U.S. patent application number 11/933616 was filed with the patent office on 2009-05-07 for density actuatable downhole member and methods.
This patent application is currently assigned to Baker Hughes Incorporated. Invention is credited to Kevin C. Holmes, Michael H. Johnson.
Application Number | 20090114395 11/933616 |
Document ID | / |
Family ID | 40586956 |
Filed Date | 2009-05-07 |
United States Patent
Application |
20090114395 |
Kind Code |
A1 |
Holmes; Kevin C. ; et
al. |
May 7, 2009 |
DENSITY ACTUATABLE DOWNHOLE MEMBER AND METHODS
Abstract
Disclosed herein is an actuatable downhole member. The
actuatable downhole member includes, a downhole member with a
selected density, the selected density being comparable to an
anticipated downhole fluid density such that a difference in the
density of the downhole member and the density of the downhole
fluid creates a bias on the downhole member to actuate the downhole
member.
Inventors: |
Holmes; Kevin C.; (Houston,
TX) ; Johnson; Michael H.; (Katy, TX) |
Correspondence
Address: |
CANTOR COLBURN, LLP
20 Church Street, 22nd Floor
Hartford
CT
06103
US
|
Assignee: |
Baker Hughes Incorporated
Houston
TX
|
Family ID: |
40586956 |
Appl. No.: |
11/933616 |
Filed: |
November 1, 2007 |
Current U.S.
Class: |
166/319 ;
166/373; 29/592 |
Current CPC
Class: |
E21B 2200/05 20200501;
Y10T 29/49 20150115; E21B 34/08 20130101 |
Class at
Publication: |
166/319 ;
166/373; 29/592 |
International
Class: |
E21B 34/00 20060101
E21B034/00; E21B 34/06 20060101 E21B034/06 |
Claims
1. An actuatable downhole member comprising: a downhole member with
a selected density, the selected density being comparable to an
anticipated downhole fluid density such that a difference in the
density of the downhole member and the density of the downhole
fluid creates a bias on the downhole member to actuate the downhole
member.
2. The actuatable downhole member of claim 1, wherein the downhole
member is a valve.
3. The actuatable downhole member of claim 1, wherein the downhole
member is a flapper.
4. The actuatable downhole member of claim 1, further comprising a
core made of a first material and a coating made of a second
material, the first material having a different density than the
second material.
5. The actuatable downhole member of claim 4, wherein one of the
first material and the second material is denser than the selected
density and the other of the first material and the second material
is less dense than the selected density.
6. The actuatable downhole member of claim 4, wherein the second
material is bonded to the first material through chemical vapor
deposition.
7. The actuatable downhole member of claim 1, wherein the downhole
member is fabricated from a powdered material.
8. The actuatable downhole member of claim 7, wherein the powdered
material is nonmetallic.
9. The actuatable downhole member of claim 7, wherein the powdered
material is coated through chemical vapor deposition.
10. The actuatable downhole member of claim 7, wherein the powdered
material is glass or ceramic.
11. The actuatable downhole member of claim 7, wherein the powdered
material is hollow or foamed.
12. The actuatable downhole member of claim 1, wherein the downhole
member is sintered.
13. A method of making a density actuatable downhole member
comprising: determining a target density for the downhole member
based on an estimated downhole fluid density; and forming the
downhole member such that it has the target density.
14. The method of claim 13 further comprising: selecting at least
one material with a density other than the target density; shaping
the material to a near final shape of the downhole member; and
processing the near final shape to a final shape having the target
density.
15. The method of claim 14, wherein the shaping and processing
include the process of powdered metallurgy.
16. The method of claim 13, further comprising: selecting a first
material with a density other than the target density; selecting a
second material with a density other than the target density; and
adhering the first material to the second material.
17. The method of claim 16, wherein one of the first material and
the second material is denser than the target density and the other
of the first material and the second material that is not denser
than the target density is less dense than the target density.
18. The method of claim 17, wherein the adhering further includes
coating.
19. The method of claim 17, wherein the adhering further includes
chemical vapor depositioning.
20. A method of actuating a downhole member comprising: positioning
the downhole member having a target density downhole where it is
submergible in fluid; and actuating the downhole member through
buoyancy forces acting upon the downhole member in response to
fluid at least partially submerging the downhole member.
Description
BACKGROUND OF THE INVENTION
[0001] Actuating downhole devices such as check valves, for
example, often is accomplished by remote control via a slickline or
wireline. Such actuation can include movement of a downhole member
directly through movement of the wireline or can include
communication to a downhole actuator such as an electric motor, for
example, through the wireline. In either case the actuation is
initiated remotely. Other systems have been developed that do not
require remote actuation but instead rely on a downhole change in
pressure to initiate an actuation. Such systems may use a
pressurized cavity with a membrane set to rupture at a selected
pressure, for example. Automated actuation of downhole tools is
desirable and systems enabling automated actuation would be well
received in the art.
BRIEF DESCRIPTION OF THE INVENTION
[0002] Disclosed herein is an actuatable downhole member. The
actuatable downhole member includes, a downhole member with a
selected density, the selected density being comparable to an
anticipated downhole fluid density such that a difference in the
density of the downhole member and the density of the downhole
fluid creates a bias on the downhole member to actuate the downhole
member.
[0003] Further disclosed herein is a method of malting a density
actuatable downhole member. The method includes, determining a
target density for the downhole member based on an estimated
downhole fluid density and forming the downhole member such that it
has the target density.
[0004] Further disclosed herein is a method of actuating a downhole
member. The method includes, positioning the downhole member having
a target density downhole where it is submergible in fluid and
actuating the downhole member through buoyancy forces acting upon
the downhole member in response to fluid at least partially
submerging the downhole member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The following descriptions should not be considered limiting
in any way. With reference to the accompanying drawings, like
elements are numbered alike:
[0006] FIG. 1 depicts a partial cross sectional view of an
actuatable downhole system disclosed herein in a closed
configuration;
[0007] FIG. 2 depicts a cross sectional view of the actuatable
downhole system of FIG. 1 in an open configuration;
[0008] FIG. 3 depicts a perspective view of the actuatable downhole
member shown in the system of FIG. 1;
[0009] FIG. 4 depicts a cross sectional view of the actuatable
member of FIG. 1 taken at arrows 4-4; and
[0010] FIG. 5 depicts a cross sectional view of an alternate
embodiment of the actuatable member of FIG. 1 taken at arrows
5-5.
DETAILED DESCRIPTION OF THE INVENTION
[0011] 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.
[0012] Referring to FIGS. 1, 2 and 3, an actuatable downhole system
10 including an embodiment of the actuatable downhole member 14
disclosed herein is illustrated. In addition to the downhole member
14, shown in this embodiment as a flapper valve, the downhole
system 10 includes, a first tubular 18, a second tubular 22 and a
third tubular 26. The first tubular 18 and the second tubular 22
define a first chamber 30 by the clearance therebetween. Similarly,
the second tubular 22 and the third tubular 26 define a second
chamber 34 by the clearance therebetween. The second tubular 22
isolates the first chamber 30 from the second chamber 34. A port 38
through the second tubular 22 fluidically connects the first
chamber 30 to the second chamber 34. This fluidic connection is
interruptible by the flapper 14. The flapper 14, in this
embodiment, is attached to the second tubular 22 by a hinge 42 such
that the flapper 14 rotates about the hinge 42 between a closed
configuration 46 as shown in FIG. 1 and an open configuration 50 as
shown in FIG. 2. In the closed configuration 46 the flapper 14 is
sealed to a seal surface 54 of the second tubular 22 thereby
preventing flow through the port 38. Alternately, in the open
configuration 50 the flapper 14 is pivoted away from the second
tubular 22 thereby allowing fluid to flow through the port 38.
[0013] Forces to actuate the flapper 14 between the closed
configuration 46 and the open configuration 50 can be generated by
a difference in density between the flapper 14 and a fluid within
which the flapper 14 is at least partially submerged. A description
of the mechanics of such actuation will be presented below after
embodiments of controlling density of the flapper 14 during
fabrication thereof are discussed.
[0014] Referring to FIG. 4, a flapper 14 with a selected density is
disclosed. Controlling the density of a flapper 14 during
fabrication thereof can be done in various ways, a few of which are
described herein. Powdered metallurgy is one process that can be
used in the fabrication of downhole components such as valves and
flappers. The powdered metallurgy process includes generating a
metal powder 58, compressing the metal powder 58 into a "green"
shape, which is similar to the final shape that the component will
take. The green shape is heated and compressed further, in a
process referred to as sintering, to cause the powdered metal
particles to adhere together to form the final, or near final,
part. Powdered metallurgy allows for some control of the density of
the final part through control of such things as physical
properties of the metal powder 58 and temperatures and pressures
used during the sintering process, for example. The potential
density range is also due, in part, to the size, shape, quantity
and distribution of voids 62 in the interstices between particles
of the metal powder 58. The density ranges achievable with the
foregoing methods, however, are limited. Such limitation is, in
part; due to variations in mechanical properties of the final part
that result from changes in the foregoing methods. For example,
using low pressure during the sintering process can produce a
low-density part, however, the same low pressure may result in
unacceptable surface finishes or a part with insufficient
mechanical strength.
[0015] An alternate embodiment can provide additional variation in
density through controlling the number, size and shape of voids in
the finished part without sacrificing mechanical properties. This
embodiment includes using a metal powder 58 made up of hollow or
foamed particles. As such the density of the finished part can have
a greater density range than systems using solid particles.
Alternately, the density can be controlled by use of particles
other than metal, such as ceramic or glass, for example. Inadequate
adhesion of particles to one another with such alternate materials,
however, can weaken the finished part. An embodiment disclosed
herein therefore, addresses this concern by coating or plating the
nonmetallic particles prior to use in the powdered metallurgy
process. One method of coating the particles is through chemical
vapor deposition or CVD. The chemical vapor deposition process can
controllably grow a coating of a specific metal onto surfaces of
the powdered material particles. The metal coating can have
excellent adhesion to the individual particles and provide an
exterior surface on each particle, susceptible to adhesion, to
other particles in the sintering process, thereby providing greater
strength in the finished part. The use of nonmetallic powder
material prior to the CVD process permits a greater range of
density of the finished part, as well as allowing for control of
other properties such as electrical conductivity, magnetic
properties, coefficient of thermal expansion and thermal
conductivity, for example.
[0016] Referring to FIG. 5, a cross sectional view of an alternate
embodiment of the flapper 74 is illustrated. The flapper 74
includes a core 78 made of a first material and a coating 82, or
plating, made of a second material. The material used to make the
core 78 could be less dense than a density of fluid into which the
flapper 74 is expected to be at least partially submerged. The
material used for the coating 82 could be denser than the expected
fluid density. Thus, by controlling the amount of coating 82
applied the overall density of the flapper 74, based on the
finished part's volume and mass, can be accurately set. As such,
the flapper 74 can be made to be denser or less dense than a fluid
into which it will be at least partially submerged to thereby
control actuation of the flapper 74 due to its density relative to
the density or change in density of the fluid. Alternately, an
embodiment with a core 78 that is denser than the fluid could be
used with a coating 82 that is less dense to achieve similar
results of relative densities.
[0017] The foregoing embodiments could also be combined to create
yet another embodiment by, for example, making the core 78 with a
powdered metallurgical process with hollow, foamed or nonmetallic
particles, the individual particles of which may or may not be
coated as disclosed above. This powdered metal core 78 could then
be coated, possibly with a CVD process, for example, to attain the
target density of the finished part.
[0018] How the density of the flapper 14 effects actuation of the
flapper 14 will be discussed here in more detail. Forces acting
upon the flapper 14 can be proportional to the mass of the flapper
14. A few examples of such forces are gravitational force and
forces due to acceleration such as centripetal force, for example.
In addition to acting upon the flapper 14, these forces also act
upon everything that has mass, including any fluid, that may be
near or in contact with the flapper 14.
[0019] Additionally, if the flapper 14 is at least partially
submerged in the fluid there will also be buoyancy forces acting
upon the flapper 14 by the fluid. The buoyancy forces are
proportional to the difference in density of the flapper 14 and the
fluid for the portion of the flapper 14 that is submerged within
the fluid. The buoyancy forces act in a direction opposite to that
of the gravitational or centripetal forces. As such, changes in the
buoyancy forces can be used to actuate the flapper 14. Changes in
buoyancy forces can result from changes in either the density of
fluid into which at least a portion of the flapper 14 is submerged
or changes in the amount of the flapper 14 that is submerged in the
fluid. As such, by selecting a density and actuation direction of
the flapper 14 relative to the density of the fluid and direction
of the forces acting thereupon, the flapper can be set to
automatically actuate in response to changes in density and
position of the fluid with respect to the flapper 14. Such
automated control of a downhole system 10 may be desirable for
multiple reasons including, faster response than an operator
initiated system and system simplification with lower costs as
compared to systems utilizing a communication link between surface
and the downhole actuatable member.
[0020] 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 claims.
* * * * *