Exploring, drilling and completing hydrocarbon and other wells are generally complicated, time consuming and ultimately very expensive endeavors. In recognition of these expenses, added emphasis has been placed on efficiencies associated with well completions and maintenance over the life of the well. Over the years, ever increasing well depths and sophisticated architecture have made reductions in time and effort spent in completions and maintenance operations of even greater focus.
In terms of architecture, the terminal end of a cased well often extends into an open-hole lateral leg section. In many cases, multiple leg sections of this nature extend from a single main vertical well bore. Such architecture may enhance access to the reservoir, for example, where the reservoir is substantially compartmentalized. Regardless, such open-hole lateral leg sections often present their own particular challenges when it comes to their completions and maintenance.
In terms of completions, a variety of hardware may be installed before the well and various legs are ready for production operations. That is, in addition to the noted casing, hardware supporting various zonal isolations or chemical injection lines may be installed. Additionally, perforating, fracturing, gravel packing and a host of other applications may be employed in completing the well and various leg sections.
With particular reference to the lateral legs and other open-hole regions, the noted gravel packing and other production related enhancements may rely on the presence of a formation isolation valve. That is, such a valve may be disposed at the interface of cased and open-hole well regions so as to ensure a separation between completion and production fluids. More specifically, comparatively heavier fluids utilized during completions may be prone to adversely affect the formation if allowed to freely flow to the production region. By the same token, production of lighter high pressure fluids into the main bore during hardware installations may adversely affect such operations. Therefore, formation isolation valves may be disposed in cased regions of the well near the interface of open-hole well regions.
Each lateral leg may be outfitted with a formation isolation valve that may be opened for gravel packing and other early stage leg applications. However, such valves may be subsequently closed to isolate the open-hole portion of the leg as other completions are carried out elsewhere in the well.
As indicated, closing the valve may avoid fluid loss during completions operations and also maintain well control in the sense of avoiding premature production of well fluids. This closure may be achieved in conjunction with removal of application tools from the open-hole region of the leg. So, for example, following a gravel packing application in a lateral leg, a shifting device incorporated into the gravel packing wash pipe may be used to close off the valve as the assembly is removed from the area. Thus, completion of the application and retrieval of the tool involved may be sufficient to close the formation isolation valve.
Unfortunately, once the well is completed and ready for production, re-opening the valve may be a bit more challenging. For example, a shifting tool may be re-introduced into the well and directed at each valve, one by one. Of course, depending on the depth and sophistication of the well architecture, this may eat up one to three days of time as well as a significant amount of footspace at the oilfield. Further, equipment costs in terms of up-rigging may also be incurred. For example, where the legs at issue are of a horizontal nature, coiled tubing operations may be required for delivery of the shifting tool. Once more, the interventional nature of shifting tool delivery inherently involves the possibility of mechanical failure and/or potential damage to the tool itself, particularly when considering the sudden emergence of high pressure conditions as each valve is sequentially opened.
In order to address the potentially costly drawbacks associated with interventional shifting tool delivery to re-open the valves, wireless, pressure based opening techniques have been developed. For example, each leg of the multilateral may be outfitted with a formation isolation valve that incorporates a pressure responsive actuator for opening the valve. Thus, sufficient pressure may be introduced into the well from the surface of the oilfield in order to trigger the actuators to open their respective valves and allow production to commence.
Unfortunately, in the described scenario, the actuators may not all open at precisely the same time. For example, the pressure increase may propagate unevenly or one actuator may be responsive to a slightly different pressure than another. When this occurs, the responsive actuators and associated open valves serve as an impediment to pressure actuation for any remaining un-open valves. That is, once one of the valves has been opened, continued efforts to pressure up the well and trigger other actuators are likely to only result in dumping fluid into the newly open-hole lateral leg. As a result, operators are then left with the only practical option being to resort to mechanical intervention in the form of a costly shifting tool application as noted above.
A valve actuator is provided that includes multiple actuation mandrels. The first mandrel is configured for tension member release actuation upon exposure to a first pressure exceeding a predetermined level. The second mandrel is configured for rupture disc actuation upon exposure to a second pressure exceeding another predetermined level. Further, the second pressure is higher than the first pressure and the actuations provide valve opening capability to the mandrels. Thus, a method of utilizing the actuator may include introducing the first pressure to free the first mandrel from a body of the actuator followed by increasing the pressure to exceed the other predetermined level thereby shifting the second mandrel to open a valve coupled to the actuator. Subsequently, the pressure may be decreased to a level below the predetermined levels thereby allowing the freed first mandrel to move in the direction of the shifting.
Embodiments are described with reference to certain downhole assemblies that make use of a valve and valve actuator. In particular, production assemblies that are configured for disposal across cased and open-hole regions at various well locations are detailed. More specifically, multiple production assemblies simultaneously disposed in different legs of a multilateral well are detailed in conjunction with corresponding formation isolation valves. However, embodiments of a multi-stage valve actuator as detailed herein may be employed in conjunction with a variety of different types of downhole valves. For example, any number of valves or other actuations may be directed through such an actuator. Additionally, the actuator may be disposed in downhole environments that are not multilateral in nature. Regardless, the actuator is multi-stage in the sense that the introduction of one high pressure stage may be utilized to set a fail-safe mandrel release actuation in advance of introducing another high pressure stage for actuation of another mandrel. Thus, in circumstances where the other high pressure stage and mandrel fail to actuate the valve, the fail-safe mandrel may be released to ensure valve actuation.
Referring now to
Continuing with reference to
The actuator 100 of
Referring now to
Continuing with more specific reference to
In order to serve as a ‘fail-safe’ or backup mode of actuation, the release mandrel 210 of the secondary mechanism 150 is structurally released from body of the actuator 100. That is, as shown, the mandrel 210 is initially secured and immobilized to the body by a tension member 250, which may be disposed between a portion of the mandrel 210 and, for example, a fitting 251. However, with the valve 175 of
The above noted increasing pressure may be imparted on locations such as the gap 201 adjacent the mandrel 210 until sufficient force for breaking the tension member 250 is achieved. The increasing pressure via the flow 200 imparts a differential as compared to external pressure at the outer side of the mandrel 210, via an annulus port 230 in the embodiment shown. Additionally, the amount of force imparted by this differential sufficient for breaking the tension member 250 is a matter of operator choice. So, for example, an operator may employ a 250-500 lb. rated tension member 250 to be sheared upon exposure to the noted 1,000-3,000 PSI differential referenced above. Of course, alternate shear ratings corresponding to a variety of different pressure differentials may also be utilized.
With breakage of the tension member 250, the mandrel 210 may slidably shift to the left in the depiction shown. Note the presence of a seal 212 and a biasing spring 225 on the mandrel 210 for controllably governing this leftward shifting. In this manner, the mandrel 210 has been released relative the body of the actuator 100. That is to say, as opposed to an immediate shift to the right for movement of the operator element 275, the mandrel 210 may be shifted leftward for release and held in place by maintaining the pressure differential within the channel 202. Thus, as detailed further below, the mandrel 210 may be held in reserve to serve as a fail-safe mode of shifting the operator element 275 should the primary mechanism 125 detailed below fail to achieve this rightward shift.
As shown in
In one embodiment, the pressure sufficient for rupturing the disc 205 and driving the mandrel 210 downhole is in excess of about 3,000 PSI. That is, the pressure sufficient for driving the primary mechanism 125 is substantially in excess of the pressure sufficient for achieving release of the release mandrel 210 of the secondary mechanism 150. As a practical matter, this means that as pressurized flow 200 is increased, the ‘fail-safe’ mandrel 210 is released by imparting an initial pressure. Subsequently, pressure is increased and this mandrel 210 is effectively held in place (or shifted slightly further uphole) as actuation of the active mandrel 215 proceeds. However, in circumstances where actuation of the active mandrel 215 fails, for example, due to failure of increased pressurization as described below, the fail-safe mandrel 210 may be subsequently employed for shifting of the operator element 275.
With particular reference to the shifting of the active mandrel 215, the rupturing of the disc 205 may lead to an influx of pressure acting on a compensating piston 209. This piston 209 may sealably float in an atmospheric oil chamber 211. Thus, the increase in pressure applied to the piston 209 imparts a differential that ultimately drives a head 219 of the mandrel 215 in the downhole direction toward the operator element 275.
Continuing with reference to
With particular reference to
Continuing with reference to
With added reference to
Referring now to
With fluid flow 200 directing both valves 175, 375 to simultaneously open an initial risk is presented that only one valve 175, 375 is opened. So, for example, with particular reference to
Fortunately, however, in the above described circumstance, the fail-safe mechanism 150 of
Referring now to
Continuing with reference to
Regardless of the particular applications, they may proceed in a securely isolated fashion once the valves 175, 375 are closed. Further, opening of the valves 175, 375 may take place in a pressure based internventionless manner even in circumstances where sequential opening thereof occurs. That is, as detailed above, the actuator 100, 300 for each valve 175, 375 is equipped with a ‘fail-safe’ mechanism 150 to allow a given valve 175 to open even in circumstances where the other valve 375 has previously opened, whether prematurely or otherwise.
Referring now to
With specific reference to
With the valve 375 now serving as a closed off formation isolation valve, uphole operations such as completions installation may proceed as detailed hereinabove. Indeed, with added reference to
Referring now to
Regardless, with valves at each region closed as noted at 645, operations may safely be performed at locations further uphole as noted at 660. Thus, even though interventionless opening of each valve is achieved through the common pathway, the availability of a multi-stage actuator to control each valve helps ensure that each is properly opened as indicated at 675. As detailed hereinabove, this is achieved by way of multi-stage pressurization of secondary ‘fail-safe’ and primary actuator mechanisms. Once more, in one embodiment, the primary mechanism may be aided by a supplemental actuation mechanism in the form of a conventional electric trigger in lieu of or in addition to the released secondary mechanism. For example, even though pressurization for shifting the primary mechanism may be insufficient, a pressure pulse or other suitable signaling technique may be employed to set off the trigger for driving of the primary mechanism.
Embodiments described hereinabove include tools and techniques which help avoid the need for reintroduction of an interventional shifting tool to re-open valves such as formation isolation valves. These tools and techniques are even effective in circumstances where conventional pressure directed interventionless control is compromised due to premature or unintended sequential valve openings in wells of multilateral architecture. As a result, countless hours and significant operational expenses may be spared.
The preceding description has been presented with reference to presently preferred embodiments. Persons skilled in the art and technology to which these embodiments pertain will appreciate that alterations and changes in the described structures and methods of operation may be practiced without meaningfully departing from the principle, and scope of these embodiments. Regardless, the foregoing description should not be read as pertaining only to the precise structures described and shown in the accompanying drawings, but rather should be read as consistent with and as support for the following claims, which are to have their fullest and fairest scope.
This divisional patent application claims the benefit of priority to co-pending U.S. patent application Ser. No. 13/398,117, filed Feb. 16, 2012 and entitled “Multi-Stage Valve Actuator”, which is incorporated herein by reference in its entirety, and in turn claims priority to U.S. Provisional App. Ser. No. 61/444,934, filed on Feb. 21, 2011, and entitled, “Isolation Device for Multi-Lateral with Dual Trip Saver”, incorporated herein by reference in its entirety.
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Number | Date | Country | |
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20170044869 A1 | Feb 2017 | US |
Number | Date | Country | |
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61444934 | Feb 2011 | US |
Number | Date | Country | |
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Parent | 13398117 | Feb 2012 | US |
Child | 15334893 | US |