DOWNHOLE FLOW CONTROL USING PERFORATOR AND
MEMBRANE
Technical Field of the Invention
[0001] The present invention relates generally to assemblies for
controlling fluid flow in a bore in a subterranean formation and, more
particularly (although not necessarily exclusively), to assemblies that
include membranes that can be perforated in response to pressure to
allow fluid flow.
Background
[0002] Various devices can be installed in a well traversing a
hydrocarbon-bearing subterranean formation. Some devices control
the flow rate of fluid between the formation and tubing, such as
production or injection tubing. An example of these devices is a flow
control device or inflow control device that can be associated with a
production interval isolated by packers and that can control
production of fluid by creating a pressure drop of fluid flowing
through the device.
[0003] A completion assembly can be ran downhole with a
packer. Pressure can be introduced in the tubing to set the packer.
Subsequent to setting the packer, openings or ports in the assembly
can be created for fluid production.
[0004] Some assemblies include components that facilitate or
allow creation of ports for fluid production. For example, an assembly
can include openings plugged with aluminum or polylactic acid (PLA)
that can dissolve on exposure to acid introduced into the bore (in the
case of aluminum) or to an environment of the bore (in the case of
PLA). PLA plugs, however, may be unable to withstand pressure
above a certain threshold.
[0005] Assemblies are desirable, however, that can allow for
relatively high pressure to set a packer and then allow for fluid flow
control.
Summary
[0006] Certain aspects of the present invention are directed to a
flow control assembly that can provide a pressure seal during a
packer setting operation and allow fluid flow subsequent to a
membrane being perforated in response to a setting pressure from an
inner area of a tubing.
[0007] One aspect relates to a flow control assembly that can be
disposed in a wellbore. The flow control assembly includes a
membrane and a perforator. The membrane can provide a pressure
seal and prevent fluid flow in the flow control assembly. The
perforator can perforate the membrane in response to a setting
pressure in the flow control assembly exceeding a threshold. The
perforated member can provide a fluid flow path in the flow control
assembly.
[0008] Another aspect relates to a flow control assembly that
includes a membrane, a perforator, and a piston. The membrane can
provide a pressure seal and prevent fluid flow in the flow control
assembly. The piston can cause at least one of the perforator or the
membrane to move in response to pressure from an inner area of a
tubing. The perforator can create a flow path through the membrane
in response to movement of the perforator or the membrane.
[0009] Another aspect relates to an assembly that includes a
tubing portion, an outer housing, a perforator, a membrane, and a
piston. The tubing portion has a tubing port that can allow access of
pressure from an internal area of the tubing portion to an external
area. The outer housing is external to the tubing portion having the
tubing port. The outer housing includes a housing opening and
defines a flow path between the outer housing and the tubing port.
The perforator is disposed in the flow path in a fixed position. The
membrane is disposed in the flow path. The membrane can provide a
pressure seal and pressure fluid flow in the flow path in response to a
packer setting pressure. The piston is disposed in the flow path and
coupled to the membrane. The piston can allow the membrane to
move toward the perforator in response to the pressure being above a
threshold. The perforator can perforate the membrane in response to
the membrane moving toward the perforator. The perforated
membrane can allow fluid flow through the flow path.
[0010] These illustrative aspects and features are mentioned not
to limit or define the invention, but to provide examples to aid
understanding of the inventive concepts disclosed in this disclosure.
Other aspects, advantages, and features of the present invention will
become apparent after review of the entire disclosure.
Brief Description of the Drawings
[001 1] Fig. 1 is a schematic illustration of a well system having
production intervals in which are flow control assemblies according to
one aspect of the present invention.
[0012] Fig. 2 is a cross-sectional view of a flow control assembly
that includes a perforator and a membrane according to one aspect of
the present invention.
[0013] Fig. 3 is a cross-sectional view of the flow control
assembly of Fig. 2 subsequent to perforation of the membrane
according to one aspect of the present invention.
[0014] Fig. 4 is a partial cross-sectional view of a flow control
assembly according to another aspect of the present invention.
[00 15 ] Fig. 5 is a partial cross-sectional view of the flow control
assembly of Fig. 4 subsequent to perforation of the membrane
according to one aspect of the present invention.
[00 16 ] Fig. 6 is a partial cross-sectional view of the flow control
assembly of Fig. 4 in an open flow position according to one aspect of
the present invention.
[0017] Fig. 7 is a partial cross-sectional view of a flow control
assembly according to yet another aspect of the present invention.
Detailed Description
[0018] Certain aspects and features relate to a flow control
assembly that includes a membrane that can be perforated in
response to a pressure, such as a setting pressure, from an inner area
of a tubing. Subsequent to the membrane being perforated, fluid can
be allowed to flow from an area external to the tubing to an area
internal to the tubing. The membrane may remain closed during a
packer setting operation and be perforated subsequent to the packer
setting operation.
[0019] In some aspects, the flow control assembly includes a
perforator, a piston, and a membrane. The piston can allow at least
one of the perforator or the membrane to move in response to a
pressure above a certain threshold. The movement can result in the
membrane being perforated by the perforator. After the pressure is
released, the piston can allow the perforator and / or the membrane
to move to an open position, allowing fluid to flow to an inner area of a
tubing through a tubing port.
[0020] In another aspect, the flow control assembly includes a
spring that can cause the piston to allow the perforator and / or the
membrane to move to the open position subsequent to perforation of
the membrane.
[002 ] These illustrative aspects and examples are given to
introduce the reader to the general subject matter discussed here and
are not intended to limit the scope of the disclosed concepts. The
following sections describe various additional features and examples
with reference to the drawings in which like numerals indicate like
elements, and directional descriptions are used to describe the
illustrative aspects but, like the illustrative aspects, should not be
used to limit the present invention.
[0022] Fig. 1 depicts a well system 100 with flow control
assemblies according to certain aspects of the present invention. The
well system 100 includes a bore that is a wellbore 102 extending
through various earth strata. The wellbore 102 has a substantially
vertical section 104 and a substantial^ horizontal section 106. The
substantially vertical section 104 and the substantially horizontal
section 106 may include a casing string 108 cemented at an upper
portion of the substantially vertical section 104. The substantially
horizontal section 106 extends through a hydrocarbon bearing
subterranean formation 110.
[0023] A tubing string 112 extends from the surface within
wellbore 102. The tubing string 112 can provide a conduit for
formation fluids to travel from the substantially horizontal section 106
to the surface. Production tubular sections 116 in various production
intervals adjacent to the formation 110 are positioned in the tubing
string 112. On each side of each production tubular section 116 is a
packer 1 8 that can provide a fluid seal between the tubing string 112
and the wall of the wellbore 102. Each pair of adjacent packers 118
can define a production interval.
[0024] One or more of the production tubular sections 116 can
include a flow control assembly. The flow control assembly can
include one or more ports in the tubing string 112 and a membrane
that can be perforated in response to a pressure to create a flow path,
which may include the ports in the tubing string.
[0025] Although Fig. 1 depicts production tubular sections 116
that can include flow control assemblies positioned in the
substantially horizontal section 106, production tubular sections 116
(and flow control assemblies) according to various aspects of the
present invention can be located, additionally or alternatively, in the
substantially vertical section 104. Furthermore, any number of
production tubular sections 116 with flow control assemblies,
including one, can be used in the well system 100 generally or in each
production interval. In some aspects, production tubular sections
116 with flow control assemblies can be disposed in simpler wellbores,
such as wellbores having only a substantially vertical section. Flow
control assemblies can be disposed in open hole environments, such
as is depicted in Fig. 1, or in cased wells.
[0026] Figs. 2-3 depict by cross-section a flow control assembly
according to one aspect. The flow control assembly includes a tubing
portion 202 and an outer housing 204. The flow control assembly
also includes a membrane 206, a perforator 208, and a piston 210
that are between an outer wall of the tubing portion 202 and an inner
wall of the outer housing 204.
[0027] The tubing portion 202 includes a tubing port 212 that
can allow fluid to flow between an inner area of the tubing portion 202
and an outer area of the tubing portion 202. The tubing port 2 12 may
also allow pressure access between the inner area of the tubing
portion 202 and the outer area of the tubing portion 202.
[0028] The piston 210 may be made from any material. An
example of material from which piston 210 can be made is stainless
steel. The piston 210 can be coupled to the outer housing 204 by a
shear mechanism 214. An example of a shear mechanism 214 is a
shear pin. Included with the piston 210 are sealing members 216A-D.
An example of a sealing member is an O-ring. Although four sealing
members are depicted, any number, including one, can be used.
Other aspects do not include sealing members.
[0029] The perforator 208 can include a base 2 18 and an
elongated member 220 extending from the base 218. The elongated
member 220 may have a pointed end that can perforate the
membrane 206. The base 218 can be coupled to the outer housing
204 such that the perforator 208 is fixed in position within the outer
housing 204. The base 218 includes openings 222A-B through which
fluid can flow from a housing opening toward the tubing port 2 12.
Bases according to various aspects can include any number of
openings, including one. The perforator 208 can be made from any
material. An example of material is tungsten carbide. In some
aspects, the elongated member 220 is made from a material such as
tungsten carbide and the base 218 is made from a different material
such as steel.
[0030] The membrane 206 can be coupled to the piston 210. In
some aspects, the membrane 206 and piston 210 are one component
made from the same material. An example of membrane 206 is a
ceramic disc.
[0031] The membrane 206 in a closed position, as shown in Fig.
2, can prevent fluid from flowing from a housing opening 224 to the
tubing port 212. For example, the membrane 206 may prevent fluid
flow during a packer setting operation or other operation. The piston
210 can prevent the membrane 206 from being perforated in response
to pressure during the packer setting operation. A setting pressure
above a certain threshold can be applied through the inner area of the
tubing portion 202 and the tubing port 2 12 to an external area of the
tubing portion 202 in the outer housing 204. The setting pressure is
depicted as "DR" in Fig. 3. In response to the pressure, the piston 210
can allow the membrane 206 to move toward the perforator 208, as
shown in Fig. 3. The shear mechanism 214 can be sheared such that
at least part of the piston 210 is decoupled from the outer housing
204. The perforator 208 can perforate the membrane 206 in response
to the movement of the membrane 206 toward the perforator 208.
[0032] For example, the elongated member 220 can break the
membrane 206 or otherwise create an opening in the membrane 206.
Sealing members 216A-D can retain pressure within the tubing
portion 202 to allow other flow control assemblies in the wellbore to be
opened using pressure from within tubing of which the tubing portion
202 is a part. Subsequently, such as after the pressure from within
the tubing is removed, fluid flow or pressure from the housing opening
224 can cause the piston 210 to allow the membrane 206 to move
away from the perforator 208 to a position that allows fluid flow from
the housing opening 224 to the tubing port 2 12. For example, force or
pressure from production fluid flowing through openings 222A-B can
cause the piston 2 10 to allow the membrane 206 to move away from
the perforator 208, creating a flow path for fluid flow through the
outer housing 204 and the tubing port 2 12 into the inner area of the
tubing portion 202.
[0033] Flow control assemblies according to some aspects can
include mechanisms that can facilitate creation of a flow path
subsequent to a membrane being perforated. Figs. 4-6 depict by
partial cross-section a flow control assembly according to another
aspect. The flow control assembly includes a tubing portion 302, an
outer housing, 304, a membrane 306, a perforator 308, and a piston
310. The tubing portion 302 includes a tubing port 312. The piston
310 extends from a base 314 of the perforator 308 toward the tubing
port 312 and includes a stop member 316. The stop member 316 can
prevent the membrane 306 from moving toward the tubing port 312
beyond a certain point. The perforator 308 also includes an elongated
member 318 extending from the base 314 toward the membrane 306.
The base 314 can be coupled to the outer housing 304 such that the
perforator 308 is in a fixed position.
[0034] The flow control assembly also includes a mechanism that
is a spring 320 between the base 314 and a movable portion of the
piston 310. As shown in Fig. 4, the spring 320 can bias the piston
310 and the membrane 306 toward the tubing port 312 such that the
membrane 306 contacts the stop member 316. In response to
pressure from an inner area of the tubing portion 302, the piston 310
can allow the membrane 306 to move toward the perforator 308 and
overcome the biasing force of the spring 320. The elongated member
318 can perforate the membrane 306 to create an opening in the
membrane 306, as shown in Fig. 5. The opening can be part of flow
path from an opening of the outer housing 304 through the tubing
port 312 to the inner area of the tubing portion 302.
[0035] Subsequent to perforation of the membrane 306, the
spring 320 can bias the moveable portion of the piston 3 10 and any
remainder part of the membrane 306 to the stop member 316 such
that the flow control assembly is in a full open position, as shown in
Fig. 6. In a full open position, fluid can flow through the flow control
assembly, including the tubing port 312, without significant
restriction. The spring 320 can basis the moveable portion of the
piston 310 and any remainder part of the membrane 306 to the stop
member 316 even if pressure from fluid from an opening of the outer
housing 304 is insufficient to move the piston 310 and the membrane
306.
[0036] Fig. 7 depicts another aspect of a flow control assembly in
which a perforator 402 is coupled to a piston 404, and can move in
response to pressure from an inner area of a tubing portion 406
through a tubing port 408 to perforate a membrane 410 that is
coupled to an outer housing 412. For example, the membrane 410
may be in a fixed position and the piston 404 can allow the perforator
402 to move in response to pressure above a certain threshold. In still
other aspects, both the perforator 402 and the membrane 410 can
move in response to pressure or the absence of pressure, as the case
may be.
[0037] The foregoing description of the aspects, including
illustrated aspects, of the invention has been presented only for the
purpose of illustration and description and is not intended to be
exhaustive or to limit the invention to the precise forms disclosed.
Numerous modifications, adaptations, and uses thereof will be
apparent to those skilled in the art without departing from the scope
of this invention.

Claims
What is claimed is:
1. A flow control assembly configured for being disposed in a
wellbore, the flow control assembly comprising:
a membrane configured for providing a pressure seal and
preventing fluid flow in the flow control assembly; and
a perforator for perforating the membrane in response to a
setting pressure in the flow control assembly exceeding a threshold,
wherein the perforated member is configured for providing an fluid
flow path in the flow control assembly.
2. The flow control assembly of claim 1, further comprising a
piston that is moveable in response to the setting pressure for
allowing the perforator to perforate the membrane.
3. The flow control assembly of claim 2, wherein the piston is
coupled to the membrane, the membrane being moveable with the
piston in response to the setting pressure, the perforator being
configured to be in a fixed position with respect to the membrane.
4. The flow control assembly of claim 2, wherein the piston is
coupled to the perforator, the perforator being moveable with the
piston in response to the setting pressure, the membrane being
configured to be in a fixed position with respect to the perforator.
5. The flow control assembly of claim 2, further comprising:
a spring member configured for moving the piston away from
the perforator subsequent to the perforator perforating the membrane.
6. The flow control assembly of claim 1, further comprising:
a tubing portion having a tubing port configured to provide fluid
communication between an inner area defined by the tubing portion
and an area external to the tubing portion;
an outer housing external to the tubing portion and comprising
a housing opening, the perforator and the membrane being disposed
in the outer housing between the housing opening and the tubing
port,
wherein the perforator comprises:
a base coupled to the outer housing, the base comprising
a base opening configured to allow fluid to flow from the housing
opening toward the tubing port; and
an elongated member extending from the base toward the
membrane.
7. The flow control assembly of claim 6, further comprising a
spring member disposed between part of a piston and at least one of
the base or the membrane.
8. The flow control assembly of claim 6, further comprising:
a shear pin coupling a piston to the outer housing prior to the
perforator perforating the membrane; and
at least one sealing member configured for preventing pressure
equalization in the outer housing and for allowing a second flow
control assembry to be set.
9. The flow control assembly of claim 1, wherein the setting
pressure is configured to be subsequent to a packer setting pressure
introduced into the wellbore, the perforator being configured to avoid
penetrating the membrane in response to the packer setting pressure.
10. Aflow control assembly, comprising:
a membrane configured for providing a pressure seal and
preventing fluid flow in the flow control assembly;
a perforator; and
a piston for causing at least one of the perforator or the
membrane to move in response to pressure from an inner area of a
tubing, the perforator being configured to create a flow path through
the membrane in response to movement of the perforator or the
membrane.
11. The flow control assembly of claim 10, wherein the piston is
coupled to the membrane, the membrane being moveable with the
piston in response to the pressure, the perforator being configured to
be in a fixed position with respect to the membrane.
12. The flow control assembly of claim 10, wherein the piston is
coupled to the perforator, the perforator being moveable with the
piston in response to the pressure, the membrane being configured to
be in a fixed position with respect to the perforator.
13. The flow control assembly of claim 10, further comprising:
a spring member configured for moving the piston away from
the perforator subsequent to the perforator perforating the membrane.
14. The flow control assembly of claim 10, further comprising:
a tubing portion having a tubing port configured to provide fluid
communication between the inner area defined by the tubing portion
and an area external to the tubing portion;
an outer housing external to the tubing portion and comprising
a housing opening, the perforator and the membrane being disposed
in the outer housing between the housing opening and the tubing
port,
wherein the perforator comprises:
a base coupled to the outer housing, the base comprising
a base opening configured to allow fluid to flow from the housing
opening toward the tubing port; and
an elongated member extending from the base toward the
membrane.
15. The flow control assembly of claim 14, further comprising:
a shear pin coupling the piston to the outer housing prior to the
perforator perforating the membrane; and
at least one sealing member configured for preventing pressure
equalization in the outer housing and for allowing a second flow
control assembly to be set.
16. The flow control assembly of claim 14, wherein the pressure is
configured to be subsequent to a packer setting pressure introduced
into a wellbore, the piston being configured to prevent the perforator
from penetrating the membrane in response to the packer setting
pressure.
17. An assembly comprising:
a tubing portion having a tubing port configured to allow access
of pressure from an internal area of the tubing portion to an external
area;
an outer housing external to the tubing portion having the
tubing port, the outer housing comprising a housing opening and
defining a flow path between the outer housing and the tubing port;
a perforator disposed in the flow path in a fixed position;
a membrane disposed in the flow path, the membrane being
configured for providing a pressure seal and preventing fluid flow in
the flow path in response to a packer setting pressure; and
a piston disposed in the flow path and coupled to the
membrane, the piston being configured for allowing the membrane to
move toward the perforator in response to the pressure being above a
threshold, the perforator being configured for perforating the
membrane in response to the membrane moving toward the
perforator, the perforated membrane being configured for allowing
fluid flow through the flow path.
18. The assembly of claim 17, wherein the perforator comprises:
a base coupled to the outer housing, the base comprising a base
opening; and
an elongated member extending from the base;
19. The assembly of claim 18, further comprising:
a spring disposed in the flow path, the spring being configured
for biasing at least part of each of the piston and the membrane away
from the base subsequent to the elongated member perforating the
membrane.
20. The assembly of claim 17, further comprising:
a shear pin coupling the piston to the outer housing prior to the
perforator perforating the membrane; and
at least one sealing member configured for preventing pressure
equalization in the outer housing and for allowing a second flow
control assembry to be set.