Patent Publication Number: US-2011073308-A1

Title: Valve apparatus for inflow control

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Patent Application having Ser. No. 61/028,740, filed on Feb. 14, 2008, which is incorporated by reference herein. 
    
    
     BACKGROUND 
     A wellbore can pass through various hydrocarbon bearing reservoirs or extends through a single reservoir for a relatively long distance. One technique to increase the production of the well is to perforate the well in a number of different zones. Such perforations can be done either adjacent the same hydrocarbon bearing zone or adjacent different hydrocarbon bearing zones. 
     However, an issue associated with producing from a well in multiple zones is the control of the flow of fluids from the wellbore into a completion assembly. For example, in a well producing from a number of separate zones, one zone can have a higher pressure than another zone. The higher pressure zone may produce into the lower pressure zone rather than to the surface. 
     Similarly, in a horizontal well that extends through a single reservoir, zones near the “heel” of the well (closest to the vertical or near vertical part of the well) may begin to produce unwanted water or gas (referred to as water or gas coning) before those zones near the “toe” of the well (furthest away from the vertical or near vertical departure point) begin producing unwanted water or gas. Production of unwanted water or gas in any one of these zones may require special interventions to be performed to stop production of the unwanted water or gas. 
     Inflow control devices can be used to manage pressure differences between different zones in a wellbore. Inflow control devices can be used in wells to balance inflow of produced hydrocarbons into the completion across different hydrocarbon bearing zones. The balanced flow can enhance reservoir management and reduce the risk of early water or gas breakthrough from a high permeability streak or heal of a well. Additionally, the use of inflow control devices can allow for increased capture of hydrocarbons from the toe of a well. 
     In addition to managing production or flow of hydrocarbons from various zones, well management may require the use of sand control devices. Sand control devices are typically utilized within a well to manage the production of solid material, such as sand. The production of solid material may result in sand production at the surface, downhole equipment damage, reduced well productivity and/or loss of the well. The sand control device may have slotted openings or may be wrapped by a screen. 
     Typically, such sand control screens are used in conjunction with a gravel pack. Gravel packing a well involves placing gravel or other particulate matter around a sand control device. In an open-hole completion, a gravel pack is typically positioned between the wall of the wellbore and a sand screen that surrounds a perforated base pipe. In a cased-hole completion, a gravel pack is positioned between a casing string having perforations and a sand screen that surrounds a perforated base pipe. Produced hydrocarbons can flow from the hydrocarbon bearing zone into the production tubing string through the gravel pack and sand control device; however, particulates above a certain size can be blocked. 
     Gravel packing operations can require passing large quantities of fluid, such as a carrier fluid, through the sand screen and inflow control device, gravel packing with inflow control devices can be difficult if not impossible using typical inflow control devices because the gravel packing and production operations utilize the same flowpath. One typical problem associated with gravel packing using inflow control devices is the formation of voids or bridges in the gravel pack. The bridging or voids can be caused by reduced return flow rate of the career fluid. 
     There is a need, therefore, for a sand completion that incorporates inflow control devices and prevents reduced return flow rates of carrier fluids. 
     SUMMARY 
     One or more apparatus and methods for gravel packing and producing a zone are provided. The apparatus can include a first tubular member disposed at least partially within a second tubular member. A chamber can be formed between the first tubular member and second tubular member. A screen can be connected with the second tubular member and can encircle at least a portion of the first tubular member. A selectively openable flow port can be formed through the first tubular member, and an inflow control device can be formed through the first tubular member. The flow port and the inflow control device can be located adjacent the chamber. 
     In one or more embodiments, a method for gravel packing and producing a zone through the apparatus can include placing a completion assembly adjacent to a hydrocarbon bearing zone within a wellbore. 
     The completion assembly can include a first tubular member disposed at least partially within a second tubular member. A chamber can be formed between the first tubular member and the second tubular member. A portion of the second tubular member can be connected with a screen. The first tubular member can have an inflow control device and a selectively openable flow port formed therethrough. The completion assembly can be disposed downhole with the flow ports in an open configuration. 
     In one or more embodiments, the method can further include isolating the hydrocarbon bearing zone, and providing a gravel slurry to the hydrocarbon bearing zone. The gravel slurry can include a carrier fluid and a particulate from the surface to an annulus formed between the completion assembly and a wall of the wellbore. The carrier fluid to the surface through the flow port. The method can also include placing the flow port in a closed configuration, and hydrocarbons can be produced to the surface through the inflow control device. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       So that the recited features can be understood in detail, a more particular description, briefly summarized above, may be had by reference to one or more embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments. 
         FIGS. 1-2  depict cross section views of an illustrative downhole gravel pack completion with an integrated inflow control device having a sliding sleeve for selectively allowing fluid flow through a selectively openable flow port, according to one or more embodiments described. 
         FIG. 3  depicts a cross section view of another illustrative downhole gravel pack completion with an integrated inflow control device having a sealing device for selectively opening fluid flow through the selectively openable flow port, according to one or more embodiments described. 
         FIG. 4  depicts a cross sectional view of another illustrative downhole gravel pack completion with an integrated inflow control device having a selectively closable flow path formed between a first zone and a second zone of a chamber for selectively allowing fluid flow though the selectively openable flow port, according to one or more embodiments described. 
         FIG. 5  depicts a cross sectional view of another illustrative downhole gravel pack completion with an integrated inflow control device having a sliding sleeve disposed within the chamber for selectively allowing fluid flow through the selectively openable flow port, according to one or more embodiments described. 
         FIG. 6  depicts a cross sectional view of another illustrative downhole gravel pack completion with an integrated inflow control device having a sliding sleeve disposed within the chamber for selectively allowing fluid flow through the selectively openable flow port, according to one or more embodiments described. 
         FIG. 7  depicts a schematic view of a system for gravel packing and producing one or more zones, according to one or more embodiments described. 
     
    
    
     DETAILED DESCRIPTION 
       FIGS. 1 and 2  depict cross section views of an illustrative downhole gravel pack completion  100  with an integrated inflow control device  170  having a sliding sleeve  190  for selectively allowing fluid flow through a selectively openable flow port  160 , according to one or more embodiments. The illustrative downhole gravel pack completion or completion assembly  100  with integrated inflow control device  170  can include one or more first tubular members  130 . A second tubular member or housing  140  can at least partially encircle or encase the first tubular member  130 . A chamber  180  can be formed between the first tubular member  130  and the second tubular member  140 . The second tubular member  140  can be connected to one or more screens  150 . One or more selectively openable flow ports  160  can be formed through the first tubular member  130 . Furthermore, one or more inflow control device or choked flow ports  170  can be formed through the first tubular member  130 . The flow ports  160  and the inflow control device  170  can be at least partially encircled by the second tubular member  140 . 
     The first tubular member  130  can be a sleeve or a base pipe, or a non-perforated tubular. The second tubular member or housing  140  can be a solid tubular or sleeve. The second tubular member  140  can be concentric with the second tubular member  130 . The screen  150  can be connected to an end of the second tubular member  140 . In one or more embodiments, the screen  150  can be connected to an intermediate portion of the second tubular member  140 . For example, the screen  150  can be wrapped around a perforated or slotted portion of the second tubular member  140 . The screen  150  can be a sand control screen. The screen  150  can be any type of sand control screen. For example, the screen  150  can be a wire wrapped screen or mechanical type screen, or a combination thereof. An illustrative sand control screen is described in more detail in U.S. Pat. No. 6,725,929. 
     The chamber  180  can be located between the second tubular member  140  and the first tubular member  130 . The chamber  180  can be a void or cavity provided between the inner diameter of the second tubular member  140  and the outer diameter of the first tubular member  130 . The chamber  180  can be in fluid communication with the exterior of the second tubular member  140  via the screen  150 . The inflow control device  170  and the flow port  160  can be formed through the first tubular member  130  and can be located on the portion of the first tubular member  130  encircled by the second tubular member  140 . 
     The flow port  160  can be an aperture or hole formed through the first tubular member  130 . The flow port  160  can have a flow area equal to the flow area of the inner bore of the first member  130 . The flow port  160  can be selectively switched from an opened or closed position or configuration using one or more flow control devices, such as the sliding sleeve  190 . 
     The sliding sleeve  190  can include a second member  198  positioned within a first member or housing  195 . The first member or housing  195  can be a tubular or sleeve. The second member  198  can be a tubular or sleeve sized to fit within the first member  195 . The second member  198  can have one or more notches or portions adapted to engage or catch a work string or service string (not shown) within the first tubular member  130 . When the work string is engaged by the second member  198 , the axial motion of the work string can be transferred to the second member  198 . 
     The first member  195  and second member  198  can be positioned around the first tubular member  130 . A first aperture  196  can be formed through the first member  195 . A second aperture  199  can be formed through the second member  198 . The first and second apertures  196 ,  199  can have the same flow area or substantially same flow area as the flow port  160 . The first aperture  196  can be permanently aligned with the flow port  160 . The second aperture  199  can be selectively aligned with the flow port  160 . For example, when the second member  198  is in a first position the second aperture  199  can be aligned with the flow port  160 , as depicted in  FIG. 1 . When the second member is in a second position, the second aperture  199  can be out of alignment with the flow port  160 , as depicted in  FIG. 2 . Accordingly, the flow port  160  can be in an opened configuration when the second member  198  is in a first position and a closed configuration when the second member  198  is in a second position. 
     The inflow control device  170  can be an aperture or flowpath configured to induce pressure drop therethrough. For example, the inflow control device  170  can be a nozzle; a choked flow path; an orifice with a nozzle insert; a tortuous path formed into a channel or orifice, a series of tubes, or other device capable of causing pressure drop therethrough. 
       FIG. 3  depicts a cross section view of another illustrative downhole gravel pack completion  300  with an integrated inflow control device  170  having a sealing device  320  for selectively opening fluid flow through the selectively openable flow port, according to one or more embodiments. The downhole gravel pack completion  300  can include the flow port  160  formed into the first tubular member  130 , and the second tubular member  140  can at least partially encircle or encase the first tubular member  130 . The chamber  180  can be formed between the first tubular member  130  and the second tubular member  140 . The screen  150  can be secured to the second tubular member  140  or integral with the second tubular member  140 , as described above. A sealing device  320  can be disposed in the chamber  180  between the screen  150  and the flow port  160 . The sealing device  320  can be actuated to prevent communication between the flow port  160  and screen  150 . When communication between the flow port  160  and screen  150  is prevented the flow port  160  can be said to be in a closed configuration. The sealing device  320  can be a ball valve, a swellable material, or any other device capable of selectively controlling flow therethrough. In one or more embodiments, the sealing device  320  can be actuated mechanically, magnetically, hydraulically, chemically, electronically, or by any other method. 
       FIG. 4  depicts a cross sectional view of another illustrative downhole gravel pack completion  400  with an integrated inflow control device  170  having a flow control device  450  formed between a first zone  430  and a second zone  440  of the chamber  180  for selectively allowing fluid flow through the selectively openable flow port  160 , according to one or more embodiments. The screen  150  can be adjacent or within the first zone  430 . The inflow control device  170  can also be located adjacent or within the first zone  430 . At least a portion of the second tubular member  140  and the flow port  160  can be part of the second zone  440 . 
     The flow control device  450  can be located between the first zone  430  and the second zone  440 . The flow control device  450  can be selectively operated to allow or prevent communication between the screen  150  and the flow port  160 . The flow control device  450  can be a ball valve or swellable member. The flow control device  450  can be disposed within a flow path  420  formed within the chamber  180  between the first zone  430  and the second zone  440 . In one or more embodiments, the flow control device  450  can be actuated mechanically, magnetically, hydraulically, chemically, electronically, or by any other method. 
       FIG. 5  depicts a cross sectional view of another illustrative downhole gravel pack completion  500  with an integrated inflow control device  170  having a sliding sleeve  510  disposed within the chamber  180  for selectively allowing fluid flow through the selectively openable flow port  160 , according to one or more embodiments. The sliding sleeve  510  can be disposed within the chamber  180  between the screen  150  and the selectively openable flow port  160 . The sliding sleeve  510  can be located on the outer diameter of the first tubular member  130 . The inner diameter of the second tubular member  140  can have a portion extending into the chamber  180  for providing a shoulder or mating surface  520 . The shoulder  520  can be sealingly engaged by the sliding sleeve  510 . When the sliding sleeve  510  is moved axially to engage the shoulder  520  the flow port  160  can be prevented from communicating with the screen  150 . Accordingly, the flow port  160  can be said to be in a closed configuration when the sliding sleeve  510  is engaged with shoulder  520 . The flow port  160  can be in an open configuration when the flow port  160  can communicate with the screen  150 . 
       FIG. 6  depicts a cross sectional view of another illustrative downhole gravel pack completion  600  with the integrated inflow control device  170  having a sliding sleeve  620  disposed within the chamber  180  for selectively allowing fluid flow through the selectively openable flow port  160 , according to one or more embodiments. The sliding sleeve  620  can be disposed in the chamber  180  on the inner diameter of the second tubular member  140 . The outer diameter of the first tubular member  130  can have a portion extending into the chamber  180  forming a channel  630  configured to receive the sliding sleeve  620  in a sealing relationship. The sliding sleeve  620  can be moved axially to sealingly engage the channel  630 . When the sliding sleeve  620  is engaged with the channel  630  communication between the screen  150  and the flow port  160  can be prevented. When the sliding sleeve  620  is engaged with the channel  630  the flow port  160  can be said to be in a closed position. 
       FIG. 7  depicts a schematic view of a system  700  for gravel packing and producing one or more zones, according to one or more embodiments. The system  700  can include one or more completion assemblies  100  with one or more integrated inflow control devices  170 . Each completion assembly  100  can be positioned between at least two packers  708 ,  710 ,  712 . A tubing string  720  can be connected between the sand completion assemblies  100 . The tubing string  720  can provide fluid communicate between the completion assemblies  100  and the surface. 
     For clarity and ease of description, the operation of the system  700  will be further described with reference to a horizontal wellbore  750  having a “left” or first hydrocarbon bearing zone  730  and a “right” or second hydrocarbon bearing zone  740 . However, the system  700  can be equally effective or useful in a vertical wellbore, deviated wellbore, multi-lateral wellbore, or any other wellbore having one or more zones. The general operation of the system  700  will be discussed referring to the illustrative embodiment of the completion assembly  100 , which is described in more detail in  FIGS. 1 and 2 ; however, any of the other above described completions assemblies or combinations of the above described completion assemblies can be integrated into the system  700  instead of the completion assembly  100 . 
     Referring to  FIGS. 1 ,  2  and  7 , a “right” or second completion assembly  100  can be located within the horizontal wellbore  750  adjacent or proximate to the second hydrocarbon bearing zone  740 . A “right” or third packer  708  can be connected with the “right” or first end of the second completion assembly  100 . The third packer  708  can isolate the right portion of the second hydrocarbon bearing zone  740  from other zones (not shown) of the wellbore  750  to the right of the second hydrocarbon bearing zone  740 . The third packer  708  can be connected with the right portion of the second completion assembly  100  by one or more tubing strings  720 . An “intermediate” or second packer  710  can be connected to a “left” or first end of the second completion assembly  100 . The second packer  710  can isolate the left part of the second hydrocarbon bearing zone  740  from the first hydrocarbon bearing zone  730 . Accordingly, the second hydrocarbon bearing zone  740  can be isolated from other hydrocarbon bearing zones within the horizontal wellbore  750  by the first and second packers  708 ,  710 . Of course, more than one packer  708 ,  710  can be connected with each end of the second completion assembly  100  and can be used to isolate the hydrocarbon bearing zone  740 . In some embodiments, the packers may also be omitted, as the gravel packed annulus in many cases will provide an annular flow restriction between the different hydrocarbon bearing zones. 
     The first completion assembly  100  can be located within the horizontal wellbore  750  adjacent the first hydrocarbon bearing zone  730 . The first completion assembly  100  can be connected with the second completion assembly  100  via the tubing string  720 . The second packer  710  can isolate the right part of the first hydrocarbon bearing zone  730  from the second hydrocarbon bearing zone  740 . In the alternative, an additional packer (not shown) can be connected with the “right” or second end of the first completion assembly  100  adjacent the second packer  710 , and can be used in conjunction with the second packer  710  to isolate the first hydrocarbon bearing zone  730  to the right of the first completion assembly  700 . A “left” or first packer  712  can be connected to a “left” or first end of the first completion assembly  100  and can be used to isolate the right portion of the first hydrocarbon bearing zone  730  to the right of the first completion assembly  100 . One or more packers can be connected to each end of the first completion assembly  100  and can be used to isolate the first hydrocarbon bearing zone  730 . A tubing string  720  connected with the first completion assembly  100  can provide fluid communication between the first completion assembly  700  and the surface. 
     Each completion assembly  100  can be conveyed into the horizontal wellbore  750  with the flow port  160  in an open configuration. A service string or wash pipe  770  can be conveyed though the tubing string  720  into the horizontal wellbore  750 . The service string  770  can be used to take return flow from the gravel slurry provide to an annulus  742  between the second completion assembly  100  and a wall  755  of the horizontal wellbore  750 . The gravel pack slurry is pumped down  741  into the annulus  750  through a gravel pack packer or similar device (not shown). The carrier fluid or fluid portion of the gravel slurry can migrate from the annulus  742  through the screen  150  of the second completion assembly  100  to the chamber  180 . When the flow port  160  is in an opened configuration there can be two flow paths for the carrier fluid from the chamber  180  to the inner bore of the first tubular member  130 . A first flowpath can be from the chamber  180  into the inner bore of the first tubular member  130  through the flow port  160 . A second flow path can be from the chamber  180  to the inner bore of the first tubular member  130  via the inflow control device  170 . Although both flow paths are available, the carrier fluid can take the first flow path, due to the higher resistance of the second flow path. Accordingly, the carrier fluid can migrate through the screen  150  into the chamber  180 , and through the flow port  160  into the inner bore of the first tubular member  130 . Consequently, when the flow port  160  is in an open configuration the inflow control device  170  can be inoperative. With the flow port  160  in an opened configuration the carrier fluid can be returned to the surface via the tubing string  720  turning into  725  the service string  770 . The port  160  allows this to take place at a flow rate sufficient to ensure a gravel pack about the second completion assembly  100  absent bridges or voids. 
     After the annulus  742  is gravel packed the gravel pack process continues up into the first hydrocarbon bearing zone  730 . 
     Gravel slurry is provided to an annulus  732  formed between the wall  755  of the horizontal wellbore  750  and the first completion  100 . The carrier fluid or fluid portion of the gravel slurry can migrate from the annulus  732  through the screen  150  into the chamber  180  of the first completion assembly  100 . The carrier fluid can enter the inner bore of the first tubular member  130  of the first completion assembly  100  via the flow port  160 , as described above. After the gravel pack is formed in annulus  732 , the service string  770  can be moved axially and can transfer axial movement to the sliding sleeves  190  of the completion string  700 . The axial movement of the sliding sleeve  190  of the completion string  700  can place the flow port  160  of the first and second completion assembly  100  in a closed configuration. The packers  708 ,  710  and  712  can also be activated by the axial movement of the service string. They may also be activated later by a timer mechanism or by time dependent swelling. Alternatively, the packers may be set prior to pumping of the gravel, but in this case a shunt system (not described) is required to allow gravel transport into the different annular sections. 
     Each of the hydrocarbon production zones  730 ,  740  can be produced. Produced hydrocarbons can flow from the horizontal wellbore  750  through the screens  150  of the first and second completion assemblies  100  into the chamber  180  of each completion assembly  100 . The produced hydrocarbons can flow into the inner bore of the first tubular member  130  of the first and second completion assemblies  100  via the inflow control device  170  of the first and second completion assemblies  100 . Of course each completion assembly  100  can have a plurality of inflow control devices  170  depending on the pressure differences between the hydrocarbon bearing zones  730 ,  740 . For example, if the pressure of the first hydrocarbon bearing zone  730  is substantially higher than the pressure of the second hydrocarbon bearing zone  740 , the first completion assembly  100  can have one, two, three, four, or more inflow control devices  170  formed through the first tubular member  130  allowing for management of the pressure between the two hydrocarbon producing zones  730 ,  740 . Consequentially, the produced hydrocarbons flowing from the wellbore  750  into the first tubular member  130  of the first completion assembly  100  will have a larger pressure drop than the produced hydrocarbons flowing from the wellbore  750  into the first tubular member  130  of the second completion assembly  100 . The pressure differences between the hydrocarbon producing zones  730 ,  740  can be calculated using logging information or other downhole data. 
     As used herein, the terms “up” and “down”; “upper” and “lower”; “upwardly” and downwardly”; “upstream” and “downstream”; and other like terms are merely used for convenience to depict spatial orientations or spatial relationships relative to one another in a vertical wellbore. However, when applied to equipment and methods for use in wellbores that are deviated or horizontal, it is understood to those of ordinary skill in the art that such terms are intended to refer to a left to right, right to left, or other spatial relationship as appropriate. 
     Certain embodiments and features have been described using a set of numerical upper limits and a set of numerical lower limits. It should be appreciated that ranges from any lower limit to any upper limit are contemplated unless otherwise indicated. Certain lower limits, upper limits and ranges appear in one or more claims below. All numerical values are “about” or “approximately” the indicated value, and take into account experimental error and variations that would be expected by a person having ordinary skill in the art. 
     Various terms have been defined above. To the extent a term used in a claim is not defined above, it should be given the broadest definition persons in the pertinent art have given that term as reflected in at least one printed publication or issued patent. Furthermore, all patents, test procedures, and other documents cited in this application are fully incorporated by reference to the extent such disclosure is not inconsistent with this application and for all jurisdictions in which such incorporation is permitted. 
     While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.