Toe Valve
20170268313 ยท 2017-09-21
Assignee
Inventors
Cpc classification
E21B34/063
FIXED CONSTRUCTIONS
E21B34/102
FIXED CONSTRUCTIONS
E21B34/14
FIXED CONSTRUCTIONS
International classification
E21B34/10
FIXED CONSTRUCTIONS
E21B34/14
FIXED CONSTRUCTIONS
Abstract
A tool includes a housing between an outer wall and an inner wall that surrounds a longitudinal tool bore. First and second axially spaced ports connect the housing to the tool bore. An unlocking piston seals across the first port and an arming sleeve seats across the second port. A locking ring is held in place by a retaining ring and prevents the arming sleeve from sliding towards the unlocking piston to open the second port. An unlocking tool bore pressure at the first port moves the unlocking piston axially to displace the retaining ring and unlock the tool. A lower, arming tool bore pressure moves the arming sleeve in the unlocked tool to open the second port and arms the tool. An actuating tool bore pressure, which is less that the unlocking pressure, actuates a valve piston via the open second port.
Claims
1. (canceled)
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5. (canceled)
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19. (canceled)
20. (canceled)
21. A downhole tool adapted for assembly into a tubular string for a well, the tool comprising: (a) a main chamber between an outer wall and an inner wall, the inner wall surrounding an axial bore; (b) a first port and a second port in the inner wall, the first and second ports being spaced axially relative to each other; (c) an unlocking piston slidably mounted in the main chamber; (d) an arming sleeve slidably mounted in the main chamber, the arming sleeve being releasably locked in a position covering the second port; (e) wherein the unlocking piston is adapted for actuation by a first pressure at the first port to unlock the arming sleeve; (f) wherein the arming sleeve, after being unlocked by the unlocking piston, is adapted for actuation in response to a second pressure at the first port to uncover the second port; and (g) wherein the second pressure is lower than the first pressure.
22. The downhole tool of claim 21 further comprising: (a) a lock ring releasably affixed at an axial position in the main chamber between the unlocking piston and the arming sleeve, the releasable lock ring retaining the arming sleeve in the position covering the second port; and (b) a displaceable capture ring between the lock ring and the outer wall, the capture ring retaining the lock ring in the axial position.
23. The downhole tool of claim 21 wherein: (a) the unlocking piston is slidably mounted on and around the inner wall and has an inner actuation surface providing a hydraulic chamber between the unlocking piston and the inner wall; (b) wherein the first port is adapted to provide fluid communication between axial bore and the hydraulic chamber.
24. The downhole tool of claim 21 wherein the arming sleeve is slidably mounted on and around the inner wall and seals across the second port.
25. The downhole tool of claim 21 wherein: (a) the outer wall includes a valve port; and (b) the tool comprises a valve piston slidably mounted on and within the outer wall, the valve piston having an initial position covering the valve port; (c) wherein the valve piston is adapted for actuation by a pressure at the uncovered second port to uncover the valve port; (d) wherein the pressure at the uncovered second port is less than the first pressure applied at the first port to unlock the arming sleeve.
26. The downhole tool of claim 25 further comprising a second chamber between the outer wall and the valve piston, said second chamber having a pressure lower than the pressure at the second port actuating the valve piston.
27. A toe valve adapted for assembly into a tubular string for a well, the toe valve comprising: (a) an outer tubular wall; (b) an inner tubular wall concentrically disposed within the outer wall and surrounding an axial bore, the inner wall having a first port and an axially spaced second port; (c) a first chamber between the outer wall and the inner wall; (d) an unlocking piston slidably mounted in the first chamber and having an inner actuation surface providing a hydraulic chamber between the unlocking piston and the inner wall; (e) wherein the first port has a rupture disc forming a breakable seal between the axial bore and the hydraulic chamber; (f) an arming sleeve slidably mounted in the first chamber, the arming sleeve covering a second port which is spaced axially from the first port; (g) a spring loaded against the arming sleeve in an axial direction towards the unlocking piston; (h) a lock ring releasably affixed at an axial position in the first chamber between the unlocking piston and the arming sleeve; and (i) a capture ring disposed between the lock ring and the outer wall.
28. The toe valve of claim 27 further comprising a second piston hydraulically coupled to the first chamber and actuatable in response to a hydraulic pressure in the first chamber.
29. The toe valve of claim 28 further comprising: (a) a valve port in the outer wall; and (b) wherein the second piston is a valve piston adapted for actuation from a position covering the valve port to a position where the valve port is uncovered.
30. The toe valve of claim 29 wherein: (a) the valve piston forms a second chamber between the valve piston and the outer wall; and (b) wherein the valve piston is adapted to uncover the valve port in response to a hydraulic pressure in the first chamber greater than a pressure in the second chamber.
31. The toe valve of claim 27 wherein the unlocking piston is moveable from a first position to a second position to displace the capture ring into a recess in the arming sleeve.
32. The toe valve of claim 31 wherein the unlocking piston is moveable from the first position to the second position by applying a first fluid pressure greater than a selectable unlocking fluid pressure at the first port.
33. The toe valve of claim 32 wherein the rupture disk is adapted to rupture at the unlocking fluid pressure.
34. The toe valve of claim 27 wherein the arming sleeve is moveable to displace the lock ring and uncover the second port.
35. The toe valve of claim 34 wherein the arming sleeve is moveable in response to reducing fluid pressure applied at the first port from the unlocking fluid pressure.
36. A method of deploying a downhole tool, the tool having a substantially tubular outer tool wall, a substantially annular housing within the tool wall and a concentric axial tool bore extending through the housing, the tool bore containing a fluid at a fluid pressure, the method comprising: (a) increasing the fluid pressure in the tool bore to at least a first pressure to unlock the tool; (b) reducing the fluid pressure in the tool bore to a second pressure to arm the tool; and (c) increasing the fluid pressure in the tool bore to a third pressure to actuate the tool, wherein the third pressure is less than the first pressure.
37. The method of claim 36 wherein unlocking the tool comprises moving an unlocking piston in the housing from a first position to a second position axially spaced from the first position to unlock an arming sleeve, the unlocking piston having an actuating surface in fluid communication with the tool bore.
38. The method of claim 36 wherein arming the tool comprises moving an arming sleeve to uncover a port in the housing and allow fluid communication between the housing and the axial bore.
39. The method of claim 36 wherein actuating the tool comprises applying the third fluid pressure through an open housing port.
40. The method of claim 39 wherein: (a) the tool includes a valve port forming an opening in the outer tool wall and a valve piston coupled to and in fluid communication with the housing, and (b) actuating further includes axially displacing the valve piston in response to the third fluid pressure being applied through the open housing port.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0025]
[0026]
[0027]
[0028]
[0029]
[0030]
[0031]
[0032]
[0033]
[0034]
[0035]
[0036]
DETAILED DESCRIPTION OF THE INVENTION
[0037] As shown in
[0038] The tubular string shown in
[0039] As shown in
[0040] It will be understood that the outer wall 21 may not be perfectly circular in cross section and may be polygonal, elliptical or include some planar surfaces, protrusions or recesses to suit tool design or downhole requirements. However, the toe valve is sufficiently tubular or cylindrical to fit within well bore 2.
[0041] Toe valve 5 also includes an inner wall 50 which can be an extension of top sub 20. Inner wall 50 is spaced radially inwards from outer wall 21 and is generally concentric with the outer wall 21. The housing of the toe valve 5 is formed in the annular space between the outer wall 21 and the inner wall 50. Inner wall 50 surrounds tool bore 55. Top sub 20 can be attached to outer wall 21 at its up-hole end via a connection sealed by upper housing seal 47a. At the downhole end of the housing, annular nut 29 extends into annular space between outer wall 21 and inner wall 50, and can couple to the inner wall 50 via a nut seal 52 to seal between the housing and the tool bore 55. The lower end of outer wall 21 can be connected to bottom sub 22 with lower housing seal 47b sealing tool bore 55 from the annular volume of well bore 2.
[0042] The housing can include a generally annular unlocking piston 23 and a cover ring 26 axially spaced from unlocking piston 23. Both unlocking piston 23 and cover ring 26 can be mounted around and coupled to slide axially along the inner wall 50. Cover ring 26 can have an annular sleeve shape and can fully or partially surround a length of inner wall 50. Cover ring 26 may also be referred to as an arming sleeve. However, in some embodiments, unlocking piston 23 and cover ring 26 may not be perfectly circular in cross section and may be polygonal, elliptical or include some planar surfaces, protrusions or recesses. Also, in some embodiments, unlocking piston 23 may not completely surround inner wall 50. Nonetheless, unlocking piston 23 and cover ring 26 should have inner surfaces that generally conform to the outer surface of inner wall 50 so as to slide axially along inner wall 50 and provide a good seal across unlocking piston port 39 and housing port 38.
[0043] Lock ring 25 can be a split ring made from a hoop of material split radially at a point on the hoop. Preferably the lock ring 25 can be made of a metal, such as spring steel or other substance that is resiliently elastic, so that although initially received in a groove 37 in an outer surface of inner wall 50, lock ring 25 can be readily removed from the groove 37 if there is no radial restraint, and yet resist a moderate axial force while received in groove 37. The hoop of lock ring 25 can be generally rectangular with a bevel along an inner edge facing the inner wall 50. The beveled inner edge of lock ring 25 can be complementary to the shape of groove 37 which also has a beveled corner in inner wall 50 and so facilitates displacing lock ring 25 from groove 37 by application of the moderate axial force exerted by the cover ring 26, unless lock ring 25 is retained radially within groove 37.
[0044] Capture ring 24, disposed between tock ring 25 and an inner surface of outer wall 21, has a radial. thickness corresponding to the radial. gap between the lock ring 25, received in groove 37, and the inner surface of outer wall 21, thereby retaining lock ring 25 in groove 37 and preventing its axial movement. Groove 37 is located between unlocking piston 23 and cover ring 26. Spring 30 is compressed between anti-rotation ring 28 and nut 29 on one side and cover ring 26 on the other. Spring 30 is loaded against cover ring 26, pushing cover ring 26 against lock ring 25 in the direction of unlocking piston 23. Rotation ring 28 facilitates assembly and can include a hole through which a pin or locking screw can be inserted to extend into a recess in the inner wall 50 to hold spring 30 in place as outer wall 21 and nut 29 are being attached. Stroke ring 27 can be received in a groove to restrict the axial motion of the cover ring 26 in the direction of the spring 30. It will be understood that unlocking piston 23, capture ring 24 and lock ring 25 can include shear pins and other temporary fasteners 36 to facilitate assembly of the toe valve 5.
[0045] Cover ring 26 includes a recess to receive capture ring 24. Unlocking piston 23 includes a member that extends axially from the end of unlocking piston 23 closest to capture ring 24. In an axial motion of unlocking piston 23 towards cover ring 26, the member can displace retaining capture ring 24 axially from the radial gap between the lock ring 25 and the outer wall 21 into the recess of the cover ring 26. Unlocking piston 23 sits over unlocking port 39 which is an opening extending through inner wall 50 to the tool bore 55. Unlocking port 39 can include a rupture disk 34 sealed across the opening that can be selected to break at a desired fluid pressure differential. Rupture disk 34 prevents the unlocking piston 23 from actuating until a desired pressure is reached in the tool bore 55, thus preventing toe valve 5 from being unlocked prematurely. Unlocking piston upper seal 33 and unlocking piston tower seal 35 straddle unlocking port 39 and form a fluid-tight seat between the inner wall 50 and the unlocking piston 23 preventing fluids in the tool bore 55 from entering the remaining housing volume once rupture disk 34 is broken.
[0046] Though not immediately apparent in the figures because of its relatively small dimensions, unlocking piston 23 has a surface facing the inner wall 50 and unlocking port 39 therein which provides an actuating surface for unlocking piston 23. The actuating surface can be tapered, staggered or otherwise shaped so that the inside diameter of the unlocking piston 23 at or near unlocking piston lower seat 35 is slightly smaller than the diameter of the unlocking piston 23 at or near unlocking piston upper seat 33. With this diameter differential, fluid pressure applied to the actuating surface via unlocking port 39 can push unlocking piston 23 towards capture ring 24. Unlocking piston lower seal 35 and upper seal 33 can be appropriately sized and configured to maintain a fluid tight seat between inner wall 50 and actuating surface of the unlocking piston 23.
[0047] When held back by lock ring 25 in groove 37, cover ring 26 sits over housing port 38. Housing port 38 is an opening in the inner wall 50 that extends from the housing into well bore 55. Housing port seals 41 straddle housing port 38 to form a fluid-tight seal between cover ring 26 and inner wall 50 when the cover ring 26 sits over and, thereby, closes housing port 38. Though not immediately apparent in the figures because of their relative small dimensions, it will be appreciated that tolerances and gaps exist between outer wall 21 on the one hand, and unlocking piston 23, capture ring 24, cover ring 26 and anti-rotation ring 28 on the other. These gaps and tolerances permit fluid communication between portions of the housing not sealed off by unlocking upper and lower piston seals 33, 35, housing port seals 41, nut seal 52 and upper housing eat 47a to form a main chamber 40. Thus, main chamber 40 can be at a substantially lower pressure than tool bore 55 when housing port 38 is closed.
[0048] It will be appreciated that the actuating surface on unlocking piston 23 defines a relatively small, annular hydraulic chamber between unlocking piston 23 and inner wall 50 which is isolated from the rest of the housing volume, i.e., from main chamber 40, by unlocking piston upper seal 33 and unlocking piston lower seal 35. With housing port 38 closed and sufficient pressure applied at unlocking port 39 to break rupture disk 34, fluid will enter the hydraulic chamber and urge unlocking piston downward against the substantially lower pressure in main chamber 40. As unlocking piston 23 slides axially towards and impacts capture ring 24, capture ring 24 will be displaced into the recess in cover ring 26, thus unlocking toe valve 5 and permitting actuation of the tool by subsequently applying a series of lower fluid pressures in tool bore 55. When the pressure applied at unlocking port 34 falls sufficiently after toe valve 5 has been unlocked, the cover ring 26, impelled by spring 30, displaces locking ring 25 axially out of groove 37. The continued sliding motion of cover ring 26 pushes unlocking piston 23 backwards and opens housing port 38 in the process. Toe valve 5 is now armed by the motion of cover 26, allowing fluid pressure in the tool bore to be applied to the main chamber and actuate the toe valve 5 as fluid pressure in the tool bore 55 is increased. It will be understood that the above-described mechanism for unlocking, arming and actuating a downhole tool is not limited to toe valves 5. The mechanism can be used to deploy a wide range of tools by similarly manipulating tool bore fluid pressure.
[0049] As best seen in
[0050] Valve piston 31 is coupled to slide axially along the tool bore 55. In an upper position, valve piston 31 couples with an annular flange on nut 29 that extends axially in a downhole direction. With valve piston 31 in this position, upper and tower valve seals 46a, 46b straddle valve port 32 closing the port and keeping fluids in tool bore 55 separated from the annular volume of well bore 2. Though not immediately apparent in the figures because of the relatively small dimensions, it will be appreciated that nut 29 can include gaps or tolerances between its peripheral surface and the outer wall 21 to allow fluid from main chamber 40 to flow into and communicate with the high pressure chamber 54 immediately adjacent the outer annular surface of the valve piston 31 between the upper piston seat 48a and the upper valve seal 46a. The outer annular surface of the valve piston 31 between the upper piston seal 48a and the upper valve seal 46a forms an actuating surface on valve piston 31, so that pressure in the high pressure chamber 54 will apply an axial downward force on valve piston 31. Thus, valve piston 31 is also hydraulically coupled to main chamber 40 via the gaps or tolerances around nut 29. Upper piston seal 48a prevents fluid in the tool bore 55 communicating with fluid in the high pressure chamber 54, while upper valve seal 46a prevents fluid in the high pressure chamber 54 from communicating with the annular volume of well bore 2.
[0051] When toe valve 5 is armed, the pressure in main chamber 40 equalizes with the pressure in the tool bore 55. To open the toe valve 5, pressure in the tool bore is increased causing fluid to flow through now open housing port 38 into main chamber 40, past nut 29, and into high pressure chamber 54. Consequently, pressure in the high pressure chamber 54 will increase until the difference between the pressure in the high pressure chamber 54 and the pressure in the low pressure chamber 45 produces a net force on the valve piston 31 sufficient to shear out shear screws 58 and displace valve piston 31 axially away from nut 29. As valve piston 31 is displaced away from nut 29, the fluid-tight seat between valve piston 31 and nut 29 is broken, the pressure from fluids in the tool bore 55 continue to apply an axial force on the actuating surface of valve piston 31 that exceeds the opposite force produced by the tower pressure in the low pressure chamber 45. Thus, valve piston 31 continues to move axially away from nut 29 at least until upper valve seal 46a and lower valve seat 46b no longer straddle and seal valve port 32, thereby opening valve port 32.
[0052]
[0053] As shown in
[0054] When the casing pressure test is complete, the pumps can be stopped and pressure in the tubular string bled off to 0 psi at the surface, as shown in
[0055] With housing port 38 open, main chamber 40 of the toe valve housing is now exposed to pressure exerted by fluid in the tubular string. The toe valve 5 is now armed so that subsequent increases in tool bore pressure can actuate toe valve 5. However, it will be understood that this unlocking, arming and actuating mechanism is not limited to toe valves. A wide variety of tools can be actuated by appropriately coupling an appropriate piston to the housing so that the piston's actuating surface is in fluid communication with main chamber 40.
[0056] It will also be understood that although the pressure in main chamber 40 is exerted by fluid through housing port 38, the applied pressure corresponds to different pressures at different elevations in the tubular string bore, such as at the unlocking port 39 and at the surface of the well 1. It will further be understood that such differences in corresponding pressure are generally caused by the head pressure due to the weight of the intervening column of fluid between the different elevational points.
[0057] In the instant toe valve 5, main chamber 40 is in fluid communication with high pressure chamber 54. As fluid from tool bore 55 applies pressure to main chamber 40 and, accordingly, to high pressure chamber 54, the pressure produces a resulting force on the actuating surface of valve piston 31. The pressure in low pressure chamber 45 is lower than the corresponding pressure in the tool bore, and preferably at or near atmospheric pressure. Accordingly, as pressure in tool bore 55 increases (corresponding to a third pressure measured at the unlocking port 39), the corresponding pressure in main chamber 40 and high pressure chamber 54 also increases. The resulting force on valve piston 31 eventually shears shear screws 58 and forces valve piston 31 to slide axially and decouple from nut 29. (FIG. 11 shows the exemplary surface pressure increasing to 8,000 psi.) But even when valve piston 31 is decoupled, tool bore pressure acting directly on the actuating surface of valve piston 31 continues to push valve piston 31 until valve port 32 is uncovered. The toe valve 5, with valve piston 31 actuated and valve port 32 opened is best seen in
[0058] Thus, although there have been described particular embodiments of the present invention of a new and useful it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims.