Enhanced high differnetial pressure port housing for icv

Abstract

An assembly includes a port housing defining a tubular body. The tubular body includes at least one port hole. A choke assembly is defined within the cylindrical body. The choke assembly includes a choke housing and a choke disposed within the choke housing. The choke housing includes at least one choke hole. The at least one choke hole is at least partially overlapping a corresponding port hole in the at least one port hole such that a fluid flow through the corresponding port hole flows through the choke hole. The choke housing further includes at least one pressure reduction port having a fluid inlet configured to receive a flow, a pressure reduction feature configured to reduce a pressure of the fluid, a pressure drop region configured to receive the fluid from the pressure reduction feature, and at least one port connecting the pressure drop region to the choke.

Description

ILC-510838-WO-2_BAO2352PCTENHANCED HIGH DIFFERNETIAL PRESSURE PORT HOUSING FOR ICVCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Application No. 19 / 058547, filed on February 20, 2025, which is incorporated herein by reference in its entirety.BACKGROUND

[0002] Due to high sand concentration, high flow rate, and high flow velocity, small port sizes and high differential pressure can lead to fast degradation on port housing and choke assemblies for ICV valves. As a result, the port housing and choke assemblies typically have extremely short useful lifecycles, requiring frequent replacement and downtime.SUMMARY

[0003] In some embodiments, an assembly includes a port housing defining a tubular body. The tubular body includes at least one port hole. A choke assembly is defined within the cylindrical body. The choke assembly includes a choke housing and a choke disposed within the choke housing. The choke housing includes at least one choke hole. The at least one choke hole is at least partially overlapping a corresponding port hole in the at least one port hole such that a fluid flow through the corresponding port hole flows through the choke hole. The choke housing further includes at least one pressure reduction port having a fluid inlet configured to receive a flow, a pressure reduction feature configured to reduce a pressure of the fluid, a pressure drop region configured to receive the fluid from the pressure reduction feature, and at least one port connecting the pressure drop region to the choke.

[0004] In other embodiments, a method includes reducing a flow speed of a fluid entering a choke by passing at least a portion of the fluid through a pressure reduction port, wherein the pressure reduction port includes a fluid inlet configured to receive a flow, a fluid pressure reduction feature configured to reduce a pressure of the fluid, a pressure drop region configured to receive the reduced pressure fluid, and at least one port connecting the pressure drop region to the choke.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:

[0006] Figure 1 illustrates a borehole system including a port housing assembly.ILC-510838-WO-2_BAO2352PCT

[0007] Figure 2A is an isometric view of a port housing for use in the borehole system of FIG. 1 and containing a choke housing assembly.

[0008] Figure 2B is a cross section of Figure 2A along plane A-A.

[0009] Figure 3 is an isometric view of a choke housing assembly isolated from the port housing assembly of Figures 2A and 2B.

[0010] Figure 4 is an isometric view of an alternate choke housing assembly isolated from the port housing assembly of Figures 2A and 2B.

[0011] Figure 5 is a schematic partial cross sectional view of the choke of Figures 2A and 2B, according to some examples.DETAILED DESCRIPTION

[0012] A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.

[0013] Referring to Figure 1, a borehole system 100 is illustrated. The system 100 comprises a borehole 102 in a subsurface formation 104. A string 106 is disposed within the borehole 102. A port housing assembly 10 as disclosed herein is disposed within or as a part of the string 106.

[0014] As used herein a downhole end refers to an end of a component that is deeper in the borehole than an uphole end of the same component. For example, in a vertically oriented borehole, the downhole end would be below an uphole end in the direction of gravity.

[0015] Figure 2A illustrates a port housing assembly 200 for utilization in the borehole system 100 of FIG. 1. Figure 2B illustrates the port housing assembly 200 of Figure 2A cut at cross sectional plane A-A.

[0016] The port housing assembly 200 according to one example includes a generally cylindrical body 210 defining an axis 202. Contained within the cylindrical body 210 is a choke assembly 300 made up of a choke 302 and a choke housing 304. A set of ports 212 are positioned along the outside of the port housing 200. In the example of Figures 2A and 2B, the ports 212 are arranged in multiple subsets of ports 212, with each subset being arranged linearly and aligned with the axis 202. By way of example, the port housing assembly 200 of Figure 2A and 2B includes four subsets, each containing six linearly arranged ports 212. Each of the ports 212 is a through hole that intrudes radially, relative to the axis 202, into the port housing assembly 200. The particular configuration illustrated in FIG. 1 is exemplary in nature and is not limiting. In alternative examples, the set of ports 212 could be arranged differentlyILC-510838-WO-2_BAO2352PCTon the cylindrical body 210, and the set of ports 212 are not required to be linearly arranged. In one alternate example, the set of ports 212 could be helically arranged. In other alternative examples, the set of ports could be oriented partially radially and partially axially (e.g. at an angle relative to the axis). Further alterations and variations on the structure and arrangement of the sets of ports 212 can be determined by one of skill in the art.

[0017] While being utilized within the borehole 102, a flow 220 of a fluid enters the choke through the ports 212. The flow speed of the flow 220 can be metered, in some examples, by adjusting the relative axial positions of the choke 302 and the port housing 200. This relative positioning alters an amount of overlap between the ports 212 and corresponding inlet holes in the choke assembly 300 thereby adjusting a volume of fluid able to pass through the port 212. The overlap adjustment is referred to as inlet hole metering.

[0018] With continued reference to the example of Figures 2A and 2B, Figure 3 illustrates a choke assembly 300 according to one example. The choke assembly 300 includes the choke housing 304, which is generally cylindrical and surrounds the choke 302. A set of inlet holes 306 intrude radially through the choke housing 304 into the choke 302.

[0019] In some implementations it is desirable to reduce the fluid speed of the fluid more than is achieved using the inlet hole metering. To provide a further reduction in flow speed, the choke housing 304 of the choke assembly 300, 400 includes one or more pressure reduction ports 310, 410 (illustrated in Figures 3 and 4 respectively).

[0020] The pressure reduction ports 310, 410 each include a fluid inlet 312, 412. Fluid from a corresponding port 212 is received at the fluid inlet 312, 412. The fluid received at the fluid inlet 312, 412 encounters a pressure reduction feature 314, 414. After the pressure reduction feature 314, 414 the flow is passed to a flow pressure drop region 316, 416. The pressure drop region 316, 416 includes one or more through holes 318, 418 through which the fluid passes into a corresponding hole in the choke 302, and then into an interior of the choke 302.

[0021] The pressure drop region 316, 416 introduces a delay to the fluid after encountering the pressure reduction feature and before the fluid is passed into the choke. The delay, in turn, causes a reduction in pressure.

[0022] With continued reference to Figures 2A and 2B, Figure 3 illustrates one example choke housing 300 having a first configuration for the pressure reduction port 310. In the example of Figure 3, the choke housing 300 inlet 312 is a radial channel 321 at an upstream / uphole end of the choke housing 300. The radial channel provides an inlet 320 into a Tesla diode 322 and the Tesla diode 322 operates as a pressure reduction feature 314. TheILC-510838-WO-2_BAO2352PCTamount of speed reduction incurred by the Tesla diode 322 is dependent on the length of the Tesla diode. In some examples, the Tesla diode 322 extends a partial circumference of the choke housing 304. In other examples, where more reduction is needed, Tesla diode 322 spirals around the choke housing 304 for longer than a single circumference of the choke housing 304.

[0023] The Tesla diode 322 outputs the fluid into a second channel 324, with the second channel 324 functioning as the pressure drop region 316. The second channel 324 includes multiple through holes 318 through which the fluid in the pressure drop region 316 is provided to the choke 302. The channels 312, 324 are inward intrusions into the choke housing 300 and extend a full circumference of the choke housing 300. The volume of fluid that can be contained within the pressure drop region 316 (second channel 324) and the inlet 312 (first channel 321) is controlled by the radial depth of the channel 321, 324 and the axial length of the channel 312, 314, with the particular dimensions utilized being dependent on the particular implementation and determinable by one of skill in the art.

[0024] With continued reference to Figures 2A and 2B, Figure 4 illustrates an alternate pressure reduction port 410 including an inlet 412, a pressure reduction feature 414 and a pressure drop region 416. The pressure reduction port 410 includes a depression 430 intruding partially into a choke housing 404. Fluid is received in the depression 430 at an upstream portion 432 of the depression 430, and the upstream portion 432 functions as the inlet. Included in the center of the depression are multiple fluid turbulators 434. At a downstream edge 436, a through hole 418 extends fully through the choke housing 404 and allows fluid to pass into the choke 302 within the choke housing 404.

[0025] Once received at the upstream edge 432, the fluid passes by the fluid turbulators 434 and to a pressure drop region 416 between the fluid turbulators 434 and the through hole 418. The fluid turbulators 434 interfere with direct flow, and cause the fluid to turbulate, thereby slowing the flow speed and operating as a pressure reduction feature 414. The magnitude by which the flow speed is reduced is dependent on the dimensional aspects of the pressure reduction feature 410 (e.g. a depth of the depression 430, a size, quantity, orientation, and shape of the flow turbulators 434, a distance between the flow turbulators 434 and the through hole 418, etc.), with the particular dimensions and required pressure reduction being dependent on the specific implementation.

[0026] While illustrated as distinct examples, it is appreciated that implementations of the port housing assembly 200 may include choke housings having both the pressure reduction port configuration of Figure 3 and Figure 4, utilized in combination.ILC-510838-WO-2_BAO2352PCT

[0027] With reference again to Figures 2A and 2B, Figure 5 illustrates a partial cross section along section lines A-A of the port housing assembly 200. In some implementations the choke 302 may be constructed of a combination of main body 602 constructed of a steel (e.g. Inconel steel), with a tip portion 604 constructed of a carbide. The tip portion 604 is positioned at an uphole end 601 of the choke 302 and provides a cap on the choke 302. The tip portion 604 is maintained in position at least partially via a press fit 610 (i.e., a negative interference fit) with the main body 602.

[0028] The press fit 610 is a radial interference fit. A radially aligned portion 612 of a contact between the main body 602 and the tip portion 604 is arranged as a straight butt joint.

[0029] Due to the material differences between the main body 602 and the tip portion 604 each piece has a different coefficient of thermal expansion. During operations the port housing assembly 200 is subjected to substantial levels of heating resulting in uneven thermal expansion. The uneven thermal expansion results in a separation between the end of the main body portion 602 and the tip portion 604.

[0030] The separation can result in a fluid pathway between the main body 602 and the tip portion 604. As fluid is flowed through the ports 312, including the pressure reduction ports 310, 410, backpressure can cause a portion of the fluid to flow toward the uphole end 601. This fluid enters the separation, and the separation acts as a channel. Fluid entering the channel can cause degradation, with a faster flow speed of the fluid resulting in a larger magnitude of degradation, and a corresponding decrease in useful lifetime of the component.

[0031] A pressure reduction coil 630 is positioned at the interference fit 610, with the pressure reduction coil 630 wrapping around the radially inward one of the main body 602 and the tip portion 604. The pressure reduction coil 630 generates a tortious path around the main body 602 in the separation that forms due to thermal expansion. The additional length of the path corresponds to the number of times the pressure reduction coil 630 is wrapped around the main body portion 602.

[0032] Set forth below are some embodiments of the foregoing disclosure:

[0033] In a first example embodiment, an assembly includes a port housing defining a tubular body. The tubular body includes at least one port hole intruding radially through the cylindrical body relative to an axis defined by the cylindrical body. A choke assembly is defined within the cylindrical body. The choke assembly includes a choke housing and a choke disposed within the choke housing. The choke housing includes at least one choke hole. The at least one choke hole is at least partially overlapping a corresponding port hole in the at least one port hole such that a fluid flow through the corresponding port hole flows through theILC-510838-WO-2_BAO2352PCTchoke hole. The choke housing further includes at least one pressure reduction port having a fluid inlet configured to receive a flow, a pressure reduction feature configured to reduce a pressure of the fluid, a pressure drop region configured to receive the fluid from the pressure reduction feature, and at least one port connecting the pressure drop region to the choke.

[0034] In a second example embodiment, any of the other embodiments further includes the pressure reduction feature being at least one turbulating element protruding radially outward from the choke assembly, relative to the axis defined by the cylindrical body, the pressure drop region includes a pooling section sunk into the choke assembly, and the at least one port connecting the pressure drop region to the choke includes a through hole at a downstream end of the pressure drop region.

[0035] A third embodiment according to any of the other embodiments wherein the at least one turbulating element is disposed at an upstream end of the pressure drop region.

[0036] A fourth embodiment according to any of the other embodiments wherein the pressure reduction feature comprises a Tesla diode at least partially circumscribing a diameter of the choke housing, and wherein the pressure drop region comprises a channel sunk into the choke housing downstream of the Tesla diode.

[0037] A fifth embodiment according to any of the other embodiments wherein the at least one port connecting the pressure drop region to the choke comprises at least one through hole in the channel.

[0038] A sixth embodiment according to any of the other embodiments wherein the Tesla diode fully circumscribes the diameter of the choke housing.

[0039] A seventh embodiment according to any of the other embodiments further comprising a second pressure drop region upstream of an inlet to the Tesla diode, the second pressure drop region being configured to receive fluid from at least one port hole in the set of port holes and provide the received fluid to an inlet of the Tesla diode.

[0040] An eight embodiment according to any of the other embodiments wherein the choke comprises a cylindrical body constructed of a first material, a tip constructed of a second material, wherein the tip is inserted into an uphole end the cylindrical body and maintained in position via a press fit, and wherein the first material has a first coefficient of thermal expansion and the second material has a second coefficient of thermal expansion distinct from the first material.

[0041] A ninth embodiment according to any of the other embodiments wherein the tip contacts the cylindrical body of the choke at a first butt joint.ILC-510838-WO-2_BAO2352PCT

[0042] A tenth embodiment according to any of the other embodiments wherein the first material is steel and the second material is carbide.

[0043] An eleventh embodiment according to any of the other embodiments further comprising a coil wire wrapped around an outer circumference of a radially inner of the tip and the cylindrical body at the press fit.

[0044] A twelfth embodiment according to any of the other embodiments, wherein the coil wire is configured to generate a tortuous flow channel during thermal expansion of the tip and the cylindrical body.

[0045] A thirteenth embodiment wherein the assembly is a component of a borehole system.

[0046] A fourteenth embodiment defining a method for controlling fluid flow in a borehole port assembly. The method includes reducing a flow speed of a fluid entering a choke by passing at least a portion of the fluid through a pressure reduction port, wherein the pressure reduction port includes a fluid inlet configured to receive a flow, a fluid pressure reduction feature configured to reduce a pressure of the fluid, a pressure drop region configured to receive the reduced pressure fluid, and at least one port connecting the pressure drop region to the choke.

[0047] A fifteenth embodiment according to any of the other embodiments wherein passing at least a portion of the fluid through a pressure reduction port comprises receiving the fluid at an upstream end of a depression, the upstream end being configured to operate as the pressure reduction port inlet, passing the fluid around at least one turbulating feature into a pressure drop region of the depression downstream of the turbulating features, and passing the fluid through an outlet hole downstream of the pressure drop region.

[0048] A sixteenth embodiment according to any of the other embodiments wherein passing at least the portion of the fluid through the pressure reduction port comprises receiving the fluid at an inlet of a Tesla diode, passing the fluid through the Tesla diode into a receiving channel configured to act as the pressure drop region, and passing the fluid from the receiving channel through an outlet to a choke.

[0049] A seventeenth embodiment according to any of the other embodiments wherein passing at least the portion of the fluid through the pressure reduction port comprises receiving the fluid at a second pressure drop channel upstream of the Tesla diode and wherein the inlet of the Tesla diode is connected to the second pressure drop channel.

[0050] An eighteenth embodiment according to any of the other embodiments further comprising defining a pressure reduction channel between a main body and a tip portion of theILC-510838-WO-2_BAO2352PCTchoke by positioning a wire coil wrapped around a radially inner of the main body and the tip portion of the choke at an interference fit position.

[0051] A nineteenth embodiment according to any of the other embodiments wherein a flow length of the pressure reduction channel is dependent on a number of times the wire coil is wrapped around the radially inner of the main body and the tip portion of the choke.

[0052] A twentieth embodiment according to any of the other embodiments wherein the main body is radially inward of the tip portion at the interference fit position.

[0053] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms “about”, “substantially” and “generally” are intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” and / or “substantially” and / or “generally” can include a range of ± 8% of a given value.

[0054] The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a borehole, and / or equipment in the borehole, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc.

[0055] While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, althoughILC-510838-WO-2_BAO2352PCTspecific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited.

Claims

ILC-510838-WO-2_BAO2352PCTCLAIMSWhat is claimed is:

1. An assembly characterized by:a port housing 200 defining a tubular body, the tubular body including at least one port 212 hole intruding radially through the cylindrical body relative to an axis defined by the cylindrical body;a choke assembly 300, 400 defined within the cylindrical body, the choke assembly 300, 400 including a choke housing 304, 404 and a choke 302 disposed within the choke housing 304, wherein the choke housing 304 includes at least one choke hole 306, the at least one choke hole 306 at least partially overlapping a corresponding port 212 hole in the at least one port 212 hole such that a fluid flow through the corresponding port 212 hole flows through the choke hole 306; andthe choke housing 304, 404 further including at least one pressure reduction port 310 having a fluid inlet 312 configured to receive a flow, a pressure reduction feature 314, 414 configured to reduce a pressure of the fluid, a pressure drop region 316, 416 configured to receive the fluid from the pressure reduction feature 314, 414, and at least one port 318, 418 connecting the pressure drop region 316, 416 to the choke 302, 402.

2. The assembly of claim 1, wherein the pressure reduction feature 314, 414 is at least one turbulating element 434 protruding radially outward from the choke assembly 400, relative to the axis defined by the cylindrical body, the pressure drop region 416 includes a pooling section sunk into the choke assembly 400, and the at least one port 418 connecting the pressure drop region 416 to the choke 402includes a through hole at a downstream end of the pressure drop region.

3. The assembly of claim 2, wherein the at least one turbulating element 434 is disposed at an upstream end of the pressure drop region 416.

4. The assembly of claim 1, wherein the pressure reduction feature 314 comprises a Tesla diode at least partially circumscribing a diameter of the choke housing 304, and wherein the pressure drop region 316 comprises a channel sunk into the choke housing 304 downstream of the Tesla diode.

5. The assembly of claim 4, wherein the at least one port 318 connecting the pressure drop region 316 to the choke comprises at least one through hole in the channel.

6. The assembly of claim 4, wherein the Tesla diode fully circumscribes the diameter of the choke housing 304.ILC-510838-WO-2_BAO2352PCT7. The assembly of claim 4, further characterized by a second pressure drop region 324 upstream of an inlet to the Tesla diode, the second pressure drop region 324 being configured to receive fluid from at least one port 212 hole in the set of port 212 holes and provide the received fluid to an inlet of the Tesla diode.

8. The assembly of claim 1, wherein the choke 302 comprises a cylindrical body 502 constructed of a first material, a tip 504 constructed of a second material, wherein the tip 504 is inserted into an uphole end 501 of the cylindrical body 502 and maintained in position via a press fit, and wherein the first material has a first coefficient of thermal expansion and the second material has a second coefficient of thermal expansion distinct from the first material.

9. The assembly of claim 8, wherein the tip 504 contacts the cylindrical body 502 of the choke 302 at a first butt joint 520.

10. The assembly of claim 9, wherein the first material is steel and the second material is carbide.

11. The assembly of claim 8, further characterized by a coil wire wrapped around an outer circumference of a radially inner of the tip and the cylindrical body at the press fit.

12. The assembly of claim 11, wherein the coil wire 630 is configured to generate a tortuous flow channel during thermal expansion of the tip 504 and the cylindrical body 502.

13. The assembly of claim 1, wherein the assembly is a component of a borehole system.

14. A method for controlling fluid flow in a borehole port assembly characterized by:reducing a flow speed of a fluid entering a choke 302, 402 by passing at least a portion of the fluid through a flow speed reduction port 314, 414, wherein the pressure reduction port 314, 414 includes, a pressure reduction feature 314, 414 configured to reduce a pressure of the fluid, a pressure drop region 316, 416 configured to receive the fluid from the pressure reduction feature 314, 414, and at least one port 318, 418 connecting the pressure drop region 316, 416 to the choke 302, 402.

15. The method of claim 14, wherein passing at least a portion of the fluid through the pressure reduction port 314, 414 comprises receiving the fluid at an upstream end of a depression, the upstream end being configured to operate as the pressure reduction port inlet, passing the fluid around at least one turbulating feature into a pressure drop region of the depression downstream of the turbulating features, and passing the fluid through an outlet hole downstream of the pressure drop region.

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