This application is the U.S. national phase, pursuant to 35 U.S.C. §371, of International Application No. PCT/GB2006/000669, published in English on Aug. 31, 2006 as International Publication No. WO 2006/090168 A1, which claims the benefit of British Application Ser. No. GB 0504055.5, filed Feb. 26, 2005. The content of each of the above-mentioned applications are incorporated by reference herein.
1. Field of the Invention
The present invention relates to valves typically used on downhole tools in oil and gas wells and in particular, though not exclusively, to a zonal control valve to regulate production flow rate from several hydrocarbon bearing zones within a well.
2. Description of Related Art
In the drilling of oil and gas wells, well bores are now typically drilled in a deviated path so that the well intersects as many hydrocarbon bearing zones over the greatest distances possible. By perforating the well casing or tubing at each zone or across a zone, the well can be produced at a number of locations simultaneously and thereby maximise production. However, this simultaneous production requires to be carefully controlled as production will flow from one zone to another zone rather than to surface, if the pressure between each zone varies.
Prior art flow control systems have been based on inserting production tubing into the well with packers between each of the producing zones. At each zone, a valve is located in the tubing, to allow production to flow from the zone into the tubing and up to surface. Typically only a single zone is produced at a time to prevent cross-talk. If more than one zone is produced at a time, the pressures between the zones must be balanced. This is achieved by locating a valve at each zone with each valve has a selected size of orifice or opening so that the flow rate through each valve is equalised into the tubing. A control line, typically hydraulic, is run to each valve and the valves are then opened as required.
There are a number of disadvantages of such control systems. In order to use a number of valves, the flow rate from each zone must be determined. This is not a simple task as flow rates from each zone can vary. The valves are then selected on the basis of the required flow rate in the tubing and these valves must be correctly positioned on the tubing in the well. Once positioned, these valves are either ‘on’ or ‘off’, so that no adjustment of the flow rate through the valve can be made when the valve is downhole. Any changes in the flow rate from a zone result in either the respective valve having to be closed which losses production from the zone, or the tubing must be removed so that the valve can be replaced and the tubing run back in the well. This causes downtime in production. Additionally a control line is required for each valve, with each control line having to be run to surface, operated and monitored individually.
U.S. Pat. No. 6,782,952 proposes a stepping valve which allows the valve to be incrementally opened or closed. This provides selective throttling of the flow downhole.
While this valve has this advantage, it also has a number of disadvantages. The valve is based on a hydraulically actuated sliding sleeve. An inherent problem in sliding sleeve valves is that these valves are long devices. This is because there must be sufficient length in the tool as the sleeve must be able to move longitudinally across a stroke distance between the open and closed positions of the valve. Additionally, this valve requires two control lines to operate. Thus in a well having a number of zones, valuable space is required to run two control lines to each valve at each zone.
It is an object of the present invention to provide a well tubing valve which provides production control over at least two zones from a single control line.
It is a further object of at least one aspect of the present invention to provide a well tubing valve which provides selective throttling over at least two zones.
Further aims and objects will become apparent from the following description.
According to a first aspect of the invention there is provided a well tubing valve comprising a substantially tubular body having first and second ends adapted for connection in a tubular string; a valve member having at least one aperture and being rotationally moveable relative to the body to align and misalign said aperture in the valve member with a port in the body to move the valve between an open position and a closed position, wherein the valve member is actuable to rotate relative to the body in a single direction.
By providing a valve member that rotates in only one direction, the valve can be actuated from a single control line in a single direction. That is, there is no requirement for a double-acting actuator, and no need for a reverse direction. In a hydraulic embodiment, this avoids the need for a return line.
Preferably, the valve member is a sleeve.
Preferably, the valve member includes a pair of apertures. More preferably, the apertures are radially oriented and diametrically opposed on the valve member.
Preferably, the body includes a pair of ports. The ports may be radially oriented and diametrically opposed on the body.
According to a second aspect of the present invention there is provided a well tubing valve, the valve comprising a substantially tubular body having first and second ends adapted for connection in a tubing string; first and second ports located through the body and spaced longitudinally apart; first and second valve members located in the body at the respective ports, each valve member being actuable to at least three operating positions to incrementally adjust flow through the respective port and the valve members being actuable from a common control line.
In this way a single pressure pulse from the surface can cause the valve members to move to one of the three operating positions. The positions may be open, closed or at an incremental value therebetween.
Preferably the valve members are sleeves including one or more apertures. The degree of overlap between the apertures and the respective ports determines the amount of fluid flow into the tubing.
More preferably the sleeves rotate when actuated. In this way the tool is inherently short as the sleeves do not require to slide. Further, by rotating the sleeves, there is no requirement for a double acting actuator as there is no need for a reverse direction.
Advantageously each sleeve includes a part spherical surface. This surface may locate on a complimentary surface of the body. This may be considered as a ball valve or ball choke. Advantageously, the part spherical surface locates against a metal seal ring, biased toward the sleeve. In this way, a metal to metal seal can be formed with constant axial loading in use.
Preferably, the first valve member has a different number of operational positions than the second valve member. These operational positions may be set by the number of degrees turned by the sleeve on each increment. Preferably the degree increment is a whole divisor of 360 degrees. In this way, each sleeve returns to the same operating position on a full rotation, but they will rotate at different rates. Advantageously the degree increment is selected for each sleeve such that operating positions will exist where both valve members are ‘open’, closed and throttled by different amounts.
Preferably the common control line is a hydraulic line which connects the two valve members to the surface of the well. The valves may then be operated by successive pressure pulses in a cyclic manner. It will be appreciated that any hydraulically operated actuating mechanism can be used to rotate each of the valve members.
The well tubing valve may further comprise one or more isolation packers. Most preferable a packer is located between each of the ports to isolate the ports from each other.
According to a third aspect of the present invention there is provided a method of controlling fluid flow from hydrocarbon bearing zones in a well bore, comprising the steps:
Preferably actuation of the valve members causes them to rotate within the well tubing valve.
More preferably the method may be cyclic so that the combination of valve member positions is repeatable over a predetermined number of control signals.
The control signal may be a pressure pulse. In this way, the control line may be a hydraulic fluid line. Alternatively the control signal may be an electrical signal passed down a transmission line or may be an acoustic signal passed down the production tubing or well fluid.
While the terms ‘up’, ‘down’, ‘top’ and ‘bottom’ are used within the specification, they should be considered as no more than relative, as the valve of the present invention may be used in any orientation to suit the deviation of the well.
According to a fourth aspect of the invention there is provided a well tubing valve comprising a substantially tubular body having first and second ends adapted for connection in a tubular string; an valve member having at least one aperture and being rotationally moveable relative to the body to align and misalign said aperture in the valve member with a port in the body to move the valve between an open position and a closed position, wherein the valve member is actuable to move from an open position to a closed position, and back to an open position by rotation in a single direction.
Embodiments of the invention will now be described by way of example only with reference to the accompanying figures in which:
a) and (b) are expanded views of a valve member within the well tubing valve of
a) and (b) are sectional views through the valve members of the well tubing valve of
a and 8b show the operation of the sealing arrangement of the embodiment of
Referring initially to
At an end 28, 30 of each of the sleeves 20, 22 respectively, there is located a ball or spherical section 32, 34. Each ball 32, 34 includes an axial bore to maintain fluid flow through the sleeve 20, 22. Additionally each ball 32, 34 has oppositely arranged apertures 58a, 58b and 60a, 60b which are perpendicular to the axis through the valve 10. These apertures 58, 60 provide a passageway from the through bores 24, 26 to the body 12.
On the body 12 at the location of the balls 32, 34 are ports 52a, 52b, 54a, 54b arranged through the wall of the body 12. The sets of ports 52, 54 are longitudinally separated on the valve 10. Each set of ports 52, 54 provides two oppositely arranged passageways between the outside 56 of the valve 10 and the bore 14. There may be any number of ports, one or more at each of the locations of the sleeves 20, 22. These ports are best seen with the aid of
Reference is now made to
The balls 32, 34 and the carbide seal rings 86 all have complimentary spherical surfaces so that the balls can rotate on the seals without the seal being broken.
Located between each sleeve 20, 22 and the body 12 is an indexing mechanism 46, 48. Such mechanisms are known to the skilled person and operate by the injection of fluid from a control line 50. Control line 50 is a hydraulic fluid line which runs from the surface to the valve 10 and commonly transmits a pressure pulse to each of the indexing mechanisms 46, 48 at the same time with a uniform pressure. Each indexing mechanism 46, 48 will cause the respective sleeve 20, 22 to rotate within the body 12. This will happen uniformly at the same time. The indexing mechanisms 46, 48 will rotate the sleeves 20, 22 in incremental steps pre-set by their design.
In the embodiment shown in
In use, the valve 10 will be introduced into a well bore which, as illustrated in
When run into the well, the valve 10 will be set in an open or closed configuration. In the embodiment shown the valve 10 is located in the well in open configuration. This is as illustrated in
Once the valve 10 is in place and the packers 72, 74 are set, the operator can then select the required degree of throttling or flow-through in each of the sleeves 20, 22 for each respective zone 68a, 68b by sending sequential pulses down the control line 50. As shown in
At the same time, this same pressure pulse will have caused the indexing mechanism 46 to rotate the sleeve 20 through 20° forming a 63% open position. Here the apertures 58 are again misaligned with the ports 52, but to not the same extent as for the sleeve 22, and thus a higher flow rate is achieved through the ball valve 32 than that of the ball valve 34.
A further pressure pulse causes the sleeves 20, 22 to rotate once more. Now the sleeve 22 is rotated to such a position that although the aperture 60 and ports 54 are misaligned there is no clear passage and this ball valve 34 is now closed. By virtue of the shorter rotation of the sleeve 20, the ball valve 32 is still open but in a substantially throttled position. This is referred to as the 27% overlap position by virtue of the orientation of the sleeve 20 and the body 12. In this location a smaller cross-sectional area is present through which the production fluid can flow.
A yet further pulse provides the fourth increment so both the valves 32, 24 are now closed due to misalignment of the apertures 58, 60 to the ports 52, 54. A further increment, increment 5, has the valves still in the closed position.
It can be seen from
The foregoing description relates to a valve comprising a pair of longitudinally displaced valve members and its use in incrementally controlling production flow. However, the invention in another of its aspects relates to a valve having a single valve member, described with reference to
In this embodiment, the valve is provided with two apertures 158a, 158b and two corresponding ports 152a, 152b, although any number of apertures and ports may be provided in alternative embodiments.
The sealing arrangement 200 is similar to that shown in
The seat 186 is has on its lower face a circular ring (not shown) which provides a “seal point” on the ball section 132. The location of the seal point is important as it defines the manner in which the sealing arrangement provides a seal under opposing differential pressures.
a and 8b show how the sealing arrangement operates in opposing different pressure regimes. In
It is important to note that the wave spring 180 functions to ensure that the seat 186 is in contact with the ball section 132, to allow the hydraulic pressure to take over and provide the seal. The wave spring 180 has a negligible contribution to the sealing load, and is used to take account of any tolerance variations in the assembly. The wave spring does not provide a large force on the seat and thus avoids high friction loads when rotating the ball section.
In this embodiment, the torque key 400 “floats” in the slot 310, and is biased downwards in the slot 310 by means of a leaf spring. The slot 310 is provided with a changing depth profile to prevent unwanted return of the torque key during actuation. The slot 310 is provided with portions of first depth 305, ramp portions 306, and raised portions 307. The torque key, travelling in the direction of the arrow A, travels up the ramped portion 306 and is then biased downwards. Shoulder 308 prevents return of the torque key into the longitudinal slot, and causes it to travel in the direction of the arrow B, ensuring one way motion. Similar depth profiles are provided in the helical portion of the slot 310.
The torque key is machined to provide a face 402 corresponding to the helical path of the slot. This provides a greater surface area of contact between the key and the slot.
In this embodiment, four such torque keys are used to further increase the contact area and reduce stress during the actuation of the indexing mechanism. This embodiment provides rotation increments of 90 degrees, and thus the valve provides two open positions and two closed positions. It will be appreciated that the indexing mechanism and sealing arrangement of this embodiment could be used with the embodiment of
The principle advantage of at least one embodiment of the present invention is that it provides a well tubing valve which regulates production and flow rate from several hydrocarbon bearing zones within a well via a single control line.
A further advantage of the present invention is that it provides a dual valve arrangement, operational via rotation of sleeves within the valves so that each valve can be parked in a desired position by simply applying a set number of pressure cycles. Unlike other rotating sleeve arrangements the proposed sealing method provides a spherical seal face i.e. not cylindrical giving normal metal to metal sealing qualities. Further due to the rotating nature of the valve there is no requirement for a double-acting actuator as there is no need for the sleeve to travel in the reverse direction. Yet further as the sleeves rotate there is no loading of axial mounted seals and thus advantageously the valve will be short.
A further advantage to the valve of the present invention is that as the incremental movement of each of the valve members is via a built-in mechanical function, there is no requirement for fluid pulsed accessories to be located individually to each of the ball valves.
As the two ball valves can be manipulated from one control line it will be appreciated that the valve is easily scalable, for example, to three lines controlling six ball valves without complex downhole targeting devices giving a cost-effective way to control flow from individual zones.
A still further advantage of the valve of the present invention is that it provides operators undertaking multi-zone production with the ability to co-mingle or isolate different zones over the life of the well as the valve can remain in the well indefinitely.
It will be appreciated that those skilled in the art that modifications may be made to the invention herein described without departing from the scope thereof. For example the control line may provide an electronic or a radio frequency signal which duly operates the indexing mechanisms. It will also be appreciated that various indexing mechanisms can be incorporated. Yet further the number of apertures within the sleeve and/or the number of ports within the body can be varied as can their relative dimensions to provide the desired flow through cross-sectional areas between the outside of the valve and the bore to surface. It will also be appreciated that the technique of a single control line in combination with ball valves operated through differing incremental steps can be extended from two ball valves to three or more to provide a greater combination of versatility to the valve.
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0504055.5 | Feb 2005 | GB | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/GB2006/000669 | 2/27/2006 | WO | 00 | 9/26/2008 |
Publishing Document | Publishing Date | Country | Kind |
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WO2006/090168 | 8/31/2006 | WO | A |
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