WO2016044059A1

WO2016044059A1 - Low shear fluid flow control

Info

Publication number: WO2016044059A1
Application number: PCT/US2015/049443
Authority: WO
Inventors: Hendricus Cornelis Adrianus VAN ELK; Mark Theodoor Looijer
Original assignee: Shell Oil Company; Shell Internationale Research Maatschappij B.V.
Priority date: 2014-09-15
Filing date: 2015-09-10
Publication date: 2016-03-24

Abstract

A system for controlling fluid flow, comprising a fluid conductor; a high pressure zone located in the fluid conductor; a low pressure zone located in the fluid conductor; a flow control device fluidly operatively coupled to the fluid conductor, where the flow control device comprises a housing and a fluid displacement element within the housing, wherein one or more chambers are formed between the housing and the fluid displacement element, and wherein the flow control device is positioned between the high pressure zone and the low pressure zone to move a fluid through the one or more chambers from the high pressure zone toward the low pressure zone, where a cycle frequency of the fluid displacement element determines the flow rate of the fluid through the flow control device; and a resistance element configured to apply an amount of friction to the fluid displacement element.

Description

LOW SHEAR FLUID FLOW CONTROL

Field of the Invention

The present disclosure relates to systems and methods for controlling fluid flow. More particularly, the present disclosure relates to systems and methods for reducing shear experienced by fluid within a fluid control system.

Background of the Invention

Valves and orifices are typically used to control the flow, level, and/or pressure of fluid within various fluid systems, including fluid control systems used in the production of oil from subterranean formations. These types of flow control devices generally operate by restricting flow of a fluid, where the flow rate is determined in part by the pressure difference across the control device as well as the physical barrier or passage provided by the flow control device.

Controlling fluid flow using these types of restriction devices generally introduces turbulence to the fluid and causes shear of the fluid. In many cases, the shear force imputed on the passing fluid can negatively impact the quality of the fluid or affect the characteristics of the fluid. For example, shear forces may decrease the viscosity of fluids containing shear-sensitive polymers. These effects may be amplified depending on the type of fluid used in the system.

One method of producing hydrocarbons from a subterranean formation can include injecting an injection fluid into the formation through an injection well to drive hydrocarbons toward a production well. In some cases, the injection fluid viscosity can be increased using a polymer additive to more efficiently push hydrocarbons within the formation. The desired viscosity of the injection fluid is typically determined with respect to the properties of formation fluids, where an increased viscosity of formation fluid generally dictates an increased injection fluid viscosity. For example, in some cases, the injection fluid is adjusted to be slightly more viscous than the formation fluid.

Using valves and/or orifices to control the flow of injection fluid containing polymers can apply shear forces to these polymers and decrease the injection fluid viscosity. To account for this drop in viscosity, the injection fluid viscosity must be increased above that desired for use within the formation. In some cases, the drop in fluid viscosity may be from 30% to 70%. As such, the addition of extra polymer required to account for the viscosity decrease can greatly increase the cost of injection fluid production and may be large enough to thwart the injection operation. As such, a system for controlling fluid flow is desired that minimizes shear forces imputed to fluid passing through a flow controller.

Summary of the Invention

In one aspect, a system for controlling fluid flow may comprise a fluid conductor structured and arranged to conduct a fluid therethrough; a high pressure zone located in the fluid conductor; a low pressure zone located in the fluid conductor; a flow control device fluidly operatively coupled to the fluid conductor, where the flow control device comprises a housing and a fluid displacement element, wherein the fluid displacement element is located within the housing structured and arranged to form one or more chambers within the housing where the one or more chambers are structured and arranged to receive fluid therein and dispense fluid therefrom, and wherein the fluid displacement element is structured and arranged to move cyclically within the housing at a cycle frequency to introduce fluid into and displace fluid from the one or more chambers, and wherein the flow control device is positioned between the high pressure zone and the low pressure zone to provide a pressure differential across the flow control device to move a fluid through the one or more chambers from the high pressure zone to the low pressure zone upon cyclic movement of the fluid displacement element displacing fluid within the one or more chambers, where the cycle frequency of the fluid displacement element determines the flow rate of the fluid through the flow control device; and a resistance element engaging the fluid displacement element and configured to apply an amount of friction to the fluid displacement element to control the cycle frequency of the fluid displacement element. Brief Description of the Drawings

These drawings illustrate certain aspects of some of the embodiments of the present disclosure, and should not be used to limit or define the disclosure.

Fig. 1 illustrates an oil and/or gas production system, according to aspects of the present disclosure.

Fig. 2 shows a cut-out view of a flow control device, according to aspects of the present disclosure.

Fig. 3 shows a cut-out view of a flow control device comprising a piston pump, according to aspects of the present disclosure.

Fig. 4 shows a cut-out view of a flow control device comprising a rotary pump, according to aspects of the present disclosure. Fig. 5 shows a flow control device installed within a pipe, according to aspects of the present disclosure.

Fig. 6 shows a flow control device installed between and connecting a first pipe and a second pipe with a braking element located within a fluid flow path, according to aspects of the present disclosure.

Fig. 7 shows a flow control device installed between and connecting a first pipe and a second pipe with an externally located braking element, according to aspects of the present disclosure.

Fig. 8 shows an example injection system comprising a plurality of flow control devices, according to aspects of the present disclosure.

Fig. 9 illustrates a fluid production system comprising a plurality of flow control devices, according to aspects of the present disclosure.

Fig. 10 is a flow-chart showing an example monitoring routine for the flow control device, according to aspects of the present disclosure.

While embodiments of this disclosure have been depicted and described and are defined by reference to example embodiments of the disclosure, such references do not imply a limitation on the disclosure, and no such limitation is to be inferred. The subject matter disclosed is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those skilled in the pertinent art and having the benefit of this disclosure. The depicted and described embodiments of this disclosure are examples only, and not exhaustive of the scope of the disclosure.

Detailed Description of the Invention

Systems and methods of the present disclosure provide a flow control device that applies little to no shear to a fluid passing through the flow control device. The flow control device may be used to control fluid flow within a fluid system, for example, an injection fluid system. As such, fluid comprising a shear-sensitive polymer may pass through the flow control device with little to no reduction in viscosity, as will be described herein.

Referring now to Fig. 1, one embodiment of a fluid system 100 of the present disclosure is illustrated. As shown by example in Fig. 1, the fluid system 100 may comprise a system for injecting fluid into one or more formations (e.g., in connection with an enhanced oil recovery operation) and/or a system for producing fluid from one or more formations. In other embodiments, the fluid system 100 may be a system for producing fluids from one or more formations. In addition, in certain embodiments, the fluid system 100 may be used in other applications to control fluid flow.

This disclosure discusses production of fluid from a formation and/or injection of fluid into a formation as an example; however, production may similarly be made from any other hydrocarbon-containing formation or a plurality of such formations. Furthermore, the fluid system of the present disclosure is described as applied to an injection system and/or a production system as illustrative embodiments only.

In certain embodiments, the fluid system 100 may include one or more formations 104, 106, and 108, and may include a body of water 102 above the one or more formations 104, 106, and 108. One or more of the formations 104, 106, and 108 may contain hydrocarbon compounds, such as oil and/or gas. The system may comprise a production facility 110 located at the surface, and a production well 112 traversing at least one formation 104 and with openings in at least one formation 106. In certain embodiments, the production well 112 may extend into one formation or a plurality of formations. In addition, in certain embodiments, the production well 112 may have openings located in one formation or a plurality of formations. In certain embodiments, the at least one formation may comprise a reservoir containing hydrocarbons such as oil and/or gas. A production fluid from the formation and/or reservoir may enter and travel up the production well 112 to a production facility 110.

One purpose of injection well 132 is to aid the flow of hydrocarbons from the reservoir to production well 112. One method is to inject water under pressure adjacent to a production zone to cause the hydrocarbons contained in the formation 106 to move toward the production well 112.

Fig. 2 shows an example flow control device 300 disposed within a fluid conductor 310. The flow control device 300 may be placed in the fluid system 100 at any point where the fluid flow rate through the system is desired to be controlled. In certain embodiments, the fluid conductor 310 may comprise a pipe, pipeline, flowline, well tubing, and/or any other conduit for fluid.

This disclosure discusses embodiments of the flow control device as it may be used to control flow of a fluid. The present disclosure does not intend to limit the composition of fluid that may be used with the flow control device. Indeed, the fluid may comprise a liquid, a liquid-gas mixture, and/or a solid suspension. For example, the fluid may comprise a mixture of hydrocarbons, water, additives, and/or polymer.

In addition, in certain embodiments, the flow control device 300 may replace any valve or other flow rate control in an existing fluid system. As described below in reference to Figs. 5 to 7, in certain embodiments, the flow control device 300 may be installed within the fluid conductor 610, be connected to a first fluid conductor and a second fluid conductor 721, 722, or be installed in the system using any configuration to direct fluid through the flow control device.

Referring back to Fig. 2, the flow control device 300 may comprise a housing 301, a housing cavity 304, and at least one fluid displacement element 306 disposed within the housing cavity 304. The flow control device 300 may be fluidly operatively coupled with the fluid conductor to permit fluid to flow from the fluid conductor through the flow control device. The flow control device 300 may create a seal with the fluid conductor 310 between a high pressure zone 312 and a low pressure zone 314. As such, fluid flow between the high pressure zone 312 and the low pressure zone 314 may be limited to fluid flow through the flow control device 300. The low pressure zone 314 and the high pressure zone 312 may consitute a pressure differential across the flow control device 300 that may drive fluid toward the low pressure zone 314.

"Fluidly operatively coupled" or "fluidly operatively connected", as used herein, defines a connection between two or more elements in which the elements are directly or indirectly connected to allow direct or indirect fluid flow between the elements. The term "fluid flow", as used in this definition, refers to the flow of a gas or a liquid; the term "direct fluid flow" as used in this definition means that the flow of a liquid or a gas between two defined elements flows directly between the two defined elements; and the term "indirect fluid flow" as used in this definition means that the flow of a liquid or a gas between two defined elements may be directed through one or more additional elements to change one or more aspects of the liquid or gas as the liquid or gas flows between the two defined elements. Aspects of a liquid or a gas that may be changed in indirect fluid flow include physical characteristics, such as the temperature or the pressure of a gas or a liquid; the state of the fluid between a liquid and a gas; and/or the composition of the gas or liquid. "Indirect fluid flow", as defined herein, excludes changing the composition of the gas or liquid between the two defined elements by chemical reaction, for example, oxidation or reduction of one or more elements of the liquid or gas.

In certain embodiments, the flow control device 300 may comprise at least one bearing 302 engaging the fluid displacement element 306. The bearing 302 may keep the fluid displacement element 306 in place within the housing cavity 304 and allow the fluid displacement element 306 to rotate within the housing cavity 304. For example, in certain embodiments, the bearing 302 may comprise a bushing.

In certain embodiments, the fluid displacement element 306 may comprise a progressive cavity rotor, screw rotor, lobe rotor, gear rotor, a piston, and/or any other positive fluid displacement element. In certain embodiments, the flow control device may displace a fixed volume of fluid through the fluid displacement element for each cycle of the fluid displacement element, where movement of the fluid displacement element from a first position to at least one other position and back to a first position may be considered a fluid displacement element cycle.

In certain embodiments, the flow control device may comprise a progressive cavity pump, where the fluid displacement element 306 may comprise a rotor. In certain embodiments, the fluid displacement element 306 may have a rotor helix structure. One or more chambers 307 may be created within the housing cavity 304, between the fluid displacement element 306 and the housing 301. In certain embodiments, the one or more chambers 307 may be of a fixed volume. In certain embodiments, the fluid displacement element 306 and the housing 301 may substantially separate each of the one or more chambers 307 from each other.

In certain embodiments, rotation of the flow control element 306 within the housing cavity 304 may displace fluid within the one or more chambers 307 through the flow control device 300 toward the low pressure zone 314. As the fluid displacement element

306 rotates, the volume within each of the one or more chambers 307 may remain unchanged as the fluid within the chamber 307 is displaced through the flow control device

300.

The fluid displacement element 306 may move cyclically. As such, the fluid displacement element 306 may have a first position which the fluid displacement element 306 may return to at the conclusion of each cycle. Thus, displacement of fluid through the fluid displacement element 306 may be described periodically, where the volume of fluid displaced by one cycle of the fluid displacement element 306 may be substantially constant.

The pressure differential across the flow control device 300 may apply a rotational force on the fluid displacement element 306 in a pressure driven direction. Rotating the fluid displacement element 306 in the pressure driven direction may translate fluid in the one or more chambers 307 through the flow control device 300 toward the low pressure zone 314 and away from the high pressure zone 312.

In certain embodiments, the one or more chambers 307 may be in fluid communication with the high pressure zone 312 at an inlet end 321, where fluid from the high pressure zone 312 may enter the one or more chambers 307. The one or more chambers 307 may be in fluid communication with the low pressure zone 312 at an outlet end 323. In certain embodiments, as the fluid displacement element 306 rotates, the fluid may translate through the one or more chambers 307 toward the low pressure zone 314. In certain embodiments, as the fluid translates between the inlet end 321 and the outlet end 323, fluid within the one or more chambers 307 may be enclosed by the housing 301 and the fluid displacement element 306. In other embodiments, the one or more chambers 307 may be in fluid communication with the high pressure zone 312 and the low pressure zone 314, where the fluid displacement element 306 may comprise a flow resistor (e.g., where the fluid displacement element comprises a screw rotor or an Archimedes screw rotor).

As shown by example in Fig. 3, in certain embodiments, the flow control device

400 may comprise a piston pump. In certain embodiments, the flow control device 400 may comprise a housing 401, a first chamber 402 and a second chamber 404 defined within the housing and substantially separated by the fluid displacement element 406. In certain embodiments, the fluid displacement element may comprise a piston head 406 and a piston rod 405 connected to the piston head 406 and extending out of the housing 401 through a piston rod port 407. The flow control device 400 may further comprise a first inlet valve 412 and a first outlet valve 422 in communication with the first chamber 402 and a second inlet valve 414 and a second outlet valve 424 in communication with the second chamber 404. A first inlet pipe 432 may be in communication with the first chamber 402 via the first inlet valve 412, wherein fluid may flow from the first inlet pipe 432 to the first chamber 402 when the first inlet valve 412 is in an open position (as shown in Figure 4). A second inlet pipe 434 may be in communication with the second chamber 404 via the second inlet valve 414, wherein fluid may flow from the second inlet pipe 434 to the second chamber 404 when the second inlet valve 414 is in an open position.

A first outlet pipe 436 may be in communication with the first chamber 402 via the first outlet valve 422 and a second outlet pipe 438 may be in communication with the second chamber 404 via the second outlet valve. When the first outlet valve 422 is open, fluid may flow between the first chamber 402 and the first outlet pipe 436 and when the second outlet valve 424 is open, fluid may flow between the second chamber 404 and the second outlet pipe 438.

The first inlet pipe 432 and the second inlet pipe 434 may be connected to a supply pipe 440. The first outlet pipe 436 and the second outlet pipe 438 may be connected to a discharge pipe 442. In certain embodiments, the supply pipe 440 may comprise a high pressure zone and the discharge pipe 442 may comprise a low pressure zone. The pressure difference between the low pressure zone and the high pressure zone within the discharge pipe 442 and the supply pipe 440, respectively, may create a pressure differential across the flow control device 400. The pressure differential may drive fluid within the supply pipe 440 toward the flow control device 400 and drive fluid within the discharge pipe 442 away from the flow control device 400.

When the piston head 406 is in a first position 450, the first inlet valve 412 and the second outlet valve 424 may open and the second inlet valve 414 and first outlet valve 422 may be closed. As a result, fluid may flow from the high pressure zone 440 into the first chamber 402 and fluid may flow from the second cavity 404 toward the low pressure zone 442. In addition, fluid flowing into the first chamber 402 may apply a force to the piston head 406 and cause the piston head 406 to translate toward the second chamber 404 (decreasing the volume of the second chamber and aiding to direct fluid from the second chamber toward the low pressure zone 442). Once the piston head has translated to a second position 452, the first inlet valve 412 and second outlet valve 424 may be closed and the first outlet valve 422 and the second inlet valve 414 may be opened, causing the piston head to move toward the first chamber 402. As the piston head 406 moves back toward the first chamber 402, fluid from the first chamber 402 may flow toward the low pressure zone 442 and fluid from the high pressure zone 440 may flow into the second chamber 404. Once the piston head 406 moves back to the first position 450, the process may repeat. As such, the piston head 406 may move cyclically within the housing 401 to displace fluid within the one or more chambers 402, 404 toward the low pressure zone 442. Fluid from the high pressure zone 440 may apply a pressure to the piston head 406 to cause the piston head 406 to reciprocate within the housing 401. Each translation from the first position 450 to the second position 452 (or vise versa) may displace a substantially consistent amount of fluid from the high pressure zone 440 toward the low pressure zone 442. The amount of fluid displaced for each repetition may be determined by the volume of the housing and/or the sum volume of the first chamber 402 and the second chamber 404.

Referring now to Fig. 4, in certain embodiments, the flow control device 500 may comprise a rotary lobe pump, which may be fluidly operatively coupled with the fluid conductor to permit fluid to flow from the fluid conductor through the flow control device 500. As such, in certain embodiments, the fluid displacement element may comprise a plurality of gears 510. The plurality of gears 510 may be located within a stator bore 504 defined by the housing 502. In certain embodiments, two or more of the plurality of gears 510 may engage each other to substantially prevent fluid flow between the gears. For example, two or more of the plurality of gears 510 may interlock with each other. Fluid may flow from the high pressure zone 512 through a fluid inlet 521 into the stator bore 504. The fluid may apply a force to the plurality of gears causing the gears to rotate. As the plurality of enaged gears 510 rotate, fluid may travel toward the low pressure zone 514 in the one or more chambers 515 defined between the plurality of gears 510 and the housing 502. As each of the one or more chambers 515 rotates to a fluid outlet 522, fluid within the cavity 515 may flow through the fluid outlet 522 and toward the low pressure zone 514. As described below, a resistance element may engage at least one of the plurality of gears 510 that make up the fluid displacement element.

Referring back to Fig. 2, in certain embodiments, the flow control device 300 may comprise a resistance element 308. In certain embodiments, the resistance element 308 may comprise a brake. The resistance element 308 may be connected to the fluid displacement element 306 and may control and/or limit the rotation rate of the fluid displacement element 306 by applying a friction force to the fluid displacement element 306. As such, rotation rate of the flow control element 306 may be from 0 rpm in a fully stopped condition to a maximum rate defined by the flow rate of fluid through the pipe without the flow control device 300. For example, the maximum rotation rate may increase as the pressure differential across the flow control device increases. In certain embodiments, a resistance actuator 316 may actuate the resistance element 308 to increase or decrease the amount of resistance applied to the fluid displacement element 306. The resistance element 308 may be connected to a controller 340 through resistance actuator 316, where the controller 340 is configured to send a control signal to the resistance actuator 316 directing the resistance element 308 to increase and/or decrease resistance applied to the fluid displacement element 306. As such, the controller 340 may control the rotation rate of the fluid displacement element 306 by adjusting the amount of resistance applied to the fluid displacement element 306 by the resistance element 308.

The controller 340 may send the control signal (and the resistance element 308 and/or the resistance actuator 316 may receive the control signal) via at least one control wire 314 and/or through a wireless connection. The control signal may comprise instructions to the resistance element 308 and/or the resistance actuator 316 to increase resistance, decrease resistance, and/or maintain resistance applied to the fluid displacement element 306. In certain embodiments, the resistance element 308 and/or the resistance actuator 316 may be configured to send a monitoring signal to the controller 340. The monitoring signal may comprise fluid flow, pressure, fluid characteristics, and/or resistance status information, such as, but not limited to, fluid flow rate, pressure level of the low pressure zone, pressure level of the high pressure zone, fluid displacement element RPMs, viscosity of the fluid exiting the flow control device, and/or resistance applied. In certain embodiments, the controller 340 may be located in the proximity of the resistance element 308 or at a remote location, such as in a control facility or central monitoring facility.

In certain embodiments, a flow control memory may store instructions received from the controller 340 and/or store monitoring information for transmission. As such, the controller 340 may be configured to send a series of control instructions to be stored in and accessed from the flow control memory. In certain embodiments, the controller 340 may execute a monitoring routine comprising instructions for operating the resistance element 308 under various conditions. The monitoring routine may comprise instructions to keep the low pressure and/or the flow rate in a specified range. In certain embodiments, the specified range may be within 5% of a pressure set point for the low pressure zone or within 5% of a pressure set point for the high pressure zone. In certain embodiments, the specified range may be within 5% of a flow rate set point. In certain embodiments, the specified range may be within 10% of a viscosity set point for the viscosity of fluid exiting the flow control device. In certain embodiments, the specified range may be from 1 % to 20% of the pressure set point. In certain embodiments, the specified range may be from 1% to 20% of the flow rate set point. In certain embodiments, the specified range may be from 1% to 20% of the viscosity set point.

An example monitoring routine 1000 for controlling fluid flow through the flow control device is shown in Fig. 10. At 1005, the monitoring routine may compare the pressure within the low pressure zone to a selected specified range of pressures. The monitoring routine may then determine at decision 1010 whether the measured value is outside of the specified range. If the measured value is not outside the specified range, the monitoring routine may return to step 1005 to obtain a new measured value. If the measured value is outside the specified range, the monitoring routine may determine if it is higher or lower than the specified range at decision 1015. If the measured value is lower than the specified range, the monitoring routine may proceed at 1020 to signal the resistance element to reduce the amount of resistance applied to the fluid displacement element to increase the flow rate through the flow control device and increase the pressure within the low pressure zone. If the measured value is higher than the specified range, the monitoring routine may proceed at 1022 to signal the resistance element to increase the amount of resistance applied to the fluid displacement element, causing the flow rate through the flow control device to decrease and decrease the pressure within the low pressure zone. The monitoring routine may return from step 1020 or 1022 to step 1005 to measure the pressure within the low pressure zone. In certain embodiments, the monitoring routine may comprise a delay step before measuring the desired system property at step 1005 to allow the system to respond to the resistance adjustment at 1020 or 1022 before comparing another measurement. As such, in certain embodiments, the monitoring routine may allow the flow control device to adaptively adjust the resistance applied to the fluid displacement element in response to changing system conditions in order to maintain a substantially constant pressure within the low pressure zone and/or a substantially constant flow rate through the flow control device.

Similar to the monitoring routine described for monitoring and maintaining pressure within the low pressure zone, a monitoring routine may monitor the flow rate of fluid through the flow control device to maintain the flow within a selected specified range.

Referring back to Fig. 2, the resistance element 308 may apply resistance of any type to the fluid displacement element 306, such as mechanical resistance (e.g. friction), hydraulic resistance, pneumatic resistance, and/or electromagnetic resistance. In certain embodiments, the resistance element 308 may comprise a mechanical brake, a hydraulic brake, an electrical brake, and/or an electromagnetic brake.

The resistance element 308 and flow control device 300 may be configured in a number of ways, as shown by example in Figs. 5 to 7. For example, the flow control device 300 may be located inside a pipe 601, within an inner flow path 610 , as shown in Figure 5, wherein the pipe 601 serves as the fluid conductor. The resistance element 605 may be located within the pipe 601 and be in contact with fluid within the pipe 601. At least one seal 608 may be located between the flow control device 300 and the pipe wall 602 and configured to direct fluid into an input end 611 and through the fluid displacement element within the flow control device. In another embodiment shown by example in Figure 6, the flow control device 300 may be located between a first pipe 721 and a second pipe 722, where an input end 711 of the flow control device may be fluidly operatively coupled to the first pipe 721 and an output end 712 of the flow control device may be fluidly operatively coupled to the second pipe 722. The first and second pipes 721, 722 may comprise the fluid conductor. The resistance element 705 may be located within an internal flow path through the flow control device 300 and in contact with fluid flowing through the flow control device 300 from the first pipe 721 toward the second pipe 722. In certain embodiments, fluid in contact with the resistance element 705 may aid in cooling the resistance element 705.

In certain embodiments, shown by example in Figure 7, the resistance element 805 may be located outside the fluid flow path through the flow control device 300. The flow control device 300 may be positioned between the first and second pipe 721, 722 of the fluid conductor as described above, and the resistance element 805 may be in contact with surrounding environment outside the flow control device and/or surrounding fluids (such as water).

Referring again to Fig. 2, in certain embodiments, the flow control device may comprise a generator (not shown) connected to the fluid displacement element 306. The generator may recover energy from the movement of the fluid displacement element 306 in the form of electrical power, thermal energy, hydraulic energy, and/or any other type of generated energy. In certain embodiments, the generator may comprise an electric generator configured to convert mechanical energy in the fluid displacement element 306 to electrical energy. In certain embodiments, the generator may be connected to the resistance element to generate electrical energy from the flow fluid displacement element 306 as the resistance element imputes resistance to the fluid displacement element 306. For example, the generator and resistance element may act as a regenerative brake to recover energy from applying friction to the flow control element. The generator may be connected to the flow control element directly to generate energy from rotation of the flow control element (driven by the pressure differential within the pipe).

The generator may be connected to a battery to store generated electrical energy. The battery may be connected to any tool, equipment, and/or device desired to be powered with electrical energy. For example, energy from the generator (as stored in the battery) may be provided to power valves, pumps, computers/processors, sensors, detection and/or measurement tools, transceivers and/or transponders, and/or any other equipment that may use electrical energy. In certain embodiments, the generator may supply resistance of fluid flow in the passive direction.

Restriction of the fluid displacement element 306 rotation may allow control of fluid flow through the flow control device 300 and/or pressure differential across the flow control device 300. In certain embodiments, the pressure differential may be about 1 bar to about 100 bar. Flow of fluid through the flow control device 300 may result in a decrease in the viscosity of the fluid. As such, fluid flowing through the flow control device 300 may have a first viscosity before flowing through the flow control device 300 and a second viscosity after flowing through the flow control device 300. In certain embodiments, the second viscosity may be from 0% to 30% lower than the first viscosity. In certain embodiments, the second viscosity may be from 0% to 20% lower than the first viscosity. In certain embodiments, the second viscosity may be up to 10% lower than the first viscosity. In certain embodiments, the first viscosity of the fluid before flowing through the flow control device 300 may be substantially the same as, or equal to, the second viscosity of the fluid after it has passed through the flow control device 300. In certain embodiments, the viscosity decrease may vary with the pressure differential across the flow control device 300. For example, for a pressure differential of 1 bar and a fluid comprising a 2 million Dalton molecular weight HP AM polymer, the viscosity decrease may be below 1%, while for a pressure differential of 100 bar and a fluid comprising a 20 million Dalton molecular weight HP AM polymer, the viscosity decrease may be between 10% and 20%. The viscosity decrease experienced by fluid flowing through the flow control device may be reduced by limiting the shear applied to the fluid. Thus, the flow control device may result in much lower shear applied to fluid flowing through the flow control device as compared to that experienced by flowing through a standard valve. As such, it may be desired to use the flow control device to control fluid flow in fluid systems comprising a fluid sensitive to shear forces (e.g. where an increase in shear applied to the fluid may cause degradation of the fluid).

For example, applying shear forces to well fluids such as hydrocarbon- water mixtures may create water-in-oil and/or oil-in- water emulsions or cause formation of small hydrocarbon droplets in water dominated streams and/or formation of water droplets in hydrocarbon dominated streams that may negatively impact the ability to separate oils from water. Shear applied to enhanced oil recovery injection fluids containing polymers, such as hydrolyzed polyacrylamide (HP AM), dissolved in water may cause degradation of the fluid (e.g., by reducing the fluid's viscosity). The flow control device 300 may be utilized to avoid or minimize the formation of emulsions of hydrocarbon-water mixtures and/or avoid or minimize viscosity reduction of polymer-containing fluids.

In certain embodiments, the flow rate through the flow control device may be controlled and/or monitored by the controller. Using a flow control device comprising a fixed flow rate pump (such as a progressive cavity pump), the flow rate of fluid can be determined and/or controlled with respect to the rotations per minute of the flow control device. As used herein, the term "fixed flow rate pump" means a pump configured so that one rotation or cycle of the pump displaces a known volume of fluid. For example, in the progressive cavity pump as described in Figure 3, each of the plurality of pump cavities containing fluid may have a known volume. In certain embodiments, each rotation of the rotor may expel the fluid contained within a known number of cavities. Thus, in certain embodiments, the volumetric flow rate through the flow control device may be provided as the rotations per minute multiplied by the volume expelled per rotation (where volume expelled per rotation is the volume of a cavity multiplied by the number of cavities expelled per rotation).

Referring to Fig. 8, one example of the fluid system is shown comprising a fluid injection system 200, wherein at least one flow control device 220 may be used to control fluid flow rate. As a result, the flow control device 220 may control the pressure, temperature, and/or fluid level of various segments of the injection system 200. For example, the flow control device 220 may be used to restrict flow through the fluid conductor to lower the pressure within the low pressure zone. Also, for example, in the case where fluid in the high pressure zone has a higher temperature than fluid in the low pressure zone, the flow control device 220 may be used to increase the temperature within the low pressure zone by lowering flow resistance, resulting in increased flow rate toward the cooler low pressure zone.

The injection system 200 may comprise an injection facility 210, a plurality of injection wells 132a, 132b, and a plurality of fluid conductors 222a, 222b configured to direct fluid received from the injection facility 210 to an injection well 132. The injection facility 210 may be connected to an injection wellhead 216 via an injection fluid conduit 212. In certain embodiments, the injection facility 210 may comprise at least one injection pump (not shown) configured to direct fluid through the injection fluid conduit 212 to the injection wellhead 216. In certain embodiments, the injection pump may comprise a polymer dosing pump. The injection pump may supply injection fluid to the injection fluid conduit 212 at a rate of at least the desired injection fluid flow rate to the combined injection wells.

The injection wellhead 216 is shown by example connected to two injection wells

132a and 132b. As such, the injection system 200 will be herein described by example as if comprised of two injection wells. However, the present disclosure does not intend to limit the injection system 200 to including only two injection wells. For example, in certain embodiments, the injection system 200 may comprise 2 to 500 injection wells; or, in certain embodiments, the injection system 200 may comprise 10 to 100 injection wells; or, in certain embodiments, the injection system 200 may comprise 20 to 50 injection wells. In addition, the plurality of injection wells may be arranged in a variety of patterns or configurations with respect to the formation geography. As will be appreciated by one of ordinary skill in the art with the benefit of the present invention, a preferred number and configuration of injection wells may depend on the properties of each hydrocarbon-bearing formation to be treated.

The injection wellhead may be connected to a first injection wellhead 218a via a first fluid conductor 222a, and connected to a second injection wellhead 218b via a second fluid conductor 222b. As such, the injection wellhead 216 may be connected to, and direct fluid to, a plurality of injection wellheads. The first injection wellhead 218a may be connected to a first injection well 132a and the second injection wellhead 218b may be connected to a second injection well 132b. The first injection wellhead 218a may pass fluid into the first injection well 132a. In certain embodiments, the injection wellhead 216 may comprise at least one injection pump (not shown) configured to direct fluid through the first fluid conductor 222a toward the first injection well 132a and/or through the second fluid conductor 222b toward the second injection well 132b. In certain embodiments, the first injection wellhead 218a and/or the second injection wellhead 218b may be placed in an open or a closed state. When in the closed state, the injection wellhead may

substantially prevent fluid flow past the injection wellhead and into the respective injection well. When in the open state, the injection wellhead may create an opening or conduit through the injection wellhead to allow fluid flow past the injection wellhead and into the respective injection well.

In certain embodiments, the injection well system 200 may comprise more than one injection well. In such multi-well injection systems, flow control devices may be used to adjust and control the flow of injection fluid to each well relative to the other wells. For example, fluid flow to one well may be increased or decreased relative to other wells. Fluid control using active (such as valves or chokes) or passive (such as orifices) constrictions in the flow path may introduce high levels of shear. This shear may mechanically degrade the injection fluid to be injected into the formation for enhanced oil recovery purposes. For example, a pressure drop of 15 to 50 bar across a flow control device may result in 50 to 80% irreversible viscosity loss in injection fluid comprising long-chain (e.g., 20 million Dalton molecular weight) hydrolyzed polyacrylamide polymer and water. As a result, much greater amounts of polymer must be added to the injection fluids to account for this viscosity loss. The fluid control system of the present disclosure comprising at least one low-shear flow control device may allow greater control of injection fluid viscosity, lower viscosity loss, and/or enable injection of high viscosity fluids into the formation. In addition, decreasing the shear applied to injection fluids may allow use of injection fluids comprising a lower concentration of shear-sensitive chemicals, which may reduce any degradation effect these chemicals may have on equipment, such as production or refining equipment. Use of high viscosity injection fluids may limit fingering of the injection fluid through hydrocarbons and allow greater control of the fluid front used for displacement of hydrocarbon-containing reservoir fluids.

The first fluid conductor 222a may be fluidly operatively coupled to a first flow control device 220a, and the second fluid conductor 222b may be fluidly operatively coupled to a second flow control device 220b. In certain embodiments, each of the fluid conductors may be fluidly operatively coupled to a flow control device. The system 200 may comprise one or more flow controllers 240. In certain embodiments, a flow controller 240 may be electrically, pneumatically, optically, wirelessly, and/or otherwise operably connected to each flow control device 220a, 220b.

The first injection well 132a may comprise a first well flow control device 230a and the second injection well 132b may comprise a second well flow control device 230b. In certain embodiments, the well flow control devices 230a, 230b may have substantially the same configuration as the flow control devices 220a, 220b, and may be controlled by input from the flow controller 240.

In certain embodiments, the fluid in the injection system may be an injection fluid comprising a processed water. In certain embodiments, the injection fluid may comprise a viscosifying agent, such as a viscosifying polymer. In certain embodiments, the viscosifying agent may comprise a hydrolyzed polyacrylamide polymer. As such, the injection fluid may be an aqueous liquid comprising a viscosifying agent and water. The viscosity of the injection fluid may be adjusted by changing the amount of viscosifying agent mixed into the injection fluid. In certain embodiments, the injection fluid may have an in-situ viscosity of between about 0.5 cP to about 100 cP. For example, once the injection fluid is in the formation, the injection fluid may have a viscosity of between about 1 cP to about 100 cP. The in-situ viscosity of the injection fluid may be a function of the pre-injection viscosity of the injection fluid. As such, the viscosity of the in-situ injection fluid may be controlled by adjusting the pre-injection viscosity of the injection fluid.

The injection system 200 may comprise a plurality of injection wells 132 and a plurality of fluid conductors 222, where each injection well 132 may be connected to one of the fluid conductors 222. The flow control device 220 may be placed in each of the fluid conductors 222 to control the flow of injection fluid to the respective injection wells. For example, flow of fluid to the first injection well may be desired to be at a rate of 2x barrels per day, while the flow rate to the second injection well may desired to be lx barrels per day.

In certain embodiments, the flow rate of injection fluid to each well may be between about 100 barrels per day (bpd) to about 100,000 bpd. The amount of injection fluid desired for each well may depend on various operations conditions, as would be appreciated by one of ordinary skill in the art with the benefit of the present disclosure. For example, in some applications using a larger number of smaller wells, the flow rate of injection fluid to each well may be between about 500 bpd to about 5,000 bpd. In addition, in an application using a smaller number of larger wells, the flow rate of injection fluid to each well may be between about 10,000 bpd to about 100,000 bpd. In certain

embodiments, the total flow rate of injection fluid to all injection wells in the system may be between about 10,000 bpd to about 500,000 bpd.

In certain embodiments, the flow through a respective flow control device may be substantially shut off by signaling the corresponding brake to prevent rotation of the flow control element with the controller (lowering the RPM limit of the rotor to 0). As such, fluid flow through the respective fluid conductor may be substantially diverted to be provided to other injection wells independently.

In certain embodiments, the flow control element may be set to maximum RPM (or, completely opened) by signaling with the controller the corresponding brake to release completely. In a maximum RPM state, the rate of flow through the flow control device may be determined by the pressure differential across the flow control device as a limited by the passive flow resistance of the flow control device, as would be understood by one of ordinary skill in the art with the benefit of the present disclosure. Since fluid flow through the flow control device is passively driven by the pressure differential across the flow control device, the controller may adjust the flow rate limit by adjusting the resistance applied by the brake. When resistance applied by the brake is 0, the flow control device is in the maximum RPM state. Thus, the flow rate through the flow control device may range from 0 to the maximum RPM flow rate.

In certain embodiments, the maximum RPM of the flow control device may be adjusted by controlling the flow rate of injection fluid to the injection wellhead. Decrease of injection fluid flow rate to the injection wellhead may decrease the maximum RPM of the flow control devices across the injection system. Increase of the flow rate to the injection wellhead may increase the potential maximum RPM of each flow control device. In addition, diversion of injection fluid from one or more injection wells toward another injection well may increase the maximum RPM of that flow control device.

Referring now to Figure 9, an embodiment is shown comprising a production system 900. The production system 900 may be configured similarly to the injection system, except where the high pressure zone 912 may be supplied by each of a plurality of production wells 905 and the low pressure zone 914 may be uphole so the pressure differential across each of the flow control devices 920 may drive production fluid from the production well 905 to a production separator 910. As such, a production fluid conductor 922 may be connected to each of the plurality of production wells 905 to allow production fluid to flow from the production well 905 to the production separator 910. Each of the production fluid conductors 922 may be connected to a production fluid main line 924, configured to direct production fluid from the plurality of production fluid conductors 922 to the production separator 910. Each of the production fluid conductors 922 may be fluidly operatively coupled to a flow control device 920.

In certain embodiments, the production fluid may comprise hydrocarbon- comprising compounds, such as oil, gas condensates, and/or gas. In certain embodiments, the production fluid may further comprise a produced water. For example, the produced water may comprise connate water and/or aqueous injection fluids. As such, in certain embodiments, the production fluid may comprise a mixture of hydrocarbon-comprising compounds and produced water. In certain embodiments, as shown in Fig. 1, liquid and/or gaseous hydrocarbon-comprising compounds may be produced to the production facility 110 and separated, where gas may be sent to gas storage 116, and hydrocarbon liquid may be sent to liquid storage 118. In addition, an aqueous fluid may be separated and sent to an aqueous fluid storage 130.

Referring back to Figure 9, in certain embodiments, the flow through a respective flow control device 920 may be substantially shut off by using a controller to signal the corresponding resistance element to prevent rotation of the fluid displacement element of a control element 920 (lowering the RPM limit of the rotor to 0). As such, fluid flow through the respective production fluid conductor 922 may be substantially restricted.

In certain embodiments, the flow control element may be set to maximum RPM (or, completely opened) by signaling to completely release the resistance element thereof with the controller. In a maximum RPM state, the rate of flow through the flow control device may be determined by the pressure differential across the flow control device as a limited by the passive flow resistance of the flow control device 920, as would be understood by one of ordinary skill in the art with the benefit of the present disclosure. Since fluid flow through the flow control device 920 may be passively driven by the pressure differential, the controller may adjust the flow rate limit by adjusting the resistance applied by the brake. When resistance applied by the brake is 0, the flow control device may be in the maximum RPM state. Thus, the flow rate through the flow control device may range from 0 to the maximum RPM flow rate. The flow control device has been described herein in connection with example injection and production systems to illustrate possible applications and/or configurations of the flow control device. However, it is to be appreciated that the flow control device may be used in any fluid system where it is desirable to direct and/or control the flow of fluid within the fluid system while reducing the shear applied to fluid within the system. As such, the present disclosure is not intended to be limited to a specific application or field of use. The flow control device of the present disclosure may be used in chemical manufacturing, food processing, and/or other fluid systems.

Therefore, the present disclosure is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure. While compositions and methods are described in terms of "comprising," "containing," or "including" various components or steps, the compositions and methods can also "consist essentially of or "consist of the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, "from about a to about b," or, equivalently, "from approximately a to b," or, equivalently, "from approximately a-b") disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. The indefinite articles "a" or "an," as used in the claims, are defined herein to mean one or more than one of the element that it introduces.

Claims

C L A I M S

1. A system for controlling fluid flow, comprising:

a fluid conductor structured and arranged to conduct a fluid therethrough;

a high pressure zone located in the fluid conductor;

a low pressure zone located in the fluid conductor;

a flow control device fluidly operatively coupled to the fluid conductor, where the flow control device comprises a housing and a fluid displacement element, wherein the fluid displacement element is located within the housing structured and arranged to form one or more chambers within the housing where the one or more chambers are structured and arranged to receive fluid therein and dispense fluid therefrom, and wherein the fluid displacement element is structured and arranged to move cyclically within the housing at a cycle frequency to introduce fluid into and displace fluid from the one or more chambers, and wherein the flow control device is positioned between the high pressure zone and the low pressure zone to provide a pressure differential across the flow control device to move a fluid through the one or more chambers from the high pressure zone to the low pressure zone upon cyclic movement of the fluid displacement element displacing fluid within the one or more chambers, where the cycle frequency of the fluid displacement element determines the flow rate of the fluid through the flow control device; and a resistance element engaging the fluid displacement element and configured to apply an amount of friction to the fluid displacement element to control the cycle frequency of the fluid displacement element.

2. The system of claim 1, further comprising a controller connected to the resistance element and configured to set or adjust the amount of resistance applied by the resistance element to the fluid displacement element.

3. The system of claim 2, wherein the controller adjusts the resistance applied by the resistance element to the fluid displacement element to maintain the pressure within the low pressure zone within 5% of a pressure set point.

4. The system of claim 2, wherein the controller adjusts the resistance applied by the resistance element to the fluid displacement element to maintain the pressure within the high pressure zone within 5% of a pressure set point.

5. The system of claim 2, wherein the controller adjusts the resistance applied by the resistance element to the fluid displacement element to maintain the flow rate through the flow control device within 5% of a flow rate set point.

6. The system of claim 2, wherein the controller adjusts the resistance applied by the resistance element to the fluid displacement element to maintain the viscosity of the fluid within 10% of a fluid viscosity set point.

7. The system of claim 1, wherein each of the one or more chambers have a discrete and substantially equivalent volume.

8. The system of claim 1, wherein the fluid conductor comprises a pipe, pipeline, flowline, or well tubing.

9. The system of claim 1, wherein the fluid displacement element is structured and arranged to rotate cyclically within the housing.

10. The system of claim 1, wherein the fluid displacement element is structured and arranged to reciprocate cyclically within the housing.

11. The system of claim 1, wherein the resistance element is structured and arranged to apply friction to the fluid displacement element by mechanical friction, hydraulic friction, pneumatic friction, or electromagnetic friction.

12. The system of claim 1, further comprising a generator connected to the fluid displacement element and configured to recover energy from movement of the fluid displacement element.

13. The system of claim 1, comprising a plurality of fluid conductors, wherein for each of the plurality of fluid conductors the flow rate of a fluid through each fluid conductor is independently controlled by the flow control device.

14. The system of claim 1, further comprising a shear-sensitive fluid comprising an aqueous polymer solution.

15. The system of claim 1, further comprising a fluid produced from a hydrocarbon- bearing formation.

16. The system of claim 1, further comprising a fluid storage fluidly operatively coupled to the at least one fluid conductor, wherein fluid flow out of the fluid storage flows through the flow control device.

17. The system of claim 1, wherein the fluid displacement element comprises a progressive cavity rotor, a lobe rotor, a piston, a screw rotor, or a gear rotor.