Patent Publication Number: US-2022220826-A1

Title: Isolation valve for use in a wellbore

Description:
BACKGROUND OF THE INVENTION 
     1. Field of Invention 
     The present disclosure relates to isolating flow within a wellbore with a valve that is actuated between open and closed configurations in response to forces that are applied axially and rotationally. 
     2. Description of Prior Art 
     Hydrocarbons are typically produced from subterranean formations by excavating wellbores that penetrate the formations and completing the wellbores to form a producing oil well. Completing an oil well generally includes lining at least a portion of the wellbore with casing, cementing the casing in place, and perforating through the casing and into the surrounding formation to allow fluid communication from the formation to inside of the wellbore. Formation fluid entering the wellbore is usually routed to surface via a string of production tubing (“production string”) that is installed in the wellbore after the step of perforating. 
     Sometimes valves are installed within the wellbore for controlling flow into or through the production tubing. One type of downhole valve is an inflow control valve (“IFD”) for controlling flow entering the production tubing, and is often employed to regulate an amount of fluid entering into a portion of the production string; such as for balancing flow when fluids entering separate sections of the production string are at different pressures. In other instances an IFD is substantially or fully closed to limit or block an inflow of water or other undesired substances. Safety valves make up another type of valves installed downhole, and which are used to block flow through production tubing and isolate all or a portion of the subterranean formation from surface. As their name implies safety valves are for use in emergency situations, such as a loss of containment downstream or unexpectedly high pressures in the formation. Safety valves typically operate similar to a check valve and are often designed in a fail-safe mode; and unless a force is applied to hold them in an open configuration, they will usually revert to a closed configuration when exposed to a flow of fluid inside the production string towards surface and isolate the upstream formation from surface. Usually hydraulic fluid or electricity is employed to generate the force to hold the safety valve in the open configuration; a drawback of this is that interruption of the supply of hydraulic fluid or electricity will allow the safety valve to close, which threatens the flow of production fluid. 
     SUMMARY OF THE INVENTION 
     Disclosed herein is an example of a system for isolating a portion of a wellbore and that includes a housing, a valve element selectively changeable between a closed configuration and positioned in a path of fluid flow in the wellbore to define a barrier to fluid flow in the wellbore, and an open configuration and positioned away from the path of fluid flow in the wellbore. The system also includes a deployment sleeve axially moveable within the housing and selectively positioned adjacent the valve element when the valve element is in the open configuration and which interferes with the valve element being changed to the closed configuration, and a retraction sleeve disposed in the housing that is in lifting engagement with the deployment sleeve when the deployment sleeve is positioned adjacent the valve element, so that when the retraction sleeve is rotated an elevational force is exerted onto the deployment sleeve to move the deployment sleeve away from the valve element. The system optionally includes a generally helical flight assembly coupled between the retraction sleeve and deployment sleeve, and through which the elevational force is transmitted from the retraction sleeve to the deployment sleeve, in an alternative the helical flight assembly is a flight element that is mounted along a surface of the retraction sleeve that circumscribes an axis of the housing. In an embodiment another flight element is mounted along a surface of the deployment sleeve that circumscribes an axis of the housing and that engages the flight element when the retraction sleeve is in lifting engagement with the deployment sleeve, and where one of the flight elements is radially compressible. Some examples include a shifting sleeve that is axially moveable within the housing and that is in abutting contact with the deployment sleeve so that sliding the shifting sleeve within the housing towards the deployment sleeve positions the deployment sleeve adjacent the valve element, and wherein the shifting sleeve is freely moveable away from the deployment sleeve in a direction away from the valve element. The system alternatively further includes a shifting sleeve that is axially moveable with respect to the retraction sleeve and rotationally coupled with the retraction sleeve by a pin and slot arrangement. In one example the valve element is a disk like member that is hingedly affixed to an inner surface of the housing. In an alternative the deployment sleeve is rotationally coupled with the valve element when the valve element is in the open configuration. Rotationally coupling the valve element and deployment sleeve optionally involves insertion of a spline that projects radially outward from an outer surface of the deployment sleeve into a groove formed on a planar surface of the disk like member. The system alternatively includes a string of production tubing that is rotationally coupled with the retraction sleeve and axially coupled with the deployment sleeve. 
     Another example of a system for isolating a portion of a wellbore is disclosed and which includes a string of production tubing, an isolation valve assembly comprising, a housing having an uphole end coupled with the string of production tubing and an opening in communication with the wellbore on a downhole end that is distal from the uphole end, a shifting sleeve axially moveable within the housing, a valve element in the housing moveable from a closed configuration to an open configuration in response to downhole movement of the shifting sleeve, a retraction sleeve having a helical thread that circumscribes an axis of the housing, and a deployment sleeve that is selectively moveable downhole with downhole movement of the shifting sleeve to an opening location that interferes with movement of the valve element from the open configuration to the closed configuration, and into anchoring engagement with the helical thread, and a packer assembly circumscribing the housing. In this example the shifting sleeve includes a main body and a collar that circumscribes a portion of the main body to define an annular gap between the main body and collar. In an example the retraction sleeve is made up of a primary section and a bushing coaxially within the primary section to define an annular space between the primary section and the bushing, wherein the collar inserts into the annular space and the bushing inserts into the annular gap. The shifting sleeve and retraction sleeve are optionally rotationally coupled by a pin attached to the collar that inserts into a slot formed axially along a length of the bushing. In one embodiment the shifting sleeve includes a shoulder having a radial surface that is in abutting contact with an end of the deployment sleeve when the shifting sleeve is being moved downhole. 
     Another example of a system for isolating a portion of a wellbore is disclosed herein and that includes a housing selectively anchored in the wellbore and having a bore, a valve element in the housing that is selectively in a closed position that is in interfering contact with flow through the bore, and selectively in an opened position that is away from interfering contact with the flow, a deployment sleeve in the housing for selectively maintaining the valve element in the opened position, a means for axially urging the deployment sleeve into a position for maintaining the valve element in the opened position, a means for securing the deployment sleeve in the position for maintaining the valve element in the opened position and that comprises a helical member, and a means for retracting the deployment sleeve from the position for maintaining the valve in the opened position by rotating the helical member with respect to the deployment sleeve to generate a lifting force that urges the deployment sleeve axially away from the valve element and out of interference with the valve element moving into the closed position. In an example the helical member is a first helical member, and wherein the means for retracting the deployment sleeve also includes a second helical member that engages the first helical member. In an alternative the helical member is mounted to an inner circumference of a retraction sleeve that is rotationally coupled to a string of production tubing. The means for axially urging the deployment sleeve into a position for maintaining the valve element in the opened position optionally involves a shifting sleeve that is axially moveable within the housing and includes a collar with a downward facing shoulder that is in abutting contact with an end of the deployment sleeve, and wherein a portion of the shifting sleeve inserts into and past the deployment sleeve into contact with the valve element and urges the valve element into the opened position when urged axially downhole. In an alternative, the means for retracting the deployment sleeve from the position for maintaining the valve in the opened position includes the shifting sleeve and a retraction sleeve that is rotationally coupled to the shifting sleeve and wherein the helical member comprises threads that are formed on an inner circumference of the retraction sleeve and that engage threads on an outer circumference of the deployment sleeve when the deployment sleeve is axially urged into the position for maintaining the valve element in the opened position, and wherein the threads on the outer circumference of the deployment sleeve are compressed radially inward when being engaged with the threads on the retraction sleeve. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  is a side partial sectional view of an example of an isolation valve disposed in a wellbore. 
         FIGS. 2-8  are side sectional views of examples of operation of the isolation valve of  FIG. 1 . 
         FIG. 9  is a side partial sectional view of an alternate example of the wellbore of  FIG. 1 . 
         FIG. 10  is a side view of an example of a deployment sleeve for use with the isolation valve of  FIGS. 1-8 . 
         FIG. 11  is a plan view of an example of a valve element for use with the isolation valve of  FIGS. 1-8 . 
     
    
    
     While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims. 
     DETAILED DESCRIPTION OF INVENTION 
     The method and system of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The method and system of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout. In an embodiment, usage of the term “about” includes +/−5% of a cited magnitude. In an embodiment, the term “substantially” includes +/−5% of a cited magnitude, comparison, or description. In an embodiment, usage of the term “generally” includes +/−10% of a cited magnitude. 
     It is to be further understood that the scope of the present disclosure is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation. 
     Shown in a partial side sectional view  FIG. 1  is an example of a downhole assembly  8  and include a valve assembly  10  disposed in a wellbore  12  and deployed on an end of a production string  14 . A packer  16  is shown circumscribing valve assembly  10  and which defines a barrier to flow in an annulus  18  between the valve assembly  10  and sidewalls of wellbore  12 . An end of the production string  14  opposite valve assembly  10  is anchored within a wellhead assembly  20  shown mounted on a surface S. In the example shown, valve assembly  10  is used to selectively isolate portions of wellbore  12  from surface S. In the example of  FIG. 1 , a flow of fluid F shown directed into a lower end of valve assembly  10 , when in a closed configuration valve assembly  10  selectively forms a barrier between the production string  14  and wellbore  12  to flow of fluid F; and when in an opened position does not impede the flow of fluid F from passing through valve assembly  10  and entering the production string  14 . 
     An example of the valve assembly  10  is shown in side sectional view in  FIG. 2  and including an outer housing  22  with an inner bore  23  extending along its axis A X . Valve assembly  10  of  FIG. 2  includes an annular shifting sleeve  24  and with threads  26  along a portion of its inner circumference that engage threads  28  formed on an outer surface of production tubing  14  on its lower end. The embodiment shown also includes an annular deployment sleeve  30  that circumscribes a portion of the shifting sleeve  24 , and that has threads  32  formed along a portion of the outer circumference of the deployment sleeve  30 . Coaxially circumscribing deployment sleeve  30  is an example of a retraction sleeve  34  having a portion with threads  36  disposed on an inner circumference of the retraction sleeve  34 , in the example of  FIG. 2  threads  36  are set downhole of the threads  32  on the deployment sleeve  30 . For the purposes of discussion herein, “downhole” from a referenced location refers to a region of the wellbore  12  ( FIG. 1 ) in a direction away or side of referenced location opposite surface S, and “uphole” refers to a region of the wellbore  12  in a direction towards the surface S from the referenced location. The example of  FIG. 2  also includes a valve element  38  and shown in a closed configuration. Valve element  38  is represented as a flapper valve and with a generally planar configuration, alternate embodiments of the valve element  38  include a bull valve or a butterfly valve. In the example shown when in the closed configuration valve element  38  spans the bore  23  in an orientation substantially perpendicular to an axis A X  of the valve assembly  10  and defines a barrier to fluid flow F axially through the bore  23 . 
     An opening  40  is shown through a sidewall of housing  22  and on an end of housing  22  opposite from where housing  22  connects with the production tubing  14 . In the alternative shown, opening  40  provides a way for the flow of fluid F to enter into the valve assembly  10  and from within wellbore  12 . A hinge assembly  42  is depicted on an end of valve member  38  and as described in more detail below, provides a place upon which valve element  38  pivots between the closed configuration of  FIG. 2  and into an open configuration which puts the valve member  38  out of the path of the flow of fluid F and allowing the flow of fluid F to travel upwards within bore  23  and into production tubing  14 . In an alternative, a closing spring (not shown) is included with the hinge assembly  42  and which provides a force for biasing the valve element  38  into the closed configuration, i.e., a clockwise direction pivoting about hinge assembly  42 . 
     The example of the shifting sleeve  24  of  FIG. 2  includes a main body  43  which is a substantially tubular section, and an annular collar  44  that circumscribes an uphole portion of the main body  43 . An inner circumference of the collar  44  is set radially outward from main body  43  to define a gap  46  between these two members. In the example shown, gap  46  is open on its uphole end and closed on its downhole end where the main body  43  and collar  44  are engaged with one another. Embodiments of the shifting sleeve  24  include a uni-body construction with the main body  43  and collar  44  being a single unit, alternatively the collar  44  is affixed to the main body  43  such as by a threaded fitting (not shown) a weld, fasteners, or any other currently known or later developed means of attachment. 
     Still referring to the example of  FIG. 2 , retraction sleeve  34  includes an annular primary portion  47  and a bushing  48  that mounts to an uphole end of the primary portion  47 . Bushing  48  is an annular member and spaced radially inward from primary portion  47  and defines an annular space  50 . In the example shown collar  44  inserts into annular space  50  in an arrangement analogous to an annular piston (collar  44 ) within an annular cylinder (annular space  50 ); similarly bushing  48  is analogous to an annular piston and inserted within gap  46 , illustrated analogous to an annular cylinder. An axial end of collar  52  distal from production tubing  14  is shown as a radial surface that is facing downhole and which defines a shoulder  52 , in the example of  FIG. 2  shoulder  52  is in abutting contact with an uphole end  54  of deployment sleeve  30 . Radially inward from end  54  an annular gap exists between deployment sleeve  30  and an outer surface of main body  43 . A seal element  56  is disposed within the gap to provide a sealing function between these two surfaces. 
     A pin  58  is illustrated mounted on an inner surface of collar  44  and shown projecting radially inward through a slot  60  that extends axially along a portion of a sidewall of the bushing  48 . Interaction between the pin  58  and slot  60  rotationally couple the collar  44  and bushing  48  and allow a range of axial movement between collar  44  and bushing  48 . In the illustrated embodiment, coupling of the collar  44  and bushing  48  respectively with shifting sleeve  24  and retraction sleeve  34  rotationally couples sleeves  24 ,  34  and allows free axial movement of the sleeves  24 ,  34  along an axial distance. Further in the example shown a spline  62  is formed along an outer surface of the retraction sleeve  30  and proximate an end adjacent the valve member  38 , spline  62  as shown is an elongated member oriented generally parallel with axis A X . As will be described in more detail below, spline  62  is formed to engage a channel  64  shown formed along an uphole facing surface of the valve element  38 . As noted above, the configuration of the valve assembly  10  is in the closed configuration and with a lower end  66  of shifting sleeve  24  adjacent to or in contact with the uphole facing surface of valve element  38 . A lower end  68  of deployment sleeve  68  is also shown adjacent to or in contact with the uphole facing surface of the valve element  38 . 
     Referring now to  FIG. 3 , illustrated in a side sectional view is an example step of reconfiguring the valve assembly  10  from a closed configuration into an open configuration to allow a flow of fluid therethrough. A force F A  is schematically illustrated being applied in an axial direction to the production tubing  14  through its threaded coupling to shifting sleeve  24  via threads  26 ,  28 , and in turn exerts a force onto shifting sleeve  24  to urge shifting sleeve  24  in a direction downhole. In an example force F A  is applied to production tubing  14  from a hoisting system (not shown) included with a drilling rig on surface. Downhole movement of the shifting sleeve  24  applies a force onto the valve element  38  causing it to pivot towards an open configuration and in a motion represented by arrow A 38 . Force from the shifting sleeve  24  is exerted to the valve element  38  from the lower end  66  of the shifting sleeve  24 . Further shown is that the abutting contact between shoulder  52  and end  54  also slides the deployment sleeve  30  a distance downhole and partially engages threads  32  on shifting sleeve  30  with threads  36  on the retraction sleeve  34 . In one example, threads  32  are radially compressible when pushed axially into contact with threads  36  on the retraction sleeve  34  which provides for threaded engagement between threads  32 ,  36  by an applied axial force to one or both of shifting sleeve  30  and retraction sleeve  34 . In an example sleeve  30  includes a section or sections that are biased radially outward by an underlying spring or springs (not shown); in this example and compress the threads  32  by applying a radial inward force exceeding a spring constant of the underlying spring onto threads  32  formed on the section or sections elastically urges the section or sections radially inward deforming the underlying spring. 
     Referring now to  FIG. 4 , shown in a side sectional view is an example step of operation and subsequent to the application of axial force to the production string  14  such that a portion of the main body  43  of the shifting sleeve  24  is moved downhole entirely past the valve element  38 . Abutting contact between the shoulder  52  and end  54  of the deployment sleeve  30  moves deployment sleeve  30  farther downhole so that threads  32 ,  36  are substantially engaged with one another along their respective axial lengths and which retains the deployment sleeve  30  in its axial location and adjacent to the valve member  38 . Valve member  38  is shown pivoted and set against a sidewall of housing and fully away from bore  23  and into its open configuration which is out of the path of the flow of fluid F through the valve assembly  10 . In a non-limiting example, the location of the deployment sleeve  30  as shown in  FIG. 4  is referred to as an opening location. While in the opening location the deployment sleeve  30  is in interfering contact with the valve element  38  and blocks return of the valve element  38  to the closed configuration of  FIG. 2 . In a non-limiting example of operation, the valve assembly  10  is maintained in the configuration of  FIG. 4  for a period of time during which portions of the wellbore  12  ( FIG. 1 ) downhole of the valve assembly  10  and the surface S ( FIG. 1 ) are in full communication with one another and isolation is not taking place. 
     Shown in side sectional view in  FIGS. 5 through 8  are example operational sequences for reconfiguring the valve assembly  10  in its open position of  FIG. 4  and back to a closed configuration. In a non-limiting example of operation illustrated in  FIG. 5  is that force F A  is being applied to the production string  14  in an uphole direction (a direction opposite to that of  FIG. 4 ). Via the threaded connection between threads  26 ,  28  shifting sleeve  24  is drawn uphole and within the housing of valve assembly by the uphold pulling of the production string  14 . As shown in the example of  FIG. 5  shifting sleeve  24  is freely moved upward with respect to the deployment sleeve  30 , and deployment sleeve  30  remains engaged with the retraction sleeve  34  via the engagement between threads  32 ,  34 . The length of slot  60  is dimensioned to allow axial travel of pin  58  and provides for a relative amount of axial movement between the shifting sleeve  24  and the retraction sleeve  34 . In the example of  FIG. 5  the location of pin  58  within slot  60  is at a location downhole from that of that illustrated in  FIG. 2 , and lower end  66  of shifting sleeve  24  is uphole of the opening  40  formed through the sidewall of housing  22 . Continued upward movement brings the shifting sleeve  24  to its location within housing  22  of  FIG. 3 , and as shown in  FIG. 6  collar  44  is substantially inserted within the annular space  50 . Further shown in  FIG. 6  is that a rotational force F R  is being applied to the production string  14  that rotates the production string  14 ; by virtue of the rotational coupling between the shifting sleeve  24  and retraction sleeve  34  via the pin  58  and slot  60 , the shifting sleeve  24  and the retraction sleeve  34  rotate when the production tubing  14  is rotated. In the illustrated example spline  62  of the deployment sleeve  30  is inserted within the channel  64  of the valve element  38 , which is engaged with the housing  22  via the hinge assembly  42 ; insertion of the spline  62  into channel  64  coupling of valve element  38  to housing  22  by hinge assembly  42  couples deployment sleeve  30  to housing  22  and provides a counterforce to resist rotation of the deployment sleeve  30 . In the example shown deployment sleeve  34  is rotatable with respect to the deployment sleeve  30  and the interaction between threads  32 ,  36  exerts an elevational lifting force F LIFT  onto the deployment sleeve  30  with continued application of rotational force F R  onto the production string  14 . As shown in  FIG. 7 , the lifting force F LIFT  repositions the deployment sleeve  30  uphole in the direction illustrated by A 30  and out of interfering contact with the valve element  38 . As depicted schematically by arrow A 38  the spring (not shown) within the hinge assembly  42  biases the valve element  38  towards the closed configuration.  FIG. 8  represents an example of the valve element having moved back to the closed configuration and which provides a barrier to a flow from opening  40  and into the production tubing  14  through the valve assembly  10 . 
     Alternatives exist where instead of threads  32 ,  36  on the deployment and retraction sleeves  30 ,  34 , flights or other helical members mount to one or both of these sleeves  30 ,  34 . Further optionally, an example one of the sleeves  30 ,  34  is equipped with a mating surface (not shown) which deforms radially inward when put into axial contact with the flights or threads of the opposing one of the sleeves  30 ,  34  when one of the sleeves  30 ,  34  is being inserted into the other. The inward radial deformation allows axial insertion of one of the sleeves  30 ,  34  into the other, and by rotating one of the sleeves  30 ,  34  results in an elevational lifting force to axially urge the deployment sleeve  30  uphole within housing  22 . Examples of mating surfaces include threads, flights, helically shaped elements, and a substrate formed from a pliable substance that forms complementary indentations when contacted by flights or threads of the opposing one of the sleeves  30 ,  34 . 
     In a side sectional view in  FIG. 9  an alternate example of the valve assembly  10 A is shown within a lateral bore  72 A 1 ; which is one of lateral bores  72 A 2 ,  72 A 3 ,  72 A 4 ,  72 A n  that each project generally laterally from a main bore  12 A. In this example, an end of the production string  14 A is supported within the wellhead assembly  15 A shown on surface; production string  14 A curves into the lateral bore  72 A 1  and used for selectively blocking flow from within lateral bore  72 A 1  into main bore  12 A. 
       FIG. 10  is a side view of one example of the shifting sleeve  30  and depicts the spline  62  extending axially along a portion of the outer surface of the deployment sleeve  30  and spaced away from the threads  32  that circumscribe the outer circumference of the sleeve  30 . In  FIG. 11  is overhead view of an example of the valve member  38  and in this example is shown with a substantially circular outer periphery and that the groove  64  extending along an upward facing surface of the valve element  38  and from adjacent where the hinge assembly  42  couples with valve element  38 . Alternatively shown is that the width of the groove  62  expands proximate the outer periphery of valve element  38  to facilitate entry of spline  62  ( FIG. 10 ) entering into groove  64 . Further in this example, is that a forward end of the spline  62  is rounded to avoid sharp edges and promote ease of inserting of the spline  62  into groove  64 . 
     The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims.