Valve assembly with a filter chamber

Abstract

A valve assembly (10) comprises a flow path extending from an assembly inlet (20) to an assembly outlet (22), a valve (24a/26a) arranged within the flow path and a filter assembly arranged within the flow path between the assembly inlet and the valve. The filter assembly comprises a filter chamber defining a particle settlement region, a filter chamber inlet for facilitating inflow of a fluid into the chamber, and a filter chamber outlet for facilitating outflow of fluid from the chamber towards the valve, wherein the filter chamber outlet includes a particle filter.

Claims

1. A downhole valve assembly for location within a wellbore, comprising: a flow path extending from an assembly inlet to an assembly outlet; a valve arranged within the flow path; and a filter assembly arranged within the flow path on one axial side of the valve and between the assembly inlet and the valve, the filter assembly comprising: a filter chamber defining a particle settlement region located at a base of the filter chamber; a filter chamber inlet located at a top of the filter chamber for facilitating inflow of a fluid into the filter chamber; an inlet tube coupled to the filter chamber inlet and configured to deviate the fluid flow from being aligned with a central axis of the downhole valve assembly; and an outlet tube defining part of the flow path and extending partially into the filter chamber from the base of the filter chamber and through the particle settlement region, the outlet tube including a filter chamber outlet in a wall thereof such that the filter chamber outlet is located within the filter chamber intermediate the base and the top of said filter chamber for facilitating outflow of fluid from the filter chamber towards the valve, wherein the filter chamber outlet includes a particle filter.

2. The downhole valve assembly according to claim 1, wherein the valve assembly is modular and comprises a valve module and a filter assembly module connected to one axial end of the valve module, the valve module and the filter assembly module defining a portion of the flow path.

3. The downhole valve assembly according to claim 1, wherein the filter chamber inlet is configured to alter aspects of the fluid flow.

4. The downhole valve assembly according to claim 1, wherein the inlet tube directs the flow of fluid.

5. The downhole valve assembly according to claim 1, wherein the outlet tube extends through the particle settlement region.

6. The downhole valve assembly according to claim 1, wherein the particle filter of the filter chamber outlet assists to prevent particles which have not settled in the particle settlement region from leaving the filter chamber via the outlet tube.

7. The downhole valve assembly according to claim 1, wherein the filter chamber outlet comprises an integrated particle filter, directly formed in the outlet tube.

8. The downhole valve assembly according to claim 1, wherein the filter chamber outlet comprises a particle filter which is fitted to the filter chamber outlet.

9. The downhole valve assembly according to claim 1, wherein the filter chamber outlet comprises a particle filter which can be removed and replaced.

10. The downhole valve assembly according to claim 1, wherein the particle filter comprises one or more layers of a filtration material.

11. The downhole valve assembly according to claim 1, wherein the valve comprises a one way valve.

12. The downhole valve assembly according to claim 1, wherein the valve comprises a two way valve.

13. The downhole valve assembly according to claim 1, wherein the assembly outlet comprises a component to agitate the fluid.

14. The downhole valve assembly according to claim 1, wherein the fluid comprises a well injection fluid.

15. The downhole valve assembly according to claim 1, wherein the fluid is designed to change state at least once when in use.

16. The downhole valve assembly according to claim 1, wherein the fluid is in communication with a wellbore.

17. The downhole valve assembly according to claim 1, wherein the fluid is in communication with a secondary device.

18. The downhole valve assembly according to claim 17, wherein the secondary device comprises a subsurface safety valve.

19. The downhole valve assembly according to claim 1, operable in inverted orientations.

20. The downhole valve assembly according to claim 1, wherein the assembly outlet is connectable to a wellbore conduit.

21. A wellbore injection system, comprising: a fluid injection conduit for injecting a fluid within a wellbore; and a downhole valve assembly according to claim 1 coupled to the fluid injection conduit.

22. A method for flow control in a wellbore, comprising locating a downhole valve assembly according to claim 1 in a wellbore and flowing a fluid through the downhole valve assembly.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) These and other aspects will now be described, by way of example only, with reference to the accompanying drawings, in which:

(2) FIG. 1 is a sectional view through a longitudinal plane of a valve assembly in accordance with an embodiment of the present invention;

(3) FIG. 2 is an enlarged view of a filter assembly of the valve assembly in FIG. 1; and

(4) FIG. 3 is a diagrammatic illustration of a wellbore system containing a valve assembly according to an embodiment of the present invention.

DETAILED DESCRIPTION OF DRAWINGS

(5) FIG. 1 is a sectional view through a longitudinal plane of a valve assembly, generally identified by reference numeral 10, in accordance with an embodiment of the present invention. The valve assembly 10 is illustrated in FIG. 1 as a standalone component, although in some embodiments the valve assembly 10 may be attached to or integrated with an external device.

(6) The valve assembly 10 is modular, consisting of a filter assembly 12, assembly inlet components 14a, 14b, valve components 16a, 16b and an assembly outlet component 18. Each of the components comprises a connector, which may be a standard connector between all of the components, which enables the components to fit together to form the entire valve assembly 10. In the illustrated embodiment the connectors each comprise a threaded section 15a-f to facilitate their connection, and a sealing component 17a-f is also present to prevent the leakage of fluid from the valve assembly 10 to the external environment. Inlet component 14a further comprises an assembly inlet 20 with a threaded section 19 to facilitate the connection of the valve assembly 10 to an external device (not shown).

(7) Each of the components of the valve assembly 10 has a circular or substantially circular lateral cross section and is generally cylindrical in shape. In alternative embodiments of the invention, the lateral cross section may be any appropriate shape. For example, the lateral cross section may take an oval, polygonal or irregular form.

(8) The valve assembly 10 shown is configured to allow an inflow of fluid (not shown) through assembly inlet 20 and an outflow through an assembly outlet 22.

(9) Valves 16a, 16b each comprise a valve member 24a, 24b and a valve seat 26a, 26b. As illustrated in FIG. 1, the valves 16a, 16b are crack valves, which function to open to permit flow in a forward direction (from inlet 20 to outlet 22) upon expose to a predetermined pressure differential. The function of valves 16a, 16b may be to permit only unidirectional flow of fluid and/or to avoid reverse flow from the outlet 22 to the inlet. In alternative embodiments of the invention, the valves 16a, 16b may be any appropriate valve type. For example, the valves 16a, 16b may be two-way valves. This may assist in circumstances where reverse flow through the valve assembly 10 is desirable, for example to clear sediment from the valve assembly 10.

(10) As noted above, the valves 16a, 16b may have a pressure relief function. For example, valves 16a, 16b may only open once a pressure value or pressure differential is exceeded. Alternatively, valves 16a, 16b may only open when there is experienced a particular change in pressure of the fluid. The valves 16a, 16b may open when flow is in one direction, but may prevent flow in the other direction.

(11) FIG. 2 is an enlarged view of the filter assembly 12 of the valve assembly 10 in FIG. 1. In the illustrated embodiment, the filter assembly includes a filter chamber 34 which is substantially cylindrical in form, and generally comprises a chamber inlet port 30 and a chamber outlet 32. An inlet tube 38 is coupled to the chamber inlet port 30 such that fluid entering into the filter chamber 34 flows through inlet tube 38. Inlet tube 38 is configured to deliver the fluid to a specific region of the filter chamber 34. Inlet tubing 38 deviates the fluid flow from being aligned with the central axis of the valve assembly 10 from being offset from the central axis. Fluid enters filter chamber 34 of the filter assembly 12 via a chamber inlet port 30 and exits via a chamber outlet port 32. The chamber inlet port 30 is defined by the filter chamber housing 36 and is positioned at the top of the filter chamber 34. The chamber inlet port 30 is aligned with the central axis of the filter assembly 12.

(12) Inlet tube 38 extends longitudinally from chamber inlet port 30. The inlet tube 38 comprises a first section 38a which extends at an acute angle relative to the top of the filter chamber 34. The inlet tube 38 comprises a section which extends from first section 38a parallel to the wall of the filter chamber 34. In this configuration, the inlet tube 38 assists to direct the flow of fluid into a specific section of the filter chamber 34.

(13) A particle settlement region 40 is defined in a lower region of the filter chamber 34. In the illustrated orientation of the filter assembly 12, the particle settlement region 40 is located at the base of the filter chamber 34. The particle settlement region 40 may be designed to hold particles which have settled out of the fluid flow, for example by the effect of gravity.

(14) Supported by the housing 36 at the base of the filter chamber 34 is an outlet tube 42. The outlet tube 42 longitudinally extends from the base of the filter chamber 34 to the approximate centre of the filter chamber 34. Outlet tube 42 is shown extending through particle settlement region 40, although in alternative orientations outlet tube 42 may be located at different sections of the filter chamber 34. Outlet tube 42 is secured to the housing 36 via an outlet tube connector 46. Outlet tube connector 46 assists to position the outlet tube 42 such that outlet tube 42 directs the fluid flow towards a downstream component in the valve assembly 10, for example a valve member 24a, 24b or assembly outlet component 18 (FIG. 1).

(15) The outlet tube connector 46 is screwed into the housing 36. A threaded portion on both the outlet tube connector 46 and the housing 36 facilitates the screw connection. The outlet tube connector 46 may connect to the housing 36 via any other appropriate method, for example chemical bonding or welding.

(16) The outlet tube 42 comprises a particle filter 44 towards the upper end. The particle filter 44 may be directly formed in the tube, as in FIG. 2, or may take the form of a separate component which is attached to the tube.

(17) As the filter assembly 12 is used, the particle settlement region 40 may begin to fill with particles which settle from the fluid flow. Positioning the filter 44 away from the base of the filter chamber 34 may allow for an increased volume of the particle settlement region 40. An increased volume of the particle settlement region 40 may maximise the effective life span of the filter assembly 12 before blocking or choking occurs.

(18) In the illustrated orientation of FIG. 2, the outlet of the inlet tube 38 is located below the chamber outlet port 32. This configuration may assist to prevent particles which may be present in the fluid flow from cascading over the chamber outlet port 32 upon entry to the filter chamber 34, thereby avoiding or minimising the risk of premature blocking or choking of the chamber outlet port 32.

(19) The particle filter 44 as illustrated in FIG. 2 comprises an array of apertures 45. The maximum width of these apertures defines the maximum width of particles which may pass through. The array of apertures therefore functions as a particle filter. Although not shown, the particle filter 44 may also or alternatively comprise a mesh structure.

(20) Alternatively, the mesh structure may be located internal or external to the outlet tube 42, to provide a secondary degree of particle filtration. The particle filter 44 may comprise as many layers as is necessary to provide the required degree of particle filtration.

(21) The outlet tube 42 directs the fluid flow from the chamber outlet port 32 towards the valves 16a, 16b (FIG. 1).

(22) As illustrated in FIG. 2, the filter assembly 12 is one modular component of the valve assembly 10. Threaded portions 48a, 48b facilitate a connection to other portions of the valve assembly 10. The connection may be achieved using any other appropriate method, for example chemical bonding or the like.

(23) FIG. 3 illustrates an example of a wellbore completion system 50 according to an embodiment of the present invention. The wellbore completion system 50 comprises a wellbore injection system 80 and a Subsurface Safety Valve (SSSV) 70.

(24) Wellbore injection system 80 comprises upper and lower valve assemblies 10a, 10b, which are each similar to valve assembly 10 described above. Upper and lower valve assemblies 10a, 10b are connected to wellbore conduit 54. Upper valve assembly 10a comprises both an inlet conduit connection 72permitting injection fluid to flow into valve assembly 10a from wellbore conduit 54and an outlet conduit connection 74permitting injection fluid to flow from valve assembly 10a into wellbore conduit 54. Valve assembly 10b comprises an inlet conduit connection 82permitting injection fluid to flow into valve assembly 10b from wellbore conduit 54and a conduit outlet module 84permitting fluid to flow through a nozzle into a wellbore 51. Injection fluid may flow from the conduit outlet module 84 in the direction of arrows 81. The conduit outlet module 84 may comprise a geometric feature to direct or agitate the fluid flowing into wellbore completion system 50.

(25) Upper and lower valve assemblies 10a, 10b may be generally similar. Both upper and lower valve assemblies 10a, 10b may be modular. Upper and lower valve assemblies 10a, 10b may comprise one or several of the same components. Upper valve assembly 10a may comprise, for example, one valve (not shown). Lower valve assembly 10b may comprise, for example two valves (not shown). Additional valves may be positioned in series to one another.

(26) An annulus space 52 exists between the wellbore injection system 80 and the wellbore pipe 51. Fluid, for example production fluids, may flow through annulus space 52 in the direction of arrows 71.

(27) Wellbore injection system 80 is connected to a flow divider 90 which facilitates a fluid connection between wellbore injection system 80 and an injection supply conduit 58. Injection supply conduit 58 provides injection fluid both to the SSSV 70 and the wellbore injection system 80 and may extend to the surface of the well. Flow divider 90 also permits the flow of fluids, for example production fluids, to flow between regions further into wellbore injection system 80 and the SSSV 70.

(28) SSSV 70 comprises a flapper valve 62 which may restrict the flow of production fluids, and a flow tube 61 which is configured to facilitate opening of the flapper valve 62. Flow tube 61 is contained within through bore section and comprises an annular seal section 65. A spring member 63 provides a biasing force on the annular seal section 65 which acts to move flow tube 61 into a position in which the flapper valve 62 is closed, as illustrated in FIG. 3. An actuation chamber 60 is connected to injection supply conduit 58. The injection supply conduit 58 may divert at least a part of the flow or at least communicate injection fluid pressure to the SSSV 70, and in particular into the actuation chamber 60. When the force acting on the annular seal section 65 due to the pressure in actuation chamber 60 exceeds the biasing force applied by the spring member 63, the flow tube 61 may move axially to force flapper valve 62 into an open configuration. When the force applied by spring member 63 is greater than that applied due to pressure in the actuation chamber 60, the flow tube 61 may move to allow flapper valve 62 to move towards a closed position. In the event of a loss of pressure of injection fluid, the pressure in actuation chamber 60 will similarly be lost and spring member 63 will act to close the flapper valve. This effect may act as a safety feature of the wellbore completion system 50. In this configuration, the injection supply conduit 58 may have dual functionality of providing both injection fluid for the wellbore injection system 80 and injection fluidwhich may act as an actuation fluidto the SSSV 70.

(29) It should be understood that the embodiments described herein are merely exemplary and that various modifications may be made thereto without departing from the scope of the present invention.