HYDRAULIC LOCK APPARATUS

Abstract

A hydraulic lock apparatus, comprising: a lock operator piston arranged to be axially moveable in a piston chamber, the lock operator piston defining a first seal area; a fluid release valve comprising a valve port and a valve member axially moveable within a valve chamber, wherein the fluid release valve is moveable from a sealing arrangement to an open arrangement, wherein the fluid release valve defines a second seal area when in the sealing arrangement; and a hydraulic chamber defined between the first seal area of the lock operator piston and the second seal area of the fluid release valve; wherein the first seal area is larger than the second seal area; and the fluid release valve is configured to be moveable from the sealing arrangement, in which the hydraulic chamber is isolated from the valve port, to the open arrangement, in which the hydraulic chamber is connected to the valve port, in response to a differential pressure cycle being applied to the valve member over the second seal area.

Claims

1. A hydraulic lock apparatus, comprising: a lock operator piston arranged to be axially moveable in a piston chamber, the lock operator piston defining a first seal area; a fluid release valve comprising a valve port and a valve member axially moveable within a valve chamber, wherein the fluid release valve is moveable from a sealing arrangement to an open arrangement, wherein the fluid release valve defines a second seal area when in the sealing arrangement; and a hydraulic chamber defined between the first seal area of the lock operator piston and the second seal area of the fluid release valve; wherein the first seal area is larger than the second seal area; and the fluid release valve is moveable from the sealing arrangement, in which the hydraulic chamber is isolated from the valve port, to the open arrangement, in which the hydraulic chamber is connected to the valve port, in response to a differential pressure cycle being applied to the valve member over the second seal area.

2. The apparatus of claim 1, wherein the lock operator piston is an annular piston.

3. The apparatus of claim 1, wherein the lock operator piston defines: a first pressure surface corresponding to the first seal area which is arrangeable to be exposed to an operating pressure; and a second pressure surface which is arrangeable to be exposed to the hydraulic chamber.

4. The apparatus of claim 3, wherein the second pressure surface comprises a protrusion that defines an end surface with a smaller surface area than the first seal area.

5. The apparatus of claim 1, wherein the piston chamber comprises an inlet, the inlet defining an inlet area which is smaller than the first seal area.

6. The apparatus of claim 5, further comprising a plug arranged to mate with the inlet, wherein the lock operator piston is configured to urge the plug into engagement with the inlet such that the plug mates with the inlet, sealing the inlet, wherein the lock operator piston is urged by a pressure acting over the seal area.

7. The apparatus of claim 6, wherein the lock operator piston comprises the plug.

8. The apparatus of claim 1, wherein the valve chamber is cylindrical.

9. The apparatus of claim 1, wherein the valve member comprises a rod.

10. The apparatus of claim 1, wherein the fluid release valve comprises a key configured to cooperate with the valve member to hold the fluid release valve in the sealing arrangement.

11. The apparatus of claim 10, wherein the key is configured to move from a blocking position, in which the fluid release valve is held in the sealing arrangement, to a free position, in which the fluid release valve is free to move to the open arrangement.

12. The apparatus of claim 11, wherein the valve member is configured to move from a first position, in which the key is held in the blocking position, to a second position, in which the key is free to move to the free position, under the action of a pressure differential across the valve member.

13. The apparatus of claim 10, wherein the fluid release valve comprises a ratchet module configured to incrementally move from a first position, in which it holds the key in the blocking position, to a second position, in which the key is free to move to the free position, in response to a cyclic pressure differential acting across the valve member.

14. The apparatus of claim 13, wherein the ratchet module comprises a first ratchet configured to restrain movement of the ratchet module relative to a rod of the valve member and a second ratchet configured to restrain movement of the ratchet module relative to the key.

15. (canceled)

16. The apparatus of claim 1, configured to be arranged in a tubular housing of a tubular.

17. The apparatus of claim 16, wherein the lock operator piston is an annular piston arranged in the tubular housing and the valve chamber is an axially-aligned bore in the tubular housing.

18. The apparatus of claim 16, wherein the valve port is arranged on the outer surface of the tubular housing.

19. The apparatus of claim 16, wherein the lock operator piston is operatively connected to a tool component such that movement of the lock operator piston actuates the tool component.

20. A downhole device comprising: a piston chamber comprising an inlet, the inlet defining an inlet area; a piston defining a seal area that is larger than the inlet area, the piston being arranged for movement within the piston chamber; a plug arranged to mate with the inlet; wherein the piston is configured to urge the plug into engagement with the inlet such that the plug mates with the inlet, sealing the inlet; wherein the piston is urged by a pressure acting over the seal area.

21. The downhole device of claim 21, wherein the piston comprises the plug.

22. (canceled)

23. A method for unlocking a hydraulic lock, the method comprising: axially moving a lock operator piston defining a first seal area by a first distance; axially moving part of a fluid release valve defining a second seal area by a second distance, thereby moving the fluid release valve from a sealing arrangement to an open arrangement; wherein the first distance is less than the second distance.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0084] These and other aspects of the present disclosure will now be provided, by way of example only, with reference to the accompanying Figures, in which:

[0085] FIG. 1 is a cross-section view of a hydraulic lock according to the disclosure;

[0086] FIGS. 2A to 2C are time-sequential cross-section views of a fluid release valve of the hydraulic lock of FIG. 1;

[0087] FIG. 3 is a further cross-section view of the hydraulic lock of FIG. 1;

[0088] FIG. 4 is a cross-section view of part of a lock operator piston of the hydraulic lock of FIG. 1;

[0089] FIGS. 5A to 5G are time-sequential cross-section views of a second fluid release valve; and

[0090] FIGS. 6A to 6C are time-sequential cross-section views of an actuator for use with the present disclosure.

DETAILED DESCRIPTION OF DRAWINGS

[0091] FIG. 1 shows a hydraulic lock 10 according to the disclosure in cross-section. The hydraulic lock 10 is located in the body 12 of a tubular.

[0092] The tubular is a downhole tubular for use in a wellbore. The tubular defines a central flow path along which fluid may flow during use F.

[0093] The hydraulic lock 10 comprises a lock operator piston 14, a fluid release valve 16 and a hydraulic chamber 18 located therebetween.

[0094] In the present example, the lock operator piston 14 is acted upon by tubular pressure. As such, the upper end 13 of the lock operator piston 14 is exposed to tubular pressure. In other embodiments, the upper end 13 of the lock operator piston 14 may be exposed to annulus pressure.

[0095] In this example, an internal sleeve of the tubular comprises a plurality of ports 45a-d) which expose the upper side of the lock operator piston to the tubular pressure (see FIG. 4).

[0096] The lock operator piston 14 may be an actuator for actuating a tubular, tool, or other component within a downhole assembly. During installation, it may be desirable to lock the lock operator piston 14 in place (axially) and thus avoid inadvertent actuation. For this reason, the hydraulic lock 10 of the present disclosure may be employed. In some embodiments, the lock operator piston 14 may be used to lock a latch a further component of the downhole string.

[0097] The lock operator piston 14 is located in an annulus in the tubular body 12. The lock operator piston 14 comprises a piston body 14a and outer and inner seals 14b, 14c.

[0098] The tubular body annulus also defines part of the hydraulic chamber 18.

[0099] The fluid release valve 16 comprises a valve chamber 20 that, in the present example, is defined by a cylindrical bore within the tubular body 12. The valve chamber 20 is axially aligned with the tubular.

[0100] The lock operator piston 14 is sealed with respect to the annulus in which it is located (e.g. the outer and inner circumferential surfaces of the tubular housing). As such, fluid is prevented from leaving the hydraulic chamber via the lock operator piston 14. The lock operator piston 14 defines a first seal area. A differential pressure across the lock operator piston 14 acts on the first seal area. In the specific example of FIG. 1, a first side of the lock operator piston 14 is exposed to the internal pressure of the tubular or toole.g. the pressure within the internal bore of the tubular. As such, in the present example and as shown in the configuration of FIG. 1, the differential pressure across the lock operator piston 14 (which acts over the first seal area) is defined by the internal tubular pressure and the hydraulic cavity 18 pressure.

[0101] The fluid release valve 16 comprises a valve port 22 that is open to the annulus (e.g. the bore annulus surrounding the tubular). The fluid release valve 16 further comprises a valve member 24, in the form of a valve member rod in the present example. In the hydraulic lock 10 of FIG. 1, the valve member 24 is axially aligned within the valve chamber 20 and is axially moveable within the valve chamber 20.

[0102] The fluid release valve 16 is configured to move from a sealing arrangement, in which fluid in the hydraulic chamber 18 is unable to communicate with the annulus via the valve port 22; to an open arrangement, in which fluid in the hydraulic chamber 18 can communicate with the annulus via the valve port 22. The valve member 24 is configured to move axially within the valve chamber 20 under the action of a differential pressure. The fluid release valve 16 is configured to move from the sealing arrangement to the open arrangement responsive to the valve member 24 moving axially within the valve chamber 20.

[0103] In this specific hydraulic lock 10, and in the configuration shown in FIG. 1, the differential pressure acting on the valve member 24 is defined by the annulus pressure and the hydraulic chamber 18 pressure. The fluid release valve 16 defines a second seal area over which the differential pressure within the fluid release valve 16 acts.

[0104] The first seal area of the lock operator piston 14 is larger (e.g. significantly larger) than the second seal area of the fluid release valve 16. This is because the first seal area is defined over an annulus of the tubular body 12, whereas the second seal area is defined within a single axial bore located within the radius of the tubular body 12. As both the first seal area and second seal area are operatively connected to the hydraulic chamber 18, and the volume of the hydraulic chamber will not change during use, a small axial movement of the lock operating piston 14 (with its larger first seal area) results in a much greater axial movement within the fluid release valve 16 (e.g. of the valve member 24).

[0105] Turning now to FIGS. 2A to 2C, FIG. 2A shows the fluid release valve 16 in the sealing arrangement, FIG. 2C shows the fluid release valve 16 in the open arrangement and FIG. 2B shows the fluid release valve 16 in a transitional arrangement.

[0106] The fluid release valve 16 comprises a valve member 24 that extends along the axis of the fluid chamber 20. In the present example, the valve member 24 comprises a cylindrical section 24a of a first diameter, a neck section 24b of a reduced diameter a head section 24c with a diameter that is larger than that of the neck section 24b. As such, the neck section 24b provides a reduced-diameter section compared to the sections 24a, 24b on either side.

[0107] A part of the cylindrical section 24a of the valve member 24a is surrounded by a spring 26. The spring 26 of this example is axially retrained at one end with respect to the valve member 24, and at its other end with respect to a carriage assembly 28.

[0108] The carriage assembly 28 is generally annular and defines a flow path therethrough. The carriage assembly 28 comprises a number of subcomponents, including a sealing assembly 30. The sealing assembly 30 is arranged to cooperate with the valve member 24 (and in particular the cylindrical section 24a thereof) to seal the fluid release valve 16 and prevent fluid flow therethrough when the fluid release valve 16 is in a sealing arrangement.

[0109] The carriage assembly 28 also houses multiple keys 32. The keys 32 are axially restrained with respect to the carriage assembly 28. Each key 32 comprises a block that is housed in a cut-out in the carriage assembly 28. Each key comprises chamfered edges to act as cam surfaces with respect to adjacent components.

[0110] In the sealing arrangement, as shown in FIG. 2A, the keys 32 are located adjacent the neck section 24b of the valve member 24, abutting the head 24c. As such, the keys 32 act to axially-retrain the valve member 24 with respect to the carriage assembly 28.

[0111] The carriage assembly 28 is axially retrained by a shear ring 34, which in the present example is axially fixed with respect to the tubular housing 12.

[0112] In order to unlock the hydraulic lock 10, and thus free the lock operator piston 14 for axial movement, an operator needs to move the fluid release valve 16 from the sealing arrangement (in which the hydraulic chamber 18 is isolated) to the open arrangement (in which the hydraulic chamber 18 is in fluidic communication with the annulus).

[0113] FIG. 2A shows the fluid release valve 16 in the sealing arrangement. The sealing assembly 30 cooperates with the valve member 24 to seal the fluid chamber 20 and prevent fluid flow therethrough. The sealing assembly 30, valve member 24 and fluid chamber 20 cooperate to define the second seal area.

[0114] The spring 26 biases the carriage assembly 28 in a first direction (i.e. to the right of FIG. 2A) and the valve member 24 in a second direction opposition to the first direction; however, the keys 32 restrict axial movement of the valve member 24 with respect to the carriage assembly 28. As such, the fluid release valve is sealed, isolating the hydraulic chamber 18.

[0115] If a user increases the pressure in the tubular, the lock operator piston 14 is urged towards the hydraulic chamber which, in turn, urges the valve member 24 and carriage assembly 28 towards the shear ring 34. Once the differential pressure across the lock operator piston 14 reaches a threshold value, the shear ring 34 shears out, freeing the carriage assembly 28 to move axially under the action of the hydraulic chamber 18. As such, the carriage assembly 28 and valve member 24 move axially under the action of the pressure differential between the hydraulic chamber 18 and the annulus (as shown in FIG. 2B).

[0116] The valve chamber 20 defines a shoulder 36 on its inner circumferential wall. The shoulder 36 defines a reduction in the inner diameter of the valve chamber 20. The shoulder 36 is arranged such that, when the fluid release valve 16 is in a sealing arrangement, the keys 32 are adjacent the shoulder 36, in the portion of the valve chamber 20 with the smaller inner diameter.

[0117] As the carriage assembly 28 and valve member 24 move axially under the action of the pressure differential between the annulus and the hydraulic chamber 18, the keys 32 traverse the shoulder 36 and thus enter a region of the valve chamber 20 with a larger diameter. This allows the keys 32 to move radially. As the keys 32 are free to move radially, they are urged outward through interaction with the axially-urged valve member 24.

[0118] The valve member 24 is urged away from the carriage assembly 28 by the spring 26. When in this configuration, fluid is able to bypass the sealing assembly 30 via the neck 24b and head 24c portion of the valve member 24. As such, the hydraulic chamber 18 is no longer isolated from the valve port 22 (and thus annulus). This open arrangement is shown in FIG. 2C.

[0119] As an illustrative example, taking the first seal area of the lock operator piston 14 to be 5 in.sup.2 (3225.8 mm.sup.2), the second seal area of the fluid release valve 16 to be 0.02 in.sup.2 (12.9 mm.sup.2) and the distance of travel required of the valve member 24 and carriage assembly 28 to move from the sealing arrangement of FIG. 2A to the intermediate position shown in FIG. 2B (which allows the opening of the fluid release valve) to be 3 mm, the lock operator piston 14 is only required to move 0.012 mm in order to move the fluid release valve from the sealing arrangement to the open arrangement. This is beneficial, as the less movement required of the lock operator piston 14, the less chance there is for the piston to become worn or damaged by debris, for example.

[0120] FIG. 3 shows the hydraulic lock 10 in a specific arrangement. In the arrangement shown in FIG. 3, the fluid release valve is in an open arrangement, such that the hydraulic chamber 18 is open to annulus pressure. As such, the pressure differential acting across the lock operator piston 14 is defined by the tubular internal pressure (acting from the left of FIG. 3) and the annulus pressure (acting from the right of FIG. 3).

[0121] In the arrangement shown in FIG. 3, the pressure differential across the lock operator piston 14 is such that the lock operator piston 14 has been urged downhole (to the right of FIG. 3). The downhole side of the lock operator piston 14that is, the side of the lock operator piston 14 adjacent the hydraulic chamber 18defines a reduced cross-section. In the present example this is in the form of a nose portion 38.

[0122] The nose portion 38 of the lock operator piston 14 is arranged to engage a restriction defined by the hydraulic chamber 18. Once engaged, the nose portion 38 provides an interference fit with the restriction 40 of the hydraulic chamber 18. Given the geometry of the nose portion 38 and restriction 40, the seal area for the annulus pressure (e.g. the surface area over which the annulus pressure can act) is now significantly less than the seal area over which the tubular pressure can act. As such, in order to urge the lock operator piston 14 in an up-hole direction (i.e. to the left of FIG. 3 and away from the fluid release valve 16), the annulus pressure must be significantly higher than the tubular pressure.

[0123] Furthermore, the interference fit is achieved by a pressure acting on a comparatively large area (the first seal area). Given this high force and relatively small area of interaction between the nose portion 38 of the lock operator piston 14 and the inlet of the piston chamber, a high degree of interference fit may be achieved, thus required a large force to dislodge the lock operator piston 14.

[0124] FIG. 4 shows an uphole end of the lock operator piston 14. As can be seen, the lock operator piston 14 can engage a further component, e.g. tool or tubular, such as a mandrel 44. In the present example this connection is facilitated by a series of sleeves 43a-c, including a key housing 43c. The key housing 43c houses a plurality of keys 47 that protrude from the inner radial surface and engage a flange on the mandrel 44. Each key 47 is held in place by a shear screw 42.

[0125] FIGS. 5A to 5G show a further example of a fluid release valve 116. The fluid release valve 116 of FIGS. 5A to 5G comprises a valve member rod 124, spring 126, carriage assembly 128, sealing assembly 130 and keys 132 as in the previous example. Limited description will be provided regarding these features as they largely correspond to those of the previous example.

[0126] The example of FIGS. 5A to 5G comprises a ratchet module 150. The ratchet module 150 may be part of the valve member. The valve member also comprises the valve member rod 124. The ratchet module 150 comprises a double ratchet. A first ratchet engages the valve member rod 124 and only allows the ratchet module 150 to move in a second direction (to the left of FIG. 5A) with respect to the valve member rod 124. A second ratchet engages the carriage assembly 126 and only allows the ratchet module 150 to move in the second direction with respect to the carriage assembly 126.

[0127] In the example of FIGS. 5A to 5G, the outer circumference of the keys 132 engage a shoulder 156 on the inside surface of the valve chamber 120, preventing axial movement of the keys 132 (and hence carriage assembly 128) relative to the valve chamber 120. The keys 132 are biased inwardly, and so wants to reduce in radius, but is prevented from doing so by a blocking member 154. The ratchet module 150 comprises the blocking member 154 which, in the arrangement shown in FIG. 5A, is arranged concentrically inside of the keys 132.

[0128] As a user increases the pressure within the tubular, the valve member rod 124 is urged in a first direction (to the right of FIG. 5A), as was the case in the above example. This causes the first ratchet to progress with respect to the valve member rod 124. When the pressure in the tubular is reduced, the spring 126 urges the valve member rod 124 in the second direction (to the left of FIG. 5A), which brings the ratchet module 150 with it, thus progressing the second ratchet with respect to the carriage assembly 128. Further cycles of pressure within the tubular incrementally move the ratchet module 150 in the second direction (i.e. to the left of FIG. 5A) which, in turn, gradually withdraws the blocking member 154 from within the keys 132. This process is shown in FIGS. 5A to 5E.

[0129] In FIG. 5F, the blocking member 154 is completely withdrawn from blocking the keys 132 and the keys 132 are free to move radially. As such, the keys no longer prevent axial movement of the carriage assembly 128. The carriage assembly 128 is free to move axially within the valve chamber 120. The carriage assembly 128 is then urged in the first direction by the spring 126, as shown in FIG. 5G, opening the fluid release valve 116.

[0130] FIGS. 6A to 6C show an actuator 200. The actuator 200 of FIGS. 6A to 6C provide a further example of a piston arranged to engage an inlet as described herein.

[0131] The actuator 200 is mounted in an annular space 202 between a housing 204 (e.g. a tubular housing) and a seat sleeve 206. The actuator 200 includes an annular piston assembly 208. In use, a first side 210 of a piston assembly 208 is exposed to tubing pressure, whereas a second side 212 is exposed to annulus pressure. As such, the annular piston assembly 208 may be moveable in response to any pressure differential applied. Specifically, where the annulus pressure dominates (referred to as an annulus/tubing pressure differential) the piston assembly 208 will be biased in the first axial direction 214, and when the tubing pressure dominates (referred to as a tubing/annulus pressure differential) the piston assembly 208 will be biased in the second axial direction 216.

[0132] The actuator 200 further includes a ratchet module 218 which is initially axially secured to the piston assembly 208 via a shear ring 220. The ratchet module 218 includes a lower ratchet box or sleeve 222 which includes a ratchet profile 224 on an inner surface thereof, and is in engagement with a corresponding ratchet profile 226 on an inner sleeve 228 which is secured to the housing 204. The ratchet profiles 224, 226 are arranged such that the ratchet module 218 may move relative to the housing 204 in the second direction 216, but is prevented from movement in the first direction 214.

[0133] The ratchet module 218 further includes an upper ratchet box 230 in the form of an axially captivated split ring which includes a ratchet profile 232 on an inner surface thereof. The piston assembly 208 includes a ratchet pin or nose 234 which includes a ratchet profile 240 on an outer surface thereof, and in the illustrated initial configuration extends axially into the upper ratchet box 230. However, the ratchet module 218 further includes a split ring spacer 236 which is initially radially interposed between the upper ratchet box 230 and the ratchet pin 234 of the piston assembly 208, thus preventing any engagement of the respective ratchet profiles 232, 240.

[0134] An annulus pressure delivery bore 242 extends axially through the inner housing sleeve 228. The delivery bore 242 opens into the annular space 202 and includes a plug seat 244 at its open end. The actuator 200 further includes a plug plunger 246 which is initially separated from the plug seat 244 in the illustrated initial configuration. The plug plunger 246 includes a shear assembly 248 which initially provides separation between the plug 246 and plug seat 244.

[0135] During use, the piston assembly 208 of the actuator 200 is driven by an annulus/tubing differential pressure to move in the first direction 214. The differential pressure overcomes the force of the shear ring 220 and the piston assembly 208 moves to the position shown in FIG. 6B. The split ring spacer 236 moves radially inwards as the ratchet pin or nose 234 moves in away.

[0136] When the differential pressure across the piston assembly 208 changes such that the piston assembly 208 is urged in the second direction 216, the piston assembly 208 moves to the right as shown in FIG. 6C. The axial end face of the ratchet pin or nose 234 of the piston assembly 208 engages an end face of the split ring spacer 236, which has moved into the path of the piston assembly 208. As the piston assembly continues to move in the second direction, the ratchet profile 240 of the tubular assembly 208 engages the corresponding ratchet profile of the upper ratchet box 230. The axial end face of the ratchet pin or nose 234 urges the split ring spacer 236 in the second direction. The piston assembly 208 and split ring spacer 236 act to urge the plug plunger 246 to engage the plug seat 244. Once the plug plunger 246 engages the plug seat 244, the seal area over which annulus pressure acts is greatly reduced compared to the area over which tubing, or tubular, pressure acts. As such, in order to urge the piston assembly 208 in a first direction the annulus pressure must greatly exceed the tubing pressure.

[0137] It should be noted that the actuator 200 may be used independently in any other apparatus, and is not exclusively for use in the present described apparatus. In this respect, an aspect of the present disclosure relates to the first actuator for use in providing actuation to any other object or apparatus.

[0138] The present invention has been described above purely by way of example. Modifications in detail may be made to the present invention within the scope of the claims as appended hereto.