U.S. patent application number 15/310225 was filed with the patent office on 2017-06-29 for valves for regulating downhole fluids using contactless actuation.
This patent application is currently assigned to Halliburton Energy Services, Inc.. The applicant listed for this patent is Halliburton Energy Services, Inc.. Invention is credited to Peter D.W. Inglis.
Application Number | 20170183938 15/310225 |
Document ID | / |
Family ID | 55019801 |
Filed Date | 2017-06-29 |
United States Patent
Application |
20170183938 |
Kind Code |
A1 |
Inglis; Peter D.W. |
June 29, 2017 |
Valves For Regulating Downhole Fluids Using Contactless
Actuation
Abstract
A contactless valve actuation system includes a conduit, which
may be a tubing segment in drill string or production string. The
system includes a valve including a sealing member that is movable
between an open position and a closed position. The system also
includes a valve actuator coupled to the valve. The valve actuator
is operable to move the sealing member between the open position
and the closed position to open and close the valve. The valve
actuator includes a sensor and a controller configured to generate
a control signal in response to the sensor detecting an actuation
signal generator. The system also includes a pump that is
fluidly-coupled to the conduit. The pump is operable to convey
fluid containing the actuation signal generator through the
conduit.
Inventors: |
Inglis; Peter D.W.;
(Tayside, GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Halliburton Energy Services, Inc. |
Houston |
TX |
US |
|
|
Assignee: |
Halliburton Energy Services,
Inc.
Houston
TX
|
Family ID: |
55019801 |
Appl. No.: |
15/310225 |
Filed: |
July 2, 2014 |
PCT Filed: |
July 2, 2014 |
PCT NO: |
PCT/US2014/045223 |
371 Date: |
November 10, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 2200/06 20200501;
E21B 47/13 20200501; E21B 47/135 20200501; E21B 47/18 20130101;
E21B 34/10 20130101; E21B 34/06 20130101; E21B 21/103 20130101;
E21B 2200/04 20200501 |
International
Class: |
E21B 34/10 20060101
E21B034/10; E21B 47/18 20060101 E21B047/18; E21B 21/10 20060101
E21B021/10; E21B 47/12 20060101 E21B047/12 |
Claims
1. A valve assembly comprising: a fluid conduit; a sealing member
to open and close the fluid conduit; and an actuator coupled to the
sealing member to move the sealing member from an open position to
a closed position, the actuator comprising a detector; wherein the
detector is a passive detector that senses an actuation signal
generator; and wherein the actuator manipulates the sealing member
in response to the detector sensing the actuation signal
generator.
2. The valve assembly of claim 1, further comprising a power source
coupled to the actuator.
3. The valve assembly of claim 1, further comprising a controller
coupled to the detector, the controller having at least one
processor and at least one memory, the at least one processor and
the at least one memory perform logical operations and calculations
in relation to the actuation signal generator sensed by the
detector.
4. The valve assembly of claim 1, wherein the sealing member
comprises a ball having a throughbore and movably arranged within
the fluid conduit, the ball movable between the open position,
where the throughbore is axially aligned with the fluid conduit,
and the closed position, where the throughbore is perpendicular to
the conduit.
5. The valve assembly of claim 1, wherein the sealing member
comprises a sleeve valve.
6. The valve assembly of claim 1, wherein the actuator comprises a
hydraulic pump fluidly-coupled to the sealing member.
7. The valve assembly of claim 1, wherein the actuation signal
generator is selected from the group consisting of a light source,
a magnetic field generator, a radioactive source, and an acoustic
signal generator.
8. The valve assembly of claim 1, wherein the actuation signal
generator comprises a light source and wherein the detector
comprises a photo sensor.
9. A contactless valve actuation system, the system comprising: a
conduit; a valve fluidly coupled to the conduit, the valve having a
sealing member that is movable between an open position and a
closed position; a valve actuator coupled to the valve, wherein the
valve actuator moves the sealing member between the open position
and the closed position, the valve actuator comprising a sensor and
a controller to generate a control signal in response to the sensor
detecting an actuation signal generator; and a pump fluidly-coupled
to the housing, wherein the pump conveys fluid containing the
actuation signal generator through the conduit of the housing.
10. The system of claim 9, wherein the valve actuator further
comprises a local power source to provide power to a movable
member.
11. The system of claim 9, wherein quantities of the actuation
signal generator are released into fluid.
12. The system of claim 9, wherein the valve actuator comprises a
hydraulic pump fluidly-coupled to the valve.
13. The system of claim 9 wherein the valve comprises a ball having
a throughbore and movably arranged with the conduit, the
throughbore axially-aligned with conduit in the open position and
perpendicular to the conduit in the closed position.
14. The system of claim 9, wherein the valve is a sleeve valve.
15. The system of claim 9, wherein the actuation signal generator
is selected from the group consisting of a light source, a magnetic
field source, a radioactive source, and an acoustic source.
16. The system of claim 9, wherein the actuation signal generator
comprises a light emitting diode and wherein the sensor comprises a
photo sensor.
17. A method of actuating a valve, the method comprising: conveying
an actuation signal generator into a conduit of a downhole tool
using a fluid; monitoring the conduit for entry of the actuation
signal generator; and actuating the valve if the actuation signal
generator is detected in the conduit; wherein the valve controls a
sealing member within the conduit thereby regulating fluid flow
therethrough.
18. The method of claim 17, further comprising the step of
releasing the actuation signal generator into the fluid.
19. The method of claim 17, wherein the actuation signal generator
is selected from the group consisting of a light source, a magnetic
field source, a radioactive source, and an acoustic source.
20. The method of claim 17, wherein the step of monitoring the
conduit comprises detecting electromagnetic radiation from a light
emitting diode using a photo-detector.
Description
TECHNICAL FIELD
[0001] The present disclosure relates generally to the recovery of
subterranean deposits, and more specifically to an actuator used to
open or close valves in a production string.
BACKGROUND
[0002] Crude oil and natural gas occur naturally in subterranean
deposits and their extraction includes drilling a well. The well
provides access to a production fluid that often contains crude oil
and natural gas. Drilling of the well generally involves deploying
a drill string into a formation. The drill string includes a drill
bit that removes material from the formation as the drill string is
lowered to form a wellbore. After drilling and prior to production,
a casing may be deployed in the wellbore to isolate portions of the
wellbore wall and prevent the ingress of fluids from parts of the
formation that are not likely to produce desirable fluids. After
completion, a production string may be deployed into the well to
facilitate the flow of desirable fluids from producing areas of the
formation to the surface for collection and processing.
[0003] A variety of packers and other tools may operate in the
wellbore to fix the production string relative to a casing or
wellbore wall, and may also function to isolate production zones
(also referred to as "intervals") of the well so that
hydrocarbon-rich fluids are collected from the wellbore instead of
undesirable fluids (such as water). These packers and tools may
operate in a wide variety of downhole environments, including
extreme downhole environments having very high pressures and very
high temperatures.
[0004] Valves may be incorporated into the production string at
intervals between packers to allow or cease flow into the
production string from the production zone that abuts the wellbore
between the packers, and for other purposes. Downhole valves may
also be included in drilling tool strings to divert drilling fluid
to, for example, facilitate a logging while drilling or measurement
while drilling measurement or sampling. Downhole valves may be
valves may be actuated by using pressure pulses or by transmitting
a control signal directly to a valve actuator using a hydraulic or
electronic control line.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Illustrative embodiments of the present disclosure are
described in detail below with reference to the attached drawing
figures, which are incorporated by reference herein and
wherein:
[0006] FIG. 1 is a schematic, elevation view with a portion shown
in cross-section of a production system that includes a downhole
valve including a contactless actuator;
[0007] FIG. 2A is a schematic, elevation view with a portion shown
in cross-section of a drilling system that includes a valve
including a contactless actuator, wherein the system is deployed in
a subterranean well;
[0008] FIG. 2B is a schematic, elevation view with a portion shown
in cross-section of a drilling system that includes a valve
including a contactless actuator, wherein the system is deployed in
a subsea well;
[0009] FIG. 3 is a detail, cross-sectional view of the downhole
valve of FIG. 1;
[0010] FIG. 4 is a schematic diagram of the downhole valve of FIG.
3; and
[0011] FIG. 5 is a schematic flowchart of an illustrative method
for contactless actuation of a downhole valve, according to an
embodiment.
[0012] The illustrated figures are only exemplary and are not
intended to assert or imply any limitation with regard to the
environment, architecture, design, or process in which different
embodiments may be implemented.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0013] In the following detailed description of the illustrative
embodiments, reference is made to the accompanying drawings that
form a part hereof. These embodiments are described in sufficient
detail to enable those skilled in the art to practice the
invention, and it is understood that other embodiments may be
utilized and that logical structural, mechanical, electrical, and
chemical changes may be made without departing from the scope of
the invention. To avoid detail not necessary to enable those
skilled in the art to practice the embodiments described herein,
the description may omit certain information known to those skilled
in the art. The following detailed description is, therefore, not
to be taken in a limiting sense, and the scope of the illustrative
embodiments is defined only by the appended claims.
[0014] In the drawings and description that follow, like parts are
typically marked throughout the specification and drawings with the
same reference numerals or coordinated numerals. The drawing
figures are not necessarily to scale. Certain features of the
invention may be shown exaggerated in scale or in somewhat
schematic form and some details of conventional elements may not be
shown in the interest of clarity and conciseness.
[0015] As noted above, downhole valves are typically actuated using
electronic or hydraulic control lines that utilize a line
connection to a surface controller. The illustrative embodiments
described herein relate to a downhole valve system having a
contactless actuator, which may incorporate a number of signal
generators and receivers to open and close a downhole valve without
utilizing a dedicated control line.
[0016] Unless otherwise specified, any use of any form of the terms
"connect," "engage," "couple," "attach," or any other term
describing an interaction between elements is not meant to limit
the interaction to direct interaction between the elements and may
also include indirect interaction between the elements described.
In the following discussion and in the claims, the terms
"including" and "comprising" are used in an open-ended fashion, and
thus should be interpreted to mean "including, but not limited to".
Unless otherwise indicated, as used throughout this document, "or"
does not require mutual exclusivity.
[0017] The various characteristics mentioned above, as well as
other features and characteristics described in more detail below,
will be readily apparent to those skilled in the art with the aid
of this disclosure upon reading the following detailed description
of the embodiments, and by referring to the accompanying drawings.
Other means may be used as well.
[0018] Referring now to the figures, FIG. 1 shows an illustrative
embodiment of a system 100 including a valve assembly 102 that is
actuated using a contactless actuator. The system 100 is depicted
in a schematic, elevation view with a portion shown in
cross-section. The system 100 includes a rig 108 atop a surface 110
of a well 112. Beneath the rig 108, a wellbore 106 is formed within
a geological formation 114, which is expected to produce
hydrocarbons in the form of production fluid 104. The wellbore 106
may be formed in the geological formation 114 using a drill string
that includes a drill bit to remove material from the geological
formation 114. The wellbore 106 of FIG. 1 is shown as being
near-vertical, but may be formed at any suitable angle to reach a
hydrocarbon-rich portion of the geological formation 114. In some
embodiments, the wellbore 106 may follow a vertical,
partially-vertical, angled, or even a partially-horizontal path
through the geological formation 114.
[0019] A production tool string 116 is deployed from the rig 108,
which may be a drilling rig, a completion rig, a workover rig, or
another type of rig. The rig 108 includes a derrick 118 and a rig
floor 120. The production tool string 116 extends downward through
the rig floor 120, through a fluid diverter 122 and blowout
preventer 124 that provide a fluidly sealed interface between the
wellbore 106 and external environment, and into the wellbore 106
and geological formation 114. Coupled to the fluid diverter 122 is
a pump 128 coupled to a control system 126. The pump 128 is
operational to deliver or receive fluid through an internal bore of
the production tool string 116 by applying a positive or negative
pressure to the internal bore. The pump 128 may also deliver or
receive fluid through an annulus 130 by applying a positive or
negative pressure to the annulus 130. The annulus 130 is formed
between an exterior of the production tool string 116 and a
wellbore casing 132 or between the wall of the wellbore 106 and the
exterior of the production tool string 116 when production tool
string 116 is disposed within the wellbore 106.
[0020] Following formation of the wellbore 106, the production tool
string 116 may be equipped with tools and deployed within the
wellbore 106 to prepare, operate, or maintain the well 112.
Specifically, the production tool string 116 may incorporate tools
that are actuated after deployment in the wellbore 106, including
without limitation bridge plugs, composite plugs, cement retainers,
high expansion gauge hangers, straddles, and packers. Actuation of
such tools may result in centering the production tool string 116
within the wellbore 106, anchoring the production tool string 116,
isolating a segment of the wellbore 106, or other functions related
to positioning and operating the production tool string 116. In the
illustrative embodiment shown in FIG. 1, the production tool string
116 is depicted with a packer 134 within a production zone of the
geological formation 114. The packer 134 is configured to provide a
fluid seal between the production tool string 116 and the wellbore
106, thereby defining an interval or production zone adjacent the
production tool string 116. Packers 134 are typically used to
prepare the wellbore 106 for hydrocarbon production during
operations such as fracturing of the formation or for service
during formation of the well during operations such as acidizing or
cement squeezing.
[0021] Below the packer 134 is the valve assembly 102 that controls
the flow of production fluid 104 into the production string 116.
The illustrative valve assembly 102 is coupled to, or includes, an
actuator that may be triggered using a contactless signal
generator, as described in more detail below. The signal generator
may be a device that emits a light source, a magnetic field, a
radio signal, an acoustic signal, a radioactive signal, or a
combination thereof.
[0022] In other embodiments, the actuator may be used to actuate
tools or assemblies within the production tool string 116, such as
the packer 134 or other tools. In an embodiment, prior to actuation
of the valve assembly 102 or other tool, fluid may be provided to
the wellbore from the pump 128. The pump 128 is coupled to the
surface controller 126, which may include a signal generator
dispenser or "hopper" that dispenses one or more signal generators
into a fluid that is being provided downhole in response to a user
generated or computer generated instruction to actuate the valve
assembly 102 or other tool. Fluid may be circulated downhole for
various purposes. In an embodiment, the signal generators may be a
clear ball or another suitable type of particle that includes a
signal generator to generate any one of the types of signals
described above.
[0023] In operation, the valve assembly 102 or other tool may be
actuated by the control system 126 dispensing a signal generator
into the wellbore 126, which may be detected by a downhole detector
that is communicatively coupled to the actuator. Detection of the
signal generator by the detector may result in actuation of the
valve or other downhole device. The detector may be selected based
on the type of signal generated by the signal generator. For
example, a photocell may be used to detect a light source, a
magnetic or electromagnetic field sensor may be used to detect a
magnetic field, an antenna may be used to detect a radio signal, a
hydrophone or similar device may be used to detect an acoustic
signal, and a radioactive isotope identification device may be used
to detect a radioactive signal.
[0024] It is noted that while the operating environment shown in
FIG. 1 relates to a stationary, land-based rig for raising,
lowering, and setting the production tool string 116, in
alternative embodiments, mobile rigs, wellbore servicing units
(e.g., coiled tubing units, slickline units, or wireline units),
and the like may be used to lower the production tool string 116.
Furthermore, while the operating environment is generally discussed
as relating to a land-based well, the systems and methods described
herein may instead be operated in subsea well configurations
accessed by a fixed or floating platform.
[0025] FIG. 2A shows an alternative deployment of a valve assembly
270 including, or coupled to, a contactless actuator and deployed
in a drilling system 200. The drilling system 200 is deployed in a
well 202 including a wellbore 206 that extends from a surface 210
of the well 202 to or through a subterranean formation 214. The
well 202 is illustrated onshore in FIG. 2A with a drill string 216
deployed to operate a drill bit 222 to form the wellbore 206. In
another embodiment, the drilling system 200 and associated valve
assembly 270 and contactless actuator may be deployed in a sub-sea
well 201 accessed by a fixed or floating platform 221, as shown in
FIG. 2B. FIGS. 2A and 2B each illustrate possible implementations
of such systems, and while the following description of the valve
assembly 270 and contactless actuator focuses primarily on the use
of the valve assembly 270 and a related control system 226 with the
onshore well 202 of FIG. 2A, the valve assembly 270 and contactless
actuator may be used instead in the well configuration illustrated
in FIG. 2B, as well as in other well configurations where it is
desirable to actuate a downhole valve or other tool using a
contactless actuator. Similar components in FIGS. 2A and 2B are
identified with similar reference numerals.
[0026] The well 202 is formed by a drilling process in which a
drill bit 222 is turned by the drill string 216 to remove material
from the formation and form the wellbore 206. The drill string 216
extends from the drill bit 222 at the bottom of the wellbore 206 to
the surface 210 of the well 202, where it is joined with a kelly
228. The drill string 216 may be made up of one or more connected
tubes or pipes of varying or similar cross-section. The drill
string 216 may refer to the collection of pipes or tubes as a
single component, or alternatively to the individual pipes or tubes
that comprise the string. The term drill string is not meant to be
limiting in nature and may refer to any component or components
that are capable of transferring rotational energy from the surface
of the well to the drill bit 222. In several embodiments, the drill
string 216 may include a central passage disposed longitudinally in
the drill string 216 and capable of allowing fluid communication
between the surface 210 of the well and downhole locations.
[0027] At or near the surface 210 of the well 202, the drill string
216 may include or be coupled to the kelly 228. The kelly 228 may
have a square, hexagonal or octagonal cross-section. The kelly 228
is connected at one end to the remainder of the drill string 216
and at an opposite end to a rotary swivel 232. The kelly 228 passes
through a rotary table 236 that is capable of rotating the kelly
228 and thus the remainder of the drill string 216 and drill bit
222. The rotary swivel 232 allows the kelly 228 to rotate without
rotational motion being imparted to the rotary cable 242. A hook
238, the cable 242, a traveling block (not shown), and a hoist (not
shown) are provided to lift or lower the drill bit 222, drill
string 216, kelly 228 and rotary swivel 232. The drill string 216
may be raised or lowered as needed to add additional sections of
tubing to the drill string 216 as the drill bit 222 advances, or to
remove sections of tubing from the drill string 216 if removal of
the drill string 216 and drill bit 222 from the well 202 are not
desired.
[0028] In normal operation, drilling fluid 204 is stored in a
drilling fluid reservoir 244 and pumped into an inlet conduit 252
using a pump 229, or plurality of pumps disposed along the inlet
conduit 252. The drilling fluid 204 passes through the inlet
conduit 252 and into the drill string 216 via a fluid coupling at
the rotary swivel 232. The drilling fluid 204 is circulated into
the drill string 216 to maintain pressure in the drill string 216
and wellbore 206 and to lubricate the drill bit 222 as it cuts
material from the formation 214 to deepen or enlarge the wellbore
206. After exiting the drill string 216, the drilling fluid 204
carries cuttings from the drill bit 222 back to the surface 210
through an annulus 230 formed by the space between the inner wall
of the wellbore 206 and outer wall of the drill string 216. At the
surface 210, the drilling fluid 204 exits the annulus 230 and is
carried to a repository. Where the drilling fluid 204 is
recirculated through the drill string 216, the drilling fluid 204
may return to the drilling fluid reservoir 244 via an outlet
conduit 264 that couples the annulus 230 to the drilling fluid
reservoir 244. The path that the drilling fluid 204 follows from
the reservoir 244, into and out of the drill string 216, through
the annulus 230, and to the repository may be referred to as the
fluid flow path.
[0029] At various times during the formation of the well 202, it
may be desirable to halt the flow of fluid to the drill bit 222
while maintaining fluid flow throughout the remainder of the
system. For example, it may be desirable to halt fluid flow
adjacent a logging-while-drilling (LWD) or
measurement-while-drilling (MWD) sensor, such as a sampling
chamber, thermometer, camera, or other device. To represent a LWD
or MWD tool, a measurement module 272 is depicted as being downhole
from the valve assembly 270. The valve assembly 270 may be oriented
in the drill string 216 such that when the valve assembly 270 is in
a first orientation, the drilling fluid 204 is directed downward
through the downhole measurement module 272 to the drill bit 222,
and when the valve is in a second orientation, the drilling fluid
bypasses the downhole measurement module 272 and is directed into
the annulus 230 and back toward the surface. This configuration may
also facilitate the continuous circulation of drilling fluid 204
through the wellbore 206 even when operation of the drill bit 222
is suspended.
[0030] As described in more detail below with regard to FIGS. 3 and
4, the valve assembly 270 includes a contactless actuator that may
be used to operate the valve assembly 270 without an established
electronic or hydraulic control line. Further, the valve assembly
270 is discussed merely as an illustrative system and it is noted
that the contactless actuator may be instead used to actuate other
types of downhole tools, including, for example, a measurement
module 272.
[0031] FIG. 3 shows a detail view, in partial cross-section, of a
valve and contactless actuator assembly 310, as indicated in FIG.
3. In several embodiments, the valve assembly 310 is the valve
assembly 102 of FIG. 1. In other embodiments, the valve assembly
310 is the valve assembly 270 of FIGS. 2A and 2B. The valve
assembly 310 includes an actuator 332, which, as described in more
detail below, may be a contactless actuator that actuates a
downhole tool, such as a valve 330. The valve 330 may be a ball
valve as shown or any other suitable type of valve, such as a
sleeve valve. The actuator 332 is coupled to a hydraulic pump 334,
which is also coupled to a movable member 336 of the valve 330.
When using a ball valve, the valve 330 includes a sealing member,
such as a valve ball 350 having an aperture 352 that allows fluid
to flow through the valve 330 when the valve 330 is open and ceases
fluid flow when the valve 330 is closed. In another embodiment the
valve 330 may include a t-valve that allows fluid to flow through
the tubing segment that includes the valve 330 when open and
diverts fluid flow outside of the tubing segment when closed.
[0032] In an illustrative embodiment, the actuator 332 includes a
passive detector or sensor 315 that detects one or more signals
generated by a signal generator. As described above, the signal
generator may be a device that emits a light source, such as a
clear ball with an embedded or enclosed LED, a permanent magnet, a
radio-frequency identification (RFID) tag, a mud-pulse telemetry
broadcasting device or speaker, or an acoustic signal, a
radioactive isotope, or a combination thereof. The detector or
sensor 315 may be selected based on the type of signal generated by
the signal generator. For example, the sensor 315 may include a
photocell, a magnetic or electromagnetic field sensor, an antenna,
a hydrophone, a radioactive isotope identification device or
radiation detector, or any other suitable sensor 4.
[0033] Upon detection of the signal generator by the sensor 315,
the actuator 332 causes the hydraulic pump 334 to actuate the
movable member 336 of the valve 330, which turns the valve ball 350
to close the valve 330 and prevent flow therethrough. Closing of
the valve 330 may facilitate the closing of a zone of the well or
enable the buildup of pressure in the tool string that includes the
valve 330 so that, for example, a packer may be set up-hole from
the valve 330. Similarly, opening of the valve 330 facilitates the
renewal of flow through the valve 330, either to or from a downhole
location.
[0034] In one embodiment, the actuator 332 includes a power source,
controller, memory, a power source, an actuating member, and a
sensor. The sensor monitors the fluid within a predetermined range
of the actuator 332 for the presence of one or more signal
generators, and is operable to detect the presence of a signal
generator and the frequency at which signal generators are detected
as a function of time. The controller of the actuator 332 is
operable to execute instructions stored in the memory for actuating
the valve 330 based on conditions detected by the sensor. The power
source, which may include a battery, provides a local power to the
components of the actuator 332, including the sensor, controller,
and actuating member. In an embodiment, the actuating member is a
motor and gearbox that are coupled to and configured to operate the
hydraulic pump. In another embodiment, the actuating member may be
a solenoid. In either case, the actuator 332 and its constituent
components are arranged about the periphery of the assembly 310 to
avoid interference with fluid flowing along a fluid flow path
through the valve 330 and assembly 310.
[0035] In response to the detection of a signal generator by the
sensor 315, the controller of the actuator 332 will operate the
actuating member of the actuator 332 to open or close the valve 330
in accordance with the operating instructions of the actuator 332.
The actuator 332 thereby operates the hydraulic pump 334, which
provides at least one hydraulic control line to the movable member
336. In an embodiment, at least one hydraulic control lines extends
from the pump 334 to the movable member 336 of the valve 330.
[0036] In an embodiment, the valve 330 comprises a substantially
cylindrical body having an axial bore running therethrough to
facilitate the flow of fluids therethrough. The body may include
ports or an access sleeve that connects the actuator to the movable
member 336. In an embodiment, the movable member 336 includes a
valve ball 350 arranged on a pivot so that the valve ball 350 can
rotate within the bore to open and close the valve 330. To
facilitate flow through the valve 330 when open, the valve ball 350
includes an aperture running therethrough, which is sized to match
the diameter of the bore. The movable member 336 may also include a
ball arm that is operated with a piston that is translated back and
forth with the hydraulic pump to open and close the valve 330. A
sealing arrangement may be used between the valve ball 350 and its
housing to prevent fluid leakage through the valve 330. In a
similar embodiment, the valve 330 may instead be formed from
concentric sleeves having overlapping flow ports that are moved in
and out of alignment by translation of one of the sleeves caused by
movement of the piston.
[0037] In another embodiment, when the sensor 315 detects a signal
generator and the actuator 332 determines to open the valve 330,
the actuator 332 operates the hydraulic pump 334 to evacuate the
control line to retract the piston or to provide pressure to a
second control line that causes the piston to retract and open.
[0038] FIG. 4 shows a schematic diagram of a contactless actuator
system 400 including a valve 402 within a downhole tool string,
such as a production string or a drilling string. A conduit 404
forms a fluid flow path 406 through the tool string, and includes a
sensor 410 operable to detect a signal generator 416 in the conduit
404. The conduit 404 is fluidly coupled to the valve 402. The
sensor 410 is coupled to a control module that includes a processor
414, a memory 415, and a power supply 412. The power supply 412 may
include a battery and/or a downhole power generation device, such
as a turbine, to generate power to be stored in the battery. The
power supply 412 supplies electrical energy to the sensor 410 and
an actuating member 408, which may be a solenoid or a motor coupled
to a hydraulic pump, as noted previously. The actuating member 408
is coupled to the valve 402, or a movable member thereof, and is
thereby operable to open and close the valve 402.
[0039] In an embodiment, the actuator system 400 functions as a
contactless tool that replaces a mechanical interface that is
typically used to open and close a valve, e.g., in the form of a
dropped ball or mechanical manipulation of an entire tool string,
such as pulling up (close) or pushing down (open) using a collet or
shifting tool that is attached to the end of the tool string. The
signal generator may be a magnet, a radioactive source (such as
strontium-90, tritium, carbon-14, phosphorus-32, nickel-63, or a
combination thereof), and electronic signal generator such as an
RFID tag, or an acoustic sound generator (such as a speaker or
projector operable to generate a periodic SONAR ping). Depending on
the selected signal generator, the sensor 410 may be a magnetic
field sensor, such as a MEMS magnetic field sensor, a radiation
detector or Gieger counter, an antenna or RFID tag reader, or a
hydrophone that is configured to detect the signal generator.
[0040] The actuator system 400 may be configured to actuate and
close the valve 402 in response to the sensor 410 detecting a
signal generator 416, the sensor 410 detecting a threshold quantity
of signal generators 416, or the passage of a time delay following
detection of a signal generator 416. Similarly, the actuator system
400 may be configured to actuate and open the valve 402 in response
to the sensor 410 detecting a signal generator 416, the sensor 410
detecting a threshold quantity of signal generators 416, the
passage of a time delay following detection of a signal generator
416, or the passage of time delay following the closing of the
valve 402. It is noted that the signal generator 416 may be a
discrete object, such as a ball or small particle deployed in the
fluid flow path 406, or a signal generator 416 that is remotely
deployed from the surface by, for example, a slickline or wireline
cable deployed within the tool string or wellbore annulus in an
area that will be detected by the sensor 410. Such a signal
generator may thereby be a contactless tool that is deployed
without a dedicated electrical connection or power supply to open
or close a downhole valve.
[0041] In an embodiment, the sensor 410 may also include a pressure
sensor and thereby be configured to detect pressure pulses, or
brief surges or variations in the fluid pressure at the sensor
location. In such an embodiment, the memory may be provided with
instructions for opening or closing the valve 402 in response to
detecting a pressure pulse or a sequence of pressure pulses. For
example, a timed sequence of pressure pulses may be associated with
a command to open the valve 402 and a second timed sequence of
pressure pulses may be associated with a command to close the valve
402. In such an embodiment, the actuator system 400 will transition
to an open state in response to the sensor 410 detecting the first
timed sequence of pressure pulses and transition to a closed state
in response to the sensor 410 detecting the second timed sequence
of pressure pulses.
[0042] In an embodiment, the sensor 410 may also include a contact
sensor or wet connect that is configured to receive an electrical
current, and a wire delivering the electrical current may be the
signal generator. The wire may be a low voltage wire that is easily
provided downhole by a slickline or wireline application. In such
an embodiment, the sensor 410 may also be configured to receive and
transmit the electrical current to the power supply 412 to charge
the battery of the actuator. In an embodiment, the electrical
current may thereby facilitate charging of a power supply 412,
thereby extending the life of such valves.
[0043] In another embodiment, the actuator system 400 or a
plurality of actuators may be coupled to one or more valves or
other tools, such as packers or measuring devices that may also be
actuated by such an actuator system 400, three way valves, etc. In
such an embodiment, the sensor 410 may include a photo-sensor, or
photo-electric cell that is selected to detect a signal generator
416 that is a LED or similar light source included in a clear glass
or plastic ball that is deployed downhole. A plurality of such
signal generators may be deployed downhole, each producing a
selected different wavelength of light. Correspondingly, a
plurality of actuator systems 400 may be configured to detect
different wavelengths of light so that each tool may be actuated by
deploying a signal generator 416 that corresponds to the tool. For
example, a first valve may be actuated by deploying a signal
generator 416 that generates a blue light to a sensor 410 of an
actuator that is configured actuate the valve in response to the
detection of blue light. Similarly, a second tool may be actuated
by deploying a signal generator 416 that emits a red light to a
sensor 410 of an actuator system 400 that is configured to actuate
the tool in response to detecting red light. Thus, deployment of
signal generators 416 that emit different wavelengths of light or
otherwise discernible signals of the types described above (such as
magnetic, radioactive, and acoustic signals) may be deployed in
succession to actuated a plurality of tools within a tool
string.
[0044] In another embodiment, the actuator 332 of FIG. 1 includes
the sensor 410, the power supply 412, the processor 414, the memory
415, and the actuating member 408 of FIG. 4, and operates in
accordance with one or more of the foregoing embodiments of the
contactless actuation system 400 of FIG. 4.
[0045] Now referring primarily to FIG. 5, a schematic flow chart
shown therein depicts an illustrative method 500 for contactless
actuation of a downhole valve, according to an embodiment. The
method 500 may be used with any of the previous illustrative
embodiments. The method 500 includes a step 502 of conveying an
actuation signal generator into a conduit of a downhole tool using
a fluid. In some embodiments, the actuation signal generator is
selected from the group consisting of a light source, a magnetic
field source, a radioactive source, and an acoustic source. The
method 500 also includes a step 504 of monitoring the conduit for
entry of the actuation signal generator. In certain embodiments,
the step 504 of monitoring the conduit includes detecting
electromagnetic radiation from a light emitting diode using a
photo-detector. The method 500 involves a decision, represented by
interrogatory 506, to determine if the actuation signal generator
has been detected. Such a determination may include detecting a
threshold quantity of actuation signal generators. If the no
actuation signal generator has been detected, the method 500
returns to the step 504 of monitoring the conduit. However, if the
actuation signal generator is detected at the interrogatory 506,
the method 500 proceeds to a step 508 of actuating the downhole
valve. After the step 508 of actuating the downhole valve, the
system may end 510, or return to a point between the step 502 and
the step 504 to wait for further signals to actuate the valve
again. In some embodiments, the method 500 further includes the
step (not shown) of releasing the actuation signal generator in the
fluid. This step is typically performed before the step 502 of
conveying the actuation signal generator.
[0046] Although the present invention and its advantages have been
disclosed in the context of certain illustrative, non-limiting
embodiments, it should be understood that various changes,
substitutions, permutations, and alterations can be made without
departing from the scope of the invention as defined by the
appended claims. It will be appreciated that any feature that is
described in connection to any one embodiment may also be
applicable to any other embodiment.
Example 1
[0047] A valve assembly comprising: [0048] a fluid conduit; [0049]
a sealing member to open and close the fluid conduit; and [0050] an
actuator coupled to the sealing member to move the sealing member
from an open position to a closed position, the actuator comprising
a detector; [0051] wherein the detector is a passive detector that
senses an actuation signal generator; and [0052] wherein the
actuator manipulates the sealing member in response to the detector
sensing the actuation signal generator.
Example 2
[0053] The valve assembly of Example 1, further comprising a power
source coupled to the actuator.
Example 3
[0054] The valve assembly of Example 1 or Example 2, further
comprising a controller coupled to the detector, the controller
having at least one processor and at least one memory, the at least
one processor and the at least one memory perform logical
operations and calculations in relation to the actuation signal
generator sensed by the detector.
Example 4
[0055] The valve assembly of Example 1 or any of Examples 2-3,
wherein the sealing member comprises a ball having a throughbore
and movably arranged within the fluid conduit, the ball movable
between the open position, where the throughbore is axially aligned
with the fluid conduit, and the closed position, where the
throughbore is perpendicular to the conduit.
Example 5
[0056] The valve assembly of Example 1 or any of Examples 2-3,
wherein the sealing member comprises a sleeve valve.
Example 6
[0057] The valve assembly of Example 1 or any of Examples 2-5,
wherein the actuator comprises a hydraulic pump fluidly-coupled to
the sealing member.
Example 7
[0058] The valve assembly of Example 1 or any of Examples 2-6,
wherein the actuation signal generator is selected from the group
consisting of a light source, a magnetic field generator, a
radioactive source, and an acoustic signal generator.
Example 8
[0059] The valve assembly of Example 1 or any of Examples 2-6,
wherein the actuation signal generator comprises a light source and
wherein the detector comprises a photo sensor.
Example 9
[0060] The valve assembly of Example 8, wherein the light source
comprises a transparent body containing a light emitting diode.
Example 10
[0061] A contactless valve actuation system, the system comprising:
[0062] a conduit; [0063] a valve fluidly coupled to the conduit,
the valve having a sealing member that is movable between an open
position and a closed position; [0064] a valve actuator coupled to
the valve, wherein the valve actuator moves the sealing member
between the open position and the closed position, the valve
actuator comprising a sensor and a controller to generate a control
signal in response to the sensor detecting an actuation signal
generator; and [0065] a pump fluidly-coupled to the housing,
wherein the pump conveys fluid containing the actuation signal
generator through the conduit of the housing.
Example 11
[0066] The system of Example 10, wherein the valve actuator further
comprises a local power source to provide power to a movable
member.
Example 12
[0067] The system of Example 10 or Example 11, wherein quantities
of the actuation signal generator are released into fluid.
Example 13
[0068] The system of Example 10 or any of Examples 11-12, wherein
the controller determines a position of the valve based on a signal
received from the sensor.
Example 14
[0069] The system of Example 10 or any of Examples 11-13, wherein
the valve actuator comprises a hydraulic pump fluidly-coupled to
the valve.
Example 15
[0070] The system of Example 10 or any of Examples 11-14, wherein
the valve comprises a ball having a throughbore and movably
arranged with the conduit, the throughbore axially-aligned with
conduit in the open position and perpendicular to the conduit in
the closed position.
Example 16
[0071] The system of Example 10 or any of Examples 11-14, wherein
the valve is a sleeve valve.
Example 17
[0072] The system of Example 10 or any of Examples 11-16, wherein
the actuation signal generator is selected from the group
consisting of a light source, a magnetic field source, a
radioactive source, and an acoustic source.
Example 18
[0073] The system of Example 10 or any of Examples 11-16, wherein
the actuation signal generator comprises a light emitting diode and
wherein the sensor comprises a photo sensor.
Example 19
[0074] A method of actuating a valve, the method comprising: [0075]
conveying an actuation signal generator into a conduit of a
downhole tool using a fluid; [0076] monitoring the conduit for
entry of the actuation signal generator; and [0077] actuating the
valve if the actuation signal generator is detected in the conduit;
[0078] wherein the valve controls a sealing member within the
conduit thereby regulating fluid flow therethrough.
Example 20
[0079] The method of Example 19, further comprising the step of
releasing the actuation signal generator into the fluid.
Example 21
[0080] The method of Example 19 or Example 20, wherein the
actuation signal generator is selected from the group consisting of
a light source, a magnetic field source, a radioactive source, and
an acoustic source.
Example 22
[0081] The method of Example 19 or Example 20, wherein the step of
monitoring the conduit comprises detecting electromagnetic
radiation from a light emitting diode using a photo-detector.
[0082] It will be understood that the benefits and advantages
described above may relate to one embodiment or may relate to
several embodiments. It will further be understood that reference
to "an" item refers to one or more of those items.
[0083] The steps of the methods described herein may be carried out
in any suitable order or simultaneous where appropriate. Where
appropriate, aspects of any of the examples described above may be
combined with aspects of any of the other examples described to
form further examples having comparable or different properties and
addressing the same or different problems.
[0084] It will be understood that the above description of the
embodiments is given by way of example only and that various
modifications may be made by those skilled in the art. The above
specification, examples, and data provide a complete description of
the structure and use of exemplary embodiments of the invention.
Although various embodiments of the invention have been described
above with a certain degree of particularity, or with reference to
one or more individual embodiments, those skilled in the art could
make numerous alterations to the disclosed embodiments without
departing from the scope of the claims.
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