SECONDARY SLURRY FLOW PATH MEMBER WITH SHUT-OFF VALVE ACTIVATED BY DISSOLVABLE FLOW TUBES

Abstract

A downhole secondary flow path member includes a tubular having a first end portion, a second end portion, and an intermediate portion having 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 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.

Description

BACKGROUND

Downhole operations often include a downhole string that extends into a formation 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

A downhole secondary flow path member includes a tubular having a first end portion, a second end portion, and an intermediate portion having 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 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.

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.

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 downhole fluid. One or more flow tubes 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. 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

Referring now to the drawings wherein like elements are numbered alike in the several Figures:

FIG. 1 depicts an uphole system operatively connected to a downhole string having a secondary flow path member, in accordance with an exemplary embodiment;

FIG. 2 depicts a partially cut-away view of the secondary flow path member of FIG. 1;

FIG. 3 depicts a cross-sectional view of a valve assembly having a valve member of the secondary flow path member of FIG. 2;

FIG. 4 depicts a dissolvable end of a flow tube following dissolution exposing the valve member of FIG. 3;

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

FIG. 6 depicts a secondary flow path member in accordance with another aspect of an exemplary embodiment.

DETAILED DESCRIPTION

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 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.

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.

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.

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.

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 96 may 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 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.

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.

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.

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 InTallic™ from Baker Hughes Incorporated Houston Tex. 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.

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 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.

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.

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.

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.

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 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.

Set forth below are some embodiments of the foregoing disclosure:

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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 a tubular; and closing the valve member in response to a dissolution of the dissolvable end portion resulting from exposure to the downhole fluid.

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.

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.

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.

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.

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.

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.

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.

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, 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.

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

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.

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.

Claims

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.

2. The downhole secondary flow member according to claim 1, wherein the valve assembly includes a comingling flow chamber fluidically connected with the first opening.

3. The downhole secondary flow member according to claim 1, wherein the valve member comprises a swellable valve member that expands upon exposure to downhole fluids.

4. The downhole secondary flow member according to claim 1, wherein the dissolvable end segment is formed from a material distinct from a remaining portion of the flow tube.

5. The downhole secondary flow member according to claim 4, wherein the dissolvable end segment is formed from a controlled electrolytic metal (CEM) material.

6. The downhole secondary flow member according to claim 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.

7. The downhole secondary flow member according to claim 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.

8. The downhole secondary flow member according to claim 7, wherein the another flow tube is fluidically connected to the flow tube through the tubular.

9. The downhole secondary flow member according to claim 7, wherein the another valve assembly includes another comingling flow chamber fluidically connected with the comingling low chamber through the tubular.

10. The downhole secondary flow member according to claim 9, wherein the another comingling flow chamber is fluidically isolated from the comingling flow chamber following dissolution of the dissolvable flow segment.

11. The downhole secondary flow member according to claim 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.

12. The downhole secondary flow member according to claim 11, wherein the another comingling flow chamber is fluidically connected to the flow comingling flow chamber through the flow passage.

13. The downhole secondary flow member according to claim 1, further comprising: an uphole system one or more pumps a fluid storage system fluidically connected to the tubular through a downhole string.

14. A downhole flow member as in claim 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.

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 a tubular; and

closing the valve member in response to a dissolution of the dissolvable end portion resulting from exposure to the downhole fluid.

16. The method of claim 15, wherein closing the valve member includes expanding the valve member in response to exposure to the downhole fluid.

17. The method of claim 15, wherein guiding the fluid from the valve member includes passing the along the tubular bypassing a formation zone.

18. The method of claim 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.

19. The method of claim 17, further comprising: passing the fluid from the tubular into another valve assembly arranged downhole of the valve assembly.

20. The method of claim 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.

21. The method of claim 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.

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.