This disclosure generally relates to a downhole valve.
Hydrocarbon fluid (oil or gas) typically is communicated from a subterranean well using a pipe, called a “production string.” The production string extends through a wellbore that is drilled through the producing formation and may include various valves for purposes of controlling the production of the hydrocarbon fluid. One such valve is a ball valve that may be operated for purposes of controlling the flow of the hydrocarbon fluid through the central passageway of the production string. Another valve that is typically part of a production string is a circulating valve, a valve that is operated to control the flow of the hydrocarbon fluid between the central passageway and the region outside of the string, called the “annulus.”
A well may be in an underbalanced state, a state in which the pressure that is exerted by the formation is greater than the hydrostatic pressure that is exerted by the fluid in the annulus. One type of circulating valve that is used in an underbalanced well has a series of check valve elements through which well fluid is circulated for purposes of opening and closing the valve. A potential challenge in using such a circulating valve is that typically, the central passageway of the production tubing string above the valve must be filled with fluid in order to properly operate the valve.
Another type of conventional circulating valve is remotely operated by communicating stimuli (pressure pulses, for example) into the fluid in the annulus near the valve. A sensor (a pressure sensor, for example) of the circulating valve detects the stimuli, and electromechanics of the valve typically decode commands from the stimuli and operate the valve accordingly. Although there is no requirement that the central passageway be filled with fluid for purposes of operating this type of circulating valve, the valve typically is not suitable for use in a high pressure high temperature (HPHT) environment due to temperature limitations of the valve.
In an embodiment of the invention, a tool that is usable with a well includes a valve element, a mechanical operator, a pressure chamber and a regulator. The valve element has a first state and a second state. The mechanical operator responds to a predetermined signature in an annulus pressure relative to a baseline level of the annulus pressure to transition the valve element from the first state to the second state. The pressure chamber exerts a chamber pressure to bias the mechanical operator to transition from the second state to the first state. The baseline level is capable of varying over time, and the regulator regulates the chamber pressure based on the baseline level.
In another embodiment of the invention, a tool that is usable with a well includes a valve element having a first state and a second state. The tool includes a spring, a pressure chamber and a mechanical operator. The mechanical operator responds to forces exerted in concert by the spring and the pressure chamber to bias transitioning of the valve element from the first state to the second state, and the mechanical operator responds to annulus pressure to transition the valve element from the second state to the first state.
In yet another embodiment of the invention, a tool that is usable with a well includes a valve element, a first mechanical operator, a pilot valve and a second mechanical operator. The valve element has a first state and a second state. The pilot valve controls communication of an annulus pressure to the first mechanical operator; and the second mechanical operator responds to the annulus pressure to control operation of the pilot valve. The second mechanical operator is adapted to cause the pilot valve to communicate the annulus pressure to the first mechanical operator to cause the first mechanical operator to transition the valve element from the first state to the second state in response to the annulus pressure exhibiting a predetermined signature and otherwise block the communication of the annulus pressure to the first mechanical operator to cause the first mechanical operator to transition the valve element from the second state to the first state.
Advantages and other features of the invention will become apparent from the following drawing, description and claims.
In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments are possible.
As used here, the terms “above” and “below”; “up” and “down”; “upper” and “lower”; “upwardly” and “downwardly”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly describe some embodiments of the invention. However, when applied to equipment and methods for use in wells that are deviated or horizontal, such terms may refer to a left to right, right to left, or diagonal relationship as appropriate.
Referring to
In general, the string 30 includes at least one valve assembly, such as a circulating valve tool 50 that is depicted in
For the following example, it is assumed that the well 10 is an underbalanced state, although this condition is not a prerequisite for the use of the tool 50. In the underbalanced state, the pressure that is exerted by the formation is greater than the hydrostatic pressure that is exerted by the fluid in an annulus 54, which is the annular region of the well 10 between the borehole wall or well casing string 22 (depending on whether the well 10 is cased or uncased) and the exterior of the tool 50. In general, the tool 50 is operated by manipulating a pressure in the annulus 54. As examples, the annulus pressure may be manipulated using a surface-disposed pump 12, although other systems and techniques may be used to induce pressure fluctuations in the annulus 54 for purposes of controlling the tool 50, as can be appreciated by one of skill in the art.
To operate the tool 50, pressure stimuli may be communicated from the surface of the well 10 downhole into the annulus 54 for purposes of delivering a command to the tool 50, such as a command to open fluid communication through radial ports 100 of the tool 50 or a command to close the fluid communication through the radial ports 100 to isolate the annulus 54 from the central passageway of the string 30, as non-limiting examples. As more specific examples, the communication of the pressure stimuli may involve momentarily increasing the pressure in the annulus 54 above a baseline annulus pressure level; momentarily decreasing the annulus pressure below the annulus baseline pressure level; a series of annulus pressure increases or decreases; etc.
In one control scheme, a sequence of pressurization cycles may be applied to the annulus 54 to operate the tool 50. The pressurization cycles may include cycles (called “up cycles”) in which the annulus pressure is increased and cycles (called “down cycles”) in which the annulus pressure is relaxed or decreased back to the annulus baseline level. In this manner, a particular number of up and down pressurization cycles may be used for purposes of transitioning the tool 50 from its closed state to its open state, and vice versa.
As described herein, the tool 50 includes a mechanical operator 130, which responds to the fluid pressure in the annulus 54. Unlike conventional arrangements, the actuation of the mechanical operator 130 does not depend on whether a full column of fluid exists in the central passageway of the string 30, and the operation of the mechanical operator does not involve circulating well fluid through the tool 50. Instead, as described herein, the tool 50 communicates the annulus pressure to the mechanical operator 130 for purposes of transitioning the tool 50 from a first state (an open or closed state, as non-limiting examples) to a different, second state (an open or closed state, as non-limiting examples).
As further described herein, a gas chamber 134 of the tool 50 exerts a force to counter the force that is produced by the annulus pressure (e.g., to bias the tool 50 to remain in the first state or return to the first state from the second state). The tool 50 has features to compensate the force that is exerted by the gas chamber 134 for purposes of causing this force to track the baseline pressure level of the annulus. In this way, the gas chamber accommodates downhole pressure and temperature fluctuations, which may otherwise adversely affect the operation of the tool 50.
Referring to
In the open state of the circulating valve element 107 (and tool 50), fluid communication is established between the annulus 54 (see
For the closed state (not depicted in
The up and down travel of the sleeve 104 is controlled by the mechanical operator 130 of the tool 50. In general, the operator 130 includes a piston head 140, which is connected through a mandrel 105 to the sleeve 106. In general, the piston head 140 is concentric with the sleeve 104 and has a central passageway to form part of the central passageway 90 of the tool 50. The piston head 140 moves up and down in response to a pressure differential between upper and lower gas chambers: the gas chamber 134 (called the “upper chamber 134” below), which exerts a downward force on an upper surface of the piston head 140 and a gas chamber 135 (called the “lower chamber 135” below), which exerts an upward force on a lower surface of the piston head 140. The upper 134 and lower 135 chambers reside inside a corresponding annular recess of the housing 99.
The volumes of the upper 134 and lower 135 gas chambers are variable in that the volume of the upper chamber 134 is maximized and the volume of the lower chamber 135 is minimized (as depicted in
The gas chamber 146 is part of a compensator 150, which transfers the annulus pressure to the gas chamber 146 while isolating the gas chamber 146 from the well fluid in the annulus 54. More specifically, the compensator 150 includes a floating compensating piston 148, which resides in an annular recess of the housing 99 to form the gas chamber 146 above the piston 148 and a chamber 149 below the piston 148, which receives annulus fluid communicated from one or more radially-disposed ports 160 (one port being shown in
As described in more detail below, a valve control network is built into the piston head 140 to allow equalization of pressures between the upper 134 and lower 135 gas chambers. However, the equalization occurs at a controlled rate for purposes of permitting pressure differentials to develop to act on the piston head 140. More specifically, the flow rate between the gas chambers 134 and 135 is initially limited when the annulus pressure first changes with respect to its steady state baseline pressure level. This limited flow rate, in turn, produces a set upward or downward force on the piston head 140.
For example, in response to an increase in annulus pressure, the pressure in the chamber 135 exceeds the pressure in the chamber 134 to cause an upward force on the piston head 140. As the piston head 140 moves upwardly, the pressures between the chambers 134 and 135 equalize to create a balanced condition after the piston head 140 is shifted to an upper position.
When the annulus pressure subsequently decreases, a downward force is initially produced on the piston head 140 due to the momentary differential pressure. Due to the valve system in the piston head 140, the pressures generally equalize so that when the piston head 140 reaches a point near its lowermost position of travel (as depicted in
Among the other features of the tool 50, in accordance with some examples, the tool 50 includes an indexer 110 to control the sequence of annulus pressurization cycles for purposes of causing the tool 50 to change states. As a non-limiting example, the indexer 110 may be a J-slot mechanism, in which a pin on the operator mandrel 105 traverses a J-slot that has a predetermined pattern that restricts the travel of the operator mandrel 105 until the end of the pattern is reached. In other words, the J-slot establishes a predetermined number up/down pressurization cycles that must occur before the tool 50 transitions from a closed state to an open state. Once at the end of the pattern, the indexer 110 may be reset by releasing pressure on the annulus to move the operator mandrel 105 back to its lowermost point of travel to close the tool 50.
The tool 50 may include a mechanism 120 to restrict all motion of the operator mandrel 105 until a predetermined force on the piston head 140 (and operator mandrel 105) builds up. This allows the pressure differential across the piston head 140 to increase to a predetermined threshold before the operator mandrel 105 shifts for purposes of increasing the tool shifting speed to avoid leaving the tool 50 in an undesirable mid state (never fully opened or fully closed, for example). In accordance with some examples, the mechanism 120 may be a collet, which includes a plurality of fingers that engage corresponding features on the operator mandrel 105 to secure the operator mandrel 105 in place until the predetermined force threshold is reached. The fingers on the collet hold the operator mandrel 105 in its original position until the pressure differential across the piston head 140 is sufficiently high to overcome the grasp of the collet fingers and quickly shift the operator mandrel 105 all the way to the end position.
Referring to
In a similar arrangement, a metered flow path 191 is disposed in the piston head 140 for purposes of equalizing pressures in the chambers 134 and 135 for the scenario in which the lower chamber 135 is de-pressurized due to a decrease in the annulus pressure. This flow path 191 includes a flow restrictor 208 and a check valve 206, which is constructed to open to allow communication through the flow restrictor 208 between the chambers 134 and 135 when the pressure in the upper chamber 134 is greater than the pressure in the lower chamber 135. Due to the metering by the flow restrictor 208, a downward force is created while the pressures in the chambers 134 and 135 are being equalized. After the piston head 130 has traveled downwardly by a sufficient distance, a cross hole 207, which is in communication with the passageway travels past the seal created by a lower o-ring 214 to therefore bypass the flow restrictor 208 to allow relatively rapid equalization of the chamber pressures.
Thus, due to the above-described valve system in the piston head 140, the pressure in the upper chamber 134 tracks the baseline pressure level in the annulus 54 to compensate its gas pressure for shrinkage or expansion due to thermal changes and changes in the annulus pressure.
More specifically, the combination of pressure from the gas chamber 264 and a spring 260 (a Belleville spring or bellows spring, as non-limiting examples) produces an upward force on a power piston head 258. The power piston head 258, in turn, is connected by way of an operator mandrel 254 to the circulating valve element 252. As also shown in
Other variations are contemplated and are within the scope of the appended claims. For example, the valve assembly 250 may include a retention mechanism, such as the above-described collet, for purposes of storing energy and ensuring a fast valve opening, which avoids half states and overcomes the effects of erosion.
More specifically, the piston 324 may be connected to operator a pilot valve 312, which controls the application of annulus pressure to a power piston 304, which, in turn, operates the circulating valve 302. As shown in
Operation of the tool 300 may be better understood with reference to
While the present disclosure has been described with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present disclosure.
This application is a divisional application of U.S. application Ser. No. 12/575,999, filed on Oct. 8, 2009.
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Number | Date | Country | |
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Number | Date | Country | |
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Parent | 12575999 | Oct 2009 | US |
Child | 13969100 | US |