Patent Publication Number: US-2017370183-A1

Title: Electro-hydraulic actuation system

Description:
BACKGROUND 
     Downhole systems employ various tools that operate to treat wellbores, extract fluids, introduced fluids and the like into a formation. Many such tools operate due to axial force that comes from pressure, load applied from the surface or another source. The axial force may take the form of a tool being moved into or out of the wellbore, or based on signals sent downhole from the surface. Signals may take the form of electronic signals and/or pressure pulses. The signals may embody a particular pattern that actuates a downhole tool. 
     SUMMARY 
     An electro-hydraulic actuator includes a housing having an interior portion a first opening and a second opening, a transducer is arranged in the interior portion. The transducer includes a sensor operatively coupled to a signal source at the first opening. A selectively activatable valve component is arranged at the second opening. The selectively activatable valve component maintains a desired pressure in the interior portion of the housing. An actuator is operatively coupled to the transducer and is operable to activate the selectively activatable valve component exposing the interior portion to a volume of fluid in response to a signal from the transducer to activate a downhole system. 
     A method of actuating a downhole system includes receiving a signal with a transducer arranged in an electro-hydraulic actuator housing, triggering an actuator based on the signal, operating a valve with the actuator allowing a volume of fluid to enter the actuator housing creating reduction in a volume of fluid exterior to the actuator housing, and activating a downhole system based on the reduction in the volume of fluid. 
     A resource exploration system includes a surface portion, and a downhole portion including a plurality of tubulars. At least one of the plurality of tubulars includes a downhole system and an electro-hydraulic actuator operable to activate the downhole system. The electro-hydraulic actuator includes a housing having an interior portion a first opening and a second opening, and a transducer arranged in the interior portion. The transducer includes a sensor operatively coupled to a signal source at the first opening. A selectively activatable valve component is arranged at the second opening. The selectively activatable valve component maintains a desired pressure in the interior portion of the housing. An actuator is operatively coupled to the transducer and is operable to activate the selectively activatable valve component exposing the interior portion to a volume of fluid in response to a signal from the transducer to activate the downhole system. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Referring now to the drawings wherein like elements are numbered alike in the several Figures: 
         FIG. 1  depicts a resource exploration system including an electro-hydraulic actuation system, in accordance with an exemplary embodiment; 
         FIG. 2  depicts a partial cross-sectional view of a tubular including the electro-hydraulic actuation system of  FIG. 1  prior to activation; 
         FIG. 3  depicts a partial cross-sectional view of a tubular including the electro-hydraulic actuation system of  FIG. 2  after actuation; 
         FIG. 4  depicts a partial cross-sectional view of the electro-hydraulic actuation system of  FIG. 2 ; 
         FIG. 5  depicts a partial cross-sectional view of an actuator portion of the electro-hydraulic actuation system, in accordance with another aspect of an exemplary embodiment; 
         FIG. 6  depicts a partial cross-sectional view of an actuator portion of the electro-hydraulic actuation system in a non-actuated state, in accordance with yet another aspect of an exemplary embodiment; and 
         FIG. 7  depicts a partial cross-sectional view of the actuator portion of  FIG. 6  in an actuated state. 
     
    
    
     DETAILED DESCRIPTION 
     A resource exploration system, in accordance with an exemplary embodiment, is indicated generally at  2 , in  FIG. 1 . Resource exploration system  2  should be understood to include well drilling operations, resource extraction and recovery, CO 2  sequestration, and the like. Resource exploration system  2  may include a surface portion  4  operatively connected to a downhole portion  6 . Surface portion  4  may include pumps  8  that aid in completion and/or extraction processes as well as fluid storage  10 . Fluid storage  10  may contain a gravel pack fluid or slurry (not shown) that is introduced into downhole portion  6 . 
     Downhole portion  6  may include a string  20  formed from a plurality of tubulars, one of which is indicated at  21  that is extended into a borehole  24  formed in formation  26 . Borehole  24  includes a surface  28 . One of tubulars  21  may include a selectively deployable downhole system  40  such as a valve  44 . It is to be understood that the particular type, nature, and components of selectively deployable downhole system  40  may vary. 
     As shown in  FIG. 2 , selectively deployable system  40  may include an outer housing  48  having an outer surface  54  and an inner surface  56  that defines a passage  57 .A first annular projection  59  extends radially inwardly from inner surface  56 . Outer housing  48  includes a first annular projection  59  is provided with an O-ring  60 . It is to be understood that outer housing  48  may be provided with various types of seals such as chevron stacks, metal-to-metal seals, elastomeric seals and the like. Outer housing  48  also includes a second annular projection  61  that extends from inner surface  56 . First projection  59  defines, in part, a valve recess  63 . Outer housing  48  also includes an activation recess  66  defined between first and second annular projections  59  and  61 . Activation recess  66  is filled, at the surface, with a volume of fluid. 
     Downhole system  40  may also include a spring mandrel  80  having an outer surface portion  82 , and an inner surface portion  84  that defines a central passage portion  86 . Spring mandrel  80  may include an annular flange  89  that supports a biasing element  91  in valve recess  63 . Biasing element  91  may take the form of a Bellville spring stack  93 . It is to be understood that biasing element  91  may take on various forms including coil springs, gas pressure, and the like. Spring mandrel  80  may support one or more dogs  98  that selectively engage annular projection  61 . Specifically, dogs  98  maintain spring mandrel  80  in a non-deployed position against a biasing force provided by Bellville stack  93 . 
     In a deployed position, spring mandrel may activate and/or deactivate valve  44 . A piston  108  extends about spring mandrel  80  and abuts dogs  98 . Piston  108  includes one or more seals  109  shown in the form of O-rings, one of which is indicated at  110 . O-rings  110  ensure that the fluid in activation recess  66  does not flow toward dogs  98 . As will be detailed below when positioned downhole, piston  108  is positioned against dogs  98  by the volume of fluid present in activation recess  66 . A change in the volume of fluid in activation recess  66  enables piston  108  to shift allowing dogs  98  to retract and release spring mandrel  80  as shown in  FIG. 3 . It is to be understood that the exemplary embodiments may also be employed in connection with packers, shear joints and other axially actuated devices. Thus, in addition to operating dogs, the exemplary embodiment may also be associated with collets, shearable members and the like as will be understood below. 
     In accordance with an exemplary embodiment, downhole system  40  includes an electro-hydraulic actuator  120  depicted in  FIG. 4  that selectively increases a volume of activation recess  66  allowing dogs  98  to retract and release spring mandrel  80 . As seen in  FIG. 3 , electro-hydraulic actuator  120  includes a housing  130  having a first end  132 , a second end  133  and an interior portion  135  that is maintained at a desired pressure as will be discussed below. In accordance with an aspect of an exemplary embodiment, the desired pressure within interior portion  135  is less than pressure external to housing  130  developed in the fluid present in activation recess  66 . In accordance with an aspect of an exemplary embodiment, the desired pressure may be atmospheric pressure. However, it is to be understood that the desired pressure may vary. 
     First end  132  incudes a first opening  140 . A portion of first opening  140  may be surrounded by a plurality of threads  142 . Second end  133  includes a second opening  146  that may be defined, at least in part, by a cap member  148 . Housing  130  includes an inner wall  153 . An annular flange element  156  extends radially inwardly from inner wall  153 . A valve chamber  159  may be defined between annular flange element  156  and cap member  148 . A selectively activatable valve component  161  is arranged in valve chamber  159 . Selectively activatable valve component  161  may include a valve support portion  163  including one or more O-rings (not separately labeled) that abut inner wall  153 . Valve support portion  163  retains a puncturable membrane  165  having a first surface  167  and a second, opposing surface  168 . First surface  167  may be is exposed to pressure external to housing  130 . Second surface  168  may be exposed to the desired pressure within housing  130 . As such, second surface  168  defines a convex surface as the pressure external to housing  130  is greater than the desired pressure within housing  130 . It is to be understood that the desired pressure may be greater than the pressure external to housing  130  thereby forming a concave surface depending upon actuation techniques being employed. 
     In further accordance with an exemplary embodiment, electro-hydraulic actuator  120  includes an actuator  180  that is operable to open selectively activatable valve component  161 . Actuator  180  includes a support collar  183  having a first end section  185  and a second end section  186 . An annular flange section  188  extends radially inwardly adjacent second end section  186 . A collet  192  may be supported by annular flange section  188 . As will be detailed more fully below, collet  192  selectively releases an actuator member  194  to open selectively activatable valve component  161 . Actuator member  194  includes a retention portion  196  that may be engaged by collet  192  and a piercing member portion  198  that may be directed through membrane  165 . Actuator member  194  may include a neck section  200  that supports a biasing member  205 . More specifically, biasing member  205 , which may take the form of a spring  207 , may be supported between annular flange element  156  and neck section  200 . 
     In still further accordance with an exemplary embodiment, electro-hydraulic actuator  120  may include a transducer  210  arranged at first end  132  of housing  130 . Transducer  210  may take the form of a pressure transducer  212  having a sensor in the form of a sensing surface  214  exposed at first opening  140 . Sensing surface  214  may receive pressure pulses directed from a signal source (not shown) to selectively actuator  180 . It is to be understood that transducer  210  may take on a variety of forms and need not be limited to pressure sensing. It is also to be understood that the signals may be provided from various sources and should not be limited to originating uphole or at the surface. Transducer  210  is arranged in housing  130  through plurality of threads  142 . Plurality of threads  142  may engage with corresponding threads (not separately labeled) on transducer  210  to form a metal-to-metal seal. 
     In still further accordance with an exemplary embodiment, transducer  210  may be operatively coupled to a circuit assembly  220  arranged within housing  130 . Additionally, a first power source  224  and a second power source  225  may reside within housing  130 . First power source  224  may provide power to circuit assembly  220  and second power source  225  may be coupled to circuit assembly  220  and provide power to activate collet  192 . 
     In accordance with an aspect of an exemplary embodiment, one or more pressure pulses may be sent to transducer  210  from the uphole signal source. The one or more pressure pulses may possess a particular magnitude or pattern that is interpreted by circuit assembly  210  as a release signal. In response, circuit assembly  210  fires or opens collet  192  releasing actuator member  194  with spring  207  driving piercing member portion  198  through membrane  165  allowing a portion of the volume of fluid in activation recess  66  to pass into housing  130 . A change in the volume of fluid in activation recess  66  allows piston  108  to shift and release dogs  98 . Upon releasing dogs  98 , spring mandrel  80  may be shifted by biasing element  91  to activate valve  44 . 
     Reference will now follow to  FIG. 5  in describing an actuator  230  in accordance with another aspect of an exemplary embodiment. Actuator  230  includes a housing  232  having a wall  233  provided with one or more openings  234  that may be exposed to fluid at downhole pressures. A support collar  236  is arranged within housing  232 . Support collar  236  includes a first end section  238 , and a second end section  239 . An outer surface  241  extends between first end section  238  and second end section  239 . Also, an inner surface  242  extends between first end section  238  and second end section  239 . Inner surface  242  defines a central bore  243 . One or more passages  244  may extend through support collar  236  from outer surface  241  to inner surface  242 . A first O-ring  246  is arranged at outer surface  241  and a second O-ring  247  is arranged at outer surface  241  spaced from first O-ring  246 . First and second O-rings  246  and  247  are arranged on opposing sides of passages  244  and one or openings  234  creating a high pressure zone  248  within housing  232 . 
     A collet  249  may be supported at second end section  239 . Collet  249  selectively retains an actuator member  255  within central bore  243 . Actuator member  255  includes a retention portion  258  that may be engaged by collet  249  and a piercing member portion  260  that is operatively coupled to retention portion  258  through a connector portion  264 . Connector portion  264 . A first O-ring  270  may extend between connector portion  264  and piercing member portion  260 , and a second O-ring  272  may extend between connector portion  264  and support collar  236 . First and second O-rings  270  and  272  may reside on opposing sides of passages  244  so as to further define high pressure zone  248 . A desired pressure zone  274  may exist axially outwardly of piercing member portion  260 . Desired pressure zone  274  may be at atmospheric pressure or another pressure that is lower than pressures externally of housing  232  or pressure within high pressure zone  248 . 
     In a manner similar to that described above, one or more pressure pulses may be sent to transducer  210 . The one or more pressure pulses may possess a particular magnitude or pattern that is interpreted by circuit assembly  210  as a release signal. In response, circuit assembly  210  fires or opens collet  249  releasing actuator member  255  allowing high pressure fluid within high pressure zone  248  to deliver a hydraulic force driving piercing member portion  260  through membrane  165  creating a pressure differential at housing  232 . A portion of the volume of fluid may pass from activation recess  66  into desired pressure zone  274  of housing  232  allowing piston  108  to shift and release dogs  98 . Upon releasing dogs  98 , spring mandrel  80  may be shifted by biasing element  91  to activate valve  44 . 
     Reference will now follow to  FIG. 6 , wherein like numbers represent corresponding parts in the respective views in describing an electro-hydraulic actuator  300  in accordance with yet another aspect of an exemplary embodiment. Electro-hydraulic actuator  300  includes an actuator  308  that is operable to expose interior portion  135  of housing  130  to downhole pressure. Actuator  308  includes a support collar  312  having a first end section  314  and a second end section  315 . An annular flange section  320  extends radially inwardly of support collar  312 . A collet  324  may be supported at second end  316 . As will be detailed more fully below, collet  324  selectively releases an actuator member  334  to expose interior portion  135  to downhole pressure. Actuator member  334  includes a retention portion  338  that may be engaged by collet  324  and a support portion  340  that supports support collar  312  against downhole pressure. Actuator member  334  may include a neck section  350  that supports a biasing member  355 . More specifically, biasing member  355 , which may take the form of a spring  357 , may be supported between annular flange element  320  and neck section  350 . 
     In accordance with an aspect of an exemplary embodiment, one or more pressure pulses may be sent to transducer  210  from the signal source. The one or more pressure pulses may possess a particular magnitude or pattern that is interpreted by circuit assembly  210  as a release signal. In response, circuit assembly  210  fires or opens collet  324  releasing actuator member  334  with spring  357  driving support portion  340  toward second end  316  of support member  312 . Once moved, downhole pressure may act on support member  312  through openings  360  formed in housing  135 . Without the support provided by support member  340 , support member  312  may buckle, bend, break tear, fracture, and/or lose pressure bearing capability at openings  360  as shown in  FIG. 7  creating pathway for a portion of the volume of fluid in activation recess  66  to enter into housing  130 . A change in the volume of fluid in activation recess  66  allows piston  108  to shift and release dogs  98 . Upon releasing dogs  98 , spring mandrel  80  may be shifted by biasing element  91  to activate valve  44 . 
     Embodiment 1. An electro-hydraulic actuator comprising: a housing having an interior portion a first opening and a second opening; a transducer arranged in the interior portion, the transducer including a sensor operatively coupled to a signal source at the first opening; a selectively activatable valve component arranged at the second opening, the selectively activatable valve component maintaining a desired pressure in the interior portion of the housing; and an actuator operatively coupled to the transducer and operable to activate the selectively activatable valve component exposing the interior portion to a volume of fluid in response to a signal from the transducer to activate a downhole system. 
     Embodiment 2. The electro-hydraulic actuator according to any prior embodiment, wherein the transducer comprises a pressure transducer. 
     Embodiment 3. The electro-hydraulic actuator according to any prior embodiment, wherein the actuator includes an actuator member and a biasing member operable to shift the actuator member toward the selectively activatable valve component. 
     Embodiment 4. The electro-hydraulic actuator according to any prior embodiment, wherein the biasing member comprises a spring. 
     Embodiment 5. The electro-hydraulic actuator according to any prior embodiment, wherein the biasing member comprises a hydraulic force. 
     Embodiment 6. The electro-hydraulic actuator according to any prior embodiment, wherein the selectively activatable valve component comprises a membrane. 
     Embodiment 7. The electro-hydraulic actuator according to any prior embodiment, wherein the actuator comprises a piercing member operable to pierce the membrane. 
     Embodiment 8. The electro-hydraulic actuator according to any prior embodiment, wherein the actuator includes a collet. 
     Embodiment 9. The electro-hydraulic actuator according to any prior embodiment, wherein the desired pressure comprises atmospheric pressure. 
     Embodiment 10. The electro-hydraulic actuator according to any prior embodiment, wherein the transducer is sealed to the housing at the first opening. 
     Embodiment 11. The electro-hydraulic actuator according to any prior embodiment, further comprising: a circuit assembly arranged in the interior portion and operatively connected to the transducer and the actuator. 
     Embodiment 12. The electro-hydraulic actuator according to any prior embodiment, further at least one power source operatively coupled to the circuit assembly. 
     Embodiment 13. The electro-hydraulic actuator according to any prior embodiment, wherein the downhole system includes a plurality of dogs. 
     Embodiment 14. A method of actuating a downhole system, comprising: receiving a signal with a transducer arranged in an electro-hydraulic actuator housing; triggering an actuator based on the signal; operating a valve with the actuator allowing a volume of fluid to enter the actuator housing creating reduction in a volume of fluid exterior to the actuator housing; and activating a downhole system based on the reduction in the volume of fluid. 
     Embodiment 15. The method of any prior embodiment, wherein operating a valve includes piercing a membrane. 
     Embodiment 16. A resource exploration system comprising: a surface portion; and a downhole portion including a plurality of tubulars, at least one of the plurality of tubulars including a downhole system and an electro-hydraulic actuator operable to activate the downhole system, the electro-hydraulic actuator comprising: a housing having an interior portion a first opening and a second opening; a transducer arranged in the interior portion, the transducer including a sensor operatively coupled to a signal source at the first opening; a selectively activatable valve component arranged at the second opening, the selectively activatable valve component maintaining a desired pressure in the interior portion of the housing; and an actuator operatively coupled to the transducer and operable to activate the selectively activatable valve component exposing the interior portion to a volume of fluid in response to a signal from the transducer to activate the downhole system. 
     Embodiment 17. The resource exploration system according to any prior embodiment, wherein the transducer comprises a pressure transducer. 
     Embodiment 18. The resource exploration system according to any prior embodiment, wherein the actuator includes an actuator member and a biasing member operable to shift the actuator member toward the selectively activatable valve component. 
     Embodiment 19. The resource exploration system according to prior embodiment, wherein the selectively activatable valve component comprises a membrane and wherein the actuator member comprises a piercing member operable to penetrate the membrane. 
     Embodiment 20. The resource exploration system according to any prior embodiment, wherein the desired pressure comprises atmospheric pressure. 
     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 one or more embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation.