Patent Publication Number: US-2022228463-A1

Title: Removable nozzle for a downhole valve

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application No. 63/139,631, filed Jan. 20, 2021, which is incorporated by reference herein in its entirety. 
    
    
     BACKGROUND 
     In the resource recovery industry, a valve tool can be disposed within a wellbore to either introduce a fluid into the wellbore or produce a fluid from the wellbore. The valve tool often has a method of varying the size of opening(s) which allow communication between the tubing and annulus. Between the time the tool is designed and installed, it may be desired to change the size opening(s), and thus the amount of flow between the tubing and annulus. Conventionally, this requires disassembly of the valve tool itself and redesigning and manufacturing new components, which is costly and inefficient. There is therefore a need to be able to change valve tool specifications without requiring disassembly of the valve tool and manufacturing of new components. 
     SUMMARY 
     In one aspect, disclosed herein is a method of manufacturing a valve of a tool for use downhole. The method includes applying a load to a first nozzle secured in a housing of the valve via a first release member, wherein a magnitude of the load is greater than a release threshold of the first release member, to release the first release member, and removing the first nozzle from the housing. 
     In another aspect, disclosed herein is a method of changing a flow characteristic of a valve for use downhole. The method includes applying a load to a first nozzle secured in a housing of the valve via a first release member, wherein a magnitude of the load is greater than a release threshold of the first release member, to release the first release member, removing the first nozzle from the housing, and securing a second nozzle in the housing via a second release member. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike: 
         FIG. 1  shows a tool for use in a wellbore in an illustrative embodiment; 
         FIG. 2  shows a perspective view of a nozzle assembly; 
         FIGS. 3A-3C  shows a top view of a release member of the nozzle assembly in various embodiments; 
         FIG. 4  shows a side cross-sectional view of the nozzle assembly with the nozzle installed in the orifice; 
         FIG. 5  illustrates an action for removing the nozzle from the orifice; and 
         FIG. 6  illustrates steps for manufacturing a valve of a downhole tool using the nozzle and nozzle assembly disclosed herein. 
     
    
    
     DETAILED DESCRIPTION 
     A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures. 
     Referring to  FIG. 1 , a tool  100  for use downhole in a wellbore is disclosed. In various embodiments, the tool  100  can be used for drilling, production, completion, etc. The tool  100  can be a tubular member having a longitudinal axis  110 . In the illustrative embodiment, the tool  100  includes a valve device  102  having a housing  104  and a plurality of nozzle assemblies  106  formed within the housing  104 . The housing  104  extends along the longitudinal axis  110  of the tool  100 . The plurality of nozzle assemblies  106  allow for flow of fluid through the housing  104  either from an exterior of the tool  100  to an interior of the tool  100  or from the interior to the exterior, depending on the use of the tool  100 . 
       FIG. 2  shows a perspective view  200  of a nozzle assembly  106 . The nozzle assembly  106  includes a cavity, hole or orifice  202  formed in the housing  104  and a nozzle  204  that is insertable into the orifice  202 . The housing  104  generally forms a cylindrical shell or opening. The orifice  202  and nozzle  204  are aligned along a nozzle assembly axis  205  that can be aligned along a radial line of the housing (i.e., a line perpendicular to longitudinal axis  110  of the housing  104 ). The orifice  202  forms a passage extending from an inner diameter of the cylindrical shell of the housing  104  to an outer diameter of the cylindrical shell, the passage allowing flow of fluid between an interior bore of the housing  104  and an exterior of the housing. In various embodiments the orifice  202  has an inner wall  206  centered on the nozzle assembly axis  205  and the nozzle  204  is a cylindrical body having an outer surface  208  forming a cylindrical surface of the nozzle  204 . The outer surface  208  conforms to the shape of the inner wall  206 . In other words, an outer diameter of the outer surface  208  is equal to or substantially equal to an inner diameter of the inner wall  206 , to allow the nozzle  204  to fit snugly within the orifice  202 . 
     A housing groove  210  is formed at the inner wall  206  of the orifice  202 . The housing groove  210  extends circumferentially around the inner wall  206  and extends away from the nozzle assembly axis  205  into the housing  104 . The housing groove  210  is located at a selected distance radially inward from an outer diameter surface  215  of the housing  104  in order to protect the housing groove  210  and anything in the housing groove  210  from the downhole environment such as erosion due to fluid flowing through the nozzle  204 . The nozzle  204  includes a nozzle groove  212  formed circumferentially in the outer surface  208  of the nozzle  204 . The nozzle groove  212  extends radially inward from the outer surface  208 . The nozzle  204  is secured within the orifice  202  by a release member  214  that is disposed in both the housing groove  210  and the nozzle groove  212 . The location of the housing groove  210  in the housing  104  (i.e., away from the outer diameter surface  215 ) therefore protects the release member  214  from the downhole environment when the tool  100  is downhole. 
       FIGS. 3A-3C  shows a top view of the release member  214  in various embodiments.  FIG. 3A  shows an embodiment of the release member  214  with a retainer ring having a first portion (i.e., outer ring portion  302 ) and second portion (i.e., inner ring portion  304 ). The dimensions of the release member  214  are such that, when the release member  214  is in a radially relaxed state, the outer ring portion  302  resides in the housing groove  210  and the inner ring portion  304  resides in the nozzle groove  212 . The release member  214  forms a semi-ring (or a ring with a gap  306  at an azimuth location along its circumference). Both the outer ring portion  302  and the inner ring portion  304  are solid along the circumference except at the gap  306 . 
       FIG. 3B  shows an embodiment of the release member  214  including radially inward tabs. The release member  214  is a retainer ring including a first portion (i.e., outer ring portion  302 ) and a second portion (i.e., tabs  304 ) protruding radially inward from the outer ring portion  302 . The outer ring portion  302  forms a semi-ring (or a ring with a gap  306  at an azimuth location along its circumference). In an embodiment, the protrusions or tabs  304  are equally spaced about the inner surface of the outer ring portion  302 . While shown with four tabs  304  for illustrative purposes, the retainer ring can have any number of tabs protruding from the inner surface of the outer ring portion, in various embodiments. 
       FIG. 3C  shows an embodiment of the release member  214  including radially outward tabs. The release member  214  is a retainer ring including a first portion (i.e., tabs  310 ) and a second portion (i.e., inner ring portion  312 ), with the tabs  310  protruding radially outward from the inner ring portion  312 . The inner ring portion  312  forms a semi-ring (or a ring with a gap  306  at an azimuth location along its circumference). In an embodiment, the protrusions or tabs  310  are equally spaced about the outer surface of the inner ring portion  312 . While shown with four tabs  310  for illustrative purposes, the retainer ring  214  can have any number of tabs protruding from the outer surface of the inner ring portion  312 , in various embodiments. 
     In other embodiments, the release member can be a garter spring or an O-ring. In various embodiments, the release member is able to expand and contract radially in order to move radially within housing groove  210  and nozzle groove  212  when the nozzle is being inserted into the orifice  202 . 
     Referring back to  FIG. 2 , a method of securing the nozzle  204  within the orifice  202  using the release member  214  is now discussed. The method is discussed with respect to using the release member  214  of  FIG. 3B  for illustrative purposes only. The release members shown in  FIGS. 3A and 3C  can secure the nozzle  204  within the orifice  202  using the same or similar method. To secure the nozzle  204  within the orifice  202 , the release member  214  is placed within the housing groove  210  of the orifice  202 . The release member  214  is lowered into the orifice  202  in a slightly radially compressed state. The gap  306  can be reduced to allow the release member  214  to compress. When the release member  214  reaches the housing groove  210 , it expands into the housing  104  so that the outer ring portion  302  is within the housing groove  210  and the tabs  304  are outside the housing groove  210 , extending radially inward. The housing groove  210  has a depth that allows the release member  214  to expand radially outward. Once the release member  214  is in place within the housing groove  210 , the nozzle  204  is lowered into the orifice  202 . As the nozzle  204  is lowered into the orifice  202 , a tapered inlet end of the nozzle  204  pushes the tabs  304  radially outward to expand the release member  214  outward into the housing groove  210 . When the nozzle groove  212  becomes axially aligned with the housing groove  210 , the release member  214  contracts to a radially relaxed state in which the outer ring portion  302  is within the housing groove  210  and the tabs  304  are within the nozzle groove  212 , thereby securing the nozzle  204  in the orifice  202 . 
       FIG. 4  shows a side cross-sectional view  400  of the nozzle assembly with the nozzle  204  installed in the orifice  202 . The nozzle  204  is disposed in the orifice  202  such that the nozzle groove  212  and the housing groove  210  are aligned axially along axis  205 . The release member  214  is disposed with its outer ring portion  302  within the housing groove  210  and the tabs  304  extending into the nozzle groove  212 . The nozzle  204  includes a seal groove  402  axially located between an outlet end of the nozzle and the nozzle groove  212 . An O-ring  404  located in the seal groove  402  seals any gap between the nozzle  204  and inner wall  206 , thereby prevent a flow of fluid through the gap between outer surface  208  of the nozzle  204  and the inner wall  206  of the orifice  202 , thereby preventing erosion of the release member  214 . 
       FIG. 5  illustrates an action  500  for removing the nozzle  204  from the orifice  202 . A force or load  502  is applied to the nozzle  204  along the nozzle assembly axis  205 . The load  502  applies a shear force at the release member  214  by forcing the tabs  304  in one direction along the nozzle assembly axis  205  while the outer ring portion  302  is maintained at its location in the housing groove  210 . When a magnitude of the load  502  is above a release threshold of the release member  214 , the tabs  304  separate from the outer ring portion  302 , thereby freeing the nozzle  204  from the housing  104  and allowing the nozzle  204  to be removed from the housing  104 . 
       FIG. 6  illustrates steps  600 ,  610  and  612  for disassembling and reassembling a valve of a downhole tool using the nozzle and nozzle assembly disclosed herein. The illustrative valve includes a housing  104  with a plurality of nozzles  602 ,  604 ,  606  and  608  disposed therein, with each nozzle  602 ,  604 ,  606  and  608  having different values of flow characteristics. Some examples of flow characteristics are flow area, valve coefficient, orifice coefficient and nozzle shape. For illustrative purposes only, the flow characteristic is discussed as being a flow area. The nozzles  602 ,  604 ,  606  and  608  can be assembled in any selected order based on a current knowledge of a downhole environment in which the valve is to be used. When the knowledge of the downhole environment is updated or improves, a valve designer or user can select to change out one or more nozzles prior to disposing the valve downhole. The nozzle assembly disclosed herein allows for the user to interchange nozzles as more information about the downhole environment is received. The nozzles  602 ,  604 ,  606  and  608  can be changed out without disassembling the valve itself. 
     In a first step  600 , the housing  104  is shown with nozzles  602 ,  604 ,  606 ,  608  which are disposed within respective orifices. The nozzles are placed within their orifices using the release member and methods disclosed hereinabove. The nozzles  602 ,  604 ,  606  and  608  can have selected flow areas. For illustrative purposes, nozzle  602  has a 0.25 in 2  flow area, nozzle  604  has a 0.50 in 2  flow area, nozzle  606  has a 0.75 in 2  flow area and nozzle  608  has a 1.00 in 2  flow area. As new information comes in regarding the downhole environment, the valve designer can make changes in the nozzle arrangement. For example, the valve designer can decide that nozzle  606  should also have a 1.00 in 2  flow area, rather than a 0.75 in 2  flow area are original designed. In a second step  610 , the nozzle  606  is removed by applying a longitudinal force on the nozzle  606  that is greater than a release threshold of the release member, thereby releasing the release member by shearing the release member. The nozzle  606  is then allowed to easily slide out of its orifice. In a third step  612 , a new release member (such as shown in  FIGS. 3A-3C ) is placed within the orifice and a new nozzle (e.g., a nozzle  614  having a 1.00 in 2  flow area) is lowered into the orifice to be secured within the housing  104  using the new release member. 
     While the tool is discussed herein as securing a nozzle within an orifice using a release member to form a nozzle assembly, the release member can be used to secure any suitable device or member within the housing or within a tool. 
     Set forth below are some embodiments of the foregoing disclosure: 
     Embodiment 1: A method of manufacturing a valve of a tool for use downhole. The method includes applying a load to a first nozzle secured in a housing of the valve via a first release member, wherein a magnitude of the load is greater than a release threshold of the first release member, to release the first release member, and removing the first nozzle from the housing. 
     Embodiment 2: The method of any prior embodiment, wherein the first nozzle is disposed within an orifice of the housing, further comprising applying the load to the first nozzle along a longitudinal axis of the orifice. 
     Embodiment 3: The method of any prior embodiment, further comprising securing a second nozzle in the orifice. 
     Embodiment 4: The method of any prior embodiment, wherein a first value of a flow characteristic of the first nozzle is different than a second value of the flow characteristic of the second nozzle. 
     Embodiment 5: The method of any prior embodiment, wherein the flow characteristic is a flow area. 
     Embodiment 6: The method of any prior embodiment, wherein the first release member includes a retainer ring having an outer ring portion disposable within a housing groove of the housing and a tab disposable within a nozzle groove of the first nozzle, further comprising applying the load to the first nozzle to separate the tab from the outer ring portion. 
     Embodiment 7: The method of any prior embodiment, wherein the release member is configured to expand and contract radially. 
     Embodiment 8: The method of any prior embodiment, further comprising securing the second nozzle in the valve by placing a second release member in the housing groove and moving the second nozzle along the orifice to locate the nozzle groove alongside the housing groove to receive the second release member. 
     Embodiment 9: The method of any prior embodiment, wherein the release member is one of: (i) a garter spring; and (ii) an O-ring. 
     Embodiment 10: A method of changing a flow characteristic of a valve for use downhole. The method includes applying a load to a first nozzle secured in a housing of the valve via a first release member, wherein a magnitude of the load is greater than a release threshold of the first release member, to release the first release member, removing the first nozzle from the housing, and securing a second nozzle in the housing via a second release member. 
     Embodiment 11: The method of any prior embodiment, wherein the first nozzle is disposed within an orifice of the housing, further comprising applying the load along a longitudinal axis of the orifice. 
     Embodiment 12: The method of any prior embodiment, wherein the first nozzle has a first value of a flow characteristic and the second nozzle has a second value of the flow characteristic different than the first value of the flow characteristic of the first nozzle. 
     Embodiment 13: The method of any prior embodiment, wherein the flow characteristic is a flow area. 
     Embodiment 14: The method of any prior embodiment, wherein the first release member includes a retainer ring having an outer ring portion disposable within a housing groove of the housing and a tab disposable within a nozzle groove of the nozzle, further comprising applying the load to the first nozzle to break the tab from the outer ring portion. 
     Embodiment 15: The method of any prior embodiment, wherein the release member is configured to expand and contract radially. 
     Embodiment 16: The method of any prior embodiment, further comprising securing the second nozzle in the valve by placing the second release member in the housing groove and moving the second nozzle along the orifice to locate the nozzle groove alongside the housing groove to receive a tab of the second release member. 
     Embodiment 17: The method of any prior embodiment, wherein the release member is one of: (i) a garter spring; and (ii) an O-ring. 
     The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms “about”, “substantially” and “generally” are intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” and/or “substantially” and/or “generally” can include a range of ±8% or 5%, or 2% of a given value. 
     The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and/or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc. 
     While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited.