Downhole hydraulic control line

Abstract

A downhole hydraulic control tool comprising a substantially tubular body adapted for connection in a tubing string, the body including a throughbore arranged coaxially with a bore of the tubing string and one or more pockets arranged on a wall of the body, the pockets including a hydraulic power source and at least two control lines, wherein the device includes a pump to drive hydraulic fluid through the control lines and a switchable flow mechanism for switching the flow of pumped fluid between the at least two control lines, and a switchable flow mechanism and a method of operating one or more downhole devices from a downhole located hydraulic control tool.

Claims

1. A downhole hydraulic control tool, comprising: a substantially tubular body adapted for connection in a tubing string, the body including a throughbore arranged coaxially with a bore of the tubing string; and one or more pockets exposed on an outer wall of the body, the one or more pockets including: at least two control lines; a pump to drive hydraulic fluid through the control lines; and a switchable flow mechanism for switching the flow of pumped fluid between the at least two control lines.

2. The downhole hydraulic control tool according to claim 1, wherein the tool includes an electronic module, the electronic module controlling the operation of the pump and the switchable flow mechanism.

3. The downhole hydraulic control tool according to claim 2, wherein the electronic module is programmable so that the tool can be preprogrammed to behave in response to a trigger signal when downhole.

4. The downhole hydraulic control tool according to claim 2, wherein the electronics module includes a stored power supply.

5. The downhole hydraulic control tool according to claim 1, wherein the tool includes a first motor and gear assembly to operate the pump.

6. The downhole hydraulic control tool according to claim 5, wherein the tool includes a second motor and gear assembly to operate the switchable flow mechanism.

7. The downhole hydraulic control tool according to claim 5, wherein the switchable flow mechanism is located between the first motor and gear assembly and a second motor and gear assembly.

8. The downhole hydraulic control tool according to claim 1, wherein the tool includes a pressure sensor acted on by the hydraulic fluid.

9. The downhole hydraulic control tool according to claim 8, wherein the tool includes a chamber in which hydraulic fluid is located and the pressure sensor measures hydraulic fluid pressure in the chamber.

10. The downhole hydraulic control tool according to claim 9, wherein there is a piston at an end of the chamber arranged so that tubing pressure can act upon a side of the piston thereby reducing the volume of the chamber.

11. The downhole hydraulic control tool according claim 8, wherein the pressure sensor is connected to an electronics module to provide a triggering signal.

12. The downhole hydraulic control tool according to claim 1, wherein there are two control lines and the pumped fluid is switched between the control lines.

13. A method of operating one or more downhole devices from a downhole located hydraulic control tool, the method comprising the steps of: a) locating a hydraulic control tool according to claim 1 in a tubing string; b) locating at least one downhole device adjacent to the hydraulic control tool and connecting control lines of hydraulic control tool to control lines of the at least one downhole device; c) running the tubing string into a well bore; d) varying wellbore fluid pressure in the tubing to create a trigger signal for the hydraulic control tool; and e) operating the at least one downhole device by pumping hydraulic fluid through at least one of the control lines between the hydraulic control tool and the downhole device.

14. The method according to claim 13 further including the step of passing fluid through the throughbore.

15. The method according to claim 13, wherein the trigger signal for the hydraulic control tool is created by varying wellbore fluid pressure in the tubing by applying a predetermined pressure for a predetermined time.

16. The method according to claim 15, wherein the predetermined pressure is within the range 500 to 5000 psi.

17. The method according to claim 1, wherein the predetermined time period is in the range 5 to 10 mins.

18. The method according to claim 15, including the step of operating a fluid switchable flow mechanism in the hydraulic control tool to switch the pumped fluid to a second control line.

19. The method according to claim 18, wherein a second function of the downhole device is operated from the second control line.

20. The method according to claim 18, wherein a further downhole device is actuated from the second control line.

21. A method of operating a plurality of downhole devices from a plurality of downhole located hydraulic control tools, the method comprising the steps of: a) locating a plurality of hydraulic control tools according to claim 1 in a tubing string; b) locating each one of a plurality of downhole devices adjacent to one of the plurality of hydraulic control tools and connecting control lines of the hydraulic control tool to control lines of the adjacent downhole device; c) running the tubing string into a well bore; d) varying wellbore fluid pressure in the tubing to create a trigger signal for at least one of the hydraulic control tools; and e) operating at least one of the plurality of downhole devices by pumping hydraulic fluid through at least one of the control lines between the adjacent hydraulic control tool and the downhole device.

22. The method according to claim 21, further including the steps of: f) further varying wellbore fluid pressure in the tubing to create a trigger signal for at least one further hydraulic control tool; and g) operating a further one of the plurality of downhole devices by pumping hydraulic fluid through at least one of the control lines between the further hydraulic control tool and the further downhole device.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the present invention will now be described, for example only, with reference to the following drawings of which:

(2) FIGS. 1(a)-(d) is a schematic illustration of an embodiment of a body of a downhole hydraulic control tool and of the tool (FIG. 1(d)), according to the present invention;

(3) FIGS. 2(a)-(c) are sectional views of an electronic module for incorporation into the body of FIG. 1;

(4) FIGS. 3(a)-(c) are sectional views of a flow mechanism module for incorporation onto the body of FIG. 1;

(5) FIGS. 4(a)-(c) are sectional views of an expansion chamber module for incorporation into the body of FIG. 1;

(6) FIGS. 5(a)-(c) are a (a) plan, (b) sectional and (c) cross-sectional view through a switchable flow mechanism according to an embodiment of the present invention;

(7) FIG. 6 is a schematic illustration of the various parts of a hydraulic control tool according to an embodiment of the present invention.

(8) FIGS. 7(a) and 7(b) are cross-sectional views through a hydraulic control unit, illustrating switching of the flow mechanism according to an embodiment of the present invention; and

(9) FIGS. 8(a) to 8(d) are a (a) plan, and (b), (c), (d) cross-sectional views through a switchable flow mechanism according to an alternative embodiment of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

(10) Reference is initially made to FIG. 1(d) of the drawings which illustrates a downhole hydraulic control tool, generally indicated by reference numeral 10, according to an embodiment of the present invention. FIGS. 1(a)-(c) illustrate the body 12 into which modules 14, 16, 18 are located. Body 12 comprises a mandrel 20 having a bore 22 therethrough. The upper 24 and lower 26 ends of the body will have suitable connectors as are known in the art to connect the body into a tubing string (not shown). When connected in the string, the bore 22 is coaxial with the bore of the tubing string.

(11) As used herein, the terms up and down; upper and lower; and other like terms indicating relative positions to a given point or element are utilized to more clearly describe some elements of the embodiments of the invention. Commonly, these terms relate to a reference point as the surface from which drilling operations are initiated as being the top point and the total depth of the well being the lowest point.

(12) The body 12 is substantially cylindrical with the bore 22 located off-axis from the centre 30 of the cylinder 32. This arrangement provides a saddle portion 28 to one side of the bore 22. It is noted that the saddle 28 does not extend the full length of the body 12. Accordingly, the ends 24, 26 of the body are also cylindrical, but have a central axis 34 which is co-linear with the centre of the bore 22.

(13) The saddle portion 28 contains three pockets, troughs or channels 36, 38, 40 located adjacent to each other around the cylinder 32. Each channel 36, 38, 40 is adapted to receive a module 14, 16, 18 Connection through to the bore 22 is present as a port 44 is milled through the saddle 28 to create a flow path between the module 14 and the bore 22. As module 18 is of a shorter length than the neighbouring modules 16, 14, channel 40 is shorter providing end supports 46a,b to support the module 18.

(14) Reference is now made to FIGS. 4(a)-(c), which together show the expansion module 14. Module 14 is a substantially cylindrical body 48 having a bore 50 located through a majority of the body 48. At a lower end 52, a port 54 is provided for fluid to access the bore 50. Port 54 can connect to the port 44 on the saddle 28 to allow fluid within the bore 22 to access the bore 50. The fluid within the bore 22 is well fluid, most likely the produced fluid from the well i.e. hydrocarbons. Alternatively the well fluid may be that which is pumped from the surface down the mandrel 20.

(15) Within the bore 50, there is located a piston 56 which includes seals 58a,b to separate fluids above and below the piston 56. This creates a second 60 and a first 62 chamber. The size of the chambers 60, 62 will vary dependent upon the position of the piston 56 which can move through the bore 50. Well fluid is located in the first chamber 62 and control fluid is located in the second 60 chamber. The fluids are kept apart by the seals 58a,b. The control fluid is typically a hydraulic oil with good lubrication properties, a low compressibility and a high temperature resistance. Such a fluid is known to those skilled in the art.

(16) At an upper end 64 of the module 14, two ports 66, 68 are provided. The first port 66 provides a flow path for the control fluid from the second chamber 60 to the flow mechanism module 18. The second port 68 accesses a pressure transducer 70, mounted on the end 64 of the module 14. The pressure transducer 70 measures the pressure of the control fluid in the second chamber 60. An electronic connection 72 is present between the transducer 70 and the electronic module 16.

(17) Referring now to FIGS. 2(a)-(c), which together show the electronic module 16. Module 16 has a substantially cylindrical body 74 sized to locate in the channel 38 of the saddle 28. At a lower end 76, there is a blanking end cap 78. Cap 78 covers a connection 80 which is used to link the electronics module 16 to a computer for programming the unit 10. The connection 80 also provides for the download of stored information, such as the readings from the pressure transducer, for later analysis. A large portion of the electronic module 16 is taken up with housing a battery 82. The battery 82 is used to power motors in the flow mechanism module 18 and to power the PCB 84 in the electronics module 16. The PCB 84 contains a microprocessor and the control electronics to operate the unit 10. The PCB 84 receives input signals from the pressure transducer 70. There is also an electrical connection between the PCB 84 and the flow mechanism module 18 so that the motors can be signalled to operate and power can be transferred to them for this purpose.

(18) Referring now to FIGS. 3(a)-(c), which together show the flow mechanism module 18. Module 18 has a substantially cylindrical body 86 adapted for connection within the channel 40 (see FIG. 1). From a lower end 86 there is arranged an end cap 88 including an electrical connection port 98 for connection to the electronic module 16; a motor 90 to a gearbox 92 driving a micropump 94; a fluid flow chamber 96 connected to a switchable flow mechanism 100; a gear box 102 and motor 104 to drive the switchable flow mechanism 100; and an end cap 106 including an electrical connection port 108 for connection to the electronic module 16.

(19) The switchable flow mechanism 100 is attached to the wall of the body of the downhole hydraulic control tool 10 and is covered with a cover plate 27.

(20) The switchable flow mechanism 100 is illustrated in FIG. 5. The mechanism 100 is a substantially cylindrical member 160 which is mounted on a central axis 140. A rounded portion, or ball 128, of the member 160 is arranged to rotate on the axis 140. Within the ball 128, there are machined two channels 136, 138 located therethrough. The channels 136, 138 are distinct in that they do not overlap or connect in any way. To achieve this, no channel is arranged through the centre 140 of the ball 128. These channels 136, 138 provide four switchable flow ports 162, 164, 166, 168 which can be used as inputs or outputs dependant upon the orientation of the ball 128.

(21) The member 160 is supported in position by end bearing rings 170, 172. Fluid paths 174, 176 are located through the member 160 so that fluid flooding the internal volume of the body 86 can pass through these flow paths 174, 176 to assist in balancing pressure across the ball 128. Mounted to one bearing ring 172 is a spindle 180. Spindle 180 connects to the gearbox 102 of motor 104. It is thus by operating motor 104, the flow mechanism 100 is actuated and the flow paths 136, 138 can be switched.

(22) FIGS. 8(a) to 8(d) depicts an alternative switchable flow mechanism 200. The mechanism 200 is a substantially cylindrical member 260 which is mounted on a central axis 240. A cylindrical valve 228 housed in the member 260 is arranged to rotate on the axis 240. Within the substantially cylindrical member 260, there are machined two channels 236, 238 located therethrough. The channels 236,238 are distinct in that they do not overlap or connect in any way. To achieve this, no channel is arranged to pass entirely through the centre 240 of the cylindrical valve 228. These channels 236, 238 provide two switchable flow ports 262, 264 which can be used as inputs or outputs dependant upon the orientation of the cylindrical valve 228.

(23) Spindle 280 connects to the gearbox 102 of motor 104. It is thus by operating motor 104, the flow mechanism 200 is actuated and the flow paths 236, 238 can be switched.

(24) In switchable flow mechanism 100, the ball 128 may be rotated 45 degrees by spindle 180 to a mid-, or neutral position. In the mid position, slots 182 of ball 128 align with fluid control lines 124, 126 (best seen in FIG. 7). In this way, a reduced fluid flow through control lines 124, 126 is permitted in order to equalise any pressure build up in the associated control lines. In this way, during run-in of the device for example, any pressure build up in one of the control lines may be equalised through the ball 128.

(25) Likewise, as best seen in FIGS. 8b, c and d which are a cross section through cylindrical member 260 in the direction of the arrow III, in switchable flow mechanism 200, the cylindrical valve 228 may be rotated 90 degrees by spindle 280 to a mid-, neutral position (FIG. 8(d)). In this position, groove 282 in the face of the cylindrical valve 228 allows a reduced fluid flow through ports 262, 264 in order to equalise any pressure build up in the associated control lines. In this way, during run-in of the device for example, any pressure build up in one of the control lines may be equalised through the cylindrical valve 228.

(26) The operation of the hydraulic control tool 10 will now be described with reference to FIG. 6 and the earlier Figures also. Like parts to those of the earlier Figures have been given the same reference numeral for ease of interpretation. Each module 16, 14, 18 is assembled and a fixed volume of control fluid is placed in the second chamber 60. The modules 14, 16, 18 are located on the body 12 in pockets 36, 38, 40 and the connections between the modules made. In this regard the control fluid from the second chamber 60 enters the flow mechanism module 18 at the switchable flow mechanism 100. The fluid floods the internal volume of the body 86. More particularly, the fluid enters the port 110, travels through flow path 112 in the fluid flow chamber 96, exits at port 114 and floods the volume 116 around the pump 94. The fluid enters the pump 94 through a port 118 from whence it is pumped at high pressure down the channel 120 to enter the switchable flow mechanism 100 at a high pressure connection 122. The operation of the switchable flow mechanism 100 will be described in greater detail with reference to FIG. 7.

(27) In use, the mandrel 20 is mounted in a string adjacent to a downhole device (not shown) and run in a well bore. Input control lines of the downhole device are connected to the fluid control lines 124, 126 which exit the flow mechanism 100 (best seen on FIG. 7). At surface, the PCB 84 has been programmed to respond to a pressure event noted at the transducer 70. This may simply be to trigger at a set pressure value. Alternatively it may be that the pressure must be held in a window for a given period of time. Various triggering events can be programmed dependent on the conditions which will be experienced in the well bore.

(28) Well fluid enters the first chamber 62. This fluid is in the bore 22 and is either production fluid or fluid introduced at surface and pumped into the bore 22 as part of an intervention procedure. The well fluid acts against the piston 56 and compresses or allows expansion of the control fluid in the second chamber 60, by movement within the expansion chamber 50. The pressure of the control fluid is monitored by the pressure transducer 70 and the signal is relayed to the PCB 84 in the electronics module 16.

(29) When a pressure event is realised, the motor 90 and/or the motor 104 are operated in a preprogrammed sequence. Motor 104 is operated to switch the high pressure output between the control lines 124, 126. This is achieved by the motor 104 and gearbox 102, rotating the ball 128 within the mechanism 100 by rotation of the spindle 180. This rotation is seen between FIGS. 7(a) and 7(b).

(30) The ball 128 is in sealing contact with three ports 122, 132, 134. Port 122 is the high pressure connection from the pump 94. Arranged perpendicularly to the port 122 are the two ports 132, 134 which connect directly to the hydraulic control lines 124, 126 respectively.

(31) In a first configuration, shown in FIG. 7(a), the ball 128 is arranged such that the high pressure input 122 is aligned with the port 134. High pressure control fluid is thus pumped down control line 126 which can be used to actuate the downhole device. The second channel 138 is also arranged such that the end 168 is aligned with the port 132, while the other end 166 is open to the body 86. The fluid exiting the end 166 mixes with the fluid from the body 86. Any high pressure fluid in the control line 124 is thus released back to the low pressure in the body 86. Such a release of pressure in control line 124 can be used to actuate the downhole device also. One skilled in the art will immediately see that the actuation mechanism in the device could be arranged to be acted upon by fluid in the control lines 124, 126 arranged on opposing surfaces of a moving member such as a piston. This creates a closed loop system.

(32) The PCB 84 can be programmed to operate the pump 94 when high pressure fluid is required by starting motor 90. The PCB 84 can also control the position of the channels 136, 138 by rotating the ball 128 via motor 104, gearbox 102 and spindle 180. As the spindle 180 is arranged perpendicularly to the ports 132, 134 and in line with the port 122, a support in the form of a bearing ring 170 is arranged on the opposite side of the ball 128 to aid rotation. Further support is provided by bearing ring 172, arranged on the opposite side of the ball 128 to further aid rotation. As can be seen between the FIGS. 7(a) to 7(b) only a 90 degree rotation of the ball 128 is required to align the ports such that the high pressure fluid is now directed through control line 124. This rotation is achieved by merely rotating the spindle by 104. A low pressure release is accordingly provided from the control line 126 to the chamber 60 via the body 86. Such a change of fluid pressure in the control lines 124, 126 can be used to actuate the downhole device to perform another function.

(33) Advantageously, by having no bore through the centre 140 of the ball, rotation of the ball 128 can simply be achieved by on axis rotation from the gearbox 102 which simplifies the construction. Additionally switching of the mechanism 100 only requires a small i.e. 90 degree, rotation of the ball 128. Yet further, in both configurations, complete flow paths are provided and no flow path is sealed by being covered or otherwise blocked. Still further, by locating the flow mechanism between the two motors 90, 104 and flooding this area with control fluid at low pressure, we gain the benefits of lubricating rotation of the ball 128 in the housing and removing the requirement to have robust seals between the ball and housing. As can be seen, the ball 128 is held at three locations by sprung loaded rings 150 at the connectors 122, 132, 134.

(34) Applicants co-pending application, GB 0803925.7, described a downhole hydraulic control unit mounted in a electronic completion installation valve. It will be apparent to those skilled in the art that the hydraulic control tool of the present invention can replace the unit, such that the valve could be any remotely operable tubing mounted valve as is known in the art. The downhole hydraulic control tool and the valve need then only be mounted adjacent to each other. Such an arrangement allows the downhole hydraulic control tool of the present invention to be used with downhole devices which currently connect to control lines run to the surface of the well.

(35) A principal advantage of the present invention is that it provides a downhole hydraulic control tool having a hydraulic power source with a control line, locatable in a tubing string. In this way, there is no requirement to have control lines passing through the length of the well, the control line will only be required to span the distance between the downhole hydraulic control tool and the downhole device.

(36) A further advantage of at least one embodiment of the present invention is that it provides a method for operating one or more downhole devices from a downhole located hydraulic control tool. Indeed multiple downhole hydraulic control tools may be located on the tubing string each operating one or more downhole devices. Each hydraulic tool can be programmed to operate on different pressure events and thus the downhole devices can be actuated in any selected order.

(37) A yet further advantage of at least one embodiment of the present invention to provide a switchable flow mechanism with switchable flow paths for a closed loop control system. By arranging for high pressure control fluid to be placed alternately down control lines at least two functions can be performed from an enclosed volume of control fluid.

(38) Modifications may be made to the invention herein described without departing from the scope thereof. For example, each module could be arranged coaxially to provide a single module. The switchable flow mechanism could be provided with further channels such that additional control lines could be operated from the tool.