1. Field of the Disclosure
The subject disclosure relates generally to recovery of hydrocarbons in subterranean formations, and more particularly to a mechanism for activating a plurality of downhole devices such as when creation of multiple production zones is desired.
2. Background of the Related Art
There are many situations when one would like to selectively activate multiple downhole devices. For example, in typical wellbore operations, various treatment fluids may be pumped into the well and eventually into the formation to restore or enhance the productivity of the well. For example, a non-reactive fracturing fluid may be pumped into the wellbore to initiate and propagate fractures in the formation thus providing flow channels to facilitate movement of the hydrocarbons to the wellbore so that the hydrocarbons may be pumped from the well.
In such fracturing operations, the fracturing fluid is hydraulically injected into a wellbore penetrating the subterranean formation and is forced against the formation strata by pressure. The formation strata is forced to crack and fracture, and a proppant is placed in the fracture by movement of a viscous-fluid containing proppant into the crack in the rock. The resulting fracture, with proppant in place, provides improved flow of the recoverable fluid (i.e., oil, gas or water) into the wellbore. Often, it is desirable to have multiple production zones which are treated differently within the same wellbore. To isolate and treat each zone separately, the prior art mechanisms have been very time consuming and expensive among other drawbacks.
Referring now to
Due to the heterogeneous nature of formation, one might not want to open all the valves simultaneously so that the fracturing operations can be performed separately for different layers of formations. The most common embodiment of doing so is using graduated balls or darts to open the valves 12 from the bottom up. For example, the radius of the valves 12, or other restriction such as a protrusion on the sliding sleeve 14, will increase from bottom up. Then, the smallest size ball is first dropped into the well and pumped toward the bottom. The size of the ball is designed so that the ball will pass through all the valves 12 except the bottom, narrowest valve 12. The ball is stopped by the bottom valve 12 so that the sliding sleeve 18 of the bottom valve 12 is pushed to the “open” position to expose the wellbore to cemented formation. Then the fracturing operation through the bottom valve 12 can be executed. After that, the next size larger ball will be dropped to activate the second to bottom valve 12.
The drawbacks of the graduated ball activation system are that there are only a finite number of restrictions/ball sizes that can be implemented. Typical limitations are a 4.5 inch casing at the top with only a minimum of 1 inch at the bottom. Hence, five or six valves across a few hundred feet of depth is the physical limit. Further, the need for restrictions prevents the full-bore access through the valves and the valves have to be activated in a fixed sequence of, in this case, bottom-up. After activation, the balls have to be dissolved or milled to gain access to the sections therebelow, which can lead to a potentially costly intervention.
Another embodiment of valve activation at varying depth utilizes control lines to activate restrictions. Once a restriction in a particular valve is activated, the restriction is then ready to catch a ball or dart dropped from the surface in order to open the respective valve. In these embodiments, common concerns are the possible damage of control lines during run-in-hole, especially in horizontal wells. A damaged control line means that only those lines below the damaged zone can be produced, severely impacting the total potential production from the well, possibly rendering it uneconomical. Another drawback of such designs is that as the thickness of the valve increases, the internal diameter of the valve decreases in order to accommodate the complex hydraulic mechanisms in the valve.
In view of the above, there is a need for an improved mechanism which permits selective activation of multiple downhole devices without comprimising fullbore diameter. It is also preferable that one can do so not necessarily following a particular pre-determined sequence. It is also desirable that the mechanism may be easily and reliably deployed and removed. The subject technology accomplishes these and other objectives.
The present technology is directed to a mechanism for selectively activating a plurality of downhole pathways including a) a valve having: i) a sleeve coupled for movement between an open and normally closed position; and ii) a valve magnet set mounted to the sleeve; and b) a dart for pumping in hole including a dart magnet set matched to the valve magnet set such that the dart couples to the valve when in close proximity and, in turn, the sleeve moves from the closed position to the open position. Preferably, the sleeve defines a recess in which the valve magnet set is mounted and the dart includes arms moveably mounted, the dart magnet set being mounted on the arms such that upon magnetic coupling, the arms move into the recess and anchor the dart to the sleeve. The recess may have a chamfer and the arms may form an anchor portion that engages the recess with a complimentary chamferred portion that engages the chamfer during retrieval of the dart.
A plurality of similar valves may included downhole, each having a unique activation dart. Springs may be coupled to the dart arms to set a normal position thereof. The dart may also include a tail block having coupling means mounted thereto, wherein the coupling means is a tail magnet set. The present technology also includes a retrieval tool including a tool magnet set coded for coupling to the tail magnet set. The retrieval tool may includes a skirt portion for creating a closing force of the arms during coupling of the tail and tool magnet sets.
Preferably, the dart further includes a plunger selectively coupled to the arms, a guide portion and seals moveably mounted to the dart such that upon the arms engaging the sleeve, the plunger is released to pass through the guide and, in turn, move the seals to engage the sleeve.
In another embodiment, the subject technology is directed to a mechanism for selectively activating a plurality of downhole devices including first means for triggering a device by moving from an off position to an on position, and second means for moving the first means from the off position to the on position. The first means may be a sliding valve sleeve having a coded valve magnet set, and the second means may be a dart having a coded dart magnet set such that the coded valve and dart magnet sets are uniquely matched to create an attractive force when in close proximity.
The subject technology is also directed to a method for selectively activating a triggering mechanism on a plurality of downhole valves including the steps of pre-determining combinations of coded magnets such that each valve sleeve of the downhole valve includes a valve magnet set that is only attracted to unique dart magnet set mounted on an activation dart, and opening the downhole valves in a sequence by selecting a sequence of unique darts to be pumped in hole. The method may also include of having mismatched magnet sets create a repulsive force when in close proximity, dissolving the unique darts, and/or retrieving the unique darts while leaving at least one respective valve open and/or closing at least one respective valve.
It should be appreciated that the present technology can be implemented and utilized in numerous ways, including without limitation as a process, an apparatus, a system, a device, a method for applications now known and later developed. These and other unique features of the system disclosed herein will become more readily apparent from the following description and the accompanying drawings.
So that those having ordinary skill in the art to which the disclosed system appertains will more readily understand how to make and use the same, reference may be had to the following drawings.
The present disclosure overcomes many of the prior art problems associated with activating a plurality of downhole devices. The advantages, and other features of the mechanism disclosed herein, will become more readily apparent to those having ordinary skill in the art from the following detailed description of certain preferred embodiments taken in conjunction with the drawings which set forth representative embodiments of the present invention and wherein like reference numerals identify similar structural elements.
All relative descriptions herein such as inward, outward, left, right, up, and down are with reference to the Figures, and not meant in a limiting sense. Additionally, for clarity common items have not been included in the Figures as would be appreciated by those of ordinary skill in the pertinent art. Unless otherwise specified, the illustrated embodiments can be understood as providing exemplary features of varying detail of certain embodiments, and therefore, unless otherwise specified, features, components, modules, elements, and/or aspects of the illustrations can be otherwise combined, interconnected, sequenced, separated, interchanged, positioned, and/or rearranged without materially departing from the disclosed systems or methods. Additionally, the shapes and sizes of components are also exemplary and unless otherwise specified, can be altered without materially affecting or limiting the disclosed technology.
In overview, several embodiments of the subject technology are directed to using correlated magnet structures to accomplish the beneficial goals noted above among others benefits. Correlated magnetic structures are programmed by imparting coded patterns of magnetic poles that determine unique magnetic field and force properties. The unique magnetic identities determine if, when and how structures will attach. The correlated magnets have strong-yet-safe magnetic fields, enable precision rotational and translational alignment, and provide rapid attachment and detachment functionality. The correlated magnets can even have multi-level magnetic fields if desired to achieve contactless attachment or repel and snap behaviors. For example, see U.S. Patent Application Publication No. 2009/0251242 A1 published on Oct. 8, 2009 to Fullerton et al., which is incorporated herein by reference in its entirety.
The correlated magnet embodiments described here involve a latching, triggering and retrieval mechanism for downhole applications. Whether the mechanism activates or not depends on a pre-determined combination of coded magnets. If the pattern of the 2 or more coded magnets matches, the mechanisms will be activated by attractive forces between these two sets of magnets. Many possible combinations can be achieved by using coded magnets. Hence, a plurality of devices, such as valves, may be selectively activated in any order without having to vary the usable wellbore diameter. One of the potential applications is multi-layer efficient fracturing valves to take advantage of the high number of stages that can be utilized without the need for control lines.
Now referring to
The sliding sleeve 114 interacts with an activation dart 130 to open the valve 112. The sleeve 114 and dart 130 include a matched pair of magnets 132, 134, respectively. The sleeve magnets 132 are imbedded adjacent a recess 136 formed in the sliding sleeve 114. The magnets 132, 134 are preferably sets of magnets to allow creation of a plurality of unique matched pairs, e.g., correlated magnets. The sets of magnets 132, 134 may include any number of magnets necessary to accomplish the performance desired. Further, the sleeve 114 and dart 130 may include a plurality of sets.
The activation dart 130 has a body or head 138 surrounded with a set of wipers or seals 140. The seals 140 form a hydraulic barrier between the space above and below the dart 130 in the wellbore, which allows dropping the dart 130 from the surface of the well and pumping the dart 130 down the well. The wipers 140 also act to clean the way in preparation for interactive latching between the dart 130 and sliding sleeve 114 to ensure that the latching operation is not contaminated by any wellbore fluid or sludge that may prevent proper operation.
The dart 130 has a set of multiple arms 142 trailing from the body 138. The arms 142 are linked to the dart body 138 by flexures or linkages (not explicitly shown) so that the arms 142 can pivot radially outward and inward from the body 138. The dart magnets 134 are imbedded at the tip or anchor 144 of the arms 142. The tips 144 protrude from the arms 142 such that during interaction with the sleeve 114, the tips 144 are captured in the recess 136. Preferably, there are small spring forces exerted on the arms 142 so that the arms 142 are normally in a neutral position as shown in
To activate a valve 112, a dart 130 with dart magnets 134 tuned to match the sleeve magnets 132 for the respective valve 112 is needed. In the event that the dart magnets 134 and sleeve magnets 132 do not match, the dart 130 passes through the valve 112 as shown in
Referring now to
Referring now to
As the pumping continues, the hydraulic forces exerted on the dart 130 push the sliding sleeve 114 to the “open” position as shown in
As can be seen, the embodiment above uses a triggering mechanism of two sets of coded magnets 132, 134. Each zone that is intended for production would have a valve 112 with a matching dart 130 and sliding sleeve 114, i.e., the magnets 132, 134 are a matched pair of correlated magnets. In other words, a particular magnetic set 132 in the recess 136 can only be triggered by a reciprocal attractively coded dart magnets 134 that will be on a unique dart 130. Thus, each zone can only be opened by the unique matched activation dart 130. This yields the benefit that the subject technology is no longer restricted to opening zones in a specific sequence, but any of the zones can now be opened. Further, as shown below, with retreivability, the ability to shut off valves 112 allows optimization of the production profile of the well. Alternatively, the dart 130 may simply be made of dissolvable material or drilled out for removal.
Turning to
There are cases where one wishes to retrieve the dart 230 so that a lower zone can be restimulated. It may be desirable to leave the valve 212 open or close the valve 212 after retrieval of the dart 230. To accomplish retrieval, the tips 244 are trapezoidal in shape or chamfered to match a chamfer 248 in the recess 236. Therefore, during retrieval of the dart 230, the tips 244 and recess chamfer 248 will interact to create a radially inward closing force on the arms 242. Depending upon the balance of resistance to moving the sliding sleeve 214 to the closed position and the resistance to retract the arms 242 radially inward, the design can be modified to close the valve 212 or have the valve 212 remain in the open position. Hence, the valve 212 can be selectively opened and closed during retrieval of the dart 230.
In order to couple to a retriever (not shown), the dart tail block 246 includes magnets 264. Thus, a simple device may be lowered or pumped down to the dart 230 and magnetically coupled to the tail block magnets 264. As the retrieval device is pulled upward, the radially inward force created between the chamfer 248 and tips 244 effectively retracts or moves the arms 242 radially inward to allow decoupling from the recess 236. The magnets 264 may also be half of a matching set so that only a retrieval tool with the corresponding matched set can be used for retrieval.
Referring now to
During retrieval, the retriever 250 is lowered or pumped in hole to the dart 230. The retriever 250 is sized and shaped to orient the bore 262 so that the dart tail block 246 is received therein. As the dart tail block 246 enters the bore 262, magnetic attraction between the retrieval tool magnets 252 and dart tail block magnets 264 acts to pull the dart tail block 246 to the bottom of the bore 262 as shown. Consequently, the skirt 260 engages an outer surface of arms 242 to close the arms 242 radially inward. Thus, as the retriever 250 couples to the dart tail block 246, the magnetic attraction decouples the arms 242 from the recess 236. With the retriever-tail block attraction force strong enough to disengage the arms 242 from the sliding sleeve 214 without moving the sliding sleeve 214, upwards pulling on the tether 254 will bring back the retriever 250 and dart 230 therewith. It is also envisioned that the mechanical forces created by the chamfer 248 and skirt 260 can cooperate to effectively close the arm 242 of the dart 230 for retrieval. As can be seen, the darts 230 can be configured wherein one dart 230 is utilized to open the valve 212 and another dart 230 is used to close the valve 212.
Turning to
Similar to above, correlated magnets 332, 334 on the sleeve 314 and arms 342, respectively, are used to initiate the secondary latching on the valve 312. The body 338 of the dart 330 forms a piloting mandrel or guide 372 to which the arms 342 pivotally mount. The arms 342 retain a plunger 374 when in the neutral position. The plunger 374 has a proximal head 376 with an opposing stem 378 extending therefrom such that a collar is formed that rests upon the proximal end or tip 344 of the arms 342. The stem 378 is elongated and extends to a distal pointed tip 380 that does not reach the piloting mandrel 372 when the arms are in the neutral position shown in
Referring particularly to
Referring now to
It is envisioned that the magnets 432, 434 would be arranged in a circular, annular or arcuate array on the respective dart and sliding sleeve but other configurations are possible. In this configuration, magnets 432i, 434i would be the bottom pair, i.e., set in the bottom sleeve and first dart dropped in hole. Each set of magnets would then correspond to the next zone up until magnets 432a, 434a were utilized for the top zone and the darts would be dropped in a bottom up sequence.
Referring now to
In view of the above, it is also envisioned that the correlated magnets may create rotational and/or snap forces on the components such as the sliding sleeves, dart and dart retrieval to accomplish the desired performance. In another embodiment, the dart arms retain a loaded spring such that upon movement of the dart arms radially outward, the spring unloads to create the secondary movement or latching. The components that are moved by the secondary action may be seals, keys or the like which get forced towards the valve forming other contact points between the dart and the valve. The keys may also have a matching profile with the surfaces in the valve to promote more effective engagement.
In still another embodiment, the dart may be provided with a motor that receives an electrical signal to rotate the dart arms so that the arms can or disengage the valve with or without the usage of correlated magnets. A further embodiment may utilize RFID technology with a power source in the dart and/or sliding sleeve or valve to accomplish the interaction between the dart and sliding sleeve. Such action may even be programmed to release after a set duration to allow simply pumping the dart to the bottom of the hole.
As would be appreciated by those of ordinary skill in the pertinent art, the subject technology is applicable to use as an actuation mechanism with significant advantages for activating and deactivating in hole zones repeatedly as well as other devices such as packers. The functions of several elements may, in alternative embodiments, be carried out by fewer elements, or a single element. Similarly, in some embodiments, any functional element may perform fewer, or different, operations than those described with respect to the illustrated embodiment. Also, functional elements shown as distinct for purposes of illustration may be incorporated within other functional elements, separated in different hardware or distributed in various ways in a particular implementation. Further, relative size and location are merely somewhat schematic and it is understood that not only the same but many other embodiments could have varying depictions.
All patents, published patent applications and other references disclosed herein are hereby expressly incorporated in their entireties by reference.
While the invention has been described with respect to preferred embodiments, those skilled in the art will readily appreciate that various changes and/or modifications can be made to the invention without departing from the spirit or scope of the invention as defined by the appended claims. For example, each claim may depend from any or all claims in a multiple dependent manner even though such has not been originally claimed.
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