Note: Descriptions are shown in the official language in which they were submitted.
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APPARATUS AND METHOD TO REMOTELY CONTROL FLUID FLOW IN TUBULAR
STRINGS AND WELLBORE ANNULUS
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of United States Provisional
Application No.
61/710,887, filed October 8, 2012.
[0002] This application claims the benefit of United States Provisional
Application No.
61/622,572, filed April 11,2012.
[0003] This application claims the benefit of United States Provisional
Application No.
61/710,823, filed October 8, 2012.
1
BACKGROUND OF INVENTION
1. Technical Field
[0004] This invention is related to tools and methods that are used, for
example, in oil
and gas drilling and completion. The present invention is related, for
example, to a device or
apparatus for controlling fluid flow within a tubular string. In a particular
example, the device or
apparatus is used in the control of fluid flow between a tubular string inner
flow passage and its
annular flow passage in the wellbore by selectively and remotely sending a
command to the
apparatus disposed within wellbore.
2. Discussion of Background
[0005] U.S. Patent Application Publication US20120255741A1 published on
October 11,
2012 for ANNULUAR CIRCULATION VALVE AND METHODS OF USING THE SAME, by
A. Stewart.
[0006] U.S. Patent Application Publication US20110088914A1 published on April
21,
2011 for METHOD OF ACTIVATING A DOWNHOLE TOOL ASSEMBLY, by M. Howell, et
al.
[0007] U.S. Patent Application Publication US20110048723A1 published on March
03,
2011 for MULTI-ACTING CIRCULATING VALVE by J. Edwards.
[0008] U.S. Patent Application Publication US20110088906A1 published on April
21,
2011 for PRESSURE EQUALIZING A BALL VALVE THROUGH AN UPPER SEAL
BYPASS, by T. Myerley.
[0009] U.S. Patent US8327954B2 issued on December 11, 2012 for OPTIMIZED
REAMING SYSTEM BASED UPON WEIGHT ON TOOL, by P. Desai.
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[0010] U.S. Patent US7905292B2 issued on March 15, 2011 for PRESSURE
EQUALIZATION DEVICE FOR DOWNHOLE TOOLS, by C. Beall, et al.
[0011] U.S. Patent US7533728B2 issued on May 19, 2009 for BALL OPERATED
BACK PRESSURE VALVE, by D. Winslow, et at.
[0012] U.S. Patent US752033662, issued on April 21, 2009 for MULTIPLE DART
DROP CIRCULATING TOOL, by M. ModeIli.
[0013] U.S. Patent US7347289B2 issued on March 25, 2008 for DART-OPERATED
BIG BORE BY-PASS VALVE, by P. Lee.
[0014] U.S. Patent US7347288B2 issued on March 25, 2008 for BALL OPERATED BY-
PASS TOOL FOR USE IN DRILLSTRING, by P. Lee.
[0015] U.S. Patent US7334650B2 issued on February 26, 2008 for APPARATUS AND
METHODS FOR DRILLING A WELLBORE USING CASING, by R. Giroux, et al.
[0016] U.S. Patent US6923255B2 issued on August 2, 2005 for ACTIVATING BALL
ASSEMBLY FOR USE WITH A BY-PASS TOOL IN A DRILL TRING, by P. Lee.
[0017] U.S. Patent US6328109B1 issued on December 11, 2001 for DOWNHOLE
VALVE, by R. Pringle, et al.
[0018] U.S. Patent US6289999B1 issued on September 18, 2001 for FLUID FLOW
CONTROL DEVICES AND METHODS FOR SELECTIVE ACTUATION OF VALVES AND
HYDRAULIC DRILLING TOOLS, by C. Dewey, et al.
[0019] U.S. Patent US6148664A issued on November 21, 2000 for METHOD AND
APPARATUS FOR SHUTTING IN A WELL WHILE LEAVING DRILL STEM IN THE
BOREHOLE, by J. Baird.
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[0020] U.S. Patent US5499687A issued on March 19, 1996 for DOWNHOLE VALVE
FOR OIL/GAS WELL,, by P. Lee.
[0021] U.S. Patent US5437308A issued on August 01, 1995 for DEVICE FOR
REMOTELY ACTUATING EQUIPMENT COMPRISING A BEAN-NEEDLE SYSTEM, by P.
Morin, et al.
[0022] U.S. Patent US5318138 issued on June 07, 1994 for ADJUSTABLE
STABILIZER, by C. Dewey, et al.
[0023] U.S. Patent US5048611 issued on September 17, 1991 for PRESSURE
OPERATED CIRCULATING VALVE, by C. Cochran.
[0024] U.S. Patent US4889199 issued on December 26, 1999 for DOWNHOLE VALVE
FOR USE WHEN DRILLING AN OIL AND GAS WELL, by P. Lee.
[0025] U.S. Patent US4655289 issued on April 07, 1987 for REMOTE CONTROL
SELECTOR VALVE, by W. Schoeffler.
[0026] U.S. Patent US4574894 issued on March 11, 1986 for BALL ACTUATED
DUMP VALVE, by R. Jadwin.
[0027] U.S. Patent US4576233 issued on March 18, 1986 for DIFFERENTIAL
PRESSURE ACTUATED VENT ASSEMBLY, by F. George.
[0028] U.S. Patent U.S. Patent US4452313 issued on June 05, 1984 for
CIRCULATION
VALVE, by M. McMahan.
[0029] U.S. Patent US4445571 issued on May 01, 1984 for CIRCULATION VALVE, by
D. Hushbeck.
[0030] U.S. Patent US4072166 issued on February 07, 1978 for VALVE APPARATUS
FOR DEEP DRILLING, by W. Tiraspolsky, et al.
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[0031] U.S. Patent US3552412 issued on January 05, 1971 for DRILL STRING DUMP
VALVE, by D. Hagar, et al.
[0032] U.S. Patent US4058165 issued on August 30, 1938 for TESTING
CIRUCLATING VALVE, by J. Holden.
[0033] U.S. Patent US2128352, issued on October 20, 1936 for METHOD AND
APPARATUS FOR RELEASING FLUID FROM DRILL PIPE, by T. Creighton.
[0034] U.S. Patent 163161 issued on May 11, 1875 for IMPROVEMENT IN
MAINSPRINGS FOR WATCHES, by JOHN A. DAWSON.
[0035] One example of the current invention is to introduce a method and
apparatus for
selectively and remotely controlling fluid flow through a tubular string and
its surrounding
wellbore annulus and, thus, changing the fluid flow profile within wellbore.
In one example, a
fraction or all of the fluid is diverted from within the inner fluid flow
passage of the tubular
string and the apparatus to the wellbore annulus. In one example, the current
invention makes it
possible to control the fluid flow profile in the wellbore and tubular string
and, accordingly,
significantly reduce risks and operating cost associated with cutting beds.
Risks associated with
fluid-losses are caused by various reasons, some of which were explained by
way of examples:
risks associated with accumulation of suspended cuttings, among other
operating risks, where
change of fluid flow profile within the wellbore is desired. In another
example of the current
invention, a method is introduced for remotely operating a downhole apparatus
selectively into a
desired state without limiting other operations, such as flow rate or flow
pressure, during periods
when it is not desired to change fluid flow pattern.
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[0036] U.S. Patent 4,889,199 to Lee discloses a plastic, i.e., deformable ball
used to block
a flow opening in the sleeve for positioning the sleeve and aligning flow
ports. This form of flow
control apparatus is operated using what is called drop ball. A ball is
inserted into the string at
the surface and pumped down the inner flow passage of the tubular string to
engage the sleeve
profile. Such drop ball-operated apparatus often introduces limitations to the
drilling practices,
causing increase in operating cost. For example, the drop ball introduces
restrictions within the
inner flow passage and imposes limitations on running services using wireline
to access, for
example, to run free point services or interact with logging while drilling
equipment located
beneath the drop ball operated apparatus.
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[0037] Another form of flow control apparatus, sometimes called bypass tool or
called
circulation apparatus, defines ports in the apparatus body which are initially
closed by an axially
movable sleeve.
[0038] Other downhole remotely-operated apparatus, such as those in sited
references,
induce limitation in the operating practice since fluid flow properties such
as flow rate or
pressure must to be kept within certain levels to maintain the apparatus in
the corresponding
state. This limitation causes the drilling operation efficiency to suffer as
it may be desirable to
operate the drilling fluid, for example, with a different flow profile, such
as at a different flow
rate or pressure that my undesirably cause the apparatus to change mode.
[0039] What is needed is a way to selectively turn on or off the flow control
device,
locking it in a particular desired fluid flow profile (or "state") when in an
"off' or disabled mode
along with a way to selectively turn "on" the flow control device (into an
"enabled" mode) and
thereby be enabled to change to another desired fluid flow profile (change to
another "state").
To further satisfy this need, what is needed is a way to communicate the
desired mode and
desired state to the flow control device using deliberate changes to the
environment surrounding
the flow control device, such as altering the pressure of the fluid in the
tubular or wellbore in a
predetermined sequence, or using a combination of sensors to discern the
communicated
command. What is further needed is a way to power the actuation of the flow
control device
between the various fluid flow states and power to set the enabled or disabled
mode.
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SUMMARY OF SOME EXAMPLES OF THE INVENTION
[0040] In one example, disclosed is an apparatus for remotely controlling
fluid flow in a
wellbore based on changing the environment in the wellbore, the apparatus
disposed on a tubular
string in the wellbore, the apparatus including: a body, an inner passage
through the body, an
orifice to the inner passage disposed on a lateral side of the body, a valve
having a movable
element, the valve disposed in fluid communication with the inner passage and
the orifice, a
means for actuating the valve element, a means for powering the means for
actuating the valve
element, a means for disabling movement of the valve element, a means for
detecting at least one
change in the environment in the wellbore, a means for decoding the at least
one change in the
environment, wherein the means for disabling movement of the valve element is
responsive to
the means for decoding, and wherein the means for actuating the valve element
is responsive to
the means for decoding.
[0041] In one example, the moveable element is rotatable to a plurality of
predetermined
positions.
[0042] In one example, the plurality of predetermined positions comprises at
least two
predetermined positions selected from the set of predetermined positions
including: restricted
fluid flow through the inner flow passage and restricted flow between the
inner flow passage and
a wellbore annulus through the orifice; fluid flow through the inner flow
passage and restricted
fluid flow between the inner flow passage and a wellbore annulus through the
orifice; fluid flow
communication between a first end of the body and a wellbore annulus and
restricted flow
between a second end of the body and the wellbore annulus; and fluid flow
communication
between the first end of the body and a wellbore annulus and fluid flow
communication between
the second end of the body and the wellbore annulus.
[0043] In one example, the rotatable element comprises at least one surface of
spherical
shape and at least two ports and one cavity.
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[0044] In one example, the detecting means comprises a sensor. In one example,
the
sensor is positioned and arranged in the wellbore environment and configured
to sense at least
one physical property of the environment.
[0045] In one example, the apparatus comprises: at least one means for
detecting a
plurality of intended changes in at least one physical property of the
environment resulting in a
detectable signal within the apparatus for processing the signal.
[0046] In one example, the means for powering comprises an electric generator.
[0047] In one example, the electric generator is an electric generator
positioned and
arranged to receive hydraulic energy from fluid in the tubular string and is
configured to provide
electrical energy to the means for actuating.
[0048] In one example, the electric generator is an electric generator
positioned and
arranged to receive hydraulic energy from a fluid pressure difference between
the inner fluid
passage and the annular fluid passage.
[0049] In one example, the means for powering comprises a means for
transforming
hydraulic energy from fluid in the wellbore.
[0050] In one example, the means for powering comprises an energized resilient
element.
[0051] In one example, the means for actuating comprises an electric motor.
[0052] In one set of examples, disclosed is an apparatus for remotely
controlling fluid
flow in a tubular string 110 and a wellbore annulus 156, the apparatus
including: a body 200
defining the boundaries between an inner flow passage 152 through the
apparatus and an annular
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flow passage 154 within the wellbore annulus 156, the body including: a first
end disposed at
one end of the body, a second end disposed at another end of the body, and at
least one lateral
hole 210 disposed in a side of the body for connecting the inner flow passage
152 and the
annular flow passage 154; a controllable valve 220 disposed in the inner flow
passage 152, the
controllable valve 220 comprising at least one moveable element, and where the
element is
movable to a plurality of predetermined positions, positioned and arranged to
alter fluid flow
between the first end, the second end, and the at least one lateral hole, and
where a
predetermined position of movable element determines a desired altered fluid
flow state of
controllable valve 220; a means for actuating the moveable element into at
least one of the
plurality of predetermined positions; a means for powering the means for
actuating the moveable
element; a means for disabling movement of the moveable element; a means for
detecting at
least one change in at least one physical property in an environmental
condition within the
wellbore; a means for decoding at least one instruction from the at least one
detected change in
the environmental condition; and where the means for disabling movement of the
valve element
is responsive to an instruction of the at least one decoded instruction; and
where the means for
actuating the valve element into the at least one of the plurality of
predetermined positions is
responsive to an instruction of the at least one decoded instruction.
[0053] In one example, the moveable element is rotatable to a plurality of
predetermined
positions.
[0054] In one example, the plurality of predetermined positions comprise at
least two
predetermined positions selected from the set of predetermined positions
including: restricted
fluid flow through the inner flow passage and restricted flow between the
inner flow passage and
the wellbore annulus through the orifice, fluid flow through the inner flow
passage and restricted
fluid flow between the inner flow passage and the wellbore annulus through the
orifice; fluid
flow communication between the first end of the body and the annular flow
passage and
restricted flow between the second end of the body and the annular flow
passage; and fluid flow
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communication between the first end of the body and the annular flow passage
and fluid flow
communication between the second end of the body and the annular flow passage.
[0055] In one example, the moveable element is suitably positioned to cause
the valve
into a at least one state such that the flow pattern will be in one of the
following patterns: (a) no
flow pattern wherein the flow passage between the upstream and the downstream
is restricted
and the flow passage between the inner flow passage and the annular flow
passage is also
restricted; (b) through flow pattern wherein the passage between the upstream
and the
downstream of the inner flow passage is not restricted whereas the passage
between the inner
flow passage and the annular flow passages is restricted; (c) diverted flow
pattern wherein the
flow passage between the upstream and the said annular flow passage is not
restricted whereas
the flow passage to the downstream is restricted; and (d) full flow pattern
wherein the flow
passage between the upstream and the downstream of the inner flow passage is
not restricted and
the flow passage between the said inner flow passage and the annular flow
passages is not
restricted.
[0056] In one example, the means for actuating the moveable element into at
least one of
the plurality of predetermined positions includes an actuation mandrel 246
connected to
actuation linkage 242 attached to push-pull point 308 causing the movable
element to rotate and
change its position. In one example, the means for actuating the moveable
element into at least
one of the plurality of predetermined positions includes a pinion 420
connected to the movable
element and at least one rack 410 connected to an actuation mandrel 246, the
rack 410 and the
pinion 420 engaged to move rack 410 in ascertain direction as the pinion 420
rotates around a
pivot 307. In one example, the means for actuating the moveable element into
at least one of the
plurality of predetermined positions includes an electric motor mechanically
connected to the
moveable element.
[0057] In one example, the means for powering the means for actuating the
moveable
element includes an actuation mandrel 246 attached to a resilient element. In
one example, the
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resilient element is a spring. In one example, the means for powering includes
an energized
spring connected to a pinion through a worm gear. In one example, the means
for powering the
means for actuating the moveable element includes an inertia element 510
disposed within the
actuation mandrel 246 having a mass capable of storing kinetic energy. In one
example, the
means for powering includes an electrical energy source. In one example, the
electrical energy
source is a battery. In one example, the electrical energy source is a
wireline from the surface.
In one example, the electrical energy source is a fluid powered electric
generator. In one
example, the means for powering includes a turbine transforming hydraulic
fluid flowing
through the wellbore. In one example, the means for powering is disposed in
the tubular string.
In one example, the means for powering is disposed in a bottom hole assembly.
[0058] In one example, the means for disabling movement of the moveable
element
includes a locking means. In one example, the means for disabling includes a
lock 277 element
engageable with a locking groove 278 connected to an actuation mandrel 246. In
one example,
the means for disabling includes a lock driver 720 driving a lock 277. In one
example, lock
driver 720 is a motor. In one example, lock driver 720 is a solenoid. In one
example, the means
for disabling includes means for disconnecting electric energy from an
electric motor or
solenoid. In one example, the means for disabling includes a controller
disconnecting electric
energy from an electric motor or solenoid.
[0059] In one example, the means for detecting at least one change in at least
one
physical property in an environmental condition within the wellbore includes a
sensor. In one
example, the means for detecting includes a pressure sensor 272 configured to
sense pressure
variation within the wellbore. In one example, the means for detecting
includes a flow sensor
272 configure to sense variation of fluid flow rate within the wellbore. In
one example, the
means for detecting includes an electrode to sense a change in voltage or
current with respect to
the tubular string 110. In one example, the means for detecting includes an
electrode to sense a
change in voltage or current from an induced electric signal into the
formation. In one example,
the means for detecting includes an accelerometer affected by change of
tubular string 110
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movement. In examples, the accelerometer is configured to sense movement in
one or more
directions. In one example, the means for detecting includes a sensor
configured to sense
magnetic field changes. In one example, the means for detecting includes a
chemical sensor.
[0060] In one example, the means for decoding at least one instruction from
the at least
one detected change in the environmental condition includes a barrel cam track
and cam
follower. In one example, the barrel cam track is disposed on a barrel cam,
the barrel cam
connected to an actuation mandrel. In one example, the means for decoding at
least one
instruction from the at least one detected change in the environmental
condition includes a
controller configured to compare a detected signal pattern to a predetermined
command pattern.
In one example, the controller is an electronic controller. In one example,
the controller is an
electronic computational device.
[0061] In one set of examples, disclosed is an apparatus for remotely
controlling fluid
flow in tubular strings and wellbore annulus, including: (a) a body defining
the boundaries
between an inner flow passage through the said apparatus and an annular flow
passage within the
wellbore annulus and having two suitable end connections and at least one
lateral hole suitable
for connecting the inner flow passage and the annular flow passage; (b) a
controllable valve
operable in plurality of desired states altering fluid flow pattern within a
wellbore, wherein the
valve is having at least one rotatable element having plurality of surfaces,
where the rotatable
element is rotatable to a plurality of desired positions wherein the valve
further divides the inner
flow passage into upstream section and downstream, wherein the upstream
section is the portion
of the inner flow passage from the valve and through one end connection of the
body and the
downstream section is the portion of the inner flow passage from the valve and
through the other
end connection of the body; (c) an activator disposed within the body capable
of selectively
changing the apparatus into either one of two modes: a disabled mode, wherein
the said valve is
not operable, and an enabled mode, wherein the said valve is operable to a
desired state,
comprising a means responsive to an intended change in an environment; and (d)
an actuator
capable of changing the position of the said rotatable element to cause the
valve into a desired
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state comprising a means for transforming a suitably available energy source
into a mechanical
movement.
[0062] In one example, the rotatable element is suitably positioned to cause
the valve into
a at least one state such that the flow pattern will be in one of the
following patterns: (a) no flow
pattern wherein the flow passage between the upstream and the downstream is
restricted and the
flow passage between the inner flow passage and the annular flow passage is
also restricted; (b)
through flow pattern wherein the passage between the upstream and the
downstream of the inner
flow passage is not restricted whereas the passage between the inner flow
passage and the
annular flow passages is restricted; (c) diverted flow pattern wherein the
flow passage between
the upstream and the said annular flow passage is not restricted whereas the
flow passage to the
downstream is restricted; and (d) full flow pattern wherein the flow passage
between the
upstream and the downstream of the inner flow passage is not restricted and
the flow passage
between the said inner flow passage and the annular flow passages is not
restricted.
[0063] In one example, the rotatable element includes at least one surface of
spherical
shape and at least two ports and one cavity.
[0064] In one example, the rotatable element includes at least one cavity.
[0065] In one example, the detecting means comprises a sensor. In one example,
the
sensor is positioned and arranged in the wellbore environment and configured
to sense at least
one physical property of the environment.
[0066] In one example, the apparatus includes: at least one means for
detecting a
plurality of intended changes in at least one physical property of the
environment resulting in a
detectable signal within the apparatus suitable for processing the signal.
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[0067] In one example, the activator includes a suitable controller disposed
within the
said apparatus suitable for processing the signal. In one example, the
suitable controller is
positioned and arranged to receive at least one signal from at least one
detecting means and
configured to interpret the one or more signals and configured to provide at
least one control
instruction to the actuator. In one example, the suitable controller compares
the at least one
signal from at least one detecting means with a predetermined pattern to
determine if the
controllable element state is desired to be changed to a different desired
state. In one example,
the suitable controller signals the actuator to actuate the controllable valve
based on the
comparison of the at least one signal from at least one detecting means with
the predetermined
pattern.
[0068] In one example, the activator further includes a suitable means for
restricting the
change of the valve state when the said apparatus is in the disabled mode, a
means for disabling.
In one example, the suitable means includes controlling power to the actuator.
In one example,
the suitable means includes providing an instruction to actuate a lock.
[0069] In one example, the activator includes a means for restricting the
movement of the
rotatable element when in the said apparatus is in the disabled mode.
[0070] In one example, the actuator includes a means for transforming a
hydraulic energy
from fluid disposed within the wellbore into another form of energy suitable
for changing
position of the rotatable element. In one example, said another form of energy
suitable for
changing position of the rotatable element is electricity.
[0071] In one example the actuator includes a means for transforming a
mechanical
energy from tubular string movement within the wellbore into another form of
energy suitable
for changing position of the rotatable element. In one example, said another
form of energy
suitable for changing position of the rotatable element is electricity.
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[0072] In one example, the actuator includes a means for transforming an
electrical
energy from source on surface through the wellbore into another form of energy
suitable for
changing position of the rotatable element. In one example, said another form
of energy suitable
for changing position of the rotatable element is mechanical energy.
[0073] In one example, the actuator includes a means for transforming an
electrical
energy source disposed within the apparatus into another form of energy
suitable for changing
position of the rotatable element. In one example, said another form of energy
suitable for
changing position of the rotatable element is mechanical energy.
[0074] In one example, the electrical energy source is a battery.
[0075] In one example, the electrical energy source is a suitable electric
generator. In
one example, a suitable electric generator is an electric generator positioned
and arranged to
receive mechanical energy from the tubular string and is configured to provide
electrical energy
to the actuator.
[0076] In one example, the electrical energy source is a suitable electric
generator. In
one example, a suitable electric generator is an electric generator positioned
and arranged to
receive hydraulic energy from fluid in the tubular string and is configured to
provide electrical
energy to the actuator. In one example, a suitable electric generator is an
electric generator
positioned and arranged to receive hydraulic energy from a fluid pressure
difference between the
inner fluid passage and the annular fluid passage.
[0077] In one example, the means for powering includes a means for
transforming
hydraulic energy from fluid in the wellbore.
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[0078] In an example, the actuator includes a means for transforming a
mechanical
energy source disposed within the apparatus into another form of energy
suitable for changing
position of rotatable element.
[0079] In an example, the mechanical energy source is an energized resilient
element.
[0080] In an example, the actuator includes an electric motor.
[0081] In one set of examples, disclosed is a method of remotely and
selectively
controlling an apparatus disposed in a tubular string within a wellbore, the
method including:
disposing in a wellbore a tubular string including an apparatus, the apparatus
including: a body
defining boundaries between an inner flow passage through the said apparatus
and an annular
flow passage within the wellbore annulus and having two suitable end
connections; at least one
controllable element operable in plurality of desired states; an activator
disposed within the body
capable of selectively changing the apparatus into either one of two modes: a
disabled mode
wherein the at least one controllable element is not operable, and an enabled
mode wherein the at
least one controllable element is operable to a desired state, including a
sensor capable of
detecting an intended change in a physical property of an environment; and an
actuator suitable
for changing the at least one controllable element into a desired state;
causing a change in a
physical property of the environment in certain sequence within a specified
period of time
resulting in a detectable pattern at the sensor, the change in a physical
property comprising a
sequence of a plurality of signal variations within a suitable period of time;
comparing the said
detectable pattern with a command pattern to determine if the controllable
element state is
desired to be changed to a different desired state and then causing the
activator to change the
apparatus mode into the suitable mode; and causing the actuator to convert a
suitably available
energy source, causing the at least one controllable element into the
different desired state.
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[0082] In an example, the change in a physical property of the environment is
a
mechanical movement of the apparatus by means of moving the tubular string
causing the
apparatus to move within the wellbore in at least one direction detectable by
the said sensor.
[0083] In an example, the change in a physical property of the environment is
a change
of property of fluid introduced from surface into the wellbore detectable by
the said sensor.
[0084] In an example, the change of physical property includes a change in one
or more
of the following fluid property: pressure, temperature, flow rate, density,
viscosity, color,
composition or another physical change detectable by the said sensor.
[0085] In an example, the change in a physical property of the environment is
a change
of electromagnetic field detectable by the said sensor.
[0086] In an example, the change in a physical property of the environment is
a change
of electric field detectable by the said sensor.
[0087] In an example, the controllable element is a valve.
[0088] In a set of examples, disclosed is a method for remotely and
selectively control
fluid flow in a tubular string and wellbore annulus, the method including:
disposing a tubular
string into a wellbore comprising at least one flow control apparatus, the
apparatus including: a
body defining boundaries between an inner flow passage through the said
apparatus and an
annular flow passage within the wellbore annulus and having two suitable end
connections and at
least one lateral hole suitable for connecting the inner flow passage and the
annular flow
passage; a controllable valve operable in a plurality of desired states
altering the fluid flow
pattern within the wellbore, where the valve includes at least one rotatable
element having
plurality of surfaces, where the rotatable element is rotatable to a plurality
of desired positions,
where the valve further divides the inner flow passage into an upstream
section and a
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downstream section, where the upstream section is the portion of the inner
flow passage from the
valve and through one end connection of the body and the downstream section is
the portion of
the inner flow passage from the valve and through the other end connection of
the body; an
activator disposed within the body capable of selectively changing the
apparatus into either one
of two modes: a disabled mode, where the valve is not operable, and an enabled
mode, where the
valve is operable to a desired state, including a means responsive to an
intended change in the
environment; and an actuator capable of changing the position of the rotatable
element to cause
the valve into a desired state, including a means for transforming a suitably
available energy
source into a mechanical movement; causing a plurality of changes in one or
more physical
property of the environment within a specified period of time resulting in a
detectable pattern at
the sensor comprising a plurality of signal variations within a suitable
period of time; comparing
the detectable pattern with a command pattern to determine if the valve state
is desired to be
changed to a different desired state and then causing the activator to cause
the apparatus mode
into the desired mode; causing the actuator to change the rotatable element
position to cause the
valve into a different state resulting in a change of the fluid flow pattern
by the desired apparatus
into a desired flow pattern.
[0089] In one example, disclosed is method for remotely and selectively
controlling fluid
flow in a tubular string and wellbore annulus, the method including: disposing
a tubular string
into a wellbore comprising at least one flow control apparatus, the apparatus
including: a body,
an inner passage through the body, an orifice disposed on a lateral side of
the body, a valve
having a movable element, the valve disposed in fluid communication with the
inner passage and
the orifice; changing at least one physical property in the environment in the
wellbore; sensing
the change in the at least one physical property in the environment; disabling
movement of the
valve element in response to a predetermined sensed change; enabling movement
of the valve
element in response to a predetermined sensed change; actuating the valve in
response to a
predetermined sensed change when movement of the valve is enabled.
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[0090] In one example, the movable element is positioned and arranged upon
actuation of
the valve into a predetermined position selected form the set of positions
including: restricted
fluid flow through the inner flow passage and restricted flow between the
inner flow passage and
the annular flow passage through the orifice, fluid flow communication through
the inner flow
passage and restricted fluid flow between the inner flow passage and the
annular flow passage
through the orifice; fluid flow communication between the first end of the
body and the annular
flow passage and restricted flow between the second end of the body and the
annular flow
passage; and fluid flow communication between the first end of the body and
the annular flow
passage and flow communication between the second end of the body and the
annular flow
passage
[0100] In one example, disclosed is a method for remotely and selectively
controlling
fluid flow in a tubular string and wellbore annulus, the method including:
disposing a tubular
string into a wellbore comprising at least one flow control apparatus, the
apparatus including: a
body, an inner flow passage through the body, an orifice disposed on a lateral
side of the body, a
valve having a movable element, the element movable to a plurality of
predetermined positions,
the valve disposed in fluid communication with the annular passage and the
orifice; actuating the
moveable element into at least one of the plurality of predetermined
positions; disabling
movement of the moveable element; detecting at least one change in at least
one physical
property in an environmental condition within the wellbore; decoding at least
one instruction
from the at least one detected change in the environmental condition; where
the disabling
movement of the moveable element is responsive to a decoded instruction of the
at least one
decoded instruction; and where the actuating the valve element into the at
least one of the
plurality of predetermined positions is responsive to a decoded instruction of
the at least one
decoded instruction.
[0100a] According to one aspect of the invention, there is provided an
apparatus for
remotely controlling fluid flow in a wellbore based on changing the
environment in the wellbore,
the apparatus disposed on a tubular string in the wellbore, the apparatus
comprising:
a body,
an inner passage through the body,
an orifice to the inner passage disposed on a lateral side of the body,
a valve element having a movable element, the valve element disposed in fluid
communication with the inner passage and the orifice,
a means for actuating the valve element,
a means for powering the means for actuating the valve element,
a means for disabling movement of the valve element,
a means for detecting at least one change in the environment in the wellbore,
a means for decoding the at least one change in the environment, and
wherein the means for disabling movement of the valve element is responsive to
the
means for decoding, and
wherein the means for actuating the valve element is responsive to the means
for
decoding, and
wherein the at least one change in the environment includes a mechanical
movement of
the apparatus by means of moving the tubular string, causing the apparatus to
move within the
wellbore in at least one direction.
[0100b] According to another aspect of the invention, there is provided a
method of remotely and
selectively controlling an apparatus disposed in a string within a wellbore,
the method including:
disposing in a wellbore a string including an apparatus, the apparatus
comprising:
a body;
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Date Recue/Date Received 2020-05-19
at least one controllable element operable in plurality of desired states;
a sensor disposed within the body capable of detecting an intended change in a
physical property of an environment; and
an actuator suitable for changing the at least one controllable element into a
desired state;
causing a change in a physical property of the environment in certain sequence
within a
specified period of time resulting in a detectable pattern at the sensor, the
change in a physical
property comprising a sequence of a plurality of signal variations within a
suitable period of time;
comparing the said detectable pattern with a command pattern to determine if a
controllable element state is desired to be changed to a different desired
state;
causing the actuator to convert a suitably available energy source, causing
the at least one
controllable element into the different desired state; and
wherein the change in a physical property of the environment comprises a
mechanical
movement of the apparatus by means of moving the string, causing the apparatus
to move within
the wellbore in at least one direction detectable by the said sensor.
[0100c] According to yet another aspect of the invention, there is provided a
method for
remotely and selectively controlling fluid flow in a tubular string and
wellbore annulus, the
method comprising:
disposing a tubular string into a wellbore comprising at least one flow
control apparatus,
the apparatus comprising:
a body defining boundaries between an inner flow passage through the said
apparatus and an annular flow passage within the wellbore annulus and having
two suitable end
connections and at least one lateral hole suitable for connecting the inner
flow passage and the
annular flow passage;
a controllable valve operable in a plurality of desired states altering the
fluid flow
pattern within the wellbore,
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wherein the valve includes at least one movable element having plurality
of surfaces,
wherein the movable element is movable to a plurality of desired positions,
wherein the valve further divides the inner flow passage into an upstream
section and a downstream section,
wherein the upstream section is the portion of the inner flow passage from
the valve and through one end connection of the body and the downstream
section is the portion
of the inner flow passage from the valve and through the other end connection
of the body;
a sensor means disposed within the body responsive to an intended change in
the
environment; and
an actuator capable of changing the position of the movable element to cause
the
valve into a desired state, comprising a means for transforming a suitably
available energy
source into a mechanical movement;
causing a plurality of changes in one or more physical property of the
environment within
a specified period of time resulting in a detectable pattern at the sensor
means comprising a
plurality of signal variations within a suitable period of time;
comparing the detectable pattern with a command pattern to determine if a
valve state is
desired to be changed to a different desired state and then causing the
activator to cause an
apparatus mode into a desired mode; and
causing the actuator to change the movable element position to cause the valve
into a
different state resulting in a change of the fluid flow pattern by a desired
apparatus into a desired
flow pattern, and
wherein at least one change in the one or more physical property of the
environment
comprises a mechanical movement of the apparatus by means of moving the
tubular string,
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causing the apparatus to move within the wellbore in at least one direction
detectable by the said
sensor means.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0101] A complete understanding of the present invention may be obtained by
reference
to the accompanying drawings, when considered in conjunction with the
subsequent, detailed
description, in which:
Fig. 1 is a section view of an example of a wellbore drilling system wherein a
plurality of
the fluid flow control apparatus are disposed within drilling tubular string;
Fig. 2 is a section view of a preferred example of the flow control apparatus;
Figs. 3A-3D are detail views of examples of a rotatable moveable element 300;
Fig. 4 is a perspective cutaway view of an example of an actuator in a form of
rack and
pinion;
Fig. 5 is a detail view of an example of an actuator linkage and mechanical
energy
source;
Fig. 6 is a section view of an example of an actuator and energy source
disposed within
the flow control apparatus body;
Figs. 7A1 through 7D1 and 7A2 through 7D2 and 7E are detail views of an
example of a
flow passage caused by having an example rotatable element disposed in
different possible
positions within the valve body, the example rotatable element having a curved
outer surface;
Figs. 8A1 through 8C1 and 8A2 through 8C2 are detail views of an example of a
flow
passage caused by having an example rotatable element disposed in different
possible positions
within the valve body, the example rotatable element is a form of a two ports
rotatable element
comprising a spherical surface and having two ports and one cavity connecting
the two ports;
Figs. 9A1 through 9C1 and 9A2 through 9C2 are detail views of an example of a
flow
passage caused by having an example rotatable element disposed in different
possible positions
within the valve body, the example rotatable element is a form of a
cylindrical shaped rotatable
element having two ports and one cavity connecting the two ports;
Figs. 10A1 through 10C1 and 10A2 through 10C2 and 10A3 through 10C3 are detail
views of an example of a flow passage caused by having an example rotatable
element disposed
in different possible positions within the valve body, the example rotatable
element is a form of a
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three ports rotatable element comprising a spherical surface and having three
ports and one
cavity connecting the three ports;
Figs. 11A, 11B, 11C are section views of an example of the activator when the
flow
control apparatus is in disabled mode (Fig. 11A), and in enabled mode (Fig.
11B and Fig. 11C);
Figs. 12A, 12B, 12C are barrel cam views from different angles of respective
Figs. 12A,
12B, 12C, showing an example cam track profile;
Fig. 13 is a detail view of an example of barrel cam track with a plurality of
track
passages and a plurality of movement levels;
Fig. 14 is a flowchart of the disclosed method describing, in one example, the
steps
suitable for remotely and selectively controlling an apparatus disposed in a
wellbore;
Fig. 15 is a flowchart of the disclosed method describing, in one example, the
steps for
selectively and remotely controlling a flow passage causing desired flow
pattern within a
wellbore;
Fig. 16 is a diagram of an example form of signal pattern comprising a
sequence of signal
variations over a period of time;
Fig. 17 is a diagram of an example form of reference (or command) pattern
comprising a
predetermined set of signal variations within a specific period of time;
Fig. 18 is a diagram of an example form of signal variations within a suitable
period of
time acceptable as matching with the reference/command pattern;
Fig. 19 is a diagram of an example form of detectable pattern of signal
variations within a
suitable period of time having an example form of matching pattern to the
reference/command
pattern;
Figs. 20A, 20B, 20C are detailed perspective cutaway views of an example
embodiment
of a means for transforming hydraulic energy from fluid in the wellbore into
electric energy
source suitable for operating the valve, or, in an example, a mechanical
movement directly into
making a suitable movement of the rotatable element. Fig. 20A is a view of the
apparatus during
no circulation. Fig. 20B is a view of the apparatus during transition between
no circulation and
mud circulation. Fig. 20C is a view of the apparatus during mud circulation;
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Fig. 21 is a section view of another preferred example of the flow control
apparatus 150
comprising plurality of valves; and
Fig. 22 is another section view of another preferred example of the flow
control apparatus
150 comprising plurality of valves.
[0102] For purposes of clarity and brevity, like elements and components will
bear the
same designations and numbering throughout the Figures.
24
[0103-0105] DETAILED DESCRIPTION
[0106] Fig. 1 is a section view of an example of a wellbore 100 drilling
system wherein a
plurality of the fluid flow control apparatus 150 are disposed within drilling
tubular string 110
during well forming operation. Majority of drilling systems used in current
days include a
tubular string 110 composed of a drill bit 120 having a plurality of
perforations 125 located
through the drill bit 120 to allow fluid flow there through. A heavy tubular
with bigger outer
diameter among other equipment such as mud motors or logging while drilling
equipment or
directional drilling control systems, or any combination thereof that is
frequently called bottom
hole assembly 130 connected to the drill bit 120 from one end. Bottom hole
assembly 130 is
normally connected by form of thread from the other end to other tubular
conduit such as drill
pipe 140 connecting the bottom hole assembly 130 to surface. The drill pipe
140 outer diameter
is commonly known to be smaller when compared to the bottom hole assembly 130,
therefore
the annular volume surrounding the drill pipe 140 within the wellbore 100 over
any particular
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length is larger than the annular volume surrounding the bottom hole assembly
130 of equivalent
length within the wellbore 100. Plurality of fluid flow control apparatus 150
disposed within the
wellbore 100 are connected to a portion of the tubular string 110 by a
suitable means normally a
form of thread on each end connection 155 of the flow control apparatus 150.
The wellbore 100
formed into the earth may have a deviated section 180 where the wellbore 100
is not vertical. A
cased hole 185 section is the portion of the wellbore 100 having a tubular of
large diameter
called casing lining the inner side of the wellbore 100 to protect wellbore
100 from damage.
While drilling a deeper section into earth formations an open hole 188 section
of the wellbore
100 is formed. A surface mud pumping system 190 is disposed with most drilling
operations and
includes a drilling fluid tank 194 to store drilling fluid and a pump 192 to
force fluid into the
inner flow passage 152 defined as the inner space within the tubular string
110. Cuttings 170
generated from hole making are carried out through the annular flow passage
154. An annular
flow passage 154 is defined as the space between the inner wall of the
wellbore 100 and the outer
wall of the tubular string 110. Cutting beds 175 are sometimes formed by
accumulation of
cuttings 170 deposited normally at the lower side of wellbore 100 particularly
in deviated section
180 of open hole 188 or cased hole 185 of wellbore 100. Plurality of fractures
160 connected to
wellbore 100 may naturally exist or formed during the drilling operations.
When fractures 160
exist in a wellbore 100, they may act as a passage causing a portion of
drilling fluid to flow into
earth formation causing what is commonly known as losses. When losses are
encountered, well
control is compromised and drilling operation risks and costs are increased.
The flow control
apparatus 150 comprises a valve 220. the said valve 220 further divides the
inner flow passage
152 into upstream 157 section and downstream 159 section where upstream 157
section is
defined as the portion of the inner flow passage 152 from the valve 220 and
through the
upstream 157 end connection 155 of the flow control apparatus 150 and the
downstream 159
section as defined as the portion of the inner flow passage 152 from the valve
220 and through
the downstream 159 end connection 155 of the flow control apparatus 150.
[0107] Fig. 2 is a section view of a preferred example of the flow control
apparatus 150
comprising a body 200 defining the boundaries between an inner flow passage
152 through the
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said apparatus and the annular flow passage 154 within the wellbore annulus
156 and having a
suitable connecting means such as a form of thread to connect the apparatus
body 200 to a
portion of the tubular string 110 through an end connection 155 disposed on
each end connection
155 of the said body 200. One of the end connections is the upstream 157 end
connection 155,
and the other end connection 155 is the downstream 159 end connection 155. The
said body 200
further comprises one or more lateral hole 210 suitable for connecting the
inner flow passage 152
to the annular flow passage 154. The flow control apparatus 150 further
comprises a valve 220.
The valve 220 is the element of the flow control apparatus 150 which allows or
restricts the flow
connectivity between the upstream 157 section, the downstream 159 section, the
inner flow
passage 152 and the lateral hole 210 connecting to the annular flow passage
154. In one example,
valve 220 is composed of a valve housing 225 and a plurality of rotatable
elements. In one
example, valve housing 225 is an integral part of the body 200. In another
example, valve
housing 225 is a separate member element inserted into an inner space of the
body 200. In one
example, a rotatable element 300 is disposed in valve housing 225. The
rotatable element 300 is
suitable to be rotated into a plurality of positions. Each position taken by
the rotatable element
300 causes the valve 220 to be in a state suitable to connect the said flow
passages to establish a
particular flow pattern within the flow control apparatus 150, hence wellbore
100 as will be
explained later when describing Figs. 7, 8, 9 and 10.
[0108] In one example, flow control apparatus 150 further comprises an
actuator 240
capable of transforming a suitably available energy into a mechanical energy
suitable for rotating
the rotatable element 300 into a desired position. By way of example, the
actuator 240 in this
figure is composed of an actuation mandrel 246 disposed within the body 200
and movable with
respect to the body 200. The said actuation mandrel 246 is having an inner
surface that is
forming part of the inner flow passage 152 and is having a flow orifice 280
profile suitable to be
affected by the fluid flowing through the inner flow passage 152. When a fluid
flows through the
actuation mandrel 246 the hydraulic energy from the said fluid flow exerts a
suitable force on the
flow orifice 280 causing the actuation mandrel 246 to move with respect to the
body 200 and
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exert a suitable force on the actuation linkage 242 suitably attached to the
rotatable element 300
push-pull point 308 causing the rotatable element 300 to rotate and change its
position.
[0109] In one example, the actuation mandrel 246 is suitably attached to a
resilient
element such as a spring 244. When the actuation mandrel 246 moves by effect
of hydraulic
energy from fluid flow, it pushes the resilient element in a suitable
direction that causes it to
deform and build strain energy which is stored within the said resilient
element. When the
resilient element is allowed to relax and deform back to the previous shape,
it will release the
said stored strain energy into a mechanical movement that is suitable for the
actuation mandrel
246 to utilize to perform the desired actuation. The above is a demonstration
of the actuator 240
causing a transformation of hydraulic energy from fluid flowing through the
wellbore 100 inner
flow passage 152 to a mechanical energy in the form of actuation mandrel 246
movement. The
above is a further demonstration of the actuator 240 causing a transformation
of mechanical
energy originating from actuation mandrel 246 movement into another form of
energy such as
strain energy stored within a suitable resilient element located within the
apparatus. The spring
244 form of the resilient element is held on the other end by a spring
retainer 254 suitably
maintained in its position by a suitable fastener such as a spring retainer
bolt 256 connecting the
spring retainer 254 to the body 200. The spring 244 form of a resilient
element is located within
the apparatus to keep the actuation mandrel 246 biased in certain direction.
[0110] In one example, the flow control apparatus 150 further comprises an
activator
270. The activator 270 includes a means of detecting a physical change in the
environment using
one or more sensor 272, in one example, disposed within the said apparatus.
The said sensor 272
is capable of being affected by intended change in one or more physical
property of the
environment caused by action initiated on surface by the operator.
[0111] In one example, activator 270 further comprises a locking means to put
the flow
control apparatus 150 into either enabled mode or disabled mode. In the
enabled mode, the
actuator 240 within the said flow control apparatus 150 will be operable,
whereas in the disabled
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mode, the actuator 240 within the said flow control apparatus 150 is
inoperable. In one example,
the locking means comprises a lock 277 element such that when engaged with a
suitable locking
groove 278 suitably connected to the actuation mandrel 246, it will restrict
the movement of one
or more of the actuator 240 elements such as the actuation mandrel 246 and
cause the flow
control apparatus 150 to be in a disabled mode. When the apparatus is in
disabled mode, the
valve 220 is not operable to change its state. When the lock 277 is disengaged
from the locking
groove 278, the actuator 240 disposed within the flow control apparatus 150
will not be restricted
by the lock 277 element and the flow control apparatus 150 will be in enabled
mode and the
valve 220 will be operable into a different state.
[0112] In one example, the activator 270 further comprises a controller 274
suitable to
analyze the signal output of the sensor 272 and compare it to a command
pattern 899 to
determine the desired mode then cause suitable changes within the activator
270, thus providing
a means for decoding signals from one or more sensors. In one example,
controller 274 is an
electronic computational device having interface electronics to the sensor(s)
and memory to store
command pattern 899 and computational instructions to perform the comparison.
In one
example, command pattern is programmable. The said controller 274 comprises a
movement
limiting means to limit the actuation linkage 242 movement and cause it to
stop after a desired
displacement. In one example, the movement limiting means of movement control
comprises a
barrel cam 248 disposed within the body 200 and suitably connected to the
actuation mandrel
246. The said barrel cam 248 comprises a cam track 740 with a profile suitable
for a cam
follower 250 disposed within the body 200 to limit the movement of the barrel
cam 248 travel
between specific predetermined two or more track point such as those explained
in Fig. 13. Any
of the said track point restricts the barrel cam 248 displacement from
movement in one or more
direction. As the barrel cam 248 is suitably connected to the actuation
mandrel 246, when the
flow control apparatus 150 is in enabled mode, the movement of the barrel cam
248 as
determined by the cam follower 250 travelling the cam track 740 causes the
actuation mandrel
246 movement to be restricted between specific desired positions.
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[0113] Figs. 3A-3D are detail views of examples of a rotatable moveable
element 300.
[0114] Fig. 3A is a view of a two ports rotatable element 310 having at least
one
spherically formed surface and having one port 305 on its surface and another
port 305 on its
surface wherein both ports are suitably connected through a cavity within the
rotatable element
300.
[0115] Fig. 3B is a view of a cylindrical rotatable element 320 having at
least one surface
curved in a cylindrical form, and having one port 305 on its surface and
another port 305 on its
surface wherein both ports are suitably connected through a cavity within the
rotatable element
300.
[0116] Fig. 3C is a view of a three ports rotatable element 330 having at
least one form of
a spherical surface and having at least three ports on its surfaces wherein
each port 305 is
suitably connected to another port 305 through a cavity within the rotatable
element 300.
[0117] Fig. 3D is a view of a general form of a possible embodiment of a
rotatable
element 300 having at least one outer surface 340 suitable to engage with one
or more fluid flow
passage such as the inner flow passage 152, upstream 157 section, downstream
159 section and a
lateral hole 210 connecting to the annular flow passage 154.
[0118] Fig. 4 is a perspective cutaway view of an example of an actuator in a
form of
rack and pinion. Actuation linkage 242 causes rotatable element 300 to change
position using a
rack 410 and a pinion 420, where at least one pinion 420 is suitably connected
to the rotatable
element 300 and at least one rack 410 is connected to the actuation mandrel
246 and both the
rack 410 and the pinion 420 are suitably engaged so that when the rack 410
moves in certain
direction the pinion 420 rotates around a suitably located pivot 307.
Engagement between rack
410 and pinion 420 is commonly formed by way of a matching thread however
other forms are
also possible, such as by way of example, a friction surface or a magnetic
coupling. In this figure
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the valve 220 is composed of a valve housing 225 located inside the body 200
and the rotatable
element 300 is in the form of three ports rotatable element 330 explained
earlier.
[0119] Fig. 5 is a detail view of an example of an actuator linkage and
mechanical energy
source. Actuation linkage 242 is configured, positioned, and arranged to cause
rotatable element
300 to change position. In this figure, movement of the actuation mandrel 246
in a suitable
direction causes the actuation linkage 242 to exert a suitable force on a push-
pull point 308
causing the rotatable element 300 to change position. An inertia element 510
is disposed within
the actuation mandrel 246 having a suitable mass capable of storing kinetic
energy in proportion
to its mass and speed of movement.
[0120] When the tubular string 110 moves in certain direction, such as when
moved
along the wellbore 100 axis by pulling in the direction out of wellbore 100 to
earth surface or
lowering it deeper into earth through the wellbore 100, the flow control
apparatus 150 follows
the same movement as it is rigidly connected at its end connection 155 through
a form of thread
to a portion of the tubular string 110 and causing elements disposed within
the flow control
apparatus 150 to follow the same movement as the tubular string 110. The
inertia element 510
will store kinetic energy in proportion to its mass and to its movement speed
and accordingly to
the movement speed of the tubular string 110. When tubular string 110 movement
changes, the
inertia element 510 will lag the change of movement in time before it follows
the new movement
of the tubular string 110, due to its stored kinetic energy. When the flow
control apparatus 150 is
in enabled mode, the change of energy stored in inertia element 510 due to
change in tubular
string 110 movement can cause movement of the actuation mandrel 246 in a
suitable direction,
causing the rotatable element 300 to change position In one example, in the
case when the
tubular string 110 is lowered into earth formation and then stops, a change of
movement occurs.
The kinetic energy stored within the inertia element 510 will cause inertia
element 510 to
continue movement in the original direction if the flow control apparatus 150
is in enabled mode.
In one example, this movement is transformed into a mechanical movement to
cause the change
of rotatable element 300 position. In one example, inertia element 510
represents an energy
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source disposed within the actuator 240 having a means of transforming
mechanical energy from
tubular string 110 movement within the wellbore 100 into mechanical energy
capable of
operating the said valve 220.
[0121] Fig. 6 is a section view of an example of an actuator and energy source
disposed
within the flow control apparatus body. In this example, actuator 240 includes
an electric motor
620 as means of transforming a suitably available electrical energy source
into a mechanical
energy capable of changing the position of the rotatable element 300 by means
of linkage in the
form of a suitable gear engagement such as worm gear 610 and pinion 420. When
the suitable
electric energy source is connected to the electric motor 620, electric motor
620 causes the worm
gear 610, connected to the electric motor 620 output, to adequately rotate the
pinion 420 that is
suitably connected to the rotatable element 300 around the pivot 307, as a
result changing the
rotatable element 300 position. In this figure, in one example, an alternative
energy source is
disposed within the said apparatus in a form of an energized resilient element
as means of
mechanical energy source disposed within the apparatus. An energized spring
630, in one
example, such as a strained coiled spring 244 or other form of strained
resilient element, is
suitably connected to the pinion 420 by means of a suitable linkage such as a
worm gear 610.
[0122] When the flow control apparatus 150 is enabled, stored mechanical
energy
disposed within the energized spring 630 that is allowed to relax to a less
strained state by
releasing strain energy into mechanical movement, causing the worm gear 610 to
adequately
move the pinion 420 that is suitably connected to the rotatable element 300
around the pivot 307
and, as a result, changing the rotatable element 300 position. The example
explained above of
strain energy stored in a resilient element is similar to the energy stored in
a watch winding
spring explained by Dawson in U.S. Patent 163161, issued May 11, 1875.
[0123] In one example, a means of transforming mechanical energy source
disposed
within the said apparatus in a form of and energized resilient element is
explained. In one
example, a means of transforming electrical energy source disposed within the
said apparatus is a
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form of electric motor. The electric motor 620 is suitable for transforming an
electrical energy
from a suitable electrical energy source disposed within the flow control
apparatus 150 in a form
of suitable battery 276 or an electric generator.
[0124] In one example, an electric generator is in the form of a turbine,
transforming
hydraulic fluid flowing through the wellbore 100 into electrical power as a
source to be used
directly or stored in a form of electrical storage such as rechargeable
battery 276 or a capacitor.
In one example, the electrical energy source is disposed within the tubular
string 110 or, in
another example, in the bottom hole assembly 130. In one example, the
electrical energy source
is on surface in a form of battery 276 or, in another example, from an
electric line from domestic
energy source or, in another example, from a drilling system electric
generator. In one example,
electrical energy sources not disposed within the flow control apparatus 150
are connected to the
said apparatus actuator 240 by a connecting means such as wireline cable
commonly used for
wireline services in the oil well, made by companies such as Schlumberger or
Halliburton, and
other electric wireline service providers.
[0125] Figs. 7A1 through 7D1 and 7A2 through 7D2 and 7E are detail views of an
example of a flow passage caused by having an example rotatable element
disposed in different
possible positions within the valve body, the example rotatable element having
a curved outer
surface. In this example, valve 220 is presented in different states by way of
presenting the
rotatable element 300 in different positions. The valve 220 is capable of
forming one of more
possible flow passage 700.
[0126] Fig. 7A1 is a section view and Fig. 7A2 is a perspective cutaway view
of the
valve 220 in one state where the rotatable element 300 is in a position such
that it restricts flow
passage between the inner flow passage 152 and the annular flow passage 154 by
way of
aligning the outer surface 340 to obstruct flow passage between the inner flow
passage 152 and
the lateral hole 210. The rotatable element 300 in this position further
restrict flow passage
within the inner flow passage 152 between the upstream 157 section and
downstream 159 section
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passages by way of aligning the outer surface 340 to obstruct the inner flow
passage 152 between
the upstream 157 section and downstream 159 section. These figures demonstrate
the "no flow"
pattern wherein the flow passage between the upstream 157 section and the
downstream 159
section is restricted and the flow passage between the inner flow passage 152
and the annular
flow passage 154 is also restricted.
[0127] Fig. 7B1 is a section view and Fig. 7B2 is a perspective cutaway view
of the valve
220 in one state where the rotatable element 300 is in a position such that it
restricts flow passage
between the inner flow passage 152 and the annular flow passage 154 by way of
aligning the
outer surface 340 to obstruct the flow passage between the inner flow passage
152 and the lateral
hole 210. The rotatable element 300 in this position does not restrict flow
passage within the
inner flow passage 152 between the upstream 157 section and downstream 159
section by way of
aligning the outer surface 340 such that the inner flow passage 152 between
the upstream 157
section and downstream 159 section is not obstructed. These figures
demonstrate the "through
flow" pattern 705 wherein the passage between the upstream 157 section and the
downstream
159 section of the inner flow passage 152 is not restricted whereas the
passage between the inner
flow passage 152 and the annular flow passages is restricted.
[0128] Fig. 7C1 is a section view and Fig. 7C2 is a perspective cutaway view
of the valve
220 in one state where the rotatable element 300 is in a position such that
one portion of the
inner flow passage 152 is connected with the annular flow passage 154 by way
of aligning the
outer surface 340 such that it does not obstruct flow passage between one
portion of the inner
flow passage 152 and the annular flow passage 154 through the lateral hole
210. The rotatable
element 300 in this position further restricts flow passage within the inner
flow passage 152
between the upstream 157 section and downstream 159 section passages by way of
aligning the
outer surface 340 such that the inner flow passage 152 between the upstream
157 section and
downstream 159 section is obstructed. These figures demonstrate the diverted
flow pattern 710
wherein the flow passage between the upstream 157 section and the annular flow
passage 154 is
not restricted whereas the flow passage to the downstream 159 section is
restricted.
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[0129] Fig. 7D1 is a section view and Fig. 7D2 is a perspective cutaway view
of the
valve 220 in one state where the rotatable element 300 is in a position such
that the inner flow
passage 152 is connected with the annular flow passage 154 through the lateral
hole 210 by way
of aligning the rotatable element 300 outer surface 340 such that it does not
obstruct flow
passage between the inner flow passage 152 and the lateral hole 210. The
rotatable element 300
in this position further does not restrict flow passage within the inner flow
passage 152 between
the upstream 157 section and downstream 159 section by way of aligning the
outer surface 340
such that the inner flow passage 152 between the upstream 157 section and
downstream 159
section is not obstructed. These figures demonstrate the full flow pattern 715
wherein the flow
passage between the upstream 157 section and the downstream 159 section of the
inner flow
passage 152 is not restricted and the flow passage between the inner flow
passage 152 and the
annular flow passages is also not restricted.
[0130] Fig. 7E shows a perspective view of an example of rotatable element 300
having a
crescent-moon shape about an intended axis of rotation, forming a three-
dimensional prism body
in the longitudinal direction along this intended axis of rotation. In one
example, a portion of the
element having a cylindrical surface is sufficient.
[0131] Figs. 8A1 through 8C1 and 8A2 through 8C2 are detail views of an
example of a
flow passage caused by having an example rotatable element disposed in
different possible
positions within the valve body, the example rotatable element is a form of a
two ports rotatable
element comprising a spherical surface and having two ports and one cavity
connecting the two
ports. In this example, valve 220 is presented in different states by way of
showing the rotatable
element 300 in different positions. In these figures, the rotatable element
300 is in the form of
two ports rotatable element 310.
[0132] Fig. 8A1 is a section view and Fig. 8A2 is a perspective cutaway view
of the
valve 220 in one state where the rotatable element 300 is in a position such
that it restricts flow
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passage between the inner flow passage 152 and the annular flow passage 154 by
way of
aligning the outer surface 340 to obstruct the flow passage between the inner
flow passage 152
and the lateral hole 210. The rotatable element 300 in this position does not
restrict flow passage
within the inner flow passage 152 between the upstream 157 section and
downstream 159 section
by way of aligning the outer surface 340 such that the inner flow passage 152
between the
upstream 157 section and downstream 159 section is not obstructed. This figure
demonstrate the
through flow pattern 705 wherein the passage between the upstream 157 section
and the
downstream 159 section of the inner flow passage 152 is not restricted whereas
the passage
between the inner flow passage 152 and the annular flow passages is
restricted.
[0133] Fig. 8B1 is a section view and Fig. 8B2 is a perspective cutaway view
of the valve
220 in one state where the rotatable element 300 is in a position such that
one portion of the
inner flow passage 152 is connected with the annular flow passage 154 by way
of aligning the
outer surface 340 such that it does not obstruct flow passage between one
portion of the inner
flow passage 152 and the annular flow passage 154 through the lateral hole
210. The rotatable
element 300 in this position further restrict flow passage within the inner
flow passage 152
between the upstream 157 section and downstream 159 section passages by way of
aligning the
outer surface 340 to such that the inner flow passage 152 between the upstream
157 section and
downstream 159 section is obstructed. These figures demonstrate the diverted
flow pattern 710
wherein the flow passage between the upstream 157 section and the annular flow
passage 154 is
not restricted whereas the flow passage to the downstream 159 section is
restricted.
[0134] Fig. 8C1 is a section view and Fig. 8C2 is a perspective cutaway view
of the valve
220 in one state where the rotatable element 300 is in a position such that
the inner flow passage
152 is connected with the annular flow passage 154 through the lateral hole
210 by way of
aligning the rotatable element 300 outer surface 340 such that it does not
obstruct flow passage
between the inner flow passage 152 and the lateral hole 210. The rotatable
element 300 in this
position further does not restrict flow passage within the inner flow passage
152 between the
upstream 157 section and downstream 159 section passages by way of aligning
the outer surface
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340 such that the inner flow passage 152 between the upstream 157 section and
downstream 159
section is not obstructed. These figures demonstrate the full flow pattern 715
wherein the flow
passage between the upstream 157 section and the downstream 159 section of the
inner flow
passage 152 is not restricted and the flow passage between the inner flow
passage 152 and the
annular flow passages is not restricted.
[0135] Figs. 9A1 through 9C1 and 9A2 through 9C2 are detail views of an
example of a
flow passage caused by having an example rotatable element disposed in
different possible
positions within the valve body, the example rotatable element is a form of a
cylindrical shaped
rotatable element having two ports and one cavity connecting the two ports. In
this example,
valve 220 is presented in different states by way of showing the rotatable
element 300 in
different positions. In these figures, the rotatable element 300 is in the
form of a cylindrical
shaped rotatable element 300.
[0136] Fig. 9A1 is a section view and Fig. 9A2 is a perspective cutaway view
of the
valve 220 in one state where the rotatable element 300 is in a position such
that it restricts flow
passage between the inner flow passage 152 and the annular flow passage 154 by
way of
aligning the outer surface 340 to obstruct the flow passage between the inner
flow passage 152
and the lateral hole 210. The rotatable element 300 in this position does not
restrict flow passage
within the inner flow passage 152 between the upstream 157 section and
downstream 159 section
by way of aligning the outer surface 340 such that the inner flow passage 152
between the
upstream 157 section and downstream 159 section is not obstructed. These
figures demonstrate
the "through flow" pattern 705 wherein the passage between the upstream 157
section and the
downstream 159 section of the inner flow passage 152 is not restricted whereas
the passage
between the inner flow passage 152 and the annular flow passages is
restricted.
[0137] Fig. 9B1 is a section view and Fig. 9B2 is a perspective cutaway view
of the valve
220 in one state where the rotatable element 300 is in a position such that
one portion of the
inner flow passage 152 is connected with the annular flow passage 154 by way
of aligning the
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outer surface 340 such that it does not obstruct flow passage between one
portion of the inner
flow passage 152 and the annular flow passage 154 through the lateral hole
210. The rotatable
element 300 in this position further restrict flow passage within the inner
flow passage 152
between the upstream 157 section and downstream 159 section passages by way of
aligning the
outer surface 340 to such that the inner flow passage 152 between the upstream
157 section and
downstream 159 section is obstructed. These figures demonstrate the "diverted
flow" pattern
710 wherein the flow passage between the upstream 157 section and the annular
flow passage
154 is not restricted whereas the flow passage to the downstream 159 section
is restricted.
[0138] Fig. 9C1 is a section view and Fig. 9C2 is a perspective cutaway view
of the valve
220 in one state where the rotatable element 300 is in a position such that
the inner flow passage
152 is connected with the annular flow passage 154 through the lateral hole
210 by way of
aligning the rotatable element 300 outer surface 340 such that it does not
obstruct flow passage
between the inner flow passage 152 and the lateral hole 210. The rotatable
element 300 in this
position further does not restrict flow passage within the inner flow passage
152 between the
upstream 157 section and downstream 159 section passages by way of aligning
the outer surface
340 such that the inner flow passage 152 between the upstream 157 section and
downstream 159
section is not obstructed. These figures demonstrate the -full flow" pattern
715 wherein the flow
passage between the upstream 157 section and the downstream 159 section of the
inner flow
passage 152 is not restricted and the flow passage between the inner flow
passage 152 and the
annular flow passages is not restricted.
[0139] Figs. 10A1 through 10C1 and 10A2 through 10C2 and 10A3 through 10C3 are
detail views of an example of a flow passage caused by having an example
rotatable element
disposed in different possible positions within the valve body, the example
rotatable element is a
form of a three ports rotatable element comprising a spherical surface and
having three ports and
one cavity connecting the three ports. In this example, valve 220 is presented
in different states
by way of showing the rotatable element 300 in different positions. In these
figures, the rotatable
element 300 is in the form of a three ports rotatable element 330.
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[0140] Fig. 10A1 is a section view and Fig. 10A2 is a perspective cutaway view
and Fig.
10A3 is an exploded view of the valve 220 in one state where the rotatable
element 300 is in a
position such that it restricts flow passage between the inner flow passage
152 and the annular
flow passage 154 by way of aligning the outer surface 340 to obstruct the flow
passage between
the inner flow passage 152 and the lateral hole 210. The rotatable element 300
in this position
does not restrict flow passage within the inner flow passage 152 between the
upstream 157
section and downstream 159 section by way of aligning the outer surface 340
such that the inner
flow passage 152 between the upstream 157 section and downstream 159 section
is not
obstructed. These figures demonstrate the through flow pattern 705 wherein the
passage
between the upstream 157 section and the downstream 159 section of the inner
flow passage 152
is not restricted whereas the passage between the inner flow passage152 and
the annular flow
passages is restricted.
[0141] Fig. 10B1 is a section view and Fig. 10B2 is a perspective cutaway view
and Fig.
10B3 is an exploded view of the valve 220 in one state where the rotatable
element 300 is in a
position such that one portion of the inner flow passage 152 is connected with
the annular flow
passage 154 by way of aligning the outer surface 340 such that it does not
obstruct flow passage
between one portion of the inner flow passage 152 and the annular flow passage
154 through the
lateral hole 210. The rotatable element 300 in this position further restrict
flow passage within
the inner flow passage 152 between the upstream 157 section and downstream 159
section
passages by way of aligning the outer surface 340 to such that the inner flow
passage 152
between the upstream 157 section and downstream 159 section is obstructed.
These figures
demonstrate the diverted flow pattern 710 wherein the flow passage between the
upstream 157
section and the annular flow passage 154 is not restricted whereas the flow
passage to the
downstream 159 section is restricted.
[0142] Fig. 10C1 is a section view and Fig. 10C2 is a perspective cutaway view
and Fig.
10C3 is an exploded view of the valve 220 in one state where the rotatable
element 300 is in a
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position such that the inner flow passage 152 is connected with the annular
flow passage 154
through the lateral hole 210 by way of aligning the rotatable element 300
outer surface 340 such
that it does not obstruct flow passage between the inner flow passage 152 and
the lateral hole
210. The rotatable element 300 in this position further does not restrict flow
passage within the
inner flow passage 152 between the upstream 157 section and downstream 159
section passages
by way of aligning the outer surface 340 such that the inner flow passage 152
between the
upstream 157 section and downstream 159 section is not obstructed. These
figures demonstrate
the full flow pattern 715 wherein the flow passage between the upstream 157
section and the
downstream 159 section of the inner flow passage 152 is not restricted and the
flow passage
between the inner flow passage 152 and the annular flow passages is not
restricted.
[0143] Figs. 11A, 11B, 11C are section views of an example of the activator
when the
flow control apparatus is in disabled mode (Fig. 11A), and in enabled mode
(Fig. 11B and Fig.
11C). In this example, a locking means causes flow control apparatus 150 into
enabled mode or
disabled mode. The locking means provides an example of a means for disabling
movement of
the moveable element 300. By way of example, the locking means comprises at
least two
elements. One element is a lock 277 element and the other element is a locking
profile such as a
locking groove 278. One of the elements is disposed in a suitable location
within the body 200
and the other element is disposed within a suitable location within an
actuator 240 element. The
lock 277 is further movable between at least two positions by means of a lock
driver 720 suitable
to change the lock 277 position from one position to another.
[0144] Fig. 11A is a section view of the lock 277 engaged with the locking
groove 278.
[0145] Fig. 11B is a view of the lock 277 disengaged from the locking groove
278, and
Fig. 11C is a view of the lock 277 disengaged from the locking groove 278 and
the actuation
mandrel 246 moved to a different position. The lock 277 viewed in these
figures is caused to
change position by a suitable lock driver 720. The lock driver 720, in one
example, is a suitable
solenoid. In another example, the lock 277 viewed these figures is driven by
lock driver 720 in a
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form of a suitable motor. It is understood that the lock 277 can be driven by
other suitable lock
driver 720 to cause it to move between at least two positions such that, in
one position the lock
277 is disengaged from the locking groove 278, and in another position the
lock 277 is suitably
engaged the locking groove 278.
[0146] In one example, when a suitable electric charge is connected to the
solenoid, the
solenoid becomes energized causing the lock 277 to retract into the body 200
and the lock 277 is
caused to disengage away from the locking groove 278 causing the flow control
apparatus 150
into enabled mode. The solenoid is operable such that when energized with a
different charge the
lock 277 is caused to extend into the inner wall of the body 200 and is caused
to be suitably
engaged with the locking groove 278 causing the flow control apparatus 150
into a disabled
mode.
[0147] In one example, the same function made by the solenoid means of lock
driver 720
is achieved by a suitable motor or, in another example, by another suitable
means, to cause the
lock 277 to change position. When the lock 277 is engaged with the suitable
locking groove 278
disposed within the actuation mandrel 246, it restricts the movement of the
actuation mandrel
246, therefore restricting the movement of the actuation linkage 242. The
movement of the
rotatable element 300 is therefore restricted and the valve 220 is restricted
from changing its
state and is not operable into a different state.
[0148] The flow control apparatus 150 is said to be in disabled mode when the
valve 220
is not operable to a different state. When the lock 277 is disengaged from the
locking groove
278, the actuator 240 mandrel disposed within the flow control apparatus 150
will not be
restricted by the lock 277 element and the flow control apparatus 150 will be
in enabled mode
and the valve 220 will be operable into a different state. The flow control
apparatus 150 is said
to be in enabled mode when the valve 220 is operable to a different state. The
locking means
explained is by way of example.
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[0149] In another example of the lock 277 means is explained; in a different
example of
the actuator 240 such as the example shown in Fig. 6, where the actuator 240
comprises a
suitable electric motor 620 is achieved by disconnecting the electric source
form the electric
motor 620 causing the electric motor 620 to be inoperable and accordingly the
rotatable element
300 is restricted from changing position by means of the gear arrangement
where the worm
engaged with the pinion 420 act as a break when the worm gear 610 is not
rotatable, and the flow
control apparatus 150 is then said to be in the disabled mode. When the
electric motor 620 is
connected to the suitable electric energy source, it rotates in certain
direction causing the worm
gear 610 to rotate and resulting in a change of the rotatable element 300
position and the valve
220 is operable into a different state and the flow control apparatus 150 is
said to be in enabled
mode.
[0150] Figs. 12A, 12B, 12C are barrel cam views from different angles of
respective
Figs. 11A, 11B, 11C, showing an example cam track profile. In one example,
bane! cam 248
(originally shown in Fig. 2) viewed from different angles in details (Figs.
11A, 11B, 11C), shows
an example cam track 740 profile. The barrel cam 248 comprises a suitable cam
track 740
disposed on a curved surface having plurality of stop points. A cam follower
250 suitably
disposed within the apparatus such that the cam follower 250 and the barrel
cam 248 are
movable to each other wherein either the cam follower 250 or the barrel cam
248 is restricted
from moving in at least one direction with respect to the body 200.
[0151] In one example, the cam follower 250 in Fig. 2 is not movable with
respect to the
body 200 main axis that is parallel to the wellbore 100 axis, while the barrel
cam 248 in Fig. 2 is
movable with respect to the cam follower 250 when the actuation mandrel 246
moves within the
body 200. The cam track 740 comprises at least one stop point 794 such that
when the cam
follower 250 traverses the cam track 740 in a traverse direction 725 and
passes a stop point 794,
the cam follower 250 will be restricted from traversing the cam track 740 in
the opposite
direction by restriction means such as a step within the cam track 740. In
this example, while the
barrel cam 248 is moving relative to the body 200, the cam follower 250
traverse the track in the
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traverse direction 725 from track point 1 (755) to track point 2 (760) then to
track point 3 (765)
then to track point 4 (770) and then continue traversing the cam track 740 to
reach the starting
track point 1 (755). Throughout the barrel cam 248 movement is controlled by
the cam track 740
profile and the cam follower 250, the axial and rotational movement of the
barrel cam 248
suitably mounted on the actuation mandrel 246 result in a controlled movement
of the actuation
mandrel 246.
[0152] Fig. 13 is a detail view of an example of a barrel cam track with a
plurality of
track passages and a plurality of movement levels In this example, cam track
740 is shown as
having multiple paths, in this example, showing an upper track 750 and a lower
track 752. In
one example, each of the upper track 750 and the lower track 752 has at least
one stop point 794
suitably located onto the cam track 740 to cause the cam follower 250
traversing the cam track
740 to have a plurality of possible combinations of sequence of stop points.
Continuing with this
example, in one path, the cam follower 250 traverses the upper track 750
starting from track
point 1 (755) then track point 2 (760) followed by track point 3 (765) and
track point 4 (770)
then to track point 1 (755) when the cam follower 250 fully travers the upper
track 750. The cam
follower 250 is also suitably controlled to traverse the lower track 752,
starting from track point
1 (755) then track point 5 (780) followed by track point 6 (785) then track
point 7 (790) then
track point 8 (795) then track point 4 (770) and then back to the starting
point at track point 1
(755) where the cam follower 250 completes the traverse of the lower track
752. It is understood
that this figure demonstrates by way of one example a possible combination of
stop points in a
cam track 740 where the cam follower 250 traversing the upper track 750 in
this example passes
by a total of four (4) track stop points, while traversing the lower track
752, the cam follower 250
passes pass by six (6) track stop points before completing the lower track 752
to the starting
point. This form of multi cam track 740 is advantageous and desirable in
control systems. It is
understood that plurality of tracks and plurality of track stop points are
possible using this
concept.
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[0153] In one example, the plurality of cam track is a means for decoding the
command
pattern as explained herein. A change in the environment will cause the cam
follower to traverse
the cam track for example as the force generated from the hydraulic fluid
flowing through the
inner flow passage exert force on the actuator, and with the cam mounted on
the inner mandrel
such that it is movable with the mandrel movement in an axial direction. When
cam follower
traverse the cam track from track point 1 755 for a particular distance
between track point 1 755
and track point 4 770 the cam follower will engage and traverse the upper
track 750 following
the track points explained earlier. When cam follower traverse the cam track
for a different
distance between track point 1 755 and track point 4 it will traverse the
lower cam track 752.
The distance traversed between track point 1 755 and track point 4 770 caused
by the movement
of the actuator mandrel due to a specific change of the at least one change of
the envieronment
will determine the track passage that the cam follower will traverse. Specific
change of the
environment will control the track traversed by the cam follower and the cam
explained in Fig.
13 is an example of a means for decoding the at least one change in the
environment.
[0154] Fig. 14 is a flowchart of the disclosed method describing, in one
example, the
steps suitable for remotely and selectively controlling an apparatus disposed
in a wellbore. In
one example, an apparatus is disposed within a wellbore 100 and includes the
step 1410 of
disposing in a wellbore 100 a tubular string 110 containing a plurality of an
apparatus
comprising a body 200, a plurality of controllable element, an activator 270
and an actuator 240.
The method also includes the step 1420 of causing a change in at least one
physical property of
the environment in certain sequence within a specified period of time
resulting in a detectable
pattern of signal variations within the apparatus comprising plurality of
signal variations within a
suitable period of time. The method also includes the step 1430 of comparing
the detectable
pattern with a predetermined pattern called a command pattern 899 to determine
whether a
controllable element state within the apparatus is desired to be changed and
then cause the
activator 270 to change the apparatus mode into enabled mode. The method also
includes the
step 1440 of causing the actuator 240 to transform a suitably available energy
source to cause the
controllable element into the different desired state.
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[0155] Fig. 15 is a flowchart of the disclosed method describing, in one
example, the
steps for selectively and remotely controlling a flow passage causing desired
flow pattern within
a wellbore. In one example, the method for selectively and remotely
controlling a flow passage
causing desired flow pattern within a wellbore 100 includes the step 1510 of
disposing a tubular
string 110 containing a plurality of an apparatus comprising a body 200, a
plurality of
controllable valve 220, an activator 270 and an actuator 240. The method also
includes the step
1520 of causing a change in at least one physical property of the environment
in certain sequence
within a specified period of time resulting in a detectable pattern of signal
variations within the
apparatus comprising plurality of signal variations within a suitable period
of time. The method
also includes the step 1530 of comparing the detectable pattern with a
predetermine pattern
called a command pattern 899 to determine whether a controllable valve 220
state within the
apparatus is desired to be changed and then cause the activator 270 to change
the apparatus mode
into enabled mode. The method also includes the step 1540 of causing the
actuator 240 to
transform a suitably available energy source to cause the controllable valve
220 into the different
state suitable for changing the flow pattern into the desired flow pattern. As
a result, the flow
pattern will take any of the flowing patterns, no flow, full flow, a diverted
flow and a through
flow as explained in Figs. 7, 8, 9, and 10.
[0156] Fig. 16 is a diagram of an example form of signal pattern comprising a
sequence
of signal variations over a period of time. This diagram is also aimed to aid
understanding the
terms used in the description in this disclosure. In one example, a signal
level point 805 is any
possible value of a signal. A signal level zone 806 is defined as any signal
value within suitable
two signal points, defining the signal level zone 806 boundaries. A time
period is referenced as
the period of time between any two time points. A time zone 546 is defined as
the time period
when the signal value stays within a signal level zone 806. When a signal
value is changed to a
different signal level zone 806, a different time zone 546 is defined. A
signal is said to have a
possible reference pattern 864 if its value stays within a particular signal
level zone 806 for a
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specific time zone 546. In one example, a sequence of reference patterns is,
or is used as, or is
referred to as, a command pattern.
[0157] Fig. 17 is a diagram of an example form of reference pattern 864
comprising a
predetermined set of signal variations within a specific period of time. For
example, a reference
pattern A (865) is defined for the signal value within signal level zone 1
(809) and for a time
zone A (825), and a reference pattern B (870) is defined for the signal value
within signal level
zone 2 (811) and for a time zone B (830). Similarly, a reference pattern C
(875) is defined for
the signal value within signal level zone 3 (816) and for a time zone C (835).
[0158] Fig. 18 is a diagram of an example form of signal variations within a
suitable
period of time acceptable as matching with the reference pattern. In this
example, the sequence
of a reference pattern A (865), a reference pattern B (870), and a reference
pattern C (875). A
signal is said to have other pattern 880 if it stays within a particular
signal level zone 806 for
other time zone 840 not matching those defined by reference pattern A (865),
or reference
pattern B (870) or reference pattern C (875).
[0159] Fig. 19 is a diagram of an example form of detectable pattern of signal
variations
within a suitable period of time having an example form of matching pattern to
the reference;
pattern. In chronological order the activator 270 processor will interpret the
sensor 272 signal by
referring to reference pattern A (865), reference pattern B (870), reference
pattern C (875), and
other pattern 880 as follows: a reference pattern C (875), then a reference
pattern B (870), then a
reference pattern A (865), then a reference pattern B (870), then a reference
pattern A (865) then
other pattern 880 then a reference pattern A (865), then a reference pattern B
(870), then a
reference pattern C (875), then other pattern 880.
[0160] Figs. 20A, 20B, 20C are detailed perspective cutaway views of an
example
embodiment of a means for transforming hydraulic energy from fluid in the
wellbore into electric
energy source suitable for operating the valve, or, in an example, a
mechanical movement
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directly into making a suitable movement of the rotatable element. Fig. 20A is
a view of the
apparatus during no circulation. Fig. 20B is a view of the apparatus during
transition between no
circulation and mud circulation. Fig. 20C is a view of the apparatus during
mud circulation.
[0161] In one example, an actuator 240 includes a means for transforming
hydraulic
energy from fluid in the wellbore 100 into electric energy source. An
actuation mandrel 246 is
disposed within the body 200 inner space having a flow orifice 280 and inner
surface and outer
surface 340. A mud compartment 905 defined as the space between the inner body
200 surface
and the actuation mandrel 246 outer surface 340 is having a suitably diameter
at one end larger
than the diameter on the other end and having at least one generator port 900
suitable for
connecting fluid within the mud compartment 905 to fluid in the annular
passage. The different
inner diameter of the mud compartment 905 is such that when the actuation
mandrel 246 moves
in certain direction will cause the volume of mud compartment 905 to change. A
suitable seal
element is disposed within the mandrel and body 200 to restrict hydraulic
communication
between inner flow passage 152 and mud compartment 905. A suitable form of
resilient element
is disposed within the mud compartment 905 such as a coil spring 244 wherein
the movement of
the actuation mandrel 246 in certain direction will cause a change in the
strain of the said spring
244 and the move of the actuation mandrel 246 in a different direction will
cause another change
in the strain of the said sprig. One or more electric coil 885 is disposed
within the present
invention and one or more magnet is further disposed within the present
invention such that
movement of the actuation mandrel 246 within the body 200 will cause the
relative location
between the magnet and the electric coil 885. In this figure, different forms
of magnets are
presented by way of example such as stud magnet 895 and ring magnet 890. An
example of
different form of a suitable electric coil 885 is also presented having
different shapes as in figure.
[0162] Fig. 20A is a view of the apparatus during no circulation. Fig. 20C is
a view of the
apparatus during mud circulation. Fig. 20B is a view of the apparatus during
transition between
no circulation and mud circulation by way of referring to wellbore 100
operation, and tubular
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string 110 disposed within a wellbore 100 comprising a drill bit 120, a bottom
hole assembly
130, a plurality of flow control apparatus 150 and drill pipe 140.
[0163] Fig. 21 is a section view of another preferred example of the flow
control
apparatus 150 comprising plurality of valves. One valve 220 comprises a
moveable element,
sliding sleeve 390, comprising a connecting hole. The sliding sleeve 390 is
movable within the
body 200 by the actuation mandrel movement by the actuator 240, causing the
connecting hole to
be in position such that it is aligned in communication with the lateral hole
210 and fluid is in
communication between the annular flow passage 154 and inner flow passage 152.
When the
sliding sleeve 390 is moved by the actuation mandrel to another position,
communication hole
920 is not in fluid communication with the lateral hole 210 and resulting in
the fluid flow
between the annular flow passage 154 to be not in communication with the inner
flow passage
152 through the communication hole. The body 200 further comprises a pressure
compensation
hole to connect the annular fluid pressure to an internal compartment of the
apparatus for
compensating the pressure between the inner mandrel and the pressure of the
annular flow
passage. The apparatus in Figs. 21 and 22 comprises another valve 220 such as
those described
in Fig. 2 in addition to the valve 220 with sliding sleeve 390 element.
[0164] Fig. 22 is another section view of another preferred example of the
flow control
apparatus 150 comprising plurality of valves. One valve 220 comprises a
sliding sleeve 390
comprising a connecting hole. The sliding sleeve 390 is movable within the
body 200 by the
actuation mandrel movement by the actuator 240, causing the connecting hole to
be in position
such that it is aligned in communication with the lateral hole 210 and fluid
is in communication
between the annular flow passage 154 and inner flow passage 152 When the
sliding sleeve 390
is moved by the actuation mandrel to another position, communication hole 920
is not in fluid
communication with the lateral hole 210 and resulting in the fluid flow
between the annular flow
passage 154 to be not in communication with the inner flow passage 152 through
the
communication hole. Within the body 200 is further disposed a means for
interpreting the signal
in a form of electronic controller 274. In one example, the electronic
controller 274 has a
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processor, a memory and a suitable wiring to connect the signal from the
sensor 272 to the
processor, and a suitable wiring to connect the power to an actuator 240 means
such as the
electric motor 620 or solenoid in order to move the movable element 380 or to
unlock the lock
277 disposed within the apparatus. The apparatus further includes a sensor 272
responsive to
chemical composition of the fluid within the wellbore 100 or, in one example,
within the tubular
string. In one example, changes in fluid chemical composition generate a
suitable signal and a
type of sensors sensitive to fluid chemical composition is used, allowing
interpretation or
analysis to identify or otherwise decode a command pattern 899.
[0165] In one example, the apparatus in Figs. 21 and 22 includes another valve
220
having a movable element 380 in the form of sliding sleeve 390 element.
[0166] Drilling risks encountered during wellbore 100 operations include by
way of
examples having cutting beds 175, having suspended cuttings 170 in the well
bore or having
fluid losses into porous formation or fractures 160. It is desirable to change
annular flow
velocity at certain points within the wellbore 100 to improve hole cleaning by
way of causing the
cutting beds 175 and suspended cuttings 170 to move up the wellbore 100
annular passage to
surface. It is further desirable to dispose certain fluid composition such as
materials and
chemicals to treat formation damage and reduce fluid losses. It is further
desirable to introduce
cement composition in a suitable form for treating a wellbore 100 fracture
through the wellbore
100 to plug the formation fractures 160 without flowing the cement through the
bottom hole
assembly 130 components. It is further desirable to control flow pattern
within the wellbore 100
and between inner flow passage 152 and annular passage at different points
within the tubular
string 110 to deal with one or more of the drilling operations risks
encountered. During
customary drilling operation such as when the drill bit 120 cuts and removes
new formation at
the bottom of the well and enlarging the wellbore 100, it is further desirable
to have continuous
mechanical access through the inner flow passage 152 to enable running
wireline services such
as gyro survey to evaluate the well directional information. It is further
desirable to dispose a
drop ball activated equipment such as under reamers within the same tubular
string 110. It is
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further desirable to enable the operator to use optimized drilling parameters
such as varying flow
rate or drilling with high pressure without undesirably causing the flow
control apparatus 150
into a different mode. It is further desirable to dispose plurality of flow
control apparatus 150
within the same tubular string 110 at various points and operate each one
individually and
selectively. It is further desirable to operate the flow control apparatus 150
to cause plurality of
fluid flow pattern including one or more of the following flow patterns:
through flow, lateral
flow, full flow or no flow. It is further desirable to dispose the flow
control apparatus 150 within
the tubular string 110 such that mechanical restrictions within the inner flow
passage 152 caused
by other components of the tubular string 110 disposed between the flow
control apparatus 150
and surface does not restrict the operation of the flow control apparatus 150.
It is further
desirable to operate the flow control apparatus 150 efficiently independent of
the depth or the
deviation of the point where the flow control apparatus 150 is disposed with
respect to the
tubular string 110. The present invention introduces an apparatus and method
to address some or
all of the above desirables without the need to pull the tubular string 110
out of the wellbore 100
and resulting in a substantial savings of operation time and reduce operating
cost.
[0167] Therefore, in one example, the apparatus for remotely and selectively
control
fluid flow in tubular strings and wellbore annulus 156 has:
a. body 200 defining the boundaries between an inner flow passage 152 through
the said
apparatus and an annular flow passage 154 within the wellbore annulus 156 and
having
two suitable end connections and at least one lateral hole 210 suitable for
connecting the
inner flow passage 152 and the annular flow passage 154;
b. a controllable valve 220 operable in plurality of desired states altering
the fluid flow
pattern within the wellbore 100 wherein the said valve 220 is having at least
one rotatable
element 300 wherein the said element is rotatable to plurality of desired
positions. The
valve 220 further divides the inner flow passage 152 into upstream 157 section
and
downstream 159 section wherein upstream 157 section is defined as the portion
of the
inner flow passage 152 from the valve 220 and through the upstream 157 end
connection
155 of the flow control apparatus 150 and the downstream 159 section as
defined as the
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portion of the inner flow passage 152 from the valve 220 and through the
downstream
159 end connection 155 of the body 200;
c. an activator 270 disposed within the body 200 capable of selectively change
the
apparatus in either one of two modes: a disabled mode wherein the said valve
220 is not
operable, and an enabled mode wherein the said valve 220 is operable to a
different state,
comprising a means for detecting an intended change in the environment; and
d. an actuator 240 capable of changing the rotatable element 300 position to
cause the
valve 220 into a desired state comprising a means for transforming a suitably
available
energy source into a mechanical movement.
[0168] In one example, the rotatable element 300 is suitably selected to cause
the valve
220 into a suitable state and to cause a change of the flow pattern into one
or more of the
following patterns:
i. no flow pattern wherein the flow passage between the upstream 157 section
and the
downstream 159 section is restricted and the flow passage between the inner
flow
passage 152 and the annular flow passage 154 is also restricted and the valve
220 is in no
flow state;
ii. through flow pattern 705 wherein the passage between the upstream 157
section and
the downstream 159 section of the inner flow passage 152 is not restricted
whereas the
passage between the inner flow passage 152 and the annular flow passages is
restricted
and the valve 220 is in through flow state;
iii. diverted flow pattern 710 wherein the flow passage between the upstream
157 section
and the said annular flow passage 154 is not restricted whereas the flow
passage to the
downstream 159 section is restricted and the valve 220 is in diverted flow
state; and
iv. full flow pattern 715 wherein the flow passage between the upstream 157
section and
the downstream 159 section of the inner flow passage 152 is not restricted and
the flow
passage between the said inner flow passage 152 and the annular flow passages
is not
restricted and the valve 220 is in full flow state.
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[0169] In one example, rotatable element 300 has a suitable embodiment
explained by
way of example in Fig. 3.
[0170] In one example, the activator 270 further comprises a plurality of
suitable sensor
272 means for detecting an intended change in at least one physical property
of the environment
resulting in a signal within the apparatus suitable for processing. By way of
example, in one
example of the apparatus, the sensor 272 means is a form of pressure sensor
272 suitable to be
affected by pressure variation within the wellbore 100 caused by way of
example by a change of
depth or change of fluid flow pressure. In another example, the sensor 272
means is a flow
sensor 272 suitable to be affected by variation of flow property such as fluid
flow rate within the
wellbore 100. In another example, the sensor 272 means is a form of an
electrode suitable for
detecting an electrical signal such as a change of the potential voltage or
electric current of the
said electrode with respect to the tubular string 110 caused by an induced
electric signal into the
formation. In another example, the sensor 272 means is a form of an
accelerometer affected by
change of tubular string 110 movement in one or more direction such as the
rotation speed or
axial movement speed or any combination thereof. In another example, the
sensor 272 means is
a form of magnetometer affected by magnetic field changes due to change of
surrounding
magnetic conductivity of the environment at the apparatus caused by change of
the detected
signal of earth magnetic field in certain pattern caused induced by a change
of the apparatus
location in earth by way of moving the tubular string 110. It is understood
that the sensor 272
means could take any other form suitable for detecting at least one change of
the environment at
the apparatus.
[0171] In one example, the activator 270 further comprises a controller 274
means
disposed within the flow control apparatus 150 in a form suitable for
processing the signal
generated by the sensor 272 means explained above.
[0172] In one example, controller 274 means is capable of comparing the
detected signal
pattern to a predetermined command pattern 899. When a command pattern 899 is
detected, the
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controller 274 means causes the suitable change within the apparatus to cause
the desire change
of the apparatus mode then to cause the change of the controller 274 to make
the suitable
changes within the apparatus to change the controllable valve 220 into the
desired state. The
controller 274 further comprises a movement limiting means to limit the
actuation linkage 242
movement and cause it to stop at a desired displacement. By a way of example,
movement
limiting means of movement control include a barrel cam 248 disposed within
the body 200 and
suitably connected to the actuation mandrel 246. The said barrel cam 248
comprises a cam track
740 with a profile suitable for the cam follower 250 disposed within the body
200 to limit the
movement of the barrel cam 248 travel between specific predetermined two or
more track point
such as those explained in Fig. 12 and Fig. 14. Any of the said track point
restricts the barrel
cam 248 displacement from movement in one or more direction. As the barrel cam
248 is
suitably connected with the actuation mandrel 246, when the flow control
apparatus 150 is in
enabled mode, the movement of the barrel cam 248 as determined by the cam
follower 250
traversing the cam track 740 causing the actuation mandrel 246 movement to be
restricted to
move to a specific position.
[0173] In one example, the activator 270 further comprises a locking means
suitable for
selectively change the apparatus mode when it is desired to change the
apparatus mode to an
enabled mode or to a disabled mode. By way of example, the locking means
comprises a lock
277 element such that when engaged with a suitable locking groove 278 suitably
connected with
the actuation mandrel 246, restricts the movement of one or more of the
actuator 240 elements
such as the actuation mandrel 246 and cause the flow control apparatus 150 to
be in a disabled
mode. When the apparatus is in disabled mode, the valve 220 is not operable to
change its state.
When the lock 277 is disengaged from the locking groove 278, the actuator 240
disposed within
the flow control apparatus 150 will not be restricted by the lock 277 element
and the flow control
apparatus 150 will be in enabled mode and the valve 220 will be operable into
a different state.
[0174] In an example as described in Fig. 11, the lock 277 is caused to change
position
by a suitable lock driver 720. The lock driver 720 in one example is a
suitable solenoid. In
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another example, the lock 277 viewed in Fig. 11 is driven by lock driver 720
in a form of a
suitable motor. It is understood that the lock 277 can be driven by other
suitable lock driver 720
to cause it to move between at least two positions such that, in one position
lock 277 is
disengaged from the locking groove 278, and in another position the lock 277
is suitably
engaging the locking groove 278. In one example where the lock driver 720 is a
solenoid, for
example, when a suitable electric charge is connected to the solenoid, the
solenoid becomes
energized causing the lock 277 to retract into the body 200 and the lock 277
is caused to
disengage away from the locking groove 278 causing the flow control apparatus
150 into enabled
mode.
[0175] In one example, the solenoid is further operable such that when
energized with a
different suitable charge the lock 277 is caused to extend through the inner
wall of the body 200
and is caused to be suitably engaged with the locking groove 278 causing the
flow control
apparatus 150 into a disabled mode. The same function made by the solenoid
means of lock
driver 720 is be achieved by a suitable motor in another example. It is
understood that the
locking means by way of example and does not limit the apparatus locking to
these mentioned
examples. When the lock 277 is engaged with the suitable locking groove 278
disposed within
the actuation mandrel 246, it restricts the movement of the actuation mandrel
246 therefore
restricting the movement of the actuation linkage 242 and therefore the
movement of the
rotatable element 300 is restricted and the valve 220 is restricted from
changing its state and not
operable into a different state. The flow control apparatus 150 is said to be
in disabled mode
when the valve 220 is not operable to a different state. When the lock 277 is
disengaged from
the locking groove 278, the actuator 240 mandrel disposed within the flow
control apparatus 150
will not be restricted by the lock 277 element and the flow control apparatus
150 will be in
enabled mode and the valve 220 will be operable into a different state. The
flow control
apparatus 150 is said to be in enabled mode when the valve 220 is operable to
a different state.
The locking means explained is by way of example. Another example of the
locking means is
explained; in a different example of the actuator 240 such as the example in
Fig. 6 where the
actuator 240 comprises a suitable electric motor 620, the locking means is
achieved by
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disconnecting the electric energy source form the electric motor 620 causing
the electric motor
620 to be inoperable and accordingly the rotatable element 300 to be
restricted from changing
position by means of the gear arrangement where the worm engaged with the
pinion 420 act as a
break when the worm gear 610 is not rotatable, and the flow control apparatus
150 is then said to
be in the disabled mode. When the electric motor 620 is connected to the
suitable electric energy
source, it rotates in a suitable direction causing the worm gear 610 to rotate
causing the pinion
420 to rotate in a suitable direction and resulting in a change of the
rotatable element 300
position and the valve 220 is operable into a different state and the flow
control apparatus 150 is
said to be in enabled mode during when the electric energy source is connected
to the said motor.
[0176] In one example, flow control apparatus 150 further comprises an
actuator 240
capable of changing the rotatable element 300 position to cause the valve 220
into a desired state
therefore causing a change in flow pattern comprising a means for transforming
a suitably
available energy source into a mechanical movement. In one example, the
actuator 240
comprises a form of an electric motor 620 powered by a suitable battery 276 or
a suitable
generator or capacitor or other suitable electric energy source disposed
within the apparatus or
available on a different location within the tubular string 110 or on surface
and connected to the
apparatus by connecting means such as wireline cable introduced form surface
to the apparatus
through wellbore 100. In this example of actuator 240 having an electric motor
620 means of
transforming a suitably available electrical energy source into a mechanical
energy is capable of
changing the position of the rotatable element 300 by means of linkage in the
form of a suitable
gear engagement such as worm gear 610 and pinion 420. When the said electric
energy source is
connected to the electric motor 620 causing the worm gear 610 connected to the
electric motor
620 output to adequately rotate the pinion 420 that is suitably connected to
the rotatable element
300 around the pivot 307 and will cause a change of the rotatable element 300
position and
accordingly a change of the controllable valve 220 state and a suitable change
of the flow
pattern.
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[0177] In another example, the actuator 240 transforms an energy source in the
form of
an energized resilient element such as a spring 244. The resilient element
stores energy when
caused to change its state from relaxed state to a strained state
alternatively called an energized
state by means of causing a strain to the resilient element such as by means
of coiling,
compressing or stretching the resilient element from a less strained state.
The said resilient
element in such a strained state when suitably connected to the rotatable
element 300 and when
the apparatus is in enabled mode will cause the rotatable element 300 into a
different position. In
another example, the form of resilient element energy source is pre-energized
before disposing
the flow control apparatus 150 into the wellbore 100. In a further other
example, the resilient
element energy source is energized while within the wellbore 100 by another
energy source such
as hydraulic flow as explained in the embodiment viewed in Fig. 20.
[0178] In an example, the actuator 240 comprises a means suitable to transform
a form of
mechanical energy source caused by an inertia mass element disposed within the
flow control
apparatus 150 into a mechanical movement suitable for changing the rotatable
element 300
position. When the flow control apparatus 150 is in enabled mode, and when the
inertia element
510 is suitably energized by way of momentum or inertia for example through
movement of
tubular string 110, the inertia element 510, suitably connected to the
rotatable element 300 as
explained earlier, will cause a change of the rotatable element 300 position
and accordingly
cause a change in the valve 220 state.
[0179] In an example, the actuator 240 is suitable for transforming a
hydraulic energy of
the fluid flowing through the inner flow passage 152 or annular flow passage
154 or any
combination thereof to generate a suitable mechanical energy causing the
rotatable element 300
to change position explained herein. The practice of introducing drilling
fluid composition into
the tubular string 110 inner flow passage 152 will cause the fluid in the
inner flow passage 152 to
have higher pressure than the fluid in the annular flow passage 154 at the
same depth, and the
fluid is called to be circulated through the inner flow passage 152 and the
operation is commonly
called mud circulation. When no fluid is introduced into the tubular string
110 inner flow
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passage 152, the fluid pressure in the inner flow passage 152 will be similar
to the fluid pressure
in the annular flow passage 154 at the same depth and the operation is
commonly called no
circulation.
[0180] In an example, the apparatus actuator 240 described in Fig. 20 harvests
energy
from the change of pressure between the inner flow passage 152 and the annular
flow passage
154 at the apparatus depth during the mud circulation and stores it through
deforming a resilient
element such as the spring 244 shown in figure. The mud compartment 905
defined as the space
between the inner body 200 surface and the actuating mandrel outer surface 340
is having a
suitably varying diameter so that fluid pressure exerted on the flow orifice
280 during mud
circulation that is higher than the fluid pressure in the mud compartment 905
causing the
actuation mandrel 246 to move in the direction suitable to compress the spring
244. During no
circulation the pressure in the mud compartment 905 is the same as the
pressure in the inner flow
passage 152 and the force exerted by the compressed spring 244 will be
released causing the
actuation mandrel 246 to move to the opposite direction. The actuator 240 is
further having an
arrangement of electric coils and magnets such as stud magnet 895 or ring
magnet 890 or any
combination thereof. When the actuation mandrel 246 moves with the effect of
mud circulation
in one direction and moves again at no circulation in the opposite direction
it will cause a change
of magnetic field detected by the electric coil 885 caused by the change of
relative position of the
electric coil 885 and the magnet element causing electric charges observed in
the electric coil
885. In a further example of the present invention, the said electric charges
is utilized to move
the electric motor 620 and in a further example, the said electric charges is
utilized to charge a
suitable means of storing electric charge such as capacitor or rechargeable
battery 276. A
method of energy harvesting is now explained where electric energy is
harvested from hydraulic
energy within the wellbore 100, and a mechanical energy is harvested from
hydraulic energy
within the wellbore 100. It is understood that the energy sources explained
herein are made by
way of example and not exhaustive. The same function is possible to be
achieved by other
means of energy sources suitably available within the apparatus.
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[0181] In one example, the actuator 240 comprises an actuation mandrel 246
having a
suitable flow orifice 280 profile that is affected by fluid flowing through
the inner flow passage
152. When fluid flows through the actuation mandrel 246 the hydraulic energy
from the said
fluid flow exerts a suitable force on the flow orifice 280 causing the
actuation mandrel 246 to
move with respect to the body 200 and exerting a suitable force on the
actuation linkage 242
suitably attached to the rotatable element 300 push-pull point 308 causing the
rotatable element
300 to move and causing the rotatable element 300 to change its position.
[0182] In one example, the flow control apparatus 150 explained herein is
normally
disposed in the wellbore 100 while in initial valve 220 state of through flow
state. Customary
drilling operation may take place by including the steps of drilling, flowing
drilling fluid into the
tubular inner flow passage 152, lowering the tubular string 110 deeper into
the earth and
extending deeper into the earth by way of removing layer of earth through
drilling process by
means of drill bit 120 operation. With reference to the preferred example
explained in Fig. 2,
when the valve 220 state is through flow state as in detail A of Fig. 10,
there is no restriction
within the inner flow passage 152. When desired, it is possible in this state
to run a suitable
wireline services such as gyro survey through the tool inner flow passage 152.
It is further
possible to operate a drop ball operated device disposed within the tubular
string 110 by means
of introducing a suitable drop ball through the tubular string 110 inner flow
passage 152
including the inner flow passage 152 portion through the flow control
apparatus 150. When it is
desired to change the flow pattern of a particular flow control apparatus 150
disposed within the
tubular string 110, a suitable change in the environment is made causing a
signal pattern to be
detected within the apparatus. A command pattern 899 is suitably formed
sequence of signal
pattern predetermined and stored within each tool and for each desired
command. By way of
example, a possible command pattern 899 to change a particular valve 220
disposed within a
particular flow control apparatus 150 from one flow state to another flow
state comprises the
following sequence in order, reference pattern A 865 followed by reference
pattern B 870 then
followed by reference pattern C 875. A controller 274 disposed within the flow
control
apparatus 150 processing the signal detected within the apparatus will observe
the said command
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pattern 899 at command time point 910. At command time point 910, the
activator 270 will
cause the desired change within the apparatus to cause it into the desired
mode. The activator
270 further will cause the actuator 240 to cause the controllable valve 220
into the desired state
by changing the rotatable element 300 into the desired position by means of
transforming a
suitably available energy source as explained earlier into a mechanical
movement. It is to note
that a suitable command pattern 899 is predetermined for each flow control
apparatus 150
disposed within the tubular string 110. This is another desired advantage of
the present invention
allowing a user to dispose a plurality of flow control apparatus 150 within
the same tubular string
110 and cause each one individually and selectively into a possible
independent valve 220 state
and accordingly a suitable flow pattern. It is further to note that the
command pattern 899 is
suitably predetermined such that change of the environment caused during
customary operations
will not cause the flow control apparatus 150 to change its mode or flow
pattern to change, this is
another desirable advantage of the present invention such that optimal
operating parameters is
possible to be deployed without the risk of undesirably causing the flow
control apparatus 150 to
change its mode or flow pattern.
[0183] In further example, it is possible to extend and apply the same method
of
selectively controlling a flow control apparatus 150 using command pattern 899
to any other
apparatus disposed within a tubular string 110 suitably equipped to detect
such a command
pattern 899 and cause the desired actuation to selectively take place. The
example explained in
Fig. 19 and detailed above for the flow control apparatus 150 may be
implemented on any other
suitably equipped apparatus having a device means suitable for any desired
action such as a
valve 220. The command pattern 899 explained and disclosed herein is another
desirable
advantage of the present invention as it provide extra flexibility of
disposing plurality of
apparatus each could have a different device means to perform a different
function. Such a
command pattern 899 provides an advantage means to enable the operator to
selectively and
remotely operate plurality of apparatus disposed within a wellbore 100 into a
desired mode or a
desired state independently.
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[0184] Furthermore, and with reference to the flow control apparatus 150, when
it is
desirable to dispose a particular fluid composition to treat formation damage
such as cement
composition to treat formation fractures 160, it would be desirable to operate
a flow control
apparatus 150 dispose within the tubular string 110 between the bottom hole
assembly 130 and
surface and cause its valve 220 into bypass state. When in bypass state such
as the state
explained in Fig. 10 detail (B1), (B2) and (B3). It is to note that fluid
composition will all exit
the lateral hole 210 into the annular passage to reach the damage formation.
It is to note that the
inner flow passage 152 downstream 159 section of the valve 220 is obstructed
in such a way that
safeguard bottom hole assembly 130 components disposed between the drill bit
120 and the said
flow control apparatus 150 from having such a cement composition undesirably
flowing into the
said bottom hole assembly 130 components. It is a further advantage that the
preferred example
explained in Fig. 2 utilizing the valve 220 detailed in Fig. 10 will allow the
user to displace all
treatment composition fluid within the inner flow passage 152 with another
composition fluid
without leaving any tangible volume of the treatment composition fluid within
the inner flow
passage 152. This is another advantage of the present invention whereas when
it is desired to
change the valve 220 state into through flow state after performing the said
disposition of
treatment composition fluid into the annular passage, there will be no
significant treatment
composition fluid within the inner flow passage 152 that would enter the
bottom hole assembly
130 inner flow passage 152 and will not be a source of risk to the bottom hole
assembly 130
components.
[0185] In one example, as the flow control apparatus 150 is rigidly attached
to the tubular
string 110 through the end connection 155 and the inner flow passage 152 is
hydraulically
connected to surface and the drilling fluid commonly used in drilling
operations is relatively
incompressible, causing any change on the surface by means of moving the
tubular string 110 in
any direction or causing the fluid flow to change in any particular pattern
will cause a suitable
change in the environment reasonably detectable by sensor 272 disposed within
the flow control
apparatus 150 nearly at the same time. This is another advantage of the
present invention will
save significant operating time when compared to a drop ball activated devices
where the drop
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ball has to consume a significant time traversing the inner flow passage 152
from surface to
reach its corresponding apparatus. It is a further advantage of the present
invention to be
operated by causing a command pattern 899 within a similar time independent of
the depth or
location of the flow control apparatus 150, and independent of the well
deviation anywhere in the
wellbore 100 where the present invention is disposed of, particularly when
compared to drop ball
activated apparatus where the drop ball will take different time to reach the
corresponding
apparatus depending on that apparatus depth, and well deviation. It is a
further advantage that
the present invention command pattern 899 does not demand a physical access
within the inner
flow passage 152 allowing the operator to dispose the flow control apparatus
150 within the
tubular string 110 below other devices that may have mechanical restriction
within the inner flow
passage 152 such a drop ball activated apparatus disposed between the flow
control apparatus
150 and surface within the same tubular string 110. It is another further
advantage that the
present invention is operable in unlimited number of times and does not suffer
from the limited
number of operable cycles that is associated with drop ball activated
apparatus imposed by what
is called a ball capture means used commonly with apparatus using drop ball
system. It is
another further advantage that the present invention is operable in one or
more of the following
flow states: through flow, diverted flow, full flow, and no flow explained
earlier providing a far
more flexibility to the operator. The through flow is commonly used in
customary drilling
operation. The diverted flow is of an advantage for composition fluid
particularly when the said
composition is not suitable to pass through equipment disposed downstream 159
of the flow
control apparatus 150, as by the way of example the disposition of cement
composition to treat
fractures 160 when equipment downstream 159 of the flow control apparatus 150
is a bottom
hole assembly 130 component. The full flow pattern 715 is a useful pattern to
suitably control or
increase the annular fluid velocity aiding to improve hole cleaning and reduce
cutting beds 175
and reduce suspended cuttings 170 within the wellbore annulus 156 while at the
same time allow
for portion of the circulated fluid to flow through the inner flow passage 152
and possibly
through the bit perforations 125 to maintain well control at all times. The no
flow mode is
another important mode suitable for securing the well as a form of sub surface
safety valve 220
and could be used in emergency cases where it is desired not to allow flow
within the bottom of
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the well and the inner flow passage 152 such as situations when well control
is compromised for
example during what is call well kick or early warning of blow out.
[0186] While this invention has been described with respect to a limited
number of
embodiments, those skilled in the art, having benefit of this disclosure, will
appreciate that other
embodiments can be devised which do not depart from the scope of the invention
disclose.
[0187] While the invention has been illustrated and described in detail in the
drawings
and foregoing description, such illustration and description are to be
considered illustrative or
exemplary and not restrictive and it is not intended to limit the invention to
the disclosed
embodiments. The mere fact that certain measures are recited in mutually
different dependent
claims does not indicate that a combination of these measures cannot be used
advantageously.
+++++++
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