Patent Publication Number: US-10323490-B2

Title: Modular multiphase flow meter system including a flow test module coupled to a flow circuit

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 14/793,404 filed Jul. 7, 2015, now U.S. Pat. No. 9,963,956, which is herein incorporated by reference. 
    
    
     BACKGROUND 
     Field 
     The present disclosure relates to techniques for measuring multiphase flows from wellbores. More particularly, the present disclosure relates to tools and methods for a mobile multiphase flowmeter system. 
     Description of the Related Art 
     In many hydrocarbon well applications, various test procedures are employed to evaluate characteristics of the produced well fluid or other reservoir characteristics. Often, the produced well fluid contains a mixture of phases, such as a mixture of oil, water, gas, and solids or other components. Test procedures have been employed to evaluate the phases of produced fluids from specific wells. For example, various types of well testing equipment utilize multiphase flow meters to measure the various phases of the produced fluid. Multiphase flow meters, however, have different flow-range ratings and are selected according to the production flow rate of the well being tested. Thus, different multiphase flow meters with different flow-range ratings are selected according to the production flow rate of a given well. Switching the multiphase flow meter to accommodate the flow range of a different well can be an expensive and time-consuming procedure. 
     SUMMARY 
     In general, an apparatus, methodology, and system provide for testing flows of fluid which may comprise mixtures of constituents. An apparatus includes a module mounted on a portable skid. The module includes a flow circuit including an inlet through which a flow of fluid enters the flow circuit, an outlet through which the flow exits the flow circuit, a flow meter to measure the flow, a first isolation valve and a second isolation valve to at least facilitate the flow through the flow meter, or prevent the flow from entering the flow meter, and a bypass manifold including a third isolation valve to at least accept the flow when the first and second isolation valves are closed, or facilitate the flow through the flow meter when the first and second isolation valves are open. 
     However, many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       So that the manner in which the above recited features can be understood in detail, a more particular description may be had by reference to embodiments, some of which are illustrated in the appended drawings, wherein like reference numerals denote like elements. It is to be noted, however, that the appended drawings illustrate various embodiments and are therefore not to be considered limiting of its scope, and may admit to other equally effective embodiments. 
         FIG. 1  is an illustration of an example of a flow test module which may be coupled into a modular flow meter system for evaluating flows of fluids, according to some embodiments of the disclosure. 
         FIG. 2  is an illustration similar to that of  FIG. 1  but with the addition of a protective framework and other features, according to some embodiments of the disclosure. 
         FIG. 3  is an illustration of a plurality of flow test modules coupled together into a modular flow meter system, according to some embodiments of the disclosure. 
         FIG. 4  is another view of the example of a modular flow meter system illustrated in  FIG. 3 , according to some embodiments of the disclosure. 
         FIG. 5  is an orthogonal view of an example of an extensible connector which may be used to couple flow circuits of flow test modules, according to some embodiments of the disclosure. 
         FIG. 6  is a cross-sectional view of the extensible connector illustrated in  FIG. 5 , according to some embodiments of the disclosure. 
         FIG. 7  is a flow diagram illustrating an example of a flow circuit of a flow test module, according to some embodiments of the disclosure. 
         FIG. 8  is a flow diagram illustrating an example of a plurality of joined flow circuits of cooperating flow test modules in the overall modular flow meter system, according to some embodiments of the disclosure. 
         FIG. 9  is a flow diagram similar to that illustrated in  FIG. 8  but in a different operational configuration, according to some embodiments of the disclosure. 
         FIG. 10  is a flow diagram similar to that illustrated in  FIG. 8  but in a different operational configuration, according to some embodiments of the disclosure. 
         FIG. 11  is a flow diagram similar to that illustrated in  FIG. 7  but in a different operational configuration, according to some embodiments of the disclosure. 
         FIG. 12  is a flow diagram similar to that illustrated in  FIG. 7  but in a different operational configuration, according to some embodiments of the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     In the following description, numerous details are set forth to provide an understanding of some embodiments of the present disclosure. However, it will be understood by those of ordinary skill in the art that the system and/or methodology may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible. 
     In the specification and appended claims: the terms “connect”, “connection”, “connected”, “in connection with”, and “connecting” are used to mean “in direct connection with” or “in connection with via one or more elements”; and the term “set” is used to mean “one element” or “more than one element”. Further, the terms “couple”, “coupling”, “coupled”, “coupled together”, and “coupled with” are used to mean “directly coupled together” or “coupled together via one or more elements”. As used herein, the terms “up” and “down”, “upper” and “lower”, “upwardly” and downwardly”, “upstream” and “downstream”; “above” and “below”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly describe some embodiments of the disclosure. 
     With respect to certain embodiments of the present disclosure, a methodology and system are provided to facilitate efficient testing of flows of well effluent or well treatment fluid to determine, for example, the constituents, e.g. phases, of the fluid. In, for example, well testing applications, the methodology and system provide a mobile, modular system which is easily and quickly adapted to the parameters, e.g. flow rates, of a given well. As described in greater detail below, the desired number of flow test modules may be combined into a modular flowmeter system, and that modular flow meter system may be rapidly adjusted to direct the flow of fluid being tested through a desired flow meter (or flow meters) without interchanging the flow meters. Instead of changing out flow meters over several hours, the modular system may be adjusted according to the parameters of a new well within a matter of minutes or even seconds, at least in some of the embodiments described herein. The modules or the overall modular flow meter system is mobile and easily transportable by, for example, standard over-the-road vehicles. 
     According to some embodiments, a modular flow meter system comprises a plurality of modules which each have a multiphase flow meter coupled into a flow circuit. The flow circuits of the plurality of modules are selectively connectable to each other via flow connectors. Additionally, portions of the flow circuits may be selectively opened and closed to enable controlled routing of the fluid being tested through the desired multiphase flow meter or meters. In some embodiments, the flow circuits may be selectively connectable via extensible flow connectors to facilitate a rapid joining of flow test modules into the overall modular flow meter system. Depending on the application, the multiphase flow meters of different modules may have different throat sizes, e.g. different Venturi throat diameters (and proportionally varied Venturi inlet diameters to maintain the same throat/inlet diameter ratio, e.g. 0.5), selected to accommodate different production fluid flows from the wells being tested. However, some embodiments may utilize two or more modules having multiphase flow meters with the same throat sizes to accommodate the same range of flow rates. 
     When performing mobile production testing of oil/gas wells using multiphase flow meters and where the flow rates are unknown, it can be useful to have flow meters with different sized Venturi throats. A conventional Venturi based multiphase flow meter may have a limited turn-down ratio of, for example, 10:1 in which the flow rate limit is dependent on the throat size. The modular flow meter system described herein, however, enables the selective use of at least two flow meters, e.g. multiphase flow meters, connected together with different throat sizes so as to substantially increase the turn-down ratio to ratios in the range of, for example, 50:1 through 100:1. If additional flow meters are added into the modular flow meter system, the turn-down ratio can be further increased. 
     According to some embodiments, the modular flow meter system may comprise a skid, e.g. a modular skid, onto which the mobile multiphase flow meter production test platforms are mounted. The modules of the modular flow meter system may each utilize an integrated bypass manifold for a more compact and lighter overall system. The bypass manifold may comprise a variety of flow circuits, as described in greater detail below, which enable selective isolation of specific flow meters, thus facilitating performance of fluid characterization measurements without having to interrupt the flow of production fluids. In a variety of applications, once the user has an understanding of the flow rates for specific wells to be tested, the modular construction enables separation of modules so that the separated flow meters may be used for different operations, hence increasing asset utilization. 
     Referring generally to  FIG. 1 , an example of a flow test module  30  is illustrated as comprising a flow meter  32 , e.g. a multiphase flow meter, coupled into a flow circuit  34 . By way of example, the flow meter  32  may comprise a Vx Spectra™ multiphase flow meter available from Schlumberger Technology Corporation for use in analyzing the flow rates and ratios of fluid constituents, such as oil, water, and gas in a produced well fluid. However, a variety of other types of flow meters  32  may be used in combination with flow circuit  34  depending on the parameters of a given fluid testing application. The flow circuit  34  comprises an inlet  36  through which the fluid to be tested, e.g. production well fluid, flows into the flow circuit  34 . The flow circuit  34  also comprises an outlet  38  through which the fluid flow is discharged from the flow circuit  34 . If the flow circuit  34  is configured to enable testing, the fluid is directed through flow meter  32  and is ultimately discharged through the outlet  38  of flow circuit  34 . 
     However, module  30  is constructed so that flow through flow circuit  34  and flow meter  32  is easily controllable. In the embodiment illustrated, the flow of fluid along flow circuit  34  may be controlled via a plurality of isolation valves  40 ,  42  and  44 . The valves  40 ,  42 ,  44  may be individually actuated between positions open to flow and closed to flow. For example, the flow of fluid entering inlet  36  may be directed through flow meter  32  by opening valves  40  and  44  while closing valve  42  located along a flow circuit bypass  46 , e.g. a bypass manifold. However, the flow meter  32  is easily bypassed, for example, by closing valves  40 ,  44  while opening valve  42  in bypass  46 . As described in greater detail below, the valves  40 ,  42 ,  44  may be used in combination with valves of corresponding modules  30  to direct desired flows of fluid through a specific flow meter  32 . In the embodiment illustrated, valves  40 ,  42 ,  44  may be in the form of ball valves although other types of valves, e.g. sleeve valves, plug valves, other types of rotary valves, may be suitable for a variety of applications. 
     To facilitate coupling of module  30  with additional flow test modules  30 , the flow circuit  34  comprises a plurality of flow connector ends  48 . The flow connector ends  48  are disposed on flow conduits  50  of flow circuit  34  and are oriented for coupling with corresponding flow connector ends  48  of corresponding modules  30 . When not in use, the flow connector ends  48  may be “blanked off” by securing blanks  52  to the flow connector ends  48  so as to prevent fluid flow therethrough. By way of example, the flow connector ends  48  may comprise flanges to which the blanks  52  are secured by suitable fasteners, e.g. threaded fasteners. 
     Depending on the application, flow circuit  34  may comprise a variety of other components or features. For example, the flow circuit  34  may comprise an access port  54  above flow meter  32  and a base sediment and water (BSW) port  56  below the flow meter  32 . The flow circuit  34  also may comprise, for example, a liquid sampling port  58  and a gas sampling port  60 . Various sensors, such as a pressure gauge  62 , also may be positioned along flow circuit  34 . 
     In some embodiments, the flow circuit  34  and flow meter  32  may be mounted on a portable skid  64 . Skid  64  also may be modular for use with corresponding skids  64  of corresponding flow test modules  30 . In some applications, the skids  64  of corresponding modules  30  may be coupled together to form an overall skid which facilitates movement of the module/modules  30  between locations, e.g. between well sites, to enable fluid testing procedures. The skids  64  are constructed to enhance the mobility and transportability of the modules  30  and may include features, such as forklift pockets  66  which facilitate lifting and movement of the skids  64  via forklift. In some applications, forklifts may be used to load and unload the modules  30  with respect to a suitable transport vehicle. Each skid  64  may comprise a variety of other features to facilitate aspects of given application. Examples of such features include drip pans  68  and grates  70 . 
     Signals, e.g. informational data and/or control signals, may be communicated from and/or to flow meter  32  via a communication line or lines  72 . For example, data on the phase composition of fluids flowing through multiphase flow meter  32  may be output through communication lines  72 . Additionally, at least one of the communication lines  72  may be used to carry control signals to controllable isolation valves  40 ,  42 ,  44 . In this manner, specific isolation valves  40 ,  42 ,  44  may be actuated to the desired open or closed position via an appropriate command/control signal. Depending on the type of isolation valve, the corresponding communication line  72  may be an electrical line, hydraulic line, or other suitable control line(s). 
     Referring generally to  FIG. 2 , another embodiment of module  30  is illustrated. In this example, a framework  74  is attached to skid  64 . The framework  74  is constructed to surround flow circuit  34  and flow meter  32  and to provide protection during, for example, use and transport. In this example, the module  30  also may comprise various other features, such as a cover  76 , e.g. a canvas cover, which may be selectively positioned to protect flow circuit  34  and flowmeter  32  from environmental elements. Lifting hooks  78  also may be attached to framework  74  to facilitate lifting and movement of module  30  via a crane or other hoist type mechanism. 
     Referring generally to  FIGS. 3 and 4 , an embodiment of an overall modular flow meter system  80  is illustrated. In this example, the modular flow meter system  80  is formed by combining the desired number of flow test modules  30  to configure the desired modular flow meter system  80 . By way of example, the modular flow meter system  80  may be constructed by combining two modules  30 . In some applications, the modular flow meter system  80  may be constructed by combining three or more of the flow test modules  30 . 
     In various embodiments, the communication lines  72  from the plurality of modules  30  may be routed to a control system  82 , such as a programmable, computer-based control system. However, other types of control systems  82  also may be utilized to, for example, receive data from the flow meters  32  and to provide control signals to the isolation valves  40 ,  42 ,  44 . In some applications, control system  82  may be a programmable, processor-based system which is programmed to automatically actuate specific valves  40 ,  42 ,  44  of specific modules  30  so as to direct the flow of fluid, e.g. production well fluid, to the desired multiphase flow meter  32 . It should be noted that in some applications, the flow of fluid may be directed to more than one flow meter  32 . 
     By way of example, the control system  82  may be programmed to optimize utilization of the available flow meters  32  for a well having a given flow rate of production fluid. In such an application, each multiphase flow meter  32  utilizes, for example, a Venturi having a desired throat size. The control system  82  may be programmed to automatically select the flow meter  32  (or flow meters  32 ) having a flow-range rating which appropriately covers the range of actual fluid flow rates from the well. In some applications, manual selection of modules  30  and corresponding flow meters  32  also may be employed instead of the automated selection via control system  82 . It should be noted modules  30  also may be used as stand-alone units if, for example, an operator is aware that a given well application will not have to utilize one of the modules  30 . The “extra” module  30  can then be disconnected and utilized in a different application, thus maximizing asset utilization. 
     The corresponding, e.g. adjacent, modules  30  of modular flow meter system  80  may be coupled together by joining corresponding flow circuits  34  via flow connectors  84  (see  FIG. 4 ). The flow connectors  84  may be connected between selected flow connector ends  48  of the corresponding, e.g. adjacent, flow circuits  34 . The appropriate blanks  52  are simply removed from flow connector ends  48  so that corresponding flow connector ends  48  of corresponding modules  30  may be coupled together in fluid communication via the flow connectors  84 . By way of example, the flow connectors  84  may be sealingly coupled to flow connector ends  48  of adjacent flow circuits  34  via flange-style connectors. In some applications, the adjacent skids  64  (and/or frameworks  74 ) also may be coupled together by a suitable connector  86  which may be in the form of bolts, other threaded fasteners, or other coupling mechanisms. As illustrated, the flow connector ends  48  which are not coupled together via flow connectors  84  remain closed via blanks  52 . 
     Referring generally to  FIGS. 5 and 6 , an embodiment of flow connector  84  is illustrated. In this example, the flow connector  84  is an extensible flow connector to facilitate coupling of corresponding flow circuits  34  of corresponding modules  30 . Due to the tolerancing or positioning of adjacent flow circuits  34 , the extendable nature of the illustrated flow connector  84  facilitates coupling of adjacent flow circuits  34 . In this example, the flow connector  84  is linearly extensible although the flow connector can be constructed to accommodate other types of movement. 
     In the illustrated embodiment, flow connector  84  comprises a pair of flanges  88  constructed for coupling to corresponding flow connector ends  48  via a suitable threaded fasteners. The flanges  88  are coupled to telescopic piping  90  which allows linear movement of the flanges  88  with respect to each other. By way of example, the telescopic piping  90  may be constructed with a female union  92  slidably engaged with a male union  94  (see  FIG. 6 ). The female union  92  and the male union  94  may be sealed with respect to each other via an internal seal  96 . 
     Additionally, a threaded nut  98  may be used to secure female union  92  and male union  94  while also enabling linear adjustment of the distance between flanges  88 . In the illustrated embodiment, threaded nut  98  comprises an abutment portion  100  which abuts against a corresponding abutment  102  of male union  94 . The threaded nut  98  also comprises a threaded portion  104  which is threadably engaged with a corresponding threaded portion  106  of female union  92 . By rotating threaded nut  98 , female union  92  and male union  94  are forced to slide linearly with respect to each other along seal  96 . Accordingly, the threaded nut  98  may be turned in one direction or the other to move flanges  98  closer together or farther apart, respectively. It should be noted that other components and component configurations may be utilized in providing an extensible or otherwise adjustable flow connector  84 . 
     Depending on the application, various numbers of modules  30  may be coupled together to provide a desired number of flow meters  32  arranged in parallel. In many applications, when connecting the flow circuits  34 , selected inlets  36  and outlets  38  may be blinded by, for example, blanks  52  to ensure the plurality of modules uses a single inlet  36  and a single outlet  38 . The flow circuits  34  each effectively provide an integrated bypass manifold via flow circuit bypass  46  so that opening and closing of the desired valves  40 ,  42 ,  44  of selected modules  30  enables rapid diversion of the fluid flow to the desired flow meter  32  (or flow meters  32 ). 
     Referring generally to  FIG. 7 , a flow diagram is provided and represents an example of flow circuit  34  of a single module  30 . As illustrated, the flow circuit  34  comprises valves  40 ,  42 ,  44 , e.g. remotely controllable ball valves, which control fluid flow with respect to the corresponding flow meter  32  of this particular module  30 . In this example, valve  42  is again positioned in flow circuit bypass  46  while valve  44  is positioned along an inflow passage  108  and valve  40  is positioned along an outflow passage  110 . Inflow passage  108  receives inflowing fluid from inlet  36  and outflow passage  110  delivers the flowing fluid to outlet  38  after passing through flow meter  32 . Flow circuit bypass  46  extends between inflow passage  108  and outflow passage  110 . 
     As illustrated in  FIG. 8 , a plurality of the flow circuits  34  may be coupled together. In the illustrated example, two flow circuits  34  are coupled together at corresponding flow connector ends  48  to form the overall modular flow meter system  80 . Each flow circuit  34  is coupled with its corresponding flow meter  32  and comprises three isolation valves  40 ,  42 ,  44 . In this particular example, the flow meter  32  of each module  30  has a different flow-range rating from the flow meter  32  of the other module  30 . The different flow rates may result from each flow meter  32  having a different Venturi throat diameter size, while keeping the same Venturi throat/inlet diameter ratio, to accommodate different production fluid (or other fluid) flow rates. In this embodiment, the inlet  36  and outlet  38  associated with one of the flow circuits  34  are blanked off while the inlet  36  and outlet  38  associated with the other flow circuit  34  is used to accommodate the inflow and outflow of fluid being tested. Additional flow circuits  34  may be coupled into the overall modular flow meter system  80  as desired for a given application. 
     In an operational example, the modular flow meter system  80  is used for well flow testing and is connected to a well. The flow of well fluid from the well is directed through the flow meter  32  having the larger throat size, i.e. larger flow-range rating, as illustrated in  FIG. 9 . In this example, the flow meter  32  on the left side of the diagram has the larger throat size, and the flow of well fluid is directed through this flow meter  32  by opening valves  40 ,  44  of the corresponding flow circuit  34  while closing all of the other valves as illustrated. By checking the measured differential pressure, a determination may be made as to whether the selected flow meter  32  is the proper flow meter or whether the flow should be diverted through the other flow meter  32  having a smaller throat size. By way of example, the differential pressure may be measured across the Venturi inlet and throat by a differential pressure sensor (not shown) that forms part of the flow meter  32 . If a determination is made that the flow of well fluid should be directed through the other flow meter  32  (the flow meter on the right in this illustrated example), valves  40 ,  44  of the flow circuit  34  on the right are opened and all other valves are closed, as illustrated in  FIG. 10 . 
     As illustrated in  FIG. 11 , when a given flow meter  32  is selected and used, the bypass manifold  46  is closed off via closure of isolation valve  42 . While isolation valve  42  is closed, valves  40 ,  44  are opened to ensure the fluid being tested is routed through the desired flow meter  32 . As indicated by arrows  112 , well fluid enters through inlet  36  and is blocked from moving through bypass  46 . Accordingly, the flow of fluid is directed through isolation valve  44 , through the appropriate flow meter  32 , through isolation valve  40 , and out through outlet  38 . 
     When the subject flow meter  32  is to be isolated, however, the isolation valve  42  is opened and the isolation valves  40 ,  44  are closed, as illustrated in  FIG. 12 . The closure of isolation valves  40 ,  44  prevents flow of fluid through the flow meter  32  and effectively isolates the flow meter  32 . The configuration of flow circuit  34  enables isolation of the flow meter  32  without interrupting the flow of fluid because the fluid can pass through bypass  46  and out through outlet  38 , as indicated by arrows  114 . 
     When the flow circuits  34  of corresponding flow test modules  30  are coupled together, various combinations of valves  40 ,  42 ,  44  may be opened or closed to direct the flow of fluid through desired flow meters  32  while isolating other flow meters  32  without interrupting flow. Accordingly, the configuration of flow circuit  34  in each module  30  along with the ability to easily combine a desired number of modules  30  provides great flexibility with respect to different testing operations. Additionally, the use of flow circuits  34  and isolation valves  40 ,  42 ,  44  enable easy and rapid selection of the desired flow meter  32  (or flow meters  32 ) for a specific fluid testing evaluation. 
     In well applications, the modular flow meter system  80  is readily constructed and transportable between well sites. The modularity of the system and the easily adjustable flow circuits  34  enable rapid selection of the appropriate multiphase flow meter  32  for evaluation of oil, water, gas phase mixtures of a well production fluid at each well site. In many applications, the system may utilize control system  82  to automate analysis of data from the desired flow meter(s)  32  and/or to automate actuation of valves  40 ,  42 ,  44  to enable selection of the optimal flow meter or meters  32  for a given testing operation. 
     It should be noted the methodologies and systems described herein may be used to determine the presence and phase fraction of a variety of desired constituents of various fluids. In many well applications, the constituents of interest are oil, water and gas. However, the embodiments described herein also may be used in a variety of other applications, including non-hydrocarbon fluid testing applications. 
     Additionally, each module  30  may comprise many types of components and may be constructed in various configurations. The overall modular flow meter system  80  similarly may comprise a variety of components in addition to modules  30 . Various numbers of modules  30  also may be combined to accommodate the range of parameters of a given application. In many well applications, the flow meters  32  are multiphase flow meters, however other types of flow analysis meters also may be employed in each module  30 . Additional and/or other types of sensors and evaluation tools may be integrated into each of the modules  30  to facilitate various fluid testing procedures. 
     Although the preceding description has been described herein with reference to particular means, materials and embodiments, it is not intended to be limited to the particulars disclosed herein; rather, it extends to all functionally equivalent structures, methods, and uses, such as are within the scope of the appended claims.