Note: Descriptions are shown in the official language in which they were submitted.
SPECIFICATION
TITLE OF INVENTION
HYDRAULIC DELAY TOE VALVE SYSTEM AND METHOD
[0001] Intentionally Blank
FIELD OF THE INVENTION
[0002] An apparatus and method for providing a time delay in
injection of pressured fluid into a geologic formation. More
specifically, it is a toe valve apparatus activated by fluid
pressure that opens ports after a predetermined time interval
to allow fluid to pass from a well casing to a formation.
PRIOR ART AND BACKGROUND OF THE INVENTION
Prior Art Background
[0003] It has become a common practice to install a pressure
responsive opening device at the bottom or toe of a casing string
within horizontal well bores and in some vertical bores. These
devices make up and run as an integral part of the casing string.
After the casing has been cemented and allowed to solidify, the
applied surface pressure is combined with the hydrostatic
pressure and a pressure responsive valve is opened. The
combination of hydrostatic and applied pressure is customarily
used to overcome a number of shear pins or to overcome a
precision rupture disc. Once communication with the well bore
[i.e., area outside of the casing] is achieved, the well can be
hydraulically fractured or the valve can be used as an injection
port to pump down additional wire line
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perforating guns, plugs or other conveyance means such as
well tractors. Other known methods of establishing
communication with the cemented and cased well include
tubing conveyed or coil tubing conveyed perforators. These
are all common methods to achieve an injection point but
require increased time and money.
[0004] The present invention provides an improved
apparatus and method that provides a time delay in fluid
injection through the casing.
[0005] Current time delay tools that open instantly do
such in an uncontrolled manner wherein a piston slams in an
uncontrolled manner. Therefore, there is a need for a time
delay tool that may be opened instantly in a controlled
manner. Current time delay tools are not capable of opening
multiple downhole tools. For example, when there are two
tools that need to open to a formation, one tool may be
opened to the formation due to the variation in actuation
pressure of the rupture disks, however the pump pressure
cannot reach the second tool to actuate due to the first
tool that is already connected to a formation. Therefore,
there is a need for opening multiple tools within a short
period of time without the need for deploying each tool
separately.
[0006] Prior art tools also do not provide for a
repeatable and reproducible time delays due to the
uncontrolled manner of the tool opening. Therefore there is
a need for a reliable, repeatable and reproducible time
delay tool for opening connection to a formation in a
controlled manner.
[0007] US 6,763,892 patent entitled, "Sliding sleeve
valve and method for assembly," discloses the following:
"A sliding sleeve valve and method for assembly is
disclosed. The valve comprises a segmented main body that
is assembled from a top, middle and bottom segments. The
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middle segment has flow apertures. A closing sleeve is co-
axially mounted in the assembled main body. The closing
sleeve has flow apertures that are intended to communicate
with the flow apertures of the middle section when the
valve is open. The closing sleeve is sealed by seal means
within the main body to prevent undesired fluid flow across
the valve. The seal means comprise primary, secondary and
tertiary seals acting in cooperative combinations. The
seals comprise 0-Ring and Vee-stack seals located within
the body of the valve. The sliding sleeve valve has a fluid
pressure equalization means to permit equalization of fluid
pressure across the valve before it is fully opened or
fully closed in order to reduce wear on the seals. The
equalization means comprises a plurality of pressure
equalization ports in the sliding sleeve that are intended
to communicate with the main body apertures prior to the
sliding sleeve apertures when opening and subsequent to the
sliding sleeve apertures when closing."
[0008] Prior art assembly and manufacturing of the valve
as aforementioned comprises a number of individual
components threadedly connected together with suitable
seals. The components of the tubular body may include top,
middle and bottom segments, end couplings and coupling
adapters that are connected together and integrated into a
well casing. However, due to the number of connections the
valve cannot withstand the torque specifications of a
typical wellbore casing. In addition, more number of
segments and connections increases the propensity of leaks
through the valve and therefore rendering the valve
unreliable. Therefore, there is a need for a single piece
mandrel or tubular body to withstand the torsional and
torque specifications of the wellbore casing when the valve
is threaded into the wellbore casing. There is a need for a
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valve manufactured from a single piece mandrel provides for
more reliability and reduces the propensity of leaks.
Deficiencies in the Prior Art
[0009] The prior art as detailed above suffers from the
following deficiencies:
[0010] Prior art systems do not provide for economical
time delay tools with simple construction and less
expensive time delay elements.
[0011] Prior art systems do not provide for reliable
time delay tools that open at high pressure for connection
to a geologic formation.
[0012] Prior art systems do not provide for opening time
delay tools with reverse acting rupture disks that resist
plugging from wellbore debris and fluids.
[0013] Prior art systems do not provide for opening
multiple time delay tools in a staged manner.
[0014] Prior art systems do not provide for a short-
delay controlled tool that appears to open immediately to
an operator.
[0015] Prior art systems do not provide a time delay
tool with a larger inner diameter.
[0016] Prior art systems do not provide for a short time
delay tool that is controlled within a range of 0.5 seconds
to 3 minutes.
[0017] Prior art systems do not provide for a long time
delay tool that is controlled within a range of 60 minutes
to 2 weeks.
[0018] Prior art systems do not provide for a long time
delay tool that is controlled with a large pressure
reservoir.
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[0019] Prior art systems do not provide for a long time
delay tool that is controlled with an extremely high
viscosity fluid.
[0020] Prior art systems do not provide for a long time
delay tool that is controlled with plugging agent.
[0021] Prior art systems do not provide for a long time
delay tool that is controlled stacked delay agents
connected in series or parallel.
[0022] Prior art systems do not provide for a dual
actuated controlled time delay valves.
[0023] Prior art systems do not provide for a single-
actuated controlled time delay valves.
[0024] Prior art systems do not provide for a dual
actuated controlled time delay valves manufacture from a
single mandrel.
[0025] Prior art systems do not provide for a single
actuated controlled time delay valves manufacture from a
single mandrel.
[0026] Prior art systems do not provide for fracturing
through a controlled time delay valves.
[0027] Prior art systems do not provide for detecting a
wet shoe with a toe valve.
[0028] Prior art systems do not provide for removing
debris from well with a multi injection apparatus.
[0029] Prior art systems do not provide for
manufacturing a controlled time delay apparatus from a
single mandrel that can carry all of the tensile,
compressional and torsional loads of the well casing.
[0030] Prior art systems do not provide for a valve
manufactured from a single piece mandrel for more
reliability and reduces the propensity of leaks.
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[0031] While some of the prior art may teach some
solutions to several of these problems, the core issue of a
controlled time delay apparatus for establishing injection
into a subterranean formation has not been addressed by
prior art.
OBJECTIVES OF THE INVENTION
[0032] Accordingly, the objectives of the present
invention are (among others) to circumvent the deficiencies
in the prior art and affect the following objectives:
[0033] Provide for economical time delay tools with
simple construction and less expensive time delay elements.
[0034] Provide for reliable time delay tools that open
at high pressure for connection to a geologic formation.
[0035] Provide for opening time delay tools with reverse
acting rupture disks that resist plugging from wellbore
debris and fluids.
[0036] Provide for opening multiple time delay tools in
a staged manner.
[0037] Provide for a short delay controlled tool that
appears to open immediately to an operator.
[0038] Provide a time delay tool with a larger inner
diameter.
[0039] Provide for a short time delay tool that is
controlled within a range of 0.5 seconds to 3 minutes.
[0040] Provide for a long time delay tool that is
controlled within a range of 60 minutes to 2 weeks.
[0041] Provide for a long time delay tool that is
controlled with a large pressure reservoir.
[0042] Provide for a long time delay tool that is
controlled with an extremely high viscosity fluid.
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[0043] Provide for a long time delay tool that is
controlled with plugging agent.
[0044] Provide for a long time delay tool that is
controlled stacked delay agents connected in series or
parallel.
[0045] Prior art systems do not provide for a dual
actuated controlled time delay valves.
[0046] Prior art systems do not provide for a single-
actuated controlled time delay valves.
[0047] Provide for a dual actuated controlled time delay
valves manufacture from a single mandrel.
[0048] Provide for a single actuated controlled time
delay valves manufacture from a single mandrel.
[0049] Provide for fracturing through a controlled time
delay valves.
[0050] Provide for detecting a wet shoe with a toe
valve.
[0051] Provide for removing debris from well with a
multi injection apparatus.
[0052] Provide for manufacturing a controlled time delay
apparatus from a single mandrel that can carry all of the
tensile, compressional and torsional loads of the well
casing.
[0053] Provide for a valve manufactured from a single
piece mandrel for more reliability and reduces the
propensity of leaks.
[0054] While these objectives should not be understood
to limit the teachings of the present invention, in general
these objectives are achieved in part or in whole by the
disclosed invention that is discussed in the following
sections. One skilled in the art will no doubt be able to
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select aspects of the present invention as disclosed to
affect any combination of the objectives described above.
BRIEF SUMMARY OF THE INVENTION
System Overview
[0055] The present invention in various embodiments
addresses one or more of the above objectives in the
following manner. The present invention includes an
apparatus integrated into a well casing for injection of
pressurized fluid into a subterranean formation. The
apparatus comprises a housing with openings, a piston, a
stacked delay restrictor, an actuating device and a high
pressure chamber with a hydraulic fluid. The stacked delay
restrictor is configured to be in pressure communication
with the high pressure chamber and a rate of travel of the
piston is restrained by a passage of the hydraulic fluid
from the high pressure chamber into a low pressure chamber
through the stacked delay restrictor. Upon actuation by the
actuating device, the piston travels for an actuation time
period, after elapse of the actuation time period, the
piston travel allows opening of the openings so that the
pressurized fluid flows through the openings for a port
opening time interval.
Method Overview
[0056] The present invention system may be utilized in
the context of a controlled time delay method, wherein the
system as described previously is controlled by a method
having the following steps:
(1) installing a wellbore casing in a wellbore along
with the apparatus;
(2) injecting the fluid into the wellbore casing so
as to increase pressure to a maximum;
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. .
(3) actuating the actuating device when the maximum
pressure exceeds a rated pressure of the
actuating device;
(4) allowing the piston to travel for the actuation
time period;
(5) enabling the piston to travel to open said
openings for the port opening time interval so
that the pressurized fluid flows into the
subterranean formation.
[0057] Integration of this and other preferred exemplary
embodiment methods in conjunction with a variety of
preferred exemplary embodiment systems described herein in
anticipation by the overall scope of the present invention.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0058] For a fuller understanding of the advantages
provided by the invention, reference should be made to the
following detailed description together with the
accompanying drawings wherein:
[0059] FIG. la is a plan view of an apparatus of an
embodiment of the invention.
[0060] FIG. lb is a plan view of a cross section of an
apparatus of an embodiment of the invention.
[0061] FIG. 2 is an exploded section view of the
apparatus displayed in Figure la and lb in which the ports
are closed.
[0062] FIG. 3 is an exploded section view of the
apparatus displayed in Figure la and lb in which the ports
are open.
[0063] FIG. 4 is a plan view of an apparatus of an
embodiment of the invention.
[0064] FIG. 5 is an exploded section view AE of a
section of the apparatus of an embodiment of the invention
displayed in Figure 4.
[0065] FIG. 6 is an exploded section view AC of a
section of displayed in Figure 4.
[0066] FIG. 7 is an exploded section view AD of a
section of an embodiment of the invention the apparatus
displayed in Figure 4.
[0067] FIG. 8 is a graphic representation of results of
a test of the operation of an apparatus of an embodiment of
the invention.
[0068] FIG. 9a and FIG. 9b illustrate an exemplary
controlled time delay apparatus with stacked delay elements
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arranged in series in a restrictor according to a preferred
embodiment of the present invention.
[0069] FIG. 9c and FIG. 9d illustrate an exemplary
controlled time delay apparatus with stacked delay elements
arranged in series and parallel combination in a restrictor
according to a preferred embodiment of the present
invention.
[0070] FIG. 10a, FIG. 10b, FIG. 10c are exemplary cross
sections of a controlled time delay apparatus illustrating
closed time, actuation time and port open time according to
a preferred embodiment of the present invention.
[0071] FIG. ha is an exemplary chart for a casing
pressure test with a controlled toe valve apparatus
illustrating delayed actuation time and port open time
according to a preferred embodiment of the present
invention.
[0072] FIG. lib is an exemplary chart for a casing
pressure test with a controlled toe valve apparatus
illustrating instant actuation time and port open time
according to a preferred embodiment of the present
invention.
[0073] FIG. 12a illustrates a prior art system cross
section of a rupture disk.
[0074] FIG. 12b illustrates an exemplary system cross
section of a reverse acting rupture disk for use in a
controlled time delay apparatus according to a preferred
embodiment of the present invention.
[0075] FIG. 13 illustrates an exemplary system cross
section of a circular shaped housing opening and a circular
shaped mandrel port in a toe valve to produce a jetting
action according to a preferred embodiment of the present
invention.
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[0076] FIG. 14 illustrates an exemplary system cross
section of an oval shaped housing opening and an oval
shaped mandrel port in a toe valve to produce a jetting
action according to a preferred embodiment of the present
invention.
[0077] FIG. 15a illustrates an exemplary system cross
section of an oval shaped housing opening and a circular
shaped mandrel port in a toe valve to produce a jetting
action according to a preferred embodiment of the present
invention.
[0078] FIG. 15b illustrates an exemplary system cross
section of a circular shaped housing opening and an oval
shaped mandrel port in a toe valve to produce a jetting
action according to a preferred embodiment of the present
invention.
[0079] FIG. 16 is an exemplary flow chart that
illustrates a controlled time delay method with a time
delay toe valve apparatus according to a preferred
embodiment of the present invention.
[0080] FIG. 16a is an exemplary flow chart that
illustrates a casing integrity test method with a
controlled time delay with a time delay toe valve apparatus
according to a preferred embodiment of the present
invention.
[0081] FIG. 17a illustrate an exemplary dual actuating
controlled time delay apparatus comprising dual controlled
toe valves according to a preferred embodiment of the
present invention.
[0082] FIG. 17b illustrates an exemplary cross section
of a dual actuating controlled time delay apparatus
comprising dual controlled toe valves according to a
preferred embodiment of the present invention.
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[0083] FIG. 18 illustrates an exemplary perspective view
of a dual actuating controlled time delay apparatus
according to a preferred embodiment of the present
invention.
[0084] FIG. 19 illustrates an exemplary dual actuating
controlled time delay apparatus integrated into a wellbore
casing according to a preferred embodiment of the present
invention.
[0085] FIG. 20 is an exemplary chart that illustrates a
controlled time delay method with a dual time delay toe
valve apparatus according to a preferred embodiment of the
present invention.
[0086] FIG. 21a, 21b, 21c illustrate an exemplary cross
section of a single actuating controlled time delay
apparatus according to a preferred embodiment of the
present invention.
[0087] FIG. 22 illustrates an exemplary perspective view
of a single actuating controlled time delay apparatus
according to a preferred embodiment of the present
invention.
[0088] FIG. 23 is an exemplary flow chart illustrating a
controlled time delay method with a single actuating dual
time delay toe valve apparatus according to a preferred
embodiment of the present invention.
[0089] FIG. 24 is an exemplary flow chart illustrating a
fracturing and perforating method through a time delay toe
valve apparatus according to a preferred embodiment of the
present invention.
[0090] FIG. 25 illustrates an exemplary cross section of
a toe valve apparatus with a ball seat according to a
preferred embodiment of the present invention.
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[0091] FIG. 26 illustrates an exemplary perspective view
of a toe valve apparatus with a ball seat according to a
preferred embodiment of the present invention.
[0092] FIG. 27 is an exemplary flow chart illustrating a
wet shoe detection with a time delay toe valve apparatus
and a restriction plug element according to a preferred
embodiment of the present invention.
[0093] FIG. 28a, 28b, 28c are an exemplary dual
injection apparatus illustrating a first injection point,
debris collection and a second injection point according to
a preferred embodiment of the present invention.
[0094] FIG. 29 is an exemplary flow chart illustrating
debris removal with a controlled dual injection apparatus
according to a preferred embodiment of the present
invention.
[0095] FIG. 30 is an exemplary flow chart illustrating
debris removal with a controlled dual time delay apparatus
according to a preferred embodiment of the present
invention.
[0096] FIG. 31 is an exemplary flow chart illustrating
debris removal with a controlled time delay apparatus and a
perforating gun according to a preferred embodiment of the
present invention.
[0097] FIG. 32 is an exemplary flow chart illustrating
debris removal with a controlled time delay apparatus
comprising a first tool, a second tool and a third tool
according to a preferred embodiment of the present
invention.
[0098] FIG. 33 is an exemplary sliding sleeve apparatus
with a one piece mandrel according to a preferred
embodiment of the present invention.
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[0099] FIG. 34 is an exemplary flow chart illustrating
assembly of a sliding sleeve apparatus with a one piece
mandrel according to a preferred embodiment of the present
invention.
DESCRIPTION OF THE PRESENTLY PREFERRED EXEMPLARY
EMBODIMENTS
[0100] While this invention is susceptible of embodiment
in many different forms, there is shown in the drawings and
will herein be described in detailed preferred embodiment
of the invention with the understanding that the present
disclosure is to be considered as an exemplification of the
principles of the invention and is not intended to limit
the broad aspect of the invention to the embodiment
illustrated.
[0101] The numerous innovative teachings of the present
application will be described with particular reference to
the presently preferred embodiment, wherein these
innovative teachings are advantageously applied to the
particular problems of a establishing injection to a
hydrocarbon formation system and method. However, it should
be understood that this embodiment is only one example of
the many advantageous uses of the innovative teachings
herein. In general, statements made in the specification of
the present application do not necessarily limit any of the
various claimed inventions. Moreover, some statements may
apply to some inventive features but not to others.
[0102] The present invention is an improved "toe valve"
apparatus and method to allow fluid to be injected through
ports in an oil or gas well casing wall section (and casing
cement) into a geologic formation in a time delayed manner.
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[0103] The
apparatus, in broad aspect, provides time-
delayed injection of pressurized fluid through openings in
a well casing section to a geological formation comprising:
a housing with openings that can communicate through
ports in the walls of the apparatus housing to a
formation;
a movable piston or pistons capable of moving into
position to provide covering and sealing the port(s)
and to a position where the ports are uncovered;
means for moving the piston to a final position
leaving the port(s) uncovered; and means for
activation the movement of the piston.
[0104] The present invention represents several
improvements over conventional pressure responsive devices
improvements that will be appreciated by those of ordinary
skills in the art of well completions. The
greatest
limitation of current devices is that the sleeve or power
piston of the device that allows fluid to flow from the
casing to a formation (through openings or ports in the
apparatus wall) opens immediately after the actuation
pressure is reached. This limits the test time at pressure
and in many situations precludes the operator from ever
reaching the desired casing test pressure. The present
invention overcomes that limitation by providing a
hydraulic delay to afford adequate time to test the casing
at the required pressure and duration before allowing fluid
communication with the well bore and geologic formation.
This is accomplished by slowly releasing a trapped volume
of fluid through a hydraulic metering chamber that allows a
piston covering the openings to move to a position where
the openings are uncovered. This feature will become even
more advantageous as federal and state regulators mandate
the duration or dwell time of the casing test pressure. The
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metering time can be increased or tailored to a specific
test requirement through manipulation of the fluid type,
fluid volume, by altering the flow rate of the hydraulic
liquid flow restrictor and by appropriate placement and
setting of pressure valves on either or both sides of the
flow restrictor.
[0105] A second advantage of this invention is that two
or more valves can be installed (run) as part of the same
casing installation. This optional configuration of running
two or more valves is made possible by the delay time that
allows all of the valves to start metering before any of
the valves are opened. The feature and option to run two or
more valves in a single casing string increases the
likelihood that the first stage of the well can be fracture
stimulated without any well intervention whatsoever. Other
known devices do not allow more than a single valve to
operate in the same well since no further actuation
pressure can be applied or increased after the first valve
is opened.
[0106] A third significant advantage is that in the
operation of the valve, the ports are opened slowly so that
as the ports are opened (uncovered) the liquid is injected
to the cement on the outside of the casing in a high
pressure jet (resulting from the initial small opening of
the ports), thus establishing better connection to the
formation. As the ports are uncovered the fluid first jets
as a highly effective pinpoint cutting jet and enlarges as
the ports are opened to produce an effect of a guide-hole
that is then enlarged.
[0107] Referring to the Figures, Figure lA represents a
controlled time delay tool comprising an inner mandrel, 29,
that is inserted directly into the casing string and shows
an overall external view of an embodiment of the apparatus
of the invention. Slotted ports 28 through which fluid will
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be transported into the geologic formation surrounding the
casing. Figure 1B shows a cross section view of the
apparatus of Figure 1A. The integral one-piece design of
the mandrel carries all of the tensile, compressional and
torsional loads encountered by the apparatus. The entire
toe valve apparatus is piped into the casing string as an
integral part of the string and positioned where
perforation of the formation and fluid injection into a
formation is desired. The apparatus may be installed in
either direction with no change in its function.
[0108] Figure 2 (a section of Figure 1B) shows details
of the apparatus of an embodiment of the invention. A
pressure activated opening device 23 preferably a Reverse
Acting Disc but conventional rupture discs may be used for
initiating a piston. Since the rupture disc is in place in
the casing string during cementing it is very advantageous
to have a reverse acting rupture disc that will not be
easily clogged and not require extra cleaning effort. The
valve mandrel is machined to accept the opening device 23
(such as rupture discs) that ultimately controls actuation
of the piston, 5. The opening piston, 5, is sealed by
elastomeric seals (16, 18 and 20 in Figure 2 and 45, 47 and
49 in Figure 6) to cover the inner and outer ports, 25-27
and 28, in the apparatus.
[0109] The openings 25-27 (and a fourth port not shown)
shown in Figures 2 and 3 are open ports. In one embodiment
the ports 25-27 (and other inside ports) will have means to
restrict the rate of flow such as baffles (50 in Figure 7)
as, for example, with a baffle plate consisting of
restrictive ports or a threaded and tortuous pathway, 50.
This will impede rapid influx of well bore fluids through
the rupture discs, 23 in Figure 2 and 52 in Figure 7 into
the piston chamber 32. In Figure 5, the mandrel housing 54
18
is similar to inner mandrel 29 in Figure 2 and 52 is the rupture
disc that corresponds to 23 in Figure 2. The mandrel housing 51
which is same as mandrel housing 6.
[0110] In one embodiment, the piston, 5, has dual diameters
(Figure 6 shows the piston, 5 (46 and 48), with one section, 46,
having a smaller diameter at one end than at the other end, 48.
This stepped diameter piston design will reduce the internal
pressure required to balance out the pressure across the piston
when the piston is subjected to casing pressure. This pressure
reduction will increase the total delay time afforded by a
specific restrictor. The resistance to flow of a particular
restrictor is affected by the differential pressure across the
component. By reducing the differential across the component,
the rate of flow can be skillfully and predictably manipulated.
This design provides increased delay and pressure test intervals
without adding a larger fluid chamber to the apparatus. The dual
diameter piston allows the pressure in the fluid chamber to be
lowered. This has several advantages; in particular the delay
time will be increased by virtue of the fact that the
differential pressure across a given restrictor or metering
device will be reduced. With a balanced piston area, the pressure
in the fluid chamber will be at or near the well bore pressure.
With the lower end of the piston 46 smaller and the piston area
adjacent to the fluid chamber, 48, larger the forces will balance
with a lower pressure in the fluid chamber. In this way it will
be easy to reduce the fluid chamber pressure by 25% or more.
[0111] A series of outer sections 4, 6, and 8 illustrated in
Figures 1A, 1B and 2 are threadedly connected to form the fluid
and pressure chambers for the apparatus. The tandem, 3, not only
couples outer section 4
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Date Rectie/Date Received 2023-04-14
and piston 5 but also houses a hydraulic restrictor 22. The
area, 32, to the left of the piston, 5, is a fluid chamber and
the area to the left of tandem 3 is the low pressure chamber
that accommodates the fluid volume as it traverses across the
hydraulic restrictor. The chambers are both capped by the upper
cap 8.
[0112] The rupture disc 23 or 52 is the activation device
that sets the valve opening operation into play. When ready to
operate (i.e., open the piston), the casing pressure is
increased to a test pressure condition. This increased pressure
ruptures the rupture disc 23 or 52 and fluid at casing pressure
(hydrostatic, applied or any combination) enters the chamber
immediately below and adjacent to the piston 5 (in Figure 2 this
is shown at the right end of piston 5 and to the left of valve
14). This entry of fluid causes the piston 5 to begin moving (to
the left in the drawings). This fluid movement allows the piston
to move inexorably closer to an open position. In actual lab and
field tests a piston movement of about 4.5 inches begins to
uncover the inner openings 25-27 and the outer openings 28.
These openings are initially closed or sealed off from the casing
fluid by the piston 5. As piston 5 moves toward the open and
final position, the slots, 28, are uncovered allowing fluid to
flow through openings 25, 26 and 27 through slots 28. Thus, the
restrained movement of the piston allows a time delay from the
time the disc, 23 is ruptured until the slots uncovered for
fluid to pass. This movement continues until the piston has
moved to a position where the ports are fully opened. Piston 5
surrounds the inner mandrel 29. As fluid pressure increases
through valve 14 it moves piston 5 into the fluid chamber 32.
Hydraulic fluid in the fluid chamber restrains the movement of
the piston. There is a hydraulic
Date Rectie/Date Received 2023-04-14
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flow restrictor 22 that allows fluid to pass from chamber
32 to lower pressure chamber 34. This flow restrictor
controls the rate of flow of fluid from chamber 32 to
chamber 34 and thereby controls the speed of the movement
of the piston as it moves to the full open position. Slots
28 in the apparatus mandrel that will be the passageway for
fluid from the casing to the formation. Figure 3 shows the
position of piston 5 when "opened" (moved into chamber 32).
Initially, this movement increases pressure in the fluid
chamber to a value that closely reflects the hydrostatic
plus applied casing pressure. There is considerable
predetermined control over the delay time by learned
manipulation of the fluid type, fluid volume, initial
charging pressure of the low pressure chamber and the
variable flow rate through the hydraulic restrictor. The
time delay can be set as desired but generally will be
about 5 to 60 minutes. Any hydraulic fluid will be suitable
if capable of withstanding the pressure and temperature
conditions that exist in the well bore. Those skilled in
the art will easily be able to select suitable fluids such
as Skydrol SOOB_4TM.
[0113] In another embodiment there are added controls on
the flow of fluid from the piston chamber 32 to the low
pressure piston chamber 34 to more precisely regulate the
speed at which the piston moves to open the ports. As
illustrated in Figure 5 (a sectional enlarged view of the
section of the tool housing the flow restrictor that allows
fluid to flow from the piston chamber 32 to the lower
pressure chamber 34) there is a Back Pressure Valve or
Pressure Relief Valve 42 placed downstream of the Flow
Metering Section 22 to maintain a predetermined pressure in
the Fluid Chamber. This improves tool reliability by
reducing the differential pressure that exists between the
Fluid Chamber 34 and the well bore pressure in the piston
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chamber 32. This Back Pressure Valve or Pressure Relief
Valve 42 may be selected based on the anticipated
hydrostatic pressure. Back pressure valve(s) may also be
placed in series to increase the trapped pressure. Another
Back Pressure Valve or Pressure Relief Valve 44 may be
placed downstream of the Fluid Metering Section 22 to
ensure that only a minimum fluid volume can migrate from
the Fluid Metering Section 22 to the Low Pressure Chamber
34 during transport, when deployed in a horizontal well
bore or when inverted for an extended period of time. By
selecting the appropriate pressure setting of these back
pressure valves "slamming" (forceful opening by sudden
onrush of pressurized fluid) of the flow control valve is
reduced.
[0114] In operation an apparatus of the invention will
be piped into a casing string at a location that will allow
fluid injection into the formation where desired. The
apparatus may be inserted into the string an either
direction. An advantage of the present invention is that
two or more of the valves of the invention may be used in
the string. They will, as explained above, open to allow
injection of fluid at multiple locations in the formation.
It can also be appreciated by those skilled in the art how
two or more of valves of the invention may be used and
programmed at different time delays to open during
different stages of well operations as desired (e.g. one or
more at 5 minute delay and one or more at 20 minutes
delay). For example, the apparatus may be configured so
that an operator may open one or more valves (activating
the sliding closure) after a five minute delay, fracture
the zone at the point of the open valves, then have one or
more valves and continue to fractures the zone.
[0115] In general the apparatus will be constructed of
steel having properties similar to the well casing.
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[0116] A prototype apparatus had the general dimensions
of about 60 inches in length, with a nominal outside
diameter of 6.5 inches and an inside diameter of 3.75
inches. Other dimensions as appropriate for the well and
operation in which the apparatus is intended to be used are
intended to be included in the invention and may easily be
determined by those of ordinary skill in the art.
[0117] Figure 8 represents the results of a test of a
prototype of the apparatus. As shown, a 5-minute test shows
constant pressure for 5 minutes while the piston movement
uncovered openings in the apparatus.
[0118] In the foregoing specification, the invention has
been described with reference to specific embodiments
thereof. It will, however, be evident that various
modifications and changes can be made thereto without
departing from the broader spirit and scope of the
invention as set forth in the appended claims. The
specification is, accordingly, to be regarded in an
illustrative rather than a restrictive sense. Therefore,
the scope of the invention should be limited only by the
appended claims.
Preferred Exemplary Controlled Time Delay Apparatus with
Stacked Delay Restrictor (0900 - 0940)
[0119] The present invention is generally illustrated in
more detail in FIG. 9a (0910) wherein a controlled time
delay apparatus with a stacked delay restrictor is
integrated and conveyed with a wellbore casing. An expanded
view of the stacked delay restrictor is further illustrated
in FIG. 9b (0920). The apparatus may comprise a piston that
moves from a high pressure chamber to a low pressure
chamber, when actuated. The stacked delay restrictor (0902)
is in communication with a high pressure chamber (0903),
may comprise multiple stacked delay elements connected in a
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series, parallel or combination thereof. The delay element
may be a conventional hydraulic restrictor such as a
ViscoJetTM. The stacked delay restrictor allows fluid to
pass from a high pressure chamber (0903) to lower pressure
chamber (0901). This flow restrictor controls the rate of
flow of fluid from the high pressure chamber (0903) to the
low chamber (0901) and thereby controls the speed of the
movement of the piston (0904) as it moves to the full open
position. The number of delay elements may be customized to
achieve a desired time delay for the piston to travel from
a closed position to open an opening in housing of the
apparatus. According to another preferred exemplary
embodiment, the delay elements are connected in a parallel
fashion as illustrated in FIG. 9c (0930). An expanded view
of the stacked delay restrictor with parallel delay
elements (0902, 0912) is further illustrated in FIG. 9d
(0940). According to yet another preferred exemplary
embodiment, the delay elements are connected in a series
and parallel combination. According to a preferred
exemplary embodiment, a time delay is greater than 60
minutes and less than 2 weeks. The time delay may be
controlled by manipulating the fluid type fluid volume in
the delay elements, initial charging pressure of the low
pressure chamber and the variable flow rate through the
hydraulic restrictor. According to yet another exemplary
embodiment, the hydraulic fluid is solid at the surface
that changes phase to liquid when in operation as a toe
valve in the wellbore casing. Any hydraulic fluid will be
suitable if capable of withstanding the pressure and
temperature conditions that exist in the well bore. The
viscosity of the hydraulic fluid may range from 3
centistokes to 10,000 centistokes. According to a further
exemplary embodiment, the time delay in the restrictor may
be increased by addition of plugging agents. The size and
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shape of the plugging agents may be designed to effect a
longer or shorter time delay. For example, larger particle
size plugging agents may delay the rate of travel of a
piston as compared to smaller size plugging agents.
[0120] According to yet another preferred exemplary
embodiment, the delay elements may be designed as a
cartridge that may be slide in and out of the restrictor.
The cartridge may have a form factor that is compatible
with the restrictor. According to a preferred exemplary
embodiment, the cartridge may be positioned and customized
to achieve a desired time delay.
Preferred Exemplary ID/OD Controlled Time Delay Ratio
[0121] Table 1.0
illustrates an exemplary ratio of inner
diameter (ID) to outer diameter (OD) in an exemplary
controlled time delay apparatus. According to a preferred
exemplary embodiment the ratio of ID/OD ranges from 0.4 to
0.99. According to a preferred exemplary embodiment, a full
bore version wherein the inner diameter of the apparatus is
almost equal to the inner diameter of the wellbore casing
enables substantially more fluid flow during production.
Table 2.0 illustrate the inner casing ID and outer casing
ID corresponding to the Name column of Table 1Ø For
example, a name of 4 refers to
a casing OD of 4.5 in
table 2Ø
CA 02939553 2016-08-22
Table 1.0
Name Outer Diameter Inner Diameter
(in) (in)
4 1/2 5.65 3.34
5.65 3.34
5 1/2 6.88 3.75
4 Full Bore
5 t..1 Full Bore 7.38 4.6
Table 2.0
Casing OD Casing Casing ID
Weight
(in) (1b/ft) (in)
4.5 13.50 3.03
4.5 11.60 3.11
5.5 23.00 3.78
5.5 20.00 3.90
5.5 17.00 4.03
[0122] According to a preferred exemplary embodiment, an
inner tool diameter and an inner casing diameter ratio
ranges from 0.4 to 1.1.
Preferred Exemplary Section of a Controlled Toe Valve
Apparatus illustrating Port Closed time. Actuation Time Period
and Port Den Time Interval (1000 - 10301
Port Closed Time (1010):
[0123] As generally illustrated in FIG. 10a (1010), when
ready to operate, the casing pressure is increased to a
test pressure condition. The piston (1001) is held in its
place while the piston covers the openings (1002) in the
housing of the controlled time delay apparatus. The piston
(1001) remains in place until an actuation event takes
place. The time the piston remains in a static position
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. .
between a pressure ramp-up event to just before an
actuation event may be considered a port closed time.
Port Actuation Time Period (1020):
[0124] As generally illustrated in FIG. 10b (1020), when
ready to operate, the casing pressure is increased to a
test pressure condition which is generally the maximum
pressure that a well casing is designed to operate. When
the casing pressure increases beyond an actuation pressure
of a pressure actuation device, the increased pressure
ruptures a pressure actuation device such as a rupture disc
and fluid at casing pressure enters the chamber immediately
below and adjacent to the piston (1001) into a high
pressure chamber. This fluid movement allows the piston to
move inexorably closer to an open position. The piston
moves toward the openings in the housing of the apparatus.
The time the piston travels after an actuation event to
just before uncovering a port may be considered actuation
time period. The restrained movement of the piston (1001)
allows a time delay from the time the pressure actuation
device is ruptured until the openings ("slots") (1002)
uncovered for fluid to pass. This movement continues until
the piston has moved to a position where the ports are
almost open to fully open. Hydraulic fluid in the fluid
chamber restrains the movement of the piston. A stacked
delay restrictor or a restriction element such as a
viscojetTM may control the rate of flow of fluid from a high
pressure chamber to a low pressure chamber and thereby
control the speed of the movement of the piston as it moves
to a full open position.
Port Open Time Interval (1030):
[0125] As generally illustrated in FIG. 10c (1030), as
the piston (1001) moves toward the fully open and final
position, the openings (1002) in the housing are uncovered
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allowing fluid to flow through the ports in the mandrel.
This movement continues until the piston has moved to a
position where the openings are fully uncovered. The time
the piston travels from a position (1001) just before
uncovering the openings (1002) to fully uncovering the
openings (1002) may be considered port opening time
interval.
Preferred Exemplary Chart of a Pressure Casing Test with a
Controlled Time Delay Toe Valve Apparatus (1100 - 1190)
[0126] Figure ha (1140) illustrates an exemplary
pressure test with a controlled time delay toe valve
apparatus. The chart shows the pressure in the casing on
the Y-axis plotted against time on the X-axis. The pressure
in the casing may be increased from an initial pressure
(1101) to 80% of the maximum test pressure (1102). A
pressure actuating device such as a reverse acting rupture
disk may rupture at 80-90% of the test pressure (1103) at
time (1107). The piston may be actuated then and begin to
move as the pressure is further increased to max casing
pressure (1104). The actuation time period may be defined
as the time taken by the piston to travel when the piston
is actuated to the time the piston starts uncovering the
housing openings. For example, as illustrated in FIG. ha
(1140), the time of travel of the piston from time (1107)
to time (1108) is the actuation time (1105). When the
piston starts to uncover the openings of the housing, the
ports in the mandrel align with the openings as the piston
moves slowly in a controlled manner. The port opening time
interval may be defined as the time taken by the piston to
start opening the openings to completely open the openings.
For example, as illustrated in FIG. ha (1140), the time of
travel of the piston from time (1108) to time (1109) is the
port opening time (1106). During the port opening time, the
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pressure in the casing may drop to the hydrocarbon
formation pressure as the connection to the formation is
complete. According to a preferred exemplary embodiment,
the piston moves past the housing openings slowly in a
controlled manner resulting in a jetting action for
connection of the pressurized fluid to the formation. The
port opening time and the actuation time may be controlled
by various factors including size of the high pressure
chamber, hydraulic restrictor fluid, length of the
hydraulic restrictor, plugging agents and design of the
hydraulic restrictor. The diameter of the plugging agent
may range from 1 micron to 50 microns.
[0127] According to a preferred exemplary embodiment,
the port opening time interval may range from 1 second to 1
hour. According to a more preferred exemplary embodiment
the port opening time interval may range from 0.5 second to
20 minutes. According to another preferred exemplary
embodiment, the port opening time interval is almost 0
seconds.
[0128] Similar to the chart in FIG. lla (1140), a chart
illustrating an instant open is generally illustrated in
FIG. lib (1160) wherein the piston make a connection to the
formation instantaneously in a controlled manner. The port
actuation time period (1115) is relatively short and
controlled as compared to the port actuation time period
(1105) in FIG. ha (1140). According to a preferred
exemplary embodiment, the port actuation time period ranges
from 0.5 seconds to less than 5 minutes. According to a
more preferred exemplary embodiment, the port actuation
time period is almost zero or instantaneous. According to
another preferred exemplary embodiment, the port actuation
time period ranges from 60 minutes to less than 2 weeks.
The time delay or the actuation time period may be
controlled by factors such as shorter hydraulic restrictor
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length, lower viscosity hydraulic restrictor fluid, and
shorter high pressure chamber. To an operator controlling
the fluid pressure from the surface, it would appear that
the connection to the formation occurred instantaneously as
the pressure response is too quick to detect. In this case,
the connection to the subterranean formation occurs
instantaneously in a controlled manner as compared to prior
art methods wherein the piston is slammed to open the ports
to the formation. According to a preferred exemplary
embodiment, the apparatus makes connection to the formation
instantaneously in a controlled manner.
Preferred ExemPlary Reverse Actina Rupture Disk (1200 - 1220)
[0129] As generally illustrated in FIG. 12a (1210) a
prior art rupture disk is prone to plugging with cement and
other debris (1201). The plugging of the rupture disk
(1210) may fluctuate the actuation pressure at which the
rupture disk ruptures and may prevent actuation of the
device. Therefore, there is a need for a rupture disk that
functions as rated without plugging. As generally
illustrated in FIG. 12b (1220) an exemplary reverse acting
rupture disk may be used in a controlled time delay
apparatus as a pressure actuating device. The reverse
acting rupture disk (1202) has the unique advantage of not
getting plugged during cementing and other wellbore
operations. This advantage results in the rupture disk to
function as it is rated when compared to a conventional
forward acting rupture disk which is susceptible to
plugging.
Preferred Exemplary Controlled Time Delay Apparatus with
Mandrel Ports and Housing Openina Shapes (1300 - 15001
[0130] FIG. 13 (1300), FIG. 14 (1400), FIG. 15a (1510),
and FIG. 15b (1520) generally illustrate a jetting action
of pressurized fluid from the wellbore casing to the
CA 02939553 2016-08-22
hydrocarbon formation. As the piston moves slowly across
the openings in the housing of the toe valve uncovering the
openings in the housing, the ports in the mandrel align
with the openings to produce a guided hole jet effect of
the pressurized fluid through the openings. The shape of
the guided hole jet depends on the shape of the port in the
piston and shape of the opening in the housing. The valve
may open at maximum pressure and an initial restricted flow
area, which increases to maximum design flow area over time
as the piston moves slowly across. According to a preferred
exemplary embodiment, the shape of the port in the mandrel
may be selected from a group comprising a circle, oval and
a square. According to another preferred exemplary
embodiment, the shape of the opening in the housing may be
selected from a group comprising a circle, oval and a
square.
[0131] FIG. 13 (1300) illustrates a jet that may be
formed with a circle shaped opening (1303) in the housing
and a circle shaped port (1304) in the mandrel (1302) when
a piston uncovers the openings in the housing (1301).
Similarly, FIG. 14 (1400) illustrates a jet that may be
formed with an oval shaped opening (1403) in the housing
and an oval shaped port (1404) in the mandrel (1402) when a
piston uncovers the openings in the housing (1401).
Likewise, FIG. 15a (1510) illustrates a jet that may be
formed with an oval shaped opening (1503) in the housing
and a circle shaped port (1504) in the mandrel (1502) when
a piston uncovers the openings in the housing (1501). Also,
FIG. 15b (1520) illustrates a jet that may be formed with a
circle shaped opening (1513) in the housing and an oval
shaped port (1514) in the mandrel (1512) when a piston
uncovers the openings in the housing (1511).
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[0132] A constant width slot or variable width slot such
as a tear drop may also be used as an opening in the
housing or a port in the mandrel. Any shape that is
constant width as the piston travels may be used as an
opening in the housing or a port in the mandrel. Similarly,
a shape such as a tear drop that may become wider or
narrower as the piston moves past the openings and the
ports may be used as an opening in the housing or a port in
the mandrel. The flow area of the inner mandrel may be
designed for limited entry applications so that flow is
diverted to multiple injection points at high enough flow
rate.
Preferred Exemplary Flowchart of a Controlled Time Delay
Apparatus (1600)
[0133] As generally seen in the flow chart of FIG. 16
(1600), a preferred exemplary controlled time delay method
with a controlled time delay apparatus may be generally
described in terms of the following steps:
(1) installing a wellbore casing in a wellbore along
with the toe valve apparatus (1601);
(2) injecting the fluid to increase well pressure to
80 to 100% of the maximum pressure (1602);
(3) actuating the actuating device when a pressure of
said fluid exceeds a rated pressure of the
actuating device (1603);
(4) allowing a piston in the toe valve to travel for
an actuation time period (1604); and
(5) enabling the piston to travel to open openings
for the port opening time interval so that the
pressurized fluid flows into the subterranean
formation (1605).
32
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Preferred Exemplary Flowchart of a Controlled Time Delay
Apparatus (1610)
[0134] As generally seen in the flow chart of FIG. 16a
(1610), a preferred exemplary controlled time delay method
with a controlled time delay apparatus may be generally
described in terms of the following steps:
(1) installing a wellbore casing in a wellbore along
with said apparatus (1611);
(2) injecting the fluid to increase well pressure to
80 to 100% of the maximum pressure (1612);
(3) testing for casing integrity (1613);
(4) increasing pressure of said pressurized fluid so
that said pressure exceeds a rated pressure of
said actuating device (1614);
(5) increasing pressure of said pressurized fluid to
about 100% of said maximum casing pressure
allowing a piston to travel for said actuation
time period (1615);
(6) testing casing integrity for said actuation time
period (1616); and
(7) enabling said piston to travel to open said
openings for said port opening time interval so
that said pressurized fluid flows into said
subterranean formation (1617).
Preferred Exemplary Dual Actuatina Controlled Time Delay
Apparatus (1700 - 1900)
[0135] As generally illustrated in FIG. 17a (1710) and
FIG. 17b (1720) a dual actuating controlled time delay
apparatus comprises dual controlled toe valves (1701, 1702)
for use in a wellbore casing. Each of the dual toe valves
33
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(1701, 1702) is similar to the aforementioned toe valve
apparatus in FIG. lA and FIG. 1B. Toe valve (first delay
tool) (1701) may comprise a first piston (1704) that moves
when actuated by a first pressure actuating device (1703),
first openings (1705) in the housing and first ports (1707)
in the mandrel. Similarly, toe valve (second delay tool)
(1702) may comprise a second piston (1714) that moves when
actuated by a second pressure actuating device (1713),
second openings (1715) in the housing and second ports
(1717) in the mandrel. The first delay tool (1701) may be
integrated into the well casing at a first location and the
second delay tool (1702) may be integrated into the well
casing at a second location. The first location and the
second locations may be determined by an open-hole log
before casing is placed in a wellbore, seismic data that
may include 3 dimensional formation of interest to stay in
a zone, and a mud log. According to a preferred exemplary
embodiment, the dual actuating controlled time delay
apparatus may further comprise a third delay tool
integrated into the wellbore casing at a third location.
The third tool may comprise a third housing with third
openings, a third piston, and a third actuating device. It
should be noted that the number of delay tools
aforementioned may not be construed as a limitation. One
ordinarily skilled in the art may use three or more delay
tools that may be integrated into the wellbore casing to
achieve staggered delay openings at various times. Other
operations including pumping down tools, injecting fluid or
plugging may be performed at any time while the delay tools
are opening. Rate of travel of each of the pistons (1704,
1714) in the toe valves (1701, 1702) is controlled
independently of each other. According to a preferred
exemplary embodiment, the dual actuating controlled time
delay apparatus may be manufactured from an integral one-
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piece design of the mandrel that carries all of the
tensile, compressional and torsional loads encountered by
the apparatus. The entire dual actuating controlled time
delay apparatus may be piped into the casing string as an
integral part of the string and positioned where
perforation of the formation and fluid injection into a
formation is desired. The dual actuating controlled time
delay apparatus may be installed in either direction with
no change in its function.
[0136] Prior art systems do not provide for two or more
toe valves in a single system due to the fact that the
first connection to the formation releases all the pressure
in the well casing, therefore making a potential second toe
valve ineffective. This is caused by the tolerance in
actuation pressure inherent in the actuation devices.
According to a preferred exemplary embodiment, the time
delays of individual toe valves are controlled
independently so that multiple connection points to the
formation are created. The effect of multiple connection
points to the formation may result in increased connection
efficiency and increased flow area to the formation.
According to a preferred exemplary embodiment, the flow
area may be increased by 50% to more than 1000%. According
to a preferred exemplary embodiment, the time delays of the
individual toe valves are the same. According to another
preferred exemplary embodiment, the time delays of the
individual toe valves are not equal. According to yet
another preferred exemplary embodiment, a ratio of the
first actuation time period and the second actuation time
period ranges from 0.01 to 100. According to a further
preferred exemplary embodiment, a ratio of the first port
open time interval and the second port open time interval
ranges from 0.01 to 100. According to yet another preferred
exemplary embodiment, one valve provides a fail-safe
CA 02939553 2016-08-22
mechanism for connection to the formation. The difference
in rated pressures of the first actuating device (1713) and
the second actuating device (1703) may be within 500 PSI.
This is particularly important as the rated pressure of
actuating devices such as rupture disks are rated within +-
500 PSI. In order to account for the differences in rated
pressure, two delay tools with a rated pressure difference
of +-500 PSI may be used to minimize the uncertainty in the
actuation pressure. In the event that one valve fails to
open or function the other valve may act as a replacement
or fail-safe to provide connection to the formation. FIG.18
(1800) illustrates a perspective view of a controlled dual
time delay controlled apparatus. The controlled dual time
delay controlled apparatus may be integrated into a
wellbore casing (1901) as illustrated in FIG. 19 (1900).
The casing with the integrated dual control apparatus may
be cemented with a cement (1902). The apparatus may
comprise two individually controlled time delay apparatus,
a first delay tool (1903) and a second delay tool (1904).
According to a preferred exemplary embodiment, the
controlled dual time delay controlled apparatus may be
integrated at a toe end of the casing. According to another
preferred exemplary embodiment, the controlled dual time
delay controlled apparatus may be integrated at a heal end
of the casing.
Preferred Exemplary Flowchart of a Controlled Time Delay with
a Dual Actuatina Toe Valve (20001
[0137] As
generally seen in the flow chart of FIG. 20
(2000), a preferred exemplary controlled time delay method
with a dual actuating controlled apparatus aforementioned
in FIG. 17a (1710) may be generally described in terms of
the following steps:
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(1) installing a wellbore casing in a wellbore along
with the dual actuating controlled apparatus
(2001);
(2) injecting the fluid to increase well pressure to
80 to 100% of the maximum pressure (2002);
(3) activating a first actuating device when the
maximum pressure exceeds a rated pressure of the
first actuating device and activating the second
actuating device when the maximum pressure
exceeds a rated pressure of the second actuating
device (2003);
(4) allowing a first piston to travel for a first
actuation time period and allowing a second
piston to travel for a second actuation time
period (2004); and
(5) enabling the first piston to travel to open the
first openings for a first port opening time
interval and enabling the second piston to travel
to open the second openings for a second port
opening time interval, so that the pressurized
fluid flows into the subterranean formation
(2005).
Preferred Exemplary Single Actuating Controlled Dual Time
Delay Apparatus (2100 - 2200)
[0138] As generally illustrated in FIG. 21a (2110), FIG.
21b (2120), and FIG. 21c (2130) a single-actuating
controlled dual time delay apparatus comprising dual time
delay valves with pistons (2103, 2113), a mandrel (2105),
openings (2101, 2111) and ports (2102, 2112) for use in a
wellbore casing. The single-actuating controlled dual time
delay apparatus may comprise a first piston (2103) and a
second piston that move in opposite directions when
37
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actuated by a pressure actuating device (2104). The first
delay valve may be integrated into the well casing at a
first location and the second delay valve may be integrated
into the well casing at a second location. The first
location and the second locations may be determined by an
open-hole log before casing is placed in a wellbore,
seismic data that may include 3 dimensional formation of
interest to stay in a zone, and a mud log. According to a
preferred exemplary embodiment, the single actuating
controlled time delay apparatus may further comprise a
third delay tool integrated into the wellbore casing at a
third location. The third tool may comprise a third housing
with third openings, a third piston, and an actuating
device. It should be noted that the number of delay tools
aforementioned may not be construed as a limitation. One
ordinarily skilled in the art may use three or more delay
tools that may be integrated into the wellbore casing to
achieve staggered delay openings at various times.
According to a preferred exemplary embodiment, two or more
time delay valves may be actuated by a single actuating
device. The rate of travel of each of the pistons (2103,
2113) in the apparatus may be controlled independently of
each other. According to a preferred exemplary embodiment,
the single-actuating controlled time delay apparatus may be
manufactured from an integral one-piece design of the
mandrel that carries all of the tensile, compressional and
torsional loads encountered by the apparatus. The entire
single-actuating controlled time delay apparatus may be
piped into the casing string as an integral part of the
string and positioned where perforation of the formation
and fluid injection into a formation is desired. The
single-actuating controlled time delay apparatus may be
installed in either direction with no change in its
function. Prior art systems do not provide for two or more
38
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toe valves in a single system due to the fact that the
first connection to the formation releases all the pressure
in the well casing, therefore making a potential second toe
valve ineffective. According to a preferred exemplary
embodiment, the time delays of individual toe valves are
controlled independently so that multiple connection points
to the formation are created. The effect of multiple
connection points to the formation may result in increased
connection efficiency and increased flow area to the
formation. According to a preferred exemplary embodiment,
the flow area may be increased by 50% to more than 1000%.
According to a preferred exemplary embodiment, the time
delays of the individual toe valves are the same. According
to another preferred exemplary embodiment, the time delays
of the individual toe valves are not equal. According to
yet another preferred exemplary embodiment, one valve
provides a fail-safe mechanism for connection to the
formation. In the event that one valve fails to open or
function the other valve may act as a replacement or fail-
safe to provide connection to the formation. FIG.22 (2200)
illustrates a perspective view of a controlled single-
actuating dual time delay controlled apparatus. The
controlled single-actuating dual time delay controlled
apparatus may be integrated into a wellbore casing. The
single-actuating may comprise two individually controlled
time delay apparatus, a first delay tool and a second delay
tool. According to a preferred exemplary embodiment, the
controlled dual time delay controlled apparatus may be
integrated at a toe end of the casing. According to another
preferred exemplary embodiment, the controlled dual time
delay controlled apparatus may be integrated at a heal end
of the casing.
39
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Preferred Exemplary Flowchart of a Controlled Time Delay with
a Single Actuating Toe Valve (2300)
[0139] As generally seen in the flow chart of FIG. 23
(2300), a preferred exemplary controlled time delay method
with a single-actuating controlled dual time delay
apparatus may be generally described in terms of the
following steps:
(1) installing a wellbore casing in a wellbore along
with the dual toe valve apparatus (2301);
(2) injecting the fluid to increase well pressure to
80 to 100% of the maximum pressure (2302);
(3) activating an actuating device when the maximum
pressure exceeds a rated pressure of the
actuating device (2303);
(4) allowing a first piston to travel for a first
actuation time period and allowing a second
piston to travel for a second actuation time
period (2304); and
(5) enabling the first piston to travel to open the
first openings for a first port opening time
interval and enabling the second piston to travel
to open the second openings for a second port
opening time interval, so that the pressurized
fluid flows into the subterranean formation
(2305).
Preferred Exemplary Flowchart of Perforatina and Fracturina
throuah a Controlled Time Delay Toe Valve (2400)
[0140] As generally seen in the flow chart of FIG. 24
(2400), a preferred exemplary fracturing method through a
controlled time delay apparatus may be generally described
in terms of the following steps:
CA 02939553 2016-08-22
(1) installing a wellbore casing in a wellbore along
with the time delay apparatus (2401);
the time delay apparatus may be configured with a
seating surface so that a restriction plug
element may be seated in the seating surface.
(2) pumping up wellbore pressure to a maximum
pressure (2402);
(3) activating an actuating device when a maximum
pressure exceeds a rated pressure of the
actuating device (2403);
(4) performing a casing integrity test for an
actuation time period at the maximum pressure
(2404);
(5) enabling a piston to travel to open openings so
that a connection is established to a
subterranean formation (2405);
(6) pumping fracturing fluid through the time delay
apparatus (2406);
acid stimulation with HCL may be performed prior
to or during pumping fracturing fluid so that an
improved connection is created to the formation
and further fracturing operations are effective
in creating fractures.
(7) pumping a perforating gun into the wellbore
casing (2407); and
The perforating gun may be pumped along with a
frac plug so that the frac plug isolates the next
stage. A restriction plug element may be deployed
to seat in the seating surface of the apparatus.
(8) perforating through the perforating gun (2408).
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Preferred Exemplary Apparatus Ball Seat in a Controlled Time
Delay Injection Valve (2500 - 2600)
[0141] The wiper plug designs used in today's horizontal
well bores were initially developed for use in vertical
well bores. The horizontal well bores present a more
challenging trajectory for the equipment due to the
extended casing length and concentrated friction on only
one side of the wiper plug. As a consequence, the
elastomeric fins of a wiper plug can become worn on one
side and render incapable of sealing properly in the
dimensions of the conventional shoe joint. This causes a
phenomena called "wet shoe." The downfalls of having a wet
shoe in a cemented wellbore casing include possible leak
paths, lack of isolation, and no pressure integrity of the
casing. Therefore, when a pressure casing integrity test
fails, the cause of the failure is either a wet shoe or
leak in the casing. According to a preferred exemplary
embodiment, time delay injection valve or a toe valve with
a ball seat enables detection of wet shoe when a ball or a
restriction plug element dropped into the wellbore casing
seats in the ball seat and seals the toe end to remediate
the wet shoe. On the other hand, if the ball seated in the
time delay injection valve still causes a casing integrity
test to fail, then the cause of the failure is not the wet
shoe which further indicates that the cause of failure is
related to the casing integrity. In some instances, the
casing integrity failure may be due to weaker joints or a
hole in the casing. According to a preferred exemplary
embodiment, the time delay injection valve is a hydraulic
controlled time delay valve. For example the time delay
injection valve may be a hydraulic controlled time delay
valve as illustrated in FIG. 1A. An additional seat may be
located below the valve, providing a means to test the toe,
the valve and the well. According to another preferred
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exemplary embodiment, the time delay injection valve is a
hydraulic controlled dual actuated time delay valve. For
example the time delay injection valve may be a hydraulic
controlled dual actuated time delay valve as illustrated in
FIG. 17a. According to yet another preferred exemplary
embodiment, the time delay injection valve is a hydraulic
controlled single actuated time delay valve. For example
the time delay injection valve may be a hydraulic
controlled single actuated time delay valve as illustrated
in FIG. 21a.
[0142] FIG. 25 (2500) generally illustrates a
restriction plug element (2503) seated in a seating surface
(2502) of a controlled time delay apparatus (2501). The
controlled time delay apparatus (2501) may be installed at
a toe end of a wellbore casing. The restriction plug
element (2503) may be a ball that may be dropped to seat in
the valve (2501). The seated restriction plug element
(2503) may seal any leaks past the restriction plug element
(2503) in a toe ward direction, thereby enabling detection
of a wet shoe in a wellbore casing. According to a
preferred exemplary embodiment, a toe valve with a ball
seat is used to isolate wet shoe failures from casing
integrity failures. According to a preferred exemplary
embodiment, a restriction plug element seated in a
controlled time delay apparatus may be used to create the
first stage in a perforation and fracturing operation. FIG.
26 (2600) generally illustrates a perspective view of a
restriction plug element seated in a seating surface of a
controlled time delay apparatus. According to a preferred
exemplary embodiment, the restriction plug element is
degradable in wellbore fluids.
[0143] According to another preferred exemplary
embodiment, the restriction plug element is non-degradable
43
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in wellbore fluids. According to a preferred exemplary
embodiment, the restriction plug element has a shape that
may be selected from a group comprising a sphere, dart,
oval, or cylinder.
Preferred Exemplary Flowchart of Wet Shoe Detection with a
Controlled Time Delay Toe Valve (2700)
[0144] As generally seen in the flow chart of FIG. 27
(2700), a preferred exemplary wet shoe detection method
through a controlled time delay apparatus with a ball seat
may be generally described in terms of the following steps:
(1) installing a wellbore casing in a wellbore along
with the apparatus (2701);
(2) performing a casing integrity test at 80 to 100 %
of maximum pressure (2702);
the casing integrity test may be performed at 80%
or 100% of the maximum pressure. Fluid may be
injecting to increase well pressure to 80 to 100%
of the maximum pressure.
(3) checking if the casing integrity test passes, if
so, proceeding to step (9) (2703);
(4) deploying a restriction plug element into the
wellbore casing (2704);
(5) seating the restriction plug element in a
conforming seating surface of the apparatus
(2705);
(6) performing a casing integrity test at maximum
pressure (2706);
the casing integrity test may be performed at 80%
or 100% of the maximum pressure.
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(7) checking if the casing integrity test passes, if
so, proceeding to step (9) (2707);
(8) fixing a source of the leak (2708); and
(9) performing injection, perforation, or fracturing
operations (2709).
Preferred Exemplary System of Debris Removal in a Wellbore
Casino (2800)
[0145] In a
fracture treatment application, the well can
contain residual cement or other "debris" which can block
or restrict the function of perforations or casing conveyed
completion valves. This blockage may occur during initial
injection at low rates to pump down a tool string, or when
the pumping rate increases during a fracture stimulation
treatment, or after some time at the increased pumping
rate. FIG. 28a (2810), FIG. 28b (2820), FIG. 28c (2830)
illustrate a dual injection system with a time delay
mechanism that may be used in a staged or sequential delay
fashion with multiple injection points. As illustrated in
FIG. 28a, a first tool (2801) and a second tool (2802) may
be conveyed with a wellbore casing or deployed into a
wellbore casing (2805). The wellbore casing may be lined
with cement (2803) or open hole. For instance, injection
point one is open as illustrated in FIG 28b. (2820), and
flow rate ramps up, carrying debris preferentially to clog
injection point one. Injection point two then opens as
illustrated in FIG. 28c (2830), allowing unobstructed flow
to the wellbore. Staggered sequential time delayed tools
(used in conjunction with already open connections or in
sets by themselves) such that debris from cementing,
perforation or other sources is preferentially drawn toward
the tool that connects to the reservoir first, whether
uphole or downhole from second tool, that opens leaving
second tool to be free of debris with an improved
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connection to the reservoir. In the interval between the
opening of the first injection point in the first tool
(2801) and opening of the second injection point in the
second tool (2802), fluid may be pumped into the well
casing to move debris (2804) to the first injection point.
According to a preferred exemplary embodiment, the second
injection point may open after the first injection point
plugs. For example, if the first tool is a controlled time
delay valve with a 5 minute time delay and the second tool
is a controlled time delay valve with a 30 minute time
delay, after the first tool opens at 5 minutes after
actuation, fluid may be pumped for 25 minutes to collect
debris in the first tool before the second tool is opened.
According to a preferred exemplary embodiment, the dual
injection apparatus may be manufactured from an integral
one-piece design of the mandrel that carries all of the
tensile, compressional and torsional loads encountered by
the apparatus. The entire dual injection apparatus may be
piped into the casing string as an integral part of the
string and positioned where perforation of the formation
and fluid injection into a formation is desired. The dual
injection apparatus may be installed in either direction
with no change in its function. According to a preferred
exemplary embodiment, the first tool and the second tools
are controlled time delay tools. According to another
preferred exemplary embodiment, the first tool is a
controlled time delay tool and the second tool is a
perforating gun. According to yet another preferred
exemplary embodiment, the first tool is a valve that may be
actuated by a ball and the second tool is a controlled time
delay tool. According to a further preferred exemplary
embodiment, the first tool and the second tools are valves
that may be actuated by a ball. It should be noted that any
combination of a controlled time delay tool, perforating
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gun, valve actuated by a ball may be used as the first tool
and the second tool to create the first injection point and
the second injection point.
[0146] In a cemented liner application, it is common
practice to over displace the cement by 20-40% of cement
volume to achieve a good liner lap (good cement job across
the liner top for pressure integrity). When the running
tool is disconnected from the liner hanger system, the over
displaced cement then falls back into the liner top, which
leaves behind cement stringers, and other debris. These
stringers, and debris then gravitate to the heel of the
well, and later will be pumped from the heel to the toe
when opening the toe valves. These stringers and debris
have been known to plug or lock up toe valves.
[0147] According to a preferred exemplary embodiment,
two or more injections points may be used in a staggered
fashion in order to collect debris before creating an
obstruction free connection to the formation. This is
particularly important for a liner hanger job wherein a
liner hangs of the inside surface of the casing. If the
casing is not substantially clean, the liner may not hang
on to the inside surface.
Preferred Exemplary Flowchart of Debris Removal with a
Controlled Dual Injection Apparatus (2900)
[0148] As generally seen in the flow chart of FIG. 29
(2900), a preferred exemplary debris removal method with a
controlled dual injection apparatus comprising a first tool
and a second tool may be generally described in terms of
the following steps:
(1) installing a wellbore casing in a wellbore along
with the controlled dual injection apparatus
(2901);
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(2) injecting fluid so as to increase pressure to
about 80 to 100% of the maximum pressure (2902);
(3) opening a first injection point in the first tool
(2903);
(4) collecting debris in the first tool (2904);
(5) opening a second injection point in the second
tool (2905); and
(6) performing a downhole operation through the
second injection point (2906).
Preferred Exemplary Flowchart of Debris Removal with a
Controlled Dual Time Delay Apparatus (3000)
[0149] As
generally seen in the flow chart of FIG. 30
(3000), a preferred exemplary debris removal method with a
controlled dual injection apparatus comprising a first
delay tool and a second delay tool may be generally
described in terms of the following steps:
(1) installing a wellbore casing in a wellbore along
with the controlled dual time delay apparatus
(3001);
(2) injecting fluid so as to increase wellbore
pressure to about 80 to 100% of the maximum
pressure (3002);
(3) allowing a first piston in first delay tool to
travel for a first actuation time period and
allowing a second piston in second delay tool to
travel for a second actuation time period (3003);
(4) opening a first injection point in the first
delay tool after elapse of the first actuation
period (3004);
(5) collecting debris in the first tool (3005);
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(6) opening a second injection point in the second
tool after elapse of the second actuation period
(3006); and
(7) performing a downhole operation through the
second injection point (3007).
Preferred Exemplary Flowchart of Debris Removal with a
Controlled Time Delay Apparatus and a Perforating Gun (3100)
[0150] As
generally seen in the flow chart of FIG. 31
(3100), a preferred exemplary debris removal method with a
controlled apparatus comprising a first delay tool and a
perforating gun may be generally described in terms of the
following steps:
(1) installing a wellbore casing in a wellbore along
with the controlled apparatus (3101);
(2) injecting fluid so as to increase pressure to 80
to 100% of the maximum pressure (3102);
(3) allowing a piston in the delay tool to travel for
a actuation time period (3103);
(4) opening a first injection point in the delay tool
after elapse of the first actuation period
(3104);
(5) collecting debris in the first tool (3105);
(6) opening a second injection point in the second
tool after elapse a predetermined time (3106);
and
(7) performing a downhole operation through the
second injection point (3107).
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,
. .
Preferred Exemplary Flowchart of Debris Removal with a
Controlled Dual Injection Apparatus (3200)
[0151] As generally seen in the flow chart of FIG. 32
(3200), a preferred exemplary debris removal method with a
staged time delay system comprising a first tool, a second
tool and a third tool may be generally described in terms
of the following steps:
(1) installing a wellbore casing in a wellbore
(3201);
(2) injecting fluid into the wellbore casing so as to
increase pressure to a maximum pressure (3202);
(3) opening a first injection point in the first tool
(3203);
(4) collecting debris present in the wellbore casing
at first injection point in the first tool for a
predetermined time (3204);
(5) opening a second injection point in the second
tool and a third injection point in the third
tool (3205); and
(6) performing a downhole operation through the
second injection point and the third injection
point (3206).
[0152] According to a preferred exemplary embodiment,
the first tool is plugged with debris during the
predetermined time.
[0153] According to another preferred exemplary
embodiment, the second tool and the third tool are
controlled time delay valves.
[0154] According to a yet another preferred exemplary
embodiment, the second tool and the third tool are actuated
CA 02939553 2016-08-22
by a pressure of the pressurized fluid.
[0155] According to a further preferred exemplary
embodiment, the first tool and the second tool are actuated
by a first actuating device and the third tool actuated by
a second actuating device.
[0156] According to a more preferred exemplary
embodiment, the first tool and second tool are actuated by
pressure and the third tool is actuated by a ball. The ball
is deployed into the wellbore casing after the first tool
collects debris from the wellbore casing.
[0157] According to a more preferred exemplary
embodiment, the
system may further comprises a fourth
controlled time delay tool which is configured to be
collects debris through a fourth injection point along with
the first injection point.
Preferred Exemplary Sliding Sleeve Apparatus manufactured
from a One Piece Mandrel
[0158] As
generally illustrated in FIG. 33, the sliding
sleeve valve may be manufactured by installing a pressure
actuating disk (23) such as a rupture disk or a reverse
acting rupture disk onto the one piece mandrel (29). A
piston (5) may be installed onto the mandrel (29) to cover
openings (25) in the mandrel (29). The piston (5) may be
installed from the first threaded end (41) towards the
second threaded end (51) and hydraulically locking in
place. A first outer housing (6) may be slid over the
piston (5) from the first threaded end (41) and stopping on
a first shoulder (40). A first outer housing (6) may be
slid or glided over the piston (5) from the first threaded
end (41) and stop on a first shoulder (50). A high pressure
chamber (32) may be installed with a hydraulic fluid from
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the first threaded end (41) and stop adjacent to said
piston (5). A restriction assembly (44) may be installed
from the first threaded end (41) and stop adjacent to the
high pressure chamber (32). A second outer housing (4) may
be slid or glided over the mandrel adjacent to the
restriction assembly (44). An end cap (43) is attached to
the mandrel (29) and creating a low pressure chamber (34)
adjacent to the restriction assembly (44). The wellbore
casing (60) may be threaded to the mandrel (29) with the
threads (62). It should be noted that even though there is
one threaded end (41) illustrated in the FIG.33 with
threads (62), a second thread is made on the second
threaded end (51) of the mandrel to customize the kind of
thread used to thread into a wellbore casing. According to
a preferred exemplary embodiment, the threads may be
designed to casing torque specification.
[0159] According
to a preferred exemplary embodiment, a
sliding sleeve valve for use in a wellbore casing comprises
a mandrel with a first threaded end and a second threaded
end. The sliding sleeve valve may be conveyed with said
wellbore casing. The sliding sleeve valve may be installed
on a toe end of said wellbore casing. The mandrel may be a
tubular annular single piece member. The mandrel may be
made from materials selected from a group comprising of
steel, cast iron, ceramics or, composites. The one piece
integral piece enables the mandrel to carry the full
torsional load 10,000 ft-lbs to 30,000 ft-lbs of a wellbore
casing when the first threaded end and the second threaded
end are threaded to ends of the wellbore casing. The first
threaded end and the second threaded end may be designed to
carry the wellbore casing (60) specification. According to
a further preferred exemplary embodiment the first threaded
end and the threaded end are configured with threads that
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CA 02939553 2016-08-22
are configured to conform to the wellbore casing torque
specification.
[0160] According to a further preferred exemplary
embodiment the sliding sleeve valve is assembled with
components from one end only. For example, the rupture disk
(23), the piston (5), the first outer housing (6), the high
pressure chamber (32), the restriction assembly (44), the
second outer housing (4) and the end cap (43) are all
slid/glided or installed from the first threaded end (41)
towards the direction of the second threaded end (51).
According to another preferred exemplary embodiment a
plurality of components are installed longitudinally from
either end of the mandrel. The components may be installed
from
[0161] According to a preferred exemplary embodiment a
plurality of components are installed on an outer surface
of the mandrel. For example, the rupture disk (23), the
piston (5), the first outer housing (6), the high pressure
chamber (32), the restriction assembly (44), the second
outer housing (4) and the end cap (43) are all slid/glided
or installed on the outer surface of the mandrel (29).
According to another preferred exemplary embodiment the
plurality of components are installed on an inner surface
of the mandrel. According to yet another preferred
exemplary embodiment the plurality of components are
installed on an inner surface of the mandrel and an outer
surface of the mandrel.
[0162] According to a preferred exemplary embodiment
said sliding sleeve valve is a controlled hydraulic time
delay valve. According to a further preferred exemplary
embodiment the controlled hydraulic time delay valve
comprises dual time delay valves which are each actuated by
dual actuating devices. According to a further preferred
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exemplary embodiment the controlled hydraulic time delay
valve comprises dual time delay valves which are both
actuated by a single actuating device.
Preferred Exemplary Flowchart of Assemblina a Slidina Sleeve
Valve with a One Piece Mandrel (3400)
[0163] As
generally seen in the flow chart of FIG. 34
(3400), a preferred exemplary method of assembly of a
sliding sleeve valve with a one piece mandrel is described
in terms of the following steps:
(1) installing a pressure actuating disk onto said
mandrel (3401);
(2) installing a piston onto said mandrel to cover a
plurality of openings in said mandrel from said
first threaded end towards said second threaded
end and hydraulically locking in place (3402);
(3) sliding a first outer housing over said piston
from said first threaded end and stopping on a
first shoulder (3403);
(4) installing a high pressure chamber with the fluid
from said first threaded end and stopping
adjacent to said piston (3404);
(5) installing a restriction assembly from said first
end and stopping adjacent to said high pressure
chamber (3405);
(6) sliding a second outer housing over said mandrel
adjacent to said restriction assembly (3406);
(7) installing an end cap in said mandrel and
creating a low pressure chamber adjacent to said
restriction assembly (3407); and
(8) threading said wellbore casing to said sliding
sleeve valve with said mandrel (3408).
54
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=
System Summary
[0164] The present invention system anticipates a wide
variety of variations in the basic theme of time delay
valves, but can be generalized a controlled time delay
apparatus integrated into a well casing for injection of
pressurized fluid into a subterranean formation, the
apparatus comprising: a housing with openings, a piston, a
delay restrictor, an actuating device and a high pressure
chamber with a hydraulic fluid; the delay restrictor is
configured to be in pressure communication with the high
pressure chamber; a rate of travel of the piston is
restrained by a passage of the hydraulic fluid from the
high pressure chamber into a low pressure chamber through
the delay restrictor;
wherein
upon actuation by the actuating device, the piston
travels for an actuation time period, after elapse of the
actuation time period, the piston travel allows opening of
the openings so that the pressurized fluid flows through
the openings for a port opening time interval.
[0165] This general system summary may be augmented by
the various elements described herein to produce a wide
variety of invention embodiments consistent with this
overall design description.
Method Summary
[0166] The present invention method anticipates a wide
variety of variations in the basic theme of implementation,
but can be generalized as a controlled time delay method
wherein the method is performed on a controlled time delay
apparatus integrated into a well casing for injection of
pressurized fluid into a subterranean formation, the
apparatus comprising: a housing with openings, a piston, a
delay restrictor, an actuating device and a high pressure
CA 02939553 2016-08-22
chamber with a hydraulic fluid; the delay restrictor is
configured to be in pressure communication with the high
pressure chamber; a rate of travel of the piston is
restrained by a passage of the hydraulic fluid from the
high pressure chamber into a low pressure chamber through
the delay restrictor;
wherein
upon actuation by the actuating device, the piston
travels for an actuation time period, after elapse of the
actuation time period, the piston travel allows opening of
the openings so that the pressurized fluid flows through
the openings for a port opening time interval;
wherein the method comprises the steps of:
(1) installing a wellbore casing in a wellbore along
with the apparatus;
(2) injecting the pressurized fluid into the wellbore
casing;
(3) actuating the actuating device when the maximum
pressure exceeds a rated pressure of the
actuating device;
(4) allowing the piston to travel for the actuation
time period; and
(5) enabling the piston to travel to open the
openings for the port opening time interval so
that the pressurized fluid flows into the
subterranean formation.
[0165] This
general method summary may be augmented by
the various elements described herein to produce a wide
variety of invention embodiments consistent with this
overall design description.
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=
=
Casing Integrity Test Method Summary
[0166] The present invention method anticipates a wide
variety of variations in the basic theme of implementation,
but can be generalized as a casing integrity test method
wherein the method is performed with a controlled time
delay apparatus the time delay apparatus comprising: a
housing with openings, a piston, a restrictor, an actuating
device and a high pressure chamber with a hydraulic fluid;
the restrictor is configured to be in pressure
communication with the high pressure chamber; a rate of
travel of the piston is restrained by a passage of the
hydraulic fluid from the high pressure chamber into a low
pressure chamber through the restrictor;
wherein upon actuation by the actuating device, the
piston travels for an actuation time period, after elapse
of the actuation time period, the piston travel allows
opening of the openings so that the pressurized fluid flows
through the openings for a port opening time interval;
wherein the method comprises the steps of:
(1) installing a wellbore casing in a wellbore along
with the apparatus;
(2) injecting the fluid to about 80% of a maximum
casing pressure;
(3) testing for casing integrity;
(4) increasing pressure of the pressurized fluid so
that the pressure exceeds a rated pressure of the
actuating device;
(5) increasing pressure of the pressurized fluid to
about 100% of the maximum casing pressure
allowing the piston to travel for the actuation
time period;
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(6) testing casing integrity for the actuation time
period; and
(7) enabling the piston to travel to open the
openings for the port opening time interval so
that the pressurized fluid flows into the
subterranean formation.
[0167] This general method summary may be augmented by
the various elements described herein to produce a wide
variety of invention embodiments consistent with this
overall design description.
System/Method Variations
[0168] The present invention anticipates a wide variety
of variations in the basic theme of oil and gas extraction.
The examples presented previously do not represent the
entire scope of possible usages. They are meant to cite a
few of the almost limitless possibilities.
[0169] This basic system and method may be augmented
with a variety of ancillary embodiments, including but not
limited to:
[0170] An embodiment wherein the delay restrictor is a
cartridge comprising a plurality of delay elements
connected as a series chain.
[0171] An embodiment wherein the delay restrictor is a
cartridge comprising a plurality of delay elements
connected in a combination of series chain and a parallel
chain.
[0172] An embodiment wherein the hydraulic fluid has a
viscosity ranging from 3 to 10000 centistokes.
[0173] An embodiment wherein the hydraulic fluid further
has plugging agents that are configured to further retard
the rate of travel of the piston.
[0174] An embodiment wherein the hydraulic fluid is
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CA 02939553 2016-08-22
configured to change phase from a solid to a liquid.
[0175] An embodiment wherein the actuation time period
ranges from greater than 60 minutes to less than 2 weeks.
[0176] An embodiment wherein the actuation time period
is almost 0 seconds so that the openings open
instantaneously.
[0177] An embodiment wherein the actuation time period
ranges from 0.5 seconds to 60 minutes.
[0178] An embodiment wherein the actuation time period
is ranges from 2 minutes to 3 minutes.
[0179] An embodiment wherein the port opening time
interval ranges from 0.5 seconds to 20 minutes.
[0180] An embodiment wherein the port opening time
interval is almost 0 seconds.
[0181] An embodiment wherein the apparatus is associated
with an inner diameter and an outer diameter; the ratio of
inner diameter to outer diameter ranges from 0.4 to 0.9.
[0182] An embodiment wherein the apparatus is associated
with an inner tool diameter and the well bore casing is
associated with an inner casing diameter ratio; the ratio
of inner tool diameter to outer casing diameter ranges from
0.4 to 1.1.
[0183] An embodiment wherein the actuating device has a
rating pressure that is substantially equal to a pressure
of the wellbore casing.
[0184] An embodiment wherein the actuating device is a
reverse acting rupture disk.
[0185] An embodiment wherein the actuating device is a
rupture disk.
[0186] An embodiment wherein the mandrel further
comprises ports; the ports are configured to align to the
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openings in the housing during the port opening time
interval.
[0187] An embodiment wherein a shape of the openings in
the housing is selected from a group consisting of: a
circle, an oval, a triangle, and a rectangle.
[0188] An embodiment wherein a shape of the ports in the
mandrel is selected from a group consisting of: a circle,
an oval, a triangle or a rectangle.
[0189] An embodiment wherein a jet of the pressurized
fluid is produced when the pressurized fluid injects into
the subterranean formation as the ports in the mandrel
travel slowly across the openings in the housing.
[0190] An embodiment wherein a shape of the jet is
determined by a shape of the ports and a shape of the
openings.
[0191] One skilled in the art will recognize that other
embodiments are possible based on combinations of elements
taught within the above invention description.
Controlled Dual Time Delay System Summary
[0192] The present invention system anticipates a wide
variety of variations in the basic theme of time delay
valves, but can be generalized a controlled dual time delay
system for injection of pressurized fluid through a
wellbore casing at a plurality of locations into a
subterranean formation, the system comprising:
a first delay tool integrated into the wellbore casing
at a first location; the first tool comprises a first
housing with first openings, a first piston, and a
first actuating device;
a second delay tool integrated into the wellbore
casing at a second location; the second tool comprises
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a second housing with second openings, a second
piston, and a second actuating device;
wherein
upon actuation by the first actuating device, the
first piston travels for a first actuation time
period, after elapse of the first actuation time
period, the first piston travel allows opening of the
first openings so that the pressurized fluid flows
through the first openings for a first port opening
time interval; and
upon actuation by the second actuating device, the
second piston travels for a second actuation time
period, after elapse of the second actuation time
period, the second piston travel allows opening of the
second openings so that the pressurized fluid flows
through the second openings for a second port opening
time interval.
Controlled Dual Time Delay Method Summary
[0193] The
present invention method anticipates a wide
variety of variations in the basic theme of implementation,
but can be generalized as a controlled dual time delay
method for controlled injection of pressurized fluid into a
subterranean formation at a plurality of locations, the
method operating in conjunction with a controlled dual time
delay system, the controlled dual time delay system
comprising: a first delay tool integrated into the wellbore
casing at a first location; the first delay tool comprises
a first housing with first openings, a first piston, and a
first actuating device; a second delay tool integrated into
the wellbore casing at a second location; the second delay
tool comprises a second housing with second openings, a
second piston, and a second actuating device;
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wherein
the controlled dual time delay method comprises the
steps of:
(1) installing a wellbore casing in a wellbore along
with the dual time delay system;
(2) injecting the pressurized fluid at about maximum
pressure;
(3) activating the first actuating device when the
maximum pressure exceeds a rated pressure of the
first actuating device and activating the second
actuating device when the maximum pressure
exceeds a rated pressure of the second actuating
device;
(4) allowing the first piston to travel for a first
actuation time period and allowing the second
piston to travel for a second actuation time
period;
(5) enabling the first piston to travel to open the
first openings for a first port opening time
interval and enabling the second piston to travel
to open said second openings for a second port
opening time interval, so that the pressurized
fluid flows into the subterranean formation.
(194) This general method summary may be augmented by
the various elements described herein to produce a wide
variety of invention embodiments consistent with this
overall design description.
Sinale-Actuatino Controlled Time Delay System Summary
(195) The present invention system anticipates a wide
variety of variations in the basic theme of time delay
valves, but can be generalized a single-actuating
controlled time delay system integrated into a wellbore
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casing for injecting pressurized fluid through the wellbore
casing into a subterranean formation, the dual toe valve
comprising: a housing with first openings and second
openings, a first piston, a second piston, and an actuating
device;
wherein
upon actuation by the actuating device, the first
piston travels for a first actuation time period,
after elapse of the first actuation time period, the
first piston travel allows opening of the first
openings so that the pressurized fluid flows through
the first openings for a first port opening time
interval;
upon actuation by the actuating device, the second
piston travels for a second actuation time period,
after elapse of the second actuation time period, the
second piston travel allows opening of the second
openings so that the pressurized fluid flows through
the second openings for a second port opening time
interval; and
upon actuation by the actuating device, the first
piston and the second piston travel in opposite
directions.
Sinale-Actuatinq Controlled Time Delay Method Summary
(196) The present invention method anticipates a wide
variety of variations in the basic theme of implementation,
but can be generalized as a single-actuating controlled
time delay method for controlled injection of pressurized
fluid into a subterranean formation at a plurality of
locations, the method operating in conjunction with a
controlled single-actuating time delay toe valve integrated
into a wellbore casing for injecting pressurized fluid
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through the wellbore casing into a subterranean formation,
the single-actuating time delay toe valve comprising: a
housing with first openings and second openings, a first
piston, a second piston, and an actuating device;
wherein
the single-actuating time delay method comprises the
steps of:
(1) installing a wellbore casing in a wellbore along
with the single actuating dual toe valve;
(2) injecting the pressurized fluid at about maximum
pressure;
(3) activating the actuating device when the maximum
pressure exceeds a rated pressure of the
actuating device;
(4) allowing the first piston to travel for a first
actuation time period and allowing the second
piston to travel for a second actuation time
period;
(5) enabling the first piston to travel to open the
first openings for a first port opening time
interval and enabling the second piston to travel
to open the second openings for a second port
opening time interval, so that the pressurized
fluid flows into the subterranean formation.
(197) This general method summary may be augmented by
the various elements described herein to produce a
wide variety of invention embodiments consistent with
this overall design description.
Wet Shoe Detection System Summary
(198) The present invention system anticipates a wide
variety of variations in the basic theme of time delay
valves, but can be generalized an apparatus integrated into
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a well casing, a time delay injection valve with a seating
surface built into the valve; the seating surface is
configured to seat a restriction plug element; whereby,
when a leak is detected in the well casing during a casing
integrity test, a restriction plug element is dropped to
seat in the conforming seating surface to determine if the
leak is due to the wet shoe.
Wet Shoe Detection Method Summary
(199) The
present invention method anticipates a wide
variety of variations in the basic theme of implementation,
but can be generalized as a method for detecting a wet shoe
in a wellbore casing, the method operating in conjunction
with an apparatus integrated into a toe end of the well
casing, the apparatus a time delay injection valve with a
seating surface built into the valve; the seating surface
is configured to seat a restriction plug element; whereby,
when a leak is detected in the well casing during a casing
integrity test, a restriction plug element is dropped to
seat in the conforming seating surface to determine if the
leak is due to the wet shoe;
wherein said method comprises the steps of:
(1) installing a wellbore casing in a wellbore along
with the apparatus;
(2) performing a casing integrity test at maximum
pressure;
(3) checking if the casing integrity test passes, if
so, proceeding to step (9);
(4) deploying the restriction plug element into the
wellbore casing;
(5) seating the restriction plug element in the
conforming seating surface of the apparatus;
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(6) performing a casing integrity test at maximum
pressure;
(7) checking if the casing integrity test passes, if
so, proceeding to step (9);
(8) fixing the source of the leak; and
(9) performing perforation and fracturing operations.
[0200] This general method summary may be augmented by
the various elements described herein to produce a wide
variety of invention embodiments consistent with this
overall design description.
Fracturina Method Summary
[0201] The present invention method anticipates a wide
variety of variations in the basic theme of implementation,
but can be generalized as a fracturing method for pumping
fracturing fluid into a subterranean formation through a
controlled time delay apparatus, the controlled time delay
apparatus comprising: a housing with openings, a piston, a
restrictor, an actuating device and a high pressure chamber
with a hydraulic fluid; the stacked delay restrictor is
configured to be in pressure communication with the high
pressure chamber; a rate of travel of the piston is
restrained by a passage of the hydraulic fluid from the
high pressure chamber into a low pressure chamber through
the stacked delay restrictor;
wherein the fracturing method comprises the steps of:
(1) installing a wellbore casing in a wellbore along
with the time delay apparatus;
(2) pumping up wellbore pressure to a maximum
pressure;
(3) activating the actuating device when the maximum
pressure exceeds a rated pressure of the
actuating device;
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(4) performing a casing integrity test for an
actuation time period at the maximum pressure;
(5) enabling the piston to travel to open the
openings so that a connection is established to
the subterranean formation; and
(6) pumping fracturing fluid through the time delay
apparatus.
(0201) This general method summary may be augmented by
the various elements described herein to produce a wide
variety of invention embodiments consistent with this
overall design description.
Staged Time Delay System Summary
(0202) The present invention system anticipates a wide
variety of variations in the basic theme of time delay
valves, but can be generalized a staged time delay system
for removal of debris in a wellbore casing, the staged time
delay system comprising a first tool and a second tool; the
first tool is conveyed with the wellbore casing;
wherein when pressurized fluid is injected into the
wellbore casing at a maximum pressure, a first injection
point in the first tool is opened; the first injection
point collects debris from the wellbore casing for a
predetermined time; and a second injection point in the
second tool is opened after the predetermined time; the
second injection point is configured to enable downhole
operations after the debris is collected in the first tool
leaving the second injection point free of the debris.
Staaed Iniection Method Summary
(0203) The present invention method anticipates a wide
variety of variations in the basic theme of implementation,
but can be generalized as a staged injection method for
removal of debris in a wellbore casing, the method
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operating in conjunction with a staged time delay system,
the staged time delay system comprising a first tool and a
second tool;
wherein the staged injection method comprises the
steps of:
(1) installing a wellbore casing in a wellbore;
(2) injecting pressurized fluid into the wellbore
casing at a maximum pressure;
(3) opening a first injection point in the first
tool;
(4) collecting debris present in the wellbore casing
at first injection point in the first tool for a
predetermined time;
(5) opening a second injection point in the second
tool; and
(6) performing a downhole operation through the
second injection point.
[0203] This general method summary may be augmented by
the various elements described herein to produce a wide
variety of invention embodiments consistent with this
overall design description.
Slidina Sleeve Valve System Summary
[0204] The present invention system anticipates a wide
variety of variations in the basic theme of time delay
valves, but can be generalized a sliding sleeve valve for
use in a wellbore casing comprising a mandrel with a first
threaded end and a second threaded end; the mandrel
manufactured from one integral piece such that the mandrel
carries a torque rating of the wellbore casing when the
mandrel is threaded to ends of the wellbore casing.
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Slidina Sleeve Valve Method Summary
[0205] The present invention method anticipates a wide
variety of variations in the basic theme of implementation,
but can be generalized as a method of manufacturing a
sliding sleeve valve for use in a wellbore casing; the
sliding sleeve valve comprising a mandrel with a first
threaded end and a second threaded end; the mandrel
manufactured from one integral piece such that the mandrel
carries a torque rating of the wellbore casing when mandrel
is threaded to the wellbore casing;
wherein the method comprises the steps of:
(1) installing a pressure actuating disk onto the
mandrel;
(2) installing a piston onto the mandrel to cover a
plurality of openings in the mandrel from the
first threaded end towards the second threaded
end and hydraulically locking in place;
(3) sliding a first outer housing over the piston
from the first threaded end and stopping on a
first shoulder;
(4) installing a high pressure chamber with the fluid
from the first threaded end and stopping adjacent
to the piston;
(5) installing a restriction assembly from the first
end and stopping adjacent to the high pressure
chamber;
(6) sliding a second outer housing over the mandrel
adjacent to the restriction assembly;
(7) installing an end cap in the mandrel and creating
a low pressure chamber adjacent to the
restriction assembly; and
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. ,
(8) threading the wellbore casing to the sliding
sleeve valve with the mandrel.
[0206] This general method summary may be augmented by
the various elements described herein to produce a wide
variety of invention embodiments consistent with this
overall design description.
[0207] Although a preferred embodiment of the present invention
has been illustrated in the accompanying drawings and described
in the foregoing Detailed Description, it will be understood
that the invention is not limited to the embodiments disclosed,
but is capable of numerous rearrangements, modifications, and
substitutions without departing from the spirit of the
invention.
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Date Rectie/Date Received 2023-04-14
