Patent Application
20160010427
In the completion and production industry for natural resources, the formation of boreholes/completions for the purpose of production or injection of fluid is common. The boreholes/completions are used for exploration or extraction of natural resources such as hydrocarbons, oil, gas, water, and alternatively for CO2 sequestration. Coiled tubing or string is run into the borehole/completion for varying purposes and valves, such as circulation valves, have been used on the tubing or string to enable circulation of fluids between the inside and the outside of the tubing. Such valves are typically mechanically operable including ball-activated features and pressure-operated features.
The art would be receptive to improved alternative devices and methods for operating a valve within a borehole/completion.
A downhole tool assembly includes a tubular having a flowbore extending along a longitudinal axis of the tubular; an electric actuating mechanism supported by the tubular and distanced from the longitudinal axis of the tubular; and, a valve assembly connected to the tubular and fluidically connected to the flowbore, the valve assembly including: an outer portion having at least one port; and an electrically actuated inner portion concentrically positioned within the outer portion and operable by the actuating mechanism to selectively block the at least one port in a first condition of the valve assembly and unblock the at least one port in a second condition of the valve assembly.
A method of actuating a valve assembly in a downhole tubular, the method includes inserting a tubular having a flowbore into a borehole; employing a peripherally positioned electric motor within the tubular; actuating an electrically activated valve assembly with the motor, the valve assembly including an outer portion having at least one port and an inner portion movably configured within the outer portion; and, selectively moving the inner portion to block the at least one port in a first condition of the valve assembly and selectively moving the inner portion to expose the at least one port in a second condition of the valve assembly; wherein fluid flow through the tubular during both the first and second conditions of the valve assembly is not blocked.
The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
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.
A power source 28 providing electrical energy may be provided at the surface location 22, and sends an electrical signal, such as via line 30. A surface control unit 38 is used to electrically control operation of a valve assembly 40, such as a circulation valve, by using a motor powered by the power source 28 or a power generation sub as will be further described below. Whenever valve operation is necessary, the valve assembly 40 is activated by an actuation mechanism to move to a full or partially open condition based on required flow regimes to allow for circulation of fluids from inside to outside, outside to inside, downhole to uphole, or uphole to downhole, either as a one off operation or multi-repeated cycles.
While the valve assembly 40 may be controlled via the control unit 38 at any time, whether programmed or by operator input, in an exemplary embodiment of the downhole tool assembly 100, sensor modules 32 may also be directly incorporated into the string 14 or tool 18 to detect changes in the environment of the string 14 within the borehole 10 to indicate when an operation of a circulation valve assembly 40 is necessary. The sensor module 32 could be incorporated into a logging bottom hole assembly 34, provided separately along interconnections of the string 14 or other locations along the string 14, or provided within the tool 18. The sensor module 32 may contain sensors 36, circuitry, and processing software and algorithms relating to environment of the borehole indicative of a necessity for operation of a valve assembly 40. Such parameters may include pressure, flow speed, and other measurements related to the environment of the string 14. Signals from sensors 36 in the sensor module 32 or sensors 36 provided elsewhere along the string 14 are either processed by the sensor module 32, sent to a surface location 22 such as surface control unit 38 for operator evaluation, or directly to a valve assembly 40 for immediate or subsequent action. The surface control unit 38 or processor may receive signals from the sensors 36 and processes such signals according to programmed instructions provided to the surface control unit 38. The surface control unit 38 may also display information on a display/monitor utilized by an operator. The surface control unit 38 may include a computer or a microprocessor-based processing system, memory for storing programs or models and data, a recorder for recording data, and other peripherals. The control unit 38 may be adapted to notify the operator when operating conditions indicate a need for circulation or other valve operation. The surface control unit 38 may also be used for other operations of the string 14 and tool 18 not described herein. A communication sub (not shown) may obtain the signals and measurements and transfers the signals, using two-way telemetry, for example, to be processed at the surface location 22. Alternatively, the signals can be processed using a downhole processor in the tool 18 or sensor module 32. In the event a signal is sent indicating a need for circulation or other valve operation, the valve assembly 40 is electrically activated.
The selective valve operation does not impede operation of the tool(s) 18, string 14, or any downhole procedure. Furthermore, as will be further described below, even when the valve assembly 40 is activated, flow through a flowbore 42 of the string 14 is not blocked or restricted so as to allow for flow therethrough for use by the tool 18 or downhole operations requiring such flow, such as production through the coiled tubing of the string 14.
Turning now to
An exemplary embodiment of the downhole tool assembly 100 includes a logging bottom hole assembly (“BHA”) 34. The logging BHA may be a separate component from the valve assembly 40. Also included in the downhole tool assembly is a motor 46, which may be incorporated into a power supply sub 48, and an electrically activated valve assembly 40.
The logging BHA 34 is attachable to the string 14. The logging BHA 34 includes an uphole end 54 connected to the string 14, and a downhole end 56. The logging BHA 34 also includes flowthrough, such that a flowbore 58 of the logging BHA 34 is in fluid communication with the flowbore 42 of the string 14. The logging BHA 34 may create any type of geophysical log by making at least one type of measurement of rock or fluid property in the borehole 10 or within the flowbore 58 of the logging BHA 34 itself The measurements are taken using at least one type of sensor, including, but not limited to, sensors to measure pressure, temperature, spontaneous potential, and radiation, as well as a variety of sensors such as acoustic (sonic), electric, inductive, magnetic resonance, etc. One of the sensors in the logging BHA 34 may be the sensor 36 that detects environmental conditions within the borehole 10. The data from the measurements secured by the logging BHA 34 may be recorded at the surface control unit 38, or alternatively the logging BHA 34 may include a memory storage unit for subsequent creation of a well log. Since the information from the logging BHA 34 can be used by operators to gain an understanding of the borehole 10 for any desired downhole operation, the logging BHA 34 need not be directly part of the valve assembly 40 even if information obtained from the logging BHA 34 is utilized by the valve assembly 40. Alternatively, the valve assembly 40 may be electrically operated using signals initiated by an operator or from other sensors 36, 28 as previously described.
Connected downhole of string 14, and the logging BHA 34 if utilized, is a power supply sub 48. The power supply sub 48 includes an uphole end 60 and a downhole end 62 and includes flowthrough via a flowbore 66. The uphole end 60 of the power supply sub 48 is connected downhole of the logging BHA 34 or string 14. In one exemplary embodiment, a conductor 64 passes through the string 14, logging BHA 34, and into the power supply sub 48. The conductor 64 is formed of one or more insulated wires or bundles of wires adapted to convey power and/or data, and may be included with or part of the signal conducting line 30 that delivers signals from the surface location 22 to motor 46. The conductor 64 can include metal wires, or alternatively other carriers such as fiber optic cables that may be provided in a tubing encapsulated cable (“TEC”) such as an armored metal clad water sealed cable. The conductor 64 can deliver the signal provided by the sensors 28 or operator input previously described, as well as carry the signals from the downhole sensors 36. Additionally, by use of either direct or alternating current transmittal through the conductor 64, the power supply sub 48 is capable of providing sufficient power to operate the valve assembly 40 connected downhole of the power supply sub 48. The conductor 64 is either provided within a protective channel (not shown) incorporated within the string 14 or passed through the flowbores 42, 58 of the string 14 and logging BHA 34, such as via a wireline. Advantages of using conductor 64 to conduct current from the surface 22 include the ability to conduct high amounts of electrical energy from the surface 22 and the supply from the surface 22 is relatively unlimited.
The power supply sub 48 is a tubular that peripherally supports the motor 46 and may alternatively or additionally include a power storage unit such as one or more batteries 68. Batteries 68 can be used as a local source of power for downhole electrical devices, such as the electrically activated valve 40 or a tool 18, but the batteries 68 must be arranged to fit within space constraints that exist within the borehole 10 and string 14. Electrically recharging the battery 68 can occur through the conductor 64, and replacing the battery 68, if required, may be accomplished via a wireline operation or upon retrieval of the battery 68 from the borehole 10.
When necessary to open the valve assembly 40, or close the valve assembly 40, such as determined by a surface operator or via the logging BHA 34 or sensor 36 or 28 that a condition within or exterior to the string 14 has necessitated valve operation, then the power supply sub 48 will utilize an actuating mechanism linked to the motor 46 to activate the electrically operated valve assembly 40. The electrically operated valve assembly 40 shares substantially the same flowpath, and likewise may share substantially the same longitudinal axis when interconnected with the power supply sub 48, logging BHA 34, and string 14. While the valve assembly 40, power supply sub 48, and logging BHA 34 have been described and illustrated as separate elements, another exemplary embodiment would include the integration of any combination of such subs, although separating the components into different subs generally eases replacement of defective parts. Also, while the different subs are described as interconnected, it should be understood that the elements may be separated from each other by any additional lengths of string 14 or connectors.
When actuated by the power supply sub 48, the electrically operated valve assembly 40 will either open or close or be positioned at an interim location between fully opened and fully closed. The valve assembly 40 is accessible to the flow bore 42 of the assembly 100, but does not block or restrict the flow bore 104 even when in use, nor does it interrupt the normal flow through the flow bore 104 and string 14. Thus, any downhole tools, such as tool 18, which depend on the flow through the flow bore 42, still receive the flow. Also, the downhole tool assembly 100 is suited for well production through the flow bore 42, since the flow bore 42 is not blocked by any of the above-described portions of the assembly 100.
As depicted in
In other exemplary embodiments, the power supply sub 48 may include a downhole electrical generating mechanism 70 (
In the embodiments described above, neither the valve assembly 40, 140, 240 nor the actuating mechanism 115, 215 required to actuate the valve assembly 40, 140, 240 block flow through the flowbore of the downhole tool assembly 100. Any of the above described embodiments of an electrically operated valve assembly and power supply sub may be used in plurality and sections of string 14 may be interposed therebetween. While fluid flow is illustrated in one particular direction, it should be understood that the fluid flow within the flowbores 42, 58, 66, 104 of the above described exemplary embodiments may be in either uphole or downhole direction depending upon the particular application of the string.
A method of operating a valve assembly 40, 140, 240 in a downhole tool assembly 100 includes inserting a tubular such as the string 14 into the borehole 10, determining a need for opening or blocking flow between the flowbore of the tubular and the annulus between the tubular and the borehole 10, sending a signal to a control unit 28 or motor 46 in response to the determined need, actuating an electrically activated valve assembly 40, the valve assembly 40 having a flow bore 104 fluidically connected to a flowbore 42 of the tubular, and altering the flow between the tubular and surrounding borehole 10 by operation of the valve assembly 40. The method enables a partial opening of flow between the flowbore and annulus. Flow through the flowbores 42, 104 of the string 14 and valve assembly 40 is not blocked during activation and non-activation of the valve assembly 40. The method further includes generating power in a power generating sub 48.
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, although specific 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. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
