Abstract:
In some embodiments a method of shifting a downhole-located device between positions with an actuator includes inserting the actuator into the well, engaging the actuator with the shiftable device and actuating the actuator to shift the shiftable device between positions.

Description:
[0001]    This application claims priority to U.S. provisional patent application Ser. No. 61/058,908 filed Jun. 4, 2008, entitled “Remote Hydraulic Shifting Apparatus, Systems and Methods”, which is hereby incorporated by reference herein in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present disclosure relates generally to downhole valves and other devices that are movable between positions and, more particularly, to selectively remotely shifting such valves or other devices. 
       BACKGROUND OF THE INVENTION 
       [0003]    In hydrocarbon recovery operations in subterranean wells, it is often desirable to selectively shift a valve or other device between positions. For example, there are instances when it is necessary or desirable to selectively close a downhole device to isolate the well, such as to remove, repair or replace equipment. Likewise, there are occasions when it is necessary to shift open the downhole device, such as to allow the recovery of produced fluids. 
         [0004]    In many applications, it may be particularly useful to be able to selectively remotely shift a valve or other device between positions on multiple occasions. For example, in hydrocarbon producing wells having a generally low bottom-hole pressure, an electric submersible pump is often inserted into the well to assist in drawing produced fluids up into the production tubing. However, these pumps typically have a limited useful life-span as compared to the producing life of the well, so operations must be interrupted to replace the pump. In such instances, it is often desirable to isolate the well below the pump by closing one or more valves during removal and replacement of the pump, and thereafter to re-open the valve(s) and continue production. 
         [0005]    Some present techniques for selectively shifting downhole devices require the insertion into the well of a shifting tool carried on pipe, coiled tubing or the like to mechanically shift the valve between positions. This process, which often requires the use of a rig or other equipment, may be time consuming and costly. 
         [0006]    It should be understood that the above-described discussion is provided for illustrative purposes only and is not intended to limit the scope or subject matter of the appended claims or those of any related patent application or patent. Thus, none of the appended claims or claims of any related patent application or patent should be limited by the above discussion or required to address, include or exclude all or any of the above-cited examples, features and/or disadvantages merely because of their mention above. 
         [0007]    Accordingly, there exists a need for improved systems, apparatus and methods capable of shifting a valve or other device disposed in a subterranean well and having one or more of the attributes, capabilities or features described below or in the subsequent sections of this disclosure, or shown in the appended drawings: may be remotely actuated from the surface with hydraulic pressure; may be remotely actuated from the surface with pneumatic pressure; may be remotely actuated from the surface by electric power; may be capable of both opening and closing the shiftable device multiple times as desired; may be capable of selectively repeatedly shifting the shiftable device between at least two positions; may be connected to a production tubing and releasably engageable with the shiftable device; is not part of the lower completion assembly or components; may be disengaged from the shiftable device, removed from the well, reinserted into the well and re-engaged with the device multiple times; may be capable of shifting the shiftable device without requiring the insertion or manipulation of pipe or coiled tubing in the well, or the use of a rig, wet connect or slick line; allows well zone isolation for quickly replacing, adding, removing or servicing equipment or other operations; does not require the engagement of control lines to the shiftable device; may be useful to quickly open and close off the well at will and repeatedly; is easily engageable and disengageable with the shiftable device; is slideably engageable with the shiftable device; allows the well to be sealed before starting operations; or a combination thereof. 
       BRIEF SUMMARY OF THE DISCLOSURE 
       [0008]    In some embodiments, the present disclosure involves methods of shifting a shiftable device between at least first and second positions with a removable actuator. The shiftable device is anchored within a subterranean well. The actuator is inserted into the well and releasably engaged with the shiftable device. When the shiftable device is in a first position, the actuator may be actuated by providing at least one among hydraulic pressure, pneumatic pressure and electric power thereto to shift the shiftable device into a second position without requiring the use of either a rig or a slick line. The actuator may be disengaged from the shiftable device. 
         [0009]    In various embodiments, the present disclosure involves methods of shifting a shiftable device between at least first and second positions with an actuator. The shiftable device is anchored within a subterranean well. These embodiments include coupling the actuator to a production tubing. After the shiftable member is anchored in the well, the production tubing is inserted into the well and the actuator is slideably engaged with the shiftable device. Whenever and as many times as desired, the actuator may be actuated by providing at least one among hydraulic pressure, pneumatic pressure and electric power to the actuator to shift the shiftable device between positions without requiring the use of either a rig or a slick line. 
         [0010]    There are embodiments of the present disclosure that involve a method of remotely shifting a downhole valve between open and closed positions with a hydraulic valve actuator. These embodiments include inserting the valve actuator into the well and engaging the valve actuator with the valve (in a closed position). Thereafter and whenever the valve is in a closed position, the valve actuator may be hydraulically actuated to shift the valve into an open position. Likewise, when the valve is in an open position, the valve actuator may be hydraulically actuated to shift the valve into a closed position. 
         [0011]    In accordance with the present disclosure, some embodiments involve an apparatus useful for shifting a shiftable device between at least first and second positions. The shiftable device is anchored in a subterranean well. The apparatus includes a housing insertable into and out of the well without disturbing the location of the shiftable device within the well. A hydraulically-driven piston is disposed within the housing. At least two hydraulic control lines are fluidly coupled to the housing and capable of providing hydraulic pressure from the surface to the housing to cause the piston to move up and down within the housing. An engagement arm extends from the piston and is releasably engageable with the shiftable device. The engagement arm moves up and down with the piston and is capable of mechanically shifting the shiftable device between at least first and second positions without requiring the use of either a rig or a slick line. The piston and engagement arm may thus be hydraulically-actuated to selectively remotely shift the shiftable member between positions. 
         [0012]    Accordingly, the present disclosure includes features and advantages which are believed to enable it to advance downhole device shifting technology. Characteristics and potential advantages of the present disclosure described above and additional potential features and benefits will be readily apparent to those skilled in the art upon consideration of the following detailed description of various embodiments and referring to the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    The following figures are part of the present specification, included to demonstrate certain aspects of various embodiments of this disclosure and referenced in the detailed description herein: 
           [0014]      FIG. 1  is a partial schematic and partial cross-sectional view of an embodiment of a valve actuator useful for shifting an example valve disposed in a subterranean well in accordance with an embodiment of the present disclosure; 
           [0015]      FIG. 2  is a cross-sectional view of a portion of an example shifter of an embodiment of a valve actuator in accordance with the present disclosure; 
           [0016]      FIG. 3A  is a partial cross-sectional view of a portion of the valve actuator of  FIG. 1  shown with the example valve in a closed position; 
           [0017]      FIG. 3B  is a partial cross-sectional view of a portion of the valve actuator of  FIG. 1  shown with the example valve in an open position; 
           [0018]      FIG. 3C  is a partial cross-sectional view of a portion of the valve actuator of  FIG. 1  shown with the example valve in a closed position; 
           [0019]      FIG. 3D  is a partial cross-sectional view of a portion of the valve actuator of  FIG. 1  shown releasing from the exemplary valve in a closed position; 
           [0020]      FIG. 4A  is a partial schematic and partial cross-sectional view of another embodiment of a valve actuator useful for shifting an example sleeve disposed in a subterranean well in accordance with an embodiment of the present disclosure; 
           [0021]      FIG. 4B  a partial schematic and partial cross-sectional view of the exemplary valve actuator of  FIG. 4A  shown shifting the illustrated sleeve into a closed position; 
           [0022]      FIG. 5A  is a partial perspective and partial cross-sectional view of a portion of another embodiment of a valve actuator having an exemplary engagement arm shifting an example sliding sleeve into an open position in accordance with the present invention; 
           [0023]      FIG. 5B  shows the exemplary valve actuator of  FIG. 5A  after having shifted the illustrated sliding sleeve into an open position. 
           [0024]      FIG. 5C  shows the exemplary engagement arm of  FIG. 5A  shifting the illustrated sliding sleeve into a closed position; and 
           [0025]      FIG. 5D  shows the exemplary valve actuator of  FIG. 5A  after having shifted the illustrated sliding sleeve into a closed position. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0026]    Characteristics and advantages of the present disclosure and additional features and benefits will be readily apparent to those skilled in the art upon consideration of the following detailed description of exemplary embodiments of the present disclosure and referring to the accompanying figures. It should be understood that the description herein and appended drawings, being of example embodiments, are not intended to limit the appended claims or claims of any patent or patent application claiming priority hereto. On the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the claims. Many changes may be made to the particular embodiments and details disclosed herein without departing from such spirit and scope. 
         [0027]    In showing and describing preferred embodiments, common or similar elements are referenced in the appended figures with like or identical reference numerals or are apparent from the figures and/or the description herein. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness. 
         [0028]    As used herein and throughout various portions (and headings) of this patent application, the terms “invention”, “present invention” and variations thereof are not intended to mean every possible embodiment encompassed by this disclosure or any particular claim(s). Thus, the subject matter of each such reference should not be considered as necessary for, or part of, every embodiment hereof or of any particular claim(s) merely because of such reference. The terms “coupled”, “connected”, “engaged” and the like, and variations thereof, as used herein and in the appended claims are intended to mean either an indirect or direct connection or engagement. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection via other devices and connections. Also, the terms “upward” and “downward” as used herein and in the appended claims may be relative to the top and/or bottom of a component, assembly or space and are not necessarily limited to movement in a vertical axis or plane. 
         [0029]    Certain terms are used herein and in the appended claims to refer to particular components. As one skilled in the art will appreciate, different persons may refer to a component by different names. This document does not intend to distinguish between components that differ in name but not function. Also, the terms “including” and “comprising” are used herein and in the appended claims in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . .” Further, reference herein and in the appended claims to components and aspects in a singular tense does not necessarily limit the present disclosure or appended claims to only one such component or aspect, but should be interpreted generally to mean one or more, as may be suitable and desirable in each particular instance. 
         [0030]    Referring initially to  FIG. 1 , an embodiment of a valve actuator  10  useful for shifting a valve  14  or other device disposed in a subterranean well  12  is shown. The illustrated well  12  is vertically oriented, but could instead be horizontal, deviated or have any other orientation. In this embodiment, the valve  14  is a mechanical isolation ball valve  16 , which may be shifted between open and closed positions, as desired, with the valve actuator  10 . The illustrated ball valve  16  is contained within a valve assembly  18 , which is connected within a lower completion arrangement  22  coupled to a casing  24 , such as with a seal/locator assembly  28  and packer  30 . For example, the lower completion arrangement  22  may be run into and set in the well  12  in one trip with the valve  14  in a closed position before the valve actuator  10  is introduced into the well  12 . However, this set of components, configuration and sequence are provided for illustrative purposes only and are not required for, or limiting upon, the present disclosure. 
         [0031]    It should be understood that the valve actuator  10  may be used to move any type or configuration of valve  14  or other device between any desired positions. Some examples of such valves and other devices are flapper valves, ball valves, mechanical or hydraulic sliding sleeves, gravel pack closing sleeves and other fluid loss or recovery devices. Thus, the present invention is not limited to use with any particular type of valve or other shiftable device. As used herein and in the appended claims, unless specified otherwise, the term “valve” includes any type of device that is moveable between at least two positions. Further, the present invention is not limited by the number or nature of positions between which the valve may be shifted. Additionally, the valve may be disposed at any desired location in a subterranean well and in any desired downhole arrangement of components. Accordingly, the present disclosure is not limited by the type, configuration, action, purpose or operation of the device(s) that may be shifted in accordance with this disclosure. 
         [0032]    Still referring to  FIG. 1 , the valve actuator  10  may have any desired form, configuration and operation. In this embodiment, the valve actuator  10  includes a shifter  32  which effectively moves the valve  14  between positions. In some embodiments, referring to  FIG. 2 , the shifter  32  may include at least one balanced piston  34  and at least one engagement arm  38  extending therefrom and moveable therewith. The exemplary piston  34  is disposed and reciprocable within a housing  42  by surface-controlled hydraulic (or pneumatic) pressurization through control lines  46 ,  48 . In other embodiments, the piston  34  may be electrically-actuated. For example, one or more electric power line (not shown) may extend from the surface to an electric motor (not shown) connected with and used for powering the piston  34 . 
         [0033]    Still referring to  FIG. 2 , the illustrated piston  34  is shown in a “down” position after hydraulic fluid pressurization in the housing  42  via the control line  46 . If it is desired to move the exemplary piston  34  (and engagement arm  38 ) to an “up” position (not shown), sufficient hydraulic fluid pressurization is provided via the control line  48 . Thus, the piston  34  and engagement arm  38  of this embodiment are selectively, remotely moveable via hydraulics (or pneumatics) between “up” and “down” positions. However, the valve actuator  10  of the present disclosure is not limited to this configuration. For example, a different arrangement and number of control lines may be used. For other examples, the piston  34  (and engagement arm  38 ) may be moveable between more than two positions or actuated in a different manner (other than hydraulics or pneumatics; e.g. electrical power). Further, the piston  34  and engagement arm  38  may be separate components coupled together, integrally formed or part of or contained within other components. Also, in many embodiments, the shifter  32  may include different or additional components. Thus, the present invention is not limited by the type, configuration and operation of the shifter  32  or other embodiments of the valve actuator  10 . 
         [0034]    Referring back to  FIG. 1 , the valve actuator  10  may be associated with the valve assembly  18  in any suitable manner and with any desired components to cause the valve  14  to move between positions. In this embodiment, for example, the engagement arm  38  is slideable into and out of the upper end of the valve assembly  18 . The exemplary arm  38  includes at least one profile, or rib,  52  that is engageable with upper and lower collets, or ribs,  56 ,  58  disposed on an internal sleeve  60  in the valve assembly  18 . As the engagement arm  38  moves up or down (such as, e.g., by action of the piston  34  of  FIG. 2 ), the profile  52  engages and pushes one of the collets  56 ,  58  to move the valve  16  between positions. 
         [0035]    In  FIG. 3A , for example, the engagement arm  38  is engaged with the valve assembly  18  and the ball valve  16  is in a closed position. This position of the engagement arm  38  is between “up” and “down” positions. As the piston (not shown) is actuated to move from an “up” to a “down” position, it causes the exemplary engagement arm  38  to move down (left to right in  FIGS. 3A-D ). The downward movement of the arm  38  causes the profile  52  to abut the lower collet  58  and push it and the internal sleeve  60  downwardly.  FIG. 3A  thus illustrates the position of the exemplary profile  52  as it engages the lower collet  58  to begin opening the valve  14 . 
         [0036]    Continued downward movement of the exemplary arm  38  and internal sleeve  60  will cause the ball valve  16  to be shifted from a closed position to an open position, as shown in  FIG. 3B . In this example, with sufficient downward movement to open the valve  16 , the lower collet  58  will seat in a lower undercut  66  in the valve assembly  18 , allowing the profile  52  to move down past the lower collet  58  ( FIG. 3B ), such as, for example, to accommodate any overstroke of the piston (not shown). 
         [0037]    In this embodiment, the reverse movement of the piston (not shown) and engagement arm  38  with cause the profile  52  to engage the upper collet  56  and drive the internal sleeve  60  in the upward direction to move the valve  14  from an open to a closed position. Referring to  FIG. 3B , for example, when the illustrated ball valve  16  is in an open position, the upward movement of the engagement arm  38  will cause the profile  52  to pass by the lower collet  58  (if the profile  52  previously bypassed it) and abut the upper collet  56  ( FIG. 3C ), pushing it and the internal sleeve  60  upwardly. This movement will shift the ball valve  16  into a closed position. As shown in  FIGS. 3C and 3D , in this example, continued upward movement of the engagement arm  38  will cause the upper collet  56  to seat in an upper undercut  64  in the valve assembly  18  and the illustrated profile  52  to pass over the upper collet  56 . The engagement arm  58  and, thus, the shifter  32  may thereafter be slideably disengaged from the valve assembly  18 , allowing the exemplary valve actuator  10  (e.g.  FIG. 1 ) to be entirely removable from the well  12  without disturbing the location of the valve  14  therein. However, the present disclosure is not limited to this particular operation or arrangement of components. 
         [0038]    If desired, the valve actuator  10  may be removed from the well  12 , replaced back into the well  12  and again used for shifting the valve  14 . This procedure may be repeated as many times as desired, such as for equipment service or replacement, to isolate the well for conducting other downhole operations, or any other desired purpose. Referring back to  FIG. 1 , for example, the exemplary valve actuator  10  is coupled to the lower end of a production tubing  74 , which also carries an electric submersible pump  70 . The pump  70  is useful to assist in drawing produced oil and/or gas up into the production tubing  74 , such as in a low bottom-hole pressure well, as is and becomes further known. In this arrangement, if it becomes necessary to replace or service the pump  70  (production tubing  74 , valve actuator  10 , etc.), it may be desirable to close the valve  14 , isolate the well  12  and remove the tubing  74  and associated components from the well  12 . Accordingly, after the exemplary valve actuator  10  is actuated to shift the valve  14  to a closed position, the production tubing  74  (with submersible pump  70  and valve actuator  10 ) may be retrieved up and out of the well  12 . After the pump  70  (or other equipment) is serviced or replaced, the tubing  74  and connected components may be returned into the well  12 . 
         [0039]    Still referring to  FIG. 1 , if desired, one or more re-entry guide  78  may be associated with the valve actuator  10 , tubing  74  or other component to assist in alignment and reinsertion of the tubing  74  and valve actuator  10 . Also, in the illustrated example, as shown in  FIG. 3D , the valve assembly  18  includes a guide  82  to assist in aligning the engagement arm  38  within the valve assembly  18 . After the arm  38  is slideably engaged with the valve assembly  18 , downward movement of the illustrated arm  38  will cause the exemplary profile  52  to bypass the upper collet  56  and eventually engage the lower collet  58  to shift the valve  16  from a closed to an open position, such as described above. The valve actuator  10  may thereafter be used as needed to shift the exemplary valve  16  between open and closed positions, and the entire process may be repeated as desired. 
         [0040]    In  FIG. 4A , another embodiment of the valve actuator  10  is shown in a multi-flow production configuration. In this example, the valve actuator  10  is useful to open and close a mechanical closing sleeve  86 . The illustrated valve actuator  10  is disposed at the end of the production tubing  74  and includes a shifter  32  having a piston (not shown) disposed in a housing  42  and operable such as described above with respect to  FIGS. 1 &amp; 2 . In this example, the piston drives a perforated inner pipe  88  upon which the engagement arm  38  is disposed. The illustrated engagement arm  38  is a support mandrel for at least one engager  90  that is engageable with the sleeve  86 . The engager  90  may be a collet, retractable finger or any other suitable component or member. 
         [0041]    Still referring to  FIG. 4A , the illustrated closing sleeve  86  opens and closes at least one port  87  formed in the lower completion arrangement  22 , or otherwise provided in the well  12  below a packer  30 . The port  87  allows fluid flow from an annulus  92  into the perforated pipe  88  during production, such as shown with flow arrows  94 . The lower completion arrangement  22 , shown mounted in the well  12 , includes a check, or standing, valve  96  that is liftable off a seat  98  by upward fluid pressure to allow fluid flow through the pipe bore  100  in a lower pipe section  102  of the arrangement  22 . The illustrated lower pipe section  102  is perforated, so that upwardly flowing fluid may pass both through the bore  100  (e.g. flow arrows  104 ) and into the annulus  92  (e.g. flow arrows  106 ). Accordingly,  FIG. 4A  illustrates the “down” position of the exemplary engagement arm  38  and the open positions of the closing sleeve  86  and check valve  96  during production. 
         [0042]    If production ceases or it is desirable to isolate or seal off the well  12  at this interval, such as to replace the submersible pump  70  or other hardware, or for other operations, the piston (not shown) of the shifter  32  may be actuated from surface to move the perforated pipe  88  and engagement arm  38  upwardly. Referring to  FIG. 4B , sufficient upward movement of the illustrated engagement arm  38  causes the engager(s)  90  to engage and close the sleeve  86 . In this embodiment, continued upward movement of the engagement arm  38  will allow the engager(s)  90  to collapse or otherwise bypass or move above the sleeve  86 , allowing removal of the production tubing  74  and all attached equipment (the valve actuator  10 , perforated inner pipe  88 , submersible pump  70 , etc.) from the well  12 . Later, the production tubing  74  and other components may be reinserted into the well and the valve actuator  10  used to re-open the sleeve  86  generally similarly as described above with respect to other embodiments. 
         [0043]    In  FIGS. 5A-D , another embodiment of an engagement arm  38  in accordance with the present disclosure is shown useful for opening and closing a sliding sleeve  110 . The illustrated sliding sleeve  110  includes and at least one passageway  112  alignable with at least one port  114  formed in a pipe  116  (or other component), such as to allow fluid flow into or out of a bore  117 . The sleeve  110  also includes a B-shifting profile arrangement with upper and lower profiles  124 ,  126 . 
         [0044]    The illustrated engagement arm  38  includes a multi-action, collapsible, B-shifting body portion  106  with collets  118 ,  120 . The upper collet  118  is releasably engageable with the lower profile  126  of the sleeve  110  and the lower collet  120  is releasably engageable with the upper profile  124 . The illustrated arm  38  is driven by a piston (not shown) as part of a shifter  32  and operates generally similarly as previously described with respect to other embodiments. 
         [0045]    In  FIG. 5A , the exemplary engagement arm  38  is shown shifting the sleeve  110  into an open-port position. As the arm  38  is moved downwardly (from left to right in  FIGS. 5A-D ), the upper collet  118  engages the lower profile  126  to move the sleeve  110 , aligning the passageway  112  with the port  114 , as shown in  FIG. 5B . If desired, continued downward movement of the arm  38  may cause the body  106  of the arm  38  to collapse, if necessary, to allow the upper collet  118  to disengage from and bypass the lower profile  126 . 
         [0046]    Referring now to  FIGS. 5C-D , the exemplary engagement arm  38  is shown shifting the sleeve  110  into a closed-port position. As the arm  38  is moved upwardly, the lower collet  120  will engage the upper profile  124  and move the sleeve  110  upwardly until the passageway  112  and port  114  are misaligned and out of fluid communication. If desired, continued upward movement of the arm  38  will cause the body  106  to collapse, if necessary, to allow the lower collet  120  to disengage from and bypass the upper profile  124  and the arm  38  to disengage completely from the sleeve  110  and pipe  116 , if desired. 
         [0047]    Preferred embodiments of the present disclosure thus offer advantages over the prior art and are well adapted to carry out one or more of the objects of this disclosure. However, the present invention does not require each of the components and acts described above and is in no way limited to the above-described embodiments, methods of operation. Any one or more of the above components, features and processes may be employed in any suitable configuration without inclusion of other such components, features and processes. Moreover, the present invention includes additional features, capabilities, functions, methods, uses and applications that have not been specifically addressed herein but are, or will become, apparent from the description herein, the appended drawings and claims. 
         [0048]    The methods that are provided in or apparent from the description above or claimed herein, and any other methods which may fall within the scope of the appended claims, may be performed in any desired suitable order and are not necessarily limited to any sequence described herein or as may be listed in the appended claims. Further, the methods of the present invention do not necessarily require use of the particular embodiments shown and described herein, but are equally applicable with any other suitable structure, form and configuration of components. 
         [0049]    While exemplary embodiments of the invention have been shown and described, many variations, modifications and/or changes of the system, apparatus and methods of the present invention, such as in the components, details of construction and operation, arrangement of parts and/or methods of use, are possible, contemplated by the patent applicant(s), within the scope of the appended claims, and may be made and used by one of ordinary skill in the art without departing from the spirit or teachings of the invention and scope of appended claims. Thus, all matter herein set forth or shown in the accompanying drawings should be interpreted as illustrative, and the scope of the disclosure and the appended claims should not be limited to the embodiments described and shown herein.