Locking backpressure valve

Abstract

A downhole tool includes a tubular having an outer surface and an inner surface defining a flowbore having a longitudinal axis, and a backpressure valve arranged in the flowbore. The backpressure valve includes a flapper valve having a first side and an opposing second side pivotally mounted to the inner surface to selectively extend across the flowbore and a locking system mounted to the inner surface in the flowbore and snap-fittingly engageable with the flapper valve. The flapper valve is pivotable between a first position, wherein the flapper valve is free to pivot relative to the inner surface, and a second position, wherein the flapper valve is pivoted away from the flowbore and locked open by the locking system such that the first side forms part of the flowbore.

Description

BACKGROUND

In the drilling and completion industry boreholes are formed to provide access to a resource bearing formation. Occasionally, it is desirable to install a plug in the borehole in order to isolate a portion of the resource bearing formation. When it is desired to access the portion of the resource bearing formation to begin production, a drill string is installed with a bottom hole assembly including a bit or mill. The bit or mill is operated to cut through the plug. After cutting through the plug, the drill string is removed, and a production string is run downhole to begin production. Withdrawing and running-in strings including drill strings and production strings is a time consuming and costly process. The industry would be open to systems that would reduce costs and time associated with plug removal and resource production.

SUMMARY

Disclosed is a downhole tool including a tubular having an outer surface and an inner surface defining a flowbore having a longitudinal axis, and a backpressure valve arranged in the flowbore. The backpressure valve includes a flapper valve having a first side and an opposing second side pivotally mounted to the inner surface to selectively extend across the flowbore and a locking system mounted to the inner surface in the flowbore and snap-fittingly engageable with the flapper valve. The flapper valve is pivotable between a first position, wherein the flapper valve is free to pivot relative to the inner surface, and a second position, wherein the flapper valve is pivoted away from the flowbore and locked open by the locking system such that the first side forms part of the flowbore.

Also disclosed is a resource exploration and recovery system including a first system and a second system fluidically connected to the first system. The second system includes at least one tubular extending into a formation. The at least one tubular supports a downhole tool and includes an outer surface and an inner surface defining a flow path having a longitudinal axis. The downhole tool includes a backpressure valve arranged in the flowbore. The backpressure valve includes a flapper valve including a first side and an opposing second side pivotally mounted to the inner surface to selectively extend across the flowbore and a locking system mounted to the inner surface in the flowbore and snap-fittingly engageable with the flapper valve. The flapper valve is pivotable between a first position, wherein the flapper valve is free to pivot relative to the inner surface, and a second position, wherein the flapper valve is pivoted away from the flowbore and locked open by the locking system such that the first side forms part of the flowbore.

Still further disclosed is a method of operating a backpressure valve including preventing fluid flow through flowbore in a backpressure valve during a milling operation, pumping off a bottom hole assembly at a completion of the milling operation, introducing an object into a tubular string supporting the backpressure valve, shifting a flapper valve open with the object, and locking the flapper valve open with a snap fastener, the flapper valve forming a surface of the flowbore.

BRIEF DESCRIPTION OF THE DRAWINGS

The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:

FIG. 1 depicts a resource exploration and recovery system including a locking backpressure valve, in accordance with an exemplary embodiment;

FIG. 2 depicts a cross-sectional side view of the locking backpressure valve in a run-in configuration, in accordance with an exemplary aspect;

FIG. 3 depicts a cross-sectional side view of the locking backpressure valve showing an object shifting a flapper valve open; and

FIG. 4 depicts a cross-sectional side view of the locking backpressure valve a production configuration with the flapper valve locked open, in accordance with an exemplary aspect.

DETAILED DESCRIPTION

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 resource exploration and recovery system, in accordance with an exemplary embodiment, is indicated generally at 2, in FIG. 1. Resource exploration and recovery system 2 should be understood to include well drilling operations, resource extraction and recovery, CO₂ sequestration, and the like. Resource exploration and recovery system 2 may include a first system 4 which takes the form of a surface system operatively connected to a second system 6 which takes the form of a subsurface or subterranean system. First system 4 may include pumps 8 that aid in completion and/or extraction processes as well as fluid storage 10. Fluid storage 10 may contain a gravel pack fluid or slurry, or drilling mud (not shown) or other fluid which may be introduced into second system 6.

Second system 6 may include a downhole string 20 formed from one or more tubulars such as indicated at 21 that is extended into a wellbore 24 formed in formation 26. Wellbore 24 includes an annular wall 28 that may be defined by a wellbore casing 29 provided in wellbore 24. Of course, it is to be understood, that annular wall 28 may also be defined by formation 26. In the exemplary embodiment shown, subsurface system 6 may include a downhole zonal isolation device 30 that may form a physical barrier between one portion of wellbore 24 and another portion of wellbore 24. Downhole zonal isolation device 30 may take the form of a bridge plug 34. Of course, it is to be understood that zonal isolation device 30 may take on various forms including frac plugs formed from composite materials and/or metal, sliding sleeves and the like.

In further accordance with an exemplary embodiment, downhole string 20 defines a drill string 40 including a plug removal and production system 42. Plug removal and production system 42 is arranged at a terminal end portion (not separately labeled) of drill string 40. Plug removal and production system 42 includes a bottom hole assembly (BHA) 46 having a plug removal member 50 which may take the form of a bit or a mill 54. Of course, it is to be understood that plug removal member 50 may take on various forms such as a mill or a bit. BHA 46 may take on a variety of forms known in the art.

Plug removal and production system 42 includes a selective sand screen 60 arranged uphole of BHA 46. Selective sand screen 60 includes a screen element 62 that is arranged over a plurality of openings (not shown) formed in drill string 40. It is to be understood that the number of screen elements may vary. Further, it is to be understood that screen opening size may vary. It is also to be understood that screen element 62 may include a number of screen layers. The openings in drill string 40 fluidically connect wellbore 24 with a flow path 66 extending through drill string 40.

In yet still further accordance with an exemplary embodiment, plug removal and production system 42 includes a backpressure valve (BPV) 80 arranged downhole of selective sand screen 60 and uphole of BHA 46. Referring to FIG. 2, BPV 80 includes a tubular 84 that forms part of drill string 40. Tubular 84 includes an outer surface 86 and an inner surface 88 that defines a flowbore 90 having a longitudinal axis “L” that receives BPV 80. Inner surface 88 includes a recess 92 having an annular wall 94. Annular wall 94 includes a surface 95 that is substantially perpendicular to longitudinal axis “L” which defines a valve seat 96. While valve seat 96 is shown to be integrally formed with tubular 84, it should be understood that valve seat 96 may be provided as a separate component.

In an embodiment, recess 92 includes valve receiving portion 98. A flapper valve 104 is mounted in first portion 98. Flapper valve 104 is supported by a hinge 108 arranged in valve receiving portion 98 of recess 92. Flapper valve 104 may pivot about hinge 108 between a first or run-in position (FIG. 2) and a second or production position (FIG. 4). In the run-in position, flapper valve 104 is free to rotate along about a 90° arc in flowbore 90. In the second position, flapper valve 104 is rotated beyond 90° and held open to allow production fluids to pass through flowbore 90.

Flapper valve 104 includes a first side 112 and an opposing second side 114. First side 112 includes a sealing surface 116 that engages with valve seat 96. Flapper valve 104 also includes a pivot nub 118. Pivot nub 118 is a generally semi-spherical protrusion extending outwardly from first side 112. Flapper valve 104 is further shown to include a snap feature 120 arranged in second side 114. Snap feature 120 includes a recess 122 having a first diameter portion 123 and a second diameter portion 124 that is larger than first diameter portion 123.

In an embodiment, BPV 80 includes a locking system 128 mounted in tubular 84. Locking system 128 includes aa snap member 130 that extends radially inwardly from inner surface 88 within valve receiving portion 98. Snap member 130 includes a base portion 132 having a first diameter mounted to inner surface 88 in valve receiving portion 98 and a resiliently deformable head portion 134 having a second diameter, that is larger than the first diameter, coupled to base portion 132. Resiliently deformable head portion 134 may compress or deform as snap member 130 passes into snap feature 120. Resiliently deformable head portion 134 may pass into second diameter portion 124 of recess 122 and re-expand to lock flapper valve 104 in valve receiving portion 98.

In accordance with an exemplary embodiment, after mill 54 opens a downhole most plug (not shown), BHA 46 may be pumped off and allowed to fall and collect at a toe (not shown) of wellbore 24. During drilling, flapper valve 104 is arranged in the first position (FIG. 2). In the first position, flapper valve 104 is free to pivot about a 90° arc. In this manner, drilling fluids may pass downhole toward BHA 46, but pressure may not pass uphole beyond BPV 80. That is, pressure moving in an uphole direction would act against second side 114 causing flapper valve 104 to close against valve seat 96.

After pumping off BHA 46, it may be desirable to produce fluids through drill string 40. As such, flapper valve 104 is moved to the second position (FIG. 4) opening flowbore 90. An object, such as a drop ball 144 may be introduced into drill string 40 and allowed to fall toward BPV 80. Drop ball 144 engages pivot nub 118 as shown in FIG. 3 forcing flapper valve 104 to pivot greater than 90° into valve receiving portion 98 of recess 92 as shown in FIG. 4. At this point it should be understood that while described as a drop ball, the object may take on various forms including balls, darts, plugs, and the like.

As flapper valve 104 pivots past 90° from the first position, snap member 130 engages with snap feature 120. As drop ball 144 acts on pivot nub 118, resiliently deformable head portion 134 compresses and passes into first diameter portion 123 of snap feature 120. Snap member 130 continues to move into recess 122 allowing resiliently deformable head portion 134 to re-expand in second diameter portion 124. At this point, flapper valve 104 is locked in valve receiving portion 98 of recess 92 and first side 112 forms part of flowbore 90. That is, when open, first side 112 of flapper valve 104 is exposed to fluids passing uphole along flowbore 90. Once flapper valve 104 is locked open, drop ball 144 may be allowed to pass towards the tow of wellbore 24 or dissolve thereby opening flowbore 90. Alternatively, additional pressure may be applied causing drop ball 144 to fracture and/or pass beyond locking system 128 to open flowbore 90.

At this point it should be understood that the exemplary embodiments describe a system for actuating a backpressure valve by guiding a flapper valve into contact with a snap member. The flapper valve moves beyond 90° from a closed or flowbore sealing configuration into a recess and is captured by the snap member locking the flapper valve in the recess and opening the flowbore to production fluids. It should be understood that while shown as including one flapper valve, the backpressure valve may include any number of valves.

Set forth below are some embodiments of the foregoing disclosure:

Embodiment 1. A downhole tool comprising: a tubular having an outer surface and an inner surface defining a flowbore having a longitudinal axis; and a backpressure valve arranged in the flowbore, the backpressure valve including: a flapper valve including a first side and an opposing second side pivotally mounted to the inner surface to selectively extend across the flowbore; and a locking system mounted to the inner surface in the flowbore and snap-fittingly engageable with the flapper valve, wherein the flapper valve is pivotable between a first position, wherein the flapper valve is free to pivot relative to the inner surface, and a second position, wherein the flapper valve is pivoted away from the flowbore and locked open by the locking system such that the first side forms part of the flowbore.

Embodiment 2. The downhole tool according to any prior embodiment, wherein the tubular includes a valve seat, wherein the first side of the flapper valve selectively seals against the valve seat.

Embodiment 3. The downhole tool according to any prior embodiment, wherein the valve seat is integrally formed with the tubular.

Embodiment 4. The downhole tool according to any prior embodiment, wherein the locking system includes a snap member extending radially inwardly from the inner surface.

Embodiment 5. The downhole tool according to any prior embodiment, wherein the snap member includes a base portion mounted to the inner surface and a resiliently deformable head portion.

Embodiment 6. The downhole tool according to any prior embodiment, wherein the second side of the flapper valve includes a snap feature selectively receptive of the resiliently deformable head portion.

Embodiment 7. The downhole tool according to any prior embodiment, wherein the inner surface includes a recess, the flapper valve being mounted in the recess.

Embodiment 8. The downhole tool according to any prior embodiment, wherein the first position is spaced from the second position along an arc that is greater than 90°.

Embodiment 9. A resource exploration and recovery system comprising: a first system; a second system fluidically connected to the first system, the second system including at least one tubular extending into a formation, the at least one tubular supporting a downhole tool and including an outer surface and an inner surface defining a flow path having a longitudinal axis, the downhole tool comprising: a backpressure valve arranged in the flowbore, the backpressure valve including: a flapper valve including a first side and an opposing second side pivotally mounted to the inner surface to selectively extend across the flowbore; and a locking system mounted to the inner surface in the flowbore and snap-fittingly engageable with the flapper valve, wherein the flapper valve is pivotable between a first position, wherein the flapper valve is free to pivot relative to the inner surface, and a second position, wherein the flapper valve is pivoted away from the flowbore and locked open by the locking system such that the first side forms part of the flowbore.

Embodiment 10. The resource exploration and recovery system according to any prior embodiment, wherein the tubular includes a valve seat, wherein the first side of the flapper valve selectively seals against the valve seat.

Embodiment 11. The resource exploration and recovery system according to any prior embodiment, wherein the valve seat is integrally formed with the tubular.

Embodiment 12. The resource exploration and recovery system according to any prior embodiment, wherein the locking system includes a snap member extending radially inwardly from the inner surface.

Embodiment 13. The resource exploration and recovery system according to any prior embodiment, wherein the snap member includes a base portion mounted to the inner surface and a resiliently deformable head portion.

Embodiment 14. The resource exploration and recovery system according to any prior embodiment, wherein the second side of the flapper valve includes a snap feature selectively receptive of resiliently deformable head portion.

Embodiment 15. The resource exploration and recovery system according to any prior embodiment, wherein the inner surface includes a recess, the flapper valve being mounted in the recess.

Embodiment 16. The resource exploration and recovery system according to any prior embodiment, wherein the first position is spaced from the second position along an arc that is greater than 90°.

Embodiment 17. A method of operating a backpressure valve comprising: preventing fluid flow through flowbore in a backpressure valve during a milling operation; pumping off a bottom hole assembly at a completion of the milling operation; introducing an object into a tubular string supporting the backpressure valve; shifting a flapper valve open with the object; and locking the flapper valve open with a snap fastener, the flapper valve forming a surface of the flowbore.

Embodiment 18. The method according to any prior embodiment, wherein locking the flapper valve open includes urging the flapper valve against a snap member extending into the flowbore.

Embodiment 19. The method according to any prior embodiment, wherein urging the flapper valve against a snap member included directing a snap member including a resiliently deformable head int a snap feature provided on the flapper valve.

Embodiment 20. The method according to any prior embodiment, wherein shifting the flapper valve open includes pivoting the flapper valve along an arc that is greater than 90°.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.

The terms “about” and “substantially” are intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” and/or “substantially” can include a range of ±8% or 5%, or 2% of a given value.

The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and/or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc.

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.

Claims

1. A downhole tool comprising: a tubular having an outer surface and an inner surface defining a flowbore having a longitudinal axis; anda backpressure valve arranged in the flowbore, the backpressure valve including: a flapper valve including a first side and an opposing second side pivotally mounted to the inner surface to selectively extend across the flowbore, the second side including a snap feature; anda locking system including a snap member having a resiliently deformable head portion extending radially inwardly from the inner surface in the flowbore, the resiliently deformable head portion snap-fittingly engageable with the snap feature in the flapper valve, wherein the flapper valve is pivotable between a first position, wherein the flapper valve is free to pivot relative to the inner surface, and a second position, wherein the flapper valve is pivoted away from the flowbore into contact with the snap member, the resiliently deformable head portion deforming upon being received by the snap feature and locked open by re-expanding the resiliently deformable head portion in the snap feature such that the first side forms part of the flowbore.

2. The downhole tool according to claim 1, wherein the tubular includes a valve seat, wherein the first side of the flapper valve selectively seals against the valve seat.

3. The downhole tool according to claim 2, wherein the valve seat is integrally formed with the tubular.

4. The downhole tool according to claim 1, wherein the snap member includes a base portion mounted to the inner surface and a resiliently deformable head portion.

5. The downhole tool according to claim 4, wherein the snap feature is selectively receptive of the resiliently deformable head portion.

6. The downhole tool according to claim 1, wherein the inner surface includes a recess, the flapper valve being mounted in the recess.

7. The downhole tool according to claim 1, wherein the first position is spaced from the second position along an arc that is greater than 90°.

8. A resource exploration and recovery system comprising: a first system;a second system fluidically connected to the first system, the second system including at least one tubular extending into a formation, the at least one tubular supporting a downhole tool and including an outer surface and an inner surface defining a flow path having a longitudinal axis, the downhole tool comprising: a backpressure valve arranged in the flowbore, the backpressure valve including:a flapper valve including a first side and an opposing second side pivotally mounted to the inner surface to selectively extend across the flowbore, the second side including a snap feature; anda locking system including a snap member having a resiliently deformable head portion extending radially inwardly from the inner surface in the flowbore, the resiliently deformable head portion snap-fittingly engageable with the snap feature in the flapper valve, wherein the flapper valve is pivotable between a first position, wherein the flapper valve is free to pivot relative to the inner surface, and a second position, wherein the flapper valve is pivoted away from the flowbore into contact with the snap member, the resiliently deformable head portion deforming upon being received by the snap feature and locked open by re-expanding the resiliently deformable head portion in the snap feature such that the first side forms part of the flowbore.

9. The resource exploration and recovery system according to claim 8, wherein the tubular includes a valve seat, wherein the first side of the flapper valve selectively seals against the valve seat.

10. The resource exploration and recovery system according to claim 9, wherein the valve seat is integrally formed with the tubular.

11. The resource exploration and recovery system according to claim 8, wherein the snap member includes a base portion mounted to the inner surface and a resiliently deformable head portion.

12. The resource exploration and recovery system according to claim 11, wherein the snap feature selectively receptive of resiliently deformable head portion.

13. The resource exploration and recovery system according to claim 8, wherein the inner surface includes a recess, the flapper valve being mounted in the recess.

14. The resource exploration and recovery system according to claim 8, wherein the first position is spaced from the second position along an arc that is greater than 90°.

15. A method of operating a backpressure valve comprising: preventing fluid flow through a tubular having an inner surface defining a flowbore in a backpressure valve during a milling operation;pumping off a bottom hole assembly at a completion of the milling operation;introducing an object into a tubular string supporting the backpressure valve;shifting a flapper valve having a snap feature open with the object; andlocking the flapper valve open with a snap member extending radially inwardly from the inner surface, the snap member having a resiliently deformable head portion that resiliently compresses upon being received by the snap feature on the flapper valve such that the flapper valve forms a surface of the flowbore.

16. The method of claim 15, wherein locking the flapper valve open includes deforming a head of the snap member.

17. The method of claim 15, wherein shifting the flapper valve open includes pivoting the flapper valve along an arc that is greater than 90°.

18. The method of claim 15, wherein locking the flapper valve open further includes re-expanding the resiliently deformable head portion in the snap feature.