Valve having a modular activation system

A valve includes a body having a wall including an outer surface, an inner surface defining a passage, an opening extending from the passage through the outer surface. The outer surface includes a recess. A valve sleeve is arranged in the passage and is selectively positioned over the opening. A valve actuator module is detachably mounted in the recess. The valve actuator module includes a housing having an inlet fluidically exposed to the passage, an outlet fluidically exposed to the valve sleeve, and a valve member arranged between the inlet and the outlet. The valve member includes an actuator delay mechanism.

BACKGROUND

In the resource recovery industry valves are ubiquitous. Valves control fluid flow from a tubular into a formation and from the formation into the tubular. Valves also control fluid pressure acting on various downhole tools. Often times, the valves employ sleeves that are shifted to expose and/or cover ports. The sleeves may be shifted hydraulically, electrically, and/or mechanically. A toe sleeve is a valve that selectively opens at a toe of a well bore to allow fluid communication to an annulus. Often times, the toe sleeve is opened to perform a pressure check prior to fracturing operations.

A toe sleeve relies on an entire cross-section to house components that promote pressure cycling and timed delay mechanisms. The pressure cycling and time delay mechanisms includes large springs, snap rings, and other precision made components that detract from an overall flow area of the toe sleeve. Local conditional may necessitate a need to adjust/replace springs and other components. The limited flow and the time and expertise needed to manufacture the precision components as well as the need to adjust internal parts to meet local conditions add to an overall manufacturing and usage cost of the toe sleeve.

SUMMARY

Disclosed is a valve including a body having a wall including an outer surface, an inner surface defining a passage, an opening extending from the passage through the outer surface. The outer surface includes a recess. A valve sleeve is arranged in the passage and is selectively positioned over the opening. A valve actuator module is detachably mounted in the recess. The valve actuator module includes a housing having an inlet fluidically exposed to the passage, an outlet fluidically exposed to the valve sleeve, and a valve member arranged between the inlet and the outlet. The valve member includes an actuator delay mechanism.

Also disclosed is a resource exploration and recovery system including a surface system, and a subsurface system including a well bore extending into a formation. The well bore has a toe. A tubular string extends from the surface system into the well bore toward the toe. The tubular string supports a valve including a body including a wall having an outer surface, an inner surface defining a passage, and an opening extending from the passage through the outer surface. The outer surface includes a recess. A valve sleeve is arranged in the passage and is selectively positioned over the opening. A valve actuator module is detachably mounted in the recess. The valve actuator module includes a housing having an inlet fluidically exposed to the passage, an outlet fluidically exposed to the valve sleeve, and a valve member arranged between the inlet and the outlet. The valve member includes an actuator delay mechanism.

Further disclosed is a method of selectively shifting a valve sleeve including detachably mounting a valve actuator module to a tubular, applying a fluid force through the tubular into an inlet of the valve actuator, shifting a valve member arranged in a valve chamber of the valve actuator allowing the fluid to pass from the inlet to an outlet of the valve module, applying the fluid pressure from the outlet to a sleeve in the tubular, and shifting the sleeve with the fluid pressure.

DETAILED DESCRIPTION

A resource exploration and recovery system, in accordance with an exemplary embodiment, is indicated generally at10, inFIG.1. Resource exploration and recovery system10should be understood to support well drilling operations, completions, resource extraction and recovery, CO2sequestration, and/or the like. Resource exploration and recovery system10may include a first system12which, in some environments, may take the form of a surface system14operatively and fluidically connected to a second system18which, in some environments, may take the form of a subsurface or downhole system (not separately labeled).

Surface system14may include a control system23that may provide power to, monitor, communicate with, and/or activate one or more downhole operations as will be discussed herein. Surface system16may also include additional systems such as pumps, fluid storage systems, cranes, and the like (not shown). Second system18may include a casing tubular30that extends into a wellbore34formed in a formation36. Casing tubular30defines an inner surface38of wellbore34. A tubular string44, that may be formed from one or more tubulars, extends from surface system14toward a toe48of wellbore34.

In a non-limiting example, tubular string44supports a valve58that may take the form of a toe sleeve60. However, as will become more fully evident herein, valve58may be employed in a variety of locations and configurations. For example, valve58may be arranged within casing tubular30or in an open hole portion (not separately labeled) of wellbore34. Referring toFIG.2, valve58includes a tubular66having a body68that extends along a longitudinal axis “A”. Body68includes an outer surface70and an inner surface72that defines a passage74. An opening80extends through body68and selectively fluidically connects passage74with an area defined outwardly of outer surface70such as an annulus (not separately labeled) of wellbore34.

Body68also includes a recess83formed in outer surface70and an activation passage86that extends from recess83through body68along axis “A”. Activation passage86includes a first end portion (not separately labeled) and a second end portion (also not separately labeled). Inner surface72includes a shoulder92that is defined by a reduced diameter portion (also not separately labeled) of passage74. A valve sleeve98is arranged in passage74. Valve sleeve98is selectively shiftable along inner surface72as will be detailed herein.

Valve sleeve98includes a first end portion103, a second end portion105, and an intermediate portion (not separately labeled) having a shoulder portion108. Shoulder portion108selectively engages with shoulder92when valve sleeve98shifts to expose opening80. Valve sleeve98includes an annular recess113at first end portion103. Annular recess113forms a skirt (not separately labeled) that is received in a recess portion (also not separately labeled) formed in body68. Activation passage86terminates at the recess portion to deliver an activation fluid to first end103of valve sleeve98. Valve sleeve98is detachably fixed in passage74by a plurality of frangible dogs, one of which is indicated at118. A plurality of seals, one of which is indicated at122is arranged about valve sleeve98and seal against inner surface72.

In accordance with a non-limiting example, a valve actuator module130that delivers an actuation force to valve sleeve98. In the non-limiting example shown and described herein, valve actuator module130operates on fluid, but it should be appreciated that other operation principles may also be applied. Valve actuator module130is arranged in recess83over an inlet passage132. In the non-limiting example shown, inlet passage132may include a frangible disc135that establishes a pressure barrier between passage74and valve actuator module130until a predetermined pressure threshold is met.

In a non-limiting example depicted inFIGS.3and4, valve actuator module130includes a housing140having an inlet142that registers with inlet passage132and an outlet144that registers with activation passage86. A valve chamber146is disposed between inlet142and outlet144. A first access member148is mounted to a first end (not separately labeled) of housing140and a second access member150is mounted to a second, opposing end (also not separately labeled) of housing140. Valve chamber146includes a first end152that is accessible through first access member148and a second end154that is accessible through second access member150.

In a non-limiting example, a valve member160is arranged in valve chamber146. Valve member160is shiftable between first end152and second end154through an actuator delay mechanism165. In a non-limiting example, actuator delay mechanism165takes the form of a J-track member168fixed in valve chamber146. Valve member160supports a pin170that transition into and out of a number of slots (not separately labeled) formed in J-track member168. The number of slots may vary and could depend on the number of activation pulses desired before exposing opening80.

Valve member160includes a seal element174that engages with an inner surface of valve chamber146. A spring179is disposed between seal element174and second access member150. An orifice184is mounted at first end152of valve chamber146. Orifice184may be installed through first access member148. Orifice184supports an O-ring (not separately labeled) or, in the absence of the frangible disc, may be chosen to provide a selected application pressure on valve member160. In a non-limiting example, fluid may be passed through passage74. The fluid may travel through inlet passage132and into valve actuator module130via frangible disc135.

The fluid enters into first end152of valve chamber146and acts on valve member160. Valve member160travels toward second end154compressing spring179. As valve member160travels in valve chamber146, pin170transitions in J-track member168. Pressure may then be alleviated thereby allowing spring179to bias valve member160back towards first end152. Each application of pressure causes pin170to travel in J-track member168.

After a select number of pressure applications, pin170passes through an open track allowing seal element174to fully transition to second end154thereby exposing outlet144to fluid pressure. At this point, fluid pressure may be increased or simply applied to valve sleeve98via activation passage86. Valve sleeve98shifts within passage74until shoulder portion108abuts shoulder92. At this point, opening80may be exposed to wellbore34. Fluid may pass through opening80to perform a pressure check on wellbore34prior to initiating, for example, a fracking operation.

Embodiment 1. A valve comprising: a body including a wall having an outer surface, an inner surface defining a passage, an opening extending from the passage through the outer surface, the outer surface including a recess; a valve sleeve arranged in the passage and selectively positioned over the opening; and a valve actuator module detachably mounted in the recess, the valve actuator module including a housing having an inlet fluidically exposed to the passage, an outlet fluidically exposed to the valve sleeve, and a valve member arranged between the inlet and the outlet, the valve member including an actuator delay mechanism.

Embodiment 2. The valve according to any prior embodiment, wherein the body includes an inlet portion, an outlet portion, and an activation passage extending therebetween, the inlet portion being exposed to the inlet and the outlet portion being exposed to the valve actuator.

Embodiment 3. The valve according to any prior embodiment, wherein the actuator delay mechanism includes a J-track member operable to shift the valve member past the outlet following a predetermined number of pressure cycles.

Embodiment 4. The valve according to any prior embodiment, wherein the housing includes a valve chamber having a first end exposed to the inlet, a second end, the outlet being spaced from the second end.

Embodiment 5. The valve according to any prior embodiment, wherein the valve member includes a seal element that engages internal surfaces of the valve chamber.

Embodiment 6. The valve according to any prior embodiment, further comprising: a spring arranged between the second end and the seal element.

Embodiment 7. The valve according to any prior embodiment, further comprising: a first access member mounted to the housing at the first end of the valve chamber and a second access member mounted to the housing at the second end of the valve chamber, each of the first access member and the second access member providing access to the valve chamber.

Embodiment 8. The valve according to any prior embodiment, further comprising: a selectively removable orifice member arranged between the inlet and the valve member, the selectively removable orifice creating a pressure barrier between the inlet and the valve chamber.

Embodiment 9. The valve according to any prior embodiment, wherein the valve defines a toe sleeve.

Embodiment 10. A resource exploration and recovery system comprising: a surface system; a subsurface system including a well bore extending into a formation, the well bore having a toe; a tubular string extending from the surface system into the well bore toward the toe, the tubular string supporting a valve comprising: a body including a wall having an outer surface, an inner surface defining a passage, an opening extending from the passage through the outer surface the outer surface including a recess; a valve sleeve arranged in the passage and selectively positioned over the opening; and a valve actuator module detachably mounted in the recess, the valve actuator module including a housing having an inlet fluidically exposed to the passage, an outlet fluidically exposed to the valve sleeve, and a valve member arranged between the inlet and the outlet, the valve member including an actuator delay mechanism.

Embodiment 11. The resource exploration and recovery system according to any prior embodiment, wherein the body includes an inlet portion, an outlet portion, and an activation passage extending therebetween, the inlet portion being exposed to the inlet and the outlet portion being exposed to the valve actuator.

Embodiment 12. The resource exploration and recovery system according to any prior embodiment, wherein the actuator delay mechanism includes a J-track member operable to shift the valve member past the valve outlet following a predetermined number of pressure cycles.

Embodiment 13. The resource exploration and recovery system according to any prior embodiment, wherein the housing includes a valve chamber having a first end exposed to the inlet, a second end, the outlet being spaced from the second end.

Embodiment 14. The resource exploration and recovery system according to any prior embodiment, wherein the valve member includes a seal element that engages internal surfaces of the valve chamber.

Embodiment 15. The resource exploration and recovery system according to any prior embodiment, further comprising: a spring arranged between the second end and the seal element.

Embodiment 16. The resource exploration and recovery system according to any prior embodiment, further comprising: a first access member mounted to the body at the first end of the valve chamber and a second access member mounted to the body at the second end of the valve chamber, each of the first and second access members providing access to the valve chamber.

Embodiment 17. The resource exploration and recovery system according to any prior embodiment, further comprising: a selectively removable orifice member arranged between the inlet and the valve member, the selectively removable orifice creating a pressure barrier between the inlet and the valve chamber.

Embodiment 18. The resource exploration and recovery system according to any prior embodiment, wherein the valve defines a toe sleeve.

Embodiment 19. A method of selectively shifting a valve sleeve comprising: detachably mounting a valve actuator module to a tubular; applying a fluid force through the tubular into an inlet of the valve actuator; shifting a valve member arranged in a valve chamber of the valve actuator allowing the fluid to pass from the inlet to an outlet of the valve module; applying the fluid pressure from the outlet to a sleeve in the tubular; and shifting the sleeve with the fluid pressure.

Embodiment 20. The method according to any prior embodiment, wherein detachably mounting the valve actuator includes bolting an actuator housing to an outer surface of the tubular.

Embodiment 21. The method according to any prior embodiment, wherein applying fluid pressure to the inlet includes directing fluid pressure onto a valve member arranged in a valve chamber.

Embodiment 22. The method according to any prior embodiment, wherein directing fluid pressure onto the valve member compresses a spring in the valve chamber.

Embodiment 23. The method according to any prior embodiment, wherein shifting the valve member includes applying pressure cycles to the valve actuator.

Embodiment 24. The method according to any prior embodiment, wherein applying pressure cycles includes shifting a pin through a J-slot member arranged in the valve chamber.

Embodiment 25. The method according to any prior embodiment, further comprising: opening an access member exposing the valve chamber to install a selected spring into the valve actuator module to establish a selected operating pressure for the valve actuator module.

Embodiment 26. The method according to any prior embodiment, opening another access member exposing another end of the valve chamber to install an orifice member that may create a pressure barrier between the inlet and seal element.