Patent Application
20240060392
Tools are run into wellbores in the oil and gas industry to accomplish a variety of different tasks. One type of tool is a packer, which may be run into the well as part of a string of tubulars (e.g., a casing string). Upon reaching a desired position in the well, the packer may be expanded to engage and seal with the well, thereby blocking the annulus between the tubular string and the well at a desired position.
Inflatable packers are one such type of packer. The inflatable packers are typically run into the well and then expanded by forcing fluid from within the string into a contained volume radially between an inflatable element and a mandrel or another tubular. The inflatable element may be pressed radially outward by the continuing application of pressure, and thereby expand outward and block the annulus. Generally, the inflation process is controlled by pressure in the string and in the inflatable element, along with a valve assembly. The pressure may initially be increased above a threshold, which may open an “opening” valve, permitting fluid to be delivered to the inflatable element to commence inflation. The pressure in the inflatable element may eventually reach a level that indicates it has fully expanded, which may trigger a “closing” valve to close, so as to prevent further fluid flow into the inflatable element and lock the fluid within the inflated inflatable element.
Occasionally, the inflatable element may fail, e.g., rupture, such that fluid fed to the inflatable member flows into the wellbore. When this happens, the pressure rise in the inflatable element may not be experienced, and thus the closing valve may not close. Accordingly, fluid flow through the tubular string may be permitted to flow out into the wellbore through the ruptured inflatable element in an uncontrolled manner.
A valve assembly for an inflatable packer includes an opening valve configured to actuate into an open position in response to a first pressure within a tubular string, so as to permit fluid flow from the tubular string, through the valve assembly, and into an inflatable packer element. The valve assembly also includes a closing valve configured to actuate into a closed position so as to prevent fluid flow from the tubular string, through the valve assembly, and into the inflatable packer element in response to a second pressure within the inflatable packer element. The valve assembly also includes a contingency valve configured to actuate into a closed position so as to prevent fluid flow from the tubular string, through the valve assembly, and into the inflatable packer element in response to a third pressure in the tubular string.
An inflatable packer is also disclosed. The inflatable packer includes an inflatable packer element fluidly connected to a tubular string. The inflatable packer also includes a valve assembly coupled to and positioned between the tubular string and the inflatable packer element. The valve assembly includes an opening valve, a closing valve, and a contingency valve. The valve assembly includes a plurality of configurations including a run-in configuration in which the opening valve is in a closed position, the closing valve is in an open position, and the contingency valve is in an open position. The configurations also include an inflation configuration. The valve assembly is configured to actuate from the run-in configuration to the inflation configuration in response to a first pressure within the tubular string. In the inflation configuration, the opening valve is in an open position to permit fluid flow from the tubular string, through the valve assembly, and into the inflatable packer element, and the closing and contingency valves remain in the respective open positions. The configurations also include a first closed configuration. The valve assembly is configured to actuate from the inflation configuration to the first closed configuration in response to a second pressure in the inflatable packer element. In the first closed configuration, the closing valve is in a closed position to prevent fluid flow from the tubular string, through the valve assembly, and into the inflatable packer element, and the open and contingency valves remain in the respective open positions. The configurations also include a contingency configuration in response to the second pressure not being reached. The valve assembly is configured to actuate from the inflation configuration to the contingency configuration in response to a third pressure in the tubular string. In the contingency configuration, the contingency valve is in a closed position to prevent fluid flow from the tubular string, through the valve assembly, and into the inflatable packer element, and the opening and closing valves remain in the respective open positions. The third pressure is greater than the first pressure and independent of a pressure in the inflatable packer element.
A method for operating an inflatable packer includes deploying a valve assembly into a wellbore in a run-in configuration. The valve assembly includes an opening valve, a closing valve, and a contingency valve. In the run-in configuration, the opening valve is in a closed position, the closing valve is in an open position, and the contingency valve is in an open position. The method also includes increasing a pressure within a tubular string to a first pressure level, which actuates the valve assembly from the run-in configuration into an inflation configuration. The opening valve drives into an open position when actuating into the inflation configuration so as to permit fluid flow from the tubular string, through the valve assembly, and into an inflatable packer element, while the closing and contingency valves remain in the respective open positions. The method also includes increasing a pressure within the tubular string to a third pressure level in response to not being able to reach a second pressure level in the inflatable packer element. Increasing the pressure within the tubular string to the third pressure level actuates the valve assembly from the run-in configuration into a contingency configuration. The contingency valve drives into a closed position when actuating into the contingency configuration to prevent fluid flow from the tubular string, through the valve assembly, and into the inflatable packer element, while the opening and closing valves remain in the respective open positions.
The present disclosure may best be understood by referring to the following description and accompanying drawings that are used to illustrate some 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 at least some embodiments, pressure within the inflatable element 102 may rise during the inflation operation until it reaches a second pressure (pressure level), which may represent that the inflatable element 102 has fully inflated. This second pressure may be communicated back to the valve assembly 104, which may, in response, actuate to a closed configuration, in which fluid is again blocked from proceeding from the tubular string 106 to the inflatable element 102. The value of the second pressure may be the same, less than, or equal to the value of the first pressure.
In at least some embodiments, the second pressure may not be reached, e.g., because the inflatable element 102 (or some other part of the inflatable packer 100) has failed (e.g., ruptured). For example, as indicated by the dashed arrow, fluid may escape from within the inflatable element 102 and into the surrounding wellbore annulus, thereby preventing the pressure rise that cause the valve assembly 104 to actuate from the inflation configuration to the closed configuration. Accordingly, a third pressure may be applied via fluid in the tubular string 106 to the valve assembly 104, which may be independent of the pressure in the inflatable element 102 and may be higher than the first pressure. Upon reaching the third pressure (pressure level), the valve assembly 104 may actuate to a contingency configuration, in which a contingency valve is closed, thereby blocking fluid flow from the tubular string 106 to the inflatable element 102, despite the pressure in the inflatable element 102 not reaching the second pressure. The value of the third pressure may be greater than the value of the first pressure and/or independent of the pressure in the inflatable element 102.
The closing valve 202 may include a closing valve cylinder 212, defined in the valve housing 200, and a closing valve member 214. The closing valve member 214 may be movable in the closing valve cylinder 212 between an open position, as illustrated, and a closed position (e.g., shifted upwards from the view shown in
The closing valve 202 may further include a restraint 213, which may, at least initially, prevent the closing valve member 214 from moving upward. The restraint 213 may include a body 211 and a shearable member 215. The body 211 may be received at least partially into the closing valve cylinder 212, and may, for example, be threaded or otherwise retained therein. The shearable member 215 may be coupled to or otherwise engage the closing valve member 214, so as to prevent displacement of the closing valve member 214 at least in the upward direction, through the body 211. The shearable member 215 may be any type of member that is configured to break or otherwise yield, in response to the pressure in the inflatable element 102 acting on the closing valve member 214 (e.g., at second pressure level), as discussed above. Once the shearable member 215 yields, the closing valve member 214 may be free to slide upwards, until an enlarged section thereof abuts the body 211.
Additionally, an outlet conduit 216 and a first intermediate conduit 218 may extend from the closing valve cylinder 212 in opposite lateral directions. In the open position of the closing valve member 214 (and thus of the closing valve 202), as illustrated, fluid flow is permitted between the first intermediate conduit 218 and the outlet conduit 216 via the closing valve cylinder 212 (around the narrow section of the closing valve member 214).
The opening valve 204, which may be positioned immediately adjacent to the closing valve 202, may include an opening valve cylinder 220 and an opening valve member 222. The first intermediate conduit 218 may extend from the opening valve cylinder 220. A second intermediate conduit 223 may extend from the opening valve cylinder 220 in an opposite lateral direction as the first intermediate conduit 218. The opening valve member 222 has an open position that permits fluid flow between the first and second intermediate conduits 218, 223, and a closed position (illustrated) that prevents such fluid flow.
Further, the opening valve member 222 may be biased toward the bottom (in this view) of the opening valve cylinder 220 (e.g., toward the closed position) by a biasing member 224 (e.g., a spring). The opening valve 204 may also include a restraint 226, which may include a shearable member 228 that initially holds the opening valve member 222 in a closed position, near the bottom. The restraint 226 may be received at least partially into and (e.g., threaded in engagement with) the valve housing 200, particularly, at least partially in the opening valve cylinder 220. Pressure in the tubular string 106 reaching the first pressure level may act on the opening valve member 222, yielding the shearable member 228, such that the opening valve member 222 is permitted to travel upwards, at least partially through the restraint 228, to the open position. The restraint 226 may also include a lock 229, which may engage the opening valve cylinder 220, after it has stroked down to the closed position, and prevent it from returning to the open position.
The contingency valve 206 may include a contingency valve cylinder 230 formed in the valve housing 200 and a contingency valve member 232. The contingency valve 206 may be immediate adjacent to the opening valve 204, such that the opening valve 204 is positioned between the contingency valve 206 and the closing valve 202. Further, the second intermediate conduit 223 may extend from the contingency valve cylinder 230, and the contingency valve cylinder 230 may be in communication with the inlet 208. Additionally, the bottom of the contingency valve cylinder 230 may be in communication with the interior of the tubular string 106 (
The contingency valve 206 may include a restraint 234, which may be received at least partially in the contingency valve cylinder 230 and (e.g., threaded into connection with) the valve housing 200. The restraint 234 may include a body 236 and a shearable member 238. The contingency valve member 232 may be received at least partially through the body 236 and may be coupled to the shearable member 238. At least initially, the shearable member 238 may restrain the contingency valve member 232 in an open position, as shown. The pressure in the tubular string 106 reaching the third pressure level, as noted above, may act on the contingency valve member 232, such that the shearable member 238 yields and permits the contingency valve member 232 to stroke upwards into a closed position. The body 236 may be threaded into connection with the contingency valve cylinder 230.
Eventually, the inflatable element 102, if it does not rupture, may experience a pressure rise as it continues to inflate and engages the surrounding tubular (e.g., wellbore). The pressure in the inflatable element 102 is communicated back to the valve assembly 104, as noted above, and specifically to the closing valve 202 (e.g., the bottom of the closing valve cylinder 212). The pressure in the inflatable element 102 is thus communicated to the closing valve member 214, and, upon reaching the second pressure, causes the restraint 213 to release (e.g., the shearable member 215 yields) the closing valve member 214.
Proceeding to
In some cases, pressure in the inflatable element 102 (
To address this potential, the provision of the contingency valve 206 permits the valve assembly 104 to be actuated into a contingency configuration, as depicted in
The method 700 may include deploying the valve assembly 104 into a wellbore in a run-in configuration, as at 710. In an embodiment, the inflatable packer 100 (e.g., the inflatable element 102, the valve assembly 104, and/or the tubular string 106) may be deployed simultaneously.
As described above, in the run-in configuration, the valve element 104 blocks the fluid from the tubular string 106 from reaching the inflatable element 102, thereby retaining the inflatable element 102 uninflated while being deployed in the wellbore. More particularly, one or more of the valve members 214, 222, 232 in the valve element 104 may block the fluid from the tubular string 106 from reaching the inflatable element 102. In the example shown in
Once the inflatable packer 100 (e.g., the valve assembly 104) reaches the desired location in the wellbore, the method 700 may also include actuating the valve assembly 104 from the run-in configuration to an inflation configuration, as at 720. Actuating the valve assembly 104 into the inflation configuration may include moving the opening valve member 222 from the closed position (e.g., vertically upward) to the open position. An example of this is shown in
The method 700 may also include actuating the valve assembly 104 from the inflation configuration to a first closed configuration, as at 730. Actuating the valve assembly 104 into the first closed configuration may include moving the closing valve member 214 from the open position (e.g., vertically upward) to the closed position. An example of this is shown in
The method 700 may also include actuating the valve assembly 104 from the first closed configuration to a second closed configuration, as at 740. Actuating the valve assembly 104 into the second closed configuration may include moving the opening valve member 222 from the open position (e.g., vertically downward) to the closed position. An example of this is shown in
In at least some embodiments, the second pressure level may not be reached (e.g., because the inflatable element 102 or some other part of the packer 100 has ruptured). In this case, steps 730 and/or 740 may be bypassed, and the method 700 may instead include actuating the valve assembly 104 from the inflation configuration to a contingency configuration, as at 750. Actuating the valve assembly 104 into the contingency configuration may include moving the contingency valve member 232 from the open position (e.g., vertically upward) to the closed position. An example of this is shown in
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 Patent Application No. 63/371,775, filed on Aug. 18, 2022, which is incorporated by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| 63371775 | Aug 2022 | US |
