Patent Publication Number: US-11384614-B2

Title: Pressure balanced running tool

Description:
BACKGROUND 
     There are a variety of tools and components that are deployed downhole to facilitate production of hydrocarbons. Such components can include safety valves, inflow control valves, production screens and inflow control devices. In some cases, tools and components are deployed downhole using a running tool. For example, casing strings (e.g., liners) and completion strings can be deployed using coiled tubing in conjunction with a hydraulically activated running tool that is operated using borehole fluid pressure. 
     Some downhole operations, such as coiled tubing drilling operations, utilize high circulation pressures (e.g., greater than 5,000 psi). Running a liner or other component as part of such operations using a hydraulically activated running tool presents a risk of premature releasing of the liner, due to the high circulation pressures. Accordingly, it would be desirable to have a hydraulically activated running tool that can be effectively utilized at high circulating pressures. 
     SUMMARY 
     An embodiment of a running tool configured to deploy a downhole component includes a tool body having a fluid conduit, and an actuation assembly including an actuator member connected to a release mechanism, the actuator member moveable in an axial direction from a first position to a second position to cause the release mechanism to disengage with a downhole component. The actuation assembly includes a first pressure chamber in pressure communication with the fluid conduit, where the running tool is configured to be activated to release the downhole component by applying fluid pressure above a threshold value to the first pressure chamber to generate an actuation force that moves the actuator member to the second position. The running tool also includes a second pressure chamber in pressure communication with the same fluid conduit. The second pressure chamber is configured to receive borehole fluid from the fluid conduit during deployment and apply a balancing force to the actuator member during the deployment and prior to activating the running tool, the balancing force opposing the actuation force. 
     An embodiment of a method of deploying a downhole component in a borehole includes releasably connecting the downhole component to a running tool. The running tool includes a tool body having a fluid conduit and an actuation assembly including an actuator member connected to a release mechanism, the actuator member moveable in an axial direction from a first position to a second position to cause the release mechanism to disengage with a downhole component. The actuation assembly includes a first pressure chamber in pressure communication with the fluid conduit and configured to apply an axial force to the actuator member. The method also includes deploying the running tool and the downhole component into the borehole until the downhole component reaches a desired location, the deploying including applying a balancing force to the actuator member during the deployment and prior to activating the running tool by a second pressure chamber in pressure communication with the same fluid conduit, the balancing force opposing the axial force from the first pressure chamber. The method further includes activating the running tool to release the downhole component by applying fluid pressure above a threshold value to the first pressure chamber to generate an actuation force that moves the actuator member to the second position. 
    
    
     
       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  depicts an embodiment of a hydraulically activated running tool that includes a pressure balancing configuration; 
         FIG. 2  depicts the running tool of  FIG. 1  and illustrates activation of the running tool by isolating a section of a fluid conduit; 
         FIG. 3  depicts the running tool of  FIGS. 1 and 2 , and illustrates re-establishment of fluid flow through the running tool after activation; 
         FIG. 4  illustrates an embodiment of a system for performing energy industry operations and depicts components used to deploy a downhole component; and 
         FIG. 5  is a flow chart depicting an embodiment of a method of deploying a downhole component. 
     
    
    
     DETAILED DESCRIPTION 
     A detailed description of one or more embodiments of the disclosed apparatus and method presented herein by way of exemplification and not limitation with reference to the figures. 
     Embodiments described herein include a hydraulically activated running tool configured for use in deploying downhole components in a borehole. The running tool includes a main pressure chamber in pressure communication with a borehole fluid conduit. The main pressure chamber is operably connected to an actuator piston connected to a release mechanism. Increasing pressure in the main pressure chamber to a selected pressure causes the pressure chamber to move the actuator piston and activate the release mechanism. 
     In one embodiment, the running tool includes a pressure balancing configuration that includes a second pressure chamber in pressure communication with the borehole fluid conduit. The second pressure chamber acts to oppose axial forces exerted by the main pressure chamber during run-in or otherwise before the running tool is activated. To activate the running tool, the second pressure chamber is isolated from the main pressure chamber and the main pressure chamber is pressurized to activate the release mechanism. 
     Embodiments described herein provide a number of advantages and technical effects. For example, embodiments of the pressure balancing mechanism act to balance forces on the actuator piston to prevent premature activation at high circulation pressures. Accordingly, the running tool can be used without the need to limit pump pressures or rates when deploying a liner or other component. 
       FIGS. 1-3  illustrate an embodiment of a running tool  10 . The running tool  10  is used to deploy various tools and/or components into a borehole, which may be a pilot borehole and/or a lateral borehole. The running tool  10  is configured to be releasably attached or connected to a downhole component, so that once the downhole component is disposed at a desired depth or location, the running tool  10  can be released and retracted to the surface. 
     The running tool  10  includes a tool body  12  having an upper end  14  and a lower end  16 , one or more of which may be connected to components of a borehole string, such as a coiled tubing or other tubular running string. It is noted that “upper” and “lower” are terms used to indicate a relative position in a borehole as measured from the surface. In vertical boreholes, a lower component has a vertical depth that is greater than an upper component. However, in deviated and horizontal boreholes, an upper and lower component can have the same vertical depth, or the upper component can have a greater vertical depth than the lower component. 
     The tool body  12  includes a mandrel  18  that defines a central fluid conduit  20 . The central fluid conduit  20  allows borehole fluid to be circulated through the running tool  10  to and from other downhole components. The running tool  10  also includes a release mechanism such as a collet  22 , which is retracted or otherwise actuated to release a connected downhole component. 
     An actuation assembly  30  of the tool  10  includes an actuator having an elongated body connected to the collet  22  or other release mechanism. In one embodiment, the actuator is an actuator piston  32  configured as a cylindrical (or partially cylindrical) member. The actuator piston  32  extends axially and is connected to the collet in any suitable manner, such that axial movement of the actuator piston  32  moves the collet  22  to release the downhole component. The actuator piston  32  and the collet  22  may be integrated into a single body as shown in  FIG. 1 , or be attached or otherwise operably connected so that the collet  22  can be moved by moving the actuator piston. 
     In one embodiment, the actuator piston  32  is connected via a shear assembly  34  to the mandrel  18 . When the shear assembly  34  is intact, the actuator piston  32  is maintained at a first axial position, and the collet  22  is in an axial position (a “run-in” position), in which the collet  22  is engaged with the downhole component. 
     In one embodiment, the running tool  10  is hydraulically activated. For example, the actuation assembly  30  includes a first pressure chamber  40 , also referred to as a main pressure chamber  40 . The main pressure chamber  40  is defined by the mandrel  18  and the actuator piston  32 , and includes O-rings  42  and  44  or other sealing mechanisms. 
     The actuator piston  32  is moveable in an axial direction (i.e., a direction parallel or partially parallel to a longitudinal axis of the tool  10 ) relative to the mandrel  18 , such that the pressure chamber  40  increases in volume as the actuator piston  32  slides upward relative to the mandrel  18 . At least one fluid port  46  provides fluid communication with the central conduit  20 , which in turn provides fluid communication with the surface. 
     To release a connected downhole component, a force is applied to the shear assembly  34  to allow axial movement of the actuator piston  32 . The force may be applied by pressurizing fluid in the fluid conduit  20  (e.g., in conjunction with a ball seat assembly as discussed below), applying hydraulic pressure via a control line, or otherwise. Fluid pressure from the conduit  20  forces the actuator piston  32  upward, which correspondingly retracts the collet  22  and disengages the connected component. 
     The running tool  10  also includes a pressure balancing assembly or configuration that establishes a second pressure chamber  50  in the actuation assembly. The second pressure chamber  50  is in fluid and pressure communication with the fluid conduit  20  via, for example, at least one fluid port  52 . The fluid port  52  can be selectively closed or blocked to allow for pressurization of the first pressure chamber  40  and actuation of the actuator piston  32 . 
     The second pressure chamber  50  is defined, for example, by the mandrel  18  and the actuator piston  32 , and O-rings  54  and  56  or other sealing mechanisms. Pressure in the second pressure chamber  50  exerts an axial force (a balancing force) that opposes the axial force applied by the main pressure chamber  40 . 
     In one embodiment, the second pressure chamber  50  is exposed to fluid flowing through the fluid conduit  20 , so that pressure is applied to both chambers  40  and  50  and thereby balances the chambers and balances the axial force on the actuator piston  32  and shear assembly  34 . This allows for circulation of fluid during run-in with a circulating pressure that is higher than the running tool shear pressure (pressure required to shear the shear assembly  34 ). 
     In use, the second pressure chamber  50  balances axial forces on the actuator piston  32  as the running tool  50  and a connected component are deployed into a borehole. During deployment (e.g., run-in), fluid pressure through the running tool  10  is maintained at a selected circulation or run-in pressure. During the deployment, the fluid ports  46  and  52  allow fluid and pressure communication with both pressure chambers  40  and  50 , effectively balancing the axial forces. Upon positioning the component at a selected location or depth, the second pressure chamber  50  is isolated from the first pressure chamber  40  and from fluid in the fluid conduit  20 . The circulation pressure can then be increased to a shear pressure. At this pressure, the main pressure chamber  40  exerts an axial force that breaks the shear assembly  34  and forces the actuator member  32  to move and thereby retract the collet  22  and release the component. 
     Operation of the running tool is described below with reference to  FIGS. 1-3 .  FIG. 1  shows the running tool  10  and the actuator piston  32  in a deployment or run-in position, in which the shear assembly  34  is intact and both pressure chambers are exposed to fluid in the fluid conduit  20 . In this position, the collet  22  is in engagement with a connected downhole component. 
     In the embodiment of  FIGS. 1-3 , the shear assembly  34  includes a shear pin  58 . Also in this embodiment, a fluid isolation assembly such as a ball seat assembly  60  is attached to the mandrel  18  and located axially between the pressure chambers  40  and  50 . The ball seat assembly  60  includes a ball seat  62  that defines a restriction in the fluid conduit  20  on which a ball or other deployable object is seated to isolate the second pressure chamber  50  and permit pressurization to the shear pressure. 
     As shown in  FIG. 1 , in the run-in position, borehole fluid  64  applies pressure to both chambers to balance axial forces on the piston  32 . Referring to  FIG. 2 , when the component is to be released, a ball  66  is landed on the ball seat  62  and fluid pressure is applied only to the main pressure chamber  40 . Upon pressurization to the shear pressure, the shear pin  58  shears off and pressure in the main pressure chamber  40  forces the actuator piston  32  upwards and thereby retracts the collet  22 . Movement of the actuator piston  32  increases the volume of the main pressure chamber  40  and reduces the volume of, or entirely eliminates, the second pressure chamber  50 . 
     As shown in  FIG. 3 , after the component has been released, the ball  66  is moved past the ball seat  62  to reestablish fluid flow through the length of the running tool  10 . In this embodiment, to move the ball  66 , pressure above the ball is increased to a pressure sufficient to shear a ball seat shear pin  68  and detach the ball seat  62  from the mandrel  18 . The ball  66  and the ball seat  62  are caught in a catcher  70  and flow is regained. 
       FIG. 4  illustrates an embodiment of a system  100  for performing energy industry operations, such as a completion and hydrocarbon production system  10 , and also illustrates an embodiment of a deployment system for running or deploying downhole components using the running tool  10 . 
     The system  100  includes a liner assembly  102  that is deployed into a borehole  104  in an earth formation  105  using a running string  106 . In one embodiment, the running string  106  is a coiled tubing (CT) string. The running string  106  is connected to the running tool  10 , which is releasably attached to the liner assembly  102 . The liner assembly  102 , as shown in  FIG. 4 , can be deployed using the running string  106  and the running tool  10  into a lateral borehole  108  extending from the borehole  104 . 
     The liner assembly  102  in this embodiment includes a liner (casing string)  110 , which is typically deployed through a previous casing string and suspended via a liner hanger. The liner assembly  102  may include various components, such as a packer assembly  112 , a landing collar  114  and a casing shoe  116 . Other components may include sensing or measurement devices, fluid control devices, screens, sleeves, valves and/or any other desired components. 
     Various components may be configured to communicate with a surface location and/or a remote location, for example, via one or more conductors  118  (e.g., hydraulic lines, electrical conductors and/or optical fibers) and/or wireless telemetry (e.g., mud pulse, electromagnetic, etc.) 
     The liner assembly  102  and the running string  106  are shown as examples for illustration purposes and are not intended to be limiting. For example, the system  100  may include a variety of other components, such as a completion string or a production assembly. The running string  106  and/or other components may be deployed using any type of running string, such as a pipe string. 
     The system  100  also includes surface equipment  120  such as a drill rig, rotary table, top drive, blowout preventer and/or others to facilitate deploying the liner assembly, releasing the running tool  10  and/or controlling downhole components. For example, the surface equipment  120  includes a fluid control system  122  including one or more pumps in fluid communication with a fluid tank  124  or other fluid source. 
     In one embodiment, the system  10  includes a processing device such as a surface processing unit  130 , and/or a subsurface processing unit  132  disposed in the borehole  104  and/or  108  and connected to one or more downhole components. The surface processing unit  130 , in one embodiment, includes a processor  134 , an input/output device  136  and a data storage device (or a computer-readable medium)  138  for storing data, files, models, data analysis modules and/or computer programs. The processing device may be configured to perform functions such as controlling downhole components, controlling deployment of downhole components, controlling fluid circulation, monitoring components during deployment, transmitting and receiving data, processing measurement data and/or monitoring operations. For example, the storage device  138  stores processing modules  140  for performing one or more of the above functions. 
       FIG. 5  is a flow chart that illustrates an embodiment of a method  200  of deploying or running a downhole component into a borehole, and/or controlling aspects of an energy industry operation. Aspects of the method  200 , or functions or operations performed in conjunction with the method, may be performed by one or more processing devices, such as the surface processing unit  130 , either alone or in conjunction with a human operator. 
     The method  200  includes one or more stages  201 - 204 . In one embodiment, the method  200  includes the execution of all of the stages  201 - 204  in the order described. However, certain stages may be omitted, stages may be added, or the order of the stages changed. 
     The method  200  is discussed in conjunction with the system  100  of  FIG. 4  for illustrative purposes. It is noted that the method is not limited to the specific embodiment discussed below. 
     Although the method is discussed in conjunction with running a liner assembly, it is not so limited and can be used to deploy a variety of components and systems. Examples of such components and systems include, completions, lower completions (e.g., in two-trip operations), intelligent production systems and others. 
     In the first stage  201 , a downhole component such as the liner assembly  102  deployed into a borehole (e.g., the lateral borehole  108 ) by connecting the running tool  10  to the liner assembly  102  and connecting the running tool  10  to a running string such as a coiled tubing running string  106 . The running tool  10  and the liner assembly  102  are advanced through the borehole until the liner assembly  102  is located at a desired depth or location. Borehole fluid is circulated through the running string  106  and the running tool  10  at a selected circulating pressure (run-in pressure). Due to the balancing configuration including the main pressure chamber  40  and the second pressure chamber  50 , the running tool  10  is unaffected by differential pressures from the fluid conduit  20  to the annulus of the liner assembly  102  until it is desired to release the running tool  10 , so that circulation rates do not need to be limited when running the liner assembly  102 . 
     In the second stage  202 , when the liner assembly  102  reaches the desired location, the second pressure chamber  50  is isolated from the main pressure chamber  40  so that pressure in the main pressure chamber  40  can be increased. For example, a ball  66  is dropped into the running string  106  and pumped to the running tool  10 , where it lands on the ball seat  62 . 
     In the third stage  203 , the running tool  10  is released by increasing the pressure in the fluid conduit  18  to a shear pressure, i.e., a pressure sufficient to cause the main pressure chamber  40  to exert an axial force sufficient to shear off the shear assembly  34  and cause the actuator piston  32  to move upward. This movement in turn causes the collet  22  to retract and release the running tool  10  from the liner assembly  102 . In the third stage,  204 , the running string  106  and the running tool  10  are retracted or tripped to the surface. 
     Set forth below are some embodiments of the foregoing disclosure: 
     Embodiment 1: A running tool configured to deploy a downhole component, the running tool comprising: a tool body having a fluid conduit; an actuation assembly including an actuator member connected to a release mechanism, the actuator member moveable in an axial direction from a first position to a second position to cause the release mechanism to disengage with a downhole component, the actuation assembly including a first pressure chamber in pressure communication with the fluid conduit, wherein the running tool is configured to be activated to release the downhole component by applying fluid pressure above a threshold value to the first pressure chamber to generate an actuation force that moves the actuator member to the second position; and a second pressure chamber in pressure communication with the same fluid conduit, the second pressure chamber configured to receive borehole fluid from the fluid conduit during deployment and apply a balancing force to the actuator member during the deployment and prior to activating the running tool, the balancing force opposing the actuation force. 
     Embodiment 2: The running tool of any prior embodiment, wherein the first pressure chamber and the second pressure chamber are defined by the tool body and the actuator member. 
     Embodiment 3: The running tool of any prior embodiment, wherein the first pressure chamber is connected to the fluid conduit by a first fluid port, and the second pressure chamber is connected to the fluid conduit by a second fluid port. 
     Embodiment 4: The running tool of any prior embodiment, further comprising a shear assembly, the shear assembly configured to be sheared to allow for axial movement of the actuator member, the first pressure chamber disposed at a first location on one side of the shear assembly, and the second pressure chamber disposed at a second location on an opposite side of the shear assembly. 
     Embodiment 5: The running tool of any prior embodiment, further comprising a fluid isolation assembly configured to be to be operated to isolate the first pressure chamber from the second pressure chamber. 
     Embodiment 6. The running tool of any prior embodiment, wherein the fluid isolation assembly is disposed at a location along the fluid conduit between the first pressure chamber and the second pressure chamber. 
     Embodiment 7: The running tool of any prior embodiment, wherein the fluid isolation assembly includes a ball seat. 
     Embodiment 8: The running tool of any prior embodiment, wherein the actuator member is configured to be moved to the second position by deploying a ball through a running string, landing the ball on the ball seat to isolate the first pressure chamber from the second pressure chamber, and applying the fluid pressure to borehole fluid upstream of the ball and the ball seat. 
     Embodiment 9: The running tool of any prior embodiment, wherein the downhole component includes a liner assembly. 
     Embodiment 10: The running tool of any prior embodiment, wherein the running tool is configured to be connected to a running string for deployment of the downhole component. 
     Embodiment 11: A method of deploying a downhole component in a borehole, the method comprising: releasably connecting the downhole component to a running tool, the running tool including a tool body having a fluid conduit and an actuation assembly including an actuator member connected to a release mechanism, the actuator member moveable in an axial direction from a first position to a second position to cause the release mechanism to disengage with a downhole component, the actuation assembly including a first pressure chamber in pressure communication with the fluid conduit and configured to apply an axial force to the actuator member; deploying the running tool and the downhole component into the borehole until the downhole component reaches a desired location, the deploying including applying a balancing force to the actuator member during the deployment and prior to activating the running tool by a second pressure chamber in pressure communication with the same fluid conduit, the balancing force opposing the axial force from the first pressure chamber; and activating the running tool to release the downhole component by applying fluid pressure above a threshold value to the first pressure chamber to generate an actuation force that moves the actuator member to the second position. 
     Embodiment 12: The method of any prior embodiment, wherein the first pressure chamber and the second pressure chamber are defined by the tool body and the actuator member. 
     Embodiment 13: The method of any prior embodiment, wherein the first pressure chamber is connected to the fluid conduit by a first fluid port, and the second pressure chamber is connected to the fluid conduit by a second fluid port. 
     Embodiment 14: The method of any prior embodiment, wherein activating the running tool includes isolating the first pressure chamber from the second pressure chamber, and applying a fluid pressure to the first pressure chamber to shear a shear assembly to allow for axial movement of the actuator member, the first pressure chamber disposed at a first location on one side of the shear assembly, and the second pressure chamber disposed at a second location on an opposite side of the shear assembly. 
     Embodiment 15: The method of any prior embodiment, further comprising a fluid isolation assembly configured to be to be operated to isolate the first pressure chamber from the second pressure chamber. 
     Embodiment 16: The method of any prior embodiment, wherein the fluid isolation assembly is disposed at a location along the fluid conduit between the first pressure chamber and the second pressure chamber. 
     Embodiment 17: The method of any prior embodiment, wherein the fluid isolation assembly includes a ball seat. 
     Embodiment 18: The method of any prior embodiment, wherein activating the running tool includes deploying a ball through a running string, landing the ball on the ball seat to isolate the first pressure chamber from the second pressure chamber, and applying the fluid pressure to borehole fluid upstream of the ball and the ball seat to move the actuator member to the second position. 
     Embodiment 19: The method of any prior embodiment, wherein the downhole component includes a liner assembly. 
     Embodiment 20: The method of any prior embodiment, wherein the running tool is configured to be connected to a running string for deployment of the downhole component. 
     In support of the teachings herein, various analysis components may be used, including a digital and/or an analog system. For example, embodiments such as the system  10 , downhole tools, hosts and network devices described herein may include digital and/or analog systems. Embodiments may have components such as a processor, storage media, memory, input, output, wired communications link, user interfaces, software programs, signal processors (digital or analog), signal amplifiers, signal attenuators, signal converters and other such components (such as resistors, capacitors, inductors and others) to provide for operation and analyses of the apparatus and methods disclosed herein in any of several manners well-appreciated in the art. It is considered that these teachings may be implemented in conjunction with a set of computer executable instructions stored on a non-transitory computer readable medium, including memory (ROMs, RAMs), optical (CD-ROMs), or magnetic (disks, hard drives), or any other type that when executed causes a computer to implement the method of the present invention. These instructions may provide for equipment operation, control, data collection and analysis and other functions deemed relevant by a system designer, owner, user or other such personnel, in addition to the functions described in this disclosure. 
     Elements of the embodiments have been introduced with either the articles “a” or “an.” The articles are intended to mean that there are one or more of the elements. The terms “including” and “having” are intended to be inclusive such that there may be additional elements other than the elements listed. The conjunction “or” when used with a list of at least two terms is intended to mean any term or combination of terms. The terms “first,” “second” and the like do not denote a particular order, but are used to distinguish different elements. 
     While the invention has been described with reference to exemplary embodiments, it will be understood 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 will be appreciated to adapt a particular instrument, 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 appended claims.