Hydrocarbon products such as oil and natural gas are generally extracted from wells drilled into the earth. One aspect of drilling such wells is known as “completion.” Completion is the process of making a well ready for production or injection. There are several techniques to complete a well. Such techniques generally involve lining the well with casing, and cementing the casing in place.
Cementing operations begin by pumping cement down into casing and back up through the annulus between the casing and the wall of the wellbore. After filling the annulus with cement, an operator typically wipes the wellbore by pumping a wiper device such as a wiper plug, dart, or ball through the casing. The wiper device is designed as a barrier to prevent cement contamination with displacement of wellbore fluids as well as to “wipe” excess or superfluous cement from the string.
After cementation, the wellbore is reopened downhole to allow circulation of fluids to continue the completion process. In some cases, this is done using a downhole tool known as a “toe valve” or an “initiation valve.” However, in some instances, the toe valve may fail to open and can block circulation. One factor that plays a role in these failures is cement left behind in the toe valve that the cement wiper plug did not remove.
Embodiments of the disclosure may provide a downhole tool including a first sub defining a port extending radially therethrough, a second sub spaced axially apart from the first sub, and a housing connected with the first and second subs. A valve element is disposed at least partially within the housing, and is movable from a closed position to an open position. In the closed position, the valve element blocks fluid communication between a bore and an opening in the housing, and when the valve element is in the open position, fluid communication between the bore and the opening is permitted. an actuation chamber defined between the first sub, the housing, and the valve element, the actuation chamber being in fluid communication with the bore via a flow path that includes the port, and a flow restrictor positioned in the flow path. The flow restrictor is configured to slow fluid flow from the bore to the actuation chamber via the flow path, while allowing fluid flow from the bore to the actuation chamber via the flow path.
Embodiments of the disclosure may also provide a method for operating a downhole tool. The method includes deploying the downhole tool into a wellbore, the downhole tool including a sleeve that is initially held in a closed position. The sleeve in the closed position blocks fluid communication between a central bore of the downhole tool and an exterior of the downhole tool via an opening in the downhole tool. The method also includes causing an increase in a pressure in the central bore by increasing a pressure in the wellbore, and maintaining the pressure in the central bore at least until a pressure in an actuation chamber defined within the downhole tool reaches an actuation pressure. Pressure changes in the actuation chamber are delayed with respect to pressure changes in the central bore. The method further includes producing a pressure differential across the sleeve by reducing the pressure in the wellbore. Producing the pressure differential causes the sleeve to move a first time toward an open position. The sleeve in the open position exposes the opening to the central bore for allowing communication between the central bore and the exterior of the downhole tool.
The present disclosure may best be understood by referring to the following description and accompanying drawings that are used to illustrate one or more embodiments. In the drawings:
The following disclosure describes several embodiments for implementing different features, structures, or functions of the invention. Embodiments of components, arrangements, and configurations are described below to simplify the present disclosure; however, these embodiments are provided merely as examples and are not intended to limit the scope of the invention. Additionally, the present disclosure may repeat reference characters (e.g., numerals) and/or letters in the various embodiments and across the Figures provided herein. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed in the Figures. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact. Finally, the embodiments presented below may be combined in any combination of ways, e.g., any element from one exemplary embodiment may be used in any other exemplary embodiment, without departing from the scope of the disclosure.
Additionally, certain terms are used throughout the following description and claims to refer to particular components. As one skilled in the art will appreciate, various entities may refer to the same component by different names, and as such, the naming convention for the elements described herein is not intended to limit the scope of the invention, unless otherwise specifically defined herein. Further, the naming convention used herein is not intended to distinguish between components that differ in name but not function. Additionally, in the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.” All numerical values in this disclosure may be exact or approximate values unless otherwise specifically stated. Accordingly, various embodiments of the disclosure may deviate from the numbers, values, and ranges disclosed herein without departing from the intended scope. In addition, unless otherwise provided herein, “or” statements are intended to be non-exclusive; for example, the statement “A or B” should be considered to mean “A, B, or both A and B.”
In general, the present disclosure provides a downhole tool, e.g., a valve that may be used as a toe valve in wellbore completions. The valve operates to selectively expose an opening that provides an initial injection point for hydraulic fracturing of the surrounding formation. The valve may be run downhole with casing while the valve in a closed configuration. Upon reaching a desired depth, the valve may be configured to initially remain closed, continuing to prevent fluid communication between an interior bore of the valve and an exterior of the valve, until an actuation event occurs, such as when a casing bore pressure test completes. The actuation event may trigger the valve to open, thereby exposing the casing bore to the wellbore. The valve opening, however, may be delayed, e.g., occurring after a predetermined amount of time passes from when the actuation event occurs. For example, the valve may include a valve element (e.g., a sleeve) that is movable in response to increases in pressure in the casing. However, fluid communication to the valve element may be constricted, which may delay the valve opening following the actuating event. Various other aspects of the present disclosure will be apparent from the following description of several example embodiments.
Turning now to the illustrated embodiments,
The housing 106 may define one or more openings 105 radially therethrough. When the tool 100 is opened, the openings 105 may fluidly communicate with the bore 101, allowing communication from the bore 101 to the exterior of the tool 100.
The tool 100 may include a valve element that opens and closes the tool 100. In an embodiment, the valve element may be a sleeve 108 that is positioned generally concentric to and at least partially radially between the first sub 102 and the housing 106 and/or between the second sub 104 and the housing 106. The sleeve 108 may be movable, e.g., slidable relative to the first sub 102, the second sub 104, and/or the housing 106, between a closed position (as shown) and an open position (to the right of what is shown). In the closed position, the sleeve 108 may extend across the openings 105 and block fluid communication between the bore 101 and the openings 105. Further, in the closed position, the sleeve 108 may seal against the first sub 102 and the housing 106 using seals 115, 118, 119. In the closed position, the sleeve 108 may also be axially constrained from movement with respect to the housing 106 by a shearable member 114, such as a shear pin or shear screw, that connects the shearable member 114 to the housing 106. In response to an actuation event, as will be described in greater detail below, the sleeve 108 may slide to the right (e.g., in the downhole direction), so as to expose the openings 105 to the bore 101. This is the open position for the sleeve 108, which corresponds to the tool 100 being open.
The tool 100 may generally include an actuating mechanism configured to effect such sliding of the sleeve 108 and thereby open the sleeve 108. The actuating mechanism may also provide the aforementioned time-delay for such opening. The actuating mechanism may include, for example, an actuation chamber 103 and a flow restrictor which may slow fluid flow into the actuation chamber 103, while allowing fluid to flow; that is, the flow restrictor may be configured to limit the non-zero rate of fluid flow, e.g., by limiting the flow path area, e.g., choking flow. In one example, the flow restrictor may be or include a one-way valve assembly 112, as shown.
The sleeve 108 may be movable in response to the actuation chamber 103 and the bore 101 reaching a predetermined pressure differential. The actuation chamber 103 may be in fluid communication with the bore 101 through the one-way valve assembly 112. The one-way valve assembly 112 may, however, impede fluid flow to the actuation chamber 103, thus allowing the pressure to increase in the chamber 103 in response to pressure increases in the bore 101, but over a period of time.
In a specific embodiment, the one-way valve assembly 112 is located generally concentric with and radially between the first sub 102 and the housing 106. The one-way valve assembly 112 may seal against the first sub 102 and the housing 106 using seals 120 and 121 respectively. Further, the chamber 103 may be defined between (e.g., by) the first sub 102, the housing 106, the sleeve 108, and the one-way valve assembly 112.
The actuating mechanism may also include a biasing member (e.g., a spring) 107, which may be positioned within the chamber 103, to assist with sliding the sleeve 108. For example, the biasing member 107 may bear on the housing 106 on one side, and the sleeve 108 on the other. In other embodiments, the biasing member 107 may bear on the first sub 102 instead of the housing 106. The biasing member 107 may be compressed when the sleeve 108 is in the closed position. Accordingly, the biasing member 107 may apply an axial force on the sleeve 108, directed away from the first sub 102 and toward the open position of the sleeve 108.
Accordingly, pressure in the bore 101 may be communicated to the chamber 103 via the flow path. However, fluid flow from, and thus communication of pressure changes in, the bore 101 to the chamber 103 may be delayed by the one-way valve assembly 112. Thus, the pressure in the chamber 103 may lag or follow behind the pressure in the bore 101, and, correspondingly, pressure changes in the chamber 103 may be delayed with respect to pressure changes in the bore 101.
After this delay, pressure within the bore 101 may be bled out to a lower pressure. The one-way valve assembly 112 may serve to impede or block a corresponding reduction of pressure in the chamber 103, thereby trapping the higher pressure in the chamber 103 and achieving a differential pressure between the chamber 103 and the cavity 126 located within the bore 101. This may generate a force on the sleeve 108. Once this force reaches a predetermined magnitude, the shearable member 114 may break allowing the sleeve 108 to slide into the cavity 126. Referring additionally to
A filter 302 may also be positioned in the fluid flow path, e.g., upstream of the aperture 304 (e.g., between the port 202 and the one-way valve assembly 112). The filter 302 may be a sintered metal filter, or any other filter media configured to prevent debris, particulate matter, etc., from entering and potentially blocking the aperture 304. In other embodiments, the fluid filter 302 may be positioned downstream from the aperture 304, or may be within the aperture 304. The filter 302 may be, in an embodiment, a 100 micron filter. In other embodiments, the filter 302 size may be larger or smaller, e.g., between about 10 microns and about 500 microns, about 50 microns and about 250 microns, or about 75 microns and about 150 microns. Further, the filter 302 may be configured to prevent particles of a certain size from passing into the posterior annulus 206. For example, the filter 302 may be configured to prevent particles of a size greater than or equal to about 0.001 inches, about 0.002 inches, about 0.003 inches, about 0.004 inches, about 0.005 inches, about 0.010 inches, or about 0.100 inches from passing through.
In addition, as shown in
As also shown in
Accordingly, in operation, the pressure in the bore 101 may increase to a first level, upon which the first rupture disk 402 may break, allowing fluid communication through the port 202 to the intermediate chamber 600 via the choke 404 (or another fluid restrictor). The fluid restrictor serves to delay the filling/pressurization of the intermediate chamber 600. The pressure in the intermediate chamber 600 may eventually rise to a second level, which may be the same, greater than, or less than the first level. At the second level, the second rupture disk 604 may break, allowing fluid flow from the intermediate chamber 600 to the actuation chamber 103. The filling/pressurization of the actuation chamber 103 may occur over a duration, as the flow restrictor may impede the movement of fluid from the bore 101 to the actuation chamber 103 via the port 202 and the intermediate chamber 600.
It will be appreciated that rupture disks 402 and/or 604 may be employed in embodiments in which the cavity 126 is exposed to the pressure of the bore 101 (e.g., as shown in
The casing string may undergo a pressure test, which may involve applying pressure through the casing string and into the bore 101 of the tool 100, as at 704. Upon reaching a desired pressure within the bore 101, a hold period may follow. During this time, fluid within the bore 101 may communicate into the chamber 103 until the pressure within the chamber 103 equalizes with the pressure within the bore 101. The flow restrictor (e.g., check valve 306 and/or choke 404) may delay the pressure increase from the bore 101 into the chamber 103. Further, when the check valve 306 is provided, it may seal a compressed gas and liquid mixture within the chamber 103. Once the hold period has expired, pressure within the bore 101 may be bled to a lower pressure, as at 706.
At a predetermined bore pressure, the differential pressure across the sleeve 108 may cause the shearable member 114 to break, thereby releasing the sleeve 108 to eject into the cavity 126 and exposing openings 105 within the housing 106 to the bore 101 and allowing fluid communication from the bore 101 to the outside wellbore. The axial movement of the sleeve 108 may be aided by the biasing member 107 to ensure that the sleeve 108 reaches the next position.
Optionally, the valve (e.g., tool 500) may be configured to have multiple actuating actions, which may each be completed prior to the tool 500 opening. Accordingly, the pressure increasing at 704 and bleeding at 706 may repeat until the multiple actuators occur. For example, the shear pins 114A-C may be arranged in a series along the housing 106. The slots 502, 504, 506 within the sleeve 108 may be configured so that after the first actuation, the next set of shearable members 114B restrain the sleeve 108 until the aforementioned operation of the valve assembly is repeated.
In other embodiments, the increasing pressure at 704 may not need to be followed by bleed-down to create the sequence of actuations. Rather, the increasing pressure itself (whether applied, hydrostatic, or both) may cause the multiple actuations, e.g., with a time delay between each such actuation as the fluid fills the increasing size of the actuation chamber 103 after each time the sleeve 108 moves.
Further, in some embodiments, the bleed-down of the pressure of the bore 101 may not cause the actuation. Rather the increase in the bore 101 pressure may be communicated to the chamber 103 over time, which may result in a pressure differential building between the chamber 103 and an isolated cavity 126 on an opposite axial side of the sleeve 108, as noted above.
As used herein, the terms “inner” and “outer”; “up” and “down”; “upper” and “lower”; “upward” and “downward”; “above” and “below”; “inward” and “outward”; “uphole” and “downhole”; and other like terms as used herein refer to relative positions to one another and are not intended to denote a particular direction or spatial orientation. The terms “couple,” “coupled,” “connect,” “connection,” “connected,” “in connection with,” and “connecting” refer to “in direct connection with” or “in connection with via one or more intermediate elements or members.”
The foregoing has outlined features of several embodiments so that those skilled in the art may better understand the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.
This application claims priority to U.S. Provisional Application having Ser. No. 62/432,987, which was filed on Dec. 12, 2016 and is incorporated herein by reference in its entirety.
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Number | Date | Country | |
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20180163508 A1 | Jun 2018 | US |
Number | Date | Country | |
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