Patent Publication Number: US-11041367-B2

Title: System and method for operating inflow control devices

Description:
BACKGROUND OF THE INVENTION 
     1. Field of Invention 
     The present disclosure relates to controlling flow in a wellbore. More specifically, the present disclosure relates to controlling flow in a wellbore by manipulating inflow control devices with a bottom-hole assembly having a means for generating a manipulating force. Yet more specifically, the present disclosure relates to applying a bi-directional manipulating force from a bottom-hole assembly to open or close inflow control devices. 
     2. Description of Prior Art 
     Wellbores for the production of hydrocarbon are typically open hole or lined with casing, For cased wellbores, they are usually perforated adjacent a producing or formation zone. Fluid produced from the zone is typically directed to surface within production tubing that is inserted within the casing. Formation fluids generally contain one or more of stratified layers of gas, liquid hydrocarbon, and water. Boundaries between these three layers are often not highly coherent, thereby introducing difficulty for producing a designated one of the fluids. Also, some formations have irregular rock properties or defaults that cause production to vary along the length of the casing. It is usually desired that the fluid flow rate remain generally consistent inside the formation to control the hydrocarbons and water movement for strategic prolonged production. 
     A fluid flow rate from one formation (or segment of the formation) that varies within the casing may inadvertently cause production from another zones or zones, or produces unnecessary amounts of water from high potential segments or zones; which is undesirable because it can lead to a water breakthrough inside the formation which often results in trapped unproduced hydrocarbons. To overcome this challenge and to control frictional losses in wells, an inflow control device (“ICD”) is sometimes run in the wellbore as part of a lower completion connected to the production tubing. The ICD is useful for controlling fluid flow into the wellbore by controlling pressure drop across each zone. Multiple fluid flow devices may be installed, each controlling fluid flows along a section of the wellbore. These fluid control devices may be separated from each other by conventional packers. Other benefits of using fluid control devices include increasing recoverable reserves, minimizing risks of bypassing reserves, and increasing completion longevity. Usually a profiled is formed within each ICD to provide a latching surface for engagement and actuating the ICD. Sometimes the force required to actuate an ICD rises sharply, and may be sufficient to buckle coiled tubing applied in compression in an attempt to operate the ICD. 
     SUMMARY OF THE INVENTION 
     Disclosed herein is an example of an intervention system for use in a wellbore, and which includes coiled tubing selectively inserted within production tubing disposed in the wellbore, and a bottom-hole assembly that is selectively moveable adjacent to an inflow control device coupled with the production tubing. In this example the bottom-hole assembly includes a housing coupled with coiled tubing, an arm having a portion that is coupled with the housing, and a profiled portion distal from the housing that is selectively moved into engagement with a profile on the inflow control device, and an anchor coupled with the housing that is selectively engaged with sidewalls of the production tubing to define a path along which a force resulting from engagement between the profiled portion of the arm and the profile on the inflow control device is transferred. A nozzle is optionally included that has an inlet in communication with the coiled tubing, and an exit in communication with the inflow control device to define a fluid flow path between the coiled tubing and the inflow control device. Embodiments exist where the ICD is part of a lower completion of the production tubing, and where a data logger is provided with the coiled tubing. In an alternative, the housing further includes a motor that is coupled to the arm, so that when the motor is energized the profiled portion of the arm is selectively moved into engagement with the profile on the inflow control device. An option in this example is that the inflow control device is made up of a body, a valve member moveable within the body, and a port formed radially through a side wall in the body, where the profile on the inflow control device is formed on the valve member, and an inside of the production tubing is in fluid communication with sidewalls of the wellbore through the port. Another option in this example, is that the inflow control device is in an open configuration when the valve member is spaced away from the port, the inflow control device is in a flow control configuration when the valve member is set adjacent a portion of the port, the inflow control device is in a closed configuration when the valve member is adjacent all of the port, and the inflow control device is selectively moved between each of the open, flow control, and closed configurations by energizing the motor. In an example, the housing further contains an anchor motor that is coupled to the anchor, so that when the motor is energized the anchor is selectively moved into anchoring engagement with the sidewalls of the production tubing. In an alternate embodiment, the bottom-hole assembly further has a power source in the housing that selectively provides energy used to actuate the arm and the anchor. Optionally, a portion of the coiled tubing distal from the housing mounts to a reel disposed outside of the wellbore. In one example, disengaging the profiled portion of the arm with the profile on the inflow control device frees the bottom-hole assembly to move within and out of the wellbore. 
     Another example of an intervention system for use in a wellbore is disclosed, and which includes coiled tubing having a deployed end selectively inserted into production tubing that is installed within the wellbore, a housing attached to the deployed end, an actuator coupled with the housing and equipped with a portion indented with a pattern to define an actuator profile that is selectively engaged with an inflow control device profile, and an anchor coupled with the housing and that is selectively moved between a retracted configuration adjacent the housing, and a deployed configuration radially outward from the housing and into anchoring engagement with an inner surface of the production tubing. Optionally included with this embodiment of the intervention system is a monitoring system in the housing that is responsive to conditions in the wellbore that include temperature, pressure, and depth. In an alternative, the actuator profile is changeable to correspond to the inflow control device profile. 
     A method of intervening in a wellbore is also disclosed, and which includes handling an intervention system having a portion disposed inside of production tubing that is inserted in the wellbore, and where the intervention system includes a string of coiled tubing, and a bottom-hole assembly that is attached to the coiled tubing. The method of this example also includes adjusting a flow configuration of an inflow control device coupled with the production tubing with the bottom-hole assembly and isolating the coiled tubing from a force resulting from the step of adjusting by securing the bottom-hole assembly to the production tubing. In an alternative, the force is a resultant force, and wherein adjusting a flow configuration of an inflow control device involves engaging complementary profiles on the bottom-hole assembly and inflow control device and applying an adjustment force from the bottom-hole assembly to the inflow control device so that a flow of fluid through the inflow control device is adjusted. In an embodiment the adjustment force is generated within the bottom-hole assembly. Optionally included with the method is conditioning the wellbore by discharging fluid from the bottom-hole assembly that flows downhole inside the coiled tubing. Examples exist where the fluid that flows downhole inside the coiled tubing is acid. A cross section of a bore inside the coiled tubing is optionally filled entirely with the fluid. In an alternate example, the inflow control device is a first inflow control device, the method further involving moving the bottom-hole assembly to a location in the production tubing that is spaced away from the first inflow control device and adjacent to a second inflow control device, engaging the second inflow control device with the bottom-hole assembly, and adjusting a flow configuration of the second inflow control device. Moving the bottom-hole assembly optionally includes manipulating the coiled tubing. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  is a side partial sectional view of an example of a downhole operation in a wellbore. 
         FIG. 2  is a side partial sectional view of a leg of production tubing of the wellbore of  FIG. 1  having a bottom-hole assembly and an inflow control device. 
         FIG. 3  is a schematic example of the bottom-hole assembly of  FIG. 2  engaging the inflow control device. 
         FIG. 4  is a schematic example of the bottom-hole assembly of  FIG. 2  manipulating the inflow control device into a flow control configuration. 
         FIG. 5  is a schematic example of the bottom-hole assembly of  FIG. 2  manipulating the inflow control device into a closed configuration. 
     
    
    
     While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims. 
     DETAILED DESCRIPTION OF INVENTION 
     The method and system of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The method and system of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout. In an embodiment, usage of the term “about” includes +/−5% of a cited magnitude. In an embodiment, the term “substantially” includes +/−5% of a cited magnitude, comparison, or description. In an embodiment, usage of the term “generally” includes +/−10% of a cited magnitude. 
     It is to be further understood that the scope of the present disclosure is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation. 
     Shown in partial side section view in  FIG. 1  is an example of a wellbore circuit  10  formed into a subterranean formation  12 . The wellbore circuit  10  includes a main bore  14  which in the example is substantially vertical and non-deviated, and lateral bores  16   1-4  that project radially outward from the main bore  14 . In this example, casing  18  lines the main bore  14 , whereas lateral bores  16   1-4  are not lined with casing, and are referred to herein as open hole. Further in the example of  FIG. 1 , a production tubing circuit  20  is installed within wellbore circuit  10 , and which includes a main production line  22  installed within main bore  14 , and production tubing legs  24   1-4  set respectively in lateral wells  16   1-4 . Examples of inflow control valves (“ICDs”)  26   11 ,  26   12 ,  26   13  are depicted in the production tubing leg  24   1 . Similarly, ICDs  26   21 ,  26   22 ,  26   23  are in production tubing leg  24   2 , ICDs  26   31 ,  26   32 ,  26   33  are in production tubing leg  24   3 , and ICDs  26   41 ,  26   42 ,  26   43  are in production tubing leg  24   4 . Packers  28   11 ,  28   12 ,  28   13  are set respectively between adjacent ICDs  26   11 ,  26   12 ,  26   13  of production tubing leg  24   1 . Similarly, packers  28   21 ,  28   22 ,  28   23  are set respectively between adjacent ICDs  26   21 ,  26   22 ,  26   23 , packers  28   31 ,  28   32 ,  28   33  are set respectively between ICDs  26   31 ,  26   32 ,  26   33 , and packers  28   41 ,  28   42 ,  28   43  are set respectively between adjacent ones of the ICDs  26   41 ,  26   42 ,  26   43 . 
     As illustrated in the example of  FIG. 1 , and as will be described in more detail below, the aforementioned ICDs provide selective flow control from formation  12  into one of the production legs  24   1-4 . In the annuli between respective production legs  24   1-4  and lateral wells  16   1-4 , isolation zones are formed by strategic placement of the aforementioned packers so that fluid in a particular isolation zone is directed to a single one of the ICDs. The combination of the ICDs and the packers form a system capable of controlling or blocking a flow rate of production fluid from a particular isolation zone into the production tubing circuit  20 . Examples exist where controlling the flow rate of production fluid reduces influx of an undesired fluid (such as water), increases an influx of a desirable fluid (such as a hydrocarbon), and introduces a pressure drop across an ICD to balance pressure and/or flow in the production tubing circuit  20 . In further examples, the combination of the ICDs and packers in the wellbore circuit  10  prevent flow from a particular zone from entering another zone in the formation  12 . 
     In an embodiment, the wellbore circuit  10  further includes a wellhead assembly  30 , an example of which is schematically illustrated in  FIG. 1  mounted over an opening of the main bore  14 . A string of coiled tubing  32  is shown inserted into wellbore circuit  10  and through wellhead assembly  30 . The coiled tubing  32  is part of an intervention system  34 , which as described in more detail below is selectively deployed for manipulating the ICDs. A portion of coiled tubing  32  outside of wellbore circuit  10  is shown wound on a reel  36 , which in an example of operation generates forces for inserting the coiled tubing  32  downhole, or for withdrawing the coiled tubing  32  from within the wellbore circuit  10 . In this example, reel  36  is mounted to a service truck  38  shown outside of wellbore circuit  10  and on surface  40 . 
     Depicted in side sectional view in  FIG. 2  is a schematic example of a well intervention operation in which ICD  26   11  is being manipulated. ICD  26   11  of  FIG. 2  includes an annular body  42   11  shown having opposing ends integrally mounted within production tubing leg  24   1 . A chamber  43   11  extends axially through body  42   11  that circumscribes axis A X  of lateral well  16   1 , and is in fluid communication with production tubing leg  24   1 . A port  44   11  is formed radially through a sidewall of body  42   11  so that chamber  43   11  is in communication with lateral well  16   1  through port  44   11 . The communication between chamber  43   11  and lateral well  16   1  allows for a flow of fluid F L , illustrated by the curved arrows, to flow from perforations  46   1  formed radially outward into formation  12  from lateral wellbore  16   1 . An optional screen  48   11  circumscribes body  42   11 , and which provides a way to block or capture solid particles within the flow of fluid F L , such as sand or rock particles. 
     Shown adjacent the ICD  26   11  is a bottom-hole assembly  50 , which is deployed into the production tubing leg  24   1  on an end of the coiled tubing  32 . A housing  52  is included as part of the bottom-hole assembly  50  and which connects to a lower end of the coiled tubing  32 . In this example housing  52  is attached to coiled tubing  32  by a coupling  53 , which is shown as a flange type connection; however, other embodiments exist where housing  52  is attached or otherwise engaged to a lower end of coiled tubing  32  by any other type of coupling such as threaded, welded, and the like. An elongated latching arm  54  is shown projecting from a side of housing  52  opposite tubing  32 . A motor  56  is schematically illustrated within housing  52 , which in a non-limiting example of operation exerts forces to latching arm  54  to selectively move latching arm  54  into designated positions and orientations; and also selectively exerts forces to latching arm  54  for manipulating ICD  26   11 . An actuating profile  58  is shown on an end of actuating arm  54  distal from housing  52 ; which in an example is a pattern of depressions and projections that corresponds to a similar pattern of depressions and projections that define an ICD profile  60   11 . In the example of  FIG. 2 , ICD profile  60   11  is disposed on an inner surface of an annular sleeve  62   11 ; which in in the embodiment illustrated is an annular member inside bore  43   11  and within body  42   11 . Further in this example, annular sleeve  62   11  is selectively slideable within body  42   11  in an axial direction and along axis A X . As described in more detail below, strategic positioning of sleeve  62   11  alters a flow configuration of the ICD  26   11 . In the example of the flow configuration of  FIG. 2 , the ICD  26   11  is in a full flow configuration so that all of the cross-section of the port  44   11  is fully exposed to the chamber  43   11 . 
     Referring now to  FIG. 3 , latching arm  54  is shown having been manipulated by actuation of motor  56  so that actuator profile  58  is engaged with ICD profile  60   11 . A controller  64  is schematically illustrated within housing, and which in one example provides operational instructions to motor  56 , which result a response by motor  56  to position actuator arm  54  into a designated configuration, such as engagement of profile  85  with ICD profile  60   11 . In one embodiment, the combination of the motor  56 , actuator arm  54 , actuator profile  58 , and controller  64  define an actuator system  65 . Schematically represented within housing  52  and included with bottom-hole assembly  50  is an optional monitoring system  66 , which provides selective sensing of ambient conditions within tubing  24   1  such as pressure, temperature, and depth. In another non-limiting example of operation, communication between monitoring system  66  and controller  64  selectively triggers actuation of certain instructions for operation of bottom-hole assembly  50 . 
     Also included in the example of  FIG. 3  is an optional nozzle  68  shown mounted on housing  52 , and which is in communication with an inner bore of the coiled tubing  32 . A fluid  70  is shown being discharged from an open end of nozzle  68  and into the production tubing leg  24   1 . Examples exist where the fluid  70  is applied for conditioning formation  12 , and examples of fluid include an acid, brine, diesel, and any other fluid used in treating a wellbore. In an example, lines for power, communication or control are not inserted within coiled tubing  32 ; so that a bore  71  inside the coiled tubing  32  contains only the fluid  70 . Advantages of reserving the bore  71  for the fluid  70  maximizes a flow rate of the fluid  70  being delivered into the production tubing leg  24   1 . Another advantage exists that any interaction between potentially corrosive fluids, such as acid, and the lines in the bore  71 . 
     Referring now to  FIG. 4 , in a non-limiting example of operation actuating arm  54  is shown having been manipulated by motor  56  so that the actuator profile  58  is put into engagement with ICD profile  60   11 . Further in this example, surface areas of the protrusions and depressions of the respective profiles  58 ,  60   11 , in combination with material properties of profiles  58 ,  60   11 , form surfaces of interfering contact having adequate structural integrity to transfer a force or forces from the actuating arm  54  to the sleeve  62   11  of sufficient magnitude to move the sleeve  62   11  within the body  44   11 . In an example, an actuating force F A , which is schematically illustrated by an arrow, represents a force transferred from actuating arm  54  to sleeve  62   11 , and having sufficient magnitude to move sleeve  62   11  within body  44   11 . Further in the example, actuating force F A  draws sleeve  62   11  axially and along an axis A X  of lateral well  16   1 . As depicted in  FIG. 4 , sleeve  62   11  is drawn adjacent to a portion of port  44   11  by the actuation force F A  to block communication through that portion of port  44   11 ; blocking communication through that portion restricts the area for which fluid F L  may flow into production tubing leg  24   1 . For the purposes of illustration, ICD  26   11  is put into a flow control configuration by positioning the sleeve  62   11  adjacent to the portion of port  44   11 . 
     Referring back to  FIG. 2 , actuating arm  54  is shown free from ICD  26   11  and not engaged with other devices in the well circuit  10 . A baseline force F BL  as illustrated by arrow, represents a force applied to the coiled tubing  32  to effectuate axial movement within production tubing leg  24   1  of coiled tubing  32  and bottom-hole assembly  50  alone. In a non-limiting example, a magnitude of baseline force F BL  is obtained by monitoring the force necessary for the axial movement of bottom-hole assembly  50  and attached coiled tubing  32 . Further in this example, a confirmation that the actuating arm  54  is engaged with the sleeve  62   11  via their respective profiles  54 ,  62   11  is established by comparing a magnitude of a previously recorded baseline force F BL  with a magnitude of a force currently being applied to the coiled tubing  32 . In an example of operation, moving coiled tubing  32  and bottom-hole assembly  50  within well circuit  10  and when profiles  54 ,  62   11  are engaged, requires a force with a magnitude greater than that of the baseline force F BL ; and confirmation of engagement between the profiles  54 ,  62   11  is obtained by comparing these magnitudes of force. 
     Referring back to  FIG. 4 , schematically illustrated is an example of anchors  72  in a deployed configuration, and in anchoring engagement with an inner surface of the production tubing leg  24   1 . This is in contrast to the retracted configuration of the anchors  72  depicted in  FIGS. 2 and 3  where each anchor  72  is spaced radially inward from sidewalls of inner tubing leg  24   1 . Optionally, an anchor motor  74  is used for deploying and setting anchor  72 , and which is illustrated disposed within housing  52 . In one embodiment, anchor  72  is made up of pads  76  that are shown engaged with the inner surface of production tubing leg  24   1  and that mount on pins  78  which project radially outward from housing  52 . Engagement of the production tubing leg  24   1  by anchors  72  is by a force that is directed radially outward from housing  52  through pins  78  and pads  76  and along path P. Urging pads  76  against production tubing leg  24   1  generates a resistive anchoring force F R  shown oriented in a direction parallel to actuating force F A . An advantage of the anchors  72  is that the magnitude of the resistive force F R  produced by the deployment of anchors  72  is at least that of the actuating force F A . In a non-limiting example of operation, engaging production tubing leg  24   1  with anchors  72  diverts reactive forces resulting from actuating the ICD  26   11  away from the coiled tubing  32  and onto the production tubing leg  24 . An advantage of redirecting or absorbing these forces is that it avoids the risk of buckling the coiled tubing  32  or other failure mode deformations that can occur when transmitting forces axially through coiled tubing for operation or manipulation of an inflow control device. 
     Referring now to  FIG. 5 , shown in a side sectional view is a schematic example of the ICD  26   11  configured into a closed configuration with sleeve  62   11  positioned within bore  43   11  and adjacent the entirety of port  44   11  so there is no communication through port  44   11 . In a non-limiting example of operation, sleeve  62   11  is moved into the position of  FIG. 5  directly from the flow control configuration of  FIG. 4 ; directly from the open configuration of  FIG. 2 , or from another position. In the example of  FIG. 5 , sleeve  62   11  is moved into the position shown in response to actuating force F A  in the manner described above. In the closed configuration, fluid F L  exiting perforations  46   1  is blocked from entering the chamber  43   11  by the presence of sleeve  62   11  adjacent all of port  44   11 . 
     In an alternative example of operation manipulation of the ICD  26   11  is performed with the intervention system  34  of  FIG. 1 , and where downhole assembly is moved adjacent to ICD  26   11  when in a closed configuration, and the profiles  58 ,  60   11  are then engaged similar to the method described above, and an actuating force F A  is applied to sleeve  62   11  to reconfigure the ICD  26   11  into a flow control configuration or optionally a full flow or open configuration. Schematically representing the direction of actuating force F A  and resistive force F R  are the double-headed arrows shown in  FIG. 5 , and depicting how a direction of the reactive force F R  changes with that of actuating force F A , and which again diverts any forces resulting from actuating force F A  away from the coiled tubing  32 . 
     An alternative, a power source  80  is shown included within housing  52  in  FIGS. 2 through 5 , and which is selectively used for powering one or both of motor  56  and motor  74 . Non-limiting examples of power source  80  include stored energy in the form of electricity or pressurized fluid, as well as a method of transferring energy from fluid flowing within coiled tubing  32 . 
     Referring back to  FIG. 1 , a controller  82  is shown on surface  40  and which is selectively used to generate and/or provide instructive signals downhole as well as receive signals from bottom-hole assembly  50 . A communication means  84  is depicted that optionally provides a way for controller  82  to be in communication with bottom-hole assembly  50 . Examples of communication means  84  include wireless telemetry, mud pulses, or fiber optics. In an alternative, fiber optic elements are included with tubing  32  to provide communication between surface  40  and within the wellbore circuit  10 . In an alternative, a fluid source  86  is shown in  FIG. 1  which is delivered downhole by communication to service  38  truck and coiled tubing  32  via line  88 . An optional pump  90  provides pressurization for fluid in the fluid source  86  to be delivered into coiled tubing  32 . 
     In a non-limiting example of operation of the intervention system  34 , bottom-hole assembly  50  is deployed into the wellbore circuit  10  on an end of coiled tubing  32 . A force is applied to further insert coiled tubing  32  into wellbore circuit  10 , such as from reel  36 , to urge bottom-hole assembly  50  adjacent to a designated location within wellbore circuit  10 ; such as adjacent to ICD  26   11  inside production tubing leg  24   1 . Optionally, bottom-hole assembly  50  is urged adjacent to ICD  26   12  or  26   13 , or to any of the other ICDs in the other production tubing legs  24   2-4 . Alternatives exist where bottom-hole assembly  50  is urged through one or more uphole ICDs to be positioned adjacent to a downhole ICD in a particular production tubing leg. Further optionally, a steering arm (not shown) or other steering system is included with the intervention system  34  for directing the bottom-hole assembly  50  into a designated one of the production tubing legs  24   1-4 . Further in this example, operations are conducted with the intervention system  34  the same or similar to that described above to manipulate ICD  26   11 . Alternative actions after completing a designated manipulation of ICD  26   11  include moving the bottom-hole assembly  50  away from the ICD  26   11  by applying a force to coiled tubing  32 . Optional destinations for the bottom-hole assembly  50  include adjacent to another ICD in the production tubing circuit  20  and where manipulation of another ICD is conducted, and outside of the wellbore circuit  10 . Further in this example, the bottom-hole assembly  50  is withdrawn from the wellbore circuit  10 , or repositioned to a lesser depth inside the wellbore circuit  10  applying a force to the coiled tubing  32  in a direction substantially opposite when inserting or lowering the bottom-hole assembly  50  in the wellbore circuit  10 . 
     The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims.