Note: Descriptions are shown in the official language in which they were submitted.
CA 02954173 2017-01-03
WO 2016/007236 PCT/US2015/033504
ELECTRICALLY OPERATED VALVE AND METHOD THEREOF
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Application No. 14/325873,
filed
on July 8, 2014, which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] In the completion and production industry for natural resources, the
formation
of boreholes/completions for the purpose of production or injection of fluid
is common. The
boreholes/completions are used for exploration or extraction of natural
resources such as
hydrocarbons, oil, gas, water, and alternatively for CO2 sequestration. Coiled
tubing or string
is run into the borehole/completion for varying purposes and valves, such as
circulation
valves, have been used on the tubing or string to enable circulation of fluids
between the
inside and the outside of the tubing. Such valves are typically mechanically
operable
including ball-activated features and pressure-operated features.
[0003] The art would be receptive to improved alternative devices and methods
for
operating a valve within a borehole/completion.
BRIEF DESCRIPTION
[0004] A downhole tool assembly includes a tubular having a flowbore extending
along a longitudinal axis of the tubular; an electric actuating mechanism
supported by the
tubular and distanced from the longitudinal axis of the tubular; and, a valve
assembly
connected to the tubular and fluidically connected to the flowbore, the valve
assembly
including: an outer portion having at least one port; and an electrically
actuated inner portion
concentrically positioned within the outer portion and operable by the
actuating mechanism
to selectively block the at least one port in a first condition of the valve
assembly and unblock
the at least one port in a second condition of the valve assembly.
[0005] A method of actuating a valve assembly in a downhole tubular, the
method
includes inserting a tubular having a flowbore into a borehole; employing a
peripherally
positioned electric motor within the tubular; actuating an electrically
activated valve
assembly with the motor, the valve assembly including an outer portion having
at least one
port and an inner portion movably configured within the outer portion; and,
selectively
moving the inner portion to block the at least one port in a first condition
of the valve
assembly and selectively moving the inner portion to expose the at least one
port in a second
1
CA 02954173 2017-01-03
WO 2016/007236 PCT/US2015/033504
condition of the valve assembly; wherein fluid flow through the tubular during
both the first
and second conditions of the valve assembly is not blocked.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The following descriptions should not be considered limiting in any
way.
With reference to the accompanying drawings, like elements are numbered alike:
[0007] FIG. 1 shows a schematic diagram of a downhole tool assembly in a
borehole
incorporating an exemplary electrically operable valve assembly;
[0008] FIG. 2 shows a cross sectional exploded side view of an exemplary
embodiment of the downhole tool assembly of FIG. 1;
[0009] FIG. 3 shows cross-sectional side view of an exemplary embodiment of an
axially shiftable valve assembly;
[0010] FIG. 4 shows a cross-sectional view of the axially shiftable valve
assembly
taken along line 4-4 of FIG. 3;
[0011] FIG. 5 shows a cross sectional side view of an exemplary embodiment of
a
rotatably adjustable valve assembly;
[0012] FIG. 6 shows a cross-sectional view of the rotatably adjustable valve
assembly
taken along line 6-6 of FIG. 5;
[0013] FIG. 7 shows a side plan view of an exemplary inner portion of the
valve
assembly of FIG. 5; and,
[0014] FIGS. 8A-8C show cross sectional views of alternate exemplary
embodiments
of a power generation sub for the downhole tool assembly of FIG. 2.
DETAILED DESCRIPTION
[0015] A detailed description of one or more embodiments of the disclosed
apparatus
and method are presented herein by way of exemplification and not limitation
with reference
to the Figures.
[0016] FIG. 1 shows a downhole tool assembly 100 positioned within a borehole
10
lined with a casing 12. The borehole 10 has a generally vertical section and
may further
include a deviated or horizontal section 20. Alternatively, the borehole 10 is
an open-type
borehole where the formation wall 16 is not lined with casing 12. The downhole
tool
assembly 100 includes a tubular string 14, such as, but not limited to, coiled
tubing,
production string, and drilling string. The string 14 includes any number of
connected tubing
pieces and may be spoolable onto a reel (not shown) provided at a surface
location 22. At a
2
CA 02954173 2017-01-03
WO 2016/007236 PCT/US2015/033504
downhole end 24 of the string 14, a tool 18 may be carried for performing a
downhole
operation. While illustrated at the downhole end 24, one or more tools 18 may
be provided
anywhere between the downhole end 24 and surface location 22. Alternatively,
the string 14
need not include any tool 18. The string 14 may also be used primarily for
well production
stages using coiled tubing, where the valve assembly 40 is employed for
circulating or
redirecting production fluids as needed to direct such fluids to surface,
bypass blockages, etc.,
or for injection of stimulating or fracturing fluids as needed from an
interior to an exterior of
the string 14.
[0017] A power source 28 providing electrical energy may be provided at the
surface
location 22, and sends an electrical signal, such as via line 30. A surface
control unit 38 is
used to electrically control operation of a valve assembly 40, such as a
circulation valve, by
using a motor powered by the power source 28 or a power generation sub as will
be further
described below. Whenever valve operation is necessary, the valve assembly 40
is activated
by an actuation mechanism to move to a full or partially open condition based
on required
flow regimes to allow for circulation of fluids from inside to outside,
outside to inside,
downhole to uphole, or uphole to downhole, either as a one off operation or
multi-repeated
cycles.
[0018] While the valve assembly 40 may be controlled via the control unit 38
at any
time, whether programmed or by operator input, in an exemplary embodiment of
the
downhole tool assembly 100, sensor modules 32 may also be directly
incorporated into the
string 14 or tool 18 to detect changes in the environment of the string 14
within the borehole
to indicate when an operation of a circulation valve assembly 40 is necessary.
The sensor
module 32 could be incorporated into a logging bottom hole assembly 34,
provided
separately along interconnections of the string 14 or other locations along
the string 14, or
provided within the tool 18. The sensor module 32 may contain sensors 36,
circuitry, and
processing software and algorithms relating to environment of the borehole
indicative of a
necessity for operation of a valve assembly 40. Such parameters may include
pressure, flow
speed, and other measurements related to the environment of the string 14.
Signals from
sensors 36 in the sensor module 32 or sensors 36 provided elsewhere along the
string 14 are
either processed by the sensor module 32, sent to a surface location 22 such
as surface control
unit 38 for operator evaluation, or directly to a valve assembly 40 for
immediate or
subsequent action. The surface control unit 38 or processor may receive
signals from the
sensors 36 and processes such signals according to programmed instructions
provided to the
surface control unit 38. The surface control unit 38 may also display
information on a
3
CA 02954173 2017-01-03
WO 2016/007236 PCT/US2015/033504
display/monitor utilized by an operator. The surface control unit 38 may
include a computer
or a microprocessor-based processing system, memory for storing programs or
models and
data, a recorder for recording data, and other peripherals. The control unit
38 may be adapted
to notify the operator when operating conditions indicate a need for
circulation or other valve
operation. The surface control unit 38 may also be used for other operations
of the string 14
and tool 18 not described herein. A communication sub (not shown) may obtain
the signals
and measurements and transfers the signals, using two-way telemetry, for
example, to be
processed at the surface location 22. Alternatively, the signals can be
processed using a
downhole processor in the tool 18 or sensor module 32. In the event a signal
is sent
indicating a need for circulation or other valve operation, the valve assembly
40 is electrically
activated.
[0019] The selective valve operation does not impede operation of the tool(s)
18,
string 14, or any downhole procedure. Furthermore, as will be further
described below, even
when the valve assembly 40 is activated, flow through a flowbore 42 of the
string 14 is not
blocked or restricted so as to allow for flow therethrough for use by the tool
18 or downhole
operations requiring such flow, such as production through the coiled tubing
of the string 14.
[0020] Turning now to FIG. 2, the downhole tool assembly 100 is shown
including
the valve assembly 40. The string 14 includes a tubular wall 44 surrounding
the flowbore 42.
While the valve assembly 40 is depicted downhole of the string 14, additional
lengths of the
string 14 may also be connected downhole of the valve assembly 40.
Additionally, multiple
valve assemblies 40 may be provided along the string 14 as exemplified in FIG.
1.
[0021] An exemplary embodiment of the downhole tool assembly 100 includes a
logging bottom hole assembly ("BHA") 34. The logging BHA may be a separate
component
from the valve assembly 40. Also included in the downhole tool assembly is a
motor 46,
which may be incorporated into a power supply sub 48, and an electrically
activated valve
assembly 40.
[0022] The logging BHA 34 is attachable to the string 14. The logging BHA 34
includes an uphole end 54 connected to the string 14, and a downhole end 56.
The logging
BHA 34 also includes flowthrough, such that a flowbore 58 of the logging BHA
34 is in fluid
communication with the flowbore 42 of the string 14. The logging BHA 34 may
create any
type of geophysical log by making at least one type of measurement of rock or
fluid property
in the borehole 10 or within the flowbore 58 of the logging BHA 34 itself. The
measurements are taken using at least one type of sensor, including, but not
limited to,
sensors to measure pressure, temperature, spontaneous potential, and
radiation, as well as a
4
CA 02954173 2017-01-03
WO 2016/007236 PCT/US2015/033504
variety of sensors such as acoustic (sonic), electric, inductive, magnetic
resonance, etc. One
of the sensors in the logging BHA 34 may be the sensor 36 that detects
environmental
conditions within the borehole 10. The data from the measurements secured by
the logging
BHA 34 may be recorded at the surface control unit 38, or alternatively the
logging BHA 34
may include a memory storage unit for subsequent creation of a well log. Since
the
information from the logging BHA 34 can be used by operators to gain an
understanding of
the borehole 10 for any desired downhole operation, the logging BHA 34 need
not be directly
part of the valve assembly 40 even if information obtained from the logging
BHA 34 is
utilized by the valve assembly 40. Alternatively, the valve assembly 40 may be
electrically
operated using signals initiated by an operator or from other sensors 36, 28
as previously
described.
[0023] Connected downhole of string 14, and the logging BHA 34 if utilized, is
a
power supply sub 48. The power supply sub 48 includes an uphole end 60 and a
downhole
end 62 and includes flowthrough via a flowbore 66. The uphole end 60 of the
power supply
sub 48 is connected downhole of the logging BHA 34 or string 14. In one
exemplary
embodiment, a conductor 64 passes through the string 14, logging BHA 34, and
into the
power supply sub 48. The conductor 64 is formed of one or more insulated wires
or bundles
of wires adapted to convey power and/or data, and may be included with or part
of the signal
conducting line 30 that delivers signals from the surface location 22 to motor
46. The
conductor 64 can include metal wires, or alternatively other carriers such as
fiber optic cables
that may be provided in a tubing encapsulated cable ("TEC") such as an armored
metal clad
water sealed cable. The conductor 64 can deliver the signal provided by the
sensors 28 or
operator input previously described, as well as carry the signals from the
downhole sensors
36. Additionally, by use of either direct or alternating current transmittal
through the
conductor 64, the power supply sub 48 is capable of providing sufficient power
to operate the
valve assembly 40 connected downhole of the power supply sub 48. The conductor
64 is
either provided within a protective channel (not shown) incorporated within
the string 14 or
passed through the flowbores 42, 58 of the string 14 and logging BHA 34, such
as via a
wireline. Advantages of using conductor 64 to conduct current from the surface
22 include
the ability to conduct high amounts of electrical energy from the surface 22
and the supply
from the surface 22 is relatively unlimited.
[0024] The power supply sub 48 is a tubular that peripherally supports the
motor 46
and may alternatively or additionally include a power storage unit such as one
or more
batteries 68. Batteries 68 can be used as a local source of power for downhole
electrical
CA 02954173 2017-01-03
WO 2016/007236 PCT/US2015/033504
devices, such as the electrically activated valve 40 or a tool 18, but the
batteries 68 must be
arranged to fit within space constraints that exist within the borehole 10 and
string 14.
Electrically recharging the battery 68 can occur through the conductor 64, and
replacing the
battery 68, if required, may be accomplished via a wireline operation or upon
retrieval of the
battery 68 from the borehole 10.
[0025] When necessary to open the valve assembly 40, or close the valve
assembly
40, such as determined by a surface operator or via the logging BHA 34 or
sensor 36 or 28
that a condition within or exterior to the string 14 has necessitated valve
operation, then the
power supply sub 48 will utilize an actuating mechanism linked to the motor 46
to activate
the electrically operated valve assembly 40. The electrically operated valve
assembly 40
shares substantially the same flowpath, and likewise may share substantially
the same
longitudinal axis when interconnected with the power supply sub 48, logging
BHA 34, and
string 14. While the valve assembly 40, power supply sub 48, and logging BHA
34 have
been described and illustrated as separate elements, another exemplary
embodiment would
include the integration of any combination of such subs, although separating
the components
into different subs generally eases replacement of defective parts. Also,
while the different
subs are described as interconnected, it should be understood that the
elements may be
separated from each other by any additional lengths of string 14 or
connectors.
[0026] When actuated by the power supply sub 48, the electrically operated
valve
assembly 40 will either open or close or be positioned at an interim location
between fully
opened and fully closed. The valve assembly 40 is accessible to the flow bore
42 of the
assembly 100, but does not block or restrict the flow bore 104 even when in
use, nor does it
interrupt the normal flow through the flow bore 104 and string 14. Thus, any
downhole tools,
such as tool 18, which depend on the flow through the flow bore 42, still
receive the flow.
Also, the downhole tool assembly 100 is suited for well production through the
flow bore 42,
since the flow bore 42 is not blocked by any of the above-described portions
of the assembly
100.
[0027] As depicted in FIGS. 3-4, one exemplary embodiment of the valve
assembly
140 includes a longitudinally displaceable or axially shiftable inner portion
110 of the valve
assembly 140 that covers/blocks or uncovers/exposes at least one port 112 in
an outer portion
114 of the valve assembly 140. The outer portion 114 may be connected with the
tubular of
the power supply sub 48 so as to substantially share the same longitudinal
axis as the power
supply sub 48 and downhole tool assembly 100 and to fluidically connect with
the flowbore
42 of the downhole tool assembly 100. One exemplary embodiment of an actuating
6
CA 02954173 2017-01-03
WO 2016/007236 PCT/US2015/033504
mechanism 115 to move the inner portion 110 in an uphole or downhole direction
includes a
screw rod 116 rotated by motor 46 within a threaded aperture 118 in the inner
portion 110.
The inner portion 110 has a substantially tubular-shaped cross-section, with
at least one
section 120 of the inner portion 110 sized to accommodate the threaded
aperture 118. The
section 120 may have a larger peripheral wall thickness than a wall thickness
of the
remainder of the peripheral wall. As can be mechanically understood, rotation
of the screw
rod 116 in a first direction will move the inner portion 110 in a downhole
direction (further
from surface location 22), while rotation of the screw rod 116 in a second
direction, opposite
the first direction, will move the inner portion 110 in an uphole direction.
The outer portion
114 may include two or more longitudinally spaced ports 112 such that movement
of the
inner portion 110 in the uphole or downhole direction provides more or less
fluid access
between the flow bore 42 and the annulus surrounding the downhole tool
assembly 100. For
example, if the inner portion is positioned as shown in FIG. 3 in a first
condition, the valve
assembly 140 is fully closed/blocked. If the inner portion 110 is moved by the
motor 46 to
reveal all the ports 112, then the valve assembly 140 is fully opened in a
second condition of
the valve assembly 140. The valve assembly 140 may further include any number
of
additional conditions between fully closed and fully opened. For example, in
the illustrated
embodiment, if one or more of the ports 112 are unblocked, but one or more of
the ports 112
are blocked, and then the motor 46 is intentionally stopped to halt further
movement of the
inner portion 110, then the valve assembly 100 is in a partially opened
position, a third
condition. The inner portion 110 may be positionable in any of the port
revealing positions
described above, and may then be subsequently partially or fully closed or
fully opened by
selecting the appropriate rotation direction of the screw rod 116. While the
inner portion 110
has been depicted to reveal the ports 112 successively by moving the inner
portion 110 in an
uphole direction, alternatively the inner portion 110 could be arranged such
that the inner
portion 110 must move in a downhole direction to successively reveal the ports
112. Also,
while discrete axially spaced ports 112 have been illustrated, the outer
portion 114 may
alternatively include an elongated longitudinal slot where a third condition
(between fully
opened and fully closed) is achieved by halting the inner portion 110 at a
position where the
longitudinal slot is both partially covered and partially revealed by the
inner portion 110. In
still another exemplary embodiment, the inner portion 110 may include
apertures that align or
misalign with the ports 112 of the outer portion 114.
[0028] FIGS. 5-7 show an alternative arrangement of a valve assembly 240 for
rotatably moving the inner portion 210 relative to the outer portion 214. An
actuating
7
CA 02954173 2017-01-03
WO 2016/007236 PCT/US2015/033504
mechanism 215 includes a gear set 216 that meshes with a rotatable driving
gear 218 which
in turn meshes with gear teeth 220 on a surface, such as an interior surface
222, of the inner
portion 210. The gear teeth 220 need only be limited to a first section of the
inner portion
210, while a remainder of the surface 222 may be free of gear teeth 220. The
driving gear
218 is rotated in a first direction or an opposite second direction, such as
by rotation of motor
shaft 224 fixedly attached to an initial gear in the gear set 216. Rotation of
the driving gear
218 rotates the inner portion 210. The inner portion 210 may be axially
constrained by
uphole and downhole shoulders 230, 232 protruding radially inwardly from outer
portion
214. The inner portion 210 includes one or more windows 226 that are alignable
with or
cover one or more ports 212 in the outer portion 214. As in the valve assembly
140, the
valve assembly 240 is configured to be selectively movable between a first
condition in
which the valve ports 212 are fully covered by an imperforate portion 228 of
the inner portion
210, a second condition in which the valve ports 212 are completely accessible
to a flow bore
42 of the downhole tool assembly 100, and a third condition in which the valve
ports 212 are
only partially blocked by the imperforate portion 228 of the inner portion
210.
[0029] In other exemplary embodiments, the power supply sub 48 may include a
downhole electrical generating mechanism 70 (FIGS. 8A-8D) to continuously
generate
electricity and supply electricity as needed to the motor 46 or a storage
location, such as the
electrical generating apparatus described by U.S. Pat. No. 5,839,508 to Tubel
et al, herein
incorporated by reference in its entirety. The electrical generating mechanism
70 may utilize
the power of passing fluid (hydraulic energy), magnetic field, a turbine,
spring energy,
piezoelectrics, etc. When the power supply sub 48 is employed as a power
generation sub 72,
power is scavenged, or harvested, from sources of potential energy within the
borehole 10
including, but not limited to, fluids moving inside the flowbore 66. The power
generation
sub 72 may harvest vibrational energy, such as the vibrational energy
harvesting mechanism
described by U.S. Patent Application 2009/0166045 to Wetzel et al. The flow
through the
flowbore 66 is a source of vibrational energy downhole, and vibration
enhancement
mechanisms as described in Wetzel et al. may be added in the flowbore 66 to
produce a
locally more turbulent flow. Additionally, vibrations created by the tool 18
are also
harvestable by the power generation sub 72. When harvesting energy from the
movement of
fluid within the flowbore 66, the fluid can be used to rotate a rotatable
element such as a
turbine or a rotatable magnet within a coil. The rotating turbine can be
connected to an
electrical generator that communicates with an energy storage device, such as
a battery 74.
Rotation of a magnet within a coil will induce magnetic flux on the coil and a
converter can
8
CA 02954173 2017-01-03
WO 2016/007236 PCT/US2015/033504
convert AC electrical output to DC electrical energy as needed. As shown in
FIG. 3A, the
electrical generating mechanism 70 of the power generation sub 72 may occupy a
lateral
passageway 76 so as not to block the main flowbore 66, or may alternatively be
positioned
within an annulus 78 surrounding the flowbore 66 as depicted in FIG. 3B.
Alternatively, as
shown in FIG. 3C, hydraulic pressure from the surface 22 can be used to
generate power in
an electrical generating mechanism 70 by delivering fluid under pressure via a
hydraulic line
80 to react with the electrical generating mechanism 70.
[0030] In the embodiments described above, neither the valve assembly 40, 140,
240
nor the actuating mechanism 115, 215 required to actuate the valve assembly
40, 140, 240
block flow through the flowbore of the downhole tool assembly 100. Any of the
above
described embodiments of an electrically operated valve assembly and power
supply sub may
be used in plurality and sections of string 14 may be interposed therebetween.
While fluid
flow is illustrated in one particular direction, it should be understood that
the fluid flow
within the flowbores 42, 58, 66, 104 of the above described exemplary
embodiments may be
in either uphole or downhole direction depending upon the particular
application of the string.
[0031] A method of operating a valve assembly 40, 140, 240 in a downhole tool
assembly 100 includes inserting a tubular such as the string 14 into the
borehole 10,
determining a need for opening or blocking flow between the flowbore of the
tubular and the
annulus between the tubular and the borehole 10, sending a signal to a control
unit 28 or
motor 46 in response to the determined need, actuating an electrically
activated valve
assembly 40, the valve assembly 40 having a flow bore 104 fluidically
connected to a
flowbore 42 of the tubular, and altering the flow between the tubular and
surrounding
borehole 10 by operation of the valve assembly 40. The method enables a
partial opening of
flow between the flowbore and annulus. Flow through the flowbores 42, 104 of
the string 14
and valve assembly 40 is not blocked during activation and non-activation of
the valve
assembly 40. The method further includes generating power in a power
generating sub 48.
[0032] While the invention has been described with reference to an exemplary
embodiment or embodiments, it will be understood by those skilled in the art
that various
changes may be made and equivalents may be substituted for elements thereof
without
departing from the scope of the invention. In addition, many modifications may
be made to
adapt a particular situation or material to the teachings of the invention
without departing
from the essential scope thereof. Therefore, it is intended that the invention
not be limited to
the particular embodiment disclosed as the best mode contemplated for carrying
out this
invention, but that the invention will include all embodiments falling within
the scope of the
9
CA 02954173 2017-01-03
WO 2016/007236 PCT/US2015/033504
claims. Also, in the drawings and the description, there have been disclosed
exemplary
embodiments of the invention and, although specific terms may have been
employed, they
are unless otherwise stated used in a generic and descriptive sense only and
not for purposes
of limitation, the scope of the invention therefore not being so limited.
Moreover, the use of
the terms first, second, etc. do not denote any order or importance, but
rather the terms first,
second, etc. are used to distinguish one element from another. Furthermore,
the use of the
terms a, an, etc. do not denote a limitation of quantity, but rather denote
the presence of at
least one of the referenced item.
