Note: Descriptions are shown in the official language in which they were submitted.
SECONDARY SLURRY FLOW PATH MEMBER WITH SHUT-OFF VALVE
ACTIVATED BY DISSOLVABLE FLOW TUBES
BACKGROUND
[0001/0002] Downhole operations often include a downhole string that extends
into a
foimation having multiple zones. One or more of the multiple zones may be
isolated from
others of the zones. In this manner, recovery, treatment and/or other
operations may be
carried out in each zone independent of other zones. At times, it is desirable
to perform an
operation that sends fluid to or receives fluid from one zone through a bypass
passage that
traverses other zones. The bypass passage is fluidically isolated from the
other zones. After
the operation, it is often times desirable to close the bypass passage.
Current techniques for
closing the bypass passage require actions that originate uphole and often
times include
running additional tools and/or fluid downhole to operate a valve, sleeve, or
the like.
SUMMARY
[0003] A downhole secondary flow path member includes a tubular having a first
end
portion, a second end portion, and an intermediate portion having an outermost
surface
defining a flow passage extending therebetween. The tubular includes a first
opening
arranged adjacent the first end portion and a second opening arranged adjacent
the second
end portion. A valve assembly is provided on the tubular at the first opening.
The valve
assembly includes a valve member. A flow tube runs along at least a portion of
the outermost
surface of the tubular. The flow tube has a dissolvable end section
mechanically linked to the
valve assembly. The dissolvable end segment selectively shields the valve
member from
exposure to downhole fluids. The valve member changes from an open position to
a closed
position following dissolution of the dissolvable end segment.
[0004] A method of controlling fluid flow through a secondary flow member
includes
directing fluid into a flow tube having a dissolvable end portion exposed to a
downhole fluid,
passing the fluid into a valve assembly having a selectively closeable valve
member, guiding
the fluid from the valve assembly into an opening formed in a tubular, and
closing the valve
member in response to a dissolution of the dissolvable end portion resulting
from exposure to
the downhole fluid.
[0005] A downhole secondary flow path member includes a first valve assembly
and
a second valve assembly. At least one of the first and second valve assemblies
includes a
selectively swellable valve member including a material that expands when
exposed to a
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downhole fluid. One or more flow tubes running along and fluidically connect
the first valve
member and the second valve member. The one or more flow tubes include at
least one
dissolvable end segment mechanically linked to the one of the first and second
valve
assemblies including the selectively swellable valve member and a second
opposing end
section connected to the other of the first and second valve assemblies. The
at least one
dissolvable end segment selectively shielding the selectively swellable valve
member from
exposure to downhole fluids, wherein the valve member changes from an open
position to a
closed position following dissolution of the dissolvable end segment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Referring now to the drawings wherein like elements are numbered alike
in
the several Figures:
[0007] FIG. 1 depicts an uphole system operatively connected to a downhole
string
having a secondary flow path member, in accordance with an exemplary
embodiment;
[0008] FIG. 2 depicts a partially cut-away view of the secondary flow path
member of
FIG. 1;
[0009] FIG. 3 depicts a cross-sectional view of a valve assembly having a
valve
member of the secondary flow path member of FIG. 2;
[0010] FIG. 4 depicts a dissolvable end of a flow tube following dissolution
exposing
the valve member of FIG 3;
[0011] FIG, 5 depicts the valve member of FIG. 4 in a closed position
following
dissolution of the dissolvable end portion of the flow tube, in accordance
with an aspect of an
exemplary embodiment; and
[0012] FIG. 6 depicts a secondary flow path member in accordance with another
aspect of an exemplary embodiment.
DETAILED DESCRIPTION
[0013] A resource exploration system, in accordance with an exemplary
embodiment,
is indicated generally at 2, in FIG. 1. Resource exploration system 2 should
be understood to
include well drilling operations, resource extraction and recovery, CO2
sequestration, and the
like. Resource exploration system 2 may include an uphole system 4 operatively
connected
to a downhole system 6. Uphole system 4 may include pumps 8 that aid in
completion and/or
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extraction processes as well as fluid storage 10. Fluid storage 10 may contain
a gravel pack
fluid or slurry (not shown) that is introduced into downhole system 6.
[0014] Downhole system 6 may include a downhole string 20 that is extended
into a
wellbore 21 formed in formation 22. Downhole string 20 may include a number of
connected
downhole tools or tubulars 24. One of tubulars 24 may include secondary flow
path member
28. Formation 22 may include a number of zones, one of which is indicated at
30.
Secondary flow path member 28 may include a sand screen 33 that facilitates a
fluid
exchange between downhole string 20 and zone 30. As will be detailed more
fully below,
secondary flow path member 28 also allows fluids, such as the gravel pack
slurry from fluid
storage 10 to be pumped downhole.
[0015] In accordance with an exemplary embodiment illustrated in FIG, 2,
secondary
flow path member 28 includes a first tubular 42 having a body 44 including a
first end
portion 48, a second end portion 50 and an intermediate portion 51. In the
exemplary
embodiment shown, first end portion 48 connects with tubulars 24 extending
uphole while
second end portion 50 connects with tubulars extending downhole. In accordance
with an
aspect of an exemplary embodiment, intermediate portion 51 includes an outer
surface (not
separately labeled) which may support sand screen 33 and an inner surface 54.
First tubular
42 also includes a first opening 56 arranged toward first end portion 48 and a
second opening
58 arranged toward second end portion 50.
[0016] A second tubular 63 is arranged within first tubular 42. Second tubular
63
include a body 65 having a first end 68, a second end 69 and an intermediate
zone 70
extending therebetween. Intermediate zone 70 includes an outer surface 72
that, together
with inner surface 54 of first tubular 42 defines a flow passage 78 that is
generally defined
between first and second openings 56 and 58. Second end 69 also carries one or
more seals,
such as indicated at 81 in FIG. 3 that provide a fluid tight connection
between first and
second tubulars 42 and 63. Additional seals (not separately labeled) may be
arranged at first
end 68.
[0017] In further accordance with an aspect of an exemplary embodiment,
secondary
flow member 28 includes a first valve assembly arranged near first end portion
48 and a
second valve assembly 92 arranged near second end portion 50. A first
plurality of fluid
transport members or flow tubes 94 extend from uphole and may fluidically
connect fluid
storage 10 with first valve assembly 90 and a second plurality of fluid
transport members or
flow tubes 96may connect with, and extend downhole relative to, second valve
assembly 92
and extends downhole. As will be detailed more fully below, secondary flow
path member
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28 provides a bypass that allows a fluid from, for example, fluid storage 10,
to bypass by
zone 30 without being in direct contact with fluids entering tubular 24
through sand screen
52.
[0018] As each valve assembly 90 and 92 and first and second pluralities of
flow
tubes 94 and 96 may be substantially similarly formed, a detailed description
will follow with
respect to FIG. 3 in describing second valve assembly 92 and second plurality
of flow tubes
96 with an understanding that first valve assembly 90 and first plurality of
flow tubes 94 may
include similar structure.
[0019] First valve assembly 90 includes a valve body 110 having a flange
member
112 that connects to first tubular 42 through a seal 114 and a second,
cantilevered end 115.
First valve assembly 90 includes a comingling chamber 118 that is arranged
across second
opening 58. Valve assembly 92 also includes a valve member 120 that
selectively closes
flow passage 78. In accordance with an aspect of an exemplary embodiment,
valve member
120 is formed from a swellable material that expands when exposed to downhole
fluids.
Thus, in the exemplary embodiment shown, valve assembly 92 includes a shield
element 122
that prevents and/or substantially reduces contact between valve member 120
and downhole
fluids. In accordance with another aspect of an exemplary embodiment, valve
assembly 92
may include a spring activated valve that closes flow passage 78.
[0020] In further accordance with an exemplary embodiment, second flow tube 96
is
formed with a dissolvable end section 133 that engages with valve member 120.
In
accordance with an aspect of an exemplary embodiment, dissolvable end section
133 may be
formed from a material that is distinct from remaining portions of second flow
tube 96. In
accordance with one aspect of an exemplary embodiment, dissolvable end section
133 may
be formed from a controlled electrolytic metal (CEM) such as InTallictm from
Baker Hughes
Incorporated Houston Texas which dissolves over a period of time when exposed
to
downhole fluids. Of course, it should be understood that dissolvable end
portion 133 may be
formed from a variety of materials that dissolve when exposed to downhole
fluids. Further,
the particular material and/or materials chosen may be tailored to establish a
desired
dissolution rate for dissolvable end portion 133.
[0021] In operation, a fluid, such as a gravel pack slurry is introduced into
first flow
tube 94. The slurry passes into first valve assembly 90 and through first
opening 56. The
slurry travels along flow passage 78 and exits second opening 58 into valve
assembly 92 and
continues along tubular 24 through second flow tube 96. In this manner, the
slurry does not
interact with other fluids passing along turbular 24 from, for example, zone
30. After a
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period of time, gravel packing operations downhole from zone 30 are complete
and
dissolvable end section 133 begins to dissolve as shown in FIG. 4. Once
dissolved, valve
member 120 is exposed to downhole fluids.
[0022] Exposure to downhole fluids results in an expansion of valve member 120
as
shown in FIG. 5. First valve assembly 90 experiences a similar dissolution and
expansion.
Thus, without the need for any uphole intervention, first and second valve
assembly 90 and
92 are closed cutting off fluid through flow passage 78. At this point, it
should be understood
that the number if secondary flow members arranged downhole may vary. Further,
it should
be understood that secondary flow member may be employed in connection with a
number of
operations and should not be considered as being limited to gravel packing
operations.
[0023] FIG. 6, wherein like reference numbers represent corresponding parts in
the
respective views, illustrates a secondary flow path member 200 in accordance
with another
aspect of an exemplary embodiment. Secondary flow path member 200 includes a
first valve
assembly 202, a second valve assembly 204 and one or more flow passage tubes
210
extending therebetween. First valve assembly 202 is fluidically connected to
first plurality of
flow tubes 94 while second valve assembly 204 is fluidically connected to
second plurality of
flow tubes 96. One or more flow passage tubes 210 extend between and
fluidically connect
first plurality of flow tubes 94 and second plurality of flow tubes 96 via
first and second
valve members 202 and 204. In the exemplary embodiment shown, one or more flow
tubes
96 are arranged externally of secondary flow path member 200.
[0024] In further accordance with an exemplary aspect, each valve assembly
202, 204
includes a corresponding first and second selectively swellable valve member
220 and 224
that selectively, fluidically isolates one or more flow tubes 210 from first
plurality of flow
tubes 94 and second plurality of flow tubes 96. In accordance with an aspect
of an exemplary
embodiment, first and second selectively swellable valve members 220 and 224
are formed
from a material that expands when exposed to downhole fluids.
[0025] In still further accordance with an exemplary aspect, each of one or
more flow
tubes 210 includes one or more dissolvable end segments 230 and 234 arranged
proximate to
corresponding ones of first and second valve assemblies 202 and 204.
Dissolvable end
segments 230 and 234 selectively shield corresponding ones of first and second
selectively
swellable valve members from exposure to downhole fluids. In a manner similar
to that
described above, exposure to downhole fluids will, over time, lead to
dissolution of one or
more dissolvable end segments 230 and 234. The dissolution of one or more
dissolvable end
segments 230 and 234 exposes corresponding ones of first and second
selectively swellable
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valve members 220, 224 to downhole fluids. Upon being exposed to downhole
fluids, first
and second selectively swellable valve members 220 and 224 expand to
fluidically isolate
one or more flow tubes 210 from first plurality of flow tubes 94 and second
plurality of flow
tubes 96. Of course, it should be understood that while shown with two valve
assemblies,
secondary flow path member may include a single valve member with one or more
flow
tubes 210 having a single dissolvable end.
[0026] Set forth below are some embodiments of the foregoing disclosure:
[0027] Embodiment 1: A downhole secondary flow path member comprising: a
tubular including a first end portion, a second end portion, and an
intermediate portion having
a flow passage extending therebetween, the tubular including a first opening
arranged
adjacent the first end portion and a second opening arranged adjacent the
second end portion;
a valve assembly provided on the tubular at the first opening, the valve
assembly including a
valve member; and a flow tube running along at least a portion of the tubular,
the flow tube
having a dissolvable end section mechanically linked to the valve assembly,
the dissolvable
end segment selectively shielding the valve member from exposure to downhole
fluids,
wherein the valve member changes from an open position to a closed position
following
dissolution of the dissolvable end segment.
[0028] Embodiment 2: The downhole secondary flow member according to
embodiment 1, wherein the valve assembly includes a comingling flow chamber
fluidically
connected with the first opening.
[0029] Embodiment 3: The downhole secondary flow member according to
embodiment 1, wherein the valve member comprises a swellable valve member that
expands
upon exposure to downhole fluids.
[0030] Embodiment 4: The downhole secondary flow member according to
embodiment 1, wherein the dissolvable end segment is formed from a material
distinct from a
remaining portion of the flow tube.
[0031] Embodiment 5: The downhole secondary flow member according to
embodiment 4, wherein the dissolvable end segment is formed from a controlled
electrolytic
metal (CEM) material.
[0032] Embodiment 6: The downhole secondary flow member according to
embodiment 1, further comprising: another a valve assembly provided on the
first tubular at
the second opening, the another valve assembly including another valve member
activatable
upon exposure to downhole fluids.
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[0033] Embodiment 7: The downhole secondary flow member according to
embodiment 6, further comprising: another flow tube running along at least a
portion of the
second tubular downhole relative to the flow tube, the another flow tube
having a dissolvable
end section mechanically linked to the another valve assembly, the dissolvable
end segment
selectively shielding the another valve member from exposure to downhole
fluids.
[0034] Embodiment 8: The downhole secondary flow member according to
embodiment 7, wherein the another flow tube is fluidically connected to the
flow tube
through the tubular.
[0035] Embodiment 9: The downhole secondary flow member according to
embodiment 7, wherein the another valve assembly includes another comingling
flow
chamber fluidically connected with the comingling low chamber through the
tubular.
[0036] Embodiment 10: The downhole secondary flow member according to
embodiment 9, wherein the another comingling flow chamber is fluidically
isolated from the
comingling flow chamber following dissolution of the dissolvable flow segment.
[0037] Embodiment 11: The downhole secondary flow member according to
embodiment 9, further comprising: another tubular arranged within the tubular,
the another
tubular having an outer wall spaced from the inner wall of the tubular to form
a portion of the
flow passage.
[0038] Embodiment 12: The downhole secondary flow member according to
embodiment 11, wherein the another comingling flow chamber is fluidically
connected to the
flow comingling flow chamber through the flow passage.
[0039] Embodiment 13: The downhole secondary flow member according to
embodiment 1, further comprising: an uphole system one or more pumps a fluid
storage
system fluidically connected to the tubular through a downhole string.
[0040] Embodiment 14: A downhole flow member as in embodiment 1, wherein the
flow tube includes a first plurality of flow tubes fluidically connected to
the first opening and
running along the portion of the tubular uphole and a second plurality of flow
tubes
fluidically connected to the second opening and running along another portion
of the tubular
downhole, the first and second pluralities of flow tubes fluidically
connecting the first and
second end portions.
[0041] Embodiment 15: A method of controlling fluid flow through a secondary
flow
member comprising: directing fluid into a flow tube having a dissolvable end
portion
exposed to a downhole fluid; passing the fluid into a valve assembly having a
selectively
closeable valve member; guiding the fluid from the valve assembly into an
opening formed in
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a tubular; and closing the valve member in response to a dissolution of the
dissolvable end
portion resulting from exposure to the downhole fluid.
[0042] Embodiment 16: The method of embodiment 15, wherein closing the valve
member includes expanding the valve member in response to exposure to the
downhole fluid.
[0043] Embodiment 17: The method of embodiment 15, wherein guiding the fluid
from the valve member includes passing the along the tubular bypassing a
formation zone.
[0044] Embodiment 18: The method of embodiment 17, wherein passing the fluid
from the comingling chamber includes passing the fluid into a fluid passage
defined between
a first tubular and a second tubular.
[0045] Embodiment 19: The method of embodiment 17, further comprising: passing
the fluid from the tubular into another valve assembly arranged downhole of
the valve
assembly.
[0046] Embodiment 20: The method of embodiment 18, further comprising:
exposing another valve member of the another valve assembly to downhole fluid
following
dissolution of another dissolvable end portion of another flow tube coupled to
the another
valve assembly.
[0047] Embodiment 21: The method of embodiment 15, wherein passing the fluid
into the flow tube includes pumping the fluid from an uphole system along a
downhole string
through the flow tube.
[0048] Embodiment 22: A downhole secondary flow path member comprising: a
first valve assembly; a second valve assembly, at least one of the first and
second valve
assemblies including a selectively swellable valve member including a material
that expands
when exposed to a downhole fluid; and one or more flow tubes fluidically
connecting the first
valve member and the second valve member, the one or more flow tubes having at
least one
dissolvable end segment mechanically linked to the one of the first and second
valve
assemblies including the selectively swellable valve member, the at least one
dissolvable end
segment selectively shielding the selectively swellable valve member from
exposure to
downhole fluids, wherein the valve member changes from an open position to a
closed
position following dissolution of the dissolvable end segment.
[0049] The teachings of the present disclosure may be used in a variety of
well
operations. These operations may involve using one or more treatment agents to
treat a
formation, the fluids resident in a formation, a wellbore, and/or equipment in
the wellbore,
such as production tubing. The treatment agents may be in the form of liquids,
gases, solids,
semi-solids, and mixtures thereof Illustrative treatment agents include, but
are not limited to,
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fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement,
permeability
modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers
etc. Illustrative
well operations include, but are not limited to, hydraulic fracturing,
stimulation, tracer
injection, cleaning, acidizing, steam injection, water flooding, cementing,
etc.
[0050] The terminology used herein is for the purpose of describing particular
embodiments only and is not intended to be limiting of the present disclosure.
As used
herein, the singular forms "a", "an" and "the" are intended to include the
plural forms as well,
unless the context clearly indicates otherwise. It will be further understood
that the terms
"comprises" and/or "comprising," when used in this specification, specify the
presence of
stated features, integers, steps, operations, elements, and/or components, but
do not preclude
the presence or addition of one or more other features, integers, steps,
operations, element
components, and/or groups thereof
[0051] The term "about" is intended to include the degree of error associated
with
measurement of the particular quantity based upon the equipment available at
the time of
filing the application. For example, "about" can include a range of + 8% or
5%, or 2% of a
given value.
[0052] While one or more embodiments have been shown and described,
modifications and substitutions may be made thereto without departing from the
spirit and
scope of the invention. Accordingly, it is to be understood that the present
invention has been
described by way of illustrations and not limitation.
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