Thermally Activated Autonomous Inflow Control Device

The present disclosure is directed to a wellbore for an oil and gas extraction, and more specifically, to a control of fluid within a wellbore.

Controlling a flow of fluid within a wellbore is crucial for efficient and safe oil and gas production. This involves managing the inflow of hydrocarbons (of oil and gas) and water from the surrounding reservoir into the wellbore to optimize production rates and extend the well's productive life. Techniques such as the use of inflow control device (ICD) and isolation packers are employed to regulate the pressure and flow of fluids, ensuring a balanced and controlled extraction.

Implementations described herein provides a system for controlling a flow of fluid within a wellbore. The system includes an inflow control device (ICD) configured to modulate an inflow of hydrocarbons within the wellbore. The sleeve can be slidably disposed adjacent to the ICD and connected to an elastic material with a thermal memory. The elastic material can change its shape based on a change in temperature. Based on (i) the elastic material being in a compressed state below a temperature threshold and (ii) the sleeve being at a first position relative to the ICD, the elastic material can allow a fluid communication between the ICD and outside the wellbore. Based on (i) the elastic material being in a stretched state at or above the temperature threshold and (ii) the sleeve being at a second position relative to the ICD, the elastic material can block a fluid communication between the ICD and outside the wellbore.

A method includes using an elastic material with a thermal memory and a sleeve disposed adjacent to the elastic material to control fluid communication between an inflow control device (ICD) and outside a wellbore. Using the elastic material and the sleeve includes, based on (i) the elastic material being in a compressed state below a temperature threshold and (ii) the sleeve being at a first position relative to the ICD, allowing the fluid communication between the ICD and outside the wellbore. Moreover, using the elastic material and the sleeve includes, based on (i) the elastic material being in a stretched state at or above the temperature threshold and (ii) the sleeve moving to a second position relative to the ICD, blocking the fluid communication between the ICD and outside the wellbore.

A method includes receiving a fluid including a formulation water within a wellbore and based on (i) a temperature of the formulation water heating up an elastic material disposed adjacent to an inflow control device (ICD) at or over a threshold temperature and (ii) the elastic material being stretched out based on the threshold temperature, shutting a fluid communication between the ICD and outside the wellbore.

In the drilling industry, once the reservoir section is drilled, isolation packers and inflow control devices can be installed and run to regulate oil or gas production and minimize or restrict water production from the well. During a life of the well, once water cut increases beyond the threshold in one of the compartments (e.g., each compartment defined between the respective isolation packers), it restricts oil or gas production from the rest of the lateral wellbore. Therefore, extensive diagnostic work, including reservoir characterization logging, is carried out to identify the water-producing compartment(s). Ultimately, a coil tubing operation is conducted to isolate the water-producing compartment(s) by shifting a pre-installed isolation sleeve to a closed position. One major disadvantage of this approach is that, since many wells are completed with closed ended upper completion, it is difficult to access inflow control devices (ICD). For example, dedicated rig operations may be required to de-complete the well to regain accessibility to the ICDs for the diagnosis and shut-off operation. Additionally, identifying the source of water or water-producing compartment(s) can be an exhaustive and costly operation through running logs, data analysis, and human interpretation.

Implementations described in this disclosure provides system and method for addressing the issues addressed above. For example, a sleeve is slidably disposed adjacent to the ICD and connected to an elastic material with a thermal memory. Such clastic material can change its shape based on a change in temperature. For example, when the elastic material (e.g., nitinol, nickel and titanium mixture, etc.) is heated to a certain threshold temperature, the elastic material can stretch out from a compressed state to a stretched state, thereby moving the sleeve from a first position to a second position. For example, the first position of the sleeve corresponds to a position when the elastic material is compressed, and the second position of the sleeve corresponds to a position when the elastic material is stretched. As such, for example, when hydrocarbon is produced, the elastic material is in compressed state and the sleeve is at its first position, and when unwanted formation water (that is hotter than hydrocarbon) is produced and heats up the elastic material, the elastic material stretches out to thereby move the sleeve to the second position. When the sleeve is at the second position, the sleeve shuts off the ICD such that the fluid communication between the ICD and outside the wellbore (as well as the wellbore) is blocked. By doing so (e.g., controlling the fluid communication or fluid flow based on a temperature change), water-producing compartment can be automatically identified and shut down.

is a schematic diagram of an example of a systemfor controlling a flow of fluid within a wellbore. The systemincludes a wellbore, a casing, an apparatus or a housing, an inflow control device (ICD), a sleeve, an elastic material, and isolation packers.

The wellborecan be connected or in fluid communication with a reservoir, and the casingmay be disposed (e.g., installed) within the wellbore. The apparatus or the housingcan be integrated into or disposed within the casing.

The housingcan include the ICD, the sleeve, and the elastic material. The housingcan define a hole or an opening such that the housingmay be in fluid communication with the wellboreand outside the wellbore(e.g., reservoir), as well as the wellbore. For example, the housingmay have a porous structure that allows inflow of reservoir fluids. For example, the housingcan define openings or equalization ports(shown in) that fluidly connects the outside space of the casingto the housing.

The ICDcan be installed within the compartment defined between the respective isolation packers. The ICDcan be used to control the flow of fluid within the wellbore. For example, the ICDcan control the flow rate of reservoir fluids into the compartment between the isolation packers. For example, the ICDcan modulate an inflow of hydrocarbons (e.g., hydrocarbons from the reservoir) to the compartment. For example, by providing a flow restriction at a certain point within the compartment defined by the isolation packers, the ICDcan help to manage pressure differential within the wellboreor across the specific compartment within wellbore.

The sleevecan be slidably disposed adjacent to the ICD. For example, the sleevecan be (i) positioned below the opening or the equalization ports(shown in) defined at the housingand (ii) disposed adjacent to the ICD. The sleevecan be made of metal or other feasible material.

The sleevecan be connected to the elastic materialwhich can move the sleeveto a certain position. For example, the elastic materialcan be a material that has a thermal memory, in which the elastic materialcan change its shape based on a change in temperature. Moreover, for example, the sleeveand the elastic materialcan be housed in a frame or a sleeve-elastic material housing (e.g., sleeve-elastic material housingof) that is disposed within the housing. Such frame or the sleeve-elastic material housing can be connected to (e.g., coupled with) the ICD.

The elastic materialcan be made of Nitinol or nickel-titanium. Because the Nitinol or the nickel-titanium is a thermally-sensitive material and has thermal memory, the elastic materialcan be compressed (e.g., referred herein as “compressed state”) when the temperature of the elastic materialor its surrounding is below a certain temperature threshold. Moreover, for example, the elastic materialcan be stretched (e.g., referred herein as “stretched state”) when the temperature of the elastic materialor its surrounding is at or above the certain temperature threshold. Moreover, the elastic materialcan have a shape of a spring, as shown in.

As described above, the sleevecan be configured to move to a certain position based on the elastic materialbeing in the compressed state or the stretched state. For example, this movement of the sleeveis illustrated in.

In operation, when the elastic materialis at the compressed state, the elastic materialcan modulate the flow of hydrocarbons and the sleevecan be at its first position. When formation water (that is hotter than the hydrocarbons) flows in and heats up the elastic materialat the certain temperature threshold, the elastic materialcan stretch out (e.g., to its stretched state), thereby moving the sleeveto a second position. When the sleevemoves to the second position, the sleeve can block the fluid communication between the ICDand the wellbore, as well as outside the wellbore. For example, the sleevecan slide into the ICDsuch that the sleevecloses an opening or a port defined at a surface of the ICDand block the fluid communication between the ICDand the wellbore, as well as outside the wellbore.

In some implementations, the ICDcan include a sliding rail (e.g., sliding railof) disposed within the ICD, which guides a sliding of the sleeve.

In some implementations, the sleevecan be connected to the ICD. For example, the sleevecan be connected to the ICDsuch that when the sleevemoves in a direction toward the ICD, such connection helps to guide the sleeveto slide in or penetrate through the opening defined at the ICD.

In some implementations, one or more elastomeric seals (e.g., one or more elastomeric sealsof) can be disposed at or attached to the sleeveand configured to seal against the sliding rail. For example, the one or more elastomeric seals can include or be a O-ring seal, or a stack of O-ring seals.

In some implementations, regarding the elastic materialbeing the Nitinol or a nickel and titanium alloy, based on a change in a composition ratio of nickel and titanium, the threshold temperature can change and the sleevecan be thermally activated and move to the second position based on changed threshold temperature. Such threshold temperature can be referred herein as the “transformation temperature.”

Moreover, for example, such transformation temperature can vary depending on the depth of the well or the wellbore. For example, the temperature of the hydrocarbons within the wellboremay be under 40 degrees Celsius (° C.) at certain depth of the well or the wellbore, and under 60 degrees ° C. at certain other depth of the well or the wellbore. For example, the temperature of the hydrocarbons and the formation water can vary depending on the depth of the well or the wellbore. As such, to identify the source of unwanted water or the formation water, to block such unwanted water or the formation water from flowing outside the wellboreto the wellboreor to specific compartment, or to block such unwanted water or the formation water from flowing to other compartments, the transformation temperature can be controlled depending on the depth of the well or the wellboreand thus, different composition ratio of nickel and titanium. For example, the composition ratio of nickel and titanium can be varied or formulated before forming the nitinol or the nickel and titanium alloy depending on the depth of the well or the wellbore, or depending on the pre-determined or preferred transformation temperature of the elastic material.

In some implementations, the elastic materialcan have different shapes including rods, sheets, foils, etc. For example, when the elastic materialis in a shape of the rod, then the elastic materialmay flex and elongate (rather than compress and stretch) based on the change in temperature. For example, when the elastic materialis in a shape of the sheets, the elastic materialcan bend and flatten (rather than compress and stretch) based on the change in temperature. For example, when the elastic materialis in a shape of the foil, the elastic materialcan bend and twist (rather than compress and stretch).

In some implementations, whole component referred by the housingcan be referred to as the ICD. For example, the housingcan referred to as an housing of the ICD, and the sleeveand the elastic materialcan be detachably attached to or integrated into the ICD, so as to be considered to form a part of the ICD.

is a schematic diagram of an example of the systemfor controlling a flow of fluid within the wellbore.illustrates an example of the ICD, the wellbore, the casing, the apparatus or the housing, the sleeve-elastic material housing, the ICD, the sleeve, the elastic material(in a form of a spring), and the isolation packers.

are schematic diagrams of an example of a movement of the sleevebased on the elastic material. In particular,illustrate the elastic materialin the form or shape of a spring. Moreover,illustrates the elastic materialin a compressed state and the sleeveat a first position, andillustrates the elastic materialin a stretched state and the sleeveat a second position. In the second position, the sleevecan move through an openingdefined at the sleeve-elastic material housing. One or more seals can be disposed at or within the openingto facilitate or guide the movement of the sleeveinto the ICD. Although the ICDis not shown in, the IDCcan be positioned next to the sleeve-elastic material housingor connected to the sleeve-elastic material housing.

are schematic diagrams of an example of an operation of the system. In particular,illustrate scenarios where formation waterencroaches the housingor the ICD. For example,illustrates an initial stage of where the formation waterstarts to encroach the housingor the ICD, for example, through the equalization ports.illustrates the elastic materialin a compressed state and the sleeveat a first position, as the elastic materialhas not yet been heated up to a threshold temperature or a transformation temperature of the elastic material.illustrates the elastic materialin a stretched state and the sleeveat a second position, after the elastic materialhas been heated at or above the threshold temperature by the formation water. In some implementations, the formation watercan be supplanted with other forms water, such as heater water formed during oil and gas operation or other source of water.

are schematic diagrams of an example of a movement of the sleeverelative to the ICD. One or more elastomeric sealscan be disposed at or attached to the sleeveand configured to seal against sliding rail. For example, the one or more elastomeric sealscan include or be a O-ring seal, or a stack of O-ring seals.illustrates a scenario where the sleeveis not yet fully slid into or penetrated through an opening defined at the ICD.illustrates a scenario where the sleeveis fully slid into or penetrated through the opening defined at the ICD, thereby blocking a fluid communication between the ICDand the wellbore, as well as the outside of the wellbore.

is a flowchart of a techniquefor controlling a flow of fluid within a wellbore (e.g., the wellbore). The techniquecan be implemented in conjunction with the systemand the implementations described above.

At, fluid is received. For example, a housing (e.g., the housingthat houses an elastic material (e.g., the elastic material) with a thermal memory and an ICD (e.g., the ICD)) can receive the fluid. For example, the fluid can be received through an opening (e.g., the equalization ports) defined at the housing or an opening defined at the ICD.

In some implementations, the fluid can include hydrocarbons. In some implementations, the fluid can include hydrocarbons and formation water. In some implementations, the fluid can include formation water.

At, based on the temperature of the fluid, fluid communication between the ICD and outside wellbore is controlled. For example, because the elastic material (e.g., in a shape of a spring) can change its shape based on a change in temperature, the elastic material that is positioned adjacent to a sleeve (e.g., the sleeve) can move the sleeve to shut the ICD, as described above.

For example, the elastic material can be made of Nitinol or nickel-titanium. Because the Nitinol or the nickel-titanium is a thermally-sensitive material and has the thermal memory, the elastic material can be compressed (e.g., being in a compressed state) when the temperature of the elastic material or its surrounding is below a certain temperature threshold (e.g., transformation temperature). Moreover, for example, the elastic material can be stretched (e.g., being in a stretched state) when the temperature of the elastic material or its surrounding is at or above the certain temperature threshold.

For example, the temperature threshold or the transformation temperature can be configured to match, or based on, an expected temperature of the fluid or the formation water. For example, in a case where it is be preferred to receive or manage inflow of the hydrocarbons and block inflow of the formation water or block the formation water from flowing into other compartments, the composition ratio of Nitinol or the nickel and titanium can be varied or formulated to configure the transformation temperature to match an average formation water temperature.

Moreover, for example, as described above, such transformation temperature can vary depending on a depth of well or the wellbore. For example, the temperature of the hydrocarbon within the wellboremay be under 40 degrees Celsius (° C.) at certain depth of the well and under 60 degrees ° C. at certain other depth of the well or the wellbore. For example, the temperature of the hydrocarbon and the formation water can vary depending on the depth of the well or the wellbore. As such, to identify the source of unwanted water or formation water (that is colder than the hydrocarbons), to block such unwanted water or the formation water from flowing outside the wellbore to the wellbore or to a specific compartment, or to block such unwanted water or the formation water from flowing into other compartments, the transformation temperature can be controlled depending on the depth of the well or the wellbore. Such transformation temperature can be configured by varying a composition ratio of nickel and titanium of the elastic material. For example, the composition ratio of nickel and titanium can be varied or formulated before forming the nitinol or the nickel and titanium alloy, depending on (i) the depth of the well or the wellbore or (ii) pre-determined or preferred transformation temperature of the elastic material.

At, when the temperature of the elastic material or its surrounding is below the temperature threshold, the elastic material can be in the compressed state and the sleeve can be at its first position, thereby allowing a fluid communication between the ICD and outside the wellbore. For example, when the transformation temperature is below the average formation water temperature, the elastic material can be in the compressed state and allow or manage inflow of hydrocarbons.

At, when the temperature of the elastic material or its surrounding is at or above the temperature threshold, the elastic material can stretch out so as to move the sleeve to a second position, in which the sleeve at the second position shuts the ICD and blocks the fluid communication between the ICD and outside the wellbore. For example, when the transformation temperature at or above the average formation water temperature, the elastic material can be stretched out (being in the stretched state) so as to block the inflow of the formation water.

In some implementations, the elastic material can have other shapes including rods, sheets, foils, etc. For example, when the elastic material is in a shape of the rod, then the elastic material may flex and elongate (rather than compress and stretch) based on the change in temperature. For example, when the elastic material is in a shape of the sheets, the elastic material can bend and flatten (rather than compress and stretch) based on the change in temperature. For example, when the elastic material is in a shape of the foil, the elastic material can bend and twist (rather than compress and stretch).

In some implementations, a sliding rail (e.g., the sliding rail) can be disposed within the ICD and guide a sliding of the sleeve.

In some implementations, elastomeric seals (e.g., the one or more elastomeric seals) can be attached to the sleeve and configured to seal against the sliding rail.

is a flowchart of a techniquefor controlling a flow of fluid within a wellbore (e.g., the wellbore). The techniquecan be implemented in conjunction with the system, the technique, and the implementations described above.

At, fluid containing formulation water is received. For example, housing (e.g., the housingthat houses an elastic material (e.g., the elastic material) with a thermal memory and an ICD (e.g., the ICD)) can receive the fluid. For example, the fluid can be received through an opening (e.g., the equalization ports) defined at the housing or an opening defined at the ICD.

At, the fluid or the formulation water heats up the elastic material. For example, the fluid or the formulation water can heat up the elastic material to a certain threshold temperature.

At, the elastic material stretches out from a compressed state to a stretched state. For example, when the elastic material disposed adjacent to the ICD reaches the threshold temperature, the elastic material can be stretched out. As the elastic material stretches out, the sleeve that is connected to the elastic material moves through an opening defined at the ICD, thereby shutting a fluid communication between the ICD and outside the wellbore, as well as between the ICD and the wellbore.

In some implementations, one or more elastomeric seals can be disposed on or attached to the sleeve and configured to seal against a sliding rail positioned at the opening of the ICD. For example, one or more elastomeric seals can include or be a O-ring seal, or a stack of O-ring seals.

At, the sleeve can seal the ICD. By sealing the ICD, the fluid communication between the ICD and outside the wellbore is blocked.

While this specification contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features that may be specific to particular implementations. Certain features that are described in this specification in the context of separate implementations can also be implemented, in combination, in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations, separately, or in any sub-combination. Moreover, although previously described features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.

As used in this disclosure, the terms “a,” “an,” or “the” are used to include one or more than one unless the context clearly dictates otherwise. The term “or” is used to refer to a nonexclusive “or” unless otherwise indicated. The statement “at least one of A and B” has the same meaning as “A, B, or A and B.” In addition, it is to be understood that the phraseology or terminology employed in this disclosure, and not otherwise defined, is for the purpose of description only and not of limitation. Any use of section headings is intended to aid reading of the document and is not to be interpreted as limiting; information that is relevant to a section heading may occur within or outside of that particular section.

Values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. The statement “X to Y” has the same meaning as “about X to about Y,” unless indicated otherwise. Likewise, the statement “X, Y, or Z” has the same meaning as “about X, about Y, or about Z,” unless indicated otherwise.

Particular implementations of the subject matter have been described. Other implementations, alterations, and permutations of the described implementations are within the scope of the following claims as will be apparent to those skilled in the art. While operations are depicted in the drawings or claims in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed (some operations may be considered optional), to achieve desirable results. In certain circumstances, multitasking or parallel processing (or a combination of multitasking and parallel processing) may be advantageous and performed as deemed appropriate.

Moreover, the separation or integration of various system modules and components in the previously described implementations should not be understood as requiring such separation or integration in all implementations, and it should be understood that the described components and systems can generally be integrated together or packaged into multiple products.