Autofill, circulation, and production valve for well completion systems

A valve for use in a wellbore includes a replaceable choke device that is threaded into at least one opening formed through a sidewall of a tubular housing of the valve. The choke device is sealable on the sidewall of the tubular housing with an elastomeric sealing component, and the choke device controls at least one of fluid pressure within the tubular string and a pressure drop across the valve. The valve also includes a flow sleeve carried by the tubular housing for movement relative thereto between a first position in which fluid flow s permitted across the valve, a second position in which the flow sleeve prevents fluid flow across the valve, and a third position in which the flow sleeve is locked in place relative to the tubular housing by a lock ring.

BACKGROUND

When a completion string is run in a well, it is generally advantageous to allow entry of fluid in the well into the tubular string as the tubular string is being lowered into the well. It is also generally advantageous to allow circulation capabilities across sidewalls of a tubular string when the tubular string is run in hole. Moreover, in order to ensure successful operations, it is generally considered good practice to pressure test the tubular string periodically as it is being run in the well. Finally, after the tubular string has been installed and pressure testing has concluded, or in other situations, it may be advantageous to prevent fluid flow through the tubular string wall. From the foregoing, there is a continuing need to provide improved apparatus and methods that realize the aforementioned functionalities.

SUMMARY

According to one or more embodiments of the present disclosure, a valve for use in a wellbore includes: a tubular housing have at least one opening formed through a sidewall thereof, the tubular hosing connectable with a tubular string via an upper sub and a lower sub; a replaceable choke device that is threaded into the at least one opening formed through the sidewall of the tubular housing, wherein the replaceable choke device controls at least one of fluid pressure within the tubular string, and a pressure drop across the valve; and a flow sleeve carried by the tubular housing for movement relative thereto between a first position in which fluid flow is permitted across the valve, a second position in which the flow sleeve prevents fluid flow across the valve, and a third position in which the flow sleeve is locked in place relative to the tubular housing by a lock ring.

In a method of operating a valve positioned in a wellbore along a tubular according to one or more embodiments of the present disclosure, the method includes: initiating fluid flow though the tubular string and to the valve adequate to shift a flow responsive sleeve of the valve from a first open position to a second closed position; with the valve in the second closed position, reducing or removing fluid flow through the tubular string and to the valve to shift the flow responsive sleeve from the second closed position to the first open position; and with the valve at the second closed position, increasing fluid pressure in the tubular string to shift the valve from the second closed position to a third closed position.

DETAILED DESCRIPTION

In the specification and appended claims: the terms “up” and “down,” “upper” and “lower,” “upwardly” and “downwardly,” “upstream” and “downstream,” “uphole” and “downhole,” “above” and “below,” “top” and “bottom,” and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly describe some embodiments of the disclosure.

One or more embodiments of the present disclosure relates generally relate to equipment utilized in conjunction with wellsite operations. More specifically, one or more embodiments of the present disclosure provide an apparatus for certain practical and important downhole functionalities for a tubular string, including: (1) automatically filling a tubular string as it is run in a well; (2) allowing steady circulation from tubular to annulus, or vice versa, as the tubular string is run in a well; (3) pressure testing the tubular string as it is run in a well; and (4) preventing fluid flow through the tubular sidewall at desired instances.

First, when a completion string is run in a well, it is generally advantageous for fluid in the well to enter the tubular string as the tubular string is being lowered into the well. In this manner, fluid pressure in the tubular string may be equalized. With that, in an annulus formed between the tubular string and the wellbore, subsequent operations that require fluid in the tubular string are made more convenient.

Second, it is also generally advantageous to allow circulation capabilities across sidewalls of the tubular string when the tubular string is run in hole. For example, when a formation is under loss, it is beneficial to be able to pump down tubing lost circulation material to maintain well stability. On the other hand, if objects (e.g., debris, balls, etc.) in the tubing string need to be circulated out of the well, it is beneficial to be able to pump down the annulus and circulate fluid out of the tubing string.

Third, in order to ensure successful operations, it is generally considered good practice to pressure test the tubular string periodically as the tubular string is being run in the well. However, if the tubular string is open-ended, or otherwise open to fluid communication with the annulus, (e.g., via an opening formed through a sidewall of the tubular string), it may be difficult or uneconomical to periodically close off the opening to perform the pressure test, and then reopen the tubular string so that the tubular string may continue to fill while it is lowered further in the well. Additionally, when other items of equipment are pressure tested, such as after setting a packer, it may be advantageous to permit fluid flow through the opening in the tubular string. Thus, it may be seen that the ability to open and close the opening in the tubular string at will to permit automatic filling of the tubular string, pressure testing of the tubular string, and pressure testing of other equipment in the well, is very beneficial in these operations.

Fourth, after the tubular string has been installed and pressure testing has concluded, or in other situations, it is sometimes advantageous to prevent fluid flow through the tubular string sidewall. For example, after a production tubing string has been installed, it may be desirable to close off any opening through the tubing string sidewall, except at particular locations. Thus, an apparatus that permits automatic filling of a tubular string should, in some cases, have the capability of preventing any fluid flow through a sidewall of the apparatus. As further described below, a valve and corresponding method according to one or more embodiments of the present disclosure integrates the four aforementioned functionalities to facilitate shifting of the valve into three positions by simply turning on/off tubular flow rates.

An apparatus according to one or more embodiments of the present disclosure controls fluid flow of a tubular string in a wellbore in response to a pressure drop in the apparatus. Referring now toFIG.1, a cross-sectional product layout of a valve100according to one or more embodiments of the present disclosure in an open position is shown. Further,FIGS.2,3and4show further detail of portions A, B, and C shown inFIG.1, respectively, according to one or more embodiments of the present disclosure. An auto-fill circulation valve100according to one or more embodiments of the present disclosure includes a set of choke devices12in a tubular housing9. The choke devices12can be configured in various quantities and choke hole sizes to produce either a steady flow across the tubular string, or a desired pressure drop in the valve100. The valve100body contains four sets of seals23,24,29,30and a flow sleeve10that change the valve states100between first (open), second (temporarily closed), and third (permanently closed) positions in response to a pressure drop in the valve100. A replaceable spring11in the valve100is designed to bias a certain piston effect force generated by the pressure drop in the valve100. A set of shear devices19,20is included in the lower section of the valve100, which activates and shifts the shear sleeve18in a downward direction when a desired flow-induced pressure drop is achieved in the valve100. After the shear sleeve18shifts and the flow sleeve10engages the lower seal units23, a lock ring6locks the valve100in the closed position, preventing any further fluid communication across the valve100. As shown inFIG.1, for example, the lock ring6may be a component of a lock ring housing7in one or more embodiments of the present disclosure. The lock ring housing7may be affixed to the upper sub1of the valve100, and the tubular housing9may be affixed to the lock ring housing7via at least one screw8or other type of fastener according to one or more embodiments of the present disclosure.

As previously mentioned, the valve100according to one or more embodiments of the present disclosure includes a set of choke device12in a tubular housing9. More specifically, the tubular housing9of the valve100includes at least one opening formed through a sidewall of the tubular housing9, and a replaceable choke device12is threaded into the at least one opening formed through the sidewall of the tubular housing9, as shown inFIGS.1and3. As shown inFIG.3, the replaceable choke device12may be sealable on the sidewall of the tubular housing9with an elastomeric sealing component32, for example. As further shown inFIG.1, the tubular housing9is connectable with a tubular string via an upper sub1and a lower sub22of the valve100. In one or more embodiments of the present disclosure, the replaceable choke device12controls at least one of fluid pressure within the tubular string, and a pressure drop across the valve100. Advantageously, the replaceable choke device12is a flow restriction device that may be replaced at different times or locations of service in one or more embodiments of the present disclosure.

Still referring toFIG.1, the valve100includes a flow sleeve10carried by the tubular housing9for movement relative to the tubular housing9between a first position (FIGS.1,5A) in which fluid flow is permitted across the valve, a second position (FIG.5B) in which the flow sleeve10prevents fluid flow across the valve100, and a third position (FIG.5C) in which the flow sleeve10is locked in place relative to the tubular housing9by a lock ring6. In this way, the valve100according to one or more embodiments of the present disclosure respectively opens, temporarily closes, or permanently closes bypass ports in response to flow-induced pressure in the valve100. In one or more embodiments of the present disclosure, the valve100is operable from a remote surface location. As further described below, the valve bypass ports may be repeatedly cycled from the first open position to the second temporarily closed position by selectively raising and lowering the fluid pressure, according to one or more embodiments of the present disclosure. As previously described, one or more of the replaceable choke devices12, which are sized to produce a desired flow-induced pressure drop across the valve100, may control the fluid pressure within the valve100.

As shown inFIGS.1-3, the flow sleeve10includes a first set of sealing units24,29in one or more embodiments of the present disclosure. The first set of sealing units24,29includes differential sealing units according to one or more embodiments of the present disclosure. In this way, the first set of sealing units24,29generates a piston effect force and pushes the flow sleeve10downward when a sufficient flow-induced pressure drop is achieved within the valve100. For example, the piston effect generated by the first set of sealing units24,29, shifts the flow sleeve10from the first position to the second position, and from the second position to the third position, according to one or more embodiments of the present disclosure. In one or more embodiments, the downward movement of the flow sleeve10allows the flow sleeve10to seal on a second set of sealing units29,30within a sealing carrier13of the valve100(FIGS.3,4), reaching the temporarily closed second position. The sealing carrier13provides sealing and prevents flow across the valve100when the valve100is in the second position (i.e., the temporary closed position). As shown inFIG.4, in addition to the second set of sealing units, the sealing carrier13may also include a back-up ring27, and o-rings15,31, for example. In one or more embodiments of the present disclosure, a retaining ring16, such as a c-type retaining ring, may be used to hold the position of the sealing carrier13when the valve100is in the second position. In this second position, communication between the tubular string and an annulus of the wellbore is isolated by sealing units24,29,30, allowing tubing pressure testing. In one or more embodiments of the present disclosure, one or both of the first and second sealing units24,29,30may be protected by at least one back-up ring28as shown inFIG.3, for example. Further, the sealing carrier13may be affixed to the valve100with a screw14or another type of fastener, as shown inFIG.4, for example.

In addition to the above, the flow sleeve10is capable of shifting from the second position back to the first position in one or more embodiments of the present disclosure. As shown inFIG.4, and as further described below, a set of replaceable shear devices19,20along a shear sleeve18limits the pressure that can be applied by preventing the flow sleeve10from moving from the second position to third position until shear device activation occurs. In one or more embodiments of the present disclosure, the valve100includes a biasing spring11, as shown inFIG.1. When tubular flow/pressure is removed from surface, the biasing spring11pushes the flow sleeve10upward, shifting the valve100from the second temporarily closed position (FIG.5B) back to the first open position (FIG.1,5A). In this way, the valve100and the associated method according to one or more embodiments of the present disclosure allows free, two-way movement of the flow sleeve10until shear device activation, which locks the valve100permanently closed in the third position when desired.

As previously described, a set of shear devices19,20along a shear sleeve18limits the pressure that can be applied by preventing the flow sleeve10from moving from the second position to third position until shear device activation occurs. That is, when a desired flow-induced pressure drop is achieved across the valve100, the set of shear devices19,20shears, causing shear device activation, which shifts the shear sleeve18. Stated another way, the set of shear devices19,20and the shear sleeve18prevent the flow sleeve10from moving from the second position to the third position until the shear device activation. Once the flow sleeve10moves from the second position to the third position after shear device activation, the lock ring6locks the valve100in the third position by expanding into a groove of the flow sleeve10. Using the set of shear devices19,20of the shear sleeve18in this way is beneficial insofar as the pressure required for a tubing pressure test does not affect the pressure drop required to change the valve state (i.e., position) of the valve100, thereby making higher tubing pressure tests possible.

As shown inFIGS.2and4, the valve100may also include at least one production seal stack23,24according to one or more embodiments of the present disclosure. For example, as shown inFIGS.1,2, and4, the production seal stack23,24may be protected by one or more of the upper sub1, the lower sub22, and one or more debris barrier rings25,26, with or without a seal bearing ring17, as the tubular string is run in the wellbore or is otherwise in service, according to one or more embodiments of the present disclosure. An upper seal cap2of the valve100may further protect the production seal stack23, as shown inFIGS.1and2, for example. In one or more embodiments of the present disclosure, one or both of the production seal stacks23,24may prevent flow across the valve100when the valve100is in the third permanently closed position. In this way, one or both of the production seal stacks23,24may be activated to provide sealing when the flow sleeve10seals on one or both of the production seal stacks23,24upon shear device activation (i.e., shifting of the shear sleeve18), as the flow sleeve10assumes the third permanently closed position. In one or more embodiments of the present disclosure, a retaining ring3, such as a c-type retaining ring4, may be used to hold the position of the of the production seal stacks23,24when the valve100is in the third position.