed configuration to a production configuration. In the production configuration, the flow control apparatus212becomes disposed for receiving production of hydrocarbon material from the subterranean formation104. In this respect, and referring toFIGS.19and20, to transition the flow control apparatus212from the intermediate closed configuration to the production configuration, the flow controller222is displaced (such as, for example, in the uphole direction), relative to the housing214, with effect that the second flow communicator220becomes opened, while the first flow communicator218remains disposed in the closed condition. As a result, because the hydrocarbon material408, being produced from the subterranean formation104, is being diverted from the closed first flow communicator218to the second flow communicator220, solids can be filtered from the hydrocarbon material408, which is being produced, by the formed gravel pack404, before being conducted uphole to the surface102

In some embodiments, for example, the displacing of the flow controller222, with effect that the flow control apparatus212is transitioned from the intermediate closed configuration to the production configuration, is effectible by the shifting tool228. In some of these embodiments, this transitioning is effectible by the shifting tool228in response to a pulling up force being applied to the tool string204.

In some embodiments, for example, the transitioning from the production-readying mode to the intermediate closed configuration, and then from the intermediate closed configuration to the production mode, requires displacement of the flow controller222, relative to the housing214, in two separate sequential uphole movements of the flow controller222, is effected in response to pulling up of the tool string204. In some of these embodiments, for example, an indication is provided to an operator at the surface102, when the flow controller222has become disposed relative to the flow communicators218,220such that the flow control apparatus212becomes disposed in the intermediate closed configuration (both of the flow communicators218,220are disposed in closed conditions). Such an indication is provided so as to provide the operator sufficient time to respond by suspending the pulling up on the tool string204. Otherwise, the flow controller222could be inadvertently pulled past the position which corresponds to the flow control apparatus212being disposed in the intermediate closed configuration. In this respect, such uphole indication, that the pulling up on the tool string204should be suspended, is effectuated by integrating a transition impeder300into the flow control apparatus212.

Without the transition impeder300, it may be necessary to co-operatively configure the flow controller222and the wellbore string200such that an intermediate interference to the displacement of the flow controller222is dynamically introduced such that positioning of the flow controller222is establishable in more than two (2) positions by hard stops provided by the wellbore string200. This would necessitate the flow controller222undergoing displacements in both uphole and downhole directions during transitioning between each of these positions. In this respect, by providing the transition impeder300, amongst other things, the transitioning between the first and third configurations is effectible in the absence of a displacement of the flow controller222in the downhole direction.

Referring toFIGS.4,9,13,17, and21to25, the transition impeder300includes a transition-impeding fluid passage302and a viscous fluid304disposed for flow within the transition impeding fluid passage302. The flow of the viscous fluid304, through the transition impeding fluid passage302, is effected in response to the transitioning of the flow control apparatus212from the intermediate closed configuration to the production configuration. Resistance to the flow, of the viscous fluid304through the transition impeding fluid passage302, impedes the transition in the configuration of the flow control apparatus212from the intermediate closed configuration to the production configuration.

This resistance to flow is able to be detected by an operator at the surface102with a weight indicator. In response to the detected resistance, the operator would then suspend the pulling up on the tool string204.

Referring toFIGS.21to23, in some embodiments, for example, the flow control apparatus212includes an impeder piston306. In some embodiments, for example, the impeder piston306is in the form of a sleeve. In some embodiments, for example, the impeder piston306is displaceable relative to the housing214along an axis that is parallel to the central longitudinal axis of the apparatus passage216, and the displaceability of the flow controller222relative to the housing214is also along an axis that is parallel to the central longitudinal axis of the apparatus passage216. The flow controller222and the impeder piston306are configurable in a translatable configuration. In the translatable configuration, the impeder piston306translates with the flow controller222as a co-operating unit, along an axis that is parallel to the central longitudinal axis of the apparatus passage216, in response to urging of displacement of the flow controller222, relative to the housing214, along an axis that is parallel to the central longitudinal axis of the apparatus passage216. During the transitioning of the flow control apparatus212from the intermediate closed configuration to the production configuration, the impeder piston306and the flow controller222are disposed in the translatable configuration. In some embodiments, for example, the translatable configuration is obtained in response to engagement of the flow controller222with the impeder piston306.

Referring toFIGS.4,9,13,17, and25, the impeder piston306and the housing214are co-operatively configured such that a contractible compartment308is defined between the impeder piston306and the housing214. The contractible compartment308is disposed in flow communication with the transition impeding fluid passage302. Referring toFIGS.21to23, the transition impeding fluid passage302is defined within the impeder piston306and is disposed in flow communication with the compartment308via an inlet3022. In some embodiments, for example, at least a portion of the transition impeding fluid passage302defines a tortuous path. In some embodiments, for example, the transition impeding fluid passage302effects flow communication between the contractible compartment308and the apparatus passage216, such that viscous fluid, which is flowing through the transition impeding fluid passage302, is dischargeable into the apparatus passage216via a transition impeding fluid passage outlet3026. In some embodiments, for example, the transition impeding fluid passage302is defined between first and second counterparts3028,3030. In some embodiments, for example, the first counterpart3028defines the tortuous path that extends into the outlet3026. The second counterpart3030functions as a cap that is press fit over the first counterpart3028, and defines the slots3022for effecting communication with the compartment308. At least a portion of the viscous fluid is disposed within the contractible compartment308, and, in this respect, the impeder piston306is disposed in force communication with the viscous fluid304.

The flow controller222, the impeder piston306, the housing214, the contractible compartment308, and the viscous fluid304are co-operatively configured such that, during the transitioning of the configuration of the flow control apparatus212from the intermediate closed configuration to the production configuration, the impeder piston306translates with the flow controller222in the translatable configuration, such that contraction of the contractible compartment308is effected, and such that the viscous fluid, disposed within the contractible compartment, is urged to flow through the transition-impeding fluid passage302. The urging of the flow of the viscous fluid is with effect that the flow of the viscous fluid304, through the transition impeding fluid passage302, is established, and such that the displacement of the co-operating unit, including the flow controller222, is impeded.

In some embodiments, for example, the impeder piston306, the flow controller222, and the housing214are co-operatively configured such that, while the impeder piston306is translating with the flow controller222in the translatable configuration, prior to the flow control apparatus212becomes disposed in the production configuration, the translatability of the impeder piston306with the flow controller222is defeated. The defeating of the translatability of the impeder piston306with the flow controller222is with effect that there is an absence of impeding of the remainder of the transitioning of the flow control apparatus212, from the intermediate closed configuration to the production configuration, by resistance to the flow, of the viscous fluid304through the transition impeding fluid passage302.

In this respect, in some embodiments, for example, the impeder piston306includes an engagement tab310. The translation of the impeder piston306with the flow controller222is effected only while the flow controller222is engaged to the engagement tab310, such that the translatable configuration is established only while the flow controller222is engaged to the engagement tab310.

In some embodiments, for example, the impeder piston306includes a sleeve322, and the engagement tab310is nested within a recessed surface312, defined within an outer surface of the sleeve322, and is free to be displaced outwardly relative to the recessed surface312. The engagement tab310includes an inwardly-depending projection314extending through an aperture316defined through the sleeve322. The inwardly-depending projection314is for interfering with displacement of the flow controller222, relative to the housing214, in the uphole direction along an axis that is parallel to the central longitudinal axis of the apparatus passage216. In response to the interference, the co-operating unit is established.

In some embodiments, for example, a pair of retaining tabs318,320, extend outwardly from the recessed surface312, for retaining the engagement tab310relative to the sleeve322, with effect that axial displacement of the engagement tab310, relative to the sleeve322, is prevented, and with effect that lateral displacement of the engagement tabs310, relative to the sleeve322, is prevented. In this respect, an uphole end310A of the engagement tab310is disposed in abutting engagement with the retaining tabs318,320, for preventing the axial displacement, and an axially extending projection310B is disposed between the retaining tabs318,320for preventing the lateral displacement.

The flow controller222and the impeder piston306are co-operatively configured such that, while the translatable configuration is established, and while displacement of the flow controller222, relative to the housing214, is being urged along an axis that is parallel to the central longitudinal axis of the apparatus passage216, the engagement tab310is urged outwardly relative to the central longitudinal axis of the apparatus passage216. So long as there is interference to the outwardly displacement of the engagement tab310, the co-operating unit remains established while the outwardly displacement is being urged (seeFIG.17). Once the interference is defeated, the urging of the outwardly displacement causes the outwardly displacement, thereby resulting in the defeating of the engagement between the projection314and the flow controller222(seeFIG.25). The defeating is with effect that there is an absence of impeding of further displacement of the flow controller222, relative to the housing214, in the uphole direction, by resistance to the flow, of the viscous fluid304through the transition impeding fluid passage302.

In this respect, the flow controller222, the impeder piston306, and the housing214are co-operatively configured for disposition in an impeding configuration. In the impeding configuration, while the translatable configuration is established, and the outwardly displacement of the engagement tab310, relative to the central longitudinal axis of the apparatus passage216, is being urged, and while displacement of the flow controller222, relative to the housing214, is being urged along an axis that is parallel to the central longitudinal axis of the apparatus passage216, the housing214is interfering with the outwardly displacement of the engagement tab310, such that the engagement of the flow controller222to the engagement tab310is maintained. In this respect, in the impeding configuration, the housing214is closely spaced relative to the engagement tab310.

The flow controller222, the impeder piston306, and the housing214are further co-operatively configured for disposition in a non-impeding configuration. In the non-impeding configuration, while the translatable configuration is established, and the outwardly displacement of the engagement tab310, relative to the central longitudinal axis of the apparatus passage216, is being urged, and while displacement of the flow controller222, relative to the housing214, is being urged along an axis that is parallel to the central longitudinal axis of the apparatus passage216, there is an absence of interference, by the housing214, to the outwardly displacement of the engagement tab310, such that the engagement tab310is displaced outwardly relative to the central longitudinal axis of the apparatus passage216, with effect that the engagement of the flow controller222and the engagement tab310is defeated. The defeating of the engagement is with effect that the impeding, by the transition impeder, of the transitioning of the flow control apparatus212from the intermediate closed configuration to the production configuration, is defeated. While there is an absence of the impeding, in response to further urging of the displacement of the flow controller222, relative to the housing214in the uphole direction, the flow controller222is displaced through the impeder piston306, with effect that the flow control apparatus212becomes disposed in the closed configuration. In this respect, in the non-impeding configuration, the housing214defines a housing portion214that is sufficiently spaced from the engagement tab310such that the engagement tab310is sufficiently displaceable, in response to the urging of the displacement of the flow controller222relative to the housing214, for effecting the defeating of the impeding.

In some embodiments, for example, transitioning from the impeding configuration to the non-impeding configuration is effectible in response to the displacement of the co-operating unit relative to the housing. In this respect, the flow controller222, the impeder piston306, and the housing214are further co-operatively configured for transitioning from the impeding configuration to the non-impeding configuration. The transitioning of the configuration of the flow controller222, the impeder piston,306and the housing214from the impeding configuration to the non-impeding configuration is effected in response to the displacement of the co-operating unit relative to the housing214. In some embodiments, for example, the housing214is co-operatively shaped such that, in response to the displacement of the co-operating unit relative to the housing214, the engagement tab310becomes disposed in a wider passage-defining portion214A of the housing214such that the interference to the outward displacement of the engagement tab310is defeated.

In some embodiments, for example, the retaining tabs318,320are configured to fracture, in response to application of sufficient force (such as, for example, force applied by jars on the tool string204), when the impeder piston306becomes inadvertently locked relative to the apparatus212, while the impeder piston306is disposed in engagement with the flow controller222during the transitioning of the flow control apparatus212from the intermediate closed configuration to the production configuration. In this respect, in response to the fracturing of the retaining tabs318,320, the retaining tabs318,320continue to remain engaged to the flow controller222and become moveable along the recessed surface in response to urging of the displacement of the flow controller222, relative to the housing214, in the uphole direction. Sufficient space is provided for permitting sufficient displacement of the fractured retaining tabs318,320, in response to the urging by the flow controller222, while the flow controller222is being displaced relative to the housing, such that the flow control apparatus212becomes disposed in the production configuration.

In some embodiments, for example, the transition impeder300is configurable in an enabled configuration and in a disabled configuration. While the flow control apparatus212is transitioning from the intermediate closed configuration to the production configuration, the transition impeder300is disposed in the enabled configuration for impeding the transitioning. However, while the flow control apparatus212is transitioning from the production-readying configuration to the intermediate closed configuration, the transition impeder300is disposed in the disabled configuration such that there is absence of impeding of the transitioning.

In this respect, in some embodiments, for example, there is an absence of flow of the viscous fluid304, through the configuration change-impeding fluid passage302, while the flow control apparatus212is transitioning from the production-readying configuration to the intermediate closed configuration. Also in this respect, in some embodiments, for example, while the flow control apparatus212is transitioning from the production-readying configuration to the intermediate closed configuration, there is an absence of translation of the impeder piston306with the flow controller222. Also, in this respect, the flow controller222, the impeder piston306, the housing214, the contractible compartment308, and the viscous fluid304are co-operatively configured such that, during the transitioning of the configuration of the flow control apparatus212from the production-readying configuration to the intermediate closed configuration, there is an absence of translation of the impeder piston306with the flow controller222. In some embodiments, for example, while the flow control apparatus212is transitioning from the production-readying configuration to the intermediate closed configuration, the flow controller222is disposed in a spaced-apart relationship with the impeder piston306. In this respect, the flow controller222, the impeder piston306, the housing214, the contractible compartment308, and the viscous fluid304are co-operatively configured such that, during the transitioning of the configuration of the flow control apparatus212from the production-readying configuration to the intermediate closed configuration, the flow controller222is disposed in a spaced-apart relationship with the impeder piston306.

In the above description, for purposes of explanation, numerous details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be apparent to one skilled in the art that these specific details are not required in order to practice the present disclosure. Although certain dimensions and materials are described for implementing the disclosed example embodiments, other suitable dimensions and/or materials may be used within the scope of this disclosure. All such modifications and variations, including all suitable current and future changes in technology, are believed to be within the sphere and scope of the present disclosure. All references mentioned are hereby incorporated by reference in their entirety.