U.S. patent application number 11/263753 was filed with the patent office on 2007-05-03 for full bore injection valve.
Invention is credited to Robert J. Coon, Jeffrey John Lembcke.
Application Number | 20070095545 11/263753 |
Document ID | / |
Family ID | 37547099 |
Filed Date | 2007-05-03 |
United States Patent
Application |
20070095545 |
Kind Code |
A1 |
Lembcke; Jeffrey John ; et
al. |
May 3, 2007 |
Full bore injection valve
Abstract
The present invention generally relates to controlling the flow
of fluids in a wellbore. In one aspect, a valve for selectively
closing a flow path through a wellbore in a first direction is
provided. The valve includes a body and a piston surface formable
across the flow path in the first direction. The piston surface is
formed at an end of a shiftable member annularly disposed in the
body. The valve further includes a flapper member, the flapper
member closable to seal the flow path when the shiftable member
moves from a first position to a second position due to fluid flow
acting on the piston surface. In another aspect, a valve for
selectively closing a flow path through a wellbore in a single
direction is provided. In yet another aspect, a method for
selectively closing a flow path through a wellbore in a first
direction is provided.
Inventors: |
Lembcke; Jeffrey John;
(Cypress, TX) ; Coon; Robert J.; (Missouri,
TX) |
Correspondence
Address: |
PATTERSON & SHERIDAN, L.L.P.
3040 POST OAK BOULEVARD, SUITE 1500
HOUSTON
TX
77056
US
|
Family ID: |
37547099 |
Appl. No.: |
11/263753 |
Filed: |
October 31, 2005 |
Current U.S.
Class: |
166/386 ;
166/332.8 |
Current CPC
Class: |
E21B 34/08 20130101;
E21B 2200/05 20200501 |
Class at
Publication: |
166/386 ;
166/332.8 |
International
Class: |
E21B 33/12 20060101
E21B033/12 |
Claims
1. A valve for selectively closing a flow path through a wellbore
in a first direction, the valve comprising: a body; a piston
surface formable across the flow path in the first direction, the
piston surface formed at an end of a shiftable member annularly
disposed in the body; and a flapper member, the flapper member
closable to seal the flow path when the shiftable member moves from
a first position to a second position due to fluid flow acting on
the piston surface.
2. The valve of claim 1, wherein the piston surface includes a
plurality of members.
3. The valve of claim 2, wherein each member is annularly disposed
within the shiftable member.
4. The valve of claim 2, wherein each member is biased inward
toward a centerline of the body.
5. The valve of claim 1, wherein the piston surface is formable
across the flow path upon fluid flow in a second direction.
6. The valve of claim 1, wherein the flapper member is movable
between an open position and a closed position.
7. The valve of claim 6, wherein the flow tube retains the flapper
member in the open position when the flow tube is in the first
position.
8. The valve of claim 1, wherein the piston surface is coated with
an abrasion resistant material.
9. The valve of claim 1, wherein the shiftable member is biased in
the first position by a biasing member.
10. A valve for selectively closing a flow path through a wellbore
in a single direction, the valve comprising: a housing; a variable
piston surface area formable across the flow path in the single
direction; a flow tube axially movable within the housing between a
first and a second position due to fluid flow acting on the
variable piston surface; and a flapper for closing the flow path
through the valve upon movement of the flow tube to the second
position.
11. The valve of claim 10, wherein the variable piston surface
includes a plurality of members.
12. The valve of claim 11, wherein each member is movable between a
smaller surface area position and a larger surface area
position.
13. The valve of claim 12, wherein each member is biased in the
larger surface area position.
14. The valve of claim 10, wherein the variable piston surface area
is formable across the flow path upon fluid flow in a direction
opposite the single direction.
15. A method for selectively closing a flow path through a wellbore
in a first direction, the method comprising: positioning a valve in
the wellbore, the valve having a body, a formable piston surface at
an end of a shiftable member, and a flapper member; reducing the
flow in the first direction, thereby forming the piston surface;
commencing a flow in a second direction against the piston surface
to move the shiftable member away from a position adjacent the
flapper member; and closing the flapper member to seal the flow
path through the wellbore.
16. The method of claim 15, wherein the piston surface includes a
plurality of members.
17. The method of claim 16, further including moving the plurality
of members from an open position to a closed position to form the
piston surface.
18. The method of claim 17, further including biasing the plurality
of members in the closed position.
19. The method of claim 15, further including reducing the flow in
the second direction to move the shiftable member adjacent the
flapper, thereby opening the flow path in the first direction.
20. The method of claim 19, further including locking the valve in
an open position to maintain the flow path through the wellbore.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] Embodiments of the present invention generally relate to
controlling the flow of fluids in a wellbore. More particularly,
the present invention relates to a valve for selectively closing a
flow path through a wellbore in a single direction.
[0003] 2. Description of the Related Art
[0004] Generally, a completion string may be positioned in a well
to produce fluids from one or more formation zones. Completion
devices may include casing, tubing, packers, valves, pumps, sand
control equipment, and other equipment to control the production of
hydrocarbons. During production, fluid flows from a reservoir
through perforations and casing openings into the wellbore and up a
production tubing to the surface. The reservoir may be at a
sufficiently high pressure such that natural flow may occur despite
the presence of opposing pressure from the fluid column present in
the production tubing. However, over the life of a reservoir,
pressure declines may be experienced as the reservoir becomes
depleted. When the pressure of the reservoir is insufficient for
natural flow, artificial lift systems may be used to enhance
production. Various artificial lift mechanisms may include pumps,
gas lift mechanisms, and other mechanisms. One type of pump is the
electrical submersible pump (ESP).
[0005] An ESP normally has a centrifugal pump with a large number
of stages of impellers and diffusers. The pump is driven by a
downhole motor, which is typically a large three-phase AC motor. A
seal section separates the motor from the pump for equalizing
internal pressure of lubricant within the motor to that of the well
bore. Often, additional components may be included, such as a gas
separator, a sand separator, and a pressure and temperature
measuring module. Large ESP assemblies may exceed 100 feet in
length.
[0006] The ESP is typically installed by securing it to a string of
production tubing and lowering the ESP assembly into the well. The
string of production tubing may be made up of sections of pipe,
each being about 30 feet in length.
[0007] If the ESP fails, the ESP may need to be removed from the
wellbore for repair at the surface. Such repair may take an
extended amount of time, e.g., days or weeks. Typically, a
conventional check valve is positioned below the ESP to control the
flow of fluid in the wellbore while the ESP is being repaired. The
check valve generally includes a seat and a ball, whereby the ball
moves off the seat when the valve is open to allow formation fluid
to move toward the surface of the wellbore and the ball contacts
and creates a seal with the seat when the valve is closed to
restrict the flow of formation fluid in the wellbore.
[0008] Although the conventional check valve is capable of
controlling the flow of fluid in the wellbore, there are several
problems in using the conventional check valve in this type of
arrangement. First, the seat of the check valve has a smaller inner
diameter than the bore of the production tubing, thereby
restricting the flow of fluid through the production tubing.
Second, the ball of the check valve is always in the flow path of
the formation fluid exiting the wellbore which results in the
erosion of the ball. This erosion may affect the ability of the
ball to interact with the seat to close the valve and restrict the
flow of fluid in the wellbore.
[0009] Therefore, a need exists in the art for an improved
apparatus and method for controlling the flow of fluid in the
wellbore.
SUMMARY OF THE INVENTION
[0010] The present invention generally relates to controlling the
flow of fluids in a wellbore. In one aspect, a valve for
selectively closing a flow path through a wellbore in a first
direction is provided. The valve includes a body and a piston
surface formable across the flow path in the first direction. The
piston surface is formed at an end of a shiftable member annularly
disposed in the body. The valve further includes a flapper member,
the flapper member closable to seal the flow path when the
shiftable member moves from a first position to a second position
due to fluid flow acting on the piston surface.
[0011] In another aspect, a valve for selectively closing a flow
path through a wellbore in a single direction is provided. The
valve includes a housing and a variable piston surface area
formable across the flow path in the single direction. The valve
also includes a flow tube axially movable within the housing
between a first and a second position, wherein the variable piston
surface is operatively attached to the flow tube. Further, the
valve includes a flapper for closing the flow path through the
valve upon movement of the flow tube to the second position.
[0012] In yet another aspect, a method for selectively closing a
flow path through a wellbore in a first direction is provided. The
method includes positioning a valve in the wellbore, wherein the
valve has a body, a formable piston surface at an end of a
shiftable member, and a flapper member. The method further includes
reducing the flow in the first direction, thereby forming the
piston surface. Further, the method includes commencing a flow in a
second direction against the piston surface to move the shiftable
member away from a position adjacent the flapper member.
Additionally, the method includes closing the flapper member to
seal the flow path through the wellbore.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] So that the manner in which the above recited features of
the present invention can be understood in detail, a more
particular description of the invention, briefly summarized above,
may be had by reference to embodiments, some of which are
illustrated in the appended drawings. It is to be noted, however,
that the appended drawings illustrate only typical embodiments of
this invention and are therefore not to be considered limiting of
its scope, for the invention may admit to other equally effective
embodiments.
[0014] FIG. 1 is a view illustrating a control valve disposed in a
wellbore.
[0015] FIG. 2 is a view illustrating the valve in an open
position.
[0016] FIG. 3 is a view illustrating the piston surface formed in a
bore of the valve.
[0017] FIG. 4 is a view taken along line 4-4 of FIG. 3 to
illustrate the piston surface.
[0018] FIG. 5 is a view illustrating the valve in the closed
position.
DETAILED DESCRIPTION
[0019] FIG. 1 is a view illustrating a control valve 100 disposed
in a wellbore 10. As shown, the control valve 100 is in a lower
completion assembly disposed in a string of tubulars 30 inside a
casing 25. An electrical submersible pump 15 may be disposed above
the control valve 100 in an upper completion assembly. As
illustrated, a polished bore receptacle and seal assembly 40 may be
used to interconnect the electrical submersible pump 15 to the
valve 100 and a packer arrangement 45 may be used to seal an
annulus formed between the valve 100 and the casing 25. Generally,
the valve 100 is used to isolate the lower completion assembly from
the upper completion assembly when a mechanism in the upper
completion assembly, such as the pump 15, requires modification or
removal from the wellbore 10.
[0020] The electrical submersible pump 15 serves as an artificial
lift mechanism, driving production fluids from the bottom of the
wellbore 10 through production tubing 35 to the surface. Although
embodiments of the invention are described with reference to an
electrical submersible pump, other embodiments contemplate the use
of other types of artificial lift mechanisms commonly known by
persons of ordinary skill in the art. Further, the valve 100 may be
used in conjunction with other types of downhole tools without
departing from principles of the present invention.
[0021] FIG. 2 is a view of the valve 100 in an open position. The
valve 100 includes a top sub 170 and a bottom sub 175. The top 170
and bottom 175 subs are configured to be threadedly connected in
series with the other downhole tubing. The valve 1 00 further
includes a housing 105 disposed intermediate the top 170 and bottom
175 subs. The housing 105 defines a tubular body that serves as a
housing for the valve 100. Additionally, the valve 100 includes a
bore 110 to allow fluid, such as hydrocarbons, to flow through the
valve 100 during a production operation.
[0022] The valve 100 includes a piston surface 125 that is formable
in the bore 110 of the valve 100. The piston surface 125 shown in
FIG. 2 is in an unformed state. The piston surface 125 is
maintained in the unformed state by a fluid force acting on the
piston surface 125 created by fluid flow through the bore 110 of
the valve 100 in the direction indicated by arrow 115. The piston
surface 125 generally includes three individual members 120. Each
member 120 has an end that is rotationally attached to a flow tube
155 by a pin 195 and each member 120 is biased rotationally inward
toward the center of the valve 100. Additionally, each member 120
is made from a material that is capable of withstanding the
downhole environment, such as a metallic material or a composite
material. Optionally, the members 120 may be coated with an
abrasion resistant material.
[0023] As illustrated in FIG. 2, the valve 100 also may include a
biasing member 130. In one embodiment, the biasing member 130
defines a spring. The biasing member 130 resides in a chamber 160
defined between the flow tube 155 and the housing 105. A lower end
of the biasing member 130 abuts a spring spacer 165. An upper end
of the biasing member 130 abuts a shoulder 180 formed on the flow
tube 155. The biasing member 130 operates in compression to bias
the flow tube 155 in a first position. Movement of the flow tube
155 from the first position to a second position compresses the
biasing member 130 against the spring spacer 165.
[0024] The valve 100 further includes a flapper member 150
configured to seal the bore 110 of the valve 100. The flapper
member 150 is rotationally attached by a pin 190 to a portion of
the housing 105. The flapper member 150 pivots between an open
position and a closed position in response to movement of the flow
tube 155. In the open position, a fluid pathway is created through
the bore 110, thereby allowing the flow of fluid through the valve
100. Conversely, in the closed position, the flapper member 150
blocks the fluid pathway through the bore 110, thereby preventing
the flow of fluid through the valve 100.
[0025] As shown in FIG. 2, a lower portion of the flow tube 155 is
disposed adjacent the flapper member 150. The flow tube 155 is
movable longitudinally along the bore 110 of the valve 100 in
response to a force on the piston surface 125. Axial movement of
the flow tube 155, in turn, causes the flapper member 150 to pivot
between its open and closed positions. In the open position, the
flow tube 155 blocks the movement of the flapper member 150,
thereby causing the flapper member 150 to be maintained in the open
position. In the closed position, the flow tube 155 allows the
flapper 150 to rotate on the pin 190 and move to the closed
position. It should also be noted that the flow tube 155
substantially eliminates the potential of contaminants from
interfering with the critical workings of the valve 100.
[0026] FIG. 3 illustrates the piston surface 125 formed in the bore
of the valve 100. To seal the bore 110, the flow of fluid through
the bore 110 of the valve 100 in the direction indicated by the
arrow 115 is reduced. As the flow of fluid is reduced, the fluid
force holding the piston surface 125 in the unformed state becomes
less than the biasing force on the piston surface 125. At that
point, each member 120 of the piston surface 125 rotates around the
pin 195 toward the center of the valve 100 to form the piston
surface 125 illustrated in FIG. 4. After the piston surface 125 is
formed, the flow of fluid in the direction indicated by arrow 145
is commenced, thereby creating a force on the piston surface 125.
As the force on the piston surface 125 increases, the force
eventually becomes stronger than the force created by the biasing
member 130. At that point, the force on the piston surface 125
urges the flow tube 155 longitudinally along the bore 110 of the
valve 100.
[0027] FIG. 5 is a view illustrating the valve 100 in the closed
position. After the piston surface 125 is formed, the flow tube 155
moves axially in the valve 100. This moves the lower end of the
flow tube 155 out of its position adjacent the flapper member 150.
This, in turn, allows the flapper member 150 to pivot into its
closed position. In this position, the bore 110 of the valve 100 is
sealed, thereby preventing fluid communication through the valve
100. More specifically, flow tube 155 in the closed position no
longer blocks the movement of the flapper member 150, thereby
allowing the flapper member 150 to pivot from the open position to
the closed position and seal the bore 110 of the valve 100.
[0028] The flapper member 150 in the closed position closes the
flow of fluid through the bore 110 of the valve 100, therefore no
fluid force in the bore 110 acts on the members 120. To move the
flapper member 150 back to the open position, the flow of fluid in
the direction indicated by arrow 145 is reduced and the fluid on
top of the flapper member 150 is pumped or sucked off the top of
the flapper member 150. At a predetermined point, the biasing
member biasing the flapper member 150 is overcome and subsequently
the biasing member 130 extends axially to urge the flow tube 155
longitudinally along the bore 110 until a portion of the flow tube
155 is adjacent the flapper member 150. In this manner, the flapper
member 150 is back to the open position, thereby opening the bore
110 of the valve 100 to flow of fluid therethrough, as illustrated
in FIG. 2.
[0029] In one embodiment, the valve 100 may be locked in the open
position as shown in FIG. 2 by disposing a tube (not shown) in the
bore 110 of valve 100. The tube is configured to prevent the axial
movement of flow tube 155 from the first position to the second
position by preventing the formation of the piston surface 125.
Thus, the flapper member 150 will remain in the open position and
the valve 100 will be locked in the open position. To lock the
valve 100, the tube is typically pulled into the bore 110 from a
position below the valve 100. In a similar manner, the valve 100
may be unlocked by removing the tube from the bore 110 of the valve
100.
[0030] Although the invention has been described in part by making
detailed reference to specific embodiments, such detail is intended
to be and will be understood to be instructional rather than
restrictive. For instance, the valve may be used in an injection
well for controlling the flow of fluid therein. It should be also
noted that while embodiments of the invention disclosed herein are
described in connection with a valve, the embodiments described
herein may be used with any well completion equipment, such as a
packer, a sliding sleeve, a landing nipple, and the like.
[0031] While the foregoing is directed to embodiments of the
present invention, other and further embodiments of the invention
may be devised without departing from the basic scope thereof, and
the scope thereof is determined by the claims that follow.
* * * * *