Abstract:
A valve having a sealing surface that is rotated 90 degrees on trunnions that move along a track is provided. A sleeve that moves into position to protect the valve mechanism when the valve is in an open position is provided. A second sleeve locks the sealing element of the valve in place in the closed position. The valve may be used during drilling of wells to prevent flow in casing when the drill pipe and bit are raised above the valve.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    This invention relates to a valve that may be used in wells during drilling operations or may be used in any application requiring a valve having a large bore compared with its outside diameter. More particularly, a hydraulically operated valve having a sleeve to protect the valve element when open and a mechanism for locking the valve closed is provided. 
         [0003]    2. Description of Related Art 
         [0004]    Drilling of wells in an underbalanced or balanced pressure condition has well-known advantages. In this condition, pressure in the formation being drilled is equal to or greater than pressure in the wellbore. When there is a need to withdraw the drill pipe from the well, pressure in the wellbore must be controlled to prevent influx of fluids from a formation into the wellbore. The usual remedy of preventing influx of fluid from a formation—by increasing fluid density in the wellbore—may negate the advantages of balanced or underbalanced drilling. Therefore, downhole valves have been developed to isolate fluid pressure below the valve. They have been variously called “Downhole Deployment Valves” (DDV) or “Downhole Isolation Valves” (DIV). Technical literature includes reports of the usage of such valves in Under-Balanced Drilling (UBD) For example, SPE 77240-MS, “Downhole Deployment Valve Addresses Problems Associated with Tripping Drill Pipe During Underbalanced Drilling Operations,” S. Herbal et al, 2002, described uses of such valves in industry. The DDV or DIV as a tool in the broad area of “Managed Pressure Drilling” can be generally surmised from the survey lecture “Managed Pressure Drilling,” by D. Hannagan, SPE 112803, 2007. There it is listed under “Other Tools” and called a “Downhole Casing Isolation Valve—(DCIV)” or “Downhole Deployment Valve.” Services and products for providing Managed Pressure Drilling have been commercialized by AtBalance of Houston, Tex., Weatherford International, Inc. of Houston, Tex. and other companies. 
         [0005]    A DCIV is placed in a casing at a selected depth, considering conditions that may be encountered in drilling the well. The valve is normally placed in an intermediate casing string, and the effective Outside Diameter (OD) of the valve is limited by the Inside Diameter (ID) of the surface casing through which it must pass. For example, in a 7-inch intermediate casing, the valve preferably will be a full-opening (have a bore at least equal to the ID of the 7-inch casing, about 6.276 inch, or at least be as large as the drill bit to be used) and must pass through the drift diameter of the surface casing, which may be 8.5 inches. Therefore, the valve must be designed to severely limit the thickness of the valve body while being large enough for a bit to pass through. 
         [0006]    A DCIV is disclosed in U.S. Pat. No. 6,209,663. A flapper valve is illustrated, but other types of valves, such as ball valves or other rotary valves are disclosed. The valves may be operated hydraulically or by biasing means (e.g., springs). U.S. Pat. No. 6,167,974 discloses a flapper-type DCIV valve that is operated by a shifting device that is carried on a drill bit and deposited in the valve when the drill string is tripped out of the well. 
         [0007]    Prior art valves relying on a flapper mechanism have been commercially successful, but improvements in reliability and absence of leakage are needed. A rotary valve having minimum difference between outside diameter and inside diameter is needed. The ability of the valve to seal with differential pressure in two directions is also preferred. 
         [0008]    It should be understood that valves designed for downhole isolation may also be used for a variety of purposes. In wells, there may be a need to open or close a valve to control pressure near the bottom of the well when the hydrostatic pressure of fluid in the well is higher than desired, or there may be a need to isolate pressure in a well bore drilled from another well bore. In industry, valves requiring a minimum of wall thickness between the interior passage through the valve and the exterior surface of the valve may be needed for a variety of applications, such as: conventional products pipelines; piping in plants such as power plants, refineries or chemical plants; marine installations; biomedical devices and other devices where a thin-wall, stemless valve that can be operated by remote hydraulic pressure is needed. 
       SUMMARY OF INVENTION 
       [0009]    A hydraulically activated, bi-directional (will isolate fluid pressure in either direction), rotary- and linear-motion valve is disclosed, referred to herein as the HBRL Valve. The valve element is mounted on trunnions. As the trunnions move along a track, the valve element is rotated from a position parallel to the axis of the bore of the valve (open) to a position perpendicular to the axis of the bore (closing). Further motion along the track seats the valve element. The trunnions are moved by force from a sleeve moving in response to hydraulic pressure. A second sleeve is moved to protect the valve mechanism when the valve is open. After closing, the valve is locked into position to isolate fluid pressure differential across the valve in either direction. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a sketch of a well having a hydraulically operated HBRL valve used as a DCIV in an intermediate casing. 
           [0011]      FIGS. 2   a - 2   f  illustrate the valve disclosed herein in the open position. 
           [0012]      FIGS. 3   a - 3   f  illustrate the valve disclosed herein in the closed position. 
           [0013]      FIG. 4  is a detailed view of the “Wedgelock” valve assembly in the open position. 
           [0014]      FIG. 5  is a detailed view of the Wedgelock valve assembly when the “Wedgelock” is moved toward the closed position but is not rotated. 
           [0015]      FIG. 6  is a detailed view of the Wedgelock assembly when the Wedgelock has partially rotated into a closing position. 
           [0016]      FIG. 7  is a detailed view of the Wedgelock assembly when the valve is in the closed position. 
           [0017]      FIG. 8  is an end-view of a guide rail for the trunnion of the Wedgelock. 
           [0018]      FIG. 9  is an elevation view of a guide rail for the trunnion of the Wedgelock. 
           [0019]      FIG. 10  is an elevation view of a trunnion for the valve from a first direction. 
           [0020]      FIG. 11  is a side view of a trunnion adapted to move in a guide rail. 
           [0021]      FIG. 12  is a cross-section view of a trunnion as indicated in  FIG. 11 . 
           [0022]      FIG. 13  is an isometric view of the control arm of the Wedgelock assembly. 
           [0023]      FIG. 14  is an elevation view of the Wedgelock with the trunnion. 
           [0024]      FIG. 15  is a cross-sectional view along the axis of the Wedgelock valve assembly as indicated in  FIG. 3   d.    
           [0025]      FIG. 16  is an isometric view of a split ring of the valve assembly. 
       
    
    
     DETAILED DESCRIPTION 
       [0026]      FIG. 1  illustrates well  10  that is being drilled. Surface casing  12  has been placed in the well. Intermediate casing  14 , containing HBRL (Hydraulic Bidirectional Rotary-Linear) valve  20 , used as a Downhole Casing Isolation Valve (DCIV), has also been placed in the well. Inside diameter  21  of HBRL valve  20  must be large enough to allow passage of bit  16  on drill pipe  15 . The HBRL valve disclosed here is adapted to allow less difference in diameter between the inside diameter of valve  20  and the inside diameter of casing  14  than is allowed by downhole isolation valves cited in the references disclosed above. Hydraulic lines in bundle  19  are connected between HBRL valve  20  and a hydraulic pressure control system at a selected location (not shown). 
         [0027]    The elongated HBRL valve assembly is illustrated in sectional views  2   a - 2   f  and  3   a - 3   f.  In  FIG. 2 , the valve is in the open position and in  FIG. 3  it is in the closed position. Lines dividing the tools into segments from uphole to downhole are labeled as lines A thru E at the bottom and top of each figure a through f. Because some parts of the valve assembly extend over multiple drawings, operation of the valve may be better understood if drawings of  FIGS. 2   a - f  and  FIGS. 3   a - f  are laid end-to-end according to the dividing lines. 
         [0028]    Referring to  FIG. 2   a,  upper connection housing  40  is shown. Threads on upper connection housing  40  are adapted for joining to casing in which the HBRL valve  20  is to be employed. When the HBRL valve  20  is in a closed position, the top of protective sleeve  42  moves to within the upper connection housing, as shown in  FIG. 3   a.    
         [0029]    In  FIGS. 2   b  and  3   b,  upper connection housing  40  is joined to hydraulic connection housing  44 . This joining may be by a threaded connection, as shown. Hydraulic connection housing  44  contains port A and port B. These ports are adapted for connection to hydraulic lines shown bundled together as  19  in  FIG. 1 . Protective sleeve  42  is disposed toward the lower or downhole end of the valve assembly in  FIG. 2   b.  Protective sleeve  42  covers the “Wedgelock” valve element when in the open position, as will be shown in more detail below. (Wedgelock is used to identify the valve element. It may be formed by machining two curved surfaces from round stock, the surfaces being separated by the selected thickness of the valve element to form a “saddle-like” shape. The thickness is selected according to differential pressure expected across the valve.) In  FIG. 3   b,  protective sleeve  42  is disposed toward the uphole direction. Sleeve  42  may be moved downhole by application of hydraulic pressure through port B across o-ring seal  42 A, as shown in  FIG. 3   b.    
         [0030]    Referring to  FIGS. 2   c  and  3   c,  the joining of hydraulic connection housing  44  and coupling housing  48  is shown. This joining may be by a threaded connection. Hydraulic conduits from port A and port B extend through these housings. In  FIG. 3   c,  showing the valve in the closed position, protective sleeve  42  extends to just uphole from the Wedgelock assembly, which will be shown below, and in  FIG. 2   c  protective sleeve  42  extends through the figure and into the lower segment of the tool, so as to cover the Wedgelock assembly when it is in the open position. Also in  FIGS. 2   c  and  3   c,  coupling housing  48  is shown joined to valve seat housing  50 . Valve seat housing  50  also provides hydraulic conduits connected to port A and port B. Relief valve  52  may be provided in valve seat housing  50 . The function of relief valve  52  is to allow fluid to pass through HBRL valve  20  if pressure below the HBRL valve exceeds a selected value. 
         [0031]    Upper split ring  46  is also provided in coupling housing  48 . The function of split ring  46  will be described below. 
         [0032]    Referring to  FIGS. 2   d  and  3   d,  the joining of valve seat housing  50  and Wedgelock assembly housing  54 , the joining of Wedgelock assembly housing  54  and coupling housing  68 , and the joining of coupling housing  68  and lower housing  72  are shown. These joinings may be by a threaded connection. Wedgelock assembly housing  54  and coupling housing  68  also provide hydraulic conduits through the housings, as shown.  FIG. 2   d  shows that protective sleeve  42  extends through to a downhole location covering cam assembly  58  when the valve is in an open position. Protective sleeve  42  is displaced to an uphole position when the valve is closed, as shown by its absence in  FIG. 3   d.  Valve seat  51 , shown in  FIG. 2   d,  is adapted for sealing on the Wedgelock valve element and may provide for a bi-directional metal-to-metal seal. Alternatively, valve seat  51  may provide polymeric sealing material, as is known in the art. Cam assembly  58  will be described in more detail below. Wedgelock locking sleeve  74  is displaced uphole in  FIG. 3   d,  compared with  FIG. 2   d,  by hydraulic pressure as described below. Cam locking fingers  67  are provided on cam assembly  58 , which is engaged with cam finger unlocking grooves  55   a  on Wedgelock locking sleeve  74 , as shown in  FIG. 2   d.  Wedgelock locking sleeve  74  is displaced uphole in  FIG. 3   d  by hydraulic pressure until cam locking fingers  67  engage with cam finger locking groove  55   b  on Wedgelock locking sleeve  74 . Lower split ring  66  is provided in a groove in locking coupling housing  68 . The function of lower split ring  66  will be described below. 
         [0033]    Referring to  FIGS. 2   e  and  3   e,  Wedgelock locking sleeve  74  is driven uphole by hydraulic pressure across o-ring  75 . Finger locking sleeve  70  is displaced with Wedgelock locking sleeve  74 . Movement uphole continues until o-ring  75  reaches by-pass groove  76 . At this time movement of Wedgelock locking sleeve  74  ceases and movement of finger locking sleeve  70  continues upward, driven by hydraulic pressure, until the uphole end of finger locking sleeve  70  locks over locking fingers  71  of coupling housing  68  as shown in  FIGS. 2   e  and  3   e.  The distance from the initial position of o-ring  75  to by-pass groove  76  may be the same as the distance from finger locking groove  77  on Wedgelock locking sleeve  74  to the lower end of locking fingers  71 . 
         [0034]      FIGS. 2   f  and  3   f  show lower housing  72  with threads adapted to joining with the casing. Wedgelock locking sleeve  74  is shown in  FIG. 2   f  in its downhole position when the valve assembly is open. 
         [0035]      FIG. 4  shows a detail drawing of cam assembly  58  when the valve is open. Cam assembly  58  comprises control arm  64 , trunnions  62 , guide rails  60  and pivot point  61 . To close the valve, trunnion  62  is moved uphole by cam assembly  58 , causing control arm  64  to pivot as trunnion  62  moves along guide rails  60 . Wedgelock  56  is still in a completely open position, oriented parallel to the axis to the valve. In  FIG. 5 , trunnion  62  has moved along guide rails  60  to pivot point  61 . Trunnion  62  is designed to interact with pivot point  61  so as to cause rotation of Wedgelock  56 . In  FIG. 6  partial rotation of Wedgelock  56  has occurred and in  FIG. 7  a 90° rotation of Wedgelock  56  has occurred and it is now in an orientation to seat on valve seat  51 . Continued movement of Wedgelock  56  towards the seating position is made possible by linear movement of trunnion  62  along guide rails  60 . 
         [0036]      FIG. 8  is a cross-section view of guide rail  60 . It is adapted to be welded or otherwise fastened to the inside diameter of Wedgelock assembly housing  54 . Alternately, guide rail  60  can be an intrinsic part of the Wedgelock assembly housing  54 . Guide rails  60  are adapted to receive trunnions  62 . One embodiment of interlocking surfaces is illustrated in  FIG. 15 , which is the cross-section view identified in  FIG. 3   d.  It should be understood that alternative guide rail and cam assemblies may be used. Trunnions  62  are attached to Wedgelock  56 , which is the valve seating element as shown in  FIG. 14 . When Wedgelock  56  is used in casing, it is preferably designed to withstand differential pressure expected in a well in both directions. Preferably the sealing surface of Wedgelock  56  is metal, but, alternatively, polymeric valve seats such as known in industry may be used. 
         [0037]      FIG. 8  shows a cross-section view of guide rails  60 .  FIG. 9  shows an elevation view of guide rails  60 , which includes pivot point  61 , adapted to interact with a trunnion to cause rotation.  FIG. 10  shows a view of one embodiment of a trunnion and guide.  FIG. 11  shows a side view of trunnion  62  and guide  63 . The cross-section indicated in  FIG. 11  is shown in  FIG. 12 . Pivot point contact  63   a  on guide  63  is adapted to contact guide rail  60  at pivot point  61  so as to rotate Wedgelock  56  into an orientation for seating. 
         [0038]      FIG. 13  shows an isometric view of control arm  64 , having opening  64   a  adapted to receive trunnion  62 . 
         [0039]      FIG. 14  shows Wedgelock  56  having trunnions  62  and valve seating area  57 . Alternatively, Wedgelock  56  can be comprised of one or multiple sectional parts mounted on a plurality of trunnions around the outer shell of the valve element. Such arrangement and others will not change the functionality of HBRL valve  20 . 
         [0040]      FIG. 16  shows an isometric view of upper split ring  46 . Upper and lower split rings are used for functions to be described below. 
         [0041]    To move HBRL valve  20  from an open position to a closed position after drill bit  16  ( FIG. 1 ) is raised to a location above the valve, hydraulic pressure is applied to port A through a hydraulic line in bundle  19  as shown in  FIG. 1 . The first operation in the sequence of closing is application of hydraulic pressure to port A, which shifts protective sleeve  42  until it shoulder limits on hydraulic connection housing  44  at shoulder  43 . This movement of protective sleeve  42  causes engagement with upper split ring  46 , which is positioned in a groove on coupling housing  48 . Hydraulic pressure at port A is then further increased until it overcomes the force of lower split ring  66  in locking coupling housing  68 . When lower split ring  66  disengages, Wedgelock locking sleeve  74  moves uphole. Continuing uphole, Wedgelock locking sleeve  74  engages cam assembly  58  at cam finger unlocking groove  55 A with locking fingers  67 . Cam assembly  58  moves Wedgelock  56  uphole until it has seated in valve seat  51 . Rotation of Wedgelock  56  by 90° occurs as cam assembly  58  moves uphole, as described in  FIGS. 4  thru  7 . At this point the valve is seated but not locked in position. Hydraulic pressure is then increased again at port A and it begins to push Wedgelock locking sleeve  74  uphole locking finger  67  disengaging the cam finger unlocking groove  55 A causing linear movement at the Wedgelock locking sleeve  74  until it is seated against the back side of Wedgelock  56 , at which time locking fingers  67  engage cam finger locking groove  55 B At this location, o-ring  75  on Wedgelock locking sleeve  74  will be located at fluid by-pass grooves  76  of lower housing  72 . Fluid will flow around o-ring  75  and shift finger locking sleeve  70  onto locking fingers  71  of coupling housing  68 . At this point the valve is fully seated and locked. 
         [0042]    To operate HBRL valve  20  from a closed position to an open position, hydraulic pressure is applied to port B on hydraulic connection housing  44 . Pressure is applied to the opposite side of finger locking sleeve  70  until it unlocks from coupling housing  68  and begins to move downhole. Finger locking sleeve  70  will continue movement until it has reached shoulder limit  78  on Wedgelock locking sleeve  74 . Both pieces will then move simultaneously downhole. Still engaged with Wedgelock locking sleeve  74 , cam assembly  58  disengages from its seated position and also moves downhole until cam assembly  58  reaches shoulder limit  69  on coupling housing  68 . Lower snap ring  66  will reengage at this point. Pressure is increased further until protective sleeve  42  overcomes the force of upper split ring  46 . Protective sleeve  42  then shifts downhole until it reaches shoulder limit  41  against the ID of coupling housing  48 . At this time the valve is fully opened and Wedgelock  56  is covered by protective sleeve  42 . 
         [0043]    When the HBRL valve is used in other applications, it will normally be adapted to operate in confined spaces where the small difference between outside and inside dimensions of the valve is important. The difference achievable with the HBRL valve is dependent on pressure requirements for the valve. When used as a DCIV, as shown in  FIG. 1 , the valve may be constructed to withstand thousands of psi of differential pressure and still provide an inside diameter of 6.276 inches and an outside diameter of 8.5 inches. 
         [0044]    Although the present invention has been described with respect to specific details, it is not intended that such details should be regarded as limitations on the scope of the invention, except as and to the extent that they are included in the accompanying claims.