The present disclosure relates generally to downhole tools including ball valve mechanisms positioned downhole in a well system, and more specifically, though not exclusively, to an actuator assembly which provides for remote opening of a ball valve mechanism of a downhole tool.
A well system (e.g., oil or gas wells for extracting fluids from a subterranean formation) may include tools having ball valve mechanisms positioned downhole, for example tools having ball valve mechanisms. These tools may be actuated from a surface of a wellbore of the well system. Tools can include, but are not limited to, fluid loss control valves having ball valve mechanisms.
Certain aspects and examples of the disclosure relate to controlling a ball valve mechanism of a downhole tool positioned within a wellbore. The ball valve mechanism can selectively provide fluid flow between an interior region of a tubing string of the downhole tool and an annulus. In some aspects, in a closed position the ball valve mechanism can isolate the formation before an upper completion is installed in the wellbore of a well system. In the open position, fluid may flow through from the annulus into the interior of the tubing string. The ball valve mechanism may be actuated from a surface of the wellbore by applying a pressure signal that falls within a predetermined pressure window. The pressure window may be defined as a predetermined amount of pressure. In some aspects, the predetermined amount of pressure may be a range of pressures (also referred to as a pressure range). In some aspects, the pressure window for actuating the downhole tool may also include a predetermined amount of time that the predetermined amount of pressure is maintained. The ball valve mechanism may be actuated in response to a pressure signal within the predetermined pressure window being applied from the surface.
The downhole tool may be a fluid control device or any other device comprising a ball valve mechanism. The actuator assembly for the downhole tool can include a series of springs, pistons, and latches that are arranged to retain a release latch in place when a pressure signal from a surface of a wellbore falls outside of a predetermined pressure window. The release latch can be released by the series of springs, pistons, and latches when the pressure signal from the surface falls within the predetermined pressure window.
In some aspects, the actuator assembly can include a locking mechanism that prevents a release latch from being released from its engagement with a primary piston in response to the pressure signal being above the predetermined pressure range of the predetermined pressure window. The locking mechanism can prevent the primary piston from releasing the release latch by blocking the primary piston from moving in a first direction in response to the pressure signal being greater than the predetermined pressure range. The locking mechanism can block the movement of the primary piston by securing the locking mechanism in place adjacent to the primary piston by preventing the movement of the locking mechanism with at least one additional piston, for example a locking piston. In some aspects, a latch mechanism can also retain the locking mechanism in place in conjunction with the locking piston.
In some aspects, a spring coupled to the primary piston can exert a force on the primary piston in a second direction. The force exerted by the spring can prevent the primary piston from moving a predetermined amount in the first direction (and thereby releasing the release latch) in response to the pressure signal being less than the predetermined pressure range. In some aspects, the force exerted by the spring can prevent the primary piston from moving the predetermined amount in the first direction in response to the pressure signal being applied less than the predetermined amount of time.
Thus, through a series of springs, piston, and latches, the actuator assembly can control the release of a release latch that is coupled to the actuator. In response to an application of a pressure signal from the surface that falls within the predetermined pressure window, the actuator assembly can release the release latch and actuate the ball valve mechanism. In response to an application of a pressure signal from the surface that falls outside of the predetermined pressure window, for example being greater than the predetermined pressure range, being less than the predetermined pressure range, or being less than the predetermined time period of application of the pressure signal, the actuator assembly can retain the release latch in place and the ball valve mechanism may not actuate.
The downhole tool 114 may be moved from the closed position to the open position in response to a signal from the surface of the wellbore 102. The signal from the surface may be a predetermined pressure signal from the surface. The predetermined pressure signal may fall within a “pressure window” that corresponds to a predetermined pressure range. The pressure window may also correspond to the predetermined pressure range being applied for a predetermined amount time. A pressure signal that falls outside of the predetermined pressure window, either by falling outside of the predetermined pressure range of pressure or predetermined amount of time of application may not cause the downhole tool 114 to actuate. A pressure signal that falls within the predetermined pressure window may cause the downhole tool 114 to actuate. The downhole tool 114 may be a mechanical tool that does not utilize electronics.
The actuator assembly 122 of the downhole tool 114 can control the position of the ball valve mechanism 115, for example by opening the ball valve mechanism 115 in response to an application of a predetermined pressure signal from the surface of the wellbore. The ball valve mechanism 115 can include a ball valve 123, shown in
The actuator assembly 122 is shown in
The actuator assembly 122 also includes a primary piston 138 that is also coupled to a return spring 140. The return spring 140 has a spring force in the first direction (shown by arrow “A”). The ball valve mechanism 115 includes, or in some aspects is coupled to, a release latch 142 that is positioned between the outer surface 124 of the tubing string 120 and the primary piston 138 and is releasably secured in place by a projection 144 of the tubing string 120 and by the primary piston 138, as shown in
As shown in
The movement of the locking piston 128 in the second direction (shown by arrow “B”) can also cause the first end 132 of the locking piston 128 to engage with a surface of a locking mechanism 148. The latch 134 can also be engaged with a surface of the locking mechanism 148 for restraining the locking mechanism 148 in place. The engagement between the locking piston 128, the latch 134, and the locking mechanism 148 can maintain the locking mechanism 148 in a restrained position that prevents the primary piston 138 from moving in the second direction beyond an end 139 of the locking mechanism 148. As shown in
The pressure signal that falls within the predetermined pressure window can also be small enough that it may not overcome the spring force of the first spring 130 and the spring force of the second spring 136 and thereby may not cause the locking piston 128 to move in the second direction. For example, the force exerted by the pressure signal may not be sufficient to cause the locking piston 128 to move in the second direction because of the force exerted on the locking piston by the spring force of the first spring 130, as well as the force of the second spring 136 that is coupled to the latch 134.
The locking mechanism 148 can be in an unrestrained positioned when it is disengaged from the latch 134 and the locking piston 128 when the locking piston 128 is in the position shown in
As used below, any reference to a series of examples is to be understood as a reference to each of those examples disjunctively (e.g., “Examples 1-4” is to be understood as “Examples 1, 2, 3, or 4”).
Example 1 is a downhole tool positionable within a wellbore, the downhole tool comprising: a tubing string positionable downhole in the wellbore and having an outer surface that defines an inner region and an outer region of the tubing string; a release latch positioned within an inner region of the tubing string, the release latch having a restrained position and a released position, the release latch being coupled to a ball valve mechanism for actuating the ball valve mechanism in the released position; and a primary piston positioned within the inner region of the tubing string and coupled to a spring to exert a force in a first direction, the primary piston being movable a predetermined amount in a second direction to move the release latch from the restrained position to the released position in response to an application of a predetermined amount of pressure over a predetermined amount of time from a surface of the wellbore.
Example 2 is the downhole tool of example 1, wherein the second direction is opposite the first direction.
Example 3 is the downhole tool of examples 1 or 2, further comprising: a locking piston coupled to a second spring; and a locking mechanism positioned between the primary piston and a locking piston for preventing movement of the primary piston the predetermined amount in the second direction in response to an application of pressure from the surface of the wellbore that is greater than the predetermined amount of pressure.
Example 4 is the downhole tool of example 3, further comprising a latch coupled to a third spring and having a surface that engages with a surface of the locking mechanism in response to the application of pressure that is greater than the predetermined amount of pressure.
Example 5 is the downhole tool of example 4, wherein the latch includes a surface that engages with a surface of the locking piston in response to the application of pressure that is greater than the predetermined amount of pressure.
Example 6 is the downhole tool of example 4, further comprising a projection on the locking mechanism that engages with an end of the locking piston and a surface of the latch in response to the application of pressure that is greater than the predetermined amount of pressure.
Example 7 is the downhole tool of any of examples 1-3, wherein the spring coupled to the primary piston has a spring force selected to prevent the primary piston from moving the predetermined amount in the second direction in response to an application of pressure that is less than the predetermined amount of pressure.
Example 8 is an actuation assembly positionable within a wellbore, the actuation assembly comprising: a primary piston coupled to a first spring and positionable in a first position in which the primary piston is coupled to a release latch for restraining the release latch from actuating a ball valve mechanism; a locking piston coupled to a second spring; and a locking mechanism positioned between the primary piston and the locking piston; wherein the locking mechanism is moveable between (i) a restrained position for preventing the primary piston from moving a predetermined amount in a first direction in response to an application of pressure from a surface of the wellbore that is greater than a predetermined amount of pressure and (ii) an unrestrained position.
Example 9 is the actuation assembly of example 8, wherein the predetermined amount of pressure is a predetermined pressure range.
Example 10 is the actuation assembly of examples 8 or 9, wherein the first spring coupled to the primary piston has a spring force selected to permit the piston to move the predetermined amount in the first direction in response to the application of pressure from the surface of the wellbore that is within the predetermined pressure range for a predetermined period of time.
Example 11 is the actuation assembly of any of examples 8-10, further comprising a latch positionable in a locked position in which the latch contacts a surface of the locking mechanism for maintaining the locking mechanism in the restrained position in response to the application of pressure from the surface of the wellbore that is greater than the predetermined amount of pressure.
Example 12 is the actuation assembly of example 11, further comprising a third spring coupled to the latch for maintaining the latch in the first position in response to the application of pressure from the surface of the wellbore that is greater than the predetermined amount of pressure.
Example 13 is the actuation assembly of example 12, wherein the locking mechanism is held in the restrained position by a surface of the latch and a surface of the locking piston in response to the application of pressure from the surface of the wellbore that is greater than the predetermined amount of pressure.
Example 14 is the actuation assembly of any of examples 8-13, wherein the first spring has a spring force selected to compress the first spring a predetermined amount in response to an application of pressure from the surface of the wellbore that falls within a predetermined pressure range for uncoupling the release latch from the primary piston.
Example 15 is the actuation assembly of example 10, wherein the first spring has a spring force selected to compress the first spring a predetermined amount in response to an application of pressure from the surface of the wellbore that falls within the predetermined pressure range for the predetermined period of time for uncoupling the release latch from the primary piston.
Example 16 is the actuation assembly of example 12, wherein the second and third springs have a combined spring force that is greater than the predetermined pressure range for maintaining the locking mechanism in a released position in which an end of the primary piston can extend longitudinally beyond an end of the locking mechanism.
Example 17 is a method of actuating a tool positioned downhole in a wellbore, the method comprising: applying a pressure from a surface of the wellbore to the tool downhole; moving a primary piston a predetermined amount in response to the pressure being within a predetermined pressure range; and releasing a latch coupled to a ball valve mechanism in response to the primary piston moving the predetermined amount for actuating the ball valve mechanism.
Example 18 is the method of actuating a tool positioned downhole in a wellbore of example 17, wherein the pressure from the surface is maintained for a predetermined amount of time.
Example 19 is the method of actuating a tool positioned downhole in a wellbore of any of examples 17-19, further comprising: moving a locking mechanism in a first direction in response to the primary piston moving the predetermined amount.
Example 20 is the method of actuating a tool positioned downhole in a wellbore of example 19, wherein the locking mechanism is positionable in a restrained position for preventing the primary piston from moving the predetermined amount in response to an application of pressure from the surface that is greater than the predetermined pressure range.
The foregoing description of certain examples, including illustrated examples, has been presented only for the purpose of illustration and description and is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art without departing from the scope of the disclosure.
Filing Document | Filing Date | Country | Kind |
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PCT/US2018/064043 | 12/5/2018 | WO |
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WO2020/117226 | 6/11/2020 | WO | A |
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International Application No. PCT/US2018/064043, “International Search Report and Written Opinion”, dated Aug. 26, 2019, 10 pages. |
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Number | Date | Country | |
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20210381326 A1 | Dec 2021 | US |