1. Field of the Invention
Embodiments disclosed herein relate to apparatuses and methods used in hydraulic fracturing of downhole formations. More specifically, embodiments disclosed herein relate to downhole valves used in hydraulic fracturing operations.
2. Background Art
This section of this document introduces information about and/or from the art that may provide context for or be related to the subject matter described herein and/or claimed below. It provides background information to facilitate a better understanding of the various aspects of the present invention. This is a discussion of “related” art. That such art is related in no way implies that it is also “prior” art. The related art may or may not be prior art. The discussion in this section of this document is to be read in this light, and not as admissions of prior art.
Current designs for valves used in the completion method disclosed above are prone to failure because cement or other debris interferes with the opening of the valve after the cementing process has been completed. Portions of the sliding sleeve or pistons commonly used are exposed to either the flow of cement or the cement flowing between the well bore and the casing string.
The valve according to the invention overcomes the difficulties described above by isolating a sliding sleeve between an outer housing and an inner mandrel. A rupture disk in the inner mandrel ruptures at a selected pressure. Pressure will then act against one end of the sliding sleeve and shift the sleeve to an open position so that fracturing fluid will be directed against the cement casing. The sliding sleeve includes a rocking ring nut to prevent the sleeve from sliding back to a closed position.
In a first aspect, a valve comprises: a housing having an opening; a mandrel disposed in the housing, the mandrel having an opening; a rupture disk disposed in a passageway of the mandrel; a sliding sleeve disposed between the housing and the mandrel; and a ball seat disposed in the mandrel.
A second aspect includes a method for actuating a valve comprising a housing having an opening; a mandrel having an opening and a passageway; a sliding sleeve disposed between the housing and the mandrel; and a ball seat disposed in the mandrel. The method comprises: flowing a fluid through the valve; dropping a ball; seating the ball in the ball seat and blocking fluid flow through the mandrel; flowing fluid through the passageway to the sliding sleeve; moving the sliding sleeve axially within the valve; and exiting fluid through the openings of the housing and mandrel.
In a third aspect, a valve comprises: a housing having an opening; a mandrel disposed in the housing, the mandrel having an opening and a passageway; a sliding sleeve disposed between the housing and the mandrel; and a ball seat disposed in the mandrel blocking fluid communication between the mandrel and the passageway.
The above presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an exhaustive overview of the invention. It is not intended to identify key or critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is discussed later.
The invention may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements, and in which:
While the invention is susceptible to various modifications and alternative forms, the drawings illustrate specific embodiments herein described in detail by way of example. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
Illustrative embodiments of the invention are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort, even if complex and time-consuming, would be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
As shown in
Main housing 13 is a hollow cylindrical piece with threaded portions 61 at each end that receive threaded portions 18 of each end connector. End connectors 11 and 12 may be internally or externally threaded for connection to the casing string. As shown in
Valve 10 includes a mandrel 30, which is formed as a hollow cylindrical tube extending between end connectors 11, 12 as shown in
Mandrel 30 is confined between end connectors 11 and 12 by engaging a shoulder 15 in the interior surface of the end connectors. End connectors 11 and 12 include longitudinally extending portions 18 that space apart outer housing 13 and mandrel 30 thus forming a chamber 36. Portions 18 have an annular recess 32 for relieving a suitable seal. A sliding sleeve member 20 is located within chamber 36 and is generally of a hollow cylindrical configuration as shown in
A locking ring holder 25 has ratchet teeth 61 and holds locking ring 50, which has ratchet teeth 51 on its outer surface and ratchet teeth 55 on its inner surface as shown in
Locking ring holder 25 has sufficient diameter clearance so that the locking ring can ratchet on the mandrel ratcheting teeth 63, yet never loose threaded contact with the lock ring holder. Locking ring holder 25 is threaded at 26 for engagement with threads 24 on the mandrel. Locking ring holder 25 also has a plurality of bores 46 and 62 for set screws, not shown.
In use, valve 10 may be connected to the casing string by end connectors 11, 12. One or more valves 10 may be incorporated into the casing string. After the casing string is deployed within the well, cement is pumped down through the casing and out the bottom into the annulus between the well bore and the casing, as typical within the art. After the cement flow is terminated, a plug or other device is pumped down to wipe the casing and valve clean of residual cement. When the plug or other device has latched or sealed in the bottom hole assembly, pressure is increased to rupture the rupture disk at a predetermined pressure. The fluid pressure will act on sliding sleeve member 20 to cause the shear pins to break and then to move it downward or to the right, as shown in
Due to the fact that the sliding sleeve member 20 is mostly isolated from the cement flow, the sleeve will have a lesser tendency to jam or require more pressure for actuation.
In the open position, locking ring 50 engages threads 63 on the mandrel to prevent the sleeve from moving back to the closed position.
A vent 37 is located in the outer housing 13 to allow air to exit when the valve is being assembled. The vent 37 is closed by a suitable plug after assembly.
Referring now to
Housing 105 has one or more openings 111 located around valve 100. The number, location, and size of openings 111 may vary depending on the requirements for a particular embodiment of valve 100. For example, in certain embodiments, openings 111 may range from several inches to several feet in length. Additionally, the geometry of openings 111 may vary depending on the requirements of a particular operation. For example, in certain embodiments, openings 111 may be generally rectangular, while other embodiments, openings 111 may be more round/circular in geometry. In addition to openings 111 in housing 105, valve 100 also includes one or more corresponding mandrel openings 112. The openings 112 of the mandrel 110 correspond in location to the openings 111 in the housing 105, and as such, the geometry and size of mandrel 110 openings 112 may vary as housing 105 openings 111 vary.
A sliding sleeve 115 is disposed between housing 105 and mandrel 110. In this embodiment, a first chamber 120, is formed between housing 105 and mandrel 110, and is located axially above sliding sleeve 115. Similarly, a second chamber 125 is formed between housing 105 and mandrel 110, and is located below sliding sleeve 115. First and second chambers 120 and 125 are at atmospheric pressure when sliding sleeve 115 is in a closed position. Because the pressure in first and second chambers 120 and 125 is balanced, i.e., both chambers are at atmospheric pressure, the sliding sleeve does not move axially within the chambers 120 and 125, and thus valve 100 remains in a closed position.
A passageway 130 is located axially above sliding sleeve 115 and fluidly connects the inner diameter of mandrel 110 to first chamber 120. In a closed position, a rupture disk 135 may be located in passageway 130, thereby blocking a flow of fluid from the throughbore 140 of valve 100 into first chamber 120. As explained above, rupture disk 135 may be formed of a material that is designed to rupture, or break, at a specified pressure.
For example, in one embodiment, rupture disk 135 may be designed to break at approximately 3000 PSI. In other embodiments, rupture disk 135 may be designed to break at lower or higher pressures, such as, for example 1000 PSI, 5000 PSI, 10000 PSI, or 15000 PSI. The pressure at which rupture disk 135 ruptures may vary depending on specific valve 100 design and operational requirements in a manner that will be readily ascertainable by those skilled in the art having the benefit of this disclosure. For example, the pressure rating of rupture disk 135 may vary as a result of the depth of the well, properties of the fluid being pumped downhole, size of valve 100, etc.
In certain embodiments, multiple rupture disks 135 may be located around the inner diameter of mandrel 110. For example, two rupture disks 135 may be disposed at approximately 180° from one another. Those of ordinary skill in the art will appreciate that during casing of horizontal wells, because one side of the tool is relatively lower, cement may tend to settle on the lower side of the tool. To prevent settled cement from delaying or preventing the actuation of valve 100, multiple rupture disks 135 may be included in valve 100. In the event one of rupture disks 135 on a low side of valve 100 is covered with cement and cannot rupture, a second, redundant rupture disk 135, may be located on a high side of the tool. Because cement has not covered the rupture disk 135 on the high side of valve 100, the rupture disk 135 on the high side will rupture upon valve actuation, thereby allowing valve 100 to open. In a manner that will be readily ascertainable by those skilled in the art having the benefit of this disclosure, in certain valves 100, more than two rupture disks 135 may be included. For example, three, four, five, or more rupture disks 135 may be included to provide additional levels of redundancy.
Valve 100 also includes a ball seat 145 disposed in throughbore 140. In this embodiment, ball seat 145 is coupled to the inner diameter of mandrel 110 and is located axially below housing and mandrel openings 111 and 112. Ball seat 145 is configured to receive a ball (not shown), which may be dropped from the surface in order to actuate valve 100. It will be readily ascertainable to those of ordinary skill in the art that the size opening 150 through ball seat 145 may vary in order to receive a certain diameter ball. For example, ball diameter may size may vary in 1/16th inch increments in operations in which multiple valves 100 are used. In order to allow multiple valves 100 to be actuated along the length of a well, ball seats 145 that correspond to the smallest diameter balls may be disposed at a farthest distal location in the well, relative to the surface, while ball seats 145 that correspond to the largest diameter balls may be disposed at a location proximate the surface. Thus, sequentially larger balls may be dropped, thereby allowing multiple valves 100 to be opened.
Referring now to
In order to actuate valve 100 into an open position, a ball 150 is dropped from the surface of the well. The ball 150 is pumped downhole until it contacts and seats against ball seat 145, as shown. As fluid continues to build in throughbore 140, the pressure increases until a selected pressure is reached that causes rupture disk 135 to rupture. As rupture disk 135 ruptures, fluid flows through passageway 130 into first chamber 120. The fluid pressure in the tubing forces sliding sleeve 115 to traverse axially downward into second chamber 125. Sliding sleeve 115 may then be locked into place through engagement of corresponding teeth 160 on a lock ring 155 and mandrel 105. The lock ring 155 may then permanently secure sliding sleeve 115 in an open position, thereby allowing full fluid flow through housing and mandrel openings 111 and 112.
Referring to
The casing string may include a number of tools, such as packers, which may be used to isolate sections of the well. As it is common for a well to include numerous production zones, particular production zones may be isolated by disposing one or more packers below and/or above the production zone. Along the casing string between the packers one or more valves may be disposed, thereby allowing fluid, such as a fracing fluid to be pumped downhole to fracture the formation.
In order to actuate a valve and allow fracing fluid to fracture formation, fluid is initially flowed (at 200) through the valve. In this embodiment, the valve has a housing having an opening, a mandrel having an opening and a passageway, a sliding sleeve disposed between the housing and the mandrel, and a ball seat disposed in the mandrel. To actuate the valve, a ball is dropped (at 205) from the surface and pumped downhole. Once in the valve, the ball seats (at 210) into the ball seat, thereby blocking the flow of fluid through the mandrel. Because the flow of fluid is blocked, a pressure differential is created above and below the seated ball. Pressure increases above the seated ball until a selected pressure is reached, at which point a rupture disk ruptures, and fluid flows through a passageway connecting the throughbore of the valve with a first chamber.
Fluid flows (at 215) through the passageway into the first chamber and into contact with the sliding sleeve. The sliding sleeve moves (at 220) axially downward between the housing and the mandrel into a second chamber. As the sliding sleeve moves (at 220) downward, fluid communication is allowed between the throughbore of the valve and the casing and/or formation of the well. More specifically, fluid exits (at 225) the valve through the openings in the housing and Mandrel.
In certain embodiments, the sliding sleeve may lock into an open position through engagement of ratcheting teeth of a lock ring of the sliding sleeve and corresponding ratcheting teeth of the mandrel. In alternative embodiments, sliding sleeve may not be locked into place. In such an embodiment, the fluid pressure may hold the sliding sleeve in an open position.
Referring to
Housing 305 has one or more openings 311 located at various locations around valve 300. In addition to openings 311 in housing 305, valve 300 also includes one or more corresponding mandrel openings 312. Mandrel 310 openings 312 correspond in location to housing 305 openings 311, and as such, the geometry and size of mandrel 310 openings 312 may vary as housing 305 openings 311 vary.
A sliding sleeve 315 is disposed between housing 305 and mandrel 310. In this embodiment, a first chamber 320, is formed between housing 305 and mandrel 310, and is located axially above sliding sleeve 315. Similarly, a second chamber 325 is formed between housing 305 and mandrel 310, and is located below sliding sleeve 315. First and second chambers 320 and 325 are at atmospheric pressure when sliding sleeve 315 is in a closed position. Because the pressure in first and second chambers 320 and 325 is balanced, i.e., both chambers are at atmospheric pressure, the sliding sleeve does not move axially within the chambers 320 and 325, and thus valve 300 remains in a closed position.
A passageway 330 is located axially above sliding sleeve 315 and fluidly connects the inner diameter of mandrel 310 to first chamber 320. Valve 300 also includes a ball seat 345 disposed in throughbore 340. Ball seat 345 is located above openings 311 and 312 and is positioned to prevent fluid communication between throughbore 340 and first chamber 320. Ball seat 345 is connected to mandrel 310 through one or more shear pins 365. Additionally, one or more seals 370 may be disposed between ball seat 345 and mandrel 310 above and below passageway 330, thereby effectively isolating passageway 330 from throughbore 340. Because passageway 330 is isolated from throughbore 340, balanced pressure in first and second chambers 320 and 325 may be maintained.
Referring now to
In order to actuate valve 300 into an open position, a ball 350 is dropped from the surface of the well. The ball 350 is pumped downhole until it contacts and seats against ball seat 345. As fluid continues to be pumped into throughbore 340, pressure increases until a selected pressure is reached that causes shear pins 360 to break. The breaking of shear pins 360 causes ball seat 345 to move axially within throughbore 340 into a final open position. As ball seat 345 moves, fluid flows through passageway 330 into first chamber 320. The fluid pressure in the tubing forces sliding sleeve 315 to traverse axially downward into second chamber 325. Sliding sleeve 315 may then be locked into place through engagement of corresponding teeth 360 on lock ring 355 and mandrel 305. The lock ring 355 may then permanently secure sliding sleeve 315 into an open position, thereby allowing full fluid flow through housing and mandrel openings 311 and 312.
In certain embodiments, a rupture disk (not shown) may be disposed in passageway 330. In such an embodiment, the rupture disk may serve as an additional check to prevent premature actuation of valve 300. Thus, even if ball seat 345 moved prematurely, valve 300 would not open until the selected increased pressure was reached.
Referring to
In order to actuate a valve and allowing fracing fluid to fracture formation, fluid is initially flowed 400 through the valve. In this embodiment, the valve has a housing having an opening, a mandrel having an opening and a passageway, a sliding sleeve disposed between the housing and the mandrel, and a ball seat disposed in the mandrel. To actuate the valve, a ball is dropped (at 405) from the surface and pumped downhole. Once in the valve, the ball seats (at 410) into the ball seat, thereby blocking the flow of fluid through the mandrel. Because the flow of fluid is blocked, a pressure is applied to the ball seat, breaking shear pins holding the ball seat in place, and causing the ball seat to move (at 415) axially downward.
Fluid flows (at 420) through the passageway into a first chamber and into contact with the sliding sleeve. The sliding sleeve moves (at 425) axially downward between the housing and the mandrel into a second chamber. As the sliding sleeve moves (at 425) downward, fluid communication is allowed between the throughbore of the valve and the casing and/or formation of the well.
Advantageously, embodiments of the present disclosure may provide for valves used in hydraulic fracturing operations that open fully, thereby allowing for more effective fracing operations. Also advantageously, embodiments of the present disclosure may provide valves with redundant systems to prevent premature actuation of the downhole valve.
While the present disclosure has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments may be devised which do not depart from the scope of the disclosure as described herein. Accordingly, the scope of the disclosure should be limited only by the attached claims.
The present application is a continuation in part of U.S. patent application Ser. No. 13/223,909, filed Sep. 1, 2011, the entire disclosure of which is incorporated by reference herein.
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Number | Date | Country | |
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20130056220 A1 | Mar 2013 | US |
Number | Date | Country | |
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Parent | 13223909 | Sep 2011 | US |
Child | 13312517 | US |