EP4390055B1 - Vorrichtung und verfahren zur steuerung eines flüssigkeitsstroms - Google Patents

Vorrichtung und verfahren zur steuerung eines flüssigkeitsstroms

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Publication number
EP4390055B1
EP4390055B1 EP23216778.3A EP23216778A EP4390055B1 EP 4390055 B1 EP4390055 B1 EP 4390055B1 EP 23216778 A EP23216778 A EP 23216778A EP 4390055 B1 EP4390055 B1 EP 4390055B1
Authority
EP
European Patent Office
Prior art keywords
pressure
piston
constriction
fluid
fluid flow
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP23216778.3A
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English (en)
French (fr)
Other versions
EP4390055A1 (de
EP4390055C0 (de
Inventor
Christian NOMME
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
InflowControl AS
Original Assignee
InflowControl AS
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Filing date
Publication date
Application filed by InflowControl AS filed Critical InflowControl AS
Priority to EP23216778.3A priority Critical patent/EP4390055B1/de
Publication of EP4390055A1 publication Critical patent/EP4390055A1/de
Priority to PCT/EP2024/085900 priority patent/WO2025125414A1/en
Application granted granted Critical
Publication of EP4390055C0 publication Critical patent/EP4390055C0/de
Publication of EP4390055B1 publication Critical patent/EP4390055B1/de
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/12—Methods or apparatus for controlling the flow of the obtained fluid to or in wells
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B34/00—Valve arrangements for boreholes or wells

Definitions

  • the invention concerns a fluid flow control device for controlling a flow of a fluid between two isolated volumes having a differential pressure therebetween, more specifically a fluid flow control device for providing a constant flow rate of an injection fluid into a well formation independent of changes in the differential pressure between a reservoir pressure and the pressure of the injection fluid inside the pipe.
  • a well for producing hydrocarbons from a subterranean reservoir, or an injection well where pressurized fluids are injected into a well formation to aid in optimizing hydrocarbon extraction from a reservoir may extend through the reservoir or well formation in a number of orientations.
  • reservoirs were accessed by drilling vertical wells. This is simple and straight-forward technique, but one which provides limited reservoir contact per well. Therefore, in order to access more of a reservoir per well, techniques and devices were developed to drill horizontal wells, i.e. turning the well from vertical to horizontal at a predetermined depth below the surface. So-called multi-lateral wells provide even greater access to - and contact with - the reservoir.
  • injection strings are also often drilled in a horizontal orientation for similar reasons.
  • ICDs Inflow Control Devices
  • a production string in a horizontal well comprises a large number of ICDs disposed at regular intervals along its entire length.
  • the ICDs serve as inflow ports for the oil that flows from the reservoir (normally via the annulus between the production string and the well formation) and into the production string, and are ports having a fixed flow area.
  • So-called autonomous ICDs (AICDs) have a variable flow area and comprise one or more valve elements and are normally open when oil is flowing through the device but chokes the flow when and where water and/or gas enters the production string.
  • the annulus between the production string and the well formation is typically divided into zones by zonal isolation packers, e.g. annulus inflatable packers, mechanical packers or swellable packers, which is known in the art.
  • zonal isolation packers e.g. annulus inflatable packers, mechanical packers or swellable packers, which is known in the art.
  • ICDs or autonomous ICDs are then placed in each zone.
  • Injection strings are likewise arranged in a well formation, and the annulus between the injection string and the formation is typically divided into zones by zonal isolation packers.
  • a problem which may exist in longer, highly deviated and horizontal production wells is that non-uniform flow profiles may occur along the length of the horizontal section. This problem may arise because of non-uniform drawdown applied to the reservoir along the length of the horizontal section, because of variations in reservoir pressure, differing permeability of the rock structure along the length of the drill string, fractures in the formation, and/or differing mobility of fluids for example.
  • This non-uniform flow profile may cause numerous problems, e.g., premature water or gas breakthrough and screen plugging and erosion (in sand control wells) and may severely diminish well life and profitability.
  • the same phenomenon applies in reverse and may result in uneven distribution of injection fluids along the length of the injection string, leaving parts of the reservoir un-swept and resulting in loss of recoverable hydrocarbons.
  • the injection fluid may be introduced into the well formation through an outflow control device (OCD).
  • OCD outflow control device
  • Reservoir pressure variations and pressure drop inside the wellbore may cause fluids to be produced (in producer wells) or injected (in injector wells) at non-uniform rates. This may be especially problematic in long horizontal wells where pressure drop along the horizontal section of the wellbore causes maximum pressure drop at the heel of the well causing the heel to produce or accept injection fluid at a higher rate than at the toe of the well. This may cause uneven sweep in injector wells and undesirable early water breakthrough in producer wells. Pressure variations along the reservoir make it even more difficult to achieve an even production/injection profile along the whole zone of interest.
  • the purpose of the present invention is to overcome the shortcomings of the above-mentioned prior art and to obtain further advantages.
  • WO 2017/205670 which discloses a multistage flow control valve system with a pressure balanced first stage connected to one or more downstream, pressure balanced, intermediate and/or outlet stages configured to accommodate very large pressure drops across the system while maintaining a desired flow rate, and avoiding potentially destructive cavitation within the valves.
  • US 2003/041902 which discloses a flow control valve is disclosed having a cylindrical housing having inlet and outlet ends and a central portion there between; a piston slidably disposed within the central portion and having a wall at one end thereof; a piston rod having a base and a top, a filter located within the rod, and a spring surrounding the rod for urging the rod and the piston toward the inlet end; and a flow restrictor through which the rod is able to pass.
  • the invention provides a fluid flow control device which can compensate for the effect of permeability or fracture characteristics of a fluid flow zone.
  • the inventive fluid flow control device comprises a valve that predictably chokes the fluid flow to achieve a predetermined fluid flow rate for a particular differential pressure, for example a device where the valve chokes the fluid flow to the same flow rate for any differential pressure (within a range of expected differential pressures) across the valve.
  • An object of this aspect of the invention is graphically represented by Fig. 3 for the same three zones as shown in Fig. 2 , showing an autonomous outflow control device (AOCD) according to one aspect of the invention achieving the same flow rate for each zone, independent of the differential pressure ( dP ) in each zone.
  • AOCD autonomous outflow control device
  • the fluid flow control device comprises a housing comprising a flow path allowing at least a major part of a fluid to flow from a fluid flow inlet exposed to a first volume at a pressure P 1 to a fluid flow outlet exposed to a second volume at a pressure P 3 , with a differential pressure dP therebetween, where the pressures are static pressures in the volumes.
  • the housing preferably has a longitudinal shape with a first end and a second end, wherein the fluid flow inlet is located at the first end of the housing.
  • the first volume is a source of an injection fluid, with P 1 being the pressure of the injection fluid and the second volume is a well formation, with pressure P 3 being the reservoir pressure.
  • the fluid flow control device further comprises a piston which is longitudinally movable within the housing.
  • a constriction or restrictor body Connected to a first end of the piston is a constriction or restrictor body, for example a conically shaped body, arranged to variably constrict the flow path dependent upon the longitudinal position of the constriction body in relation to a flow path passageway.
  • the constriction body (restrictor) moves relative to a fixed orifice opening that may be the same size or smaller than the inlet.
  • a constricted flow area A f is established in the annular section of the orifice opening that is determined by the longitudinal position x of the constriction body (restrictor) relative to the orifice.
  • the smallest section of the flow path is referred to as the constriction section or constriction point.
  • the piston is longitudinally movable within the housing from a first position where the flow path passageway is relatively open to a second position where the flow path passageway is relatively more constricted (or closed). In one aspect, the piston moves in a direction opposite to the flow direction.
  • the second end of the piston is connected to a piston head exposed to a pressure chamber having a pressure P 2 that is dependent on pressure P 1 .
  • the pressure chamber may be defined as a volume between a distal face of the piston head and the second end of the housing.
  • a proximal face of the piston head may be exposed to a spring chamber defined as a volume between the proximal face of the piston head at one end of the spring chamber and a sealing member at another end of the spring chamber.
  • the spring chamber is exposed to pressure P 3 via one or more spring chamber openings in the housing.
  • pressure P 3 acts upon the proximal face of the piston head, biasing the piston towards the first, more open position, while pressure P 2 in the pressure chamber acts upon the distal face of the piston head biasing the piston towards the second, more constricted position.
  • Openings in the spring chamber housing may be small such that they prevent debris collecting inside the chamber. If the size of the openings is sufficiently small the minor flow path will also create a flow restriction for the transient movement of the piston when displacing the fluid in the spring chamber volume. This in effect functions as a hydraulic dampener and prevents sudden responses or slamming due to pressure spikes and fluid hammers.
  • the piston and constriction body have a throughgoing bore having a bore inlet at the first end of the piston (for example at a tip of the constriction body) in fluid communication with the flow path and a bore outlet at the second end of the piston in fluid communication with the pressure chamber located distal to the second end of the piston.
  • the bore communicates pressure P 1 to the pressure chamber thus achieving pressure P 2 in the chamber.
  • the pressure chamber is sealed with no flow, only pressure communication.
  • Pressure P 2 is then the total pressure or stagnation pressure, dependent upon a static pressure component P 1s and a dynamic pressure component P 1v given from the bore inlet velocity.
  • the dynamic component is related to the geometry of the inlet flow rate. In this case the pressure P 2 is approximately equal to the static pressure in the first volume minus any energy losses through the inlet.
  • the pressure chamber has an outlet with a flow opening large enough to purge particles or contaminants that may accumulate within the chamber, but small enough to sustain a pressure P 2 larger than P 3 .
  • the flow opening will create a secondary flow path between the first volume P1 via the throughgoing bore and the second volume P3, via the pressure chamber as an intermediate volume P2.
  • the device may comprise an elastic or resilient member arranged in the spring chamber between the proximal face of the piston head and the sealing member or other part of the housing, establishing an elastic or resilient coupling therebetween.
  • elastic and “resilient” in this context means being able to be stretched or compressed, and recoil back into shape.
  • the elastic or resilient member biases the piston towards the first, more open position.
  • An example of an elastic or resilient member is a spring.
  • the piston, the housing and the elastic/resilient member are designed such that, when a net force ⁇ F acting on and biasing the piston towards the second position exceeds a minimum threshold F pre the piston, and thus the constriction body, will move in relation to the flow path passageway towards the second, more constricted, position.
  • the threshold in one aspect is at least partly determined by the preload of the spring.
  • the preload may be set in proportion to a predetermined, desired flow rate of the device.
  • the valve will operate at full opening A f _0 with the restrictor in a fixed position until this predetermined, desired rate is reached.
  • the constriction body has a shape whereby the further the piston is moved towards the second position, the smaller the size of an annular area between the constriction body and walls of the flow path passageway or orifice becomes, thereby reducing the effective size of the flow path passageway.
  • the cross-sectional area of the constriction member may increase along the longitudinal direction of the body.
  • the constriction body is generally conical and may comprise a rounded or blunt tip. The further the constriction body is inserted into the flow path passageway, the smaller the effective size of the flow path passageway becomes.
  • the flow path outlet may be arranged at a side of the housing such that the flow path comprises an essentially 90 degrees change of direction.
  • the outlet openings may be radial slots or holes.
  • An effect of outlet arranged in this manner is to slow the velocity to P3 with minimal further effect on the function of the device. Arranging the outlet in this manner may also prevent jetting particles/ erosion from interfering with any filter screen employed with the device.
  • the fluid flow control device may comprise a rear sealing means such as one or more O-rings arranged between the rear end of the piston and an inner surface of the housing, thereby preventing any fluid communication within the housing between the pressure chamber and the spring chamber.
  • a rear sealing means such as one or more O-rings arranged between the rear end of the piston and an inner surface of the housing, thereby preventing any fluid communication within the housing between the pressure chamber and the spring chamber.
  • a spring is chosen with a predefined spring/force characteristic whereby the longitudinal distance that the conical constriction body will move in relation to the flow path passageway is a known quantity for any given differential pressure across the device (in particular the differential pressure between P 1 and P 3 ).
  • the shape of the constriction body is designed such that the constriction body, when moved a first known known distance corresponding to first differential pressure ⁇ P 1 , the constriction body will have a first diameter at that first position that forms an opening in relation to the fixed orifice, with a first annular area of a predetermined size that will result in a specific, first desired flow rate at first differential pressure ⁇ P 1 .
  • the shape of the constriction body is chosen such that when the constriction body is moved a second known distance, corresponding to a second differential pressure ⁇ P 2 the body will have a second diameter at that second position creating a second annular area that produces a second desired flow rate at second differential pressure ⁇ P 2 .
  • the first desired flow rate at first differential pressure ⁇ P 1 is chosen to be the same as the second desired flow rate at second differential pressure ⁇ P 2 then a constant flow rate will be achieved at both differential pressure ⁇ P 1 and differential pressure ⁇ P 2 .
  • the shape of the constriction body is derived according to a formula that calculates a diameter of the conical body that produces a desired flow rate at any given differential pressure within an operating window of expected differential pressures.
  • the desired flow rate is chosen to be generally the same at all differential pressures in the operating window, thereby achieving a constant flow rate.
  • the net force ⁇ F and thereby the distance the constriction body will travel, is calculated based a force balance within the housing, i.e. including the force of the spring, pressures P 1 , P 2 , P 3 as well as other forces such as friction, other forces that may also be present and may be factored into the formula to increase predictability of the distance that the constriction body moves for a given differential pressure.
  • the method of estimating the shape of the constriction body can be expressed as in the following:
  • the expression can be extended to include the spring preload F pre considering the effect of spring preload in the balance which effectively shifts all dependencies.
  • the expression can be further extended to include the forces if known or measured like mechanical friction F F , or other quantifiable known forces in the system that may cause force losses F L .
  • the resilient member is a linear spring following Hooke's law.
  • the force F 1 from the flow on the constrictor body can be expressed as the flow components acting upon the area of the constriction body curvature.
  • the inlet flow state can be described by pressure P 1 T ', static component P 1 s ' , and dynamic component P 1 d ' , is the due to the smaller flow area than the initial first volume P 1 .
  • P 1 T ′ P 1 s ′ + P 1 d ′
  • P 1 s ′ P 1 ⁇ 1 2 ⁇ v ′ 2
  • P 1 d ′ 1 2 ⁇ v ′ 2
  • F 1 can be further refined by adjusting the calculated effective area of the constriction body for each position A r ( x ) with a factor C a , this considers any acceleration of the fluid and change in force close to the orifice, that is also related to the shape (angle, radius) and size (thickness) of the orifice.
  • a r eff x C a ⁇ A r x
  • f ( x ) may be non-linear and is given by the geometry of the inlet in relation to the shape of the construction body and the portion of the dynamic and static flow components acting upon it.
  • F 1 x f x ⁇ P 1 s ′ ⁇ A r x + P 1 d ′ ⁇ A r x
  • the force from the piston F 2 is given from the force balance and can be seen as counteracting the other forces in the opposite direction.
  • the force from the piston F 2 is expressed as the total pressure in the pressure chamber P 2 times the piston area A p . If the pressure chamber is sealed and closed, the total pressure is the stagnation pressure and comprise both the static and dynamic components of the flow state in the inlet, and thereby is equal to the pressure in the volume before the valve if losses in the inlet are omitted.
  • P 2 P 1 s ′ + P ′ 1 d ⁇ P 1
  • P 2 In an embodiment where the chamber is open with a secondary flow path via the throughout bore and a pressure chamber outlet, P 2 must be obtained subtracting the pressure drop from the outmost end of the constriction body and the throughout bore and the pressure drop across the outlet.
  • dro V ( x ) is the change in differential pressure over the valve and this can be expressed relational to elements of the force balance by solving the balance for P 1 - P 3
  • the constriction body moves it changes the effective piston area on both sides of the opening.
  • the area of F 1 increases giving an area of same pressure as in F 2 , this effectively reduces the F 2 area as the force components act in opposite directions.
  • F 3 what is added to the inlet side during the stroke is subtracted from the outlet side.
  • ⁇ A x A p ⁇ A r x
  • a relation can also be established between the differential pressure over the valve and the pressure drop inside the variable flow opening of the valve.
  • the pressure drop caused by flow from the inlet to the smaller variable opening is proportional to the differential pressure across the valve and can be expressed by a constant or term where analytically c is the calculated at or near (vena contracta) the smallest flow section, the factor can be determined via CFD analysis.: dp r x ⁇ c ⁇ dp V x
  • a f x Q 2 2 ⁇ C ⁇ dp r x ⁇ + Q 2 A f _ i 2
  • the shape of the constrictor body is inverse of the calculated variable flow opening A f ( x ) in relation to the fixed orifice, the flow opening is the annular opening between fixed orifice and the constriction body. Or similar the variable flow area is given as the fixed orifice size minus the constriction body.
  • the flow through a variable annular flow opening may differ from the flow through a variable hole, which may also be captured in the correction factor C. Empirically the factor may also capture effects of turbulence losses that may vary depending on the scale of the device to the intended flow rates.
  • constriction body shape is given as the diameter D r ( x ) or radius r r ( x ) for each longitudinal position x, the function r r ( x ) may be axi-symmetric and rotated around the longitudinal axis to create a surface of revolution representing its shape, but of more importance it has a flow area that gives a predictable flow area for each position increment.
  • the mathematical function for the radius of the shape r r ( x ) calculated can be expressed as a square root function of the differential pressure that is scaled and sized by the parameters of the force balance and the flow equation.
  • scaled and sized meaning that the extent of r r ( x ) may be stretched out or have a different rate of change corresponding to the parameters.
  • a change in the factors such as the spring constant may therefore dimensionally extend or contract the curvature or change the change slope of the curvature over position.
  • the general shape is therefore given by the need to change the flow area per linear stroke increment of x if using a spring member with a linear spring characteristic, while all other parameters scale and size this shape.
  • the geometry for the curvature given by the formulae may then be validated and adjusted via CFD analysis which in turn iteratively can adjust the analytical correction factors C: C c , C d c of the mathematical model.
  • CFD analysis may be run for a set of x positions along an initial curvature outputting the force on the different bodies in the analysis. When the sum of forces is 0 manually comparing to the spring force for each position; the geometrical constriction body coincides with the mathematical model. This can be plotted as a Force / Position curve, F / x. If the CFD result does not overlap the spring curve a correction may be added to the mathematical model equal to the difference between the result and the wanted spring force. The correction may be linear or polynomial depending on the shape of the resulting difference.
  • the CFD model also provide an approximation of the largest pressure drop due to the constriction compared to the differential pressure over the valve.
  • the geometry for the curvature given by the formulae is then used to produce actual parts and tested for flow at different pressures to produce a characteristic flow curve that again may produce empirical correction factors in the mathematical model to adjust or be combined with mentioned factors c for dp(x) or C for flow equation or additional factors to density ⁇ or flow Q.
  • the resulting characteristic flow curve dp V / Q curve may have exemplary deviations from the ideal model such and offset from the wanted constant rate, a non-constant rate with a closing or opening behavior.
  • the factors in the mathematical model can be adjusted to coincide with the actual result to iterate a best fit.
  • the permanent energy loss can be estimated via traditional means and tested so that an empirical discharge coefficient may be established for each flow opening geometry.
  • the model can be used directly to produce a shape for other predetermined flow characteristics given by input parameters flow, density and geometry without further analysis and experimental testing as long as the initial factors are determined.
  • the method described estimates the characteristic shape of the constrictor body by the expression r r ( x ) . It is calculated to achieve a constant flow characteristic Q C as function of pressure difference between the third volume P 3 and the second volume P 1 when Q is set to a given function of x or constant value.
  • a fluid flow control device for regulating a fluid flow between a first volume of fluid having a pressure P 1 and a second volume of fluid having a pressure P 3 , comprising a housing having a fluid flow path for at least a major part of the fluid flow from a fluid flow inlet exposed to the first volume via a flow path passageway to a fluid flow outlet exposed to the second volume, wherein the device comprises a piston within the housing having a constriction body connected to a first end of the piston, the piston being movable in relation to the fluid flow path such that the constriction body constricts a flow area of the flow path based upon the movement of the piston, the size of the flow path area being defined as the size of an opening between the constriction body and a constriction point in the fluid flow path, wherein
  • An object of the present invention is to provide an outflow control device that establishes a predefined flow rate for various differential pressures across the device.
  • a predefined flow rate for various differential pressures across the device.
  • One example of such predefined flow rates is shown in Fig 3 , where the same flow rate is chosen for a plurality of differential pressures to which the device will be exposed (for example in connection with introduction of injection fluids into an injection well or a production of fluids in a production well). Where the same flow rate is established for the various differential pressure to which the device is exposed, the device will create a constant flow rate, regardless of the different differential pressures.
  • Fig 4 illustrates alternate objects of the invention, where different flow rates are predefined for different differential pressures, permitting the device to create various flow rate profiles, non-limiting examples of which are illustrated in Fig 4 , showing examples of possible flow curves over an operational window of the device.
  • Fig. 4A shows a flow curve that converges to a constant value independent of differential pressure.
  • Fig 4B shows a flow curve that converges to a constant value independent of differential pressure, then closes at a max dP.
  • Fig. 4C shows a flow curve that converges to a constant value independent of differential pressure, which then restricts to a lower flow regime at a certain limit dP.
  • Fig. 4D shows a flow curve that gradually chokes toward a closed position.
  • Each such profile may have advantages in various situations, and the device of the invention, as discussed in detail below, permits an operator to customize the device to a desired flow profile. Embodiments of the device and aspects of the invention will be described below with respect to a constant flow profile, however one skilled in the art will understand how the following discussion translates to various alternative flow profiles.
  • Figs. 5 and 6 illustrate a preferred embodiment of an outflow control device 10 of the invention.
  • the device 10 regulates a flow Q of a fluid from a first volume 1 to a second volume 2.
  • first volume is a source of a pressurized injection fluid 11 having a pressure P1
  • second volume 2 is a well formation 12 having a pressure P3.
  • pressure P1 is generally constant
  • pressure P3 which may also represent the resistance of the formation to the injection fluid
  • the variable pressures of the well formation may be expressed as P3', P3" etc.
  • the difference between pressure P1 and P3 ( or P3', P3" etc) is a differential pressure that may be referred to as dP or ⁇ P.
  • the device 10 comprises a housing 14 having a first end 20 and a second end 21.
  • Housing 14 in the embodiment shown in Figs. 5 and 6 is an elongated, cylindrical housing, however one skilled in the art can appreciate that other shapes are possible within the scope of the invention.
  • Injection fluid 11 follows a flow path 16 from a flow path inlet 18 located at first end 20 of the housing which is in fluid communication with first volume 1 and exits a flow path outlet 22 which is in fluid communication with second volume 2.
  • Flow path 16 flows at least partly through a flow path passageway 24 bounded by passageway wall or walls 26.
  • constriction body 34 Located within housing 14 is a longitudinally movable piston 28 having a first end 30 and a second end 32. Attached to the first end 30 is a constriction body 34.
  • constriction body 34 is generally conically shaped, however constriction body 34 may have an irregular shape along its length, for purposes which will be describe further below.
  • constriction body 34 will move longitudinally in conjunction with the longitudinal movement of piston 28.
  • Constriction body 34 is arranged to be movable in relation to flow path passageway 24 such that constriction body 34 will constrict the effective size of flow path passageway 24 to a degree of constriction that is dependent upon the longitudinal position of constriction body 34 relative to fluid flow passageway 24 or a fixed orifice 25 in fluid flow passageway 24.
  • constriction body 34 is arranged to progressively insert into fluid flow passageway 24 as piston 28 moves from a first position 36 to a second position 38.
  • constriction body 34 is generally conical
  • an annular opening 40 will be formed between constriction body 34 and passageway walls 26 (or orifice 25) at a constriction point 42, the size of annular opening 40 being determined by the diameter of constriction body 34 presented at constriction point 42 at a given longitudinal position of the constriction body.
  • the size of annular opening 40 will decrease (and the degree of constriction will increase) as constriction body 34 moves progressively from the first position 36 towards the second position 38.
  • the size of annular opening 40 may variably increase or decrease as different diameters of constriction body 34 are presented to constriction point 42 as the constriction body moves from the first position towards the second position.
  • a bore 44 extends through constriction body 34 and piston 28, with a bore inlet 46 arranged at a tip 48 of the constriction body and a bore outlet 50 arranged at the second end of piston 28.
  • a piston head 52 is arranged at the second end of piston 28, piston head 52 having a distal face 54 and a proximal face 56.
  • a pressure chamber 58 is formed between distal face 54 and second end 21 of housing 14. Pressure chamber 58 is in fluid communication with first volume 1 via bore 44. Within pressure chamber 58 is a pressure P2 that is dependent upon pressure P1. Pressure P2 acts upon distal face 54 and biases piston 28 towards second position 38.
  • Housing 14 is arranged such that proximal face 56 of piston head 52 is exposed to pressure P3 from the second volume 2. Pressure P3 act upon proximal face 56 and biases piston 28 towards first position 36.
  • a spring chamber 60 comprising a volume within housing 14 is defined between proximal face 56 and a sealing element 62. Openings 64 are provided in housing 14 to provide fluid communication between volume 2 and spring chamber 60. If sufficiently small, the openings will function as a system damper as well.
  • pressure P3 biases piston 28 towards first position 36 and pressure P2 biases piston 28 towards second position 38
  • dP differential pressure
  • pressure P2 is dependent upon pressure P1
  • dP can also be expressed as a difference between P1 and P3.
  • pressure P2 may be different than pressure P1, despite being directly exposed to pressure P1 via bore 44, due to various factors such as fluid dynamic energy losses in the flow path before and through the inlet, and if the pressure chamber is open also losses through the bore.
  • piston 28 would be biased all the way to the first position 36 if pressure P3 is greater than pressure P2, and be biased all the way towards second position 38 if pressure P2 is greater than pressure P3.
  • the device according to the invention thus comprises an elastic or resilient member 66 such as a spring arranged between proximal face 56 and sealing element 62. Spring 66 biases piston 28 towards first position 36.
  • the longitudinal position of piston 28 within housing 14 is thus dependent upon a balance of forces ⁇ F acting on piston 28, with pressure P2 biasing piston head 52 towards second position 38, and the combination of pressure P3 acting on proximal face 56, pressure against tip 48 and the force of spring 66 biasing piston 28 towards first position 36.
  • the force coefficient of a spring may be known, such as for example a spring that follows Hooke's Law.
  • a spring 66 is chosen with a force profile preselected based on an expected range of differential pressures across the device when in use. The longitudinal distance that piston 28 will move towards second position 38 for the various differential pressures within the range is then calculated. The result of the calculation provides the longitudinal position of constriction body 34 with respect to constriction point 42 for any given differential pressure within the range of expected differential pressures.
  • the invention further comprises providing a constriction body with a shape that will form an effective flow path opening of a predetermined size for a particular differential pressure.
  • a constriction body with a shape that will form an effective flow path opening of a predetermined size for a particular differential pressure.
  • the diameter of a conical constriction body along its length is chosen such that, as the body moves towards the second position as differential pressure increases, predetermined annular opening sizes are formed at various differential pressures.
  • the shape of the constriction body is chosen such that the size of the annular opening that is formed when the constriction body 34 moves a specific distance relative to the constriction point 42 creates a chosen flow rate for a particular differential pressure.
  • the shape of the constriction body is chosen such that a plurality of annular opening sizes is created for a plurality of distances that the constriction body moves in relation to the constriction point, creating a plurality of chosen flow rates for a plurality of particular differential pressures.
  • the shape of the constriction body is chosen so that a chosen flow rate profile/curve is established for a range of differential pressures to which the device is expected to be exposed.
  • Figs 8 and 9 are graphs which plot differential pressure (dP) on the vertical axis, and flow rate (Q) on the horizontal axis.
  • Both figures show three flow rate curves for three different sized openings through which a fluid flow.
  • the three circles represent relative sizes of the three openings, not necessarily the shape of said openings.
  • the three circles could represent annular openings of small, intermediate and large sizes.
  • openings of different sizes have different flow rate curves as differential pressure increases.
  • the shape of these curves can be calculated for a particular fluid flowing through a particular sized opening at various differential pressures.
  • flow rate curves are established for various sized openings for a fluid of interest.
  • the invention provides for creating an opening size in the device that will create chosen flow rates, for example flow rates Q 1 , Q 2 and Q3, for particular differential pressures, for example at one or more particular differential pressures, for example dP 1 dP 2 and dP 2 .
  • the shape of the constriction body 34 may be designed to create a flow rate profile for the device over a range of expected differential pressures.
  • Fig 7 shows an embodiment of the invention having outlet 67 arranged in second end 21 of housing 14, arranged to permit fluid to flow out of pressure chamber 58.
  • Outlet 67 is preferrable sized to permit debris to be evacuated from chamber 59, yet small enough to permit an effective pressure P2 to be established in pressure chamber 58 in order to bias piston 28 towards second position 38.
  • Fig 10 illustrates a non-limiting example of results for a device configured to provide a constant, or generally constant flow rate, compared to a theoretical flow device having a flow path with a fixed flow path opening area (i.e. a theoretical flow path opening that is not varied by a movable constriction body).
  • the flow rates for the device of the invention deviate about a predetermined constant flow rate of 1000 L/HR.
  • Figure 10 can, among other thing, be useful for one skilled in the art to understand the scope of the terms "constant flow rate” or "generally constant”.
  • Such deviations can be the result of many factors, such as model fit to the application, determination of flow factors C and c, actual parameters and geometrical manufacturing tolerances of the parts and spring stiffness tolerance. The sum of these make up the device functional tolerance which is normally set in an acceptable percentage range of the ideal function.
  • Fig 11 shows a simplified CFD analysis plot of the pressure field across a device at a given stroke increment according to the invention.
  • Via input flow Q, and differential pressure over the device other properties can be retrieved.
  • the value of total force Ftot sum of the forces on the piston and constriction body shall equal the spring force.
  • Figs. 12-16 illustrate another aspect of the invention, namely a fluid pipe comprising the device of the invention as described above.
  • This aspect of the invention will be described in relation to an injection fluid pipe for injecting fluids into an injection well, however one skilled in the art can translate the following description to other types of fluid pipes, such as a production string in a producing well.
  • Fig 12-15 shows an outflow control device 10 installed on a fluid pipe 68.
  • the device may be arranged withing an annulus 69 created by a sleeve 70.
  • a sand screen 72 may be connected to the sleeve to prevent debris from interfering with the operation of the device.
  • Fig 15 shows a fluid flowing from the pipe though openings 74 into annulus 69, where the fluid thereafter enters device 10 and exits into the formation at the flow rate established by the shape of the constriction body at various differential pressures. If the profile is chosen as constant flow rate, the device will ensure that the flow rate remains generally the same even if an isolation zone should experience a sudden reduction is pressure/resistance to the injection fluid.

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Geology (AREA)
  • Mining & Mineral Resources (AREA)
  • Physics & Mathematics (AREA)
  • Environmental & Geological Engineering (AREA)
  • Fluid Mechanics (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Flow Control (AREA)

Claims (16)

  1. Vorrichtung (10) zur Steuerung eines Fluidstroms zum Regulieren eines Fluidstroms zwischen einem ersten Fluidvolumen (1, 11), das einen Druck P1 aufweist, und einem zweiten Fluidvolumen (2, 12) das einen Druck P3 aufweist, umfassend ein Gehäuse (14), das einen Fluidströmungsweg (16) für mindestens einen Hauptteil des Fluidstroms von einem Fluidstromseinlass (18), der dem ersten Volumen ausgesetzt ist, über einen Strömungswegdurchgang (24) zu einem Fluidstromsauslass (22), der dem zweiten Volumen ausgesetzt ist, aufweist, wobei die Vorrichtung einen Kolben (28) innerhalb des Gehäuses umfasst, der einen Verengungskörper (34) aufweist, der mit einem ersten Ende (30) des Kolbens verbunden ist, wobei der Kolben in Bezug auf den Fluidströmungsweg bewegbar ist, sodass der Verengungskörper einen Strömungsbereich des Strömungswegs basierend auf der Bewegung des Kolbens verengt, die Größe des Strömungswegbereichs als die Größe einer Öffnung (40) zwischen dem Verengungskörper und einer Verengungsstelle (42) in dem Fluidströmungsweg definiert ist, wobei
    der Verengungskörper eine variable Querschnittsfläche entlang seiner längsgerichteten Länge aufweist, wodurch die Größe der Öffnung (40), die den Strömungsbereich definiert, durch die Längsposition des Verengungskörpers in Bezug auf die Verengungsstelle (42) bestimmt ist,
    der Kolben einen Kolbenboden (52) an einem zweiten Ende (32) des Kolbens aufweist, der Kolbenboden eine distale Seite (54) aufweist, die einer Druckkammer (58) ausgesetzt ist, die Druckkammer in Fluidverbindung mit dem ersten Volumen ist, wodurch in der Druckkammer ein Druck P2 erstellt wird, der von dem Druck P1 abhängt,
    der Kolbenboden eine proximale Seite (56) aufweist, die einer Federkammer (60) ausgesetzt ist, die Federkammer in Fluidverbindung mit dem zweiten Volumen ist, wodurch ein Druck in der Federkammer erstellt wird, der von dem Druck P3 abhängt, die Federkammer ein darin angeordnetes elastisches Element (66) aufweist, das durch die proximale Seite des Kolbenbodens komprimierbar ist,
    der Druck in der Federkammer zusammen mit einer Federkraft von dem elastischen Element, wenn es komprimiert wird, den Kolben vorspannt, und wodurch der Verengungskörper in eine erste Position (36) gebracht wird, wobei der Verengungskörper an Verengungsstelle (42) eine erste Querschnittsfläche zeigt, wodurch eine erste Öffnungsgröße geschaffen wird, und wobei der Druck P2 innerhalb der Druckkammer den Kolben vorspannt, und wodurch der Verengungskörper in eine zweite Position (38) gebracht wird, wobei der Verengungskörper an der Verengungsstelle (42) eine zweite Querschnittsfläche zeigt, wodurch wird eine zweite Öffnungsgröße geschaffen wird, wobei der Längsabstand zwischen der ersten Position und der zweiten Position durch ein Kräftegleichgewicht bestimmt wird, umfassend mindestens einen Differenzdruck zwischen Druck P1 und P3 und die Federkraft des elastischen Elements,
    das elastische Element mit einer vorgewählten Federkraft ausgewählt wird, wodurch eine Vielzahl von Längsabständen, um die sich der Kolben als Reaktion auf eine Vielzahl von erwarteten Differenzdrücken innerhalb eines erwarteten Betriebsfensters von Differenzdrücken bewegt, bekannte Abstände sind,
    die Querschnittsfläche des Verengungskörpers entlang seiner längsgerichteten Länge konfiguriert ist, sodass die erste Öffnungsgröße eine erste vordefinierte Strömungsrate bei einem ersten vorbestimmten Differenzdruck zwischen Druck P1 und P3 erstellt, und die zweite Öffnungsgröße eine zweite vordefinierte Strömungsrate bei einem zweiten vorbestimmten Differenzdruck zwischen Druck P1 und P3 erstellt, und
    wobei die Form der Verengungsvorrichtung konfiguriert ist, um eine Vielzahl von vorbestimmten Öffnungsgrößen (40) zu schaffen, die einer Vielzahl von erwarteten Differenzdrücken innerhalb eines Betriebsfensters von erwarteten Differenzdrücken entsprechen, denen die Vorrichtung ausgesetzt werden soll, wodurch eine Vielzahl vorbestimmter Strömungsraten geschaffen wird, die ein vorbestimmtes Strömungsratenprofil für das Betriebsfenster erstellen.
  2. Vorrichtung zur Steuerung eines Fluidstroms gemäß Anspruch 1, wobei das Gehäuse (14) länglich ist und sich der Kolben in Längsrichtung innerhalb des Gehäuses bewegt.
  3. Vorrichtung zur Steuerung eines Fluidstroms gemäß einem der vorhergehenden Ansprüche, wobei der Kolben (28) und der Verengungskörper (34) eine Durchgangsbohrung (44) umfassen, die einen Durchgang zwischen dem ersten Volumen und der Druckkammer bildet.
  4. Vorrichtung zur Steuerung eines Fluidstroms gemäß einem der vorhergehenden Ansprüche, wobei das Gehäuse (14) ein erstes Ende (20) und ein zweites Ende (21) aufweist, und Druckkammer (58) zwischen dem Kolbenboden (52) und dem zweiten Ende 21 des Gehäuses angeordnet ist.
  5. Vorrichtung zur Steuerung eines Fluidstroms gemäß einem der vorhergehenden Ansprüche, wobei Federkammer (60) als ein Volumen zwischen proximaler Seite (56) und einem Dichtungselement (62) definiert ist.
  6. Vorrichtung zur Steuerung eines Fluidstroms gemäß einem der vorhergehenden Ansprüche, wobei das elastische Element (66) eine Feder ist, die dem Hooke'schen Gesetz folgt.
  7. Vorrichtung zur Steuerung eines Fluidstroms gemäß einem der vorhergehenden Ansprüche, wobei die Federkammer durch eine oder mehrere Öffnungen (64) in dem Gehäuse (14) dem zweiten Volumen ausgesetzt ist.
  8. Vorrichtung zur Steuerung eines Fluidstroms gemäß einem der vorhergehenden Ansprüche, wobei die Druckkammer (58) einen Auslass (67) zu dem zweiten Volumen umfasst.
  9. Vorrichtung zur Steuerung eines Fluidstroms gemäß einem der vorhergehenden Ansprüche, wobei die vorbestimmten Strömungsraten für jeden der erwarteten Differenzdrücke innerhalb des Betriebsfensters generell die gleiche Strömungsrate sind, wodurch ein konstantes Strömungsprofil für das Betriebsfenster erstellt wird.
  10. Vorrichtung zur Steuerung eines Fluidstroms gemäß einem der vorhergehenden Ansprüche, wobei der Verengungskörper eine generell konische Form aufweist, die eine Spitze (48) aufweist, und die Öffnung oder Öffnungen (40) ringförmige Öffnungen in dem Fluidstromdurchgang (24) an der Verengungsstelle (42) ist/sind.
  11. Vorrichtung zur Steuerung eines Fluidstroms nach einem der vorhergehenden Ansprüche, wobei die Verengungsstelle (42) einen Ausgang (25) fester Größe umfasst.
  12. Vorrichtung zur Steuerung eines Stroms gemäß einem der vorhergehenden Ansprüche, wobei die Form des Verengungskörpers gemäß der folgenden Beziehung bestimmt wird, wobei:
    - Q die Strömung von Fluid in Kubikmetern pro Sekunde (m3/s) ist, das in den Gehäuseeinlass eintritt,
    - p die Fluiddichte in Kilogramm pro Kubikmeter ist, die sich aus dem Fluid ergibt, das durch den Körper strömt (kg/m3),
    - x die Entfernung von dem vorderen Ende zu dem vierten Volumen in Metern (m) ist,
    - Af_i die Querschnittsfläche an dem Gehäuseeinlass (5a) in Quadartmetern (m2) ist,
    - A(x) die Veränderung der aktiven Kolbenbereiche mit Position in Quadratmetern (m2) ist,
    - C (Großbuchstaben) ein Korrekturfaktor ist, der den Ausgabekoeffizienten Cd und einen anderen Korrekturfaktor aufgrund der Geometrie Ce umfasst, und
    - df_o die anfängliche Öffnung des Ausgangs in Metern (m) ist
    r r x = d f _ 0 2 − Q 2 2 ⋅ C ⋅ c ⋅ k ⋅ x Δ A x ρ + Q 2 A f _ i 2 π 4 2 .
  13. Vorrichtung zur Steuerung eines Fluidstroms gemäß einem der vorhergehenden Ansprüche, wobei das erste Volumen eine Quelle eines Injektionsfluids (11) umfasst, das zweite Volumen eine Bohrlochformation (12) umfasst, und wobei die Vorrichtung als eine Abströmungssteuerungsvorrichtung konfiguriert ist.
  14. Vorrichtung zur Steuerung eines Fluidstroms gemäß einem der vorhergehenden Ansprüche, wobei das zweite Volumen eine Bohrlochformation (12) umfasst, das erste Volumen ein Ziel für ein Produktionsfluid umfasst, und wobei die Vorrichtung als autonome Einströmungssteuerungsvorrichtung konfiguriert ist.
  15. Autonomes Abströmungssteuerungssystem, umfassend eine Vorrichtung gemäß einem der Ansprüche 1-13, die auf einem Basisrohr montiert ist.
  16. Autonomes Einströmungssteuerungssystem, umfassend eine Vorrichtung gemäß einem der Ansprüche 1-12 oder Anspruch 14, die auf einem Basisrohr montiert ist.
EP23216778.3A 2023-12-14 2023-12-14 Vorrichtung und verfahren zur steuerung eines flüssigkeitsstroms Active EP4390055B1 (de)

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PCT/EP2024/085900 WO2025125414A1 (en) 2023-12-14 2024-12-12 A fluid flow control device and method

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US6408870B1 (en) * 2001-08-31 2002-06-25 Research By Copperhead Hill, Inc. Flow control valve
NO336835B1 (no) * 2012-03-21 2015-11-16 Inflowcontrol As Et apparat og en fremgangsmåte for fluidstrømstyring
US10394254B2 (en) * 2016-05-26 2019-08-27 Sko Flo Industries, Inc. Multi-stage flow control assemblies
US10392931B2 (en) * 2018-01-09 2019-08-27 Rime Downhole Technologies, Llc Hydraulically assisted pulser system and related methods

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