U.S. patent application number 13/105371 was filed with the patent office on 2012-11-15 for system and method for actuating tools downhole.
This patent application is currently assigned to SCHLUMBERGER TECHNOLOGY CORPORATION. Invention is credited to Gary L. Rytlewski.
Application Number | 20120285702 13/105371 |
Document ID | / |
Family ID | 47141104 |
Filed Date | 2012-11-15 |
United States Patent
Application |
20120285702 |
Kind Code |
A1 |
Rytlewski; Gary L. |
November 15, 2012 |
SYSTEM AND METHOD FOR ACTUATING TOOLS DOWNHOLE
Abstract
A technique facilitates actuation of a downhole tool in a well
string. The downhole tool may be actuated hydraulically via the
controlled flow of a hydraulic fluid under pressure to the downhole
tool through a port. Flow of the pressurized fluid through the port
is controlled by a barrier member which may be opened by a plunger
working in cooperation with the barrier member. Movement of the
plunger is controlled by selectively increasing the pressure acting
on the plunger through, for example, actuation of an expansion
device or other suitable device.
Inventors: |
Rytlewski; Gary L.; (League
City, TX) |
Assignee: |
SCHLUMBERGER TECHNOLOGY
CORPORATION
SUGAR LAND
TX
|
Family ID: |
47141104 |
Appl. No.: |
13/105371 |
Filed: |
May 11, 2011 |
Current U.S.
Class: |
166/373 ;
166/105; 166/317; 166/378; 166/63 |
Current CPC
Class: |
E21B 34/063 20130101;
E21B 34/06 20130101 |
Class at
Publication: |
166/373 ; 166/63;
166/317; 166/105; 166/378 |
International
Class: |
E21B 34/06 20060101
E21B034/06; E21B 23/00 20060101 E21B023/00; E21B 43/00 20060101
E21B043/00; E21B 43/12 20060101 E21B043/12; E21B 34/00 20060101
E21B034/00 |
Claims
1. A system for use in a well, comprising: a downhole tool to be
actuated by pressure exerted by well fluid; and a downhole tool
actuation system, comprising: an inlet port in communication with
the well fluid; a pressure sensor for receiving one or more
pressure pulses; an electronics module in communication with the
pressure sensor, wherein the electronics module processes the one
or more pressure pulses to detect a command for actuating the
downhole tool; an expansion device having an expansion chamber for
expansion of a gas generating energetic material, wherein the
audible report from initiation of the expansion device does not
exceed 150 dB as measured on an ANSI type I sound level meter
placed not more than 1 meter away; a plunger disposed in a housing
and in communication with the expansion device, wherein the plunger
is constrained to movement of not more than 1 meter in any
direction; and a barrier positioned to block flow through the inlet
port such that actuation of the expansion device drives the plunger
into the barrier to enable flow through the inlet port.
2. The system as recited in claim 1, wherein the plunger is figured
to rupture the barrier.
3. The system as recited in claim 1, wherein the barrier comprises
a rupture disc.
4. The system as recited in claim 1, wherein the plunger is
configured to weaken the barrier.
5. The system as recited in claim 1, wherein the expansion device
locates the gas generating energetic material in the housing.
6. The system as recited in claim 1, wherein the downhole tool
comprises a flow valve.
7. The system as recited in claim 1, wherein the housing comprises
the inlet port to enable exposure of the downhole actuation tool to
actuating pressure of the well fluid after the plunger engages the
barrier.
8. A method for actuating a tool downhole, comprising: positioning
the tool in a well string, the tool being hydraulically actuatable
by a hydraulic fluid; locating a barrier member to block flow of
the hydraulic fluid through a port to the tool; orienting a plunger
between the barrier member and an expansion device containing a gas
generating energetic material in a manner such that any audible
report from initiation of the gas generating energetic material is
less than 140 dB as measured by an ANSI type 2 sound level meter
positioned at a distance of less than 1 meter and such that
initiation of the gas generating energetic material provides no
mechanical movement of more than 1 meter; and coupling the
expansion device to an initiator device able to receive signals
from uphole regarding actuation of the gas generating energetic
material.
9. The method as recited in claim 8, further comprising sending a
signal downhole to the initiator device to actuate the expansion
device and drive the plunger into the barrier member.
10. The method as recited in claim 8, further comprising locating a
rupture disc in the port.
11. The method as recited in claim 8, wherein orienting comprises
slidably orienting the plunger in a cylindrical housing adjacent
the barrier.
12. The method as recited in claim 9, wherein sending the signal
downhole comprises sending an acoustic signal downhole to the
initiator device.
13. The method as recited in claim 9, wherein sending the signal
downhole comprises sending an electromagnetic signal downhole to
the initiator device.
14. The method as recited in claim 9, wherein sending the signal
downhole comprises sending a seismic telemetry signal downhole to
the initiator device.
15. The method as recited in claim 9, wherein sending the signal
downhole comprises sending a radiofrequency signal downhole to the
initiator device.
16. The method as recited in claim 8, further comprising forming
the expansion device with the gas generating energetic material
located in an internal expansion chamber.
17. The method as recited in claim 8, further comprising
hydraulically actuating the tool with well fluid.
18. A method of constructing and actuatable downhole tool system,
comprising: providing a port in communication with a downhole tool
which may be hydraulically actuated; positioning a barrier member
to selectively block flow of fluid through the port; orienting a
plunger member to selectively transition the barrier member in a
manner which allows flow of actuating fluid through the port to
actuate the downhole tool; locating an expansion chamber adjacent
the plunger member; placing an expansion material in the expansion
chamber, the expansion material being selectively expandable to
drive the plunger member to transition the barrier member; and
simplifying transportability of the actuatable downhole tool system
by: ensuring the expansion chamber is not ruptured; maintaining
temperature in the area surrounding the expansion material to a
temperature that does not exceed 100.degree. C.; minimizing the
audible report from initiation of the expansion material to less
than 150 dB as measured by an ANSI type 1 sound level meter at not
more than 1 meter away; and limiting mechanical movement due to
initiation of the expansion material to less than 1 meter.
19. The method as recited in claim 18, wherein positioning the
barrier member comprises positioning a valve.
20. The method as recited in claim 18, wherein positioning the
barrier member comprises positioning a rupture disc.
Description
BACKGROUND
[0001] In a variety of well related applications, downhole tools
are actuated to perform desired functions. For example, packers,
valves, and other downhole tools may be selectively actuated at
specific times during a downhole procedure and/or at specific
locations within a wellbore. Several types of mechanisms have been
employed to enable actuation of the tool at the desired time and/or
location.
[0002] For example, rupture discs and other shear mechanisms have
been employed to control actuation of one or more downhole tools.
However, such mechanisms often limit the number of tools that can
be operated in a predetermined sequence. Additionally, these types
of mechanisms can be difficult to use in applications and
environments in which the maximum pressures available are limited.
Intelligent triggering devices also have been used to control the
selective actuation of downhole tools based on signals delivered to
the intelligent triggering devices. In various environments and
applications, however, some of these types of devices can be
difficult to use or unreliable. Explosive materials also have been
employed to open flow paths downhole. However, components with
explosive materials can be difficult to ship or transport to a well
site due, at least in part, to governmental regulations on handling
and transporting such materials.
SUMMARY
[0003] Embodiments of the claimed system or methodology may
comprise the use of a downhole tool in a well string. The downhole
tool may be actuated via the controlled flow of a fluid, e.g. a
hydraulic fluid, under pressure to the downhole tool through a
port. Flow of the pressurized fluid through the port is controlled
by a barrier member which may be opened by a plunger working in
cooperation with the barrier member. Movement of the plunger is
controlled by selectively increasing the pressure acting on the
plunger through, for example, actuation of a gas generating device
or other suitable device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Certain embodiments of the disclosure will hereafter be
described with reference to the accompanying drawings, wherein like
reference numerals denote like elements. It should be understood,
however, that the accompanying drawings only illustrate various
implementations described herein and are not meant to limit the
scope of various technologies described herein. The drawings are as
follows:
[0005] FIG. 1 is a schematic illustration of a well system deployed
in a wellbore in which the well system comprises a downhole tool
that may be selectively actuated by a tool actuation system,
according to an embodiment of the disclosure;
[0006] FIG. 2 is a schematic illustration of an embodiment of the
tool actuation system illustrated in FIG. 1, according to an
embodiment of the disclosure;
[0007] FIG. 3 is a schematic illustration of another embodiment of
the tool actuation system coupled to a downhole tool, according to
an embodiment of the disclosure; and
[0008] FIG. 4 is a schematic illustration of another embodiment of
the tool actuation system, according to an embodiment of the
disclosure.
DETAILED DESCRIPTION
[0009] In the following description, numerous details are set forth
to provide an understanding of some illustrative embodiments of the
present invention. However, it will be understood by those skilled
in the art that various embodiments of the present invention may be
practiced without these details and that numerous variations or
modifications from the described embodiments may be possible.
[0010] As described herein, a tool actuation system may be utilized
with a variety of downhole tools to provide dependable actuation of
one or more downhole tools in a variety of well related
applications. By way of example, the tool actuation system may be
used in cooperation with different types of downhole valves,
packers, and other downhole tools which are actuated by a fluid,
e.g. a hydraulic fluid, under pressure. In many applications, such
downhole tools may be actuated by the pressure of well fluid. The
tool actuation system is designed to selectively control the flow
of high pressure well fluid to the desired downhole tool or
tools.
[0011] According to one embodiment, the tool actuation system
comprises a barrier member, e.g. a pressure membrane/rupture disc
or valve, which blocks flow of pressurized actuating fluid to a
downhole tool. A plunger is movably mounted within a housing and is
oriented to transition the barrier member. For example, the plunger
may be positioned to open a valve or to impact a rupture disc in a
manner which fractures or weakens the rupture disc. The plunger is
driven by expansion of a suitable material within an expansion
chamber, and the suitable expansion material may comprise a gas
generating energetic material. However, the plunger and the
expansion material are uniquely designed so the system falls within
the US Department of Transportation (DOT) "Not Regulated" class.
The design enables shipping of the product without labeling the
product as explosive and without subjecting the product to the
shipping restrictions required with respect to explosive
devices.
[0012] Expansion of the selected material within the expansion
chamber is initiated by an initiator device which may be designed
to receive signals from an uphole location, e.g. a surface
location. A variety of techniques and types of systems may be
employed to communicate signals downhole to the initiator device to
selectively initiate opening of the port and flow of pressurized
actuating fluid to the downhole tool or tools. By way of example,
the signals may be transmitted via cable-to-surface systems,
electromagnetic telemetry systems, acoustic telemetry systems,
wireline systems, coiled tubing with wireline systems, coiled
tubing with fiber optic systems, drilling and measurement systems
(e.g. mud pulse or electromagnetic telemetry systems), or other
suitable telemetry systems. Additionally, the tool actuation system
may comprise a plurality of trigger systems, e.g. a plurality of
plungers, which cooperate with corresponding barrier members to
enable repeated closing and opening of the port for repeated
downhole tool actuations.
[0013] Referring in general to FIGS. 1 and 2, a well system 20 is
illustrated as employing an embodiment of a downhole tool actuation
system 22 which is able to selectively actuate a downhole tool 24.
By way of example, downhole tool 24 may comprise a packer, a flow
valve, or a variety of other downhole tools that are actuated by
pressurized fluid. In many applications, the downhole tool or tools
24 may be hydraulically actuated by well fluid or by another
hydraulic fluid delivered downhole along an appropriate conduit or
other flow passage.
[0014] In the example illustrated, well system 20 comprises a
downhole equipment assembly 26 which incorporates downhole tool 24.
The downhole equipment assembly 26 may comprise a bottom hole
assembly, a well completion assembly, or other types of downhole
equipment selected according to the specific well operation being
conducted. The downhole equipment assembly 26 may be delivered
downhole along a wellbore 28 from a surface location 30 via a
suitable conveyance 32. Depending on the well application,
conveyance 32 may comprise production tubing, coiled tubing, cable,
wireline, slick line, or other suitable conveyances.
[0015] The downhole tool actuation system 22 comprises a downhole
portion 34 which may be referred to as the trigger system. The
downhole portion 34 is selectively operated to control flow of
actuating fluid to downhole tool 24 based on signals received from
a control system 36. In some embodiments, downhole portion 34
operates to open a port 38 which allows high pressure well fluid to
flow into downhole tool 24 from an annulus 40 surrounding the
downhole tool 24. The high pressure well fluid serves to actuate
downhole tool 24 by shifting the downhole tool to a desired
operational configuration. However, port 38 may be positioned to
control flow through hydraulic control lines, through an interior
of conveyance 32, or through other suitable features to selectively
enable flow of actuating fluid to downhole tool 24.
[0016] In the example illustrated, control system 36 is positioned
at a surface location 30, however the control system also may be
positioned at remote locations or at both remote and well site
locations. In some applications, the control system 36 may be
manually operated while in other applications the control system 36
is partially or fully automated to act upon the occurrence of
specific parameters detected downhole or at other locations. If the
control system 36 is automated, the control may be conducted from a
downhole location in certain applications. In the example
illustrated, however, control system 36 is coupled to downhole
portion 34 by a suitable communication line 42 which may be a hard
wired or wireless communication line. Depending on the well
application, a variety of telemetry systems may be employed for
conveying signals between control system 36 and downhole portion
34. By way of example, signals/commands may be transmitted via
acoustic telemetry (e.g. mud pulse telemetry), electromagnetic
telemetry, seismic telemetry (e.g. air guns, detonation sources, or
impact sources positioned at the surface), radio frequency
telemetry (e.g. RF tag telemetry systems), electrically conductive
path systems from surface or subsurface (e.g. wireline or control
line type systems), or combinations of the telemetry systems.
[0017] Depending on the specific well application and on the type
of telemetry system employed to convey signals downhole, the
downhole portion 34 may have various configurations. As illustrated
in greater detail in FIG. 2, for example, the downhole portion 34
may comprise a barrier member 44 which initially blocks flow of
actuating fluid through port 38. By way of example, the barrier
member 44 comprises a valve or a pressure membrane, e.g. a rupture
disc. In the embodiment illustrated, a plunger member 46 is
positioned and oriented to engage barrier member 44. Plunger member
46 is movably, e.g. slidably, mounted within a surrounding housing
48, such as a cylindrical housing. Movement of plunger member 46
with respect to barrier member 44 serves to selectively transition
the barrier member 44 to a flow position which allows flow of
actuating fluid through port 38 to actuate downhole tool 24. For
example, plunger member 46 may be moved to transition a valve or to
fracture a rupture disc so that actuating fluid may freely flow
through port 38.
[0018] Plunger member 46 is moved by an expansion device 50 which
may be in the form of a gas generating device. In the example
illustrated, expansion device 50 is a gas generating device having
an expansion chamber 52 in which gases are rapidly expanded to
drive the plunger member 46 which, in turn, opens port 38. The
expansion device 50 comprises an expansion material 54 disposed in
expansion chamber 52, and the expansion material 54 may be in the
form of a gas generating energetic material, e.g. a pyrotechnic
material. The expansion material 54 rapidly expands upon initiation
of the desired reaction by an initiator device 56 which receives
command signals from control system 36 via communication line 42.
As described above, the communication line 42 may be wired or
wireless and it may carry a variety of signals depending on the
type of telemetry system employed in the downhole tool actuation
system 22.
[0019] However, the expansion device 50 is designed as a DOT "Not
Regulated" class device to facilitate handling and transport of the
device. Specifically, expansion device 50 is designed (and the
expansion material 54 and/or plunger member 46 are selected) such
that the expansion device 50 and overall tool system meet the
testing criteria required for such devices. In this example, the
testing criteria include assessing the expansion material 54 and/or
the component containing the expansion material 54, e.g. expansion
chamber 52, to ensure the component/materials are not ruptured or
fragmented. The criteria further comprise ensuring the surface
temperature in the vicinity of the expansion device 50 containing
the expansion material 54 does not exceed 100.degree. C. and
ensuring the device provides little or no smoke generation.
Additionally, the criteria require that the audible report from
initiation of the expansion material does not exceed 150 dB when
measured with an ANSI type 1 sound level meter placed not more than
1 meter away or does not exceed 140 dB when measured with an ANSI
type 2 sound level meter placed not more than 1 meter away from the
expansion material 54. Furthermore, the criteria require that no
mechanical movement of more than 1 meter occurs in any direction as
result of initiation of the expansion material 54, e.g. movement of
plunger member 46. The structure of plunger member 46 and expansion
chamber 52, the amount and type of expansion material 54, and the
overall arrangement of the expansion device 50 and downhole tool
24, as described and illustrated herein, are designed within these
criteria.
[0020] Accordingly, use of gas generating energetic material 54 to
push the plunger member 46 facilitates the handling, transport, and
implementation of the actuation system 22. By utilizing the gas
generating energetic material 54 in the manner described, the
overall actuation system 22 also avoids generation of fragments
and/or release of hot gases. The amount of gas generating energetic
material 54 and the design of plunger member 46 is selected to
enable classification of the system and components as Not Regulated
materials, as described above. This allows the expansion device 50
and other components of the actuation system to be shipped by
standard commercial carriers. Consequently, the handling,
transport, and implementation of such devices are substantially
improved and simplified.
[0021] Referring generally to FIG. 3, an embodiment of the downhole
portion 34 of downhole tool actuation system 22 is illustrated as
coupled to downhole tool 24. In this embodiment, communication line
42 is a wireless communication line and the telemetry system is an
acoustic, pressure pulse type telemetry system. Control system 36
controls the delivery of pressure pulses down hole through wellbore
28 along, for example, annulus 40. The pressure pulses are received
by initiator device 56 which comprises a pressure sensor 58
designed to detect a series of pressure pulses that represent a
signature associated with activation of expansion material 54
within expansion chamber 52.
[0022] The pressure sensor 58 works in cooperation with a battery
60 and an electronics module 62. The battery 60 is configured to
supply electrical energy to electronics module 62 which, in turn,
is designed to interpret the series of pressure pulses detected by
pressure sensor 58. If a predetermined series of pressure pulses is
detected by electronics module 62, the electronics module outputs
an activation signal via appropriate communication lines 64, e.g.
conductors, to initiate the expansion, e.g. gas generation, of
expansion material 54 in expansion device 50. By way of example,
the communication lines 64 may deliver an appropriate current,
spark, chemical, or other signal to initiate the rapid expansion
within expansion chamber 52. It should be noted that battery 60 may
be replaced with other electric energy supplies, such as capacitors
or electric supply lines routed downhole. Additionally, the
electronics module 62 may comprise a variety of electronics
modules, including processor-based modules. An example of one type
of battery and electronics module which can be employed in the
illustrated embodiment is described in U.S. Pat. No. 7,510,001.
[0023] Rapid expansion of expansion material 54 drives plunger
member 46 along an interior of housing 48. By way of example,
housing 48 may have a cylindrical interior 66 which serves as a
cylinder along which the plunger member 46 slides to transition
barrier member 44. In the embodiment illustrated, barrier member 44
comprises a valve 68 coupled to plunger member 46 by a coupling
mechanism 70. As plunger member 46 is forced along interior 66, the
coupling mechanism 70 transitions valve 68 from a closed position
to an open position which allows the flow of hydraulic actuating
fluid through port 38. Valve 68 may comprise a variety of valve
types, including sliding sleeve valves and ball valves. As with the
previously described embodiments, the expansion device 50, along
with expansion material 54/plunger member 46, is designed as a DOT
Not Regulated class device to facilitate handling and
transport.
[0024] Referring generally to FIG. 4, an alternate embodiment of
the downhole portion 34 of tool actuation system 22 is illustrated.
In this embodiment, barrier member 44 comprises a pressure membrane
72, e.g. a rupture disc, which initially prevents flow of actuating
fluid through port 38. The port 38 may be positioned in a wall of
housing 48. The plunger member 46 comprises an impact member 74
oriented to impact pressure membrane 72 when expansion material 54
expands and forces plunger member 46 to move along the interior of
housing 48. By way of example, the impact member 74 may have a
pointed end which impacts and fractures the pressure membrane 72 to
allow flow of actuating fluid through port 38 and along a conduit
76 to downhole tool 24. Alternatively, the impact member 74 and
plunger member 46 may be designed to sufficiently weaken pressure
membrane 72 upon impact to allow the pressure of the actuating
fluid to remove the barrier and enable flow to downhole tool
24.
[0025] In the example illustrated in FIG. 4, expansion material 54
may again be a gas generating energetic material located within
expansion chamber 52. The initiator device 56 is located adjacent
expansion device 50 and is designed to selectively initiate the
expansion of expansion material 54 upon receipt of an activating
command signal through communication line 42. The expansion of
material 54 then drives plunger member 46 along the interior of
housing 48 until impact member 74 impacts the pressure membrane 38
and opens a flow pathway to allow flow of pressurized fluid through
port 38 to the downhole tool 24. In this latter embodiment, the
expansion device 50 is again constructed as a DOT Not Regulated
class device.
[0026] The specific configuration of the downhole tool actuation
system 22 and its downhole portion 34 may be adjusted according to
the parameters of a given well application and/or environment. The
type of expansion material 54 may be selected according to the
temperatures, pressures, environmental conditions, and/or system
conditions related to the well operation being conducted. Also, the
configuration of the plunger member, initiator device, electronics
module, housing, barrier member, control system,
communication/telemetry system, all may be adjusted or interchanged
according to the needs of a given application.
[0027] Additionally, other mechanisms may be combined with, used in
cooperation with, or employed as an alternative to the mechanisms
described above for selectively transitioning the barrier member 44
to an open flow condition. In some embodiments, the barrier member
may initially be weakened or combined with a weakening material,
e.g. a chemical, designed to degrade the barrier member. For
example, the pressure membrane may be selectively exposed to
corrosive or reactive materials which deconstruct the membrane.
Thus, the plunger member 46 may be used in cooperation with a
variety of chemicals or other features designed to weaken or
otherwise alter the pressure membrane or other type of barrier
member 44 to facilitate opening of the flow port.
[0028] Although only a few embodiments of the present invention
have been described in detail above, those of ordinary skill in the
art will readily appreciate that many modifications are possible
without materially departing from the teachings of this invention.
Accordingly, such modifications are intended to be included within
the scope of this invention as defined in the claims.
* * * * *