DOWNHOLE VALVE ASSEMBLY WITH CEMENT-ISOLATED FLOWPATH

A valve assembly for integration within a wellbore string is provided. The valve assembly has a valve housing with a housing port, a bottom sleeve mounted and slidable within the valve housing between closed and open positions, and a top sleeve mounted within the valve housing and defining an annular region therebetween. The top sleeve has a sleeve port and is slidable within the valve housing between a first position where the top sleeve engages the valve housing and defines an annular chamber within the annular region, and a production position where the sleeve port is in fluid communication with the housing port to define a fluid pathway along which fluids flow from the reservoir through the annular chamber. While in the first position, the annular chamber has an inlet allowing fluid to flow into and pressurize the annular chamber to prevent particulates from flowing into the annular region.

TECHNICAL FIELD

The present disclosure relates to technologies for subterranean operations and, more particularly, to downhole valve assemblies, systems and methods that can be used to inject or produce fluids, and which can be implemented in cemented wellbore completions.

BACKGROUND

Recovering hydrocarbons from an underground formation can be enhanced by fracturing the formation in order to form fractures through which hydrocarbons can flow from the reservoir into a well. Fracturing can be performed prior to primary recovery where hydrocarbons are produced to the surface without imparting energy into the reservoir. Fracturing can be performed in stages along the well to provide a series of fractured zones in the reservoir.

Well completion often includes cementing the wellbore string down the wellbore prior to fractures being formed therein. The frac ports are initially closed during the cementing process, and are open to enable the fracturing of the formation. Valve assemblies can then be provided with various devices and apparatuses to enable the production of reservoir fluids. Due to some of the functionalities of these devices and apparatuses, they are often run downhole on a work string after having cemented the wellbore and fractured the reservoir in order to prevent damaging the devices. Running down work strings to reach valve assemblies dispersed along the wellbore string can be time-consuming and includes inherent costs. There is thus a general need for improvements in providing systems and devices down a wellbore.

SUMMARY

According to an aspect, a valve assembly for integration within a wellbore string disposed along a wellbore defined within a subterranean reservoir is provided. The valve assembly includes a valve housing comprising a top sub, a bottom sub and an outer wall extending between the top and bottom subs, the outer wall defining a central passage therethrough and having a housing port extending through the outer wall for establishing fluid communication between the central passage and the reservoir. The valve assembly also has a bottom sleeve operatively mounted within the valve housing and slidable within the central passage between a closed position where the bottom sleeve occludes the housing port, and an open position where the bottom sleeve is spaced from the housing port to establish fluid communication between the reservoir and the wellbore string through the housing port. The valve assembly further includes a top sleeve operatively mounted within the valve housing between the bottom sleeve and the top sub, the top sleeve and the valve housing defining an annular region therebetween with the top sleeve being provided with a sleeve port and being slidable within the valve housing between (i) a first position where the sleeve port is occluded by the outer wall of the valve housing and where a restricted flowpath is defined between the outer wall and the top sleeve at an uphole end thereof to enable an ingress of wellbore fluid into the annular region, and (ii) a second position where the sleeve port communicates with the housing port to define a fluid pathway along which reservoir fluids are flowable from the reservoir, through the housing port and the sleeve port, into the annular region, along the annular region toward the uphole end of the top sleeve and into the central passage of the valve housing; and a flow control device coupled to the top sleeve and operable to control a flow of fluids along the fluid pathway when the top sleeve is in the production position. When in the first position, the top sleeve is in sealing engagement with the valve housing for defining a dead-end chamber within the annular region, the dead-end chamber being in fluid communication with the central passage via the restricted flowpath to enable fluid pressurization of the dead-end chamber and prevent cementitious material from flowing into the annular region, the flow control device being positioned within the dead-end chamber and being isolated from the cementitious material when the top sleeve is in the first position.

According to a possible implementation, the flow control device includes a directional control valve device adapted to prevent fluid flow in at least one direction between the central passage and the reservoir, when the top sleeve is in the second position.

According to a possible implementation, the directional control valve device is adapted to prevent fluid flow from the central passage to the sleeve port via the annular region, and allow fluid flow from the sleeve port to the central passage via the annular region.

According to a possible implementation, the top sleeve comprises a sleeve mandrel defining a sleeve passage therethrough, a collet coupled to an uphole end of the sleeve mandrel and being adapted to releasably engage an inner surface of the outer wall, and a sleeve cap coupled to a downhole end of the sleeve mandrel, the sleeve cap being provided with the sleeve port, where at least one of the sleeve mandrel and the sleeve cap sealingly engages the outer wall to define the dead-end chamber.

According to a possible implementation, the top sleeve comprises a latching mechanism configured to releasably connect the top sleeve to the outer wall when the top sleeve is in the first position and/or the second position.

According to a possible implementation, the outer wall comprises inner annular grooves and the latching mechanism comprises one or more protrusions adapted to releasably engage at least one of the annular grooves when the top sleeve is in the first position and/or the second position.

According to a possible implementation, when the top sleeve is in the first position, the collet is adapted to engage the top sub and the outer wall, and wherein the restricted flowpath is defined between the top sub, the outer wall and the collet.

According to a possible implementation, the sleeve mandrel comprises a ring portion extending into the annular region and engaging the inner surface of the outer wall, the ring portion defining a downhole annular region in fluid communication with the sleeve port, and an uphole annular region in fluid communication with the central passage, the ring portion comprises one or more through channels establishing fluid communication between the uphole and downhole annular regions.

According to a possible implementation, the one or more through channels comprise a plurality of through channels provided at regular intervals around the sleeve mandrel.

According to a possible implementation, the directional control valve device comprises a displaceable member provided within the uphole annular region and being movable between an engaged position, where the displaceable member at least partially prevents fluid communication between the uphole and downhole annular regions, and a disengaged position, where fluid communication between the uphole and downhole annular regions is allowed, the directional control valve device further comprises a biasing member operatively coupled to the displaceable member for biasing the displaceable member in the engaged position.

According to a possible implementation, the displaceable member is movable from the engaged position to the disengaged position via fluid flow from the reservoir into the downhole annular region and the through channels.

According to a possible implementation, the directional control valve device comprises an axial check valve device, and wherein the displaceable member comprises a ring plug member slidably mounted about the sleeve mandrel, and the biasing member comprises a spring provided about the sleeve mandrel and operatively coupled between the ring plug member and the collet to bias the ring plug member in the engaged position.

According to a possible implementation, the ring plug member comprises a front edge adapted obstruct the through channels to at least partially prevent fluid communication between the uphole and downhole annular regions when in the engaged position, and wherein fluid flow from the reservoir into the through channels pushes on the front edge and slides the ring plug member in the disengaged position.

According to a possible implementation, the ring portion comprises an overhang extending into the uphole annular chamber, and wherein the front edge is tapered and adapted to sealingly engage the overhang when in the engaged position.

According to a possible implementation, the front edge of the ring plug member is circumferentially continuous.

According to a possible implementation, the directional control valve device comprises a radial check valve device, and wherein the displaceable member comprises a plurality of radial poppets provided about the ring portion for obstructing respective through channels when in the engaged position.

According to a possible implementation, the flow control device comprises a screen superposed with the sleeve port to allow fluid flow from the reservoir into the annular region, and prevent various particulates from entering the top sleeve and/or the central passage.

According to a possible implementation, the sleeve port comprises a plurality of elongate slots provided around the sleeve cap and opening on an outer surface of the sleeve cap, and wherein the screen comprises one or more circumferential openings defined along an interior surface of the sleeve cap and in fluid communication with the elongate openings through a bottom surface thereof.

According to a possible implementation, the circumferential openings are generally perpendicular relative to the elongate slots.

According to another aspect, a valve assembly for integration within a wellbore string disposed along a wellbore defined within a subterranean reservoir is provided. The valve assembly includes a valve housing comprising a top sub, a bottom sub and an outer wall extending between the top and bottom subs, the outer wall defining a central passage therethrough and having a housing port extending through the outer wall for establishing fluid communication between the wellbore string and the reservoir; a bottom sleeve operatively mounted within the valve housing and slidable within the central passage between a closed position where the bottom sleeve occludes the housing port, and an open position where the bottom sleeve is spaced from the housing port to establish fluid communication between the reservoir and the wellbore string through the housing port; a top sleeve operatively mounted within the valve housing between the bottom sleeve and the top sub, the top sleeve and the valve housing defining an annular region therebetween, the top sleeve being provided with a sleeve port and being slidable within the central passage between (i) a first position where the sleeve port is occluded by the outer wall of the valve housing and where a restricted flowpath is defined between the outer wall and the top sleeve at an uphole end thereof to enable an ingress of fluid into the annular region, and (ii) a production position where the sleeve port communicates with the housing port to define a fluid pathway along which fluids are flowable from the reservoir, through the housing port and the sleeve port, into the annular region, along the annular region toward the uphole end of the top sleeve and into the central passage of the valve housing; and one or more seals provided between the top sleeve and the outer wall for sealing a downhole end of the annular region and defining a dead-end chamber along the annular region when the top sleeve is in the first position, where the ingress of fluid into the annular region via the restricted flowpath pressurizes the dead-end chamber to prevent cementitious material from flowing into the annular region during completion of the wellbore.

According to a possible implementation, the valve assembly further includes a flow control device coupled to the top sleeve and operable to control a flow of fluids along the fluid pathway when the top sleeve is in the production position, and where the flow control device is provided within the dead-end chamber and isolated from the cementitious material when the top sleeve is in the first position.

According to another aspect, a valve assembly for integration within a wellbore string disposed along a wellbore defined within a subterranean reservoir is provided. The valve assembly includes a valve housing having an outer wall defining a central passage therethrough and having a housing port extending through the outer wall; a bottom sleeve operatively mounted within the valve housing and slidable within the central passage between a closed position occluding the housing port, and an open position; a top sleeve operatively mounted within the valve housing and defining an annular region therebetween, the top sleeve having a sleeve port and being slidable within the central passage between (i) a first position where a downhole end of the top sleeve sealingly engages an inner surface of the valve housing and defines an annular chamber within the annular region, and (ii) an operational position where the sleeve port is in fluid communication with the housing port to define a fluid pathway along which fluids are flowable from the reservoir through the annular chamber and into the central passage; and a flow control device provided within the annular region and being operable to control a flow of fluids along the fluid pathway when the top sleeve is in the operational position. The annular chamber is in fluid communication with the central passage for allowing wellbore fluid to flow into and pressurize the annular chamber to prevent subsequent fluid, particulates and/or slurry material from flowing into the annular chamber, and where the sleeve port and flow control device are positioned within the annular chamber when in the first position.

According to a possible implementation, the subsequent fluid, particulates and/or slurry material comprises cement.

According to a possible implementation, the wellbore fluid comprises brine, water, drilling mud or a combination thereof.

According to another aspect, a valve assembly for integration within a wellbore string disposed along a wellbore defined within a subterranean reservoir is provided. The valve assembly includes a valve housing having an outer wall defining a central passage therethrough and having a housing port extending through the outer wall; a valve sleeve operatively mounted within the valve housing and defining an annular region therebetween, the valve sleeve having a sleeve port and being slidable within the valve housing between (i) a closed position where a downhole end of the valve sleeve occludes the housing port to prevent fluid communication between the reservoir and the central passage, and (ii) an operational position where the sleeve port is in fluid communication with the housing port to define a fluid pathway along which fluids are flowable from the reservoir through the annular region and into the central passage, when in the closed position, the downhole end of the valve sleeve sealingly engages an inner surface of the outer wall and defines an annular chamber within the annular region, the annular chamber being in fluid communication with the central passage for allowing wellbore fluid to flow into and enable fluid pressurization of the annular chamber to prevent subsequent fluid, particulates and/or slurry material from flowing into the annular region, and where the sleeve port is positioned within the annular chamber when in the first position.

According to a possible implementation, the valve assembly further includes a flow control device, where the flow control device is integrated in the fluid pathway when the valve sleeve is in the operational position.

According to a possible implementation, the flow control device is provided within the annular chamber when the valve sleeve is in the closed position.

According to a possible implementation, the flow control device comprises a screen superposed with the sleeve port for enabling screened fluid communication between the reservoir and the annular region.

According to a possible implementation, the flow control device comprises a directional control valve device provided within the annular region to prevent fluid flow in at least one direction between the central passage and the reservoir.

According to a possible implementation, the top sleeve is slidable within the valve housing to an open position where the housing port is in fluid communication with the central passage, and where fluid flow from the reservoir into the annular region is prevented.

According to a possible implementation, the subsequent fluid, particulates and/or slurry material comprises cement, and the wellbore fluid comprises brine, water, drilling mud or a combination thereof.

According to another aspect, a valve assembly for integration within a wellbore string disposed along a wellbore defined within a subterranean reservoir is provided. The valve assembly includes a valve housing comprising an outer wall defining a central passage therethrough and having a housing port extending through the outer wall; a valve sleeve assembly operatively mounted within the valve housing and comprising a bottom sleeve slidable within the central passage between a closed position occluding the housing port, and an open position; a top sleeve defining an annular region between an outer surface thereof and an inner surface of the outer wall, the top sleeve being slidable within the valve housing between (i) a first position where a downhole end of the top sleeve is axially spaced from the housing port, and (ii) a second position where the downhole end at least partially extends over the housing port; and a flow-controlling sleeve having a sealed end sealingly engaging the inner surface of the outer wall to define an annular chamber within the annular region, the flow-controlling sleeve having a sleeve port and a flow control device proximate the sleeve port, the flow-controlling sleeve being slidable within the valve housing between (i) a shrouded position where the sleeve port and flow control device are provided within the annular chamber, and (ii) a flow-controlling position where the sleeve port is in fluid communication with the housing port to define a fluid pathway along which fluids are flowable from the reservoir through the housing port, through the sleeve port and into the central passage. The annular chamber being in fluid communication with the central passage for allowing wellbore fluid to flow into and enable fluid pressurization of the annular chamber to prevent subsequent fluid, particulates and/or slurry material from flowing into the annular region, and where the flow control device is provided along the fluid pathway when in the flow-controlling position.

According to a possible implementation, the downhole end of the top sleeve is adapted to prevent fluid communication between the sleeve port and the central passage when in the second position, and wherein the fluid pathway is defined by moving the top sleeve from the second position to the first position.

According to a possible implementation, the flow-controlling sleeve comprises an internal shoulder proximate the sealed end and extending into the central passage, the top sleeve being adapted to engage the internal shoulder to push the flow-controlling sleeve, whereby moving the top sleeve from the first position to the second position correspondingly displaces the flow-controlling sleeve from the shrouded position to the flow-controlling position.

According to a possible implementation, the flow-controlling sleeve comprises a latching mechanism configured to releasably connect the flow-controlling sleeve to the outer wall when the flow-controlling sleeve is in one of the shrouded position and the flow-controlling position.

According to a possible implementation, the latching mechanism is adapted to retain the flow-controlling sleeve in the flow-controlling position when moving the top sleeve from the second position to the first position.

According to a possible implementation, the flow control device comprises a screen superposed with the sleeve port to allow fluid flow from the reservoir through the screen and into the central passage, the screen being configured to prevent various particulates from entering the valve housing and/or the central passage.

According to another aspect, a valve assembly for integration within a wellbore string disposed along a wellbore defined within a subterranean reservoir is provided. The valve assembly includes a valve housing comprising an outer wall defining a central passage therethrough and having a housing port extending through the outer wall; a valve sleeve assembly operatively mounted within the valve housing and defining an annular region within the valve housing, the valve sleeve assembly comprising a valve sleeve having a sleeve port and being slidable within the valve housing between (i) a first position where a downhole end of the valve sleeve sealingly engages an inner surface of the outer wall to define an annular chamber within the annular region, and (ii) an operational position where the sleeve port is in fluid communication with the housing port to define a fluid pathway along which fluids are flowable from the reservoir into the central passage; and a flow control device provided within the annular region and being operable to control a flow of fluids along the fluid pathway when the valve sleeve is in the operational position. The annular chamber being in fluid communication with the central passage for allowing wellbore fluid to flow into and enable fluid pressurization of the annular chamber to prevent subsequent fluid, particulates and/or slurry material from flowing into the annular region, and where the sleeve port is positioned within the annular chamber when in the first position.

According to another aspect, a method of operating a well for primary production of hydrocarbons is provided. The method includes running a wellbore string provided with one or more valve assemblies as defined above down the well; pressurizing the annular chamber to create a pressure balance between the annular chamber and the central passage; pumping cement slurry down the wellbore string for cementing the wellbore string down the well; shifting one or more valve sleeves for operating the valve assembly in the open configuration; injecting fracturing fluid through the housing port for fracturing the wellbore; shifting one or more valve sleeves for defining a production fluid pathway along which reservoir fluid is flowable through the housing port, through the annular region provided with the flow control device and into the central passage.

DETAILED DESCRIPTION

As will be explained below in relation to various implementations, the present disclosure describes devices, systems and methods for various operations, such as the injection of fluids and the recovery of hydrocarbon material from a subterranean reservoir. The present disclosure more specifically relates to a well completion system, and corresponding structural features, operable for the injection and recovery of fluids, such as hydrocarbons, via a wellbore. The well completion system is configured to be installed within the wellbore and includes a wellbore string comprising one or more valve assemblies operable to inject fluid (e.g., a fluid for stimulating hydrocarbon production via a drive process, such as waterflooding, or via a cyclic process, such as “huff and puff”) into the subterranean reservoir, and also to produce reservoir fluids. In other words, the valve assemblies can be configured to enable both injection and production operations within the reservoir. The valve assembly can also include an annular chamber in which an apparatus, a subsystem or a device, such as a flow control device, is provided, enabling the device to be deployed downhole along with the wellbore string (e.g., instead of being run downhole as part of a subsequent work string).

The valve assembly can be shifted, operated, or otherwise moved, into different configurations to define different flow pathways at different stages of operation. As will be described further below, the valve assembly can be adapted to define a first flow pathway and a second flow pathway which can be defined by two partially independent passages along which fluid can flow. In other words, and for example, the first and second flow pathways are not identical (e.g., structurally), but can share common components, such as inlets.

In some implementations, the valve assembly includes a valve housing having a central passage therethrough and a plurality of frac ports extending radially through an outer wall thereof for establishing fluid communication between the passage and the reservoir. The valve assembly further includes a pair of sleeves, which can be slidably mounted within the housing and configured to selectively close and open the frac ports. The housing and the sleeves define the at least two fluid pathways which can be at least partially isolated from one another, and along which fluid flows to and/or from the reservoir. As will be described further below, one of the pathways includes the annular chamber provided with the flow control device, such that fluid is confined to flow through the annular chamber and where fluid flow is at least partially controlled by the flow control device.

It will be understood that the valve assembly described herein can be used in relation with cemented wellbore string applications, such as with multistage fracturing (also referred to as “fracking”) operations, for example. In fracturing operations, the wellbore can first be dug out (e.g., drilled) and lined with casing, and then cement slurry can be pumped down the casing towards a toe of the wellbore and back up an annulus defined between the casing and the reservoir (i.e., the walls of the wellbore). In order to push the cement slurry past the toe and into the annulus, a wiper plug can be pumped down the casing to effectively wipe the slurry from the interior of the wellbore. Once within the annulus, the cement can be allowed to cure, thus cementing the casing within the wellbore.

In the context of the present disclosure, the valve assembly can be installed between lengths of casing at desired locations. These locations can be determined based on where perforations would have been created using a perforating gun, for example. After the casing and valve assemblies are in place down the wellbore, the casing and valve assemblies are cemented in place using cementing techniques such as those noted above. It is noted that the cementing process can interfere with the operation of the sleeves or other moving parts of the valve assembly. The sleeves can therefore be designed to accommodate the cementing process whereby cement is prevented from entering any ports, slots, recesses and the like, that might not be cleaned by the wiper plug, such as the annular chamber, for example. Furthermore, in order to prevent the sleeves from being moved by the wiper plug (or by subsequent well equipment, cleaning, etc.), the sleeves can be held in position by shear pins or other securing mechanisms, as will be described further below.

The valve assembly can further include interstices defined between various components thereof (the sleeve, the housing, etc.) which establish fluid communication between a central passage of the valve assembly and the annular chamber. The interstices are sized and adapted to allow fluid, e.g., water, gas, etc., to flow into and pressurize the annular chamber. The valve assembly also includes an arrangement of seals which prevents fluid from flowing out of the annular chamber, which defines a dead-end annular chamber and facilitates pressurization thereof. As such, when pumping slurry material, e.g., cement, down the wellbore in order to secure the wellbore string, the pressurized annular chamber prevents the cement from flowing into the dead-end annular chamber, thereby preventing cement from contacting and potentially damaging the flow control device. The fluid which initially flows into the annular chamber can be residual fluid from drilling out the wellbore (e.g., brine, water, drilling mud, etc.), which pressurizes the annular chamber and prevents subsequent fluid or material being pumped downhole from flowing into the annular chamber.

It should thus be noted that the valve assembly is shaped, sized and adapted to be integrated as part of the wellbore string, and is secured in place (e.g., cemented) down the wellbore along with the wellbore string. The valve assembly is further adapted to isolate, or “shroud” components provided within the dead-end annular chamber while the valve assembly is in the run-in, or closed configuration. The valve assembly is operable between various configurations for allowing fluid to be injected within the reservoir, and reservoir fluid to be produced from the reservoir into the valve assembly for ultimate recovery to surface. In some implementation, the valve assembly is a dual-barrel valve assembly configurable between the closed configuration, where the ports of the valve housing are occluded, the open configuration, where the ports are open and fluid communication can be established between the reservoir and the fluid passage of the wellbore string, and a flow restricted configuration, where the flow control device is moved and aligned with the ports of the housing, thereby creating a fluid pathway which cooperates with the flow control device. As mentioned above, in some implementations, the flow control device is provided within the annular chamber, therefore it is noted that the fluid pathway created when in the flow restricted configuration can flow through the annular chamber defined between the valve sleeve and the exterior housing.

In an exemplary implementation, the flow control device includes a screened configured to have fluid produced from the reservoir flow through it, thus preventing large particulates from entering the wellbore string and being produced to surface. The flow control device can alternatively, or additionally include a check valve which prevents fluid flow in a specific direction. For example, the valve assembly can be operated as a production-only valve assembly, where the check valve prevents the injection of fluid into the reservoir when the valve assembly is in the flow restricted configuration. The wellbore string can include multiple valve assemblies and can thus be operated for various applications, such as asynchronous frac-to-frac operations, where the reservoir is fractured, the valve assemblies are shifted in the open configuration for the injection of fluid into the reservoir, and then shifted in the flow restricted configuration to initiate a screened production of reservoir fluids. The well completion system can also be used in other applications, such as geothermal applications. It is also noted that the well completion system can be used in applications where the formation is not required to be fractured but has a permeability that enables fluid injection or includes naturally formed fractured.

It should also be noted that enabling an initial ingress of fluids within the annular region (e.g., within the annular chamber) creates a pressure-balanced system between the annular chamber and the central passage of the valve assembly. This pressure-balanced system enables the use of valve sleeves having relatively thin walls since the wall is not submitted to a pressure differential between the annular chamber and the central passage. The pressure-balanced system therefore assists in preventing collapse of the valve assembly during pressurization of the annular region, during the cementing process and during various operations of the valve assembly. It should be understood that the annular chamber is in fluid-pressure communication with the central passage, and that this pressure-balanced system also prevents subsequent fluids or materials from flowing into the annular chamber, and instead flow towards an opened port, for example. Therefore, components provided within the annular chamber are protected from potentially damaging fluids and/or material, such as cement, for example.

It is noted that the completion system and the valve assemblies described herein can be implemented in various wellbores, formations, and for various applications. In some implementations, the wellbore can be straight, curved, or branched, and can have various wellbore sections. A wellbore section should be considered to be an axial length of a wellbore. A wellbore section can be characterized as “vertical” or “horizontal” even though the actual axial orientation can vary from true vertical or true horizontal, or can tend to undulate or corkscrew or otherwise vary. The term “horizontal”, when used to describe a wellbore section, refers to a horizontal or highly deviated wellbore section as understood in the art, such as a wellbore section having a longitudinal axis that is between 70 and 110 degrees from vertical. For simplicity, it is noted that most of the conduits, channels, passageways, pipes, tubes and/or other similar components referred to in the present disclosure have a cross-section that is preferably circular or annular, although it should be appreciated that other shapes are also possible.

With reference toFIGS.1and2, a wellbore10extends from the surface12and into a reservoir14. A well completion system20including one or more valve assemblies100can be integrated as part of a wellbore string30extending within the wellbore10. The wellbore string30defines a wellbore string passage30A for conducting fluid between the surface12and the reservoir14. In some implementations, the valve assemblies100each include at least one passage allowing fluid flow therethrough. It should therefore be understood that the valve assemblies include passages that can form part of the wellbore string passage30A along at least a portion of the wellbore, such that fluid communication between the surface12and the reservoir14can be established via the valve assemblies100. More specifically, and as will be described below, the valve assembly100can be provided with one or more ports at respective locations along the wellbore for establishing fluid communication between the wellbore string30and the reservoir14. It is also noted that conduits31of the wellbore string30can be located on either end of the valve assembly100and can be coupled to respective ends thereof by any suitable method. It is also possible to connect some or all of the valve assemblies end-to-end without any intervening conduits31.

As seen inFIG.1, the wellbore10can include a horizontal wellbore section16having a toe15and a heel17at respective ends thereof. It should be understood that, as used herein, the expression “toe” refers to an end region of the horizontal wellbore section, such as the end region furthest from surface. Similarly, the expression “heel”, as used herein, refers to the opposite end region of the horizontal section, i.e., the beginning of the horizontal wellbore section16, and may include at least part of the curved transition section between the horizontal and vertical sections of the wellbore10. Therefore, the expressions “downhole” and “uphole” used herein can refer to directional features, whereby uphole is in a general direction towards the heel17, and downhole is in a general direction towards the toe15.

With reference toFIGS.3to4, in addition toFIGS.1and2, the valve assembly100includes a valve housing102having an outer tubular wall103defining a central passage106for enabling fluid communication through the housing102(e.g., axially through the housing102). In other words, the central passage106can act as a fluid passage configured to allow a flow of fluid therethrough and along the wellbore string. Referring more specifically to FIGS.2and3, the valve housing102includes a top sub108provided at an uphole end109of the outer wall103, and a bottom sub110provided at a downhole end111thereof. The top and bottom subs108,110are secured to the outer wall103via interference fit, although other connection methods can be used, such as via threaded connectors, via a slot and key connection or via fasteners. The top and bottom subs can also be connected between lengths of conduits or other components of the valve assembly100, thereby enabling the integration of the valve assembly with the wellbore string30.

The valve housing102also includes a housing port112extending through the outer wall103and through which fluid communication between the central passage106and an environment external to the housing102(e.g., the reservoir14) is established. In some implementations, the housing port112includes a plurality of openings114(e.g., two, three, four, six, eight, etc.) defined through the outer wall103, although a single opening could be used. The openings114can be formed as generally straight and tubular openings through the outer wall103, although any other suitable shapes, configurations and/or number of openings can be used. As seen inFIGS.2and3, the openings114can be distributed (e.g., evenly/at regular intervals) about a circumference of the outer wall103. The openings can also have different cross-sectional areas and shapes, e.g., cylindrical, frustoconical, tapered toward or away from the reservoir, etc. In some implementations, the openings can also be open during deployment downhole or could have a temporary plug or cap that is expelled due to the pressure of the fracturing fluid during the fracturing operation. It should be noted that the valve assembly100can be used for fracturing operations, where fracturing fluid is injected into the reservoir via the housing port112. As such, it is appreciated that the openings114of the housing port112can correspond to frac ports.

In some implementations, the valve assembly100is configurable in a plurality of operational configurations, and each one of the operational configurations, independently, corresponds to a state of fluid communication, via the housing port112, between the central passage106and the surrounding reservoir. In other words, fluid flow through the housing port112can be at least partially controlled via a change in the operational configuration of the valve assembly100(e.g., a change from a first operational configuration to a second operational configuration). In some implementations, the valve assembly100can be configurable between a closed configuration (seen inFIG.4), where the housing port112is blocked or closed; an open configuration (seen inFIG.5), where the housing port112is unobstructed or open and where fluid can be injected within the reservoir via the housing port112; and a flow-restricted configuration (seen inFIG.6), where production fluid is produced from the reservoir and is confined to flow along a fluid pathway provided with a flow control device. The valve assembly100can also move to a configuration where production fluid is received within the passage106but does not flow along the fluid pathway if the latter is kept enclosed and sealed. In order to operate the valve assembly100in these various configurations, the valve assembly100includes one or more inner sleeves, or valve sleeves120, operatively mounted within the housing102and displaceable between various positions.

The sleeves120can be provided with various features and/or in various configurations in order to be displaceable and to provide the different (e.g., non-identical) flow pathways for fracturing, injecting and producing. Some features and implementations of possible sleeve arrangements are described below.

Still referring toFIG.4, and with further reference toFIGS.4A, the valve sleeves120are operatively mounted within the housing102and are operable for selectively closing and opening the housing port112. In this implementation, the valve sleeves120include a pair of valve sleeves slidably mounted within the housing102for moving axially therealong (e.g., sliding or shifting along inner surfaces105of the housing within the passage106). More particularly, the valve sleeves120include a bottom sleeve122(or downhole sleeve) mounted within a downhole portion of the housing102, and a top sleeve124(or uphole sleeve) mounted within an uphole portion of the housing. The valve sleeves120can be substantially aligned with one another and both include a bore therethrough such that fluid can flow freely along the valve assembly100(e.g., from one sleeve to the other and through the housing). The valve sleeves120can be independently displaced with respect to one another along the passage106and can be arranged in various positions in order to direct fluid flow into predetermined fluid pathways of the valve assembly100.

The valve sleeves120can be mounted within the housing102in a manner allowing the sleeves to shift from one position to another. It should be understood that the expression “shift” can refer to the displacement of the valve sleeves120using a shifting tool, for example, or a self-shifting mechanism provided as part of the valve assembly100such that the sleeves can be toollessly operated, for example. As seen inFIGS.4and4A, the valve assembly100can be operated in a closed configuration, with the bottom sleeve122being mounted in the housing in an occluding, or closed position, where the housing port112is blocked by the bottom sleeve122. Moreover, the top sleeve124can be mounted uphole of the bottom sleeve122in a first position, or “run-in-hole position”. It is appreciated that, when the bottom sleeve122is in the closed position, the top sleeve124remains in the first position. As will be described further below, the top sleeve124is mounted within the valve housing102in a manner defining an annular region130between an outer surface of the top sleeve124and the inner surface105of the outer wall103. In some implementations, the top and bottom sleeves122,124can be shaped and configured to sealingly engage one another and/or the outer wall103such that fluid flow is prevented, or at least reduced, along gaps defined between the housing and the sleeves. While deploying a shifting tool can be a preferred way to shift the sleeves, in an alternative scenario the sleeves can be shifted or otherwise displaced remotely or via the use of other devices.

With reference toFIGS.4to4C, when the bottom sleeve122is in the closed position, a portion of the bottom sleeve122covers the housing port112such that fluid cannot flow therethrough. The bottom sleeve122can sealingly engage the inner surface of the outer wall103such that fluid flow is prevented, or at least reduced, within interstices defined by the housing and the bottom sleeve122. In some implementations, the valve assembly100can include additional elements adapted to prevent, or at least reduce, movement of the sleeves and/or fluid flow into certain regions. For example, in the illustrated implementation, the valve assembly100includes seals140provided between the sleeves and the outer wall103. For example, in this implementation, a seal140can be provided at the uphole end of the bottom sleeve122to prevent fluid communication between the central passage106and an environment surrounding the valve assembly100when the valve assembly100is in the closed configuration.

Still referring toFIGS.4to4C, when in the closed configuration, the top sleeve124is positioned within the valve housing102in the first position, proximate the top sub108. More specifically, in this implementation, the uphole end124aof the top sleeve124can abut the top sub108, with the downhole end124bhaving a greater outer diameter to engage the inner surface105of the outer wall103. The outer wall103can also include an internal protrusion, such as an inner ring107, extending inwardly within the central passage106to enable engagement with the uphole end124aof the top sleeve124. As such, the top sleeve124and the outer wall103can define an annular chamber132within the annular region130, where the annular chamber132is defined radially between the outer surface of top sleeve124and the inner surface105of the outer wall, and defined axially between the downhole end124bof the top sleeve engaging the outer wall and the uphole end124aof the top sleeve engaging the inner ring107.

The annular chamber132can be in fluid communication with the central passage106via one or more interstices135defined between the components of the valve assembly100. As seen inFIGS.4B and4C, the interstices135can define a restricted flowpath (A) along which fluid can flow from the central passage106to the annular chamber132. The interstices135are sized and adapted to allow fluid (e.g., water) to flow into and pressurize the annular chamber132while also preventing particulates and/or slurry material (e.g., cement) from flowing into the annular chamber132. As will be described further below, the top sleeve124includes a sleeve port126adapted to be aligned with the housing port112in order to define a fluid pathway for the production of reservoir fluids. The valve assembly100can also include a flow control device150coupled to the top sleeve and positioned along the fluid pathway, within the annular region130. The sleeve port126and flow control device150are illustratively provided within the annular chamber132when the top sleeve124is in the first position. As such, it should be noted that the sleeve port126and flow control device150are isolated, or at least partially protected from particulates and/or slurry material flowing along the central passage106, such as cement when cementing the wellbore string down the wellbore.

Prior to being shifted, the valve sleeves120can be secured in their respective run-in positions using any suitable method. The valve sleeves120can be shaped and configured to engage inner surfaces105of the corresponding portion of the housing102. For example, the valve sleeves120can have one or more sections having a greater outer diameter for sealingly engaging with the housing102, and thus maintain the sleeves in position (e.g., via a press-fit connection). Alternatively, or additionally, the housing102can have portions that extend inwardly (i.e., into the passage106) at predetermined sections for engaging with corresponding parts of the valve sleeves120and further securing or stabilizing the valve sleeves120in position. In some implementations, the valve sleeves120can be secured in position using one or more fasteners, such as shear pins125extending from the housing102and engaging the valve sleeves120. The shear pins125are configured to break in order to allow the valve sleeves120to be shifted between positions. In this implementation, the shear pins125are configured to retain the sleeves in their initial positions during the completion of the wellbore, and more specifically during cementing of the casing. In other words, the shear pins125are configured to retain the sleeves while the sleeves are being installed along the wellbore, and while the wiper plug cleans the interior of the wellbore, as previously described.

The valve assembly100can be run downhole in the closed configuration (FIGS.4to4C) where the housing port112is blocked and the flow control device is shrouded within the annular chamber in order to secure (e.g., cement) the wellbore string without obstructing the port112or damaging the flow control device. Once the wellbore string is cemented, the valve assembly100can be operated in an open configuration (FIGS.5and5A) where fluid communication is established between the central passage106and the reservoir. The open configuration can also correspond to a fracturing configuration of the valve assembly100in order to initiate fracturing of the reservoir. Fracturing generally includes injection of fracturing fluid into the reservoir at high pressure for fracturing the subterranean formation surrounding the valve assembly. The injection of fluid causes the rock of the formation to fracture, thereby enabling the fluid to flow into the fractures. In this implementation, in order to operate the valve assembly100in the fracturing configuration, the bottom sleeve122can be shifted to a non-occluding position, or open position, in order to open the housing port112. In some implementation, the bottom sleeve122is displaced in the downhole direction until the housing port112is open, thus allowing fluid to be injected into the reservoir. However, it is appreciated that other configurations are possible. Furthermore, it should be noted that the top sleeve124preferably remains in the first position when operating the valve assembly100in the fracturing configuration in order to maintain the housing port112open, and the components isolated within the annular chamber132.

With reference toFIGS.5and5A, in this implementation, the valve assembly100defines a fracturing fluid pathway (B) (which can also be referred to as an injection fluid pathway) along which the fluid (e.g., fracturing fluid, injection fluid, etc.) flows to reach the housing port112. The fluid flowing along the fracturing fluid pathway (B) enters the central passage106via the top sub108, flows through the top sleeve124and exits the housing102(e.g., enters the reservoir) via the housing port112. However, it is appreciated that other pathways and configurations are possible for routing the fracturing fluid to the reservoir. As described above, the fracturing fluid can be forced through the housing port112due to pressure build-up within the housing102caused by the presence of a packer, frac plug, or other obstruction (not illustrated) deployed downhole of the valve assembly10, for example. Furthermore, once fracturing has occurred, the bottom sleeve122can be shifted uphole, back to the closed position (as seen inFIG.4) to prevent back flow of the fracturing fluid from the formation and allow “healing” or equilibration of the reservoir prior to a subsequent operation, such as production.

In some implementations, fluid production from the reservoir can be initiated using a pump coupled to the wellbore string configured to pump fluid (e.g., hydrocarbon-containing fluid) uphole along the valve assembly100and the wellbore string for recovery thereof at surface. Production can be enabled by a downhole pump, a surface pump or artificial lift, as the case may be. It should be understood that production fluid can be recovered when the valve assembly100is in the so-called “fracturing configuration”, whereby fluid is pumped through the housing port112into the housing102and follows the fracturing fluid pathway (B) in the opposite direction (e.g., uphole toward the surface). In some implementations and for some operations, the valve assembly100is indeed operated in this manner at least for some time. This operating mode can be referred to as a non-restricted production mode, as the annular chamber132remains isolated, and the production fluid pathway does not flow through the flow control device150. However, as will be described below, the valve assembly100can be operated in a flow-restricted configuration, whereby a separate fluid pathway is defined to allow production fluid to flow from the reservoir to the wellbore string through the annular region, through (or around) the flow control device, and ultimately to surface. It is noted that all of the production fluid being recovered via a particular valve assembly while in the flow-restricted configuration can be routed to flow through the annular region, although other configurations are possible.

Referring toFIGS.6and6A, the flow-restricted configuration allows production of reservoir fluid via the wellbore string for recovery thereof at surface. More specifically, the flow-restricted configuration defines a production fluid pathway (C) along which the production fluid flows to reach the central passage106of the valve assembly100. As seen inFIGS.6and6A, the top sleeve124can be disposed within the housing102in a manner defining the annular region130between at least a section of the top sleeve124and the outer wall103, and more particularly between the outer surface of the top sleeve124and the inner surface105of the outer wall103. In some implementations, the top sleeve124and the outer wall103are substantially concentric such that a relatively constant flow area is defined through the annular region130. However, it is appreciated that other configurations are possible, such as having an annular region130with a varying flow area along the top124, for example, or defining the production fluid pathway in other ways. In the illustrated implementation, the annular region130defines a notable portion of the production fluid pathway (C) and is configured to allow fluid flowing from the reservoir to reach the passage106during production.

In some implementations, the flow-restricted configuration is achieved by shifting the top sleeve124downhole to a second position, such as a production position, where the sleeve port126is aligned with the housing port112, thereby opening the annular chamber132to the reservoir. It is noted that positioning the top sleeve124in the production position can push the bottom sleeve122to the open position simultaneously. Furthermore, in this implementation, shifting the top sleeve124to the production position establishes fluid communication between the reservoir and at least a portion of the annular region130via the housing port112, thereby opening the flow control device150to fluid flow. However, it is appreciated that other configurations are possible for establishing fluid communication between the reservoir and the annular region130. For example, the housing102can be provided with a second set of ports configured to be open upon operation of the valve assembly100to the flow-restricted configuration so that the second set of ports communicates with the reservoir and the annular region.

In this implementation, the flow control device150is at least partially housed within the annular chamber132and is configured to control the fluid flowing through the annular region130during production. As mentioned above, the annular chamber132is at least partially isolated from the rest of the valve assembly100prior to shifting the top sleeve124to the production position. In some implementations, the top sleeve124can be shaped and configured to sealingly engage the housing102at the downhole end124bthereof. For example, the top sleeve124can be provided with a pair of seals140at the downhole end thereof on either side of the sleeve port126. As such, fluid flowing through the housing port112is substantially confined to flow through the sleeve port126and along the annular region130. In other words, the entire volume of production fluid flows into the housing, along the annular region130through the annular chamber132and past the uphole end of the top sleeve124to reach the central passage106(e.g., fluid flowpath (C) illustrated inFIG.6A). It is noted that in the production position, the uphole end of the top sleeve124can be free of contact from the housing102to allow fluid from within the annular region130to flow into the central passage106by simply flowing past the uphole edge of the top sleeve124.

In some implementations, the flow control device150can include a directional control valve device152adapted to prevent fluid flow in at least one direction between the central passage106and the reservoir, when the top sleeve124is in the production position. For example, in this implementation, the directional control valve device152is adapted to prevent fluid flow from the central passage106to the sleeve port126via the annular region130, and allow fluid flow from the sleeve port126to the central passage106via the annular region. In other words, the directional control valve device152is configured to prevent the injection of fluid into the reservoir through the annular region130, and allow fluid to be produced from the reservoir through the annular region130. It is thus appreciated that the directional control valve device152can enable operation of the valve assembly100as a production-only valve when the top sleeve124is in the production position. The flow control device150can further include a screen154superposed with the sleeve port126to enable a screened production of fluid from the reservoir. The screen154can be adapted to prevent various particulates and/or debris from entering the valve assembly and potentially clogging up the annular region130or being produced to surface.

Now referring toFIGS.7to10, an implementation of the top sleeve124is illustrated. The top sleeve124includes a sleeve mandrel160defining a sleeve passage161therethrough, a collet162coupled to an uphole end of the sleeve mandrel160and a sleeve cap164coupled to a downhole end of the sleeve mandrel160. In some implementations, the collet162and the sleeve cap164are secured to the sleeve mandrel160via interference fit, although other connection methods can be used. The collet162can include a latching mechanism165adapted to releasably engage valve housing102to assist in retaining the top sleeve124in position within the valve housing. For example, the outer wall can be provided with annular grooves116(seen inFIGS.4A and10, among others) along the inner surface thereof, and the latch mechanism165can include one or more protrusions166extending outwardly from the collet162for engaging the annular grooves116, thereby latching the top sleeve to the outer wall to resist displacement of the top sleeve124along the valve housing. The annular grooves116can be provided at predetermined locations along the valve housing102such that engagement of the annular grooves by the latching mechanism165corresponds to an operational configuration of the valve assembly100.

In some implementations, the latch mechanism165of the collet162includes resilient members168, each provided with one or more of the protrusions166and configured to bias the protrusions outwardly to engage the annular groove of the housing. The resilient members168are further adapted to move radially inwardly (e.g., within the sleeve passage161) upon an application of sufficient force, such as from a shifting tool, for example. It is appreciated that moving the resilient members168radially inwardly can disengage the protrusions166from the annular groove, thereby enabling a generally unhindered movement of the top sleeve124along the valve housing. The resilient members168can be distributed about the sleeve mandrel160, thereby defining openings and gaps therebetween through which fluid flowing along the fluid flowpath (C) can travel to flow past the collet162and into the central passage106. Referring back toFIG.4C, it is noted that the collet162defines the upholemost component of the top sleeve124such that the interstices135are defined between the top sub108, the outer wall103and the collet162, although other configurations are possible.

As seen inFIGS.7to10, the sleeve cap164can be provided with the sleeve port126such that aligning the sleeve cap164with the housing port112correspondingly aligns the sleeve port126with the housing port112. The sleeve port126can include a plurality of elongate slots128provided around the sleeve cap164for enabling fluid communication between the annular region and the housing port (and thus also with the reservoir). In some implementations, the housing port112includes as many openings114as the sleeve port126includes elongate slots128. However, it is appreciated that other configurations are possible, for example, and as seen inFIGS.2and7, the housing port112includes less openings114than the sleeve port126includes elongate slots128.

In this implementation, the screen154is superposed with the sleeve port126, and more specifically with the elongate slots128. As seen inFIGS.8and8A, the screen154can include one or more circumferential openings155disposed beneath the elongate slots128and through which fluid flows during production. The circumferential openings155are illustratively smaller than the elongate slots128, and are therefore adapted to prevent particulates, such as various debris, from entering the annular region. In some implementations, the elongate slots128are defined within a thickness of the sleeve cap164and opens on an outer surface of the sleeve cap164. Therefore, each elongate slot128can include a bottom surface, with the circumferential openings155being defined through and spaced along at least a portion of the bottom surface.

In some implementations, the circumferential openings are generally perpendicular relative to the elongate slots and, although not illustrated as such, are dispersed along the entirety of the bottom surface. The space between each circumferential opening155can have generally the same width as the circumferential openings themselves, such that about 50% of the bottom surface of each elongate slot128corresponds to circumferential openings155, and the other 50% corresponds to the solid bottom surface. However, it is appreciated that other configurations are possible, such as having wider circumferential openings155, thinner circumferential openings155, or circumferential openings of varying dimensions throughout the same elongate slot128or between different slots128.

With reference toFIGS.9and10, in addition toFIGS.7to8A, the annular region130is illustratively defined between the sleeve mandrel160and the outer wall103. Therefore, it is noted that the volume of the annular region130can be at least partially dependent on the thickness of the sleeve mandrel160and/or of the outer wall103. For instance, increasing the thickness of the wall of the sleeve mandrel160impedes on either the volume of the annular region130, the volume of the central passage106, or both. Similarly, increasing the thickness of the outer wall103(e.g., without increasing the width of the wellbore) reduces the volume of the annular region130. Therefore, in order to define an annular region130adapted to house one or more components, such as the flow control device150, the thickness of at least one of the outer wall103and sleeve mandrel160can be made thinner.

Reducing the thickness of either one of these walls can include risks. The outer wall103is sized and configured to withstand a pressure differential between an internal pressure (e.g., along the central passage106) and an exterior pressure (e.g., a reservoir pressure). It should thus be noted that reducing the thickness of the outer wall103risks collapsing the valve assembly. In this implementation, the sleeve mandrel160is not subjected to a pressure differential since the annular region130remains in fluid communication, or fluid-pressure communication, with the central passage106. In other words, the pressure within the annular region130(e.g., within the annular chamber132) is substantially the same as the pressure along the central passage106.

Therefore, it is noted that enabling fluid flow into the annular region (i.e., into the annular chamber132) prior to cementing the wellbore string can create a pressure-balanced system between the annular region130and the central passage106. As such, the thickness of the sleeve mandrel160can be reduced to increase the volume of the annular region130since the sleeve mandrel160is not subjected to a pressure differential.

In some implementations, the sleeve mandrel160can include a ring portion170extending into the annular region130and engaging the inner surface105of the outer wall103. The ring portion170can therefore be adapted to define a downhole annular region134in fluid communication with the sleeve port126, and an uphole annular region136in fluid communication with the central passage106. The ring portion170also illustratively includes one or more through channels172establishing fluid communication between the uphole and downhole annular regions134,136. A seal140can be provided between the ring portion170and the outer wall103to confine fluid flow through the through channels172.

Referring back toFIG.6A, when the valve assembly is in the flow-restricted configuration, the top sleeve124is in the production position and defines the fluid flowpath (C) which includes the following path: i) production fluid flowing into the valve assembly via the housing port112, ii) production fluid flowing into the downhole annular region134via the sleeve port126(e.g., through the elongate slots128and the screen154), iii) production fluid flowing into the uphole annular region136via the through channels172, and iv) production fluid flowing along the annular region, past the collet162and into the central passage106.

Referring broadly toFIGS.6to10, the directional control valve device152can be coupled to the sleeve mandrel160in the uphole annular region136, and configured to selectively control fluid flow along the annular region130, and more specifically through the through channels172of the ring portion170. For example, in this implementation, the directional control valve device152comprises a displaceable member180provided within the uphole annular region136and being movable between an engaged position (seen inFIG.10), where the displaceable member180at least partially prevents fluid communication between the uphole and downhole annular regions134,136, and a disengaged position (not shown), where fluid communication between the uphole and downhole annular regions is allowed via the through channels172. The directional control valve device152can further include a biasing member182operatively coupled to the displaceable member180for biasing the displaceable member180in the engaged position.

In this implementation, the displaceable member180can be displaced from the engaged position to the disengaged position via fluid flow, such as fluid flowing from the reservoir into the annular region130. More specifically, fluid flowing from the reservoir into the downhole annular region134can generate hydraulic pressure on the displaceable member180, causing it to move into the disengaged position and enable fluid flow through the through channels172. It is noted that fluid flow in the opposite direction, i.e., toward the reservoir is blocked as it does not displace the displaceable member180.

In some implementations, the directional control valve device152includes an axial check valve device184configured to prevent axial flow from the uphole annular region136to the downhole annular region134. The displaceable member180of the axial check valve device184can include a check valve head, such as a ring plug member186, engageable with the ring portion170of the sleeve mandrel160. Additionally, the biasing member182of the axial check valve device184can include a spring188operatively coupled between the ring plug member186and the collet162within the annular region130to bias the ring plug member186in the engaged position. As seen inFIG.10, when in the engaged position, the front edge187of the ring plug member186sealingly engages the ring portion170to prevent fluid flow between the annular regions134,136via the through channels172. In this implementation, the ring plug member186is slidably mounted about the sleeve mandrel160such that hydraulic pressure within the downhole annular region134can generate a force on the axial check valve device184, thereby compressing the spring188and moving the ring plug member186away from the ring portion170to the disengaged position. It should be noted that when fluid flow is stopped, or reduced, the spring188is configured to push the ring plug member186back to the engaged position.

Still with reference toFIGS.9and10, the ring portion170includes an outer surface which engages the inner surface105of the outer wall103. In this implementation, the outer surface of the ring portion170includes an overhang174axially extending within the uphole annular region136. The front edge187of the ring plug member186can be shaped and adapted to come into contact with the overhang174and create a seal therewith to prevent fluid flow through the ring portion170via the through channels172. The front edge187is illustratively tapered such that a portion thereof is shaped and sized to at least partially extend below the overhang174, with the tapered surface sealingly engaging the overhang174when in the engaged position. The axial check valve device184can also be provided with a seal140provided between the ring plug member186and the sleeve mandrel160such that fluid flow is prevented both above and below the ring plug member186when engaged with the ring portion170. As seen inFIG.9, the front edge187can be substantially continuous such that the tapered surface of the front edge is correspondingly continuous and uniformly engages the overhang174. However, it is appreciated that other configurations are possible, or example, the front edge187can include a plurality of plug members configured to engage and plug respective through channels172for preventing fluid flow therethrough.

Now referring toFIGS.11to15, an alternate implementation of the top sleeve124is illustrated. The sleeve mandrel160, collet162and sleeve cap164are substantially the same as those described above. However, in this implementation, the directional control valve device152includes a radial check valve device190, where the displaceable member180is configured to move radially between the sleeve mandrel160and the outer wall to selectively control fluid flow between the downhole and uphole annular regions134,136. In this implementation, the displaceable member180includes a plurality of radial poppets192provided about the ring portion170for obstructing respective through channels172, when in the engaged position. Each radial poppet192can be configured to block one end of one of the through channels172, such as the end adapted to communicate with the uphole annular region136, for example.

During production, fluid flows from the reservoir, through the housing port, through the sleeve port126and into the downhole annular region134. The hydraulic pressure increases and generates an outward radial force on a bottom surface of the radial poppets192to disengage, or “unseat”, the radial poppet192from its engaged and occluding position. As seen inFIG.14A, the radial poppet192can be provided with one or more seals140for preventing fluid flow when in the engaged, or “seated” position. Once sufficient hydraulic pressure is created below (e.g., within the through channels172and the downhole annular region134), the radial poppet192is lifted from its seat, thereby enabling fluid flow around the radial poppet192, into the uphole annular region136and finally in the central passage106. Each radial poppet192can be configured to selectively block a single through channel172, although other configurations are possible, such as providing a radial poppet192for more than one through channel, for example. It should also be noted that, in some implementations, the directional control valve device152can include a combination of axial and radial check valve devices, or any other type of flow directional control device.

With reference toFIGS.16to26, alternate implementations of flow control devices150are illustrated. For instance, with reference toFIG.16, an implementation of an axial poppet check valve200is shown. In this implementation, the poppet member202can be provided in the annular region and functions in a similar way as the axial check valve device described above.FIG.16shows the axial poppet member202in the open position, or retracted position, once fluid pressure forces the poppet away from the through channel172. Fluid communication is thus created to enable flow past and/or through the poppet (e.g., via internal channels204of the axial poppet member202), along the annular region.FIG.16shows an axial poppet check valve preventing injection outflow and enabling production inflow. An axial poppet check valve could also be provided for another valve for preventing production inflow and enabling injection outflow by reorienting the poppet member and the biasing member within the annular region, such as the implementation shown inFIGS.17and18, for example. It is appreciated that the implementations the poppet check valve ofFIGS.17and18can be used in injection-only valves, where production is prevented at predetermined stages of the wellbore.

Referring now toFIGS.18to24, a reed type check valve can be used wherein a reed is incorporated with the sleeve in various ways.

Referring toFIGS.19-21, each reed check valve can include a reed petal210that is attached at one end to the top sleeve124via an attachment212while enabling the opposed end to flex from a closed position to an open position in response to fluid pressure from one direction.FIG.19shows the reed petal210fixed proximate the uphole end of the sleeve and arranged so that an end section of the reed petal210can rest on a support portion of the sleeve in the closed position and then flex or pivot in response to fluid pressure from below to move the reed petal to the open position to define an opening that allows fluid communication past the reed petal210. InFIG.19, the reed petal210is arranged to flex radially outward in response to fluid pressure that flows from the exterior of the valve and through the through channels172. A gap can be defined between the housing103and the support portion to enable the reed petal210to flex toward the housing inner surface to enable fluid to pass through. When the fluid pressure is on the inside of the valve, the reed petal210tends to remain closed for the reed check valves ofFIG.19, which can thus be used in a production-only valve. In addition, the sleeve124can be composed of two or more parts, if desired, for ease of manufacturing and assembly of the different portions of the various features.

FIG.20shows a reed check valve for an injection-only scenario wherein the reed petal210is arranged to flex radially outward in response to fluid pressure from the interior of the valve. Fluid can flow through the annular region to force the reed petal to open and then flow through the housing port112and into the reservoir.

The reed check valves illustrated inFIGS.19-20are arranged so that the reed petal210flexes radially and thus deflects from a closed position that can be generally aligned with a longitudinal axis of the sleeve to an open position at an angle, which may be acute, with respect to the longitudinal axis. This general configuration can be referred to herein as a side-bending configuration of the reed check valve. The side-bending reed valve can be used for injection or production in various valve implementations. The side-bending reed valve can be integrated within the sleeve of the valve, as shown inFIGS.19-20, or with the housing itself if desired. As shown inFIGS.19-20, the reed valve can be arranged so that the reed petal bends outward toward the open position, rather than bending inward toward the middle of the valve. Outward bending can reduce issues related to catching tools and the like that can be run through the sleeve. Orientations of the sleeve parts, the reed petal, and related equipment that reduce the risk of catching can be beneficial (e.g., reed petals that are shielded from tool deployment, as shown inFIGS.19-20). In other terms, the reed petal210can be oriented so that it does not create an obstruction. The reed petal can also be arranged facing either axial direction (the loose end uphole or downhole) with the sleeve and channels being arranged accordingly.

Turning toFIGS.21-23, the reed check valve can be provided in an alternative arrangement that can be referred to as an end-bending configuration. In the closed position, the reed petal210can be oriented generally perpendicular to the longitudinal axis of the sleeve, and in response to fluid pressure the reed petal210flexes to an angle to allow fluid passage in one direction. In this implementation, the reed petal210can be arranged to cover an outlet of the through channels172. As shown inFIGS.22-23, each through channel172can be covered by a reed petal210. A pair of adjacent through channels172can also be covered by a single reed petal210with first and second sides that cover respective through channels172and the attachment212securing the reed petal210in between the adjacent through channels172. The reed petal210could alternatively be secured to the end of the sleeve in other configurations so that the reed petal bends in one or various directions. It is noted that the end-bending configuration could also include an additional inner sleeve part configured to shield the reed petal.

WhileFIGS.19-20show a side-bending configuration andFIG.21-23show an end-bending configuration, it should be noted that other angle of the reed petal and associated through channels172are possible. In other words, the reed petal does not have to be parallel or perpendicular to the sleeve longitudinal axis, but can be oriented at other angles.

Referring toFIG.24, it is also noted that the reed check valve can be provided in the form of an angled reed valve device220, where the reed petals210are arranged at an angle with respect to the longitudinal orientation in the closed position. For example, the reed petals can be mounted to a reed block222that includes a base plate224, angled walls226extending from the base plate224and side walls (not shown) also extending from the base plate, such that the walls define a flow cavity225. The base plate224defines a base opening228, and the angled walls include openings230over which the reed petals210are provided. The fluid can flow through the base opening, into the cavity, and out of the openings, deflecting the reed petals210in one direction (i.e., from right to left inFIG.24); but the fluid is prevented from flowing in the opposite direction. Each reed petal210can also be overlaid with a stop plate232that can be curved and configured to define the maximum open position of the reed petal. In this regard, is it noted that a dedicated stop plate component can be provided for various reed valves, or certain components of the valve (e.g., housing, sleeve, etc.) can act as a stop plate depending on the configuration of the reed petal.

Referring back toFIG.1, the wellbore10includes a casing11lining an inner surface of the wellbore10. The casing11can be adapted to contribute to the stabilization of the reservoir14after the wellbore10has been drilled, e.g., by contributing to the prevention of the collapse of the walls of the wellbore10. In some implementations, the casing11includes one or more successively deployed concentric casing strings, each of which is positioned within the wellbore10. In some implementations, each casing string includes a plurality of jointed segments of pipe. The jointed segments of pipe typically have threaded connections although other configurations are possible and may be used.

It can be desirable to seal an annulus formed within the wellbore between the casing string11and the reservoir14. Sealing of the annulus can be desirable for preventing injection fluid from flowing into remote zones of the reservoir, thereby providing greater assurance that the injected fluid is directed to the intended zones of the reservoir. To prevent or at least interfere with injecting fluid into an unintended zone of the reservoir, this annulus can be filled with an isolation material, such as cement, thereby cementing the casing to the reservoir14. It should be noted that the cement can also provide one or more of the following functions: (a) strengthens and reinforces the structural integrity of the wellbore, (b) prevents, or substantially prevents, produced fluids of one zone from being diluted by water from other zones, (c) mitigates corrosion of the casing11, and (d) at least contributes to the support of the casing11.

It is further noted that the casing11can include a plurality of casing outlets for allowing fluid flow between the wellbore string30and the reservoir (e.g., via injection and production segments of the valve assembly100). In some implementations, in order to facilitate fluid communication between the wellbore string30and the reservoir14, each of the casing outlets can be substantially aligned with, or at least proximate to, a housing port of the valve assembly100. In this respect, in implementations where the wellbore10includes the casing11, injection fluid is injected from the surface down the wellbore string30in order to reach the valve assembly100. Injection fluid then flows through the open housing port of the corresponding valve assemblies and into an annular space defined between certain portions of the wellbore string30and the casing string11, and finally into the reservoir14via the casing outlets.

In another possible implementation, and with reference toFIGS.25and26, the valve assembly can be provided with a single sleeve, such as the top sleeve124, shiftable between various positions and being adapted to close the housing port112, open the housing port112and/or restrict the housing port112. In other words, the different configurations of the valve assembly described herein can be generally replicated using only one valve sleeve (i.e., instead of the dual-sleeve assembly described above). Referring more specifically toFIG.25, the top sleeve124can include an occluding portion240adapted to be aligned with the housing port112to operate the valve assembly100in the closed configuration. The occluding portion240can correspond to a portion of the sleeve cap164which is illustratively provided with one or more seals140between the outer wall and the occluding portion240(e.g., the sleeve cap164) to prevent fluid communication between the reservoir and the central passage106.

The top sleeve124can be shifted between the closed position (shown) and a screened position, where the screen154is aligned with the housing port112, as described above. Similar to previously described implementations, the screen154can be provided on the sleeve cap164, such that shifting the top sleeve124, for example in the downhole direction, displaces the occluding portion240to no longer block the housing port112, and moves the screen154in alignment with the housing port112. In this implementation, the outer wall103includes a pair of annular grooves116where the collet162is adapted to engage via the latching mechanism165. The annular grooves are provided at predetermined locations such that engagement of a first annular groove, such as the upholemost annular groove116acorresponds to positioning the top sleeve in the closed position (e.g., with the occluding portion240aligned with the housing port112), and engagement of a second annular groove, such as the downholemost annular groove116bcorresponds to positioning the top sleeve in the screened position.

With reference toFIG.26, another implementation of the valve assembly100is shown. In this implementation, the top sleeve124includes generally the same structure as the implementation ofFIG.25. However, the valve housing102is shaped and adapted to enable movement of the top sleeve in both the uphole and the downhole directions. As such, it is appreciated that the top sleeve can be displaced into three different operational positions. As seen inFIG.26, the valve housing includes three (3) annular grooves116, including the upholemost annular groove116a, the downholemost annular groove116b, and a central annular groove116ctherebetween, although additional annular grooves can be provided. The top sleeve124can thus be displaced along the valve housing to enable engagement of the latching mechanism165in any one of the three (3) annular grooves116, which corresponds to operation of the valve assembly in three operational configurations (e.g., three different operational configurations).

For example, the valve assembly can be run downhole with the top sleeve in the run-in position, with the latching mechanism165engaging the central annular groove116c, which corresponds to the closed position in this implementation. In other words, the valve assembly100is run downhole with the occluding portion240of the top sleeve aligned with the housing port112. Once in place, the top sleeve can be either shifted downhole or uphole, for engagement of the latching mechanism with one of the other annular grooves116a,116b. In this implementation, shifting the top sleeve downhole aligns the screen154with the housing port112, thus operating the valve assembly in the screened configuration. Moreover, shifting the top sleeve uphole opens the housing port112to direct fluid communication with the central passage, thus operating the valve assembly in the open configuration (e.g., for fracturing purposes, for injection into the reservoir or for unrestricted production of reservoir fluids).

It should be noted that the structural components of the top sleeve can be “flipped” along the valve housing such that shifting the top sleeve uphole moves the top sleeve to the screened position, and shifting the top sleeve downhole moves the top sleeve to the open position, for example. In addition, althoughFIGS.25and26illustrate the top sleeve with the axial check valve device configured to operate the valve assembly in a production-only valve, it should be noted that any other suitable type or combination of flow control devices can be used, such as flow control devices configured to operate the valve assembly in an injection-only valve, for example.

Now referring toFIGS.27to29, another implementation of the valve assembly is illustrated. In this implementation, the valve assembly100includes a dual-sleeve assembly (e.g., a bottom sleeve122and a top sleeve124) and further includes a flow-controlling sleeve250coupled to one of the bottom sleeve122and the top sleeve124, such as to the top sleeve124. In some implementations, the flow-controlling sleeve250includes the flow control device, or a portion thereof, and includes a flow-controlling sleeve mandrel252provided between the top sleeve124and the outer wall103of the housing. As will be described further below, the flow-controlling sleeve250can be slidably mounted within the valve housing, such as slidably mounted between the top sleeve124and the outer wall103, for example, which enables movement of the flow-controlling sleeve250along the valve housing relative to the outer wall103and/or the top and bottom sleeves. It is thus noted that the flow-controlling sleeve250can be at least partially mounted within the annular region130, such as within the annular chamber132.

InFIGS.27and27A, the valve assembly100is operated in the closed configuration, where the bottom sleeve122occludes the housing port112to prevent fluid communication between the central passage106and the reservoir. In a similar fashion to previously described implementations, the bottom sleeve can be shifted (e.g., in the downhole direction) to an open position (seen inFIG.28) and enable operation of the valve assembly in the open configuration. It is appreciated that the open configuration of the valve assembly100enables fracturing of the reservoir, injection into the reservoir via the housing port and/or unrestricted production of reservoir fluids through the housing port into the central passage106.

In this implementation, the top sleeve124is provided with an annular inlet252adapted to establish fluid communication between the central passage and the annular region130such that wellbore fluid within the central passage can flow within the annular region. As previously described, this initial ingress of fluid can pressurize the annular chamber132and prevent subsequent fluids or material (e.g., cement) from flowing into the chamber. In this implementation, the annular inlet252includes a plurality of slotted inlets circumferentially dispersed along an inner surface of the top sleeve. Therefore, fluid flowing along the central passage can go through the slotted inlets and into the annular region130. With the flow-controlling sleeve250positioned within the annular chamber, it is appreciated that the flow-controlling sleeve250can be protected from cement due to the previous fluid pressurization of the annular chamber.

In some implementations, once the reservoir has been fractured, the bottom sleeve can be shifted back uphole to the closed position to prevent back flow of the fracturing fluid from the formation and allow “healing” or equilibration of the reservoir prior to production. Alternatively, and with reference toFIG.29, the top sleeve124can be shifted downhole to overlay and at least partially block the housing port112. In this implementation, the flow-controlling sleeve250can include a sleeve shoulder256at a downhole end thereof against which the top sleeve can abut. The sleeve shoulder256is defined by a portion of the flow-controlling sleeve250which has a smaller inner diameter, thereby enabling the top sleeve to abut thereon. It should thus be understood that shifting the top sleeve in the downhole direction pushes against the sleeve shoulder256and correspondingly displaces the flow-controlling sleeve250along with the top sleeve.

As seen inFIG.29, the valve assembly can be operated in a secondary closed configuration by shifting down the top sleeve, which displaces the flow-controlling sleeve250for alignment thereof with the housing port112. It is thus noted that, in this implementation, the downhole end of at least one of the top sleeve and the flow-controlling sleeve250can be of an occluding nature (e.g., not slotted or provided with openings) to prevent fluid communication between the reservoir and the central passage106. In some implementations, the flow-controlling sleeve250is provided with the latching mechanism165, such as the latching mechanism previous described in relation to the collet, configured to releasably engage the outer wall103for positioning and retaining the flow-controlling sleeve250at predetermined locations within the valve housing. In some implementations, shifting the top sleeve and the flow-controlling sleeve250downhole brings the flow-controlling sleeve250in abutment with the bottom sleeve122to prevent further downhole movement, although other configurations are possible.

Referring now toFIG.30, in this implementation, the downhole end of the flow-controlling sleeve250is provided with the flow control device, and more specifically, the downhole end includes the screen154. In some implementations, the screen154can define a slotted region of the flow-controlling sleeve250, whereby the flow-controlling sleeve250is provided with a plurality of openings155defined through a thickness of the flow-controlling sleeve mandrel252. As seen inFIG.30, the openings155can be substantially parallel to one another and the longitudinal axis of the valve assembly. The openings155can have any suitable shape, size and/or configuration, although it is appreciated that wider and/or a greater number of openings155can allow a greater flowrate of fluid into the valve assembly.

Still with reference toFIG.30, the valve assembly100can be operated in a screened configuration, where the screen154is aligned with the housing port112for enabling a screened production of reservoir fluids. In this implementation, to operate the valve assembly from the secondary closed configuration (seen inFIG.29) to the screened configuration (seen inFIG.30), the top sleeve is shifted back uphole, such as back to its initial run-in position. With the flow-controlling sleeve250being slidable relative to the top sleeve and coupled to the outer wall via the latching mechanism, the top sleeve can be shifted back uphole by itself (i.e., without dragging the flow-controlling sleeve250back with it). As such, the screen154remains aligned with the housing port112for operation of the valve assembly in the screened configuration.

In this implementation, the flow-controlling sleeve250can be reverted to its initial isolated position within the annular region. For example, from the secondary closed or screened configuration, the bottom sleeve122can be shifted in the uphole direction. The bottom sleeve can abut the flow-controlling sleeve250and can therefore push the flow-controlling sleeve250in the uphole direction. When in the secondary closed configuration (FIG.29), the sleeve shoulder256abuts and pushes on the top sleeve, such that all three (3) sleeves are shifted uphole when shifting the bottom sleeve in the uphole direction. When in the screened configuration (FIG.30), it is noted that the top sleeve is already in its initial uphole position such that the flow-controlling sleeve250can be pushed into the annular region130between the top sleeve and the outer wall103. It should thus be understood that the valve assembly can be operated from the closed configuration to the open configuration, to the secondary closed configuration, to the screened configuration and back to the closed configuration. In other words, the valve assembly can be operated back in any one of the operational configurations for performing any corresponding wellbore operation. For example, the valve assembly can be reverted back into the open configuration (e.g., after having produced reservoir fluid through the screen) to enable fracturing the reservoir a subsequent time.

Now referring toFIGS.31to35A, another implementation of the valve assembly is illustrated. In this implementation, the valve assembly100includes a dual-sleeve assembly (e.g., a bottom sleeve122and a top sleeve124) and further includes a flow-controlling sleeve250coupled to one of the bottom sleeve122and the top sleeve124, such as to the bottom sleeve124. In some implementations, the flow-controlling sleeve250includes the flow control device, or at least a portion thereof. As will be described further below, the flow-controlling sleeve250can be slidably mounted within the valve housing which enables movement of the flow-controlling sleeve250along the valve housing as the valve sleeves are displaced.

InFIGS.31and31A, the valve assembly100is operated in the closed configuration, where the bottom sleeve122occludes the housing port112to prevent fluid communication between the central passage106and the reservoir. While the valve sleeves122,124are in the closed position, the flow-controlling sleeve250is illustratively positioned between a downhole end of the top sleeve124and the outer wall103. It is thus noted that the flow-controlling sleeve250can be at least partially mounted within the annular region130, such as within the annular chamber132. In a similar fashion to previously described implementations, the bottom sleeve can be shifted (e.g., in the downhole direction) to an open position (seen inFIGS.32and32A) and enable operation of the valve assembly in the open configuration. It is appreciated that the open configuration of the valve assembly100enables fracturing of the reservoir, injection into the reservoir via the housing port and/or unrestricted production of reservoir fluids through the housing port into the central passage106.

In this implementation, the top sleeve124is provided with an annular inlet, or a vent252, adapted to establish fluid communication between the central passage and the annular region130such that wellbore fluid within the central passage can flow within the annular region. As previously described, this initial ingress of fluid can pressurize the annular chamber132and prevent subsequent fluids or material (e.g., cement) from flowing into the chamber. In this implementation, the annular inlet252includes one or more openings circumferentially dispersed along an inner surface of the top sleeve. Therefore, fluid flowing along the central passage can go through the openings and into the annular region130. With the flow-controlling sleeve250positioned within the annular chamber, it is appreciated that the flow-controlling sleeve250can be protected from cement due to the previous fluid pressurization of the annular chamber.

In some implementations, and as seen inFIG.33, once the reservoir has been fractured, the top sleeve124can be shifted toward the bottom sleeve (e.g., downhole) to a secondary closed position occluding the housing port112in order to prevent back flow of the fracturing fluid from the formation and allow “healing” or equilibration of the reservoir prior to production. In this implementation, the top sleeve can be provided with a latching mechanism265adapted to releasably latch onto the flow-controlling sleeve250when moved in the secondary closed position. Once the top sleeve is latched onto the flow-controlling sleeve250via the latching mechanism265, the top sleeve can be moved back uphole, thereby dragging the flow-controlling sleeve250and the bottom sleeve along with it. The flow-controlling sleeve250is moved in this manner until the flow control device is aligned with the housing port112to control fluid flow therethrough.

In this implementation, the valve assembly100can be provided with a lock ring270installed about the bottom sleeve and being adapted to at least partially limit movement of the bottom sleeve along the valve housing. As will be described further below, the lock ring270is configured to be inwardly biased such that the lock ring “squeezes” the bottom mandrel. More particularly, in this implementation, the bottom sleeve122includes a downhole end adapted to abut against an inner shoulder274of the valve housing to limit downhole movement thereof. It is noted that the bottom sleeve122can be in the open position when it abuts the inner shoulder274.

In addition, and with reference toFIGS.34to35A, the mandrel of the bottom sleeve122(i.e., the bottom mandrel) is adapted to slidably engage (e.g., contact) the inner surface of the valve housing along a portion of its length. The bottom mandrel can have an inset region276defined along a portion thereof and having a smaller outer diameter, thereby defining a sleeve shoulder278. In this implementation, moving the bottom sleeve in the open position (FIG.32) aligns the inset region with the lock ring270, thereby enabling the lock ring to engage (e.g., “snap”) onto the bottom mandrel along the inset region, but remains partially retained within an annular housing defined in the tubular wall103. As such, moving the flow-controlling sleeve250and the bottom sleeve in the uphole direction is limited by the lock ring270, which abuts against the tubular wall103and the sleeve shoulder278.

In this implementation, the flow-controlling sleeve250includes the screen154, similar to the implementation ofFIGS.27to30such that fluid flow is restricted through a slotted region of the flow-controlling sleeve250. However, it is appreciated that other configurations are possible. The valve assembly100can be operated in a screened configuration, where the screen154is aligned with the housing port112for enabling a screened production of reservoir fluids. In this implementation, to operate the valve assembly in the screened configuration (seen inFIG.35A), the top sleeve is shifted back uphole, thereby dragging the flow-controlling sleeve250and the bottom sleeve along with it via the latching mechanism265. The lock ring270, which is engaged with the inset region, abuts against the sleeve shoulder to limit uphole movement of the bottom sleeve and the flow-controlling sleeve. The latching mechanism265therefore releases the flow-controlling sleeve250(e.g., as the top sleeve is pulled further uphole), leaving the screen in position over the housing port112, as seen inFIG.35A.

The latching mechanism265can include one or more components of the top sleeve124configured to cooperate with the flow-controlling sleeve250or the bottom sleeve122to releasably couple these components together. For example, the bottom end of the top sleeve can be shaped, sized and/or adapted to engage the flow-controlling sleeve250in a releasable press-fit connection. As such, the top sleeve can be shifted uphole and drag the flow-controlling sleeve250and the bottom sleeve until the lock ring blocks the movement of the bottom sleeve. Alternatively, or additionally, the top sleeve can be adapted to engage oen or more sealing elements266, such as polymeric seals, provided about an inner surface of the flow-controlling sleeve250. The sealing elements being adapted to provide sufficient friction between the flow-controlling sleeve250and the top sleeve to enable both components to be moved together. It is appreciated that other configurations or implementations of the latching mechanism265are possible and may be used.

In this implementation, the top and bottom sleeves can be moved back and forth between the different operational positions described above. It should thus be understood that the valve assembly can be operated between the closed configuration, the open configuration, to the secondary closed configuration and the screened configuration, as desired and/or required.

Now referring toFIGS.36to38A, another implementation of the valve assembly is illustrated. In this implementation, the top sleeve124can be fixed (e.g., secured, immobile, etc.) relative to the housing, and the bottom sleeve can include the flow control device (e.g., the screen154) provided at an uphole end thereof. In this implementation the flow control device is integrated with the mandrel of the bottom sleeve such that it forms a single piece. As seen inFIGS.36and36A, the valve assembly100is operated in the closed configuration, where the bottom sleeve122occludes the housing port112to prevent fluid communication between the central passage106and the reservoir. While in the closed position, the screen is illustratively positioned between the top sleeve124and the outer wall103. It is thus noted that the screen154can be positioned within the annular region130, such as within the annular chamber132for protection thereof. In a similar fashion to previously described implementations, the bottom sleeve can be shifted (e.g., in the downhole direction) to an open position (seen inFIGS.37and37A) and enable operation of the valve assembly in the open configuration.

In this implementation, the top sleeve124is provided with an annular inlet, or vent252, adapted to establish fluid communication between the central passage and the annular region130such that wellbore fluid within the central passage can flow within the annular region. As previously described, this initial ingress of fluid can pressurize the annular chamber132and prevent subsequent fluids or material (e.g., cement) from flowing into the chamber. In this implementation, fluid flowing along the central passage can go through the annular inlet and into the annular region130.

In this implementation, the valve assembly100is provided with a lock ring270similar to the previously described implementation. More specifically, the lock ring270is configured to snap into an inset region of the bottom sleeve to limit uphole movement of the bottom sleeve as the lock ring abuts against the sleeve shoulder. When the lock ring270abuts the sleeve shoulder278, the screen154is positioned in alignment with the housing port112such that fluid flow is controlled, restricted, filtered, etc., through the screen154. In other words, when the lock ring270engages the sleeve shoulder, the valve assembly is operated in the screened configuration for enabling a screened production of reservoir fluids. In this implementation, the bottom sleeve can be moved back and forth between the different operational positions described above, with the top sleeve being fixed and secured to the valve housing. It should thus be understood that the valve assembly can be operated between the closed configuration, the open configuration and the screened configuration, as desired and/or required.

Now referring toFIGS.39to45A, another implementation of the valve assembly is illustrated. In this implementation, the top sleeve124can be fixed (e.g., secured, immobile, etc.) relative to the housing, and the bottom sleeve can include the flow control device (e.g., the screen154) provided at an uphole end thereof. As seen inFIGS.40and40A, the valve assembly100is operated in the closed configuration, where the bottom sleeve122occludes the housing port112to prevent fluid communication between the central passage106and the reservoir. While in the closed position, the screen154is illustratively positioned between the top sleeve124and the outer wall103. It is thus noted that the screen154can be positioned within the annular region130, such as within the annular chamber132for protection thereof. In a similar fashion to previously described implementations, the top sleeve124is provided with an annular inlet, or vent252, adapted to establish fluid communication between the central passage and the annular region130such that wellbore fluid within the central passage can flow within the annular region. As previously described, this initial ingress of fluid can pressurize the annular chamber132and prevent subsequent fluids or material (e.g., cement) from flowing into the chamber. In this implementation, fluid flowing along the central passage can go through the annular inlet and into the annular region130.

In this implementation, the bottom sleeve can be shifted (e.g., in the downhole direction) to an open position (seen inFIGS.41and41A) and enable operation of the valve assembly in the open configuration, and can subsequently be shifted back (e.g., in the uphole direction) to align the screen154with the housing port112(seen inFIGS.42and42A) and enable operation of the valve assembly in the screened configuration. As will be described further below, the bottom sleeve122is adapted to move axially and radially (e.g., rotate about its longitudinal axis) within the valve housing when moving between the open, closed and screened positions.

As seen inFIGS.39,41,43and45, the bottom sleeve122can include a guiding track280defined along an outer surface thereof, and the valve housing can include one or more guiding pins282configured to engage the guiding track280. As will be understood, the bottom sleeve is actuatable to move back and forth along the central passage and the guiding pins282remain generally stationary to limit movement of the bottom sleeve in either directions. For example, the guiding track280can include an elongated slot285extending longitudinally along the bottom sleeve122having opposite ends defining stops against which the guiding pin282can abut, thereby limiting movement of the bottom sleeve122in the corresponding direction. In other words, moving the bottom sleeve in the closed position can cause the guiding pin to engage a downhole end of the elongated slot, and moving the bottom sleeve in the open position can cause the guiding pin to engage an uphole end of the elongated slot.

In this implementation, the guiding track280includes a plurality of elongated slots285, dispersed radially about the bottom sleeve and extending substantially parallel to one another. The elongated slots285can include slots of varying lengths such that the bottom sleeve can be positioned at different locations along the central passage. As will be described below, the guiding track280can include angled surfaces290configured to offset the position of the guiding pin relative to the elongated slots as it slides along the angled surfaces. It is thus noted that the angled surfaces290can be adapted to rotate the bottom sleeve within the central passage as the bottom sleeve is moved to engage the angled surfaces with the guiding pin. As such, the guiding pin282can be made to engage different elongated slots285around the bottom sleeve to limit movement of the bottom sleeve in a given direction to position the screen in various, selected and/or desired locations. In this implementation, the bottom sleeve can have a symmetrical configuration, with a pair of guiding pins282engaging respective elongated slots on either side of the bottom sleeve, although other configurations are possible (e.g., a single guiding pin, three or more guiding pins, asymmetrical configuration, etc.).

Still referring toFIGS.39,41,43and45, the guiding track280includes first slots286having a first length, and second slots288having a second length. The first length can be greater than the second length such that engaging the guiding pins within the first slots to contact the downhole end thereof can position the bottom sleeve in the closed position (e.g., in the upholemost position of the bottom sleeve), as seen inFIGS.41and41A. It is thus noted that engaging the guiding pins within the second slots, as seen inFIGS.45and45A, can position the bottom sleeve in the screened position, where the screen is aligned with the housing port, as seen inFIGS.44and44A. In this implementation, the first and second slots alternate each other around the bottom sleeve. However, it is appreciated that other configurations are possible.

In this implementation, the angled surfaces290include a first set of angled surfaces290aadapted to rotate the bottom sleeve when moving in the downhole direction, and a second set of angled surfaces290badapted to rotate the bottom sleeve when moving in the uphole direction. The first and second sets of angled surfaces extend in generally opposite directions such that moving the bottom sleeve back and forth (e.g., alternating downhole and uphole movements) rotates the bottom sleeve within the central passage in the same direction. As seen inFIGS.43and43A, moving the bottom sleeve downhole causes the angled surfaces of the first set290ato engage the guiding pins until the pin is positioned in a corner of the guiding track. The bottom sleeve is thus rotated to position the guiding pin between an adjacent pair of elongated slots (seen inFIG.43). Then, the bottom sleeve can be shifted uphole, thereby engaging the angled surfaces of the second set with the guiding pins, which further rotates the bottom sleeve to align the guiding pins with an elongated slot (seen inFIG.45).

Now referring toFIGS.46to48A, another implementation of the valve assembly is illustrated. In this implementation, the valve assembly100includes a dual-sleeve assembly (e.g., a bottom sleeve122and a top sleeve124) and further includes the flow-controlling sleeve250coupled to the top sleeve124. The flow-controlling sleeve250includes the screen154, which is installed between the top sleeve124and the outer wall103of the housing. It is thus noted that the screen154is at least partially mounted within the annular region130, such as within the annular chamber132for protection thereof. The annular chamber can be in fluid communication with the central passage via interstices135defined between the top sleeve and the housing. The interstices are adapted to establish fluid communication between the central passage and the annular region130such that wellbore fluid within the central passage can flow within the annular region. Alternatively, the top sleeve can include vents configured to allow an ingress of fluid within the annular chamber. As previously described, this initial ingress of fluid can pressurize the annular chamber132and prevent subsequent fluids or material (e.g., cement) from flowing into the chamber.

InFIGS.46and46A, the valve assembly100is operated in the closed configuration, where the bottom sleeve122occludes the housing port112to prevent fluid communication between the central passage106and the reservoir. In a similar fashion to previously described implementations, the bottom sleeve can be shifted (e.g., in the downhole direction) to an open position (seen inFIG.47) and enable operation of the valve assembly in the open configuration. Then, the top sleeve can be shifted downhole to operate the valve assembly in the screened configuration, where the screen154is aligned with the housing port112for enabling a screened production of reservoir fluids.

Similar to the implementation ofFIG.6A, the top sleeve124can be shaped and configured to sealingly engage the housing102at the downhole end thereof. As such, fluid flowing through the housing port112is substantially confined to flow through the annular chamber132and past the uphole end of the top sleeve124to reach the central passage106. In this implementation, the flow control device further includes an ICD300(inflow control device) coupled about the top sleeve proximate the uphole end thereof. The ICD300can include a ring302disposed between the top sleeve and the housing and configured to restrict fluid flow therethrough. For example, the ring302can include a plurality of axial passages304extending therethrough. The top sleeve can be releasably connected to the housing via a latching mechanism (e.g., a collet305) configured to engage annular grooves defined in the housing. In some implementations, the top sleeve further includes a collet shroud310installed in the annular region and configured to at least partially protect the collet305as production fluid flows along the annular chamber, for example.

The implementation of the valve assembly illustrated inFIGS.49to51Ais similar to the implementation ofFIGS.46to48Adescribed above. From the closed configuration (FIGS.49and49A), the bottom sleeve124is shifted downhole to operate the valve assembly in the open configuration (FIGS.50and50A). Then, the top sleeve can be shifted downhole to align the screen154, which is installed in the annular chamber, with the housing port112. In this implementation, the uphole end of the top sleeve sealingly engages the tubular wall103such that production fluids are urged through the housing port112, through the screen154, along the annular chamber132and through the vents252to flow into the central passage106. An ICD300can be installed along the annular region130, such as within the annular chamber, such as between the screen154and the vents252, for example.

With reference toFIGS.52to55A, another implementation of the valve assembly100is shown. In this implementation, the screen154is coupled to the top sleeve124and installed within the annular chamber132.FIGS.52and52Aillustrate the valve assembly in the closed configuration. From there, the bottom sleeve122can be shifted downhole to open the housing port112, thereby operating the valve assembly in the open configuration, as seen inFIGS.53and53A. Then, the top sleeve can be shifted downhole to align the screen154with the housing port112(FIGS.54and54A), and subsequently shifted back uphole, leaving the screen154in alignment with the housing port to operate the valve assembly in the screened configuration (FIGS.55and55A). It is noted that, in this implementation, the screen154includes a plurality of radial openings. However, the screen can be provided with longitudinal slots (as described in relation with previous implementations), a combination of radial openings and longitudinal slots, or any other suitable configuration(s).

In this implementation, the top sleeve124includes a top sleeve latch320(e.g., a top sleeve collet) configured to releasingly engage the tubular wall103at predetermined locations. As such, the top sleeve can be coupled to the tubular wall in the run-in position (FIGS.52,53and55) and in the shifted position (FIG.54). In addition, the screen154can be provided with a screen latch325(e.g., a screen collet) configured to releasingly engage the tubular wall103at predetermined locations. As such, the screen can be coupled to the tubular wall in the run-in position (FIGS.52and53), and in an aligned position (FIGS.54and55). The top sleeve can include a shoulder adapted to engage and push the screen when moving downhole. Therefore, shifting the top sleeve from the run-in position to the shifted position simultaneously moves the screen from the run-in position to the aligned position. However, the top sleeve is adapted to disengage the screen when moving uphole such that the top sleeve can be shifted back to the run-in position while leaving the screen in the aligned position.

With reference toFIGS.56to60, another implementation of the valve assembly100is shown. In this implementation, the screen154is coupled to the top sleeve124and installed within the annular chamber132.FIGS.56and56Aillustrate the valve assembly in the closed configuration. From there, the bottom sleeve122can be shifted downhole to open the housing port112, thereby operating the valve assembly in the open configuration, as seen inFIGS.57and57A. Then, the top sleeve can be shifted downhole to align the screen154with the housing port112(FIGS.58and58A) to operate the valve assembly in the flow-restricted configuration, and subsequently shifted back uphole, leaving the screen154in alignment with the housing port to operate the valve assembly in the screened configuration (FIGS.59and59A). It should be noted that, in the flow-restricted configuration, production fluids are constrained or limited to flowing along the annular region prior to flowing into the central passage, whereas in the screened configuration, production fluids can flow from the reservoir to the central passage almost directly.

In this implementation, the top sleeve124includes a top sleeve latch320(e.g., a top sleeve collet) configured to releasingly engage the tubular wall103at predetermined locations. As such, the top sleeve can be coupled to the tubular wall in the run-in position (FIGS.56,57and59) and in the shifted position (FIG.58). In addition, the screen154can be provided with a screen latch325(e.g., a screen collet) configured to releasingly engage the tubular wall103at predetermined locations. As such, the screen can be coupled to the tubular wall in the run-in position (FIGS.56and57), and in an aligned position (FIGS.58and59). The top sleeve can include a shoulder adapted to engage and push the screen when moving downhole. Therefore, shifting the top sleeve from the run-in position to the shifted position simultaneously moves the screen from the run-on position to the aligned position. However, the top sleeve is adapted to disengage the screen when moving uphole such that the top sleeve can be shifted back to the run-in position while leaving the screen in the aligned position.

Moreover, the valve assembly100can include a flow regulator350provided along the annular region130adapted to at least partially control the fluid flowrate through the annular region when operating the valve assembly in the flow-restricted configuration. As seen inFIG.60, the flow regulator350can be defined along the outer surface of the top sleeve and can include a plurality of grooves352cooperating with one another to restrict fluid flow through the regulator. In this implementation, the flow regulator350forms part of the top sleeve (e.g., the grooves are machined into a thickness of the top sleeve) and sealingly engages the inner surface of the valve housing. As such, the tubular wall of the housing overlays the grooves, restricting fluid flow along the various groove configurations. In this implementation, the grooves352include a combination of axial grooves and arcuate grooves adapted to regulate and/or restrict fluid flow from one side of the flow regulator to the other.

Now referring toFIGS.61to64A, this implementation of the valve assembly100operates in a similar or corresponding manner as the implementation ofFIGS.56to60. More particularly, the valve assembly is operable in a closed configuration (FIG.61), an open configuration (FIG.62), a flow-restricted configuration (FIG.63) and a screened configuration (FIG.64). However, instead of the flow regulator350, the top sleeve is provided with a check valve360installed within the annular region proximate a top end of the top sleeve for controlling the fluid flow along the annular region.

It is appreciated that the implementations ofFIGS.27to64Aprovides various implementations of a valve assembly which includes a flow control device which can be isolated within an annular region and/or an annular chamber that can be pressurized to prevent cement from damaging the flow-controlling sleeve and its components (e.g., the flow control device, the latching mechanism165, etc.). The annular region and the annular chamber can be pressurized via fluid flowing therein via interstices135defined between two or more components of the valve assembly, or via vents252defined through the top sleeve, for example. Moreover, the flow control device of various implementations enables reservoir fluid to flow from the reservoir into the central passage. It is appreciated that the production flowpath does not necessarily include an annular flow area, which can reduce the overall production flowrates (e.g., when compared to the production flowrates through the volume of the central passage106). Moreover, the described implementations can be configured to enable selectively switching between the various operational configurations. In other words, and for example, the valve assembly can be actuated between the open, closed and/or screened configurations, among others, as desired, and as described above.

It should also be noted that the implementations ofFIGS.27to64Acan be run downhole (e.g., installed within the wellbore) with the sleeve assembly (e.g., the top and bottom sleeves) in a run-in position. The sleeves can be releasably secured to the valve housing in order to prevent accidental or undesired movement of the sleeves prior to the valve assemblies being in the desired location and/or configuration along the wellbore. For example, the sleeves can be pinned to the valve housing using shear pins, or via any other suitable fastening method or component which can be subsequently disengaged, disconnected, broken, etc.

It should be appreciated from the present disclosure that the various implementations of the valve assembly and related components enable providing a cementable valve assembly with a dead-ended chamber for housing a flow control device. The valve assembly can be cemented down the wellbore along with the wellbore string it is integrated with, where fluid communication with the dead-ended chamber is not blocked, but restricted, such that fluid within the wellbore (e.g., water, brine, drilling mud, etc.) can flow therein and pressurize the dead-ended chamber. Therefore, subsequent fluids or materials being pumped down the wellbore string (e.g., cementitious material) are prevented from entering the chamber. Once cemented in place, the valve assembly can be operated in various operational configurations, including a flow-restricted configuration, where the dead-ended chamber is integrated as part of the fluid pathway for production fluid, and where the flow control device is open to fluid flow from the reservoir to control the production fluid flow. It is appreciated that the flow control device comes “pre-packaged” with the valve assembly (e.g., within the annular region), and is thus not required to be run downhole as part of a separate tubing string to enable control of a flow of production fluid.

It should also be noted that, as previously mentioned, the annular chamber is initially pressurized via an ingress of wellbore fluids prior to cementing the wellbore string. The fluid which initially flows into the annular chamber can be residual fluid from drilling out the wellbore (e.g., brine, water, drilling mud, etc.). Therefore, it should be understood that, if the well is generally dry, an initial amount of fluid can be pumped downhole to pressurize the chamber (or be used as redundancy to make sure that the chamber is pressurized) before pumping cement downhole to secure the wellbore string. In some implementations, the annular region of the valve assembly can additionally be prepacked with fluid or a slurry material, such as grease, prior to running the valve assembly downhole. Having a prepacked annular region can help deter additional fluids from flowing therein. However, the annular region remains in fluid communication with the central passage such that initial wellbore fluid are still allowed to flow therein and pressurize the chamber, if need be, to prevent an inflow of cement into the annular region.

The present disclosure may be embodied in other specific forms without departing from the subject matter of the claims. The described example implementations are to be considered in all respects as being only illustrative and not restrictive. For example, in the implementations described herein, the flow control device includes both the check valve and the screen. However, it is appreciated that an implementation of the valve assembly can include only the screen or only the check valve. In implementations including only the screen, it is appreciated that defining an annular flowpath is not required since the screened production fluid can be made to flow directly into the central passage of the valve assembly.

In addition, in the above-described implementations, the annular region and annular chamber were defined about substantially the entire circumference of the top sleeve (e.g., 360 degrees around the top sleeve). However, it should be understood that the annular region and corresponding annular chamber can be defined as one or more independent section dispersed around the top sleeve. In such implementations, the annular sections can extend by any suitable angle around the top sleeve, such as about 20, 30, 45, 60, 90 or 180 degrees, for example. The annular region can alternatively be defined as multiple flow channels, similar to the through channels of the ring portion, where individual channels are defined along generally the entire length of the top sleeve, with each channel being provided with its own flow control device.

Referring toFIG.65, in some implementations, the flow control device can alternatively, or additionally, include a flow restriction component260that can take the form of a fluid channel262that can be a tortuous path that winds (e.g., boustrophedonically) across a portion of the top sleeve (e.g., defined in an outer surface of the ring portion). Shifting the top sleeve can align the fluid channel with the housing port for enabling fluid communication therewith. Once the sleeve is mounted within a valve housing, the fluid channel262is alignable with the housing port. This sleeve facilitates providing variable flow restriction for different valves using the same component designs. It may be desirable to provide different valves along a well with different levels of flow restriction. In some implementations, a flow control device, such as a check valve device could be incorporated into the fluid channels.

The present disclosure intends to cover and embrace all suitable changes in technology. The scope of the present disclosure is, therefore, described by the appended claims rather than by the foregoing description. The scope of the claims should not be limited by the implementations set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole. Furthermore, in the present disclosure, an implementation is an example or embodiment of the valve assembly and surrounding components. The various appearances of “one implementation,” “an implementation” or “some implementations” do not necessarily all refer to the same implementations. Although various features may be described in the context of a single implementation, the features may also be provided separately or in any suitable combination. Conversely, although the valve assembly may be described herein in the context of separate implementations for clarity, it may also be implemented in a single implementation. Reference in the specification to “some implementations”, “an implementation”, “one implementation”, or “other implementations”, means that a particular feature, structure, or characteristic described in connection with the implementations is included in at least some implementations, but not necessarily in all implementations.

As used herein, the terms “coupled”, “coupling”, “attached”, “connected” or variants thereof as used herein can have several different meanings depending in the context in which these terms are used. For example, the terms coupled, coupling, connected or attached can have a mechanical connotation. For example, as used herein, the terms coupled, coupling or attached can indicate that two elements or devices are directly connected to one another or connected to one another through one or more intermediate elements or devices via a mechanical element depending on the particular context.

In the above description, the same numerical references refer to similar elements. Furthermore, for the sake of simplicity and clarity, namely so as to not unduly burden the figures with several references numbers, not all figures contain references to all the components and features, and references to some components and features may be found in only one figure, and components and features of the present disclosure which are illustrated in other figures can be easily inferred therefrom. The implementations, geometrical configurations, materials mentioned and/or dimensions shown in the figures are optional, and are given for exemplification purposes only.

In addition, although the optional configurations as illustrated in the accompanying drawings comprises various components and although the optional configurations of the valve assembly as shown may consist of certain geometrical configurations as explained and illustrated herein, not all of these components and geometries are essential and thus should not be taken in their restrictive sense, i.e. should not be taken as to limit the scope of the present disclosure. It is to be understood that other suitable components and cooperations thereinbetween, as well as other suitable geometrical configurations may be used for the implementation and use of the valve assembly, and corresponding parts, as briefly explained and as can be easily inferred herefrom, without departing from the scope of the disclosure.