The present disclosure relates to downhole tools for providing a communication path from the inside of an inner tubular to the annular area between the inner tubular and an outer tubular or an uncased borehole wall, for stimulation or production.
Fracturing sleeves are common devices used in a downhole wellbore to provide a flow path for stimulation or other fluids from inside the completion string or tubular to the formation outside the tubular and/or to allow production of well fluids from the formation into the tubular. Typically fracturing sleeves are either ball actuated, RFID actuated, or pressure-actuated.
The present disclosure provides for a valve assembly for a pressure actuated downhole tool. The valve assembly may include a valve collar. The valve collar may include a valve cylinder formed in a wall of the valve collar. The valve cylinder may be coupled to the bore of the valve collar by a balancing port and a test port. The test port may include a check valve and an output port. The valve collar may include a valve piston positioned within the valve cylinder between the balancing port and the test port. The valve piston may fluidly seal to the valve cylinder and may divide the valve cylinder into a balancing cylinder in fluid communication with the balancing port and an actuating cylinder in fluid communication with the test port.
The present disclosure also provides for a balanced piston toe sleeve. The balanced piston toe sleeve may include a valve collar. The valve collar may include a valve cylinder formed in a wall of the valve collar. The valve cylinder may be coupled to the bore of the valve collar by a balancing port and a test port. The test port may include a check valve and an output port. The valve collar may include a valve piston positioned within the valve cylinder between the balancing port and the test port. The valve piston may fluidly seal to the valve cylinder and may divide the valve cylinder into a balancing cylinder in fluid communication with the balancing port and an actuating cylinder in fluid communication with the test port. The balanced piston toe sleeve may include a generally tubular mandrel coupled to the valve collar forming a continuous fluidly connected bore. The mandrel may include an aperture from its interior to its exterior. The balanced piston toe sleeve may include a generally tubular port housing coupled to the valve collar. The port housing may define an opening cylinder between an inner wall of the port housing and the exterior cylindrical surface of the mandrel. The opening cylinder may be fluidly coupled to the opening port of the valve collar. The port housing may include an aperture from its interior to the surrounding wellbore positioned to substantially align with the aperture of the mandrel. The balanced piston toe sleeve may include an opening piston positioned to slide within the opening cylinder in response to fluid pressure within the opening cylinder when fluid pressure is introduced therein via the opening port of the valve collar. The opening piston may include at least one piston aperture.
The present disclosure also provides for a method. The method may include positioning a balanced piston toe sleeve on a tool string. The balanced piston toe sleeve may include a valve collar. The valve collar may include a valve cylinder formed in a wall of the valve collar. The valve cylinder may be coupled to the bore of the valve collar by a balancing port and a test port. The test port may include a check valve and an output port. The valve collar may include a valve piston positioned within the valve cylinder between the balancing port and the test port. The valve piston may fluidly seal to the valve cylinder and may divide the valve cylinder into a balancing cylinder in fluid communication with the balancing port and an actuating cylinder in fluid communication with the test port. The balanced piston toe sleeve may include a generally tubular mandrel coupled to the valve collar forming a continuous fluidly connected bore. The mandrel may include an aperture from its interior to its exterior. The balanced piston toe sleeve may include a generally tubular port housing coupled to the valve collar. The port housing may define an opening cylinder between an inner wall of the port housing and the exterior cylindrical surface of the mandrel. The opening cylinder may be fluidly coupled to the opening port of the valve collar. The port housing may include an aperture from its interior to the surrounding wellbore positioned to substantially align with the aperture of the mandrel. The balanced piston toe sleeve may include an opening piston positioned to slide within the opening cylinder in response to fluid pressure within the opening cylinder when fluid pressure is introduced therein via the opening port of the valve collar. The opening piston may include at least one piston aperture. The method may further include running the tool string into the wellbore with the valve assembly and the opening piston in the closed positions. The method may further include pressurizing the bore of the tool string in a pressure cycle so that fluid enters the balancing cylinder through the balancing port and the actuating cylinder through the test port via the check valve. The method may further include bleeding the pressure from the bore of the tool string, so that the pressure decreases in the balancing cylinder while the pressure remains in the actuating cylinder. The method may further include traversing the valve piston in the valve cylinder, opening fluid communication between the bore and the output port. The method may further include pressurizing the bore of the tool string. The method may further include flowing fluid through at least a portion of the valve cylinder in fluid communication with the bore and into the output port. The method may further include traversing the opening piston in the opening cylinder.
The present disclosure is best understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.
It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.
Port housing 42, mandrel 44, and opening piston 46 each include at least one aperture 54, 56, and 58, respectively. Apertures 54, 56, and 58 may be positioned to align when opening piston 46 is in the open position and thereby allow fluid communication between the bore 12 of balanced piston toe sleeve 10 and the surrounding wellbore (not shown). In certain embodiments, when in the closed position, aperture 58 on opening piston 46 is not aligned with apertures 54 and/or 56 of port housing 42 and mandrel 44, and fluid communication is limited or prevented. Port housing 42, mandrel 44, and opening piston 46 may include one or more seals 60 to, for example, assist with preventing fluid flow when in the closed position, as well as with retaining fluid pressure within opening cylinder 48.
The pressure of the fluid within opening cylinder 48 is controlled by the pressure within bore 12 as controlled by valve assembly 22 within valve collar 20.
In some embodiments, valve cylinder 101 may be fluidly coupled to bore 12 of valve collar 20 by test port 109. Test port 109 may include check valve 110. Check valve 110 may, as understood in the art, allow fluid flow in only one direction through test port 109. Here, check valve 110 may allow fluid to flow from bore 12 through test port 109 into valve cylinder 101 while retarding or preventing fluid flow in the reverse. Although depicted as a flapper valve, one having ordinary skill in the art with the benefit of this disclosure will understand that any valve adapted to allow unidirectional flow may be utilized without deviating from the scope of this disclosure.
In some embodiments, valve piston 111 may be positioned within valve cylinder 101. Valve piston 111 may be adapted to fluidly seal to valve cylinder 101. In some embodiments, valve piston 111 may be adapted to separate valve cylinder 101 into balancing cylinder 113 and actuating cylinder 117. In some embodiments, balancing cylinder 113 may be defined as the portion of valve cylinder 101 between balancing port 103 and valve piston 111. In some embodiments, actuating cylinder 117 may be defined as the portion of valve cylinder 101 between test port 109 and valve piston 111.
Valve piston 111 may traverse valve cylinder 101 in response to a pressure imbalance between balancing cylinder 113 and actuating cylinder 117. For example, valve piston 111 may be positioned in the run-in position as depicted in
In some embodiments, valve piston 111 may be positioned to prevent fluid flow from valve cylinder 101 to output port 107 when in the run-in position. In some embodiments, valve piston 111 may cover output port 107 when in the run-in position. When in the open position, valve piston 111 may move such that actuating cylinder 117 is in fluid communication with output port 107, fluidly coupling bore 12 with output port 107 via test port 109.
In some embodiments that include actuating port 105 as depicted in
In operation, balanced piston toe sleeve 10 may be run into a wellbore as part of a downhole tubular. Balanced piston toe sleeve 10 may be inserted into the wellbore in the closed position, i.e. aperture 58 of opening piston 46 is not aligned with apertures 54, 56 of port housing 42 and mandrel 44 (see
During the pressure cycle, fluid may exert pressure on valve piston 111 by flowing into valve cylinder 101. Fluid may enter balancing cylinder 113 through balancing port 103. Fluid may also enter actuating cylinder 117 through test port 109, as check valve 110 allows fluid flow in this direction (
At the completion of the pressure cycle, pressure in bore 12 of balanced piston toe sleeve 10 may be bled off. As the pressure in bore 12 decreases, fluid may exit balancing cylinder 113 through balancing port 103. Fluid in actuating cylinder 117, however, is retarded or prevented from leaving actuating cylinder 117 by check valve 110. Thus, the pressure in balancing cylinder 113 decreases while the pressure in actuating cylinder 117 remains at or near the pressure attained during the pressure cycle. The differential pressure across valve piston 111 causes a resulting force across valve piston 111 in the direction of balancing cylinder 113. Once the resulting force is sufficient, shear pin 125 may mechanically fail, allowing valve piston 111 to move from the run-in position to the open position as depicted in
During a subsequent pressurization of bore 12, the pressure in actuating cylinder 117 remains, retarding or preventing valve piston 111 from moving from the open position. Alternatively, in embodiments which do not include actuating port 105, the pressure in actuating cylinder 117 and in balancing cylinder 113 remains equal or about equal as both are open to the pressure from bore 12. With valve piston 111 in the open position, fluid pressure from bore 12 may act on opening piston 46 via test port 109 or actuating port 105 and output port 107. With regard to
In some embodiments of the present disclosure, secondary valve assembly 22′ may be included in valve collar 20 as depicted in
As depicted in
One having ordinary skill in the art with the benefit of this disclosure will understand that any number of valve assemblies, given the physical constraints of the valve collar 20, may be included in valve collar 20 in such an arrangement to increase the number of test pressure cycles available before opening piston 46 is actuated.
In some embodiments, as depicted in
The foregoing outlines features of several embodiments so that a person of ordinary skill in the art may better understand the aspects of the present disclosure. Such features may be replaced by any one of numerous equivalent alternatives, only some of which are disclosed herein. One of ordinary skill in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. One of ordinary skill in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.
This application is a nonprovisional application which claims priority from U.S. provisional application No. 62/105,607, filed Jan. 20, 2015.
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Number | Date | Country | |
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Number | Date | Country | |
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62105607 | Jan 2015 | US |