Patent Abstract:
A fluid flow control device ( 130 ) for use in a wellbore to control the inflow of production fluids comprises a screen assembly ( 132 ) positioned around a base pipe ( 134 ). The base pipe ( 134 ) has a blank pipe section and a perforated section including at least one fluid passageway ( 136 ). The screen assembly ( 132 ) has a filter medium section ( 142 ) positioned around the blank pipe section and defining a first region ( 144 ) therebetween and a housing section ( 146 ) positioned around the perforated section defining a second region ( 148 ) therebetween with a sleeve ( 150 ) slidably positioned therein. When it is desired to prevent the inflow of the production fluids through the fluid flow control device ( 130 ), the sleeve ( 150 ) is operated from a first position to a second position which prevent fluid flow from the second region ( 148 ) to the fluid passageway ( 136 ).

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This is a divisional application of co-pending application Ser. No. 10/227,935, entitled Fluid Flow Control Device and Method for Use of Same, filed on Aug. 26, 2002, now U.S. Pat. No. ______. 
     
    
     TECHNICAL FIELD OF THE INVENTION  
       [0002]     This invention relates, in general, to controlling the inflow of formation fluids from a well that traverses a hydrocarbon bearing subterranean formation and, in particular, to a fluid flow control device for controlling the inflow of formation fluids and a method for use of the same.  
       BACKGROUND OF THE INVENTION  
       [0003]     Without limiting the scope of the present invention, its background will be described with reference to producing fluid from a subterranean formation, as an example. After drilling each of the sections of a subterranean wellbore, individual lengths of relatively large diameter metal tubulars are typically secured together to form a casing string that is positioned within each section of the wellbore. This casing string is used to increase the integrity of the wellbore by preventing the wall of the hole from caving in. In addition, the casing string prevents movement of fluids from one formation to another formation. Conventionally, each section of the casing string is cemented within the wellbore before the next section of the wellbore is drilled.  
         [0004]     Once this well construction process is finished, the completion process may begin. The completion process comprises numerous steps including creating hydraulic openings or perforations through the production casing string, the cement and a short distance into the desired formation or formations so that production fluids may enter the interior of the wellbore. The completion process may also include installing a production tubing string within the well casing which is used to produce the well by providing the conduit for formation fluids to travel from the formation depth to the surface.  
         [0005]     To selectively permit and prevent fluid flow into the production tubing string, it is common practice to install one or more sliding sleeve type flow control devices within the tubing string. Typical sliding sleeve type flow control devices comprise a generally tubular body portion having side wall inlet openings formed therein and a tubular flow control sleeve coaxially and slidably disposed within the body portion. The sleeve is operable for axial movement relative to the body portion between a closed position, in which the sleeve blocks the body inlet ports, and an open position, in which the sleeve uncovers the ports to permit fluid to flow inwardly therethrough into the interior of the body and thus into the interior of the production tubing string. The sliding sleeves thus function as movable valve elements operable to selectively permit and prevent fluid inflow. Generally, cylindrical shifter tools, coaxially lowered into the interior of the tubing string, are utilized to shift selected ones of the sliding sleeves from their closed positions to their open positions, or vice versa, to provide subsurface flow control in the well.  
         [0006]     It has been found, however, that typical sliding sleeve type flow control devices are not suitable in completions requiring sand control as they are not compatible with typical sand control screens. Recently, a device has been proposed that combines sand control and fluid flow control, which was disclosed in U.S. Pat. No. 5,896,928. Specifically, the device includes a generally tubular body for placement into the wellbore. The tubular body has a sand control screen at an outer surface for preventing sand from entering into tubular body. After the fluid flows through the sand control screen it must pass through a labyrinth. A slidable sleeve on the labyrinth controls the fluid velocity therethrough. The slidable sleeve is moved by a remotely and electrically-operated device placed in the tubular body. The fluid leaving the labyrinth passes to the tubing string for carrying the fluid to the surface.  
         [0007]     It has been found, however, the labyrinth type flow control devices are difficult and expensive to manufacture and can be unreliable under certain inflow conditions. Accordingly, need has arisen for a fluid flow control device for controlling the inflow of formation fluids in a completion requiring sand control. A need has also arisen for such a fluid flow control device that is not difficult or expensive to manufacture. Further, a need has arisen for such a fluid flow control device that is reliable in a variety of flow conditions.  
       SUMMARY OF THE INVENTION  
       [0008]     The present invention disclosed herein comprises a fluid flow control device for controlling the inflow of formation fluids in completions requiring sand control and a method for use of the same. The fluid flow control device of the present invention is not difficult or expensive to manufacture. In addition, the fluid flow control device of the present invention is reliable in a variety of flow conditions.  
         [0009]     The fluid flow control device of the present invention comprises a sand control screen having a base pipe with a set of openings that allows the production fluids to flow therethrough. The fluid flow control device also includes a sleeve coaxially disposed adjacent to the base pipe. The sleeve also has a set of openings that allows the production fluids to flow therethrough. The sleeve is selectively positionable relatively to the base pipe and may form an annulus therebetween such that the pressure drop in the production fluids flowing therethrough is selectively controllable by adjusting the alignment of the set of openings of the sleeve relative to the set of openings of the base pipe.  
         [0010]     In one embodiment of the fluid flow control device of the present invention, the sleeve is axially selectively positionable relative to the base pipe. In another embodiment, the sleeve is rotatably selectively positionable relative to the base pipe. In yet another embodiment, the sleeve is axially and rotatably selectively positionable relative to the base pipe. In one embodiment of the fluid flow control device of the present invention, the sleeve is coaxially positioned interiorly relative to the base pipe. In another embodiment of the fluid flow control device of the present invention, the sleeve is coaxially positioned exteriorly relative to the base pipe.  
         [0011]     In one embodiment of the fluid flow control device of the present invention, the set of openings of the sleeve has substantially the same geometry as the set of openings of the base pipe. In another embodiment, the set of openings of the sleeve has a different geometry than the set of openings of the base pipe. In one embodiment of the fluid flow control device of the present invention, the openings of the sleeve have substantially the same shape as the openings of the base pipe. In another embodiment, the openings of the sleeve have a different shape than the openings of the base pipe.  
         [0012]     The fluid flow control device of the present invention has a fully open position wherein the pressure drop in the production fluids traveling through the set of openings of the sleeve, the annulus between the sleeve and the base pipe and the set of openings of the base pipe is at a minimum. In addition, most embodiments of the fluid flow control device of the present invention have partially open or choking positions wherein the pressure drop in the production fluids is increased. Further, some embodiments of the fluid flow control device of the present invention have a fully closed position wherein the production fluids are prevented from traveling therethrough.  
         [0013]     The fluid flow control device of the present invention may be operated between its fully open position, its choking positions and its fully closed position using a variety of techniques such as using a mechanical shifting tool, using hydraulic pressure, using an electrically operated device or the like. In addition, downhole pressure sensors positioned exteriorly and interiorly of the fluid flow control device may be used to determine the pressure drop in the production fluids. Such pressure readings may be used by a downhole control circuit to automatically adjust the position of the sleeve relative to the base pipe to control the pressure drop in the production fluids. Other types of sensors may also be used in conjunction with the fluid flow control device of the present invention such as temperature sensors and fluid composition sensors that may be used to determine the constituents of the production fluids including, for example, the oil, gas, water, solids and fines content of the fluid as well as, for example, the API gravity of the fluid.  
         [0014]     In another aspect of the present invention a method for controlling the inflow of production fluids comprises providing a production conduit including a sand control screen having a base pipe with a first set of openings and a sleeve coaxially disposed adjacent to the base pipe having a second set of openings, installing the production conduit within the wellbore, producing the production fluids into the production conduit through the first set of openings of the base pipe and the second set of openings of the sleeve and selectively adjusting the sleeve relative to the base pipe such that the pressure drop in the production fluids is controlled by adjusting the alignment of the first set of openings relative to the second set of openings.  
         [0015]     The present invention also comprises a fluid flow control device that includes a tubular member having at least one fluid passageway in a sidewall section thereof. A sand control screen assembly is positioned exteriorly around the tubular member. The sand control screen assembly has a filter medium section that defines a first annular region with the tubular member and a housing section that defines a second annular region with the tubular member. A sleeve is slidably positioned within the second annular region. The sleeve has an open position wherein fluid communication is permitted between the second annular region and the fluid passageway and a closed position wherein fluid communication is prevented between the second annular region and the fluid passageway.  
         [0016]     The fluid flow control device also includes a hydraulic control line that extends from a surface location to the sand control screen assembly. The hydraulic control line has a first section with a terminus that is selectively in fluid communication with the sleeve to operate the sleeve from the open position to the closed position. A eutectic valve is positioned within the housing section to selectively prevent and permit fluid communication between the first section of the hydraulic control line and the sleeve. The hydraulic control line also has a second section that passes through the first annular region and extends downhole of the sand control screen assembly.  
         [0017]     The fluid flow control device has a sensor that may be positioned on the housing section of the sand control screen assembly to sense at least one downhole parameter such as temperature, pressure, fluid composition or the like. An energy conductor that extends from the surface and passes through the sand control screen assembly is in communication with the eutectic valve and the sensor. In operation, energy is supplied to the eutectic valve in response to one of the sensed downhole parameters, which melts the eutectic valve and establishes fluid communication between the first section of the hydraulic control line and the sleeve, thereby operating the sleeve from the open position to the closed position.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0018]     For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:  
         [0019]      FIG. 1  is a schematic illustration of an offshore oil and gas platform operating a plurality of fluid flow control devices according to the present invention;  
         [0020]      FIG. 2  is a half sectional view of a fluid flow control device according to the present invention positioned in its fully open position;  
         [0021]      FIG. 3  is a half sectional view of a fluid flow control device according to the present invention positioned in a choking position;  
         [0022]      FIG. 4  is a half sectional view of a fluid flow control device according to the present invention positioned in a choking position;  
         [0023]      FIG. 5  is a half sectional view of a fluid flow control device according to the present invention positioned in a choking position;  
         [0024]      FIG. 6  is a half sectional view of a fluid flow control device according to the present invention positioned in its fully closed position;  
         [0025]      FIG. 7  is a half sectional view of a fluid flow control device according to the present invention positioned in its fully open position;  
         [0026]      FIG. 8  is a half sectional view of a fluid flow control device according to the present invention positioned in its open position;  
         [0027]      FIG. 9  is a half sectional view of a fluid flow control device according to the present invention positioned in its closed positions; and  
         [0028]      FIG. 10  is a half sectional view of a fluid flow control device according to the present invention having a sleeve positioned exteriorly of the base pipe and positioned in its open position.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0029]     While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the present invention.  
         [0030]     Referring initially to  FIG. 1 , an offshore oil and gas platform operating a plurality of fluid flow control devices is schematically illustrated and generally designated  10 . A semi-submersible platform  12  is centered over submerged oil and gas formations  14 ,  16  located below sea floor  18 . A subsea conduit  20  extends from a wellhead installation  22  to a subsea installation  24 . A wellbore  26  extends through the various earth strata including formations  14 ,  16 . A casing string  28  is cemented within wellbore  26  by cement  30 . Casing string  28  includes perforations  32  and perforations  34  that respectively allow formation fluids from formations  14 ,  16  to enter the interior of casing string  28 .  
         [0031]     Positioned within casing string  28  and extending from wellhead installation  22  is a tubing string  36 . Tubing string  36  provides a conduit for formation fluids to travel from formations  14 ,  16  to the surface. A pair of packers  38 ,  40  provide a fluid seal between tubing string  36  and casing string  28  and define a production interval adjacent to formation  14 . Likewise, packers  42 ,  44  provide a fluid seal between tubing string  36  and casing string  28  and define a production interval adjacent to formation  16 .  
         [0032]     Positioned within tubing string  36  in the production interval adjacent to formation  14  are fluid flow control devices  46 ,  48  and  50 . Likewise, positioned within tubing string  36  within the production interval adjacent to formation  16  are fluid flow control devices  52 ,  54  and  56 . As explained in greater detail below, each of the fluid flow control devices  46 - 56  provides not only fluid flow control capability but also sand control capability.  
         [0033]     In the illustrated embodiment, there are three fluid flow control devices  46 ,  48 ,  50  associated with formation  14  and three fluid control devices  52 ,  54 ,  56  associated with formation  16 . Accordingly, the inflow of fluid from formation  14  and formation  16  may be controlled. For example, if the reservoir pressure of formation  14  is significantly higher than the reservoir pressure of formation  16 , fluid flow control devices  46 ,  48 ,  50  may be used to choke the fluid flow from formation  14  to a greater extent than fluid flow control devices  52 ,  54 ,  56  will choke the fluid flow from formation  16 . In addition, the fluid flow control devices of the present invention are independently controllable within each production interval. For example, certain ones of fluid flow control devices  46 ,  48 ,  50  may be used to choke or even close off certain sections of the production interval adjacent to formation  14  to prevent the production of water or other undesirable fluids. Similarly, one or all of the fluid flow control devices associated with a particular production interval may be adjusted over time as the adjacent formation becomes depleted or as downhole equipment experiences wear.  
         [0034]     It should be understood by those skilled in the art that even though  FIG. 1  has depicted three fluid flow control devices associated with each production interval, any number of fluid flow control devices either greater than or less than three may alternatively be used without departing from the principles of the present invention. Also, even though  FIG. 1  has depicted a vertical wellbore, the fluid flow control devices of the present invention are equally well suited for use in wellbores having other directional configuration such as incline wellbores, deviated wellbores or horizontal wellbores.  
         [0035]     It should be understood by those skilled in the art that even though  FIG. 1  has depicted an offshore production operation, the fluid flow control devices of the present invention are equally well suited for onshore operations. Also, even though  FIG. 1  has depicted a cased wellbore, the fluid flow control devices of the present invention are equally well suited for use in open hole completions.  
         [0036]     Referring next to  FIG. 2 , a fluid flow control device of the present invention is depicted and generally designated  60 . Fluid flow control device  60  includes a sand control screen assembly  62 . Sand control assembly  62  includes a base pipe  64  that has a plurality of openings  66  that allow the flow of production fluids into the production tubing. Even though openings  66  are depicted as round openings, it should be understood by those skilled in the art that openings of other configurations may alternatively be used and are considered within the scope of the present invention. For example, openings  66  could alternatively have a non circular shape such as an oval shape, a square shape, a rectangular shape or other similar shapes. Accordingly, the term openings as used herein is intended to encompass any type of discontinuity in base pipe  64  that allows for the flow of fluids therethrough including, but not limited to, perforations, holes and slots of any configuration that are presently known in the art or subsequently discovered. In addition, the exact number and size of opening  66  are not critical to the present invention, so long as sufficient area is provided for fluid production and the integrity of base pipe  64  is maintained. Openings  66  form a particular hole pattern in base pipe  64 , the importance of which will be explained in more detail below.  
         [0037]     Positioned around base pipe  64  is a filter medium  68 . In the illustrated embodiment, filter medium  68  is a fluid-porous, particulate restricting material such as a plurality of layers of a wire mesh that are diffusion bonded or sintered together to form a porous wire mesh screen designed to allow fluid flow therethrough but prevent the flow of particulate materials of a predetermined size from passing therethrough. Disposed around filter medium  68  is an outer shroud  70 . Outer shroud  70  has a plurality of openings  72  which allow the flow of production fluids therethrough. The exact number, size and shape of openings  72  are not critical to the present invention, so long as sufficient area is provided for fluid production and the integrity of outer shroud  70  is maintained. Outer shroud  70  is designed to protect filter medium  68  during installation of fluid flow control device  60  into the wellbore as well as during production therethrough.  
         [0038]     Positioned coaxially within base pipe  64  is a sleeve  74 . Sleeve  74  is slidable coupled within base pipe  64  using detents such as collets or pins (not pictured) or other suitable devices that are well known to those skilled in the art. Sleeve  74  has a plurality of openings  76 . As with openings  66  of base pipe  64 , openings  76  of sleeve  74  may have any geometric configuration that is suitable for allowing the flow of production fluids therethrough. While the illustrated embodiment depicts openings  76  of sleeve  74  as having the same shape and size as openings  66  of base pipe  64 , this relationship is not required by the present invention. For example, a fluid flow control device of the present invention could have slotted openings in sleeve  74  while having round openings in base pipe  64 . In the illustrated embodiment, the hole pattern of openings  66  of base pipe  64  and openings  76  of sleeve  74  have substantially the same geometry. In addition, openings  66  of base pipe  64  and openings  76  of sleeve  74  are substantially aligned with one another. Accordingly, when fluid flow control device  60  is in the depicted configuration, the pressure drop in the production fluids traveling therethrough is at a minimum and fluid flow control device  60  is considered to be in its fully opened position. Specifically, to enter in the interior of fluid flow control device  60 , the fluid must travel through an entry opening, one of the openings  66  of base pipe  64 , an annulus  78  between base pipe  64  and sleeve  74  and an exit opening, one of the openings  76  of sleeve  74 . As openings  66  of base pipe  64  and openings  76  of sleeve  74  are substantially aligned with one another, the distance the fluid is required to flow in annulus  78  is at a minimum.  
         [0039]     Referring now to  FIG. 3 , therein is depicted a fluid flow control device of the present invention that is generally designated  80 . The construction of fluid flow control device  80  is substantially identical to the construction of fluid flow control device  60  of  FIG. 2 . Fluid flow control device  80  is operated using a mechanical shifter  82  that may be carried downhole on a wireline  84 . To allow shifter tool  84  to interact with sleeve  74 , the interior side surfaces of sleeve  74  may have formed therein a longitudinally spaced series of annular, traversed notches, that receive a key set carried on mechanical shifter  82 . Once mechanical shifter  82  is received by sleeve  74 , sleeve  74  may be slidably shifted in the axial direction as can be seen by comparing the position of sleeve  74  relative to base pipe  64  in  FIGS. 2 and 3 .  
         [0040]     In the illustrated embodiment, sleeve  74  has been axially repositioned to increase the pressure drop experienced by production fluids traveling through annulus  78 . Specifically, as the set of openings  66  of base pipe  64  and the set of openings  76  of sleeve  74  have substantially the same hole pattern, when openings  66  and openings  76  are axially misaligned, the distance the formation fluids must travel within annulus  78  is increased, thereby increasing the pressure drop in the formation fluids. The amount of this pressure drop or choking is determined based upon a number of factors including the extent of the misalignment of openings  66  relative to openings  76 , the thickness of annulus  78 , the viscosity of the formation fluids and the like. In addition, the surface characteristics of either the exterior of sleeve  74  or the interior of base pipe  64  or both may be configured to further control the pressure drop. For example, grooves, channels, knurling, other turbulizing surfaces or the like may be added to one or both of the surfaces to increase the turbulence in the fluid flow thereby increasing the pressure drop across a given distance. Accordingly, once fluid flow control device  80  is installed downhole, the desired amount of pressure drop may be obtained by selectively misaligning openings  66  relative to openings  76  by axially shifting sleeve  74  relative to base pipe  64 . Also, it should be noted that sensors, such as position sensors, pressure sensors, temperature sensors, fluid composition sensors and the like may be used in conjunction with mechanical shifter  82  to determined the desired extent of the misaligning of openings  66  relative to openings  76 , as explained in greater detail below.  
         [0041]     Referring next to  FIG. 4 , therein is depicted a fluid flow control device of the present invention that is generally designated  90 . Fluid flow control device  90  is constructed in a manner substantially identical to fluid flow control device  60  of  FIG. 2 . In the illustrated embodiment, fluid flow control device  90  is operated by an electromechanical shifter  92  that is run downhole on an electric line  94 . Electromechanical shifter  94  may be received within sleeve  74  in a manner similar to that described above with reference to mechanical shifter  82  of  FIG. 3 . Once in place, electromechanical shifter  92  may be energized via electric line  94  such that sleeve  74  may be rotatably shifted relative to base pipe  64 .  
         [0042]     In the illustrated embodiment, sleeve  74  has been rotated ninety degrees relative to base pipe  64 . This rotation increases the distance between openings  76  of sleeve  74  and openings  66  of base pipe  64 . Accordingly, the formation fluid being produced into fluid flow control device  90  must travel an increased distance in annulus  78  relative to the position shown in  FIG. 2 . This increased distance equates to an increased pressure drop in the formation fluids. The desired amount of pressure drop may be achieved by selecting the amount of circumferential misalignment between openings  76  of sleeve  74  and openings  66  of base pipe  64 . Also, it should be noted that sensors, such as position sensors, pressure sensors, temperature sensors, fluid composition sensors and the like may be used in conjunction with electromechanical shifter  92 , these sensors may be permanently disposed downhole or may be carried downhole with the electromechanical shifter  92 .  
         [0043]     Referring next to  FIG. 5 , therein is depicted a fluid flow control device of the present invention that is generally designated  100 . Fluid flow control device  100  is constructed in substantially the same manner as fluid flow control device  60  of  FIG. 2 . Fluid flow control device  100  is operated using a downhole electrical motor  102  that is positioned within annulus  78  between sleeve  74  and base pipe  64 . Downhole electrical motor  102  receives power from energy conductors  104  that may extend to the surface or may extend to a downhole electrical power source such as a battery pack or a downhole electrical generator. Downhole electrical motor  102  includes a control circuit that commands downhole electrical motor  102  to shift sleeve  74  relative to base pipe  64  when it is desirable to adjust the pressure drop in the production fluids being produced therethrough. A pair of pressure sensors  106 ,  108  are used to monitor the pressure on the exterior of fluid flow control device  100  and the pressure on the interior of fluid flow control device  100 , respectively.  
         [0044]     The pressure information may be carried to the surface via energy conductors  104  where it may be processed then command signals may be returned to the control circuit of downhole electrical motor  102  via energy conductors  104  to initiate the operation of downhole electrical motor  102 . Alternatively, the pressure information may be sent directly to the control circuit of downhole electrical motor  102  from pressure sensors  106 ,  108  to initiate operation of downhole electrical motor  102 . Additionally, sleeve  74  may include a position sensor that identifies the relative position of sleeve  74  and base pipe  64  to further refine the operation of shifting sleeve  74 . The position sensor may be powered by energy conductors  104  and may send signals to the surface or directly to the control circuit of downhole electric motor  102 .  
         [0045]     In the illustrated embodiment, downhole electrical motor  102  is operable to axially adjust the position of sleeve  74  relative to base pipe  64  and rotatably adjust the position of sleeve  74  relative to base pipe  64 . By comparing  FIGS. 2 and 5 , it can be seen that sleeve  74  has been axially and rotatably adjusted relative to base pipe  64 . Accordingly, the distance between openings  76  of sleeve  74  and openings  66  of base pipe  64  has been increased, which in turn increases the distance the production fluids must travel in annulus  78  resulting in an increase in the pressure drop in the production fluids. This embodiment of fluid flow control device  100  is particularly suitable for precision control of the pressure drop due to the interaction of pressure sensors  106 ,  108 , the position sensor and the control circuit of downhole electrical motor  102 .  
         [0046]     Referring now to  FIG. 6 , therein is depicted another embodiment of a fluid flow control device of the present invention that is generally designated  110 . Fluid flow control device  110  is constructed in substantially the same manner as fluid flow control device  60  of  FIG. 2  with the exception that fluid flow control device  110  includes a plurality of seals  112  carried by base pipe  64 . The operation of fluid flow control device  110  is hydraulically controlled in a conventional manner by increasing and decreasing the pressure within hydraulic control lines  114 ,  116  which allows sleeve  74  to axially shift relative base pipe  64 . As described above, as openings  76  of sleeve  74  become misaligned with openings  66  of base pipe  64 , the pressure drop in the formation fluids being produced therethrough increases. In the illustrated embodiment, however, when sleeve  74  is shifted to the illustrated position relative to base pipe  64 , fluid production through fluid flow control device  110  is prevented as each of the openings  76  of sleeve  74  are positioned between a pair of seals  112 . Accordingly, fluid flow control device  110  can be operated from a fully opened position (see  FIG. 2 ) to a fully closed positioned as well as various choking positions therebetween.  
         [0047]     Referring next to  FIG. 7 , therein is depicted a fluid flow control device of the present invention that is generally designated  120 . Fluid flow control device  120  is constructed in substantially the same manner as fluid flow control device  60  of  FIG. 2 , however, sleeve  74  as depicted in  FIG. 2  has been replaced with sleeve  122 . Sleeve  122  includes a plurality of openings  124  that form a hole pattern with a geometry that is different from the hole pattern of openings  66  of base pipe  64 . Fluid flow control device  120  is operated using a downhole electrical motor  126  which is operable to rotatably shift sleeve  122  relative to base pipe  64 . This rotation aligns the various columns of openings  124  of sleeve  122  with openings  66  of base pipe  64 . In the illustrated configuration, each opening  66  of base pipe  64  is aligned with an opening  124  of sleeve  122 . When sleeve  122  is rotated using downhole electrical motor  126 , however, some of the openings  66  of base pipe  64  will no longer be aligned with an opening  124  of sleeve  122 . Accordingly, the pressure drop in the production fluids is controlled by adjusting the relative alignment of openings  124  of sleeve  122  with openings  66  of base pipe  64 .  
         [0048]     Referring now to  FIG. 8 , therein is depicted another embodiment of a fluid flow control device of the present invention that is generally designated  130 . Fluid flow control device  130  includes a sand control screen assembly  132 . Sand control screen assembly  132  includes a base pipe  134  that has a series of openings  136  that are circumferentially spaced therearound. Sand control screen assembly  132  has a pair of screen connectors  138 ,  140  that attach a sand control screen  142  to base pipe  134 . Screen connectors  138 ,  140  may be attached to base pipe  134  by welding or other suitable technique. Sand control screen  142  may comprise a screen wire wrapped around a plurality of ribs to form turns having gaps therebetween which allow the flow of formation fluids therethrough but which block the flow of particulate matter therethrough. The number of turns and the size of the gaps between the turns are determined based upon the characteristics of the formation from which fluid is being produced and the size of the gravel to be used during a gravel packing operation, if any.  
         [0049]     Screen connectors  138 ,  140  attach sand control screen  142  to base pipe  134  such that an annulus  144  is formed between sand control screen  142  and base pipe  134 . It should be noted that centralizers or other support members may be disposed within annulus  144  to support sand control screen  142  and maintain the standoff between sand control screen  142  and base pipe  134 . Coupled to the upper end of screen connector  140  is a housing member  146 . Housing member  146  forms an annulus  148  with base pipe  134  adjacent to openings  136 . Disposed within annulus  148  is a sliding sleeve  150  having a pair of seals  151  disposed on the interior side thereof to provide a seal against base pipe  134  and a pair of seals  153  disposed on the exterior side thereof to provide a seal against housing member  146 .  
         [0050]     Disposed exteriorly of base pipe  134  and extending from the surface is a hydraulic fluid conduit  152 . One portion of hydraulic fluid conduit  152  extends into a fluid passageway  154  within housing member  146 . Disposed within fluid passageway  154  is a valve  156 , such as a eutectic valve. Another portion of hydraulic fluid conduit  152  extends into and through housing member  146  and screen connector  140  into annulus  144 . This portion of hydraulic fluid conduit  152  extends through annulus  144  to exit sand control screen assembly  132  through screen connector  138 .  
         [0051]     Importantly, this portion of hydraulic fluid conduit  152  runs within a recess or channel in housing member  146  and on the inside of sand control screen  142 , instead of the outside of sand control screen  142 , which removes the need to band hydraulic fluid conduit  152  to the exterior of sand control screen  142  which would block the inflow of formation fluids through those portions of sand control screen  142  covered by the banding material. Also, this portion of hydraulic fluid conduit  152  is protected by having sand control screen  142  positioned exteriorly thereof. Alternatively, the channel on the exterior of housing member  146  could be extended along the exterior of sand control screen  142  such that hydraulic fluid conduit  152  could be positioned within the channel for protection. As can be seen in  FIG. 8 , hydraulic fluid conduit  152  is capable of providing operating fluid to fluid flow control device  130  and is also capable of providing operating fluid to other devices downhole of fluid flow control device  130  such as additional fluid flow control devices positioned further downhole.  
         [0052]     A sensor  158  is positioned on the exterior of housing member  146 . Sensor  158  may provide information relating to a variety of downhole parameters such as pressure, temperature, fluid composition or the like. Sensor  158  is in communication with the surface via energy conductors  160 . Energy conductors  160  may provide power and communication capabilities to sensor  158  as well as to valve  156 . In the case in which valve  156  is a eutectic valve and it is desirable to operate fluid flow control device  130  to the closed position, energy is conducted to valve  156  via energy conductors  160  to melt the eutectic material such that operating fluid from hydraulic fluid conduit  152  may be communicated to sliding sleeve  150 . Energy conductors  160  also extend through fluid flow control device  130  in a manner similar to hydraulic fluid conduit  152  by passing through housing member  146 , screen connector  140 , annulus  144  and screen connector  138 . Alternatively, instead of using sensor  158  to obtain information relating to downhole parameters, energy conductors  160  may include a fiber optic cable which may be used to obtain certain downhole parameters such as temperature and pressure at particular locations.  
         [0053]     In operation and referring both to  FIGS. 8 and 9 , fluid flow control device  130  is used to filter particulate matter out of production fluids and control the flow of fluids into the tubing string. More specifically, when fluid flow control device  130  is in its open position as depicted in  FIG. 8 , formation fluids are produced through sand control screen  142  into annulus  144 . These formation fluids then travel upwardly through screen connector  140  that has a plurality of axially extending openings allowing the formation fluids to pass into annulus  148  above screen connector  140 . From annulus  148 , fluid communication is allowed through openings  136  such that the formation fluids may travel to the surface via the tubing string.  
         [0054]     If it is determined that production through fluid flow control device  130  should no longer continue, fluid flow control device  130  may be operated to its closed position as depicted in  FIG. 9 . For example, if sensor  158  has sensed that the formation fluids are being produced through fluid flow control device  130  contain an undesirable percentage of water, then a signal may be sent to the surface via energy conductors  160  indicating such a fluid composition. Thereafter, power may be sent to valve  156  via energy conductors  160  and through appropriate switching or addressing circuitry such that the eutectic material of valve  156  is melted, thereby allowing fluid communication through fluid passageway  154 . Thereafter, operating fluid from hydraulic fluid conduit  152  may act on sliding sleeve  150  such that openings  136  of base pipe  134  are no longer in communication with annulus  148 . Once in this configuration, fluid flow control device  130  no longer permits formation fluids to flow therethrough.  
         [0055]     As described above, hydraulic fluid conduit  152  and energy conductors  160  pass through sand control screen assembly  132  such that similar operations may be conducted on fluid flow control devices or other devices that are positioned downhole of fluid flow control device  130 .  
         [0056]     Referring now to  FIG. 10 , therein is depicted another embodiment of a fluid flow control device of the present invention that is generally designated  170 . Fluid flow control device  170  includes a sand control screen assembly  172 . Sand control screen assembly  172  includes a base pipe  174  that has a series of openings  176 . Sand control screen assembly  172  also has a screen support member  178  that is attached by welding or other suitable technique at opposite ends to base pipe  174  and has a series of openings  180 . The filter media of sand control screen assembly  172  is depicted as a wire wrapped screen  182  such as that described above with reference to  FIG. 8 .  
         [0057]     Unlike the previously disclosed fluid flow control devices, fluid flow control device  170  is constructed with a sleeve  184  coaxially positioned exteriorly of base pipe  174 . Sleeve  184  has a plurality of openings  186  that have substantially the same geometry as openings  176  of base pipe  174 . In the illustrated embodiment, sleeve  184  is closely received around base pipe  174  such that there is a friction fit therebetween. This friction fit can operate substantially as a seal to provide significant resistance to flow between sleeve  184  and base pipe  174  when openings  186  are not aligned with openings  176 . Alternatively, an annulus may be formed between sleeve  184  and base pipe  174  operating substantially as annulus  78  discussed above. The operation of fluid flow control device  170  is hydraulically controlled in a conventional manner by increasing and decreasing the pressure within hydraulic control lines  188 ,  190  which allows sleeve  184  to axially shift relative base pipe  174 .  
         [0058]     While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.

Technology Classification (CPC): 4