WO2015153308A1

WO2015153308A1 - Supplementary control downhole valve

Info

Publication number: WO2015153308A1
Application number: PCT/US2015/022878
Authority: WO
Inventors: Robert Thomas Brooks
Original assignee: Shell Oil Company; Shell Internationale Research Maatschappij B.V.
Priority date: 2014-04-04
Filing date: 2015-03-27
Publication date: 2015-10-08

Abstract

A supplementary control downhole valve comprising: a housing and one or more flapper fingers disposed on the housing.

Description

SUPPLEMENTARY CONTROL DOWNHOLE VALVE

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 61/975,324, filed April 4, 2014, which is incorporated herein by reference.

BACKGROUND

[0002] The present disclosure relates generally to supplementary control downhole valves. More specifically, in certain embodiments, the present disclosure relates to supplementary control downhole valves and associated methods and systems.

[0003] In certain wells, when it comes time to work the well over, it is a common practice to pump water into the production liner to kill the well. In conventional wells, this often is not problematic as large amounts of water may not be needed to kill the well. However, in coal bed methane (CBM) wells, the coal seams may take up copious amounts of water pumped into the well. Thus, larger amounts of water may be required to kill the well than conventional wells.

[0004] The water used to kill the well, plus additional amounts of water from the formation itself, must later be pumped out in order to restart gas flow after the well is worked over. Most CBM water, however, is not suitable for surface discharge and must be disposed of with special care. For most disposal options the water must be transported to the disposal facilities. In the case of large amounts of produced water this can be an expensive and time consuming process. Furthermore, it may also take a substantial amount of time to return the well back to producing the gas at the production levels expected. The time and costs associated with this unproductive time after the workover may impact the economics of CBM gas production.

[0005] It is desirable to develop a device to stop gas flow in a well when working over the well without relying upon pumping water down the production liner, and into the formation, to kill the well. SUMMARY

[0006] The present disclosure relates generally to supplementary control downhole valves. More specifically, in certain embodiments, the present disclosure relates to supplementary control downhole valves and associated methods and systems.

[0007] In one embodiment, the present disclosure provides a supplementary control downhole valve comprising: a housing and a one or more flapper fingers disposed on the housing.

[0008] In another embodiment, the present disclosure provides a supplementary control downhole valve system comprising: a tubular and a supplementary control downhole valve disposed in the tubular, wherein the supplementary control downhole valve comprises a housing and one or more flapper fingers disposed on the housing.

[0009] In another embodiment, the present disclosure provides a method comprising: providing a supplementary downhole valve system comprising a supplementary control downhole valve and a tubular and activating the supplementary control downhole valve to seal the tubular.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] A more complete and thorough understanding of the present embodiments and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings.

[0011] Figure 1 is an illustration of a supplementary control downhole valve in an open position in accordance with certain embodiments of the present disclosure.

[0012] Figure 2 is an illustration of a supplementary control downhole valve in a closed position in accordance with certain embodiments of the present disclosure.

[0013] Figure 3 is an illustration of a drag block shifting tool.

[0014] Figure 4 is an illustration of a supplementary control downhole valve system in accordance with certain embodiments of the present disclosure.

[0015] Figure 5 is an illustration of a supplementary control downhole valve system in accordance with certain embodiments of the present disclosure.

[0016] Figure 6 is an illustration of a supplementary control downhole valve system in accordance with certain embodiments of the present disclosure.

[0017] The features and advantages of the present disclosure will be readily apparent to those skilled in the art. While numerous changes may be made by those skilled in the art, such changes are within the spirit of the disclosure. DETAILED DESCRIPTION

[0018] The description that follows includes exemplary apparatuses, methods, techniques, and/or instruction sequences that embody techniques of the inventive subject matter. However, it is understood that the described embodiments may be practiced without these specific details.

[0019] The present disclosure relates generally to supplementary control downhole valves. More specifically, in certain embodiments, the present disclosure relates to supplementary control downhole valves and associated methods and systems.

[0020] In certain embodiments, the present disclosure provides a supplementary control downhole valve that may be used to stop gas, and/or a gas -water mix, flow once a pump and production tubing is pulled past it out of a well. In certain embodiments, the supplementary control downhole valve may be mechanically operated so no control lines need to be run to the surface to operate the valve. In certain embodiments, the bore through the tool is full bore of the production liner and the OD is smaller than the casing it is run through or the openhole wellbore drilled size. In certain embodiments, the valve can be mechanically reopened after the workover is complete.

[0021] Referring now to Figure 1, Figure 1 illustrates supplementary control downhole valve 100 in accordance with certain embodiments of the present disclosure. As can be seen in Figure 1, in certain embodiments, supplementary control downhole valve 100 may comprise housing 110 and one or more flapper fingers 120.

[0022] In certain embodiments, housing 110 may be constructed of any conventional downhole material suitable for use as a tubular. In certain embodiments, housing 110 may be constructed out of steel, cast iron, cast steel, and/or stainless steel. In certain embodiments, housing 110 may have a cylindrical shape with a hollow center. In certain embodiments, housing 110 may comprise outside surface 111, inside surface 112, top surface 113, and bottom surface 114. In certain embodiments, housing 110 may further comprise groove 115. In certain embodiments, O-ring 118 may be disposed in groove 115.

[0023] In certain embodiments, housing 110 may be from 2 to 10 inches in length. In certain embodiments, housing 110 may have an outer diameter of from 5 to 15 inches, an inner diameter of from 4 to 12.5 inches, and/or a thickness of 0.38 to 1 inches. In certain embodiments, housing 110 may have an outer diameter of 7.29 inches, an inner diameter of 6.53 inches, and/or a thickness of 0.38 inches.

[0024] In certain embodiments, top surface 113 of housing 110 may have several indented portions comprising indented surfaces 116 and side surfaces 117a and 117b. In certain embodiments, side surfaces 117a and 117b may each define a cavity.

[0025] In certain embodiments, flapper fingers 120 may be constructed out of any conventional downhole material suitable for use as a tubular. In certain embodiments, flapper fingers 120 may be constructed out of steel, cast iron, cast steel, stainless steel, Incalloy/Inconel, and/or Titanium. In certain embodiments, flapper fingers 120 may be arrow shaped and/or comprise base portion 121, side sealing faces 122, back sealing face 123, bottom surface 124, and top surface 125. In certain embodiments, base portion 121 may define one or more cavities/indented surfaces.

[0026] In certain embodiments, the one or more flapper fingers 120 may be disposed on the top surface 113 of housing 110. In certain embodiments, supplementary control downhole valve 100 may comprise 6, 7, 8, 9, or 10 flapper fingers 120 disposed and equispaced on top surface 113 of housing 110. In certain embodiments, the base portion 121 of flapper fingers 120 may be in contact with the side surface 117 and 117b of housing 110. In certain embodiments, base portion 121 of flapper fingers 120 may be disposed within the indented portions of top surface 113 of housing 110.

[0027] In certain embodiments, flapper fingers 120 may be attached housing 110 through the use of pivot pin 130 and torsion spring 131. In certain embodiments, pivot pin 130 may be disposed in the cavities defined by side surfaces 117a and 117b and base portion 121. In certain embodiments, torsion spring 131 may be disposed around pivot pin 130. In certain embodiments, torsion spring 131 may be capable of keeping supplementary control downhole valve in a closed position, as further described below.

[0028] In certain embodiments, as shown in Figure 1, supplementary control downhole valve 100 may be in an open position. In such embodiments, flapper fingers 120 are arranged such that they do not restrict flow through supplementary control downhole valve 100. In such embodiments, flapper fingers 120 may be vertical disposed on housing 110. In certain embodiments, the top surfaces of flapper fingers 120 may be in vertical alignment with the outside surface 111 of housing 110, and held in position by an inner sleeve (not illustrated in Figure 1).

[0029] Referring now to Figure 2, Figure 2 illustrates a supplementary control downhole valve 200 in accordance with certain embodiments of the present disclosure. In certain embodiments, supplementary control downhole valve 200 may share any combination of characteristics discussed above with respect to supplementary control downhole valve 100. In certain embodiments, supplementary control downhole valve 200 may comprise housing 210 comprising outside surface 211, an inside surface (not illustrated in Figure 2), top surface 213, bottom surface 214, groove 215, O-ring 218, indented surfaces 216, and side surfaces 217a and 217b. In certain embodiments, supplementary control downhole valve 200 may comprise one or more flapper fingers 220 comprising base portion 221, side sealing faces (not illustrated in Figure 2), back sealing faces 223 (not illustrated in Figure 2), bottom surface 224 (not shown in Figure 2), and top surface 225. In certain embodiments, supplementary control downhole valve 200 may comprise one or more torsion springs 231 (not illustrated in Figure 2) and pivot pins 230 (not illustrated in Figure 2) connecting the one or more flapper fingers 220 to housing 210.

[0030] In certain embodiments, as shown in Figure 2, supplementary control downhole valve 200 may be in a closed position. In such embodiments, flapper fingers 220 are arranged such that they restrict flow through supplementary control downhole valve 200. In certain embodiments, the restriction may be a complete restriction. In certain embodiments, flapper fingers 220 may be arranged such that they restrict 97% to 100% of the flow when in the closed position. In other embodiments, flapper fingers 220 may restrict all flow through supplementary control downhole valve 200 when in the closed position.

[0031] In certain embodiments, supplementary control downhole valve 200 may be capable of providing a pressure containment up to 2000 psi when in the closed position. In certain embodiments, supplementary control downhole valve 200 may be capable of providing a pressure containment in excess of 2000 psi when in the closed position. In certain embodiments, the selection of materials used for the flapper fingers 220 and housing 210 may govern the amount of pressure containment supplementary control downhole valve 200 may withstand.

[0032] In certain embodiments, when in the closed position, the side sealing faces of each of each flapper fingers 220 may be in sealing contact with the side sealing faces of the adjacent flapper fingers 220. In certain embodiments, when in the closed position, the bottom surfaces 223 (not illustrated in Figure 2) may be in contact with top surface 213 of housing 210. In certain embodiments, bottom surfaces 223 (not illustrated in Figure 2) may only cover a portion of top surface 213 of housing 210. In other embodiments, not illustrated, bottom surfaces 223 (not illustrated in Figure 2) of the one or more flapper fingers 220 may completely cover top surface 213 of housing 210, providing a metal to metal seal. In such embodiments, flapper fingers 220 may create a self-supporting bridge effectively sealing the supplementary control downhole valve.

[0033] Referring now to Figure 3, Figure 3 illustrates a drag block shifting tool 300 that may be utilized to move the supplementary control downhole valve from the open position to the closed position and vice versa. Referring now to Figure 3, in certain embodiments drag block shifting tool 300 may comprise housing 301, drag blocks 310, and springs 315. In certain embodiments, drag blocks 310 may be spring-loaded by springs 315.

[0034] Referring now to Figure 4, Figure 4 illustrates a supplementary control downhole valve system 400. In certain embodiments, supplementary control downhole valve system 400 may comprise supplementary control downhole valve 410, outer housing 420, inner shifting sleeve 423, shear pins 431, and tubular 460. In certain embodiments, tubular 460 may comprise a casing string. Figure 4 depicts supplementary control downhole valve 410 being run into the well bore. In Figure 4, supplementary control downhole vale is in a "run position."

[0035] In certain embodiments, supplementary control downhole valve 410 may comprise any combination of features discussed above with respect to supplementary control downhole valves 100 and/or 200. In certain embodiments, supplementary control downhole valve 410 may be run to a location in the well bore above a production zone (not illustrated).

[0036] In certain embodiments, supplementary control downhole valve 410 may be disposed within outer housing 420 and run on tubular 460. In certain embodiments, outer housing 420 may match the physical and chemical ratings of tubular 460. In certain embodiments, outer housing 420 may comprise top, middle, and bottom cylindrical components that are threadedly connected to each other by conventional oilfield threaded connections or metal-to-metal premium sealing threads. In other embodiments, inner shifting sleeve 423 may be disposed within outer housing 420.

[0037] In certain embodiments inner shifting sleeve 423 may be disposed within outer housing 420. In certain embodiments, inner shifting sleeve 423 may comprise a counter bore groove 424 at an upper end of inner shifting sleeve 423. In certain embodiments, the counter bore groove 424 may be profiled to accept drag blocks of a drag block shifting tool.

[0038] In certain embodiments, inner shifting sleeve 423 may be held in a run- in/detent position by one or more shear pins 431. In this position, the inner shifting sleeve 423 is not fully in the extended position. As a result, supplementary control downhole valve 410 may be held in the run position. This may allow for running the supplementary control downhole valve 410 in the open position in the original completion phase of a well, as the completion may need to allow circulation through it as it is being run in the hole.

[0039] Once supplementary control downhole valve 410 is run into the casing, it may be moved to a fully opened "armed" position by the use of a drag block shifting tool. In certain embodiments, supplementary control downhole valve 410 may be switched to the armed position by running a drag block shifting tool down through supplementary control downhole valve 410. In certain embodiments, the drag block shifting tool (not illustrated) may be disposed above supplementary control downhole valve 410 on the production tubing (not illustrated). In such embodiments, when the drag block shifting tool reaches the inner shifting sleeve 423, the drag blocks may snap into the counter bore groove 424 of inner shifting sleeve 423. Continued downward movement of production tubing will shear shear pins 431. Once inner shifting sleeve 423 makes full down position contact with the outer housing 420, additional downward force may be applied to push the drag blocks back into the inner bore of the casing as the drag block shifting tool exits supplementary control downhole valve 410. This is an indication that the tool is now armed and fully open.

[0040] Referring now to Figure 5, Figure 5 illustrates a supplementary control downhole valve system 500. In certain embodiments, supplementary control downhole valve system 500 may comprise supplementary control downhole valve 510, outer housing 520, inner shifting sleeve 523, and tubular 560. Figure 5 depicts supplementary control downhole valve 510 in an armed and fully open position.

[0041] In certain embodiments, supplementary control downhole valve 510 may comprise any combination of features discussed above with respect to supplementary control downhole valves 100, 200, and/or 410. In certain embodiments, outer housing 520 may comprise any combination of features discussed above with respect to outer housing 420. In certain embodiments, inner shifting sleeve 523 may comprise any combination of features discussed above with respect to inner shifting sleeve 423. In certain embodiments, tubular 560 may comprise any combination of features discussed above with respect to tubular 460.

[0042] In certain embodiments, supplementary control downhole valve 510 may be switched to the closed position by running a drag block shifting tool up through supplementary control downhole valve 510. In certain embodiments, the drag block shifting tool (not illustrated) may be disposed below supplementary control downhole valve 510 on the production tubing (not illustrated). In such embodiments, when the drag block shifting tool reaches the inner shifting sleeve 523, the drag blocks may snap into the counter bore groove 524 of inner shifting sleeve 523. Continued upward movement of production tubing move inner shifting sleeve 523 to an uppermost position thereby allowing supplementary control downhole valve 510 to rotate to the closed position. Continued upward force may be applied to push the drag blocks back into the inner bore of the casing, by compressing the drag block springs, as the drag block shifting tool exits the supplementary control downhole valve 510. This is an indication that the tool is now in the closed position. Once supplementary control downhole valve 510 is in the closed position, any completion in the well can be fully removed from the well and any gas and water downhole will be contained below supplementary control downhole valve 510.

[0043] Referring now to Figure 6, Figure 6 illustrates a supplementary control downhole valve system 600. In certain embodiments, supplementary control downhole valve system 600 may comprise supplementary control downhole valve 610, outer housing 620, inner shifting sleeve 623, and tubular 660. Figure 6 depicts supplementary control downhole valve 610 in a closed position.

[0044] In certain embodiments, supplementary control downhole valve 610 may comprise any combination of features discussed above with respect to supplementary control downhole valves 100, 200, 410, and/or 510. In certain embodiments, outer housing 620 may comprise any combination of features discussed above with respect to outer housing 520. In certain embodiments, inner shifting sleeve 623 may comprise any combination of features discussed above with respect to inner shifting sleeve 523. In certain embodiments, tubular 660 may comprise any combination of features discussed above with respect to tubular 560.

[0045] In certain embodiments, supplementary control downhole valve 610 may be switched back to the open position by running a drag block shifting tool down through supplementary control downhole valve 610. In certain embodiments, the drag block shifting tool (not illustrated) may be disposed above supplementary control downhole valve 610 on the production tubing (not illustrated). In such embodiments, when the drag block shifting tool reaches the inner shifting sleeve 623, the drag blocks may snap into the counter bore groove 624 of inner shifting sleeve 623. Continued downward movement of production tubing will move inner shifting sleeve 623 to a lowermost position contacting outer housing 620, moving the flapper fingers to the fully open position and protected behind the inner shifting sleeve 623. Additional downward force may be applied to push the drag blocks back into the inner bore of the casing as the drag block shifting tool exits supplementary control downhole valve 610. This is an indication that the tool is now fully open. Once supplementary control downhole valve 610 is opened, the completion can be finalized, surface equipment hooked back up and production can be recommenced.

[0046] In certain embodiments, the present disclosure provides a method comprising: providing a supplementary control downhole valve system comprising a supplementary control downhole valve and a tubular and activating the supplementary control downhole valve. In certain embodiments, the supplementary control downhole valve system may comprise any supplementary control downhole valve system discussed above. In certain embodiments, the supplementary control downhole valve may comprise any type of supplementary control downhole valve discussed above. In certain embodiments, the tubular may comprise any type of tubular discussed above.

[0047] In certain embodiments, providing a supplementary control downhole valve system may comprise running a supplementary control downhole valve into a well bore. In certain embodiments, the supplementary control downhole valve may be run into a well bore on a tubular. In certain embodiments, the supplementary control downhole valve may be run into a well bore at a location above a production zone. In certain embodiments, the supplementary control downhole valve may be run into the well bore while it is in the run position.

[0048] In certain embodiments, providing a supplementary control downhole valve system may further comprise arming the supplementary control downhole valve. In certain embodiments, arming the supplementary control downhole valve may comprise running a drag block shifting tool down through the supplementary control downhole valve. In certain embodiments, the drag block shifting tool may be run down through the supplementary control downhole valve on a production tubing. In certain embodiments, running the drag block shifting tool down through the supplementary control downhole valve may comprise allowing the drag blocks of the drag block shifting tool to snap into the counter bore groove of the inner shifting sleeve. In certain embodiments, running the drag block shifting tool through the supplementary control downhole valve may further comprise shearing the shear pins and allowing the inner shifting sleeve to move downward making full down position contact with the outer housing. In certain embodiments, running the drag block shifting tool through the supplementary control downhole valve may further comprise allowing the drag block shifting tool to exit the supplementary control downhole valve.

[0049] In certain embodiments, the method may further comprise activating the supplementary control downhole valve to seal the tubular. In certain embodiments, activating the supplementary control downhole valve may comprise running a drag block shifting tool up through the supplementary control downhole valve. In certain embodiments, the drag block shifting tool may be run up through the supplementary control downhole valve on a production tubing. In certain embodiments, running the drag block shifting tool up through the supplementary control downhole valve may comprise allowing the drag blocks of the drag block shifting tool to snap into the counter bore groove of the inner shifting sleeve. In certain embodiments, running the drag block shifting tool up through the supplementary control downhole valve may further comprise allowing the inner shifting sleeve to move upward to an uppermost position. In certain embodiments, allowing the inner shifting sleeve to move to an uppermost position allows the flapper fingers of the supplementary control downhole valve to freely rotate bringing the supplementary control downhole valve to the closed position. In certain embodiments, running the drag block shifting tool through the supplementary control downhole valve may further comprise allowing the drag block shifting tool to exit the supplementary control downhole valve.

[0050] In certain embodiments, the method may further comprise re-arming the supplementary control downhole valve. In certain embodiments, re-arming the supplementary control downhole valve may comprise re-running a drag block shifting tool down through the supplementary control downhole valve. In certain embodiments, the drag block shifting tool may be re-run down through the supplementary control downhole valve on a production tubing. In certain embodiments, re-running the drag block shifting tool down through the supplementary control downhole valve may comprise allowing the drag blocks of the drag block shifting tool to snap into the counter bore groove of the inner shifting sleeve. In certain embodiments, re -running the drag block shifting tool through the supplementary control downhole valve may further comprise allowing the inner shifting sleeve to move downward making full down position contact with the outer housing. In certain embodiments, allowing the inner shifting sleeve to move downward rotates the flapper fingers of the supplementary control downhole valve bringing the supplementary control downhole valve to the open position. In certain embodiments, re -running the drag block shifting tool through the supplementary control downhole valve may further comprise allowing the drag block shifting tool to exit the supplementary control downhole valve.

[0051] While the embodiments are described with reference to various implementations and exploitations, it will be understood that these embodiments are illustrative and that the scope of the inventive subject matter is not limited to them. Many variations, modifications, additions and improvements are possible.

[0052] Plural instances may be provided for components, operations or structures described herein as a single instance. In general, structures and functionality presented as separate components in the exemplary configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements may fall within the scope of the inventive subject matter.

Claims

C L A I M S

1. A supplementary control downhole valve comprising: a housing and a plurality of flapper fingers disposed on the housing.

2. The supplementary control downhole valve of claim 1, wherein the supplementary control downhole valve comprises 6 flapper fingers.

3. The supplementary control downhole valve of claim 1 or 2, wherein the flapper fingers are attached to the housing through the use of pivot pins and torsion springs.

4. The supplementary control downhole valve of any one of claims 1-3, wherein the flapper fingers each comprise a base portion, a side sealing face, a back sealing face, a bottom surface, and a top surface.

5. The supplementary control downhole valve of any one of claims 1-4, wherein the housing comprises an outside surface, an inside surface, a top surface, and a bottom surface.

6. The supplementary control downhole valve of any one of claims 1-5, wherein the supplementary control downhole valve is capable of transitioning from an open position to a closed position.

7. The supplementary control downhole valve of any one of claims 1-6, wherein the supplementary control downhole valve is capable of providing a pressure containment up to 2000 psi when in a closed position.

8. The supplementary control downhole valve of any one of claims 1-7, wherein the supplementary control downhole valve is capable of restricting 97% to 100% of fluid flow through the supplementary control downhole valve when in a closed position.

9. The supplementary control downhole valve of any one of claims 1-8, wherein the one or more flapper fingers create a self-supporting bridge effectively sealing the supplementary control downhole valve when in a closed position

10. A supplementary control downhole valve system comprising: a tubular and a supplementary control downhole valve disposed in the tubular, wherein the supplementary control downhole valve comprises a housing and a one or more of flapper fingers disposed on the housing.

11. The supplementary control downhole valve system of claim 10, wherein the supplementary control downhole valve comprises the supplementary control downhole valve of any one of claims 1-9.

12. The supplementary control downhole valve system of claim 10 or 11, wherein the tubular comprises a casing string.

13. The supplementary control downhole valve system of any one of claims 10- 12, further comprising an outer housing, an inner shifting sleeve comprising a counter bore groove, and one or more shear pins.

14. The supplementary control downhole valve system of claim 13, wherein the supplementary control downhole valve and the inner shifting sleeve are disposed within the outer housing.

15. The supplementary control downhole valve system of any one of claims 10- 14, wherein the supplementary control downhole valve is in the run position.

16. The supplementary control downhole valve system of any one of claims 10-

14, wherein the supplementary control downhole valve is in the armed position.

17. The supplementary control downhole valve system of any one of claims 10- 14, wherein the supplementary control downhole valve is in the closed position.

18. A method comprising: providing a supplementary control downhole valve system comprising a supplementary control downhole valve and a tubular and activating the supplementary control downhole valve to seal the tubular.

19. The method of claim 19, wherein providing a supplementary control downhole valve system comprises: running a supplementary control downhole valve into a well bore at a location above a production zone.

20. The method of claim 18 or 19 wherein activating the supplementary control downhole valve to seal the tubular comprise running a drag block shifting tool up through the supplementary control downhole valve.