Completion system apparatus

Abstract

A completion system apparatus having a body comprising a throughbore and lateral flow ports for providing access through a wall of the body and a valve arrangement including a first, uphole, valve assembly and a second, downhole, valve assembly. The valve arrangement is configurable between a first, open, configuration in which passage of fluid through the axial throughbore is permitted and a second, activated, configuration, the valve arrangement in the second, activated, configuration preventing passage of fluid in the first, downhole, direction so as to direct the fluid through the lateral flow ports while permitting the passage of fluid through the apparatus in a second, uphole, direction so as to permit return passage of the fluid through the apparatus. A bypass arrangement is configured to permit fluid travelling in the second direction to bypass the first valve assembly.

Claims

1. A completion system apparatus, comprising: a body configured for location in a borehole, the body comprising an axial flow passage therethrough and a lateral flow passage for providing access through a wall of the body; and a valve arrangement including a first valve assembly comprising a first valve member and a second valve member, the second valve member coupled to and/or forming part of the first valve member, the second valve member taking the form of a flapper, wherein the valve arrangement is configurable between a first, open, configuration in which passage of fluid through the axial flow passage is permitted and a second, activated, configuration, wherein, when the valve arrangement is in the first configuration, a throughbore of the first valve member is aligned or substantially aligned with the axial flow passage of the body, and wherein, when the valve arrangement is in the second configuration, the throughbore of the first valve member is misaligned with the axial flow passage of the body, the valve arrangement in the second, activated, configuration preventing passage of fluid through the axial flow passage in a first, downhole, direction so as to direct the fluid through the lateral flow passage while permitting the passage of fluid through the apparatus in a second, uphole, direction so as to permit return passage of the fluid through the apparatus.

2. The apparatus of claim 1, wherein the first valve assembly comprises a valve actuator arrangement.

3. The apparatus of claim 1, wherein the valve actuator arrangement is operable to move or rotate, the first valve member of the first valve assembly to reconfigure the valve arrangement from the first configuration to the second configuration.

4. The apparatus of claim 1, wherein the valve arrangement further comprises a second valve assembly.

5. The apparatus of claim 4, wherein the second valve assembly comprises a third valve member.

6. The apparatus of claim 5, wherein: the second valve assembly is configured such that a throughbore of the valve member of the second valve assembly is aligned or substantially aligned with the axial flow passage of the body when the valve arrangement defines the first configuration; and the second valve assembly is configured such that the throughbore of the valve member of the second valve assembly and the axial flow passage of the body are misaligned when the valve arrangement defines the second configuration.

7. The apparatus of claim 4, wherein the second valve assembly comprises a valve actuator arrangement.

8. The apparatus of claim 7, wherein the valve actuator arrangement of the second valve assembly is operable to move or rotate, the third valve member of the second valve assembly to reconfigure the valve arrangement from the first configuration to the second configuration.

9. The apparatus of claim 4, wherein the second valve assembly comprises a fourth valve member.

10. The apparatus of claim 9, wherein the fourth valve member comprises or takes the form of another flapper.

11. The apparatus of claim 1, comprising a bypass arrangement configured to permit fluid travelling in the second direction to bypass the first valve assembly.

12. The apparatus of claim 11, wherein the bypass arrangement comprises at least one of: a bypass conduit; and a bypass valve configurable between a first, closed, configuration, in which lateral passage of fluid is prevented or restricted and a second, open, configuration, in which lateral passage of fluid is permitted.

13. A completion system comprising the apparatus of claim 1.

14. The completion system of claim 13, comprising one or more screens.

15. A method comprising: activating a valve arrangement of an apparatus according to claim 1 from the first, open, configuration in which passage of fluid through the axial flow passage of the body of the apparatus is permitted to the second, activated, configuration, the valve arrangement in the second, activated, configuration preventing passage of fluid through the axial flow passage in the first direction so as to direct the fluid through the lateral flow passage of the body of the apparatus while permitting the passage of fluid through the apparatus in the second direction so as to permit return passage of the fluid through the apparatus.

16. The method of claim 15, comprising at least one of: running a completion system comprising the apparatus of claim 1 into a borehole; and directing a fluid through the apparatus.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows a longitudinal section view of a first, upper, portion of a completion system apparatus;

(2) FIG. 2 shows a longitudinal section view of a second, middle, portion of the completion system apparatus shown in FIG. 1;

(3) FIG. 3 shows a longitudinal section view of a third, lower, portion of the completion system apparatus shown in FIG. 1;

(4) FIG. 4 shows an enlarged view of the valve member of the first valve assembly of the completion system apparatus shown in FIGS. 1 to 3;

(5) FIG. 5 shows an enlarged plan view of the valve member of the first valve assembly completion system apparatus shown in FIGS. 1 to 3;

(6) FIG. 6 shows an enlarged view of the valve member of the second valve assembly of the completion system apparatus shown in FIGS. 1 to 3;

(7) FIG. 7 shows an enlarged plan view of the valve member of the second valve assembly completion system apparatus shown in FIGS. 1 to 3;

(8) FIG. 8 shows part of a completion system including the completion system shown in FIGS. 1 to 3;

(9) FIG. 9 shows an enlarged view of a first, upper part of the completion system shown in FIG. 8; and

(10) FIG. 10 shows an enlarged view of a second, lower, part of the completion system shown in FIG. 8.

DETAILED DESCRIPTION

(11) FIGS. 1 to 3 of the accompanying drawings together show a completion system apparatus 10 for location in a borehole B, FIG. 1 showing a first, upper, portion of the completion system apparatus 10, FIG. 2 showing a second, middle, portion of the completion system apparatus 10 and FIG. 3 showing a third, lower, portion of the completion system apparatus 10.

(12) As shown, the apparatus 10 has a body 12 comprising an axial flow passage in the form of axial throughbore 14 and a lateral flow passage in the form of lateral flow ports 16 (two flow ports are shown in the FIG. 2) for providing access through a wall 18 of the body 12.

(13) The apparatus comprises a valve arrangement 20, the valve arrangement 20 including a first, uphole, valve assembly 22 (shown in FIG. 2) and a second, downhole, valve assembly 24 (shown in FIG. 3).

(14) The valve arrangement 20 is configurable between a first, open, configuration in which passage of fluid through the axial throughbore 14 is permitted and a second, activated, configuration, the valve arrangement 20 in the second, activated, configuration preventing passage of fluid in a first, downhole, direction so as to direct the fluid through the lateral flow ports 16 while permitting the passage of fluid through the apparatus 10 in a second, uphole, direction so as to permit return passage of the fluid through the apparatus 10.

(15) In use, the apparatus 10 is run into the borehole B in the first configuration such that fluid may be circulated through the apparatus 10, the valve arrangement 20 being reconfigured to the second, activated, configuration, on reaching the desired downhole location (as shown in FIGS. 1 to 3, and FIGS. 5 to 8 of the accompanying drawings).

(16) Beneficially, embodiments of the apparatus 10 obviate the need for a crossover tool and/or wash pipe string which in conventional gravel pack operations are required to provide separate inflow and return flow paths for the gravel slurry and returning carrier fluid during the gravel pack operation. Since there is no requirement to run the crossover tool and/or wash pipe string into the completion string, the gravel pack operation can be carried out in a single trip. Moreover, while conventional systems and techniques require the completion to be run with a separate lower completion (located across the production or injection zone) and upper completion (to surface) in order to facilitate gravel packing operations, embodiments of the apparatus additionally permit the operator to run the whole completion system in a single trip, improving reliability and/or significantly reducing operational complexity, time and cost for the operator.

(17) As shown in FIG. 2, the first valve assembly 22 comprises a valve member 26 having a throughbore 28. In the illustrated apparatus 10, the valve member 26 takes the form of a ball.

(18) In the first configuration, the valve member 26 is arranged such that the throughbore 28 is aligned or substantially aligned with the axial throughbore 14 of the body 12, thereby permitting passage of fluid through the apparatus 10.

(19) In the second configuration, the valve member 26 is arranged such that the throughbore 28 and the axial throughbore 14 of the body 12 are misaligned, thereby closing the first valve assembly 22 to passage of the fluid in the first, downhole, direction.

(20) The first valve assembly 22 further comprises a valve actuator arrangement 30 including a sleeve 32 and a piston 34, the valve actuator arrangement 30 operable so that axial movement of the sleeve 32 rotates the valve member 26.

(21) A biasing member in the form of spring 36 is provided, the spring 36 configured to act on the sleeve 32 to normally maintain the valve member 26 in the second configuration.

(22) In the illustrated apparatus 10, the valve actuator arrangement 30 is hydraulically actuable, the piston 34 coupled to the sleeve 32 such that movement of the piston 34 moves the sleeve 32 axially relative to the body 12.

(23) As can be seen from FIG. 2, the sleeve 32 is configurable to move relative to the body 12 to a position which obturates the lateral flow ports 16. In use, following completion of the borehole operation, e.g. borehole packing operation, the sleeve 32 may be moved relative to the body 12 to obturate the lateral flow ports 16.

(24) As shown in FIG. 3, the second valve assembly 24 also comprises a valve member 38 having a throughbore 40. In the illustrated apparatus 10, the valve member 38 takes the form of a ball.

(25) In the first configuration, the valve member 38 is arranged such that the throughbore 40 is aligned or substantially aligned with the axial throughbore 14 of the body 12, thereby permitting passage of fluid through the apparatus 10.

(26) In the second configuration, the valve member 38 is arranged such that the throughbore 40 and the axial throughbore 14 of the body 12 are misaligned, thereby closing the second valve assembly 24 to passage of the fluid in the first, downhole, direction.

(27) The second valve assembly 24 further comprises a valve actuator arrangement 42 including a sleeve 44 and a piston 46, the valve actuator arrangement 42 operable so that axial movement of the sleeve 44 rotates the valve member 38.

(28) A biasing member in the form of spring 48 is provided, the spring 48 configured to act on the sleeve 44 to normally maintain the valve member 38 in the second configuration.

(29) In the illustrated apparatus 10, the valve actuator arrangement 42 is hydraulically actuable, the piston 46 coupled to the sleeve 32 such that movement of the piston 46 moves the sleeve 32 axially relative to the body 12.

(30) As shown in FIGS. 2 and 3, and referring now also to FIGS. 4 to 7 of the accompanying drawings, both the first valve assembly 22 and the second valve assembly 24 have second valve members in the form of a flappers 50, 52.

(31) Flapper 50 is coupled to the valve member 26 via sprung hinge 54 (as shown in FIGS. 4 and 5).

(32) Flapper 52 is coupled to the valve member 38 via sprung hinge 56 (as shown in FIGS. 6 and 7).

(33) In use, the first valve assembly 22 defines an upper diverter valve of the apparatus 10 and the second valve assembly 24 defines a lower diverter valve of the apparatus 10, the first valve assembly 22 and the second valve assembly 24 defining a chamber 58 therebetween.

(34) As shown in FIG. 2, it can be seen that the completion system apparatus 10 further comprises a bypass arrangement 60, which in the illustrated apparatus 10 includes a bypass conduit in the form of drilled bores 62 which communicate with the chamber 58.

(35) In use, the bores 62 permit fluid travelling in the second, uphole, direction to bypass the first valve assembly 22.

(36) Beneficially, when the valve arrangement defines the second configuration the apparatus 10 permits fluid travelling in the first, downhole, direction to be diverted through the lateral flow ports 16 into the annulus between the apparatus 10 and the borehole while simultaneously permitting fluid travelling in the second, uphole, direction to bypass the first valve assembly 22 and return to surface.

(37) Embodiments of the apparatus thus obviate the need for a crossover tool and/or wash pipe string which in conventional gravel pack operations are required to provide separate inflow and return flow paths for the gravel slurry and returning carrier fluid during the gravel pack operation, this permitting the gravel pack operation to be carried out in a single trip, improving reliability and/or significantly reducing operational complexity, time and cost for the operator.

(38) As shown in FIG. 1, the bypass arrangement 60 further comprises a bypass valve in the form of return valve 64 which communicates with the bores 62.

(39) The return valve 64 takes the form of a sliding sleeve device having a lateral flow passage 66 and a sleeve 68 biased by spring 69.

(40) The return valve 64 is configurable between a first, closed, configuration, in which lateral passage of fluid is prevented or restricted and a second, open, configuration, in which lateral passage of fluid is permitted.

(41) In use, fluid returns may be directed through the bores 62 and pass through the lateral flow passage 66 of the return valve 64 into the annulus between the apparatus 10 and the borehole.

(42) As shown in FIGS. 1 and 3, the apparatus 10 comprises a packer arrangement comprising a first, uphole, packer 70 and a second, downhole, packer 72.

(43) As shown in FIG. 1, the first packer 70 comprises a bypass conduit 74 which provides communication between the return valve 64 and the bores 62.

(44) In use, the first packer 70 prevents fluid exiting the lateral flow ports 16 from passing in an uphole direction beyond the first packer 70, and prevents intermixing with the fluid returns exiting the return valve 64.

(45) As shown in FIG. 3, the second, downhole, packer 72 comprises a bypass conduit in the form of shunt tubes 76.

(46) In use, the shunt tubes 76 permit fluid to bypass the second packer 72. When utilised in a borehole packing operation, e.g. gravel pack operation, the ability to bypass the second packer 72 improves the consistency of the gravel pack by permitting the fluid and thus the gravel to be directed to the lowermost location so as pack the borehole from bottom to top.

(47) In the illustrated apparatus, the packers 70, 72 are hydraulically actuated.

(48) As shown in FIG. 1, the apparatus 10 comprises a power supply, which in the illustrated apparatus 10 takes the form of a Hydraulic Power Unit (HPU) 78.

(49) In use, HPU 78 is configured to activate the valve arrangement to reconfigure the valve arrangement from the first configuration to the second configuration.

(50) In the illustrated apparatus 10, the HPU 78 also actuates the packers 70, 72 and the return valve 64. Beneficially, this permits the apparatus 10 to be operated without the requirement to run in a mechanical setting tool, permitting the apparatus 10 to be run in a single trip into the borehole B.

(51) As described above, the apparatus 10 may be provided in combination with, form part of, and/or may be coupled to, a completion system and FIGS. 8, 9 and 10 of the accompanying drawings show a completion system 1000 comprising the apparatus 10.

(52) As shown in FIGS. 9, 10 and 11, the completion system 1000 further comprises a screen 80—in the illustrated system 1000 a shunted screen—and a pump down shoe 82.

(53) It will be recognised that the apparatus 10 and completion system 1000 described above are merely exemplary and that various modifications may be made.