Pulse width modulated downhole flow control

• US 7,484,566 B2
• Filed: 08/03/2006
• Issued: 02/03/2009
• Est. Priority Date: 08/15/2005
• Status: Expired due to Fees

• Current Assignee: Welldynamics, Inc. (Halliburton Company)
• Original Assignee: Welldynamics, Inc. (Halliburton Company)
• Inventors: Tips, Timothy R., Smithson, Mitchell C.
• Primary Examiner(s): Bates; Zakiya W.
• Application Number:
  US11/462,077
• Publication Number:
  US 20070034385A1
• Time in Patent Office: 915 Days
• Field of Search: None
• US Class Current: 166/373
• CPC Class Codes: E21B 21/103 Down-hole by-pass valve arrangements, i.e. between the inside of the drill string and the annulus valves specifically for maintaining circulation of drilling fluid while connecting or disconnecting tubular joints E21B21/019
• CPC Class Codes: E21B 34/066 electrically actuated
• CPC Class Codes: E21B 41/0085 Adaptations of electric power generating means for use in boreholes
• CPC Class Codes: E21B 47/18 through the well fluid , e.g. mud pressure pulse telemetry

Abstract

A pulse width modulated downhole flow control. A downhole flow control system includes a flow control device with a flow restrictor which variably restricts flow through the flow control device. An actuator varies a vibratory motion of the restrictor to thereby variably control an average flow rate of fluid through the flow control device. A method of controlling flow in a well includes the steps of: installing a flow control device in the well, the flow control device including a flow restrictor which variably restricts flow through the flow control device; and displacing the restrictor to thereby pulse a flow rate of fluid through the flow control device.

Claims

1. A downhole flow control system, comprising:

a flow control device including a flow restrictor which variably restricts flow through the flow control device, and an actuator which varies a vibratory motion of the restrictor to thereby variably control an average flow rate of fluid through the flow control device.

2. The system of claim 1, wherein the actuator is electrically operated.

3. The system of claim 2, wherein electricity to operate the actuator is generated in response to flow of fluid through the flow control device.

4. The system of claim 2, wherein the restrictor vibrates in response to flow of fluid through the flow control device, thereby generating electricity.

5. The system of claim 1, wherein a flow rate pulse width is modulated to thereby control the average flow rate of fluid through the flow control device.

6. The system of claim 1, wherein a flow rate dwell is modulated to thereby control the average flow rate of fluid through the flow control device.

7. The system of claim 1, wherein a flow rate amplitude is modulated to thereby control the average flow rate of fluid through the flow control device.

8. The system of claim 1, wherein a flow rate frequency is modulated to thereby control the average flow rate of fluid through the flow control device.

9. The system of claim 1, wherein the actuator alternately assists and impedes vibratory displacement of the restrictor to thereby variably control the flow rate of fluid through the flow control device.

10. The system of claim 1, further comprising a downhole control system which controls the actuator, so that the actuator maintains a selected average flow rate of fluid through the flow control device.

11. The system of claim 10, wherein the downhole control system maintains the selected average flow rate while at least one of density, viscosity, temperature and gas/liquid ratio of the fluid changes.

12. The system of claim 10, further comprising a surface control system which communicates with the downhole control system to select the selected average flow rate and to change the selected average flow rate.

13. The system of claim 1, wherein the actuator includes at least one coil which when energized applies a force to the restrictor.

14. The system of claim 1, wherein the actuator includes at least one coil which when shorted impedes displacement of the restrictor.

15. The system of claim 1, wherein the restrictor includes a projection which creates a pressure differential upstream of an opening, thereby biasing the restrictor to displace in a direction to increasingly restrict flow through the opening.

16. The system of claim 1, wherein flow through the flow control device creates a pressure differential upstream of an opening, thereby biasing the restrictor to displace in a direction to increasingly restrict flow through the opening, and further comprising a biasing device which biases the restrictor in a direction to decreasingly restrict flow through the opening.

17. The system of claim 16, wherein a biasing force applied to the restrictor by the biasing device is adjustable downhole.

18. A method of controlling flow in a well, the method comprising the steps of:

installing a flow control device in the well, the flow control device including a flow restrictor which variably restricts flow through the flow control device; and

displacing the restrictor to thereby pulse a flow rate of fluid through the flow control device, the displacing step comprising operating an actuator to variably control vibratory displacement of the restrictor.

19. The method of claim 18, further comprising the steps of generating electricity in response to flow of fluid through the flow control device, and utilizing the electricity to operate the actuator in the operating step.

20. The method of claim 18, wherein the displacing step further comprises modulating a flow rate pulse width to thereby control an average of the flow rate of fluid through the flow control device.

21. The method of claim 18, wherein the displacing step further comprises modulating a flow rate dwell to thereby control an average of the flow rate of fluid through the flow control device.

22. The method of claim 18, wherein the displacing step further comprises modulating a flow rate amplitude to thereby control an average of the flow rate of fluid through the flow control device.

23. The method of claim 18, wherein the displacing step further comprises modulating a flow rate frequency to thereby control an average of the flow rate of fluid through the flow control device.

24. The method of claim 18, wherein the displacing step further comprises alternately assisting and impeding vibratory displacement of the restrictor to thereby variably control the flow rate of fluid through the flow control device.

25. The method of claim 18, wherein the displacing step further comprises energizing at least one coil to thereby apply a force to the restrictor.

26. The method of claim 18, wherein the displacing step further comprises shorting at least one coil to thereby impede displacement of the restrictor.

27. The method of claim 18, further comprising the step of creating a pressure differential upstream of an opening, thereby biasing the restrictor to displace in a direction to increasingly restrict flow through the opening.

28. The method of claim 27, further comprising the step of utilizing a biasing device to bias the restrictor in a direction to decreasingly restrict flow through the opening.

29. The method of claim 18, further comprising the step of controlling operation of the actuator using a downhole control system, so that the actuator maintains a selected average flow rate of fluid through the flow control device.

30. The method of claim 29, wherein the controlling step further comprises maintaining the selected average flow rate while at least one of density, viscosity, temperature and gas/liquid ratio of the fluid changes.

31. The method of claim 29, further comprising the step of communicating with the downhole control system via a surface control system to select the selected average flow rate and to change the selected average flow rate.

32. A method of controlling flow in a well, the method comprising the steps of:

installing a flow control device in the well, the flow control device including a flow restrictor which variably restricts flow through the flow control device;

displacing the restrictor to thereby pulse a flow rate of fluid through the flow control device; and

vibrating the restrictor in response to flow of fluid through the flow control device, thereby generating electricity.

33. A method of controlling flow in a well, the method comprising the steps of:

installing a flow control device in the well, the flow control device including a flow restrictor which variably restricts flow through the flow control device; and

displacing the restrictor to thereby pulse a flow rate of fluid through the flow control device;

creating a pressure differential upstream of an opening, thereby biasing the restrictor to displace in a direction to increasingly restrict flow through the opening;

utilizing a biasing device to bias the restrictor in a direction to decreasingly restrict flow through the opening; and

adjusting downhole a biasing force applied to the restrictor by the biasing device.