Apparatus and Method for Mounting Flow-Control Devices to Tubular Members

Abstract

A contoured boss for conforming to an outer surface of a tubular member for deployment within a subterranean formation, the contoured boss comprising a valve receiving body having a contoured outer surface that extends radially outward from an outer surface of the tubular member; and passage for receiving a valve, the passage extending through the valve receiving body. A method for facilitating stimulation treatments in completions and a method of centering a tubular member having an outer surface within a borehole are also provided.

1 . A contoured boss for conforming to an outer surface of a tubular member for deployment within a subterranean formation, said contoured boss comprising a valve receiving body having a contoured outer surface that extends radially outward from an outer surface of the tubular member; and a passage for receiving a valve, said passage extending through said valve receiving body. 
     
     
         2 . The contoured boss of  claim 1 , wherein the contoured outer surface of the valve receiving body is rounded to reduce surface contact with a borehole surface when the tubular member is positioned within the borehole of the subterranean formation. 
     
     
         3 . The contoured boss of  claim 2 , wherein said valve receiving body includes a mounting surface for contacting the outer surface of the tubular member, said mounting surface having an outer periphery. 
     
     
         4 . The contoured boss of  claim 3 , wherein said contoured outer surface of said valve receiving body has an outer periphery, said outer periphery of said contoured outer surface located adjacent said outer periphery of said mounting surface of said valve receiving body. 
     
     
         5 . The contoured boss of  claim 4 , wherein said valve receiving body further comprises a welding chamfer, said welding chamfer positioned between said outer periphery of said contoured outer surface and said outer periphery of said mounting surface. 
     
     
         6 . The contoured boss of  claim 4 , wherein said contoured outer surface of said valve receiving body is substantially dome-shaped, tear-drop shaped, or rib-shaped. 
     
     
         7 . The contoured boss of  claim 6 , wherein said passage of said valve receiving body comprises an axial bore having a first portion having a first diameter, said first diameter sufficient to receive the valve from said contoured outer surface, said first portion of said axial bore extending partially through said valve receiving body and terminating at a valve seating shoulder. 
     
     
         8 . The contoured boss of  claim 7 , wherein said axial bore of said passage has a second portion having a second diameter, said second diameter less than said first diameter, said second portion of said axial bore initiating at said valve seating shoulder and extending through said mounting surface. 
     
     
         9 . The contoured boss of  claim 8 , wherein said axial bore of said passage includes an annular groove for receiving a lock ring for securing the valve within said axial bore. 
     
     
         10 . The contoured boss of  claim 9 , further comprising a lock ring positionable within said annular groove for securing the valve within said axial bore. 
     
     
         11 . The contoured boss of  claim 9 , further comprising a screen for preventing debris from entering the valve, said screen retained within said axial bore by said lock ring. 
     
     
         12 . The contoured boss of  claim 3 , wherein said mounting surface for contacting the outer surface of the tubular member is contoured to substantially mate with the outer surface of the tubular member. 
     
     
         13 . A method for facilitating stimulation treatments in completions, the method comprising the steps of:
 (a) drilling a hole through a tubular casing at a first distance along the tubular casing;   (b) welding a contoured boss to an outer surface of the tubular casing, the contoured boss comprising a valve receiving body; a contoured outer surface that extends radially outward from an outer surface of a tubular casing; and a passage for receiving the valve, the passage extending through the valve receiving body and in fluid communication with the hole of the casing; and   (c) positioning a valve within the passage.   
     
     
         14 . The method of  claim 13 , wherein the contoured outer surface of the valve receiving body is rounded to reduce surface contact with a borehole surface when the tubular casing is positioned within the borehole of the subterranean formation. 
     
     
         15 . The method of  claim 14 , wherein the valve receiving body includes a mounting surface for contacting the outer surface of the tubular casing, the mounting surface having an outer periphery. 
     
     
         16 . The method of  claim 15 , wherein the contoured outer surface of the valve receiving body has an outer periphery, the outer periphery of the contoured outer surface located adjacent the outer periphery of the mounting surface of the valve receiving body. 
     
     
         17 . The method of  claim 16 , wherein the valve receiving body further comprises a welding chamfer, the welding chamfer positioned between the outer periphery of the contoured outer surface and the outer periphery of the mounting surface. 
     
     
         18 . The method of  claim 17 , wherein the contoured outer surface of the valve receiving body is substantially dome-shaped, tear-drop shaped, or rib-shaped. 
     
     
         19 . The method of  claim 18 , wherein said passage of the valve receiving body comprises an axial bore having a first portion having a first diameter, the first diameter sufficient to receive the valve from the contoured outer surface, the first portion of the axial bore extending partially through the valve receiving body and terminating at a valve seating shoulder. 
     
     
         20 . The method of  claim 19 , wherein the axial bore of the passage has a second portion having a second diameter, the second diameter less than the first diameter, the second portion of the axial bore initiating at the valve seating shoulder and extending through the mounting surface. 
     
     
         21 . The method of  claim 20 , wherein the axial bore of the passage includes an annular groove for receiving a lock ring for securing the valve within the axial bore. 
     
     
         22 . The method of  claim 21 , further comprising installing a lock ring within the annular groove to secure the valve within the axial bore. 
     
     
         23 . The method of  claim 21 , further comprising installing a screen for preventing debris from entering the valve; and installing a lock ring within the annular groove to secure the valve and screen within the axial bore. 
     
     
         24 . The method of  claim 13 , further comprising the step of: (d) repeating steps (a)-(c). 
     
     
         25 . The method of  claim 13 , further comprising the step of: (d) twice repeating steps (a)-(c), wherein three valves are positioned at equal distances about the circumference of the tubular casing to establish a first treatment zone. 
     
     
         26 . The method of  claim 13 , wherein the contoured boss does not restrict tubular flow. 
     
     
         27 . The method of  claim 26 , further comprising the steps of:
 (e) drilling a hole through a tubular casing at a second distance along the tubular casing, the second distance greater than the first distance;   (f) welding a contoured boss to an outer surface of the tubular casing, the contoured boss comprising a valve receiving body; a contoured outer surface that extends radially outward from an outer surface of the tubular casing; and a passage for receiving the valve, the passage extending through the valve receiving body and in fluid communication with the hole of the casing; and   (g) positioning a valve within the axial bore.   
     
     
         28 . The method of  claim 27 , further comprising the step of: (h) thrice repeating steps (a)-(c), wherein four valves are positioned at equal distances about the circumference of the tubular casing to establish a second treatment zone. 
     
     
         29 . The method of  claim 28 , wherein the valves are check valves. 
     
     
         30 . The method of  claim 29 , wherein the check valves installed at the first distance of the tubular casing require a lower pressure to open than those installed at the second distance of the tubular casing. 
     
     
         31 . A method of centering a tubular member having an outer surface within a borehole, the method comprising the steps of:
 (a) establishing a first distance along the tubular member; and   (b) welding a plurality of contoured bosses to the outer surface of the tubular casing at the first distance, each contoured boss comprising a mounting surface for contacting the outer surface of the tubular casing, the mounting surface having an outer periphery; and a contoured outer surface that extends radially outward from an outer surface of the tubular member, the contoured outer surface rounded to reduce surface contact with the borehole surface when the tubular member is positioned within the borehole; wherein the plurality of contoured bosses are positioned at equal distances about the circumference of the tubular member.   
     
     
         32 . The method of  claim 31 , further comprising the steps of:
 (c) establishing a second distance along the tubular member; and   (d) welding a plurality of contoured bosses to the outer surface of the tubular casing at the second distance, each contoured boss comprising a mounting surface for contacting the outer surface of the tubular casing, the mounting surface having an outer periphery; and a contoured outer surface that extends radially outward from an outer surface of the tubular member, the contoured outer surface rounded to reduce surface contact with the borehole surface when the tubular member is positioned within the borehole; wherein the plurality of contoured bosses are positioned at equal distances about the circumference of the tubular member.   
     
     
         33 . The method of  claim 32 , further comprising the steps of:
 (e) establishing a third distance along the tubular member; and   (f) welding a plurality of contoured bosses to the outer surface of the tubular casing at the third distance, each contoured boss comprising a mounting surface for contacting the outer surface of the tubular casing, the mounting surface having an outer periphery; and a contoured outer surface that extends radially outward from an outer surface of the tubular member, the contoured outer surface rounded to reduce surface contact with the borehole surface when the tubular member is positioned within the borehole; wherein the plurality of contoured bosses are positioned at equal distances about the circumference of the tubular member.   
     
     
         34 . The method of  claim 33 , wherein each contoured boss further comprises a valve receiving body having an axial bore for receiving a valve, the axial bore extending through the valve receiving body, the axial bore of the contoured boss in fluid communication with the interior of the tubular member. 
     
     
         35 . A collar or sub for mounting to a tubular member for deployment within a subterranean formation, said collar or sub comprising a plurality of contoured bosses integrally formed thereon and spaced about an outer surface thereof, each of said contoured bosses comprising a valve receiving body having a contoured outer surface that extends radially outward from an outer surface of the tubular member; and a passage for receiving a valve, said passage extending through said valve receiving body. 
     
     
         36 . The collar or sub of  claim 35 , wherein the contoured outer surface of the valve receiving body is rounded to reduce surface contact with a borehole surface when the tubular member is positioned within the borehole of the subterranean formation. 
     
     
         37 . The collar or sub of  claim 36 , wherein said contoured outer surface of said valve receiving body is substantially dome-shaped, tear-drop shaped, or rib-shaped. 
     
     
         38 . The collar or sub of  claim 37 , wherein said passage of said valve receiving body comprises an axial bore having a first portion having a first diameter, said first diameter sufficient to receive the valve from said contoured outer surface, said first portion of said axial bore extending partially through said valve receiving body and terminating at a valve seating shoulder. 
     
     
         39 . The collar or sub of  claim 38 , wherein said axial bore of said passage has a second portion having a second diameter, said second diameter less than said first diameter, said second portion of said axial bore initiating at said valve seating shoulder and extending through said mounting surface. 
     
     
         40 . The collar or sub of  claim 39 , wherein said axial bore of said passage includes an annular groove for receiving a lock ring for securing the valve within said axial bore. 
     
     
         41 . The collar or sub of  claim 40 , further comprising a lock ring positionable within said annular groove for securing the valve within said axial bore. 
     
     
         42 . The collar or sub of  claim 40 , further comprising a screen for preventing debris from entering the valve, said screen retained within said axial bore by said lock ring.