Flowback sub for aicds and daicds

Abstract

A flowback sub system may include a check valve and a tubular body portion having a central bore. The check valve may be disposed along a flow path between an exterior of the tubular body portion and the central bore. The flowback sub system may also include a multi-position sleeve with a sleeve opening oriented to block fluid flow to the check valve in a closed position and allow fluid flow through the check valve in a first position. The flowback sub system may further include a shearable member configured to hold the multi-position sleeve in the closed position but to shear in response to a first threshold pressure, a biasing mechanism configured to drive the multi-position sleeve in a first axial direction from the closed position toward the first position, and a retention assembly configured to hold the multi-position sleeve in the first position.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application is a non-provisional conversion application of U.S. Patent Provisional Application No. 63 / 757,163, the entire disclosure of which is incorporated herein by reference.BACKGROUND

[0002] In hydrocarbon production wells, it may be beneficial to regulate the flow of formation fluids from a subterranean formation into a wellbore penetrating the same. A variety of reasons or purposes may necessitate such regulation including, for example, prevention of water and / or gas coning, minimizing water and / or gas production, minimizing sand production, maximizing oil production, balancing production from various subterranean zones, equalizing pressure among various subterranean zones, and / or the like.

[0003] A number of devices are available for regulating the flow of formation fluids. Some of these devices may be non-discriminating for different types of formation fluids and may simply function as a “gatekeeper” for regulating access to the interior of a wellbore pipe, such as a well string. Such gatekeeper devices may be simple on / off valves or they may be metered to regulate fluid flow over a continuum of flow rates. Other types of devices for regulating the flow of formation fluids may achieve at least some degree of discrimination between different types of formation fluids. Such devices may include, for example, tubular flow restrictors, nozzle-type flow restrictors, autonomous inflow control devices, non-autonomous inflow control devices, ports, tortuous paths, combinations thereof, and the like.

[0004] Autonomous flow control devices (e.g., AICDs and DAICDs) may be particularly advantageous in subterranean operations, since they are able to automatically regulate fluid flow without the need for operator control due to their design. In this regard, autonomous flow control devices may be designed such that they provide a greater resistance to the flow of undesired fluids (e.g., gas and / or water) than they do desired fluids (e.g., oil), particularly as the percentage of the undesired fluids increases. Accordingly, the autonomous flow control devices may limit the flow of an undesired fluid into the interior of a production string during production operations.

[0005] Unfortunately, during some completion operations (e.g., cleanup operations), limiting flow of undesired fluids may cause delays and increase costs, since such operations may require flow of undesired fluids through the autonomous flow control devices.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] These drawings illustrate certain aspects of some of the embodiments of the present disclosure and should not be used to limit or define the method.

[0007] FIG. 1 illustrates an elevation view of a well system, in accordance with some embodiments of the present disclosure.

[0008] FIG. 2 illustrates a cross-sectional view of a flowback sub with a multi-position sleeve, in accordance with some embodiments of the present disclosure.

[0009] FIG. 3 illustrates a cross-sectional view of the multi-position sleeve of the flowback sub in a closed position, in accordance with some embodiments of the present disclosure.

[0010] FIG. 4 illustrates a cross-sectional view of the multi-position sleeve of the flowback sub in a first position, in accordance with some embodiments of the present disclosure.

[0011] FIG. 5 illustrates a cross-sectional view of the multi-position sleeve of the flowback sub in a second position, in accordance with some embodiments of the present disclosure.

[0012] FIG. 6 illustrates a cross-sectional view of a multi-position sleeve configured to block fluid flow in the second position, in accordance with some embodiments of the present disclosure.

[0013] FIG. 7 illustrates a cross-sectional view of the flowback sub having a secondary flow device configured to align with a multi-position sleeve in a second position, in accordance with some embodiments of the present disclosure.

[0014] FIG. 8 illustrates a cross-sectional view of the flowback sub with an entry slot into a valve chamber, in accordance with some embodiments of the present disclosure.

[0015] FIG. 9 illustrates a cross-sectional view of the flowback sub having a plurality of retention assemblies, in accordance with some embodiments of the present disclosure.DETAILED DESCRIPTION

[0016] Provided are systems and methods for controlling the fluid flow into an interior of a production string from the surrounding formations. In particular, the systems and methods include a flowback sub with a multi-position sleeve configured to selectively provide a bypass flow path for fluid flow into the interior of the production string from the surrounding formations. Generally, downhole fluids (e.g., oil, gas, water, etc.) may be configured to flow into an interior of a production string from the surrounding formations through autonomous flow control devices (AICDs) and / or density autonomous flow control devices (DAICDs). Undesired production fluids (e.g., gas and water) may flow through the AICDs and / or DAICDs at a slower rate than desired production fluids (e.g., oil), which may be beneficial for production operations. However, during some operations (e.g., cleanup operations), the flow rate of the undesired production fluids through the AICDs and / or DAICDs may be slower than desired.

[0017] As set forth in greater detail below, the multi-position sleeve may be configured to actuate between various positions to selectively provide a bypass flow path for the downhole fluids such that the undesired fluids may flow into the interior of the production string tubing at a higher rate than through the AICDs and / or DAICDs during some operations such as cleanup operations. However, during production operations, the multi-position sleeve may be configured to block flow into the production string via the flowback sub such that the AICDs and / or DAICDs may regulate the fluid flow into the production tubing during production operations.

[0018] FIG. 1 illustrates an elevation view of a well system, in accordance with some embodiments of the present disclosure. As illustrated, well system 100 may include a wellbore 102 that comprises a generally vertical uncased section 104 that may transition into a generally horizontal uncased section 106 extending through a subterranean formation 108. In some examples, the vertical section 104 may extend downwardly from a portion of wellbore 102 having a string of casing 110 cemented therein. A tubular string, such as production tubing 112, may be installed in or otherwise extended into wellbore 102.

[0019] As depicted, a plurality of well screens 114, flow control devices 116, flowback subs 128 and packers 118 may be interconnected along production tubing 112, such as along portions of the production tubing 112 in horizontal section 106 of wellbore 102. Packers 118 may be configured to seal off an annulus 120 defined between production tubing 112 and the walls of wellbore 102. As a result, fluids 122 may be produced from multiple intervals of the surrounding subterranean formation 108 via isolated portions of annulus 120 between adjacent pairs of packers 118.

[0020] As illustrated, in some examples, a well screen 114 and a flow control device 116 and / or flowback sub 128 may be interconnected in production tubing 112 and positioned between a pair of packers 118. Without limitation, well screens 114 may be swell screens, wire wrap screens, mesh screens, sintered screens, expandable screens, pre-packed screens, treating screens, or other known screen types. In operation, well screen 114 may be configured to filter fluids 122 flowing into production tubing 112 from annulus 120. Flow control device 116 and / or flowback sub 128 may be configured to restrict or otherwise regulate the flow of fluids 122 into production tubing 112, based on certain physical characteristics of the fluids. In examples, flow control device 116 may be a centrifugal fluid selector, wherein a portion of the centrifugal fluid selector may be actuated to rotate by the flow of fluids 122 and centrifugal force.

[0021] Without limitation, flow control device 116 may be an autonomous flow control device. The autonomous flow control device may utilize fluid dynamics and delay the flow of unwanted fluids such as water and / or gas into the interior of production tubing 112. The autonomous flow control device may operate as a passive flow control device, not requiring moving components and / or electronics. The autonomous flow control device may be any suitable shape. Without limitation, a suitable shape may include, but is not limited to, cross-sectional shapes that are circular, elliptical, triangular, rectangular, square, hexagonal, and / or combinations thereof. The autonomous flow control device may be made from any suitable material. Suitable materials may include, but are not limited to, metals, nonmetals, polymers, ceramics, and / or combinations thereof. Without limitation, the autonomous flow control device may be made from tungsten carbide and / or steel.

[0022] It will be appreciated that well system 100 is merely one example of a wide variety of well systems in which the principles of this disclosure may be utilized. Accordingly, it should be understood that the principles of this disclosure are not necessarily limited to any of the details of the depicted well system 100, or the various components thereof, depicted in the drawings or otherwise described herein. For example, it is not necessary in keeping with the principles of this disclosure for wellbore 102 to include a generally vertical wellbore section 104 or a generally horizontal wellbore section 106. Moreover, it is not necessary for fluids 122 to be only produced from subterranean formation 108 since, in other examples, fluids may be injected into subterranean formation 108, or fluids 122 may be both injected into and produced from subterranean formation 108, without departing from the scope of the disclosure.

[0023] Furthermore, it is not necessary that at least one well screen 114 and flow control device 116 and / or the at least one well screen 114 and the flowback sub 128 be positioned between a pair of packers 118. Nor is it necessary for a single flow control device 116 to be used in conjunction with a single well screen 114. Rather, any number, arrangement and / or combination of such components may be used, without departing from the scope of the disclosure. In some applications, it is not necessary for flow control device 116 and / or flowback sub 128 to be used with a corresponding well screen 114. For example, in injection operations, the injected fluid could be flowed through flow control device 116 and / or flowback sub 128, without also flowing through well screen 114.

[0024] Those skilled in the art will readily recognize the advantages of being able to regulate the flow of fluids 122 into production tubing 112 from each zone of subterranean formation 108, for example, to prevent water coning 124 or gas coning 126 in subterranean formation 108. Other uses for flow regulation in a well may include, but are not limited to, balancing production from (or injection into) multiple zones, minimizing production or injection of undesired fluids, maximizing production or injection of desired fluids, etc.

[0025] FIG. 2 illustrates a cross-sectional view of a flowback sub with a multi-position sleeve, in accordance with some embodiments of the present disclosure. The flowback sub 128 may include a downhole tubular 200 forming a portion of the production tubing 112. In particular, as illustrated, the flowback sub 128 may include a tubular body portion 202 having a central bore 204 extending through the tubular body portion 202. Further, the flowback sub 128 may include a multi-position sleeve 206 disposed within the central bore 204. As set forth in greater detail below, the multi-position sleeve 206 may be configured to move axially along the central bore 204 of the flowback sub 128 between various positions. For example, the multi-position sleeve 206 may be configured to move axially along the central bore 204 of the flowback sub 128 between a closed position, a first position (e.g., an inflow position), and a second position (e.g., an outflow position). The various positions may correspond to respective openings to a flow path 208 that extends through the tubular body portion 202 between an exterior 210 of the flowback sub 128 (e.g., the annulus 120 of the wellbore 102) and the central bore 204.

[0026] At least one well screen of the plurality of well screens 114 may be disposed along the flow path between the exterior 210 of the tubular body portion 202 and at least one check valve 212. The flowback sub 128 may include a valve assembly 214 disposed along the flow path 208 extending through the tubular body portion 202 between the exterior 210 of the flowback sub 128 and the central bore 204. In particular, the valve assembly 214 may be disposed along the flow path 208 between the at least one well screen 114 and the central bore 204 such that the well screen 114 may filter out debris flowing along the flow path 208 toward the valve assembly 214.

[0027] The valve assembly 214 may include a valve chamber 216 formed within the tubular body portion 202 and disposed along the flow path 208 between the exterior 210 of the flowback sub 128 and the central bore 204. Moreover, the flow path 208 may include various branches or lines connected to valve chamber 216. In particular, the flow path 208 may include an outer fluid line 218 extending from the valve chamber 216 to the exterior 210 of the tubular body portion 202, as well as at least one inner fluid line 220 extending from the valve chamber 216 to the central bore 204. As illustrated, the at least one inner fluid line 220 may include a primary inner fluid line 222 and a secondary inner fluid line 224 each extending from the valve chamber 216 to the central bore 204 in parallel. Alternatively, the secondary inner fluid line 224 may form a separate flow path (e.g., a second flow path 208) extending independently between the exterior 210 of the flowback sub 128 and the central bore 204.

[0028] Moreover, the valve assembly 214 may include the at least one check valve 212, which may be disposed along the flow path 208 between the exterior 210 of the flowback sub 128 and the central bore 204. In particular, as illustrated, the at least one check valve 212 may be disposed along the flow path 208 in a position between the central bore 204 and the valve chamber 216. The at least one check valve 212 may include a ball valve, a poppet valve, a fluidic diode, a spring loaded ball valve, a spring loaded poppet valve, a flapper valve, or any suitable type of check valve. Further, the at least one check valve 212 may include a production only check valve 226 configured to allow fluid flow into the flowback sub 128, but block flow out of the flowback sub 128 via the flow path 208. That is, the production only check valve 226 may be configured to allow fluid flow from the exterior 210 of the flowback sub 128 to flow through the production only check valve 226 toward the central bore 204 of the flowback sub 128, but block fluid flow from the central bore 204 of the flowback sub 128 toward the exterior 210 of the flowback sub 128 via the flow path 208. Further, the at least one check valve 212 may additionally, or alternatively, include an injection only check valve 228, which may be configured to allow fluid from the central bore 204 of the flowback sub 128 to flow through the injection only check valve 228 toward the exterior 210 of the flowback sub 128, but block fluid flow from the exterior 210 of the flowback sub 128 toward the central bore 204 of the flowback sub 128 via the flow path 208.

[0029] For example, as illustrated, the at least one check valve 212 may include a first check valve 230 (e.g., the production only check valve 226) and a second check valve 232 (e.g., the injection only check valve 228). The first check valve 230 may be disposed along the primary inner fluid line 222 that is in fluid communication with the central bore 204 via a primary opening 234 disposed at a position corresponding to the first position of the multi-position sleeve 206. Further, the second check valve 232 may be disposed along the secondary inner fluid line 224 that is in fluid communication with the central bore 204 via a secondary opening 236 disposed at a position corresponding to the second position of the multi-position sleeve 206. Accordingly, as set forth in greater detail below, moving the multi-position sleeve 206 between the first position and the second position may convert the flow path 208 from a production flow path to an injection flow path.

[0030] FIG. 3 illustrates a cross-sectional view of the multi-position sleeve of the flowback sub in the closed position, in accordance with some embodiments of the present disclosure. As set forth above, the multi-position sleeve 206 may be configured to move axially along the central bore 204 of the flowback sub 128 between various positions such as the closed position, the first position (e.g., an inflow position), and the second position (e.g., an outflow position). As illustrated, the multi-position sleeve 206 is disposed in the closed position. The flowback sub 128 may be run-in-hole in the closed position of the multi-position sleeve 206. As illustrated, the multi-position sleeve 206 may include a sleeve opening 300 extending through the multi-position sleeve 206.

[0031] Further, as set forth above, the sleeve opening 300 may be aligned with the first check valve 230 in the first position and the second check valve 232 in the second position. Specifically, the sleeve opening 300 may be aligned with the primary opening 234 corresponding to the primary inner fluid line 222 with the first check valve 230 (e.g., the production only check valve) in the first position. Further, in the second position, the sleeve opening 300 may be aligned with secondary opening 236 corresponding to the secondary inner fluid line 224 with the second check valve 232 (e.g., the injection only check valve). Aligning the sleeve opening 300 with the first check valve 230 or the second check valve 232 may place the corresponding check valve in fluid communication with the central bore 204. However, as illustrated, the sleeve opening 300 is offset from both the first check valve 230 and the second check valve 232 in the closed position such that a sleeve body 302 of the multi-position sleeve 206 may block fluid communication between both the first check valve 230 and the second check valve 232 with the central bore 204. As such, fluid flow into (e.g., production) and out of (e.g., injection) the flowback sub 128 via the valve assembly 214 may be blocked in the close position. Blocking fluid flow in both directions through the valve assembly 214 may ensure well integrity in case the well kicks. Additionally, blocking the fluid flow in directions through the valve assembly 214 may prevent pressure and fluid loss through the flowback sub 128 during washdown operations, as well as allow tubing pressure to be increased to set the packers 118 and to activate the flowback sub 128 (e.g., move the flowback sub from the closed position to the first position (e.g., the inflow position).

[0032] As set forth in greater detail below, the flowback sub 128 may include a biasing mechanism 304 configured to drive the multi-position sleeve 206 in a first axial direction 306 from the closed position toward the first position. The biasing mechanism 304 may include a spring, hydrostatic chamber, or any other suitable biasing mechanism. For example, as illustrated, the biasing mechanism 304 may include a spring 308 having a first spring end 310 configured to interface with the tubular body portion 202 and a second spring end 312 configured to interface with the multi-position sleeve 206. The spring 308 may be in compression such that the spring 308 provides a biasing force to drive the multi-position sleeve 206 away from the tubular body portion 202 in the first axial direction 306 (e.g., a downhole direction).

[0033] However, the flowback sub 128 may include a shearable member 314 configured to hold the multi-position sleeve 206 in the closed position. For example, the shearable member 314 may include a shear pin 316 configured to interface with the tubular body portion 202 and the multi-position sleeve 206 to hold the multi-position sleeve 206 in the closed position. Moreover, the biasing force provided by the biasing mechanism 304 (e.g., the spring 308) is not configured to shear the shearable member 314. That is, the biasing force is configured to provide less force than required to shear the shearable member 314. Instead, the shearable member 314 is configured to shear in response to a first threshold pressure in the central bore 204. For at least the reasons set forth below, increasing the pressure in the central bore 204 is configured to drive the multi-position sleeve 206 in the second axial direction 318 (e.g., an uphole direction). Increasing the pressure in the central bore 204 above the first threshold pressure may drive the multi-position sleeve 206 in the second axial direction 318 with sufficient force to shear the shearable member 314 and release the multi-position sleeve 206 from the closed position. In response to decreasing the shearable member 314 shearing and the pressure in the central bore 204 decreasing, the biasing force from the biasing mechanism 304 may drive the multi-position sleeve 206 from the closed position toward the first position.

[0034] As illustrated, the multi-position sleeve 206 includes an upper sleeve end 320, a lower sleeve end 322, and a shoulder portion 324 disposed axially between the biasing mechanism 304 and the lower sleeve end 322. A first annular seal 326 is disposed about the multi-position sleeve 206 proximate the upper sleeve end 320 to seal the multi-position sleeve 206 against the tubular body portion 202 proximate the upper sleeve end 320. As set forth in greater detail below, a second annular seal 328 is disposed about the shoulder portion 324 to seal the shoulder portion 324 against the tubular body portion 202 in the closed position and the first position of the multi-position sleeve 206. Further, the diameter of the second annular seal 328 is greater than the diameter of the first annular seal 326 such that increasing pressure in the central bore 204 above the first threshold pressure generates a pressure differential configured to drive the multi-position sleeve 206 in the second axial direction 318 (e.g., uphole direction) to shear the shearable member 314.

[0035] FIG. 4 illustrates a cross-sectional view of the multi-position sleeve of the flowback sub in the first position, in accordance with some embodiments of the present disclosure. As set forth above, the multi-position sleeve 206 may be configured to move from the closed position to the first position (e.g., the inflow position) in response to pressure in the central bore 204 being raised at least to the first threshold pressure. That is, in response to the tubing pressure increasing above the first threshold pressure, the multi-position sleeve 206 may be driven in the second axial direction 318 (e.g., the uphole direction) with sufficient force to shear the shearable member 314 (e.g., at least one shear screw, shear pin, etc.) configured to hold the multi-position sleeve 206 in the closed position. In response to the shearable member 314 shearing, the multi-position sleeve 206 may initially move in the second axial direction 318 due to the tubing pressure being above the first threshold pressure. However, as the tubing pressure is decreased (e.g., bled down) the multi-position sleeve 206 may be configured to reverse direction and move in the first axial direction 306 (e.g., downhole direction) via the biasing force provided by the biasing mechanism 304.

[0036] As illustrated, the biasing mechanism may include the spring 308 disposed in a spring chamber 400 formed between the tubular body portion 202 and a spring shoulder 402 of the multi-position sleeve 206. The spring 308 may include a compression spring or any suitable type of spring. As illustrated, the first spring end 310 of the spring 308 may be configured to contact the tubular body portion 202 and the second spring end 312 of the spring 308 may be configured to contact the spring shoulder 402 of the multi-position sleeve 206. As such, the spring 308 may be configured to bias the multi-position sleeve 206 in the first axial direction 306. Indeed, in response to the tubing pressure decreasing below a lower threshold pressure, the spring 308 may be configured to reverse movement of the multi-position sleeve 206 and drive the multi-position sleeve 206 in the first axial direction 306 toward the first position.

[0037] The flowback sub 128 may further include a retention assembly 404 configured to secure the multi-position sleeve 206 in the first position. For example, the retention assembly 404 may include a spring loaded shear pin 406 secured to the tubular body portion 202 of the flowback sub 128. As illustrated, the spring loaded shear pin 406 is configured to engage a pin recess 408 formed in a radially outer surface of the multi-position sleeve 206 in response to multi-position sleeve 206 moving into the first position. As set forth above, the spring 308 may be configured to drive the multi-position sleeve 206 in the first axial direction 306 toward the first position. In the first position, the spring loaded shear pin 406 may be axially aligned with the pin recess 408. As such, the spring 308 may be configured to drive the multi-position sleeve 206 in the first axial direction until the pin recess 408 is aligned with the spring loaded shear pin 406. The spring loaded shear pin 406 may be configured to expand into the pin recess 408 to lock the multi-position sleeve 206 in the first position.

[0038] Moreover, in the first position, the sleeve opening 300 of the multi-position sleeve 206 may be aligned with the first check valve 230, which may open fluid communication between the exterior of the flowback sub 128 and the central bore 204 via the first check valve 230. As set forth above, the flow path 208 through the first check valve 230 may be configured to allow fluid flow into the flowback sub 128, but block flow out of the flowback sub 128. As set forth above, allowing fluid to flow into the flowback sub 128 may provide a bypass flow path for undesired fluids (e.g., water) during cleanup operations. That is, during initial flowback of the well to cleanup drilling and / or completion fluids, AICDs and DAICDs may choke water; thereby significantly slowing cleanup operations. However, the flow path 208 (e.g., the bypass flow path) through the flowback sub 128 in the first position may increase flow rate of the initial flowback for cleanup operations.

[0039] Further, the first check valve 230 may block flow out of the flowback sub 128 such that tubing pressure may be increased in the central bore 204 after cleanup operations. That is, after cleanup operations, the tubing pressure may be increased above a second threshold pressure such that the retention assembly 404 releases the multi-position sleeve 206 to move from the first position to the second position. For example, the tubing pressure may be increased above a second threshold pressure to shear the spring loaded shear pin 406 such that the biasing force from the biasing mechanism 304 may drive the multi-position sleeve 206 from the first position to the second position. Moreover, the second threshold pressure may be greater than, equal to, or less than the first threshold pressure. The second threshold pressure may include any suitable pressure configured to drive the multi-position sleeve 206 in the second axial direction 318 with sufficient force for the retention assembly 404 to release the multi-position sleeve 206 (e.g., with sufficient force to shear the spring loaded shear pin 406).

[0040] FIG. 5 illustrates a cross-sectional view of the multi-position sleeve of the flowback sub in the second position, in accordance with some embodiments of the present disclosure. As set forth above, after flowback is completed, the tubing pressure may be increased above the second threshold pressure, which is configured to shear the spring-loaded shear pin 316 and move the multi-position sleeve 206 in the second axial direction 318. However, in response to the pressure decreasing below a lower threshold pressure, the biasing force from the biasing mechanism 304 is configured to drive multi-position sleeve in the first axial direction 306 toward the second position.

[0041] As illustrated, in the second position, a lockout snap ring 500 may be configured to interface with a lockout slot 502 of the tubular body portion 202 in a second position of the multi-position sleeve 206 to secure the multi-position sleeve 206 to the tubular body portion 202 in the second position (e.g., the outflow position). In second position, the second check valve 232 (e.g., injection only check valve) is aligned with the sleeve opening 300 in the multi-position sleeve 206 to block fluid flow from the exterior 210 of the flowback sub 128 toward the central bore 204 of the flowback sub 128 and allow fluid from the central bore 204 of the flowback sub 128 to flow through the second check valve 232 toward the exterior 210 of the flowback sub 128 via the flow path 208. As such, in the second position, production fluid may be blocked from flowing into the production tubing 112 via the flowback sub 128 such that the production fluid may only flow into the production tubing 112 via the AICDs and the DAICDs.

[0042] Moreover, as set forth above, the multi-position sleeve 206 includes the upper sleeve end 320, the lower sleeve end 322, and the shoulder portion 324 disposed axially between the biasing mechanism 304 and the lower sleeve end 322. Further, the first annular seal 326 is disposed about the multi-position sleeve 206 proximate the upper sleeve end 320 to seal the multi-position sleeve 206 against the tubular body portion 202 proximate the upper sleeve end 320 and the second annular seal 328, having a larger diameter than the first annular seal 326, is disposed about the shoulder portion 324 to seal the shoulder portion 324 against the tubular body portion such that increasing pressure in the central bore above the first threshold pressure is configured to drive the multi-position sleeve 206 in the second axial direction 318.

[0043] However, the second annular seal 328 may only be configured to seal the shoulder portion 324 against the tubular body portion 202 in the closed position and the open position. As illustrated, the tubular body portion 202 includes an increased inner diameter portion 504 configured to align with the second annular seal 328 in the second position. The increased inner diameter portion 504 may be radially offset from the second annular seal 328 and the shoulder portion 324 to prevent sealing between the multi-position sleeve 206 and the tubular body portion 202 in the second position. Instead, a third annular seal 506 disposed about the multi-position sleeve 206 proximate the lower sleeve end 322 may be configured to seal against the tubular body portion 202 in the second position. The first annular seal 326 and the third annular seal 506 may have substantially similar diameters such that pressure in the central bore 204 ceases to create a pressure differential to bias the multi-position sleeve 206 to move axially with respect to the tubular body portion 202.

[0044] FIG. 6 illustrates a cross-sectional view of a multi-position sleeve configured block fluid flow in the second position, in accordance with some embodiments of the present disclosure. As set forth above, the multi-position sleeve 206 may be disposed within the central bore 204 and configured to move axially between the closed position, the first position, and the second position. Further, the multi-position sleeve 206 includes the sleeve opening 300 configured to provide fluid communication between the central bore 204 and the flow path 208 in response to the sleeve opening 300 aligning with a respective opening of the flow path (e.g., the primary opening 234). As set forth above, the sleeve opening 300 is aligned with an inner surface 600 of the tubular body portion 202 in the closed position such that fluid communication between the central bore 204 and the flow path is blocked in the closed position. In response to the multi-position sleeve 206 moving to the first position, the sleeve opening 300 may be aligned with the flow path 208 and the first check valve 230 such that fluid may flow from the exterior 210 of the tubular body portion 202 toward the central bore 204.

[0045] As set forth above, after flowback operations are complete, pressure in the central bore may be increased to the second threshold pressure to shear the spring loaded shear pin 406 such that that biasing mechanism 304 (shown in FIG. 5) may drive the multi-position sleeve 206 in the first axial direction 306 from the first position toward the second position. As illustrated, in the second position, the sleeve opening 300 may be aligned with the inner surface 600 of the tubular body portion 202 such that fluid communication between the central bore 204 and the flow path 208 is blocked in the second position.

[0046] FIG. 7 illustrates a cross-sectional view of the flowback sub having a secondary flow device configured to align with a multi-position sleeve in a second position, in accordance with some embodiments of the present disclosure. As illustrated, the flowback sub 128 may include a secondary flow device 700 disposed along the second flow path 208 (e.g., the secondary inner fluid line 224) such that the sleeve opening 300 of the multi-position sleeve 206 may be axially aligned with the secondary flow device 700 in a second position to allow fluid flow through the secondary flow device 700. As set forth above, the secondary flow device 700 may include the second check valve 232. However, the secondary flow device 700 may alternatively include a nozzle, an inflow control device, an autonomous inflow control device, density autonomous inflow control device, or some combination thereof such that the flowback sub 128 may be configured to contribute to production operations in the second position.

[0047] FIG. 8 illustrates a cross-sectional view of the flowback sub with an entry slot 800 into a valve chamber 216, in accordance with some embodiments of the present disclosure. As set forth above, the valve chamber 216 and the at least one check valve 212 may be disposed along the flow path 208 between the at least one well screen 114 and the central bore 204 such that the well screen 114 may filter out debris flowing along the flow path 208 toward the valve assembly 214. Alternatively, as illustrated, the flowback sub 128 may not include well screens 114 such that the outer fluid line 218 of the flow path 208 may extend directly from the valve chamber 216 and the at least one check valve 212, or some combination thereof, to the exterior 210 of the tubular body portion 202 via the entry slot 800.

[0048] FIG. 9 illustrates a cross-sectional view of the flowback sub having a plurality of retention assemblies, in accordance with some embodiments of the present disclosure. Indeed, as illustrated, the plurality of retention assemblies 404 may include a first spring loaded shear pin 900 configured to engage a first pin recess 902 in a first intermediate position, which may be disposed between the closed position and the first position. Further, the plurality of retention assemblies 404 may include a second spring loaded shear pin 904 configured to engage a second pin recess 906 in the first position, as well as a third spring loaded shear pin 908 configured to engage a third pin recess 910 in the second intermediate position, which may be disposed between the first position and the second position. However, the flowback sub 128 may include any suitable number of retention assemblies 404. Further, the plurality of retention assemblies 404 may include any suitable number of spring loaded shear pins 406 and corresponding pin recesses 408 disposed between main positions (e.g., the closed position, the first position, and the second position) of the multi-position sleeve206.

[0049] For example, the flowback sub 128 may include additional spring loaded shear pins 406 and corresponding pin recesses 408 between the main positions to increase a number of pressure cycles required to actuate the multi-position sleeve 206 between main positions. As set forth above, pressure in the central bore 204 may be cycled between an increased pressure and a lower pressure to move the multi-position sleeve 206 between main positions and intermediate positions. That is, pressure in the central bore 204 may be cycled between an increased pressure to shear the current engaged spring loaded shear pin 406 (e.g., the first spring loaded shear pin 900) and a lower pressure to allow the spring 308 to drive the multi-position sleeve 206 in the first axial direction 306 to engage a next spring loaded shear pin 406 (e.g., the second spring loaded shear pin 904) with its corresponding pin recess 408 (e.g., the second pin recess 906). The flowback sub 128 may include any number of spring-loaded shear pins 406 and corresponding pin recesses 408 corresponding to a desired number of pressure cycles required to move the multi-position sleeve 206 between main positions.

[0050] Accordingly, the present disclosure may provide a flowback sub configured to provide a bypass flow path for completion systems with AICDs and DAICDs during operations such as cleanup operations. The systems and methods may include any of the various features disclosed herein, including one or more of the following statements.

[0051] Statement 1. A flowback sub system, comprising: a tubular body portion having a central bore; a check valve disposed along a flow path between an exterior of the tubular body portion and the central bore; a multi-position sleeve disposed within the central bore and configured to move axially between a closed position and a first position, wherein the multi-position sleeve includes a sleeve opening extending through the multi-position sleeve, wherein the sleeve opening is positioned to block fluid flow between the central bore and the flow path in the closed position, and wherein the sleeve opening is aligned with the check valve in the first position to allow fluid flow through the check valve; a shearable member configured to hold the multi-position sleeve in the closed position, wherein the shearable member is configured to shear in response to a first threshold pressure; a biasing mechanism configured to drive the multi-position sleeve in a first axial direction from the closed position toward the first position; and a retention assembly configured to hold the multi-position sleeve in the first position.

[0052] Statement 2. The flowback sub system of statement 1, wherein the check valve is a production only check valve, wherein the production only check valve is configured to allow fluid flow from the exterior of the tubular body portion toward the central bore and block fluid flow from the central bore toward the exterior of the tubular body portion.

[0053] Statement 3. The flowback sub system of statement 1, wherein the check valve is an injection only check valve, wherein the injection only check valve is configured to block fluid flow from the exterior of the tubular body portion toward the central bore and allow fluid flow from the central bore toward the exterior of the tubular body portion.

[0054] Statement 4. The flowback sub system of any preceding statement, further comprising a secondary flow device disposed along a secondary fluid line, wherein the sleeve opening of the multi-position sleeve is axially aligned with the secondary flow device in a second position to allow fluid flow through the secondary flow device, and wherein the secondary flow device includes a second check valve, a nozzle, an inflow control device, an autonomous inflow control device, density autonomous inflow control device, or some combination thereof.

[0055] Statement 5. The flowback sub system of any preceding statement, further comprising a valve chamber disposed along the flow path, wherein the flow path includes an outer fluid line extending from the valve chamber to the exterior of the tubular body portion and primary inner fluid line extending from the valve chamber to the central bore, wherein the check valve is disposed along the primary inner fluid line, wherein the secondary fluid line includes a secondary inner fluid line extending between the central bore and the valve chamber, and wherein the secondary flow device is disposed along the secondary inner fluid line.

[0056] Statement 6. The flowback sub system of any preceding statement, wherein the retention assembly is configured to release the multi-position sleeve in response to a second threshold pressure, wherein the biasing mechanism is configured to drive the multi-position sleeve in the first axial direction from the first position to the second position in response to the retention assembly releasing the multi-position sleeve.

[0057] Statement 7. The flowback sub system of any preceding statement, wherein the retention assembly includes a spring loaded shear pin disposed in the tubular body portion, wherein the spring loaded shear pin is configured to engage a pin recess formed in the multi-position sleeve in the first position, and wherein the spring loaded shear pin is configured to shear in response to a second threshold pressure.

[0058] Statement 8. The flowback sub system of any of statements 1-6, wherein the retention assembly includes a J-slot assembly having a J-slot formed in the tubular body portion and a J-slot pin extending outward from the multi-position sleeve to interface with the J-slot, wherein the J-slot pin is disposed in a first J-slot position of the J-slot in the first position of the multi-position sleeve, and wherein a second threshold pressure driving the multi-position sleeve in a second axial direction and subsequent movement of the multi-position sleeve, via the biasing mechanism, is configured to drive the J-slot pin along the J-slot from the first J-slot position to a second J-slot position corresponding to a second position of the multi-position sleeve.

[0059] Statement 9. The flowback sub system of any preceding statement, wherein the biasing mechanism includes a spring, and wherein the spring includes a first end configured to interface with the tubular body portion and a second end configured to interface with the multi-position sleeve.

[0060] Statement 10. The flowback sub system of any preceding statement, wherein the biasing mechanism includes a hydrostatic chamber.

[0061] Statement 11. The flowback sub system of any preceding statement, wherein the check valve includes a ball valve, a poppet valve, a fluidic diode, a spring loaded ball valve, a spring loaded poppet valve, a flapper valve, or some combination thereof.

[0062] Statement 12. The flowback sub system of any preceding statement, wherein the retention assembly is configured to release the multi-position sleeve in response to a second threshold pressure, wherein the biasing mechanism is configured to drive the multi-position sleeve in the first axial direction from the first position to a second position in response to the retention assembly releasing the multi-position sleeve, and wherein the sleeve opening extending through the multi-position sleeve is aligned with an inner surface of the tubular body portion in the second position such fluid flow between the central bore and the flow path is blocked in the second position.

[0063] Statement 13. The flowback sub system of any preceding statement, wherein the shearable member includes a shear pin, wherein the shear pin is configured to interface with the tubular body portion and the multi-position sleeve to hold the multi-position sleeve in the closed position, wherein the shear pin is configured to shear in response to the first threshold pressure in the central bore of the tubular body portion.

[0064] Statement 14. The flowback sub system of any preceding statement, wherein the multi-position sleeve includes an upper end, a lower end, and a shoulder portion disposed axially between the biasing mechanism and the lower end, wherein a first annular seal is disposed about the multi-position sleeve proximate the upper end to seal the multi-position sleeve against the tubular body portion proximate the upper end, wherein a second annular seal is disposed about the shoulder portion to seal shoulder portion against the tubular body portion in the closed position and the first position of the multi-position sleeve, wherein the diameter of the second annular seal is greater than the diameter of the first annular seal such that pressure in the central bore is configured to drive the multi-position sleeve in a second axial direction to shear the shearable member.

[0065] Statement 15. The flowback sub system of any preceding statement, wherein the tubular body portion includes an increased inner diameter portion configured to align with the second annular seal in a second position, wherein the increased inner diameter portion is radially offset from the second annular seal and the shoulder portion to prevent sealing between the multi-position sleeve and the tubular body portion in the second position, wherein a third annular seal disposed about the multi-position sleeve proximate the lower end is configured to seal against the tubular body portion in the second position, wherein the first annular seal and the third annular seal have substantially similar diameters such that pressure in the central bore ceases to bias the multi-position sleeve to move axially with respect to the tubular body portion.

[0066] Statement 16. The flowback sub system of any preceding statement, further comprising a lockout snap ring configured to interface with a lockout slot of the tubular body portion in a second position of the multi-position sleeve to secure the multi-position sleeve to the tubular body portion in the second position.

[0067] Statement 17. A flowback sub system, comprising: a tubular body portion having a central bore; a check valve disposed along a flow path between an exterior of the tubular body portion and the central bore; a secondary flow device disposed along a second flow path; a multi-position sleeve disposed within the central bore and configured to move axially between a closed position, a first position and a second position, wherein the multi-position sleeve includes a sleeve opening extending through the multi-position sleeve, wherein the sleeve opening is positioned to block fluid flow between the central bore and the flow path in the closed position, wherein the sleeve opening is axially aligned with the check valve in the first position to allow fluid flow through the check valve, and wherein the sleeve opening is axially aligned with the secondary flow device in the second position to allow fluid flow through the secondary flow device; a shearable member configured to hold the multi-position sleeve in the closed position, wherein the shearable member is configured to shear in response to a first threshold pressure; a biasing mechanism configured to drive the multi-position sleeve in a first axial direction; and a retention assembly configured to hold the multi-position sleeve in the first position in response to the biasing mechanism driving the multi-position sleeve from the closed position to the first position, wherein the retention assembly is configured to release the multi-position sleeve in response to a second threshold pressure, and wherein the biasing mechanism is configured to drive the multi-position sleeve in the first axial direction from the first position to the second position in response to the retention assembly releasing the multi-position sleeve.

[0068] Statement 18. The flowback sub system of statement 17, wherein the retention assembly includes a spring loaded shear pin disposed in the tubular body portion, wherein the spring loaded shear pin is configured to engage a pin recess formed in the multi-position sleeve in the first position, and wherein the spring loaded shear pin is configured to shear in response to the second threshold pressure.

[0069] Statement 19. The flowback sub system of statement 17, wherein the retention assembly includes a J-slot assembly having a J-slot formed in the tubular body portion and a J-slot pin extending outward from the multi-position sleeve to interface with the J-slot, wherein the J-slot pin is disposed in a first J-slot position of the J-slot in the first position of the multi-position sleeve, and wherein the second threshold pressure driving the multi-position sleeve in the second axial direction and subsequent movement of the multi-position sleeve, via the biasing mechanism, is configured to drive the J-slot pin along the J-slot from the first J-slot position to a second J-slot position corresponding to the second position of the multi-position sleeve.

[0070] Statement 20. A flowback sub system, comprising: a tubular body portion having a central bore; a production only check valve disposed along a flow path between an exterior of the tubular body portion and the central bore, wherein the production only check valve is configured to allow fluid flow from the exterior of the tubular body portion toward the central bore and block fluid flow from the central bore toward the exterior of the tubular body portion; an injection only check valve disposed along the flow path between the exterior of the tubular body portion and the central bore, wherein the injection only check valve is configured to block fluid flow from the exterior of the tubular body portion toward the central bore and allow fluid flow from the central bore toward the exterior of the tubular body portion; a multi-position sleeve disposed within the central bore, wherein the multi-position sleeve includes a sleeve opening extending through the multi-position sleeve, wherein the multi-position sleeve is configured to move axially between a closed position, a first position, and a second position, wherein the sleeve opening is positioned to block fluid flow between the central bore and both the production only check valve and the injection only check valve in the closed position, wherein the sleeve opening is aligned with the production only check valve in the first position to allow fluid flow between the production only check valve and the central bore, and wherein the sleeve opening is aligned with the injection only check valve in the second position to allow fluid flow between the injection only check valve and the central bore; a shear pin configured to hold the multi-position sleeve in the closed position, wherein the shear pin is configured to shear in response to a first threshold pressure; a spring configured to drive the multi-position sleeve in a first axial direction; and a spring loaded shear pin configured to engage a pin recess formed in the multi-position sleeve in the first position, wherein the spring is configured to drive the multi-position sleeve in the first axial direction to the first position, and wherein the spring loaded shear pin is configured to shear in response to a second threshold pressure, and wherein the spring is configured to drive the multi-position sleeve in the first axial direction to the second position in response to the spring loaded pin shearing.

[0071] For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are 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 even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.

[0072] Therefore, the present embodiments are 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 embodiments may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual embodiments are discussed, all combinations of each embodiment are contemplated and covered by the disclosure. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. 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.

Examples

Embodiment Construction

[0016]Provided are systems and methods for controlling the fluid flow into an interior of a production string from the surrounding formations. In particular, the systems and methods include a flowback sub with a multi-position sleeve configured to selectively provide a bypass flow path for fluid flow into the interior of the production string from the surrounding formations. Generally, downhole fluids (e.g., oil, gas, water, etc.) may be configured to flow into an interior of a production string from the surrounding formations through autonomous flow control devices (AICDs) and / or density autonomous flow control devices (DAICDs). Undesired production fluids (e.g., gas and water) may flow through the AICDs and / or DAICDs at a slower rate than desired production fluids (e.g., oil), which may be beneficial for production operations. However, during some operations (e.g., cleanup operations), the flow rate of the undesired production fluids through the AICDs and / or DAICDs may be slower t...

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application is a non-provisional conversion application of U.S. Patent Provisional Application No. 63 / 757,163, the entire disclosure of which is incorporated herein by reference.BACKGROUND

[0002] In hydrocarbon production wells, it may be beneficial to regulate the flow of formation fluids from a subterranean formation into a wellbore penetrating the same. A variety of reasons or purposes may necessitate such regulation including, for example, prevention of water and / or gas coning, minimizing water and / or gas production, minimizing sand production, maximizing oil production, balancing production from various subterranean zones, equalizing pressure among various subterranean zones, and / or the like.

[0003] A number of devices are available for regulating the flow of formation fluids. Some of these devices may be non-discriminating for different types of formation fluids and may simply function as a “gatekeeper” for regulating access to the interior of a wellbore pipe, such as a well string. Such gatekeeper devices may be simple on / off valves or they may be metered to regulate fluid flow over a continuum of flow rates. Other types of devices for regulating the flow of formation fluids may achieve at least some degree of discrimination between different types of formation fluids. Such devices may include, for example, tubular flow restrictors, nozzle-type flow restrictors, autonomous inflow control devices, non-autonomous inflow control devices, ports, tortuous paths, combinations thereof, and the like.

[0004] Autonomous flow control devices (e.g., AICDs and DAICDs) may be particularly advantageous in subterranean operations, since they are able to automatically regulate fluid flow without the need for operator control due to their design. In this regard, autonomous flow control devices may be designed such that they provide a greater resistance to the flow of undesired fluids (e.g., gas and / or water) than they do desired fluids (e.g., oil), particularly as the percentage of the undesired fluids increases. Accordingly, the autonomous flow control devices may limit the flow of an undesired fluid into the interior of a production string during production operations.

[0005] Unfortunately, during some completion operations (e.g., cleanup operations), limiting flow of undesired fluids may cause delays and increase costs, since such operations may require flow of undesired fluids through the autonomous flow control devices.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] These drawings illustrate certain aspects of some of the embodiments of the present disclosure and should not be used to limit or define the method.

[0007] FIG. 1 illustrates an elevation view of a well system, in accordance with some embodiments of the present disclosure.

[0008] FIG. 2 illustrates a cross-sectional view of a flowback sub with a multi-position sleeve, in accordance with some embodiments of the present disclosure.

[0009] FIG. 3 illustrates a cross-sectional view of the multi-position sleeve of the flowback sub in a closed position, in accordance with some embodiments of the present disclosure.

[0010] FIG. 4 illustrates a cross-sectional view of the multi-position sleeve of the flowback sub in a first position, in accordance with some embodiments of the present disclosure.

[0011] FIG. 5 illustrates a cross-sectional view of the multi-position sleeve of the flowback sub in a second position, in accordance with some embodiments of the present disclosure.

[0012] FIG. 6 illustrates a cross-sectional view of a multi-position sleeve configured to block fluid flow in the second position, in accordance with some embodiments of the present disclosure.

[0013] FIG. 7 illustrates a cross-sectional view of the flowback sub having a secondary flow device configured to align with a multi-position sleeve in a second position, in accordance with some embodiments of the present disclosure.

[0014] FIG. 8 illustrates a cross-sectional view of the flowback sub with an entry slot into a valve chamber, in accordance with some embodiments of the present disclosure.

[0015] FIG. 9 illustrates a cross-sectional view of the flowback sub having a plurality of retention assemblies, in accordance with some embodiments of the present disclosure.DETAILED DESCRIPTION

[0016] Provided are systems and methods for controlling the fluid flow into an interior of a production string from the surrounding formations. In particular, the systems and methods include a flowback sub with a multi-position sleeve configured to selectively provide a bypass flow path for fluid flow into the interior of the production string from the surrounding formations. Generally, downhole fluids (e.g., oil, gas, water, etc.) may be configured to flow into an interior of a production string from the surrounding formations through autonomous flow control devices (AICDs) and / or density autonomous flow control devices (DAICDs). Undesired production fluids (e.g., gas and water) may flow through the AICDs and / or DAICDs at a slower rate than desired production fluids (e.g., oil), which may be beneficial for production operations. However, during some operations (e.g., cleanup operations), the flow rate of the undesired production fluids through the AICDs and / or DAICDs may be slower than desired.

[0017] As set forth in greater detail below, the multi-position sleeve may be configured to actuate between various positions to selectively provide a bypass flow path for the downhole fluids such that the undesired fluids may flow into the interior of the production string tubing at a higher rate than through the AICDs and / or DAICDs during some operations such as cleanup operations. However, during production operations, the multi-position sleeve may be configured to block flow into the production string via the flowback sub such that the AICDs and / or DAICDs may regulate the fluid flow into the production tubing during production operations.

[0018] FIG. 1 illustrates an elevation view of a well system, in accordance with some embodiments of the present disclosure. As illustrated, well system 100 may include a wellbore 102 that comprises a generally vertical uncased section 104 that may transition into a generally horizontal uncased section 106 extending through a subterranean formation 108. In some examples, the vertical section 104 may extend downwardly from a portion of wellbore 102 having a string of casing 110 cemented therein. A tubular string, such as production tubing 112, may be installed in or otherwise extended into wellbore 102.

[0019] As depicted, a plurality of well screens 114, flow control devices 116, flowback subs 128 and packers 118 may be interconnected along production tubing 112, such as along portions of the production tubing 112 in horizontal section 106 of wellbore 102. Packers 118 may be configured to seal off an annulus 120 defined between production tubing 112 and the walls of wellbore 102. As a result, fluids 122 may be produced from multiple intervals of the surrounding subterranean formation 108 via isolated portions of annulus 120 between adjacent pairs of packers 118.

[0020] As illustrated, in some examples, a well screen 114 and a flow control device 116 and / or flowback sub 128 may be interconnected in production tubing 112 and positioned between a pair of packers 118. Without limitation, well screens 114 may be swell screens, wire wrap screens, mesh screens, sintered screens, expandable screens, pre-packed screens, treating screens, or other known screen types. In operation, well screen 114 may be configured to filter fluids 122 flowing into production tubing 112 from annulus 120. Flow control device 116 and / or flowback sub 128 may be configured to restrict or otherwise regulate the flow of fluids 122 into production tubing 112, based on certain physical characteristics of the fluids. In examples, flow control device 116 may be a centrifugal fluid selector, wherein a portion of the centrifugal fluid selector may be actuated to rotate by the flow of fluids 122 and centrifugal force.

[0021] Without limitation, flow control device 116 may be an autonomous flow control device. The autonomous flow control device may utilize fluid dynamics and delay the flow of unwanted fluids such as water and / or gas into the interior of production tubing 112. The autonomous flow control device may operate as a passive flow control device, not requiring moving components and / or electronics. The autonomous flow control device may be any suitable shape. Without limitation, a suitable shape may include, but is not limited to, cross-sectional shapes that are circular, elliptical, triangular, rectangular, square, hexagonal, and / or combinations thereof. The autonomous flow control device may be made from any suitable material. Suitable materials may include, but are not limited to, metals, nonmetals, polymers, ceramics, and / or combinations thereof. Without limitation, the autonomous flow control device may be made from tungsten carbide and / or steel.

[0022] It will be appreciated that well system 100 is merely one example of a wide variety of well systems in which the principles of this disclosure may be utilized. Accordingly, it should be understood that the principles of this disclosure are not necessarily limited to any of the details of the depicted well system 100, or the various components thereof, depicted in the drawings or otherwise described herein. For example, it is not necessary in keeping with the principles of this disclosure for wellbore 102 to include a generally vertical wellbore section 104 or a generally horizontal wellbore section 106. Moreover, it is not necessary for fluids 122 to be only produced from subterranean formation 108 since, in other examples, fluids may be injected into subterranean formation 108, or fluids 122 may be both injected into and produced from subterranean formation 108, without departing from the scope of the disclosure.

[0023] Furthermore, it is not necessary that at least one well screen 114 and flow control device 116 and / or the at least one well screen 114 and the flowback sub 128 be positioned between a pair of packers 118. Nor is it necessary for a single flow control device 116 to be used in conjunction with a single well screen 114. Rather, any number, arrangement and / or combination of such components may be used, without departing from the scope of the disclosure. In some applications, it is not necessary for flow control device 116 and / or flowback sub 128 to be used with a corresponding well screen 114. For example, in injection operations, the injected fluid could be flowed through flow control device 116 and / or flowback sub 128, without also flowing through well screen 114.

[0024] Those skilled in the art will readily recognize the advantages of being able to regulate the flow of fluids 122 into production tubing 112 from each zone of subterranean formation 108, for example, to prevent water coning 124 or gas coning 126 in subterranean formation 108. Other uses for flow regulation in a well may include, but are not limited to, balancing production from (or injection into) multiple zones, minimizing production or injection of undesired fluids, maximizing production or injection of desired fluids, etc.

[0025] FIG. 2 illustrates a cross-sectional view of a flowback sub with a multi-position sleeve, in accordance with some embodiments of the present disclosure. The flowback sub 128 may include a downhole tubular 200 forming a portion of the production tubing 112. In particular, as illustrated, the flowback sub 128 may include a tubular body portion 202 having a central bore 204 extending through the tubular body portion 202. Further, the flowback sub 128 may include a multi-position sleeve 206 disposed within the central bore 204. As set forth in greater detail below, the multi-position sleeve 206 may be configured to move axially along the central bore 204 of the flowback sub 128 between various positions. For example, the multi-position sleeve 206 may be configured to move axially along the central bore 204 of the flowback sub 128 between a closed position, a first position (e.g., an inflow position), and a second position (e.g., an outflow position). The various positions may correspond to respective openings to a flow path 208 that extends through the tubular body portion 202 between an exterior 210 of the flowback sub 128 (e.g., the annulus 120 of the wellbore 102) and the central bore 204.

[0026] At least one well screen of the plurality of well screens 114 may be disposed along the flow path between the exterior 210 of the tubular body portion 202 and at least one check valve 212. The flowback sub 128 may include a valve assembly 214 disposed along the flow path 208 extending through the tubular body portion 202 between the exterior 210 of the flowback sub 128 and the central bore 204. In particular, the valve assembly 214 may be disposed along the flow path 208 between the at least one well screen 114 and the central bore 204 such that the well screen 114 may filter out debris flowing along the flow path 208 toward the valve assembly 214.

[0027] The valve assembly 214 may include a valve chamber 216 formed within the tubular body portion 202 and disposed along the flow path 208 between the exterior 210 of the flowback sub 128 and the central bore 204. Moreover, the flow path 208 may include various branches or lines connected to valve chamber 216. In particular, the flow path 208 may include an outer fluid line 218 extending from the valve chamber 216 to the exterior 210 of the tubular body portion 202, as well as at least one inner fluid line 220 extending from the valve chamber 216 to the central bore 204. As illustrated, the at least one inner fluid line 220 may include a primary inner fluid line 222 and a secondary inner fluid line 224 each extending from the valve chamber 216 to the central bore 204 in parallel. Alternatively, the secondary inner fluid line 224 may form a separate flow path (e.g., a second flow path 208) extending independently between the exterior 210 of the flowback sub 128 and the central bore 204.

[0028] Moreover, the valve assembly 214 may include the at least one check valve 212, which may be disposed along the flow path 208 between the exterior 210 of the flowback sub 128 and the central bore 204. In particular, as illustrated, the at least one check valve 212 may be disposed along the flow path 208 in a position between the central bore 204 and the valve chamber 216. The at least one check valve 212 may include a ball valve, a poppet valve, a fluidic diode, a spring loaded ball valve, a spring loaded poppet valve, a flapper valve, or any suitable type of check valve. Further, the at least one check valve 212 may include a production only check valve 226 configured to allow fluid flow into the flowback sub 128, but block flow out of the flowback sub 128 via the flow path 208. That is, the production only check valve 226 may be configured to allow fluid flow from the exterior 210 of the flowback sub 128 to flow through the production only check valve 226 toward the central bore 204 of the flowback sub 128, but block fluid flow from the central bore 204 of the flowback sub 128 toward the exterior 210 of the flowback sub 128 via the flow path 208. Further, the at least one check valve 212 may additionally, or alternatively, include an injection only check valve 228, which may be configured to allow fluid from the central bore 204 of the flowback sub 128 to flow through the injection only check valve 228 toward the exterior 210 of the flowback sub 128, but block fluid flow from the exterior 210 of the flowback sub 128 toward the central bore 204 of the flowback sub 128 via the flow path 208.

[0029] For example, as illustrated, the at least one check valve 212 may include a first check valve 230 (e.g., the production only check valve 226) and a second check valve 232 (e.g., the injection only check valve 228). The first check valve 230 may be disposed along the primary inner fluid line 222 that is in fluid communication with the central bore 204 via a primary opening 234 disposed at a position corresponding to the first position of the multi-position sleeve 206. Further, the second check valve 232 may be disposed along the secondary inner fluid line 224 that is in fluid communication with the central bore 204 via a secondary opening 236 disposed at a position corresponding to the second position of the multi-position sleeve 206. Accordingly, as set forth in greater detail below, moving the multi-position sleeve 206 between the first position and the second position may convert the flow path 208 from a production flow path to an injection flow path.

[0030] FIG. 3 illustrates a cross-sectional view of the multi-position sleeve of the flowback sub in the closed position, in accordance with some embodiments of the present disclosure. As set forth above, the multi-position sleeve 206 may be configured to move axially along the central bore 204 of the flowback sub 128 between various positions such as the closed position, the first position (e.g., an inflow position), and the second position (e.g., an outflow position). As illustrated, the multi-position sleeve 206 is disposed in the closed position. The flowback sub 128 may be run-in-hole in the closed position of the multi-position sleeve 206. As illustrated, the multi-position sleeve 206 may include a sleeve opening 300 extending through the multi-position sleeve 206.

[0031] Further, as set forth above, the sleeve opening 300 may be aligned with the first check valve 230 in the first position and the second check valve 232 in the second position. Specifically, the sleeve opening 300 may be aligned with the primary opening 234 corresponding to the primary inner fluid line 222 with the first check valve 230 (e.g., the production only check valve) in the first position. Further, in the second position, the sleeve opening 300 may be aligned with secondary opening 236 corresponding to the secondary inner fluid line 224 with the second check valve 232 (e.g., the injection only check valve). Aligning the sleeve opening 300 with the first check valve 230 or the second check valve 232 may place the corresponding check valve in fluid communication with the central bore 204. However, as illustrated, the sleeve opening 300 is offset from both the first check valve 230 and the second check valve 232 in the closed position such that a sleeve body 302 of the multi-position sleeve 206 may block fluid communication between both the first check valve 230 and the second check valve 232 with the central bore 204. As such, fluid flow into (e.g., production) and out of (e.g., injection) the flowback sub 128 via the valve assembly 214 may be blocked in the close position. Blocking fluid flow in both directions through the valve assembly 214 may ensure well integrity in case the well kicks. Additionally, blocking the fluid flow in directions through the valve assembly 214 may prevent pressure and fluid loss through the flowback sub 128 during washdown operations, as well as allow tubing pressure to be increased to set the packers 118 and to activate the flowback sub 128 (e.g., move the flowback sub from the closed position to the first position (e.g., the inflow position).

[0032] As set forth in greater detail below, the flowback sub 128 may include a biasing mechanism 304 configured to drive the multi-position sleeve 206 in a first axial direction 306 from the closed position toward the first position. The biasing mechanism 304 may include a spring, hydrostatic chamber, or any other suitable biasing mechanism. For example, as illustrated, the biasing mechanism 304 may include a spring 308 having a first spring end 310 configured to interface with the tubular body portion 202 and a second spring end 312 configured to interface with the multi-position sleeve 206. The spring 308 may be in compression such that the spring 308 provides a biasing force to drive the multi-position sleeve 206 away from the tubular body portion 202 in the first axial direction 306 (e.g., a downhole direction).

[0033] However, the flowback sub 128 may include a shearable member 314 configured to hold the multi-position sleeve 206 in the closed position. For example, the shearable member 314 may include a shear pin 316 configured to interface with the tubular body portion 202 and the multi-position sleeve 206 to hold the multi-position sleeve 206 in the closed position. Moreover, the biasing force provided by the biasing mechanism 304 (e.g., the spring 308) is not configured to shear the shearable member 314. That is, the biasing force is configured to provide less force than required to shear the shearable member 314. Instead, the shearable member 314 is configured to shear in response to a first threshold pressure in the central bore 204. For at least the reasons set forth below, increasing the pressure in the central bore 204 is configured to drive the multi-position sleeve 206 in the second axial direction 318 (e.g., an uphole direction). Increasing the pressure in the central bore 204 above the first threshold pressure may drive the multi-position sleeve 206 in the second axial direction 318 with sufficient force to shear the shearable member 314 and release the multi-position sleeve 206 from the closed position. In response to decreasing the shearable member 314 shearing and the pressure in the central bore 204 decreasing, the biasing force from the biasing mechanism 304 may drive the multi-position sleeve 206 from the closed position toward the first position.

[0034] As illustrated, the multi-position sleeve 206 includes an upper sleeve end 320, a lower sleeve end 322, and a shoulder portion 324 disposed axially between the biasing mechanism 304 and the lower sleeve end 322. A first annular seal 326 is disposed about the multi-position sleeve 206 proximate the upper sleeve end 320 to seal the multi-position sleeve 206 against the tubular body portion 202 proximate the upper sleeve end 320. As set forth in greater detail below, a second annular seal 328 is disposed about the shoulder portion 324 to seal the shoulder portion 324 against the tubular body portion 202 in the closed position and the first position of the multi-position sleeve 206. Further, the diameter of the second annular seal 328 is greater than the diameter of the first annular seal 326 such that increasing pressure in the central bore 204 above the first threshold pressure generates a pressure differential configured to drive the multi-position sleeve 206 in the second axial direction 318 (e.g., uphole direction) to shear the shearable member 314.

[0035] FIG. 4 illustrates a cross-sectional view of the multi-position sleeve of the flowback sub in the first position, in accordance with some embodiments of the present disclosure. As set forth above, the multi-position sleeve 206 may be configured to move from the closed position to the first position (e.g., the inflow position) in response to pressure in the central bore 204 being raised at least to the first threshold pressure. That is, in response to the tubing pressure increasing above the first threshold pressure, the multi-position sleeve 206 may be driven in the second axial direction 318 (e.g., the uphole direction) with sufficient force to shear the shearable member 314 (e.g., at least one shear screw, shear pin, etc.) configured to hold the multi-position sleeve 206 in the closed position. In response to the shearable member 314 shearing, the multi-position sleeve 206 may initially move in the second axial direction 318 due to the tubing pressure being above the first threshold pressure. However, as the tubing pressure is decreased (e.g., bled down) the multi-position sleeve 206 may be configured to reverse direction and move in the first axial direction 306 (e.g., downhole direction) via the biasing force provided by the biasing mechanism 304.

[0036] As illustrated, the biasing mechanism may include the spring 308 disposed in a spring chamber 400 formed between the tubular body portion 202 and a spring shoulder 402 of the multi-position sleeve 206. The spring 308 may include a compression spring or any suitable type of spring. As illustrated, the first spring end 310 of the spring 308 may be configured to contact the tubular body portion 202 and the second spring end 312 of the spring 308 may be configured to contact the spring shoulder 402 of the multi-position sleeve 206. As such, the spring 308 may be configured to bias the multi-position sleeve 206 in the first axial direction 306. Indeed, in response to the tubing pressure decreasing below a lower threshold pressure, the spring 308 may be configured to reverse movement of the multi-position sleeve 206 and drive the multi-position sleeve 206 in the first axial direction 306 toward the first position.

[0037] The flowback sub 128 may further include a retention assembly 404 configured to secure the multi-position sleeve 206 in the first position. For example, the retention assembly 404 may include a spring loaded shear pin 406 secured to the tubular body portion 202 of the flowback sub 128. As illustrated, the spring loaded shear pin 406 is configured to engage a pin recess 408 formed in a radially outer surface of the multi-position sleeve 206 in response to multi-position sleeve 206 moving into the first position. As set forth above, the spring 308 may be configured to drive the multi-position sleeve 206 in the first axial direction 306 toward the first position. In the first position, the spring loaded shear pin 406 may be axially aligned with the pin recess 408. As such, the spring 308 may be configured to drive the multi-position sleeve 206 in the first axial direction until the pin recess 408 is aligned with the spring loaded shear pin 406. The spring loaded shear pin 406 may be configured to expand into the pin recess 408 to lock the multi-position sleeve 206 in the first position.

[0038] Moreover, in the first position, the sleeve opening 300 of the multi-position sleeve 206 may be aligned with the first check valve 230, which may open fluid communication between the exterior of the flowback sub 128 and the central bore 204 via the first check valve 230. As set forth above, the flow path 208 through the first check valve 230 may be configured to allow fluid flow into the flowback sub 128, but block flow out of the flowback sub 128. As set forth above, allowing fluid to flow into the flowback sub 128 may provide a bypass flow path for undesired fluids (e.g., water) during cleanup operations. That is, during initial flowback of the well to cleanup drilling and / or completion fluids, AICDs and DAICDs may choke water; thereby significantly slowing cleanup operations. However, the flow path 208 (e.g., the bypass flow path) through the flowback sub 128 in the first position may increase flow rate of the initial flowback for cleanup operations.

[0039] Further, the first check valve 230 may block flow out of the flowback sub 128 such that tubing pressure may be increased in the central bore 204 after cleanup operations. That is, after cleanup operations, the tubing pressure may be increased above a second threshold pressure such that the retention assembly 404 releases the multi-position sleeve 206 to move from the first position to the second position. For example, the tubing pressure may be increased above a second threshold pressure to shear the spring loaded shear pin 406 such that the biasing force from the biasing mechanism 304 may drive the multi-position sleeve 206 from the first position to the second position. Moreover, the second threshold pressure may be greater than, equal to, or less than the first threshold pressure. The second threshold pressure may include any suitable pressure configured to drive the multi-position sleeve 206 in the second axial direction 318 with sufficient force for the retention assembly 404 to release the multi-position sleeve 206 (e.g., with sufficient force to shear the spring loaded shear pin 406).

[0040] FIG. 5 illustrates a cross-sectional view of the multi-position sleeve of the flowback sub in the second position, in accordance with some embodiments of the present disclosure. As set forth above, after flowback is completed, the tubing pressure may be increased above the second threshold pressure, which is configured to shear the spring-loaded shear pin 316 and move the multi-position sleeve 206 in the second axial direction 318. However, in response to the pressure decreasing below a lower threshold pressure, the biasing force from the biasing mechanism 304 is configured to drive multi-position sleeve in the first axial direction 306 toward the second position.

[0041] As illustrated, in the second position, a lockout snap ring 500 may be configured to interface with a lockout slot 502 of the tubular body portion 202 in a second position of the multi-position sleeve 206 to secure the multi-position sleeve 206 to the tubular body portion 202 in the second position (e.g., the outflow position). In second position, the second check valve 232 (e.g., injection only check valve) is aligned with the sleeve opening 300 in the multi-position sleeve 206 to block fluid flow from the exterior 210 of the flowback sub 128 toward the central bore 204 of the flowback sub 128 and allow fluid from the central bore 204 of the flowback sub 128 to flow through the second check valve 232 toward the exterior 210 of the flowback sub 128 via the flow path 208. As such, in the second position, production fluid may be blocked from flowing into the production tubing 112 via the flowback sub 128 such that the production fluid may only flow into the production tubing 112 via the AICDs and the DAICDs.

[0042] Moreover, as set forth above, the multi-position sleeve 206 includes the upper sleeve end 320, the lower sleeve end 322, and the shoulder portion 324 disposed axially between the biasing mechanism 304 and the lower sleeve end 322. Further, the first annular seal 326 is disposed about the multi-position sleeve 206 proximate the upper sleeve end 320 to seal the multi-position sleeve 206 against the tubular body portion 202 proximate the upper sleeve end 320 and the second annular seal 328, having a larger diameter than the first annular seal 326, is disposed about the shoulder portion 324 to seal the shoulder portion 324 against the tubular body portion such that increasing pressure in the central bore above the first threshold pressure is configured to drive the multi-position sleeve 206 in the second axial direction 318.

[0043] However, the second annular seal 328 may only be configured to seal the shoulder portion 324 against the tubular body portion 202 in the closed position and the open position. As illustrated, the tubular body portion 202 includes an increased inner diameter portion 504 configured to align with the second annular seal 328 in the second position. The increased inner diameter portion 504 may be radially offset from the second annular seal 328 and the shoulder portion 324 to prevent sealing between the multi-position sleeve 206 and the tubular body portion 202 in the second position. Instead, a third annular seal 506 disposed about the multi-position sleeve 206 proximate the lower sleeve end 322 may be configured to seal against the tubular body portion 202 in the second position. The first annular seal 326 and the third annular seal 506 may have substantially similar diameters such that pressure in the central bore 204 ceases to create a pressure differential to bias the multi-position sleeve 206 to move axially with respect to the tubular body portion 202.

[0044] FIG. 6 illustrates a cross-sectional view of a multi-position sleeve configured block fluid flow in the second position, in accordance with some embodiments of the present disclosure. As set forth above, the multi-position sleeve 206 may be disposed within the central bore 204 and configured to move axially between the closed position, the first position, and the second position. Further, the multi-position sleeve 206 includes the sleeve opening 300 configured to provide fluid communication between the central bore 204 and the flow path 208 in response to the sleeve opening 300 aligning with a respective opening of the flow path (e.g., the primary opening 234). As set forth above, the sleeve opening 300 is aligned with an inner surface 600 of the tubular body portion 202 in the closed position such that fluid communication between the central bore 204 and the flow path is blocked in the closed position. In response to the multi-position sleeve 206 moving to the first position, the sleeve opening 300 may be aligned with the flow path 208 and the first check valve 230 such that fluid may flow from the exterior 210 of the tubular body portion 202 toward the central bore 204.

[0045] As set forth above, after flowback operations are complete, pressure in the central bore may be increased to the second threshold pressure to shear the spring loaded shear pin 406 such that that biasing mechanism 304 (shown in FIG. 5) may drive the multi-position sleeve 206 in the first axial direction 306 from the first position toward the second position. As illustrated, in the second position, the sleeve opening 300 may be aligned with the inner surface 600 of the tubular body portion 202 such that fluid communication between the central bore 204 and the flow path 208 is blocked in the second position.

[0046] FIG. 7 illustrates a cross-sectional view of the flowback sub having a secondary flow device configured to align with a multi-position sleeve in a second position, in accordance with some embodiments of the present disclosure. As illustrated, the flowback sub 128 may include a secondary flow device 700 disposed along the second flow path 208 (e.g., the secondary inner fluid line 224) such that the sleeve opening 300 of the multi-position sleeve 206 may be axially aligned with the secondary flow device 700 in a second position to allow fluid flow through the secondary flow device 700. As set forth above, the secondary flow device 700 may include the second check valve 232. However, the secondary flow device 700 may alternatively include a nozzle, an inflow control device, an autonomous inflow control device, density autonomous inflow control device, or some combination thereof such that the flowback sub 128 may be configured to contribute to production operations in the second position.

[0047] FIG. 8 illustrates a cross-sectional view of the flowback sub with an entry slot 800 into a valve chamber 216, in accordance with some embodiments of the present disclosure. As set forth above, the valve chamber 216 and the at least one check valve 212 may be disposed along the flow path 208 between the at least one well screen 114 and the central bore 204 such that the well screen 114 may filter out debris flowing along the flow path 208 toward the valve assembly 214. Alternatively, as illustrated, the flowback sub 128 may not include well screens 114 such that the outer fluid line 218 of the flow path 208 may extend directly from the valve chamber 216 and the at least one check valve 212, or some combination thereof, to the exterior 210 of the tubular body portion 202 via the entry slot 800.

[0048] FIG. 9 illustrates a cross-sectional view of the flowback sub having a plurality of retention assemblies, in accordance with some embodiments of the present disclosure. Indeed, as illustrated, the plurality of retention assemblies 404 may include a first spring loaded shear pin 900 configured to engage a first pin recess 902 in a first intermediate position, which may be disposed between the closed position and the first position. Further, the plurality of retention assemblies 404 may include a second spring loaded shear pin 904 configured to engage a second pin recess 906 in the first position, as well as a third spring loaded shear pin 908 configured to engage a third pin recess 910 in the second intermediate position, which may be disposed between the first position and the second position. However, the flowback sub 128 may include any suitable number of retention assemblies 404. Further, the plurality of retention assemblies 404 may include any suitable number of spring loaded shear pins 406 and corresponding pin recesses 408 disposed between main positions (e.g., the closed position, the first position, and the second position) of the multi-position sleeve206.

[0049] For example, the flowback sub 128 may include additional spring loaded shear pins 406 and corresponding pin recesses 408 between the main positions to increase a number of pressure cycles required to actuate the multi-position sleeve 206 between main positions. As set forth above, pressure in the central bore 204 may be cycled between an increased pressure and a lower pressure to move the multi-position sleeve 206 between main positions and intermediate positions. That is, pressure in the central bore 204 may be cycled between an increased pressure to shear the current engaged spring loaded shear pin 406 (e.g., the first spring loaded shear pin 900) and a lower pressure to allow the spring 308 to drive the multi-position sleeve 206 in the first axial direction 306 to engage a next spring loaded shear pin 406 (e.g., the second spring loaded shear pin 904) with its corresponding pin recess 408 (e.g., the second pin recess 906). The flowback sub 128 may include any number of spring-loaded shear pins 406 and corresponding pin recesses 408 corresponding to a desired number of pressure cycles required to move the multi-position sleeve 206 between main positions.

[0050] Accordingly, the present disclosure may provide a flowback sub configured to provide a bypass flow path for completion systems with AICDs and DAICDs during operations such as cleanup operations. The systems and methods may include any of the various features disclosed herein, including one or more of the following statements.

[0051] Statement 1. A flowback sub system, comprising: a tubular body portion having a central bore; a check valve disposed along a flow path between an exterior of the tubular body portion and the central bore; a multi-position sleeve disposed within the central bore and configured to move axially between a closed position and a first position, wherein the multi-position sleeve includes a sleeve opening extending through the multi-position sleeve, wherein the sleeve opening is positioned to block fluid flow between the central bore and the flow path in the closed position, and wherein the sleeve opening is aligned with the check valve in the first position to allow fluid flow through the check valve; a shearable member configured to hold the multi-position sleeve in the closed position, wherein the shearable member is configured to shear in response to a first threshold pressure; a biasing mechanism configured to drive the multi-position sleeve in a first axial direction from the closed position toward the first position; and a retention assembly configured to hold the multi-position sleeve in the first position.

[0052] Statement 2. The flowback sub system of statement 1, wherein the check valve is a production only check valve, wherein the production only check valve is configured to allow fluid flow from the exterior of the tubular body portion toward the central bore and block fluid flow from the central bore toward the exterior of the tubular body portion.

[0053] Statement 3. The flowback sub system of statement 1, wherein the check valve is an injection only check valve, wherein the injection only check valve is configured to block fluid flow from the exterior of the tubular body portion toward the central bore and allow fluid flow from the central bore toward the exterior of the tubular body portion.

[0054] Statement 4. The flowback sub system of any preceding statement, further comprising a secondary flow device disposed along a secondary fluid line, wherein the sleeve opening of the multi-position sleeve is axially aligned with the secondary flow device in a second position to allow fluid flow through the secondary flow device, and wherein the secondary flow device includes a second check valve, a nozzle, an inflow control device, an autonomous inflow control device, density autonomous inflow control device, or some combination thereof.

[0055] Statement 5. The flowback sub system of any preceding statement, further comprising a valve chamber disposed along the flow path, wherein the flow path includes an outer fluid line extending from the valve chamber to the exterior of the tubular body portion and primary inner fluid line extending from the valve chamber to the central bore, wherein the check valve is disposed along the primary inner fluid line, wherein the secondary fluid line includes a secondary inner fluid line extending between the central bore and the valve chamber, and wherein the secondary flow device is disposed along the secondary inner fluid line.

[0056] Statement 6. The flowback sub system of any preceding statement, wherein the retention assembly is configured to release the multi-position sleeve in response to a second threshold pressure, wherein the biasing mechanism is configured to drive the multi-position sleeve in the first axial direction from the first position to the second position in response to the retention assembly releasing the multi-position sleeve.

[0057] Statement 7. The flowback sub system of any preceding statement, wherein the retention assembly includes a spring loaded shear pin disposed in the tubular body portion, wherein the spring loaded shear pin is configured to engage a pin recess formed in the multi-position sleeve in the first position, and wherein the spring loaded shear pin is configured to shear in response to a second threshold pressure.

[0058] Statement 8. The flowback sub system of any of statements 1-6, wherein the retention assembly includes a J-slot assembly having a J-slot formed in the tubular body portion and a J-slot pin extending outward from the multi-position sleeve to interface with the J-slot, wherein the J-slot pin is disposed in a first J-slot position of the J-slot in the first position of the multi-position sleeve, and wherein a second threshold pressure driving the multi-position sleeve in a second axial direction and subsequent movement of the multi-position sleeve, via the biasing mechanism, is configured to drive the J-slot pin along the J-slot from the first J-slot position to a second J-slot position corresponding to a second position of the multi-position sleeve.

[0059] Statement 9. The flowback sub system of any preceding statement, wherein the biasing mechanism includes a spring, and wherein the spring includes a first end configured to interface with the tubular body portion and a second end configured to interface with the multi-position sleeve.

[0060] Statement 10. The flowback sub system of any preceding statement, wherein the biasing mechanism includes a hydrostatic chamber.

[0061] Statement 11. The flowback sub system of any preceding statement, wherein the check valve includes a ball valve, a poppet valve, a fluidic diode, a spring loaded ball valve, a spring loaded poppet valve, a flapper valve, or some combination thereof.

[0062] Statement 12. The flowback sub system of any preceding statement, wherein the retention assembly is configured to release the multi-position sleeve in response to a second threshold pressure, wherein the biasing mechanism is configured to drive the multi-position sleeve in the first axial direction from the first position to a second position in response to the retention assembly releasing the multi-position sleeve, and wherein the sleeve opening extending through the multi-position sleeve is aligned with an inner surface of the tubular body portion in the second position such fluid flow between the central bore and the flow path is blocked in the second position.

[0063] Statement 13. The flowback sub system of any preceding statement, wherein the shearable member includes a shear pin, wherein the shear pin is configured to interface with the tubular body portion and the multi-position sleeve to hold the multi-position sleeve in the closed position, wherein the shear pin is configured to shear in response to the first threshold pressure in the central bore of the tubular body portion.

[0064] Statement 14. The flowback sub system of any preceding statement, wherein the multi-position sleeve includes an upper end, a lower end, and a shoulder portion disposed axially between the biasing mechanism and the lower end, wherein a first annular seal is disposed about the multi-position sleeve proximate the upper end to seal the multi-position sleeve against the tubular body portion proximate the upper end, wherein a second annular seal is disposed about the shoulder portion to seal shoulder portion against the tubular body portion in the closed position and the first position of the multi-position sleeve, wherein the diameter of the second annular seal is greater than the diameter of the first annular seal such that pressure in the central bore is configured to drive the multi-position sleeve in a second axial direction to shear the shearable member.

[0065] Statement 15. The flowback sub system of any preceding statement, wherein the tubular body portion includes an increased inner diameter portion configured to align with the second annular seal in a second position, wherein the increased inner diameter portion is radially offset from the second annular seal and the shoulder portion to prevent sealing between the multi-position sleeve and the tubular body portion in the second position, wherein a third annular seal disposed about the multi-position sleeve proximate the lower end is configured to seal against the tubular body portion in the second position, wherein the first annular seal and the third annular seal have substantially similar diameters such that pressure in the central bore ceases to bias the multi-position sleeve to move axially with respect to the tubular body portion.

[0066] Statement 16. The flowback sub system of any preceding statement, further comprising a lockout snap ring configured to interface with a lockout slot of the tubular body portion in a second position of the multi-position sleeve to secure the multi-position sleeve to the tubular body portion in the second position.

[0067] Statement 17. A flowback sub system, comprising: a tubular body portion having a central bore; a check valve disposed along a flow path between an exterior of the tubular body portion and the central bore; a secondary flow device disposed along a second flow path; a multi-position sleeve disposed within the central bore and configured to move axially between a closed position, a first position and a second position, wherein the multi-position sleeve includes a sleeve opening extending through the multi-position sleeve, wherein the sleeve opening is positioned to block fluid flow between the central bore and the flow path in the closed position, wherein the sleeve opening is axially aligned with the check valve in the first position to allow fluid flow through the check valve, and wherein the sleeve opening is axially aligned with the secondary flow device in the second position to allow fluid flow through the secondary flow device; a shearable member configured to hold the multi-position sleeve in the closed position, wherein the shearable member is configured to shear in response to a first threshold pressure; a biasing mechanism configured to drive the multi-position sleeve in a first axial direction; and a retention assembly configured to hold the multi-position sleeve in the first position in response to the biasing mechanism driving the multi-position sleeve from the closed position to the first position, wherein the retention assembly is configured to release the multi-position sleeve in response to a second threshold pressure, and wherein the biasing mechanism is configured to drive the multi-position sleeve in the first axial direction from the first position to the second position in response to the retention assembly releasing the multi-position sleeve.

[0068] Statement 18. The flowback sub system of statement 17, wherein the retention assembly includes a spring loaded shear pin disposed in the tubular body portion, wherein the spring loaded shear pin is configured to engage a pin recess formed in the multi-position sleeve in the first position, and wherein the spring loaded shear pin is configured to shear in response to the second threshold pressure.

[0069] Statement 19. The flowback sub system of statement 17, wherein the retention assembly includes a J-slot assembly having a J-slot formed in the tubular body portion and a J-slot pin extending outward from the multi-position sleeve to interface with the J-slot, wherein the J-slot pin is disposed in a first J-slot position of the J-slot in the first position of the multi-position sleeve, and wherein the second threshold pressure driving the multi-position sleeve in the second axial direction and subsequent movement of the multi-position sleeve, via the biasing mechanism, is configured to drive the J-slot pin along the J-slot from the first J-slot position to a second J-slot position corresponding to the second position of the multi-position sleeve.

[0070] Statement 20. A flowback sub system, comprising: a tubular body portion having a central bore; a production only check valve disposed along a flow path between an exterior of the tubular body portion and the central bore, wherein the production only check valve is configured to allow fluid flow from the exterior of the tubular body portion toward the central bore and block fluid flow from the central bore toward the exterior of the tubular body portion; an injection only check valve disposed along the flow path between the exterior of the tubular body portion and the central bore, wherein the injection only check valve is configured to block fluid flow from the exterior of the tubular body portion toward the central bore and allow fluid flow from the central bore toward the exterior of the tubular body portion; a multi-position sleeve disposed within the central bore, wherein the multi-position sleeve includes a sleeve opening extending through the multi-position sleeve, wherein the multi-position sleeve is configured to move axially between a closed position, a first position, and a second position, wherein the sleeve opening is positioned to block fluid flow between the central bore and both the production only check valve and the injection only check valve in the closed position, wherein the sleeve opening is aligned with the production only check valve in the first position to allow fluid flow between the production only check valve and the central bore, and wherein the sleeve opening is aligned with the injection only check valve in the second position to allow fluid flow between the injection only check valve and the central bore; a shear pin configured to hold the multi-position sleeve in the closed position, wherein the shear pin is configured to shear in response to a first threshold pressure; a spring configured to drive the multi-position sleeve in a first axial direction; and a spring loaded shear pin configured to engage a pin recess formed in the multi-position sleeve in the first position, wherein the spring is configured to drive the multi-position sleeve in the first axial direction to the first position, and wherein the spring loaded shear pin is configured to shear in response to a second threshold pressure, and wherein the spring is configured to drive the multi-position sleeve in the first axial direction to the second position in response to the spring loaded pin shearing.

[0071] For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are 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 even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.

[0072] Therefore, the present embodiments are 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 embodiments may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual embodiments are discussed, all combinations of each embodiment are contemplated and covered by the disclosure. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. 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.

Examples

Embodiment Construction

[0016]Provided are systems and methods for controlling the fluid flow into an interior of a production string from the surrounding formations. In particular, the systems and methods include a flowback sub with a multi-position sleeve configured to selectively provide a bypass flow path for fluid flow into the interior of the production string from the surrounding formations. Generally, downhole fluids (e.g., oil, gas, water, etc.) may be configured to flow into an interior of a production string from the surrounding formations through autonomous flow control devices (AICDs) and / or density autonomous flow control devices (DAICDs). Undesired production fluids (e.g., gas and water) may flow through the AICDs and / or DAICDs at a slower rate than desired production fluids (e.g., oil), which may be beneficial for production operations. However, during some operations (e.g., cleanup operations), the flow rate of the undesired production fluids through the AICDs and / or DAICDs may be slower t...

Claims

1. A flowback sub system, comprising:a tubular body portion having a central bore;a check valve disposed along a flow path between an exterior of the tubular body portion and the central bore;a multi-position sleeve disposed within the central bore and configured to move axially between a closed position and a first position, wherein the multi-position sleeve includes a sleeve opening extending through the multi-position sleeve, wherein the sleeve opening is positioned to block fluid flow between the central bore and the flow path in the closed position, and wherein the sleeve opening is aligned with the check valve in the first position to allow fluid flow through the check valve;a shearable member configured to hold the multi-position sleeve in the closed position, wherein the shearable member is configured to shear in response to a first threshold pressure;a biasing mechanism configured to drive the multi-position sleeve in a first axial direction from the closed position toward the first position; anda retention assembly configured to hold the multi-position sleeve in the first position.

2. The flowback sub system of claim 1, wherein the check valve is a production only check valve, wherein the production only check valve is configured to allow fluid flow from the exterior of the tubular body portion toward the central bore and block fluid flow from the central bore toward the exterior of the tubular body portion.

3. The flowback sub system of claim 1, wherein the check valve is an injection only check valve, wherein the injection only check valve is configured to block fluid flow from the exterior of the tubular body portion toward the central bore and allow fluid flow from the central bore toward the exterior of the tubular body portion.

4. The flowback sub system of claim 1, further comprising a secondary flow device disposed along a secondary fluid line, wherein the sleeve opening of the multi-position sleeve is axially aligned with the secondary flow device in a second position to allow fluid flow through the secondary flow device, and wherein the secondary flow device includes a second check valve, a nozzle, an inflow control device, an autonomous inflow control device, density autonomous inflow control device, or some combination thereof.

5. The flowback sub system of claim 4, further comprising a valve chamber disposed along the flow path, wherein the flow path includes an outer fluid line extending from the valve chamber to the exterior of the tubular body portion and primary inner fluid line extending from the valve chamber to the central bore, wherein the check valve is disposed along the primary inner fluid line, wherein the secondary fluid line includes a secondary inner fluid line extending between the central bore and the valve chamber, and wherein the secondary flow device is disposed along the secondary inner fluid line.

6. The flowback sub system of claim 4, wherein the retention assembly is configured to release the multi-position sleeve in response to a second threshold pressure, wherein the biasing mechanism is configured to drive the multi-position sleeve in the first axial direction from the first position to the second position in response to the retention assembly releasing the multi-position sleeve.

7. The flowback sub system of claim 1, wherein the retention assembly includes a spring loaded shear pin disposed in the tubular body portion, wherein the spring loaded shear pin is configured to engage a pin recess formed in the multi-position sleeve in the first position, and wherein the spring loaded shear pin is configured to shear in response to a second threshold pressure.

8. The flowback sub system of claim 1, wherein the retention assembly includes a J-slot assembly having a J-slot formed in the tubular body portion and a J-slot pin extending outward from the multi-position sleeve to interface with the J-slot, wherein the J-slot pin is disposed in a first J-slot position of the J-slot in the first position of the multi-position sleeve, and wherein a second threshold pressure driving the multi-position sleeve in a second axial direction and subsequent movement of the multi-position sleeve, via the biasing mechanism, is configured to drive the J-slot pin along the J-slot from the first J-slot position to a second J-slot position corresponding to a second position of the multi-position sleeve.

9. The flowback sub system of claim 1, wherein the biasing mechanism includes a spring, and wherein the spring includes a first end configured to interface with the tubular body portion and a second end configured to interface with the multi-position sleeve.

10. The flowback sub system of claim 1, wherein the biasing mechanism includes a hydrostatic chamber.

11. The flowback sub system of claim 1, wherein the check valve includes a ball valve, a poppet valve, a fluidic diode, a spring loaded ball valve, a spring loaded poppet valve, a flapper valve, or some combination thereof.

12. The flowback sub system of claim 1, wherein the retention assembly is configured to release the multi-position sleeve in response to a second threshold pressure, wherein the biasing mechanism is configured to drive the multi-position sleeve in the first axial direction from the first position to a second position in response to the retention assembly releasing the multi-position sleeve, and wherein the sleeve opening extending through the multi-position sleeve is aligned with an inner surface of the tubular body portion in the second position such fluid flow between the central bore and the flow path is blocked in the second position.

13. The flowback sub system of claim 1, wherein the shearable member includes a shear pin, wherein the shear pin is configured to interface with the tubular body portion and the multi-position sleeve to hold the multi-position sleeve in the closed position, wherein the shear pin is configured to shear in response to the first threshold pressure in the central bore of the tubular body portion.

14. The flowback sub system of claim 1, wherein the multi-position sleeve includes an upper end, a lower end, and a shoulder portion disposed axially between the biasing mechanism and the lower end, wherein a first annular seal is disposed about the multi-position sleeve proximate the upper end to seal the multi-position sleeve against the tubular body portion proximate the upper end, wherein a second annular seal is disposed about the shoulder portion to seal shoulder portion against the tubular body portion in the closed position and the first position of the multi-position sleeve, wherein the diameter of the second annular seal is greater than the diameter of the first annular seal such that pressure in the central bore is configured to drive the multi-position sleeve in a second axial direction to shear the shearable member.

15. The flowback sub system of claim 14, wherein the tubular body portion includes an increased inner diameter portion configured to align with the second annular seal in a second position, wherein the increased inner diameter portion is radially offset from the second annular seal and the shoulder portion to prevent sealing between the multi-position sleeve and the tubular body portion in the second position, wherein a third annular seal disposed about the multi-position sleeve proximate the lower end is configured to seal against the tubular body portion in the second position, wherein the first annular seal and the third annular seal have substantially similar diameters such that pressure in the central bore ceases to bias the multi-position sleeve to move axially with respect to the tubular body portion.

16. The flowback sub system of claim 1, further comprising a lockout snap ring configured to interface with a lockout slot of the tubular body portion in a second position of the multi-position sleeve to secure the multi-position sleeve to the tubular body portion in the second position.

17. A flowback sub system, comprising:a tubular body portion having a central bore;a check valve disposed along a flow path between an exterior of the tubular body portion and the central bore;a secondary flow device disposed along a second flow path;a multi-position sleeve disposed within the central bore and configured to move axially between a closed position, a first position and a second position, wherein the multi-position sleeve includes a sleeve opening extending through the multi-position sleeve, wherein the sleeve opening is positioned to block fluid flow between the central bore and the flow path in the closed position, wherein the sleeve opening is axially aligned with the check valve in the first position to allow fluid flow through the check valve, and wherein the sleeve opening is axially aligned with the secondary flow device in the second position to allow fluid flow through the secondary flow device;a shearable member configured to hold the multi-position sleeve in the closed position, wherein the shearable member is configured to shear in response to a first threshold pressure;a biasing mechanism configured to drive the multi-position sleeve in a first axial direction; anda retention assembly configured to hold the multi-position sleeve in the first position in response to the biasing mechanism driving the multi-position sleeve from the closed position to the first position, wherein the retention assembly is configured to release the multi-position sleeve in response to a second threshold pressure, and wherein the biasing mechanism is configured to drive the multi-position sleeve in the first axial direction from the first position to the second position in response to the retention assembly releasing the multi-position sleeve.

18. The flowback sub system of claim 17, wherein the retention assembly includes a spring loaded shear pin disposed in the tubular body portion, wherein the spring loaded shear pin is configured to engage a pin recess formed in the multi-position sleeve in the first position, and wherein the spring loaded shear pin is configured to shear in response to the second threshold pressure.

19. The flowback sub system of claim 17, wherein the retention assembly includes a J-slot assembly having a J-slot formed in the tubular body portion and a J-slot pin extending outward from the multi-position sleeve to interface with the J-slot, wherein the J-slot pin is disposed in a first J-slot position of the J-slot in the first position of the multi-position sleeve, and wherein the second threshold pressure driving the multi-position sleeve in the second axial direction and subsequent movement of the multi-position sleeve, via the biasing mechanism, is configured to drive the J-slot pin along the J-slot from the first J-slot position to a second J-slot position corresponding to the second position of the multi-position sleeve.

20. A flowback sub system, comprising:a tubular body portion having a central bore;a production only check valve disposed along a flow path between an exterior of the tubular body portion and the central bore, wherein the production only check valve is configured to allow fluid flow from the exterior of the tubular body portion toward the central bore and block fluid flow from the central bore toward the exterior of the tubular body portion;an injection only check valve disposed along the flow path between the exterior of the tubular body portion and the central bore, wherein the injection only check valve is configured to block fluid flow from the exterior of the tubular body portion toward the central bore and allow fluid flow from the central bore toward the exterior of the tubular body portion;a multi-position sleeve disposed within the central bore, wherein the multi-position sleeve includes a sleeve opening extending through the multi-position sleeve, wherein the multi-position sleeve is configured to move axially between a closed position, a first position, and a second position, wherein the sleeve opening is positioned to block fluid flow between the central bore and both the production only check valve and the injection only check valve in the closed position, wherein the sleeve opening is aligned with the production only check valve in the first position to allow fluid flow between the production only check valve and the central bore, and wherein the sleeve opening is aligned with the injection only check valve in the second position to allow fluid flow between the injection only check valve and the central bore;a shear pin configured to hold the multi-position sleeve in the closed position, wherein the shear pin is configured to shear in response to a first threshold pressure;a spring configured to drive the multi-position sleeve in a first axial direction; anda spring loaded shear pin configured to engage a pin recess formed in the multi-position sleeve in the first position, wherein the spring is configured to drive the multi-position sleeve in the first axial direction to the first position, and wherein the spring loaded shear pin is configured to shear in response to a second threshold pressure, and wherein the spring is configured to drive the multi-position sleeve in the first axial direction to the second position in response to the spring loaded pin shearing.

Images