Flow Control Tool, Method and System

In the resource recovery and fluid sequestration industries efficiency of motion is an ever-present concern. Flow control is also quite important in the industry and requires a number of different types of devices to effect control in a desirable way. Different tools are generally run to depth to manage a flow in the desired way and changed out over the life of the well as pressures and flow rates change. Advancements are always well received in the art.

An embodiment of a flow control tool including a housing, a mandrel disposed in the housing, the mandrel supporting a plurality of discrete flow control units (FCU), and a seal disposed between the housing and the mandrel, the mandrel and housing being movable relative to one another to position the seal in an operative position for one of the plurality of FCUs.

An embodiment of a method for managing flow in a borehole includes shifting a mandrel having a plurality of discrete Flow Control Units (FCU) disposed therein into a position relative to a housing where a seal between the housing and the mandrel causes an FCU of the plurality of FCUs to be in an operational position, modifying a flow of fluid by passing the fluid through the FCU, and shifting a different FCU of the plurality of FCUs into an operational position.

An embodiment of a gravel pack assembly includes a crossover tool, the tool, connected to the crossover tool, a packer connected to the crossover tool, a first seal bore formed within the packer, a port housing connected to the packer, and a second seal bore connected to the port housing wherein the plurality of FCU's includes a check valve, and a plug, the assembly configured to change directly from check to closed.

An embodiment of a method for gravel packing includes operating a gravel pack assembly in an open mode, operating the gravel pack assembly in a check mode, and operating the gravel pack assembly in a closed mode.

An embodiment of a borehole system includes a borehole in a subsurface formation, a string in the borehole, and a tool, disposed within or as a part of the string.

A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.

Referring to, a first embodiment of a flow control toolis illustrated. Toolcomprises a housingand a mandreldisposed in the housing. The mandrelsupports a plurality of discrete flow control units (FCU),, and. Two or more FCUs are contemplated, with three specifically illustrated as one example. The FCUs may be configured mechanically to manage a number of different parameters of the flow. For example, as illustrated FCUis a flow regulator, FCUis a check valve, and FCUis a plug. Other types of FCU are also contemplated including but not limited to a back pressure valve, relief valve, orifice, choke, etc. Each FCU also includes bypass portsandupstream and downstream (respectively or in reverse depending upon flow direction) of the operative portion thereof (i.e. the flow regulator or check valve, etc.) Note that where two FCUs are beside one another, a single port structure between them will serve as both portand port. Optionally, in some embodiments, FCUs may also comprise a weepholeto allow some fluid passage even if in a checked or plugged position (see). A sealis disposed between the housingand the mandrel. The sealis of a dynamic type allowing fluid isolation while also allowing movement between the housingand the mandrel. The seal may be mounted to either the housing or the mandrel, or could be floating therebetween, in embodiments, but is illustrated as mounted to the housing. The housingand mandrelalso have interacting between them an indexer, such as a J-slot. Accordingly, the positions of the mandrel and housing are selectable by picking up and slacking off on the string of which the toolis a part. As will be appreciated by one of ordinary skill, the toolis generally employed in a casing string and so may use profiles in on the casing or on the toolto interact with the casing thereby supporting the movement of the housingrelative to the mandrel.

The housingfurther includes a bypass area(,) that functions to allow fluid to flow around one or more of the plurality of FCUs thereby bypassing those FCUs and not affecting the flow with whatever the particular FCUs are capable of doing. In embodiments, the bypass areawill be as long as the number of FCUs that are present to ensure that if the FCUs are positioned within the bypass area, none of them would be active. This is the case illustrated inand hence, the toolis termed open in.

Cycling (pick up and slack off) the indexer(or otherwise just moving the mandrel relative to the housing, such as with hydraulics or shifting tool) to position FCUin an operable position including sealing to seal, as illustrated in. FCU, in the illustrated embodiment, is a flow regulator. FCUis shown with its bypass portsandon either axial side of the seal. Accordingly, a fluid flow in the mandrelmust flow through the FCU rather than around it. In the position of, flow in the mandrelwill necessarily be rate limited due to the configuration of FCU.

In, another position of the same embodiment moves the FCUout of sealing engagement with sealand moves both portsandfor FCUinto the bypass areaadjacent and to the left (in the figure) of the seal. In this position, flow will exit the mandrelupstream of the FCUand reenter the mandreldownstream of the FCUwhile FCUwill have a negligible effect on the flow through tool. FCUis disposed in the seal, exposing one porton one side of sealto one bypass areaand the other bypassin a different bypass area. Flow then must run through FCU, which as illustrated is a check valve. Fluid can flow infrom right to left but not vice versa. In one embodiment, the check valve is a trapped ball type having a seat, a balland a baffle.

Referring to, another movement between housingand mandrel(happening to be in the same direction in the Figures but other directions are contemplated as any of the FCUs may be selected and in any order one might way to employ them), FCUhas moved into position with the sealsimilarly to the way the foregoing FCUs discuss have done. In this position, the toolis closed because the FCUis a plug.

Referring to, another embodiment of toolis illustrated. This embodiment differs from the forgoing embodiment in that two sealsandare employed in this embodiment. This embodiment allows the employment of two FCUs in series as well as just one at a time. It will be appreciated that FCUand FCUare the same but a different FCU, a back pressure valve, is illustrated. It is reiterated that any combination of FCUs may be employed and that they need not all be different. One or more may be the same as each other and may be placed (among a number of adjacent FCUs) for easier access thereto as a sequence operation.is in an open position. Similar to, bypass portsandfor each of the FCUs are disposed within one bypass area, hence allowing fluid to flow around the FCUs.

Referring toillustrates a position where the second embodiment operates similarly to that of. FCUis disposed in sealing contact with seal, essentially duplicating the action illustrated in. In, however, FCUis moved into sealing contact with sealand FCUis moved into sealing contact with seal. In this position, portis in bypass area, while port(portfor FCU) is disposed between sealsandand hence is a dead head. FCUportis in bypass area. Fluid in the mandrelmust flow through both of FCUand FCUand will skip the FCUwhose portsandare both disposed in bypass area

Referring to, mandrelhas been moved again relative to housing, which moves FCUfully into bypass areaand FCUand FCUinto position with sealsand. In this configuration it is both FCUand FCUthat will be in operation for any flow in the mandrel.

Referring to, a borehole systemis illustrated. The systemcomprises a boreholein a subsurface formation. A stringis disposed within the borehole. A toolas disclosed herein is disposed within or as a part of the string.

In a particular embodiment referring tothat illustrates some of the benefits of the disclosure hereof, a gravel pack assemblyincludes a crossover tool, a packer, a first seal bore, a port housing, a second seal bore, and the toolas described above. In the embodiment of assembly, toolis configured with a check valve and a plug as FCUs. The assembly configured as such enables functional benefits not seen in the prior art. Specifically, the assembly may be placed in;

This is beneficial in that a CHECK mode allows confirmation of flow control tool'sselector cycle by application of hydraulic pressure against the check valve; clean fluid returns through Check valve during gravel pack circulation; Pressure can be applied against the check valve post gravel pack, before any tool movement takes place. This ensures that flow does not go the wrong way when tool movement reconfigures flow paths. Further, flow is reduced substantially in the checked direction of check valve or through the plug when closed. A small incidental or intentional leak, e.g. through a weephole, may occur in either CHECK or CLOSED mode.

Also due to the configuration of the indexer that allows for movement in the assemblywith or without something happening to the FCUs, the Crossover Tool can be moved between treatment and reverse positions multiple times while the FCU Tool remains in OPEN mode. This allows fluid flow through the entire assemblyfrom an uphole end to a downhole end. Additionally, this supports moving the flow control toolwithout swabbing fluid from downhole of the assembly. This also supports accurate monitoring of bottomhole pressure using gauges (not shown) that are located uphole of the assembly.

When desired, the assemblymode of operation may be changed from OPEN to CHECK by picking up the crossover toolabove reverse position () and returning the assembly to the treat position ().

After gravel packing is completed through assembly, an upward movement of the crossover toolfrom TREAT () to REVERSE () position cycles the flow control tooldirectly from CHECK to CLOSED.

The reverse position is also easily (automatically) confirmed with hydraulic pressure. Since the flow control toolis put in CLOSED mode before the crossover toolreaches the reverse position, it is reliably ensured that CLOSED mode has been achieved.

Set forth below are some embodiments of the foregoing disclosure:

Embodiment 1: A flow control tool includes a housing, a mandrel disposed in the housing, the mandrel supporting a plurality of discrete flow control units (FCU), and a seal disposed between the housing and the mandrel, the mandrel and housing being movable relative to one another to position the seal in an operative position for one of the plurality of FCUs.

Embodiment 2: The tool as in any prior embodiment, wherein the seal is affixed to the housing and the mandrel moves relative to the seal.

Embodiment 3: The tool as in any prior embodiment, wherein the housing includes a bypass area.

Embodiment 4: The tool as in any prior embodiment, wherein the mandrel includes openings at each axial end of each FCU of the plurality of discrete FCUs communicating an inside diameter flow path of the mandrel to the bypass area.

Embodiment 5: The tool as in any prior embodiment, wherein the openings adjacent a particular FCU of the plurality of discrete FCUs are positioned on opposite axial ends of the seal when the seal is in an operative position for that particular FCU.

Embodiment 6: The tool as in any prior embodiment, wherein the seal is a plurality of seals.

Embodiment 7: The tool as in any prior embodiment, wherein the plurality of seals are positionable relative to the mandrel to render a plurality of the plurality of discrete FCUs in an operative condition.

Embodiment 8: The tool as in any prior embodiment, wherein the plurality of FCUs in an operative condition operate in parallel with one another.

Embodiment 9: The tool as in any prior embodiment, wherein the plurality of FCUs in an operative condition operate in series with one another.

Embodiment 10: The tool as in any prior embodiment, wherein the plurality of discrete FCUs includes at least one of a check valve, a block, a metering nozzle, or a pressure regulator.

Embodiment 11: The tool as in any prior embodiment, further comprising an indexer.

Embodiment 12: A method for managing flow in a borehole includes shifting a mandrel having a plurality of discrete Flow Control Units (FCU) disposed therein into a position relative to a housing where a seal between the housing and the mandrel causes an FCU of the plurality of FCUs to be in an operational position, modifying a flow of fluid by passing the fluid through the FCU, and shifting a different FCU of the plurality of FCUs into an operational position.

Embodiment 13: The method as in any prior embodiment, further including modifying the flow of fluid by passing the fluid through the different FCU.

Embodiment 14: The method as in any prior embodiment, further including bypassing fluid around one of the FCU and the different FCU that is not in the operational position.

Embodiment 15: The method as in any prior embodiment, wherein the seal is a plurality of seals, at least two of the seals being in operational positions for two of the plurality of FCUs.

Embodiment 16: The method as in any prior embodiment, further modifying the fluid flow by passing the fluid through the FCU and the different FCU in parallel.

Embodiment 17: The method as in any prior embodiment, further modifying the fluid flow by passing the fluid through the FCU and the different FCU in series.

Embodiment 18: A gravel pack assembly includes a crossover tool, the tool as in any prior embodiment, connected to the crossover tool, a packer connected to the crossover tool, a first seal bore formed within the packer, a port housing connected to the packer, and a second seal bore connected to the port housing wherein the plurality of FCU's includes a check valve, and a plug, the assembly configured to change directly from check to closed.

Embodiment 19: A method for gravel packing includes operating a gravel pack assembly in an open mode, operating the gravel pack assembly in a check mode, and operating the gravel pack assembly in a closed mode.

Embodiment 20: A borehole system includes a borehole in a subsurface formation, a string in the borehole, and a tool as claimed in any prior embodiment, disposed within or as a part of the string.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms “about”, “substantially” and “generally” are intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” and/or “substantially” and/or “generally” can include a range of ±8% of a given value.

The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a borehole, and/or equipment in the borehole, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc.

While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited.