Battery-Powered and Logic-Controlled Gas Lift Valve for Use in Wells and Methods of Using and Making Same

Abstract

A flow control device is provided that in one embodiment includes a flow-through region configured to receive formation fluid at an inflow region and discharge the received fluid at an outflow region and a setting device configured to adjust the flow of the fluid through the flow-through region to a selected level. The setting device includes a coupling member configured to be coupled to an external latching device adapted to move the coupling member to cause the setting device to alter the flow of the fluid from the flow-through region to the selected level.

1 . An apparatus for controlling flow of gas into a wellbore, comprising:
 a flow control device configured for placement in the wellbore;   a source of gas supply configured to supply gas under pressure to the flow control device;   a transmitter at the surface configured to transmit a wireless command signal into the wellbore;   a sensor associated with the flow control device configured to detect the wireless command signal; and   a control unit in the wellbore configured to adjust the flow control device to a selected position in response to the detected signal by the sensor, wherein the sensor and the control unit are powered by an electrical device placed in the wellbore.   
     
     
         2 . The apparatus of  claim 1 , wherein the electrical device is a battery. 
     
     
         3 . The apparatus of  claim 2 , wherein the control unit attains an active mode when the sensor detects the wireless command signal and an inactive (sleep) mode when the flow control device is set to the selected position to conserve electrical power consumption from the battery. 
     
     
         4 . The apparatus of  claim 1 , wherein the flow control device is an electrically-adjustable valve and the control unit is configured to adjust the electrically-controllable valve to the selected position based on programmed instructions stored downhole. 
     
     
         5 . The apparatus of  claim 1 , wherein the transmitter sends the wireless command signal in a form that is one of: acoustic signals, pressure pulses through a fluid in the wellbore; vibration signals; and radio signals. 
     
     
         6 . The apparatus of  claim 1 , wherein the flow control device includes a valve and a motor that operates the valves. 
     
     
         7 . The apparatus of  claim 1  further comprising a pressure sensor for determining a differential pressure and wherein the control unit adjusts the flow control device at least in part in response to the determined differential pressure. 
     
     
         8 . The apparatus of  claim 1  further comprising a charge device configured for placement in the wellbore to charge the battery. 
     
     
         9 . The apparatus of  claim 1  further comprising a surface control unit including a transmitter and a surface controller for controlling transmission of the wireless command signal in response programmed instructions. 
     
     
         10 . A method of controlling supply of gas into a wellbore, comprising:
 providing a flow control device in the wellbore;   injecting a gas from a surface location into the flow control device;   transmitting a wireless command signal from a surface location to downhole;   detecting the transmitted command signal by a sensor in the wellbore;   processing the detected command signal by a control unit coupled to the flow control device to determine a selected position of the flow control device corresponding to the command signal;   adjusting the flow control device to the selected position; and   supplying power to the sensor and the control unit by a power device placed in the wellbore.   
     
     
         11 . The method of  claim 10 , further comprising causing the sensor and the control unit to attain an active mode when the sensor detects the command signal and an inactive mode when the flow control is set to the selected position. 
     
     
         12 . The method of  claim 10 , further comprising determining a stable flow of gas through the valve and causing the sensor and the control unit to attain an inactive mode when the flow of gas is stable. 
     
     
         13 . The method of  claim 12 , further comprising using a pressure drop determination across the flow control device to determine when the flow of gas is stable. 
     
     
         14 . The method of  claim 10 , wherein the flow control device is an electrically-adjustable valve and the control unit is configured to set the electrically-controllable valve to the desired position based on programmed instructions stored downhole. 
     
     
         15 . The method of  claim 10 , wherein transmitting the wireless command signal comprises using a transmitter at a surface location to transmit the command signal to the sensor. 
     
     
         16 . The method of  claim 15 , wherein the transmitter at the surface sends the command signal in a form that is one of: acoustic signals, pressure pulses through a fluid in the wellbore; vibration signals; and radio signals. 
     
     
         17 . The method of  claim 16 , further comprising charging the power device by a charging device placed in the wellbore, wherein the power device is a battery.