ADJUSTABLE FLOW CONTROL DEVICE
BACKGROUND
[0001] Wellbores are sometimes drilled into subterranean formations to produce one or
more fluids from the subterranean formation. For example, a wellbore may be used to produce
one or more hydrocarbons. Additional components such as water may also be produced with
the hydrocarbons, though attempts are usually made to limit water production from a wellbore
or a specific interval within the wellbore. Other components such as hydrocarbon gases may
also be limited for various reasons over the life of a wellbore.
[0002] Where fluids are produced from a long interval of a formation penetrated by a
wellbore, it is known that balancing the production of fluid along the interval can lead to
reduced water and gas coning, and more controlled conformance, thereby increasing the
proportion and overall quantity of oil or other desired fluid produced from the interval. Various
devices and completion assemblies have been used to help balance the production of fluid from
an interval in the wellbore. For example, inflow control devices (ICD's) have been used in
conjunction with well screens to restrict the flow of produced fluid through the screens for the
purpose of balancing production along an interval. For example, in a long horizontal wellbore,
fluid flow near a heel of the wellbore may be more restricted as compared to fluid flow near a
toe of the wellbore, to thereby balance production along the wellbore.
SUMMARY
[0003] In an embodiment, a flow control device comprises a fluid pathway configured to
provide fluid communication between an exterior of a wellbore tubular and an interior of the
wellbore tubular, a flow restriction disposed in a fluid pathway, a flow blockage disposed in the
fluid pathway, and a retaining member configured to maintain the flow blockage within the
fluid pathway and allow access to the flow blockage within the fluid pathway. The flow
blockage substantially prevents a fluid flow through the fluid pathway.
[0004] In an embodiment, a method comprises providing a flow control device comprising:
a plurality of fluid pathways between an exterior of a wellbore tubular and an interior of the
wellbore tubular, and a plurality of flow restrictions disposed in corresponding fluid pathways
of the plurality of fluid pathways, selectively installing or removing one or more flow blockages
from the plurality of fluid pathways, and producing a fluid through one or more fluid pathways
clear of the flow blockages.
[0005] In an embodiment, a method of adjusting a fluid resistance to flow comprises
determining a desired fluid flow resistance from an interval in a wellbore, and selectively
blocking or unblocking one or more fluid pathways through individual flow restrictors to
provide an overall fluid pathway with the desired fluid flow resistance.
[0006] These and other features will be more clearly understood from the following detailed
description taken in conjunction with the accompanying drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] For a more complete understanding of the present disclosure and the advantages
thereof, reference is now made to the following brief description, taken in connection with the
accompanying drawings and detailed description:
[0008] Figure 1 is a cut-away view of an embodiment of a wellbore servicing system
according to an embodiment.
[0009] Figure 2 is a partial cross-sectional view of a well screen assembly comprising an
embodiment of a flow control device.
[0010] Figure 3 is a partial cross-sectional view of an embodiment of a flow control device
along line A-A' of Figure 2.
[0011] Figure 4 is a partial cross-sectional view of a well screen assembly comprising still
another embodiment of a flow control device.
[0012] Figure 5 is a partial cross-sectional view of a well screen assembly comprising yet
another embodiment of a flow control device.
[0013] Figure 6 is a partial cross-sectional view of a well screen assembly comprising
another embodiment of a flow control device.
[0014] Figure 7 is a partial cross-sectional view of a well screen assembly comprising still
another embodiment of a flow control device.
[0015] Figure 8 is a partial cross-sectional view of a well screen assembly comprising yet
another embodiment of a flow control device.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0016] In the drawings and description that follow, like parts are typically marked
throughout the specification and drawings with the same reference numerals, respectively. The
drawing figures are not necessarily to scale. Certain features of the invention may be shown
exaggerated in scale or in somewhat schematic form and some details of conventional elements
may not be shown in the interest of clarity and conciseness.
[0017] Unless otherwise specified, any use of any form of the terms "connect," "engage,"
"couple," "attach," or any other term describing an interaction between elements is not meant to
limit the interaction to direct interaction between the elements and may also include indirect
interaction between the elements described. In the following discussion and in the claims, the
terms "including" and "comprising" are used in an open-ended fashion, and thus should be
interpreted to mean "including, but not limited to . . .". Reference to up or down will be made
for purposes of description with "up," "upper," "upward," "upstream," or "above" meaning
toward the surface of the wellbore and with "down," "lower," "downward," "downstream," or
"below" meaning toward the terminal end of the well, regardless of the wellbore orientation.
The various characteristics mentioned above, as well as other features and characteristics
described in more detail below, will be readily apparent to those skilled in the art with the aid of
this disclosure upon reading the following detailed description of the embodiments, and by
referring to the accompanying drawings.
[0018] Disclosed herein is an adjustable flow control device for use in a wellbore, which
may be used as an ICD. The flow control device may form a part of a well screen assembly and
may comprise a fluid pathway that may be selectively adjusted to either allow fluid flow or
substantially prevent fluid flow. The flow through the flow control device can then be adjusted
based on a desired resistance to flow and/or flow rate from an interval in a wellbore, thereby
allowing for the production from one or more intervals in a wellbore to be balanced. In some
embodiments, the flow control device can include a plurality of fluid pathways and flow
restrictions, each of which may be selectively and individually adjusted to provide a desired
total resistance to flow and/or overall flowrate to be selected. The plurality of flow restrictions
may each have different resistances to flow, thereby providing for a wide range of overall
resistances and/or flowrates. Thus, the adjustable flow control device may be used to fine tune
the production from a wellbore, which may be advantageous relative to other ICDs having
relatively fixed resistances and/or flow rates.
[0019] The adjustable flow control device disclosed herein may allow for selective
adjustment of an individual fluid pathway without removing a flow restriction disposed in the
fluid pathway. To enable this type of access, a retaining member can be used to provide
individual and direct access to each fluid pathway and allow for a flow blockage to be disposed
and/or removed from the fluid pathway. This may be advantageous relative to other ICDs
requiring entire sets of pathways to either be opened or sealed shut. In addition, the retaining
member may be directly accessible from an exterior of the flow control device, thereby saving
time relative to other designs requiring the removal of a cover and/or sleeve. Further, the ease
with which the flow control device disclosed herein may be adjusted can allow for the
adjustment and/or readjustment of the flow through the flow control device one or more times
between being manufactured and being disposed in a wellbore.
[0020] Referring to Figure 1, an example of a wellbore operating environment in which a
flow control device may be used is shown. As depicted, the operating environment comprises a
workover and/or drilling rig 106 that is positioned on the earth's surface 104 and extends over
and around a wellbore 114 that penetrates a subterranean formation 102 for the purpose of
recovering hydrocarbons. The wellbore 114 may be drilled into the subterranean formation 102
using any suitable drilling technique. The wellbore 114 extends substantially vertically away
from the earth's surface 104 over a vertical wellbore portion 116, deviates from vertical relative
to the earth's surface 104 over a deviated wellbore portion 136, and transitions to a horizontal
wellbore portion 117. In alternative operating environments, all or portions of a wellbore may
be vertical, deviated at any suitable angle, horizontal, and/or curved. The wellbore may be a
new wellbore, an existing wellbore, a straight wellbore, an extended reach wellbore, a
sidetracked wellbore, a multi-lateral wellbore, and other types of wellbores for drilling and
completing one or more production zones. Further, the wellbore may be used for both
producing wells and injection wells.
[0021] A wellbore tubular string 120 may be lowered into the subterranean formation 102
for a variety of drilling, completion, workover, treatment, and/or production processes
throughout the life of the wellbore. The embodiment shown in Figure 1 illustrates the wellbore
tubular 120 in the form of a completion assembly string disposed in the wellbore 114. It should
be understood that the wellbore tubular 120 is equally applicable to any type of wellbore
tubulars being inserted into a wellbore including as non-limiting examples drill pipe, casing,
liners, jointed tubing, and/or coiled tubing. Further, the wellbore tubular 120 may operate in
any of the wellbore orientations (e.g., vertical, deviated, horizontal, and/or curved) and/or types
described herein. In an embodiment, the wellbore may comprise wellbore casing 112, which
may be cemented into place in the wellbore 114.
[0022] In an embodiment, the wellbore tubular string 120 may comprise a completion
assembly string comprising one or more wellbore tubular types and one or more downhole tools
(e.g., zonal isolation devices 118, screens, valves, etc.). The one or more downhole tools may
take various forms. For example, a zonal isolation device 118 may be used to isolate the
various zones within a wellbore 114 and may include, but is not limited to, a packer (e.g.,
production packer, gravel pack packer, frac-pac packer, etc.). In an embodiment, the wellbore
tubular string 120 may comprise a plurality of well screen assemblies 122, which may be
disposed within the horizontal wellbore portion 117. The zonal isolation devices 118, may be
used between various ones of the well screen assemblies 122, for example, to isolate different
zones or intervals along the wellbore 114 from each other.
[0023] The workover and/or drilling rig 106 may comprise a derrick 108 with a rig floor
110 through which the wellbore tubular 120 extends downward from the drilling rig 106 into
the wellbore 114. The workover and/or drilling rig 106 may comprise a motor driven winch
and other associated equipment for conveying the wellbore tubular 120 into the wellbore 114 to
position the wellbore tubular 120 at a selected depth. While the operating environment depicted
in Figure 1 refers to a stationary workover and/or drilling rig 106 for conveying the wellbore
tubular 120 within a land-based wellbore 114, in alternative embodiments, mobile workover
rigs, wellbore servicing units (such as coiled tubing units), and the like may be used to convey
the wellbore tubular 120 within the wellbore 114. It should be understood that a wellbore
tubular 120 may alternatively be used in other operational environments, such as within an
offshore wellbore operational environment.
[0024] The flow control device described herein allows for the resistance to flow and/or the
flow rate through the flow control device to be selectively adjusted. The flow control device
described herein generally comprises a flow restriction disposed in a fluid pathway between an
exterior of a wellbore tubular and an interior of the wellbore tubular, a flow blocker disposed in
the fluid pathway, where the flow blocker is configured to substantially prevent a fluid flow
through the fluid pathway, and a retaining member configured to maintain the flow blocker
within the fluid pathway. The flow control device may be adjusted while leaving the flow
restriction in position in the fluid pathway. In addition, the flow control device may be adjusted
by directly accessing the fluid pathway through the retaining member from the outside of the
flow control device.
[0025] Referring now to Figure 2, a schematic partially cross-sectional view of one of the
well screen assemblies 122 comprising a flow control device is representatively illustrated at an
enlarged scale. The flow control device of the well screen assembly 122 is one of several
different examples of flow control devices described below in alternate configurations. The well
screen assembly 122 generally comprises a filter portion 202 and a flow control device 204.
The filter portion 202 is used to filter at least a portion of any sand and/or other debris from a
fluid that generally flows from an exterior 216 to an interior of the screen assembly 122. The
filter portion 202 is depicted in Figure 2 as being of the type known as "wire-wrapped," since it
is made up of a wire closely wrapped helically about a wellbore tubular 206, with a spacing
between the wire wraps being chosen to keep sand and the like that is greater than a selected
size from passing between the wire wraps. Other types of filter portions (such as sintered, mesh,
pre-packed, expandable, slotted, perforated, etc.) may also be used.
[0026] The flow control device 204 may perform several functions. In an embodiment, the
flow control device 204 is an ICD which functions to restrict flow therethrough, for example, to
balance production of fluid along an interval. The flow control device 204 generally comprises
a flow restriction 208 disposed within a fluid pathway 210 between an exterior 216 of the
wellbore tubular 206 and an interior throughbore 218 of the wellbore tubular 206. In an
embodiment, the flow restriction 208 is disposed within a housing 226. The housing 226 can
comprise a generally cylindrical member disposed about the wellbore tubular 206. The housing
226 may be fixedly engaged with the wellbore tubular 206 and one or more seals may be
disposed between the housing 226 and the exterior surface of the wellbore tubular 206 to
provide a substantially fluid tight engagement between the housing 226 and the wellbore
tubular 206.
[0027] A sleeve 228 comprises an annular member disposed about a portion of the housing
226 and a portion of the filter portion 202 to provide a seal against the exterior 216 of the
wellbore tubular 206 and the fluid pathway 210 through the housing 226. The sleeve 228 forms
a sealing engagement with an outer surface of the housing 226, and one or more seals (e.g., orings)
may be used in corresponding recesses in the sleeve 228 and/or the housing 226 to aid in
forming the sealing engagement. The sleeve 228 may be configured to engage a portion of the
filter portion 202 and prevent fluid from passing into the housing 226 without first passing
through the filter portion 202. A chamber 232 may be defined between the interior surface of
the sleeve 228, the outer surface of the wellbore tubular 206, the housing 226 and the filter
portion 202. While illustrated as a separate component from the housing 226, the sleeve 228
may be integral with the housing 226 and/or the housing 226 and the sleeve 228 may be a
single, unitary component.
[0028] Any fluid passing through the filter portion 202 and the chamber 232 may be
directed to the fluid pathway 210 disposed in a generally longitudinal direction through the
housing 226. The fluid pathway 210 may provide a fluid communication route between the
interior throughbore 218 and the exterior 216 of the wellbore tubular 206. The fluid pathway
210 may generally comprise a cylindrical throughbore, though other cross-sectional shapes such
as oval, square, rectangular, trapezoidal, etc. may also be used. The fluid pathway 210
generally extends from a first end 234 of the housing 226 in fluid communication with the
chamber 232 to a second portion 236 of the housing 226 having one or more ports 222 disposed
therein. The ports 222 may align with one or more ports 224 disposed in the wellbore tubular
206, and together, the ports 222, 224 may provide a fluid communication route between the
fluid pathway 210 and the interior throughbore 218 of the wellbore tubular 206.
[0029] In an embodiment, a plurality of fluid pathways 210 can be disposed in the housing
226 about the circumference of the wellbore tubular 206. Figure 3 illustrates a cross-sectional
view of an embodiment of a flow control device along line A-A' of Figure 2. In this
embodiment, eight flow restrictions 302, 304 are disposed in eight corresponding fluid
pathways in the housing 226 about the wellbore tubular 206. Each of the fluid pathways may
be configured to provide fluid communication between the exterior 216 of the wellbore tubular
206 and the interior throughbore 218 of the wellbore tubular 206. While Figure 3 illustrates
eight fluid pathways any number of fluid pathways may be used with the flow control device
described herein within the limits of the available space for fluid pathways 210 in the housing
226. In an embodiment, the flow control device may comprise between about 1 and about 12
fluid pathways, alternatively between about 2 and about 10 fluid pathways. In some
embodiments, more than 12 fluid pathways may be provided in the housing 226 to provide a
greater flow area for a larger fluid flowrate through the flow control device.
[0030] In an embodiment, the fluid pathways may be evenly distributed about the wellbore
tubular 206 or the fluid pathways 210 may not be evenly distributed. For example, an eccentric
alignment of the wellbore tubular 206 within the housing 226 may allow for the use of an
eccentric alignment of the fluid pathways about the wellbore tubular 206. In an embodiment,
each fluid pathway 210 may have the same or different diameter and/or longitudinal length.
[0031] Returning to Figure 2, the flow restriction 208 may generally be disposed within the
fluid pathway 210 between the first end 234 and the one or more ports 222. The flow
restriction 208 is configured to provide a desired resistance to fluid flow through the flow
restriction 208. The flow restriction 208 may be selected to provide a resistance for balancing
the production along an interval. Various types of flow restrictions 208 can be used with the
flow control device described herein. In the embodiment shown in Figure 2, the flow restriction
comprises a nozzle that comprises a central opening (e.g., orifice) for creating the resistance and
pressure drop in a fluid flowing through the flow restriction 208. Other suitable flow
restrictions may also be used including, but not limited to, narrow flow tubes, annular passages,
bent tube flow restrictors, helical tubes, and the like. Narrow flow tubes may comprise any tube
having a ratio of length to diameter of greater than about 2.5 and providing for the desired
resistance to flow. Similarly, annular passages comprise narrow flow passages that provide a
resistance to flow due to frictional forces imposed by surfaces of the fluid pathway. A bent tube
flow restrictor comprises a tubular structure that forces fluid to change direction as it enters and
flows through the flow restrictor. Similarly, a helical tube flow restrictor comprises a fluid
pathway that forces the fluid to follow a helical flow path as it flows through the flow restrictor.
The repeated change of momentum of the fluid through the bent tube and/or helical tube flow
restrictors increases the resistance to flow and can allow for the use of a larger flow passage that
may not clog as easily as the narrow flow passages of the narrow flow tubes and/or annular
passages. Each of these different flow restriction types may be used to provide a desired
resistance to flow and/or pressure drop for a fluid flow through the flow restrictor. Since the
resistance to flow may change based on the type of fluid, the type of flow restriction may be
selected to provide the desired resistance to flow for one or more type of fluid.
[0032] The flow restriction can be subject to erosion and/or abrasion from fluids passing
through the flow restriction. Accordingly, the flow restriction, or at least those portions
contacting the fluid flow can be formed from any suitable erosion and/or abrasion resistant
materials. Suitable materials may comprise various hard materials such as various steels,
tungsten, niobium, vanadium, molybdenum, silicon, titanium, tantalum, zirconium, chromium,
yttrium, boron, carbides (e.g., tungsten carbide, silicon carbide, boron carbide), nitrides (e.g.,
silicon nitride, boron nitride), oxides, silicides, alloys thereof, and any combinations thereof. In
an embodiment, one or more of these hard materials may form a portion of a composite
material. For example, the hard materials may form a particulate or discontinuous phase useful
in resisting erosion and/or abrasion, and a matrix material may bind the hard particulate phase.
Suitable matrix materials may comprise copper, nickel, iron, cobalt, alloys thereof, and any
combination thereof. Since machining hard, abrasion, erosion and/or wear resistant materials is
generally both difficult and expensive, the flow restrictions may be formed from a metal in a
desired configuration and subsequently one or more portions of the flow restriction may be
treated to provide the desired abrasion, erosion and/or wear resistance. Suitable surface
treatments used to provide erosion and/or abrasion resistance can include, but are not limited to,
carburizing, nitriding, heat treating, and any combination thereof. In embodiments in which
erosion and/or abrasion is not a concern, additional suitable materials such as various polymers
may also be used.
[0033] In an embodiment in which multiple fluid pathways 210 are disposed in the housing
226 about the wellbore tubular 206, a flow restriction 208 may be disposed in each fluid
pathway 210. The design and type of flow restriction 208 may change for each flow restriction
disposed in each fluid pathway 210. For example, the type of flow restriction 208 in each fluid
pathway may be the same or different.
[0034] In an embodiment, the design of each flow restriction disposed in each fluid
pathway 210 may also be the same or different. In an embodiment as shown in Figure 3, the
size of the central opening in a nozzle type flow restriction 302, 304 may determine the
resistance to flow and pressure drop through each flow restriction 302, 304. Each of the flow
restrictions 302, 304 disposed in each fluid pathway 210 may have a differently sized central
opening, thereby providing some flow restrictions 302 with a lower resistance to flow (e.g.,
using larger central openings) than other flow restrictions 304 with a higher resistance to flow
(e.g., using smaller central openings). In the embodiment illustrated in Figure 3, the flow
restrictions 302 may have larger central openings that the flow restrictions 304. A combination
of the large flow restrictions 302 and small flow restrictions 304 may then be used to provide a
desired total flow resistance and/or flow rate through the flow control device. While only two
central opening sizes are illustrated in Figure 3, it should be appreciated that there may also be
three or more different sizes, and in an embodiment, each flow restriction may have a
differently sized restriction. In an embodiment, the total or overall flow rate and resistance to
flow through the flow control device may be a function of the combination of each of the
individual flow rates and resistances as provided by the plurality of flow restrictions 208
disposed in the plurality of fluid pathways 210. The ability to use combinations of flow
restrictions 208 having different resistances to fluid flow may allow a wide range of total flow
rates and resistances to flow to be selected for a given flow control device, thereby providing
for the ability to balance production along an interval.
[0035] Returning the embodiment of Figure 2, the flow restriction 208 may be fixedly
engaged within the fluid pathway 210. For example, the flow restriction 208 may be press
fitted, snap fitted, bonded (e.g., adhered, soldered, welded, etc.), and/or integrally formed with
the housing so as to not be removable from the housing 226. In some contexts this may be
referred to as being permanently installed within the housing 226. In some embodiments, the
flow restriction 208 may be engaged with the housing 226 so as not to be permanently engaged
with the housing 226, but so as to only be accessible through the removal of one or more
portions of the flow control device, such as the sleeve 228. In an embodiment, the flow
restriction 208 may not be accessible and/or removable through the access port 230 and/or
retaining member 214 recess in the housing 226.
[0036] During production operations, the fluid 220 would typically flow from the exterior
216 of the wellbore tubular 206 to the screen assembly 122, through the filter portion 202, and
to the flow control device 204. Within the flow control device 204, the fluid 220 can flow
through the chamber 232, through the flow restriction 208, which may provide a resistance to
the flow of the fluid 220, through the fluid pathway 210, through the one or more ports 222 in
the housing 226, and then through the one or more ports 224 disposed in the wellbore tubular
206. The fluid 220 can then flow into the interior throughbore 218 of the wellbore tubular 206,
which extends longitudinally through the flow control device as part of the tubular string 120.
The fluid 220 can be produced through the tubular string 120 to the surface. The fluid 220 may
also flow outwardly through the filter portion 202 and/or the flow control device 204. For
example, at times during completion operations the fluid 220 may flow from the interior
throughbore 2 18 of the wellbore tubular 206 outwardly towards the exterior 216 of the wellbore
tubular 206. While described in terms of the specific arrangement of the filter portion 202 and
the flow control device 204, the flow control device 204 could be upstream of the filter portion
202 relative to a fluid flowing from the exterior 216 of the wellbore tubular 206 to the interior
throughbore 218.
[0037] A flow blockage 212 may be disposed in the fluid pathway 210 and may be retained
in the fluid pathway 210 by a retaining member 214. The retaining member 214 may
removably engage the housing 226 to allow for the disposition and/or removal of the flow
blockage 212 within the fluid pathway 210. In the embodiment illustrated in Figure 2, the
retaining member comprises an access plug having a threaded exterior that is configured to
engage corresponding threads disposed on the housing 226. In an embodiment, the access plug
may be press fitted, snap fitted, and/or retained in engagement with the housing 226 through the
use of a retaining element such as a retaining clip (e.g., a split ring), set screw, or the like. In an
embodiment comprising a plurality of fluid pathways 210 disposed in the housing 226 about the
wellbore tubular 206, a corresponding retaining member 214 may be used with each fluid
pathway 210 to allow for access to each individual fluid pathway 210.
[0038] The retaining member 214 may be accessible from an exterior 216 of the flow
control device through an access port 230 that allows direct access to each individual fluid
pathway 210. The access port 230 may be accessible from the exterior 216 without needing to
remove any additional components of the flow control device and/or any other completion
assembly components. Since the retaining member 214 may be directly exposed to the
wellbore environment, the retaining member 214 may form a substantially fluid tight seal with
the housing 226. One or more seals (e.g., o-ring seals, etc.) may be used to provide a seal
between the retaining member 214 and the housing 226. The ability to directly access
individual fluid pathways 210 may present an advantage relative to previous designs having a
cover or sleeve that must be removed to access the interior fluid pathways 210.
[0039] The flow blockage 212 may serve to substantially prevent fluid flow through the
fluid pathway 210 when disposed within the fluid pathway 210, and may comprise any
mechanism capable of substantially preventing or blocking fluid flow through the fluid pathway
210. The flow blockage 212 may allow for selective restriction of one or more fluid pathways
210 in the housing 226. In combination with access through the retaining member 214, the
arrangement of the flow blockage 212 within the fluid pathway 210 can be used to quickly
configure and/or reconfigure the resistance to flow and/or pressure drop through the flow
control device having a number of flow restrictions 208 that are fixed within the housing 226.
[0040] In an embodiment shown in Figure 2, the flow blockage 212 may comprise a rod or
plug. The rod can be configured to be removably disposed within the fluid pathway and have a
corresponding shape to mate with the fluid pathway 210. The rod may have a relatively small
tolerance with respect to the fluid pathway 210 such that only a small annular gap may remain
between the rod and the fluid pathway 210 when the rod is disposed within the fluid pathway
210. The rod may have a length sufficient to extend into the fluid pathway 210 beyond the one
or more ports 222 disposed within the housing 226, thereby substantially preventing flow
through the fluid pathway 210. The rod may have a diameter greater than the pathway through
the flow restriction (e.g., the central opening of a nozzle) and thereby be retained within the
fluid pathway 210 between the retaining member 214 and the flow restriction 208. In an
embodiment, the rod may not form a fluid tight seal with the fluid pathway 210. However, any
small annular space between the outer surface of the rod and the inner surface of the fluid
pathway 210 may form an annulus having a relatively high resistance to flow, which may be
substantially greater than any resistance to flow through another fluid pathway 210 on the same
or different flow control device. Due to the increased resistance to flow, a fluid flow may be
substantially prevented through the fluid pathway 210 having the rod disposed therein. In an
embodiment, one or more seals (e.g., o-ring seals) may be disposed in a recess on the rod and/or
the fluid pathway 210 to provide a fluid tight seal between the rod and fluid pathway 210.
[0041] The rod may be removed from the fluid pathway 210 by removing the retaining
member 214 from the housing 226, which may be accessed through the access port 230. The
retaining member 214 and the access port 230 may be sized to allow for the removal of the rod.
The rod may then be removed and the retaining member 214 can then be re-engaged with the
housing 226 to allow flow through the fluid pathway 210. Similarly, the rod may be disposed
within the fluid pathway by removing the retaining member 214 from the housing, and inserting
the rod into the fluid pathway 210. The retaining member 214 can then be re-engaged with the
housing 226, thereby substantially preventing fluid flow through the fluid pathway 210.
[0042] In an embodiment illustrated in Figure 4, another embodiment of a flow control
device is shown. In this embodiment, the flow blockage 412 comprises a rod having a tapered
(e.g., conical, frusto-conical, curved, etc.) end section 402. The rod may be disposed within the
fluid pathway 210 so that a greater pressure within the interior throughbore 218 than the
exterior 216 of the wellbore tubular 206 may act against an end 406 of the rod and bias the rod
into contact with the flow restriction 208. The tapered end section may engage the opening of
the flow restriction 208 (e.g., the central opening of a nozzle type flow restriction), which may
have a corresponding angled and/or beveled seat 404. The interaction of the tapered end
section 402 with the seat 404 may provide a substantially fluid tight seal against the flow of
fluid through the fluid pathway 210 towards the chamber 232.
[0043] When the pressure at the exterior 216 of the wellbore tubular 206 is greater than the
pressure within the interior throughbore 218, the rod may be biased towards the retaining
member 214 and retained in the fluid pathway 210 by the retaining member 214. In this
configuration, the narrow annular gap between the exterior surface of the rod and the interior
surface of the fluid pathway 210 may provide a substantial resistance to fluid flow, thereby
substantially preventing a fluid flow through the fluid pathway 210. In an embodiment, one or
more seals (e.g., o-ring seals) may be disposed in a recess on the rod and/or fluid pathway 210
to provide a fluid tight seal between the rod and fluid pathway 210, which may serve as a
redundant seal with respect to the seal formed between the end of the tapered end section 402
and the flow restriction 208.
[0044] The rod may be removed from the fluid pathway 210 by removing the retaining
member 214 from the housing 226, which may be accessed through the access port 230. The
retaining member 214 and the access port 230 may be sized to allow for the removal of the rod.
The rod may then be removed and the retaining member 214 can then be re-engaged with the
housing 226 to allow flow through the fluid pathway 210. Similarly, the rod may be disposed
within the fluid pathway 210 by removing the retaining member 214 from the housing, and
inserting the rod into the fluid pathway 210. The retaining member 214 can then be re-engaged
with the housing 226, thereby substantially preventing fluid flow through the fluid pathway
210.
[0045] In an embodiment illustrated in Figure 5, another embodiment of a flow control
device is shown. In this embodiment, the flow blockage 512 comprises a ball. The ball may be
formed from any suitable material and may be substantially spherical, though other shapes may
also be possible. The ball may be disposed within a chamber 506 defined within the fluid
pathway 210. The ball may have a diameter greater than the diameter of an opening 502 in
fluid communication with the flow restriction 208, and greater than the diameter of an opening
504 of a port 222 disposed in the housing 226. The opening 502 and/or the opening 504 may
have a beveled and/or spherically matched surface to act as a seat for contacting the ball.
[0046] Upon an engagement between the ball and the opening 502 and/or the opening 504,
the ball may form a substantial seal to fluid flow through the opening 502 and/or the opening
504, respectively. As noted herein, a perfect fluid seal is not needed since some amount of
leakage may be allowable so long as the resistance to flow is substantially greater than through
an alternative pathway between the exterior 216 of the wellbore tubular 206 and the interior
throughbore 218. The ball may then substantially prevent fluid flow through the fluid pathway
210 upon the application of a pressure differential through the fluid pathway 210. For example,
when a greater pressure exists within the interior throughbore 218 than the exterior 216 of the
wellbore tubular 206, the pressure and any resulting fluid flow may act to bias the ball against
the opening 502. The ball may engage the opening 502 of the fluid pathway and thereby form a
seal against flow through the fluid pathway 210. Similarly, when the pressure at the exterior
216 of the wellbore tubular 206 is greater than the pressure within the interior throughbore 218,
the ball may be biased against the opening 504. The ball may engage the opening 504 of the
fluid pathway 210 and thereby form a seal against flow through the fluid pathway 210. In an
embodiment, the opening 502 may have a diameter greater than the diameter of the ball. In this
embodiment, the ball may be configured to engage an opening of the flow restriction 208 to
thereby substantially form a seal.
[0047] The ball may be removed from the fluid pathway 210 by removing the retaining
member 214 from the housing 226, which may be accessed through the access port 230. The
retaining member 214 and the access port 230 may be sized to allow for the removal of the ball.
The ball may then be removed from the chamber 506 and the retaining member 214 can then
be re-engaged with the housing 226 to allow flow through the fluid pathway 210. Similarly, the
ball may be disposed within the fluid pathway by removing the retaining member 214 from the
housing 226, and inserting the ball into the chamber 506 within the fluid pathway 210. The
retaining member 214 can then be re-engaged with the housing 226, thereby substantially
preventing fluid flow through the fluid pathway 210.
[0048] In an embodiment illustrated in Figure 6, another embodiment of a flow control
device is shown. In this embodiment, the flow blockage 612 comprises a plug disposed within
the fluid pathway 210 between the flow restriction 208 and the port 222 in the housing 226.
The plug may be removably and/or releasably engaged within the fluid pathway 210 using any
suitable attachment mechanisms or means. In the embodiment illustrated in Figure 6, the plug
comprises a threaded exterior that is configured to engage corresponding threads disposed on an
interior of the fluid pathway 210. In an embodiment, the plug may comprise a press fitting,
snap fitting, and/or be retained through the use of a retaining element such as a retaining clip
(e.g., a split ring), set screw, or the like. The plug may substantially prevent fluid flow through
the fluid pathway 210. The plug may provide a substantially fluid tight seal based on the
engagement of the plug with the fluid pathway 210. In an embodiment, one or more seals (e.g.,
o-rings) may be disposed in a corresponding recess in the plug and/or fluid pathway 210 to
provide a seal between the plug and the fluid pathway 210.
[0049] The plug may be removed from the fluid pathway 210 by removing the retaining
member 214 from the housing 226, which may be accessed through the access port 230. The
retaining member 214 and the access port 230 may be sized to allow for the removal of the
plug. The plug may then be disengaged from the fluid pathway 210 and removed from the flow
control device. The retaining member 214 can then be re-engaged with the housing 226 to
allow flow through the fluid pathway 210. Similarly, the plug may be disposed within the fluid
pathway 210 by removing the retaining member 214 from the housing 226, and inserting the
plug into the fluid pathway 210. The plug may then be engaged with the fluid pathway 210.
The retaining member 214 can then be re-engaged with the housing 226, thereby substantially
preventing fluid flow through the fluid pathway 210.
[0050] In an embodiment illustrated in Figure 7, another embodiment of a flow control
device is shown. In this embodiment, the flow blockage 712 comprises a plug similar to the
plug described with respect to Figure 6. However, the plug illustrated in Figure 7 comprises a
thinned section 702 in the center of the plug. The plug can be configured to substantially
prevent a fluid flow through the fluid pathway 210 and withstand the expected pressure
differentials between the exterior 216 of the wellbore tubular 206 and the interior throughbore
218. The plug can also be configured to allow the thinned section 702 to be punctured and/or
ruptured by an appropriate punch or perforating mechanism to thereby establish fluid
communication through the plug. In the embodiment illustrated in Figure 7, the plug comprises
a threaded exterior that is configured to engage corresponding threads disposed on an interior of
the fluid pathway 210. In an embodiment, the plug may comprise a press fitting, snap fitting,
and/or be retained through the use of a retaining element such as a retaining clip (e.g., a split
ring), set screw, or the like. The plug may substantially prevent fluid flow through the fluid
pathway 210 prior to be punctured. In an embodiment, one or more seals (e.g., o-rings) may be
disposed in a corresponding recess in the plug and/or fluid pathway 210 to provide a seal
between the plug and the fluid pathway 210.
[0051] When engaged in the fluid pathway 210, fluid communication through the plug
having the thinned section 702 may be established by removing the retaining member 214 from
the housing 226, which may be accessed through the access port 230. The retaining member
214 and the access port 230 may be sized to allow for the use of a punch or other perforating
mechanism to pass into the fluid pathway 210. The plug may then be punctured and/or ruptured
to provide a fluid communication path through the plug. The retaining member 214 can then be
re-engaged with the housing 226 to allow flow through the punctured plug along the fluid
pathway 210.
[0052] In order to substantially prevent fluid flow through the fluid pathway 210, the
ruptured plug may be replaced with a new plug. A new plug may be disposed within the fluid
pathway 210 by removing the retaining member 214 from the housing, and removing the
punctured plug from the fluid pathway 210. A new plug may then be inserted and engaged in
the fluid pathway 210. The retaining member 214 can then be re-engaged with the housing
226, thereby substantially preventing fluid flow through the fluid pathway 210.
[0053] In an embodiment illustrated in Figure 8, still another embodiment of a flow control
device is shown. In this embodiment, the flow blockage 812 comprises a deformable plug. The
deformable plug may comprise one or more deformable materials and may be configured to be
disposed within the fluid pathway 210 by press fitting or other suitable method. Upon being
press-fitted into the fluid pathway 210, the plug may deform (e.g., elastically and/or plastically)
and engage the inner surface of the fluid pathway 210, thereby a substantially preventing fluid
flow through the fluid pathway 210. Suitable materials useful in forming the deformable plug
can include any number of relatively soft metals such as lead, zinc, copper, silver, antimony,
gold, tin, bismuth, indium, aluminum, combinations thereof, and alloys thereof. In an
embodiment, one or more suitable polymeric components may be used to form the deformable
plug. Various polymeric components may be suitable for use in a downhole wellbore
environment including but not limited to, nitrile rubbers (e.g., nitrile butadiene rubber,
hydrogenated nitrile butadiene rubber, etc.), fluoropolymers (e.g., perfluoroelastomers,
tetrafluoroethylene, tetrafluoroethylene/ propylene mixtures), polyamides, ethylene propylene
diene rubbers, and the like. Additional suitable materials capable of being deformed within the
fluid pathway 210 may also be used.
[0054] In order to substantially prevent fluid flow through the fluid pathway 210, the
retaining member 214 may be removed from the housing 226, which may be accessed through
the access port 230. The deformable plug may then be disposed at least partially within the
fluid pathway 210. The deformable plug may then be press fitted within the fluid pathway 210,
thereby deforming the deformable plug and forcing the deformable plug within the fluid
pathway 210. The deformable plug may then substantially prevent fluid flow through the fluid
pathway 210. The retaining member 214 may then be reengaged with the housing 226.
[0055] When engaged in the fluid pathway 210, the deformable plug may be removed by
first removing the retaining member 214 from the housing 226. In an embodiment, the
deformable plug may be removed by grasping and removing the deformable plug. In an
embodiment, the deformable plug may be drilled and/or milled out to remove at least a portion
of the deformable plug, thereby establishing fluid communication through the deformable plug
and along the fluid pathway 210. The retaining member 214 can then be re-engaged with the
housing 226 to allow flow through any remaining portion of the deformable plug.
[0056] In an embodiment in which a plurality of fluid pathways is used with the flow
control device, any of the flow restrictions, flow blockages, and methods of installing and/or
removing the flow blockages in the fluid pathways may be used with any of the fluid pathways.
Each of the fluid pathways may comprise the same type of flow blockages or different types of
flow blockages. Further, each of the types of flow blockages may be used with any of the flow
restrictions described herein. All of the combinations between the flow restrictions and flow
blockages are envisioned as part of the flow control device described herein. It can also be
noted from the description above that in each instance the flow blockage can be disposed in
and/or removed from the fluid pathway without removing the flow restriction, which may be
fixedly disposed within the fluid pathway.
[0057] In an embodiment, a plurality of flow control devices may be used with one or more
wellbore tubular sections that may cover one or more intervals in a wellbore. A wellbore
tubular string generally refers to a plurality of wellbore tubular sections connected together for
conveyance within the wellbore. For example, the wellbore tubular string may comprise a
production tubing string conveyed within the wellbore for producing one or more fluids from a
wellbore. The number and type of flow control devices and the spacing of the flow control
devices along the wellbore tubular may vary along the length of the wellbore tubular based on
the expected conditions within the wellbore and locations of the intervals. In an embodiment, a
plurality of flow control devices comprising one or more flow restrictions and/or fluid
blockages disposed in one or more corresponding fluid pathways may form a portion of a
wellbore tubular string. The wellbore tubular string may then be placed in the wellbore
disposed in a subterranean formation and used to produce one or more fluids from the
subterranean formation. In an embodiment, the flow control devices, which may form a portion
of one or more well screen assemblies, may be used to balance the production from one or more
intervals in the subterranean formation.
[0058] The ability to access the fluid pathways to dispose and/or remove a flow blockage
within the fluid pathway may allow a flow control device to be reconfigured to provide a
desired resistance to flow, and therefore, a desired flow rate through the flow control device for
the expected conditions in the wellbore section. The flow control device may begin with flow
blockages disposed in all of the fluid pathways, in none of the fluid pathways, or in some
portion of the fluid pathways. The flow blockages may then be selectively adjusted by
installing and/or removing a flow blockage in individual pathways to provide a desired
resistance to flow through the flow control device as needed. In an embodiment, the flow
blockages may be adjusted based on a variety of reasons including, but not limited to, the
determination of a desired fluid resistance and/or flow rate.
[0059] In an embodiment, a flow control device may be provided comprising a plurality of
fluid pathways between an exterior of a wellbore tubular and an interior of the wellbore tubular.
Each fluid pathway may comprise a flow restriction and a flow blockage configured to
substantially prevent fluid flow through the fluid pathway. A corresponding plurality of
retaining members may be configured to maintain the flow blockages within each fluid
pathway. In this configuration, flow through all of the fluid pathways may be substantially
prevented. In order to selectively adjust the flow control device to provide a desired resistance
to flow, one or more of the flow blockages may be selectively removed from one or more of the
plurality of fluid pathways using any of the methods described above. For example, the flow
blockages may be removed from the fluid pathways having the appropriate combination of flow
restrictions, which may each be the same, different, or any combination thereof, to provide the
desired total resistance to flow through the flow control device. A fluid may then be allowed to
flow through the one or more fluid pathways having the flow blockages removed. For example,
the flow control device may be used to produce a fluid from a subterranean formation and/or
inject a fluid into a subterranean formation through the one or more fluid pathways having the
flow blockages removed.
[0060] Having a flow control device with all of the fluid pathways comprising flow
blockages may be useful to provide some degree of adjustability to a wellbore tubular string
comprising additional flow control devices that are configured for the expected wellbore
conditions. In this embodiment, the one or more flow control devices may serve as backups
along the string for use in adjusting the overall resistance to flow within a zone of the wellbore.
For example, when an increased flow rate and/or decreased overall resistance to flow through a
zone is desired, one or more of the flow blockages may be removed from the fluid pathways.
The ability to access individual flow blockages may allow for a fine tuning of the flow rate
and/or resistance to flow at any time prior to disposing the flow control device within the
wellbore.
[0061] In an embodiment, a flow control device may be provided comprising a plurality of
fluid pathways between an exterior of a wellbore tubular and an interior of the wellbore tubular.
Each fluid pathway may comprise a flow restriction while being free of any flow blockage. A
plurality of retaining members may be configured to allow access to each fluid pathway and be
accessible from an exterior of the flow control device without removing an additional
component such as a cover or sleeve. In this configuration, flow through all of the fluid
pathways may be allowed, thereby providing an overall resistance to flow resulting from the
combination of the individual resistances to flow through each of the fluid restrictions. In order
to selectively adjust the flow control device to provide a desired resistance to flow less than the
overall resistance to flow, one or more of the flow blockages may be selectively disposed
and/or installed within one or more of the plurality of fluid pathways using any of the methods
described above. For example, flow blockages may be disposed in one or more fluid pathways
to leave one or more open fluid pathways having the appropriate combination of flow
restrictions, which may each be the same, different, or any combination thereof, to provide the
desired total resistance to flow through the flow control device. A fluid may then be allowed to
flow through the one or more fluid pathways without the flow blockages installed. For
example, the flow control device may be used to produce a fluid from a subterranean formation
and/or inject a fluid into a subterranean formation through the one or more fluid pathways
without the flow blockages installed.
[0062] Having a flow control device without any fluid pathways comprising flow
blockages may be useful to provide an initial assembly that can be adjusted as needed. For
example, a plurality of flow control devices can be provided and selectively adjusted to provide
a desired flow rate and/or resistance to flow based on the expected operating conditions within
the wellbore. In this embodiment, one or more of the flow blockages may be installed to
provide the desired resistance to flow at any point between being manufactured and being
disposed within a wellbore.
[0063] In an embodiment, a flow control device may be provided comprising a plurality of
fluid pathways between an exterior of a wellbore tubular and an interior of the wellbore tubular.
One or more of the fluid pathways, but not necessarily all of the fluid pathways, may comprise
a flow restriction and a flow blockage configured to substantially prevent fluid flow through the
corresponding fluid pathway. A plurality of retaining members may be configured to allow
access to each fluid pathway and to maintain the flow blockages within each fluid pathway
comprising a flow blockage. In this configuration, flow through each of the fluid pathways
comprising a flow blockage may be substantially prevented. In order to selectively adjust the
flow control device to provide a desired resistance to flow, one or more of the flow blockages
may be selectively installed and/or removed from one or more of the plurality of fluid pathways
using any of the methods described above. For example, the flow blockages may be installed
and/or removed from one or more of the fluid pathways to provide the appropriate combination
of flow restrictions, which may each be the same, different, or any combination thereof, to
provide the desired total resistance to flow through the flow control device. A fluid may then
be allowed to flow through the one or more fluid pathways clear of the flow blockages. For
example, the flow control device may be used to produce a fluid from a subterranean formation
and/or inject a fluid into a subterranean formation through the one or more fluid pathways clear
of any flow blockages.
[0064] The flow control devices may be selectively adjusted at any point prior to being
disposed in a wellbore. For example, the flow control devices can be manufactured with or
without any flow blockages disposed in the fluid pathways. The flow control devices may then
pass through various shipping and distribution centers where the fluid pathways may be
selectively adjusted. When delivered to a wellsite for use in a wellbore, the flow control
devices can be selectively adjusted at the surface prior to being disposed in the wellbore. Still
further, the flow control device may be retrieved from a wellbore after being disposed within
the wellbore. The flow control device can then be selectively adjusted after being retrieved and
prior to be re-disposed within the wellbore.
[0065] In an embodiment, the flow control device may be selectively adjusted using any of
the methods described above based on a determination of a desired fluid resistance and/or flow
rate through the flow control device. In general, the fluid resistance and/or flow rate through a
flow control device may be selected to balance the production of fluid along an interval. The
determination of the fluid resistance and/or flow rate for an interval may be determined based
on the desired production from the interval and the expected conditions within the interval
including, but not limited to, the permeability of the formation within the interval, the total
length of the interval, the types of fluids being produced from the interval, and/or the fluid
properties of the fluids being produced in the interval. Once a desired fluid resistance and/or
flow rate for an interval is determined, the flow control device may be selectively adjusted by
installing and/or removing one or more flow blockages from one or more corresponding fluid
pathways within the flow control device to provide a total fluid pathway having the desired
fluid resistance and/or flow rate. In an embodiment, the flow control device may be selectively
adjusted without removing the flow restriction. In an embodiment, the flow control device may
be selectively adjusted by accessing the fluid pathway through a retaining member directly
accessible from an exterior of the flow control device, without needing to remove a sleeve,
cover, and/or other access mechanism.
[0066] Having described various systems and methods herein, various embodiments may
include, but are not limited to:
[0067] In a first embodiment, a flow control device comprises a fluid pathway configured
to provide fluid communication between an exterior of a wellbore tubular and an interior of
the wellbore tubular, a flow restriction disposed in the fluid pathway, a flow blockage
disposed in the fluid pathway, and a retaining member configured to maintain the flow
blockage within the fluid pathway and allow access to the flow blockage within the fluid
pathway. The flow blockage substantially prevents a fluid flow through the fluid pathway.
In a second embodiment, the flow control device of the first embodiment may also include a
filter portion disposed in the fluid pathway between the exterior of the wellbore tubular and
the interior of the wellbore tubular. In a third embodiment, the flow restriction of the first or
second embodiments may comprise a nozzle, a narrow flow tube, an annular passage, a bent
tube flow restrictor, or a helical tube. In a fourth embodiment, the flow restriction of any of
the first to third embodiments may be permanently installed within the fluid pathway. In a
fifth embodiment, the flow blockage of any of the first to fourth embodiments may comprise
a rod configured to be removably disposed within the fluid pathway. In a sixth embodiment,
the rod of the fifth embodiment may comprise a tapered end section, and the tapered end
section may be configured to sealingly engage the flow restriction. In a seventh embodiment,
the flow blockage of the first embodiment may comprise a ball, and the ball may be
configured to engage one or more openings within the fluid pathway to substantially prevent
the fluid flow through the fluid pathway. In an eighth embodiment, the flow blockage of the
first embodiment may comprise a plug configured to be removably disposed within the fluid
pathway. In a ninth embodiment, the plug of the eighth embodiment may comprise a thinned
section, and the thinned section may be configured to be punctured to establish fluid
communication through the plug. In a tenth embodiment, the plug of the eighth embodiment
may comprise a deformable plug configured to be disposed within the fluid pathway. In an
eleventh embodiment, the flow control device of any of the first to tenth embodiments may
also include a plurality of flow restrictions disposed in a corresponding plurality of fluid
pathways between the exterior of the wellbore tubular and the interior of the wellbore
tubular, and the flow blockage may be disposed in a first fluid pathway of the plurality of
fluid pathways. In a twelfth embodiment, an overall resistance to flow may be provided by a
flow path comprising each of the plurality of fluid pathways of the eleventh embodiment that
is clear of a flow blockage. In a thirteenth embodiment, the flow control device of the
eleventh or twelfth embodiments may also include a plurality of retaining members
corresponding to the plurality of fluid pathways, and each retaining member of the plurality
of retaining members may be configured to provide direct access to each corresponding fluid
pathway. In a fourteenth embodiment, wherein a first of the plurality of flow restrictions of
any of the eleventh to thirteenth embodiments may have a different resistance to a fluid flow
than a second of the plurality of flow restrictions.
[0068] In a fifteenth embodiment, a method comprises providing a flow control device,
selectively installing or removing one or more flow blockages from the plurality of fluid
pathways, and producing a fluid through one or more fluid pathways clear of the flow
blockages. The flow control device comprises a plurality of fluid pathways between an
exterior of a wellbore tubular and an interior of the wellbore tubular, and a plurality of flow
restrictions disposed in corresponding fluid pathways of the plurality of fluid pathways. In a
sixteenth embodiment, the plurality of flow restrictions of the fifteenth embodiment may
remain within the fluid pathways during the selective installation or removal of the one or
more flow blockages. In a seventeenth embodiment, selectively installing or removing the
one or more flow blockages of the fifteenth or sixteenth embodiments may comprise
accessing one or more of the fluid pathways through an access port, and the access port may
provide direct access to the fluid pathway from the exterior of the wellbore tubular. In an
eighteenth embodiment, the flow blockages of any of the fifteenth to eighteenth embodiments
may comprise at least one of a rod removably disposed within one or more of the fluid
pathways, a tapered rod removably disposed within one or more of the fluid pathways, a ball
configured to engage one or more openings within one or more of the fluid pathways, a plug
configured to be removably disposed within one or more of the fluid pathways, a plug
comprises a thinned section that is configured to be punctured to establish fluid
communication through the plug, or a deformable plug configured to be disposed within one
or more of the fluid pathways.
[0069] In a nineteenth embodiment, a method of adjusting a fluid resistance to flow
comprises determining a desired fluid flow resistance from an interval in a wellbore, and
selectively blocking or unblocking one or more fluid pathways through individual flow
restrictors to provide an overall fluid pathway with the desired fluid flow resistance. In a
twentieth embodiment, the method of the nineteenth embodiment may also include producing
a fluid from a subterranean formation through each of the unblocked individual flow
restrictors.
[0070] At least one embodiment is disclosed and variations, combinations, and/or
modifications of the embodiment(s) and/or features of the embodiment(s) made by a person
having ordinary skill in the art are within the scope of the disclosure. Alternative
embodiments that result from combining, integrating, and/or omitting features of the
embodiment(s) are also within the scope of the disclosure. Where numerical ranges or
limitations are expressly stated, such express ranges or limitations should be understood to
include iterative ranges or limitations of like magnitude falling within the expressly stated
ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10
includes 0.1 1, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit,
Ri, and an upper limit, Ru, is disclosed, any number falling within the range is specifically
disclosed. In particular, the following numbers within the range are specifically disclosed:
R=Ri+k*(Ru-Ri), wherein k is a variable ranging from 1 percent to 100 percent with a 1
percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, 50
percent, 5 1 percent, 52 percent, . . ., 95 percent, 96 percent, 97 percent, 98 percent, 99 percent,
or 100 percent. Moreover, any numerical range defined by two R numbers as defined in the
above is also specifically disclosed. Use of the term "optionally" with respect to any element
of a claim means that the element is required, or alternatively, the element is not required,
both alternatives being within the scope of the claim. Use of broader terms such as
comprises, includes, and having should be understood to provide support for narrower terms
such as consisting of, consisting essentially of, and comprised substantially of. Accordingly,
the scope of protection is not limited by the description set out above but is defined by the
claims that follow, that scope including all equivalents of the subject matter of the claims.
Each and every claim is incorporated as further disclosure into the specification and the
claims are embodiment(s) of the present invention.
CLAIMS
What is claimed is:
1. A flow control device comprising:
a fluid pathway configured to provide fluid communication between an exterior of a
wellbore tubular and an interior of the wellbore tubular;
a flow restriction disposed in the fluid pathway;
a flow blockage disposed in the fluid pathway, wherein the flow blockage
substantially prevents a fluid flow through the fluid pathway; and
a retaining member configured to maintain the flow blockage within the fluid
pathway and allow access to the flow blockage within the fluid pathway.
2. The flow control device of claim 1, further comprising a filter portion disposed in the
fluid pathway between the exterior of the wellbore tubular and the interior of the wellbore
tubular.
3. The flow control device of claim 1 or 2, wherein the flow restriction comprises a
nozzle, a narrow flow tube, an annular passage, a bent tube flow restrictor, or a helical tube.
4. The flow control device of any of claims 1 to 3, wherein the flow restriction is
permanently installed within the fluid pathway.
5. The flow control device of any of claims 1 to 4, wherein the flow blockage comprises
a rod configured to be removably disposed within the fluid pathway.
6. The flow control device of claim 5, wherein the rod comprises a tapered end section,
and wherein the tapered end section is configured to sealingly engage the flow restriction.
7. The flow control device of claim 1, wherein the flow blockage comprises a ball,
wherein the ball is configured to engage one or more openings within the fluid pathway to
substantially prevent the fluid flow through the fluid pathway.
8. The flow control device of claim 1, wherein the flow blockage comprises a plug
configured to be removably disposed within the fluid pathway.
9. The flow control device of claim 8, wherein the plug comprises a thinned section,
wherein the thinned section is configured to be punctured to establish fluid communication
through the plug.
10. The flow control device of claim 8, wherein the plug comprises a deformable plug
configured to be disposed within the fluid pathway.
11. The flow control device of any of claims 1 to 10, further comprising:
a plurality of flow restrictions disposed in a corresponding plurality of fluid pathways
between the exterior of the wellbore tubular and the interior of the wellbore
tubular, wherein the flow blockage is disposed in a first fluid pathway of the
plurality of fluid pathways.
12. The flow control device of claim 11, wherein an overall resistance to flow is provided
by a flow path comprising each of the plurality of fluid pathways that is clear of a flow
blockage.
13. The flow control device of claim 11 or 12, further comprising:
a plurality of retaining members corresponding to the plurality of fluid pathways,
wherein each retaining member of the plurality of retaining members is
configured to provide direct access to each corresponding fluid pathway.
14. The flow control device of any of claims 11to 13, wherein a first of the plurality of
flow restrictions has a different resistance to a fluid flow than a second of the plurality of
flow restrictions.
15. A method comprising:
providing a flow control device comprising: a plurality of fluid pathways between an
exterior of a wellbore tubular and an interior of the wellbore tubular, and a
plurality of flow restrictions disposed in corresponding fluid pathways of the
plurality of fluid pathways;
selectively installing or removing one or more flow blockages from the plurality of
fluid pathways; and
producing a fluid through one or more fluid pathways clear of the flow blockages.
16. The method of claim 15, wherein the plurality of flow restrictions remain within the
fluid pathways during the selective installation or removal of the one or more flow blockages.
17. The method of claim 15 or 16, wherein selectively installing or removing the one or
more flow blockages comprises accessing one or more of the fluid pathways through an
access port, wherein the access port provides direct access to the fluid pathway from the
exterior of the wellbore tubular.
18. The method of any of claims 15 to 17, wherein the flow blockages comprise at least
one of a rod removably disposed within one or more of the fluid pathways, a tapered rod
removably disposed within one or more of the fluid pathways, a ball configured to engage
one or more openings within one or more of the fluid pathways, a plug configured to be
removably disposed within one or more of the fluid pathways, a plug comprises a thinned
section that is configured to be punctured to establish fluid communication through the plug,
or a deformable plug configured to be disposed within one or more of the fluid pathways.
19. A method of adjusting a fluid resistance to flow comprising:
determining a desired fluid flow resistance from an interval in a wellbore; and
selectively blocking or unblocking one or more fluid pathways through individual
flow restrictors to provide an overall fluid pathway with the desired fluid flow
resistance.
20. The method of claim 19, further comprising:
producing a fluid from a subterranean formation through each of the unblocked
individual flow restrictors.