Abstract: A method and apparatus including a subsurface tool, such as a flapper closure valve, that has an integrally formed body and that includes at least one of an internal void located within the body of the flapper closure plate; and an indentation extending from an exterior surface of the body of the flapper closure plate, the indentation having an opening defining a first dimension along a first direction at the exterior surface of the body, the indentation defining an indentation surface extending within the body, the indentation surface defining a second dimension along the first direction within the body, the second dimension being greater than the first dimension. In one or more exemplary embodiments, the flapper closure plate is at least partially manufactured using an additive manufacturing process.

Abstract: A downhole fluid flow control apparatus is disclosed. The fluid flow control apparatus includes a substantially tubular housing. In one embodiment, the fluid flow control device includes an inner diameter and an outer diameter, the inner diameter having a profile defined by one or more contour lines. The fluid flow control apparatus further includes a plurality of circular orifices defined on the tubular housing. In another embodiment, the fluid flow control apparatus includes a plurality of slotted orifices defined on the tubular housing.

Abstract: A method and apparatus including a subsurface tool, such as a flapper closure valve, that has an integrally formed body and that includes at least one of an internal void located within the body of the flapper closure plate; and an indentation extending from an exterior surface of the body of the flapper closure plate, the indentation having an opening defining a first dimension along a first direction at the exterior surface of the body, the indentation defining an indentation surface extending within the body, the indentation surface defining a second dimension along the first direction within the body, the second dimension being greater than the first dimension. In one or more exemplary embodiments, the flapper closure plate is at least partially manufactured using an additive manufacturing process.

Abstract: A downhole circulating valve includes a generally tubular outer housing having a generally axially extending internal passageway. At least one generally longitudinally extending circulating passageway is formed through at least a portion of the housing. At least one exterior port and at least one interior port are in fluid communication with the circulating passageway. At least one seal plug is disposed within the circulating passageway. The seal plug has a first position relative to the housing wherein the seal plug is remote from the exterior port and the interior port, thereby allowing fluid flow between the exterior port and the interior port through the circulating passageway. The seal plug has a second position relative to the housing wherein the seal plug is between the exterior port and the interior port and wherein the seal plug forms at least one metal-to-metal seal with the circulating passageway, thereby preventing fluid flow between the exterior port and the interior port.

Abstract: A downhole circulating valve includes a generally tubular outer housing having an axially extending internal passageway including an internal seat and at least one generally radially extending opening formed through the housing intersecting the internal seat. A valve element is rotatably disposed within the internal passageway. The valve element has an axially extending internal bore and a head portion disposed at least partially within the internal seat. The head portion includes at least one generally radially extending seal element. The valve element has a first position relative to the housing, wherein the seal element is not aligned with the opening, thereby allowing fluid communication between the opening and the internal passageway.

Abstract: A downhole fluid flow control apparatus is disclosed. The fluid flow control apparatus includes a substantially tubular housing. In one embodiment, the fluid flow control device includes an inner diameter and an outer diameter, the inner diameter having a profile defined by one or more contour lines. The fluid flow control apparatus further includes a plurality of circular orifices defined on the tubular housing. In another embodiment, the fluid flow control apparatus includes a plurality of slotted orifices defined on the tubular housing.

Abstract: Certain aspects and embodiments of the present invention are directed to a subsurface safety valve that can be disposed in a wellbore that is through a fluid-producing formation. The subsurface safety valve can include a closure mechanism, a sleeve, and a control line. The closure mechanism can be positioned in a passageway defined by a tubing string. The closure mechanism can be configured to prevent a flow of fluid to a portion of the passageway that is closer to a surface of the wellbore than the closure mechanism. The sleeve can be positioned in the passageway adjacent to the closure mechanism. The control line can communicate pressure to a piston from a pressure source within an inner diameter of the tubing string, causing the piston to apply a force to the sleeve. The sleeve can open the closure mechanism in response to the force being applied to the sleeve.

Abstract: A sealing array for positioning in an annular space between tubular members to provide a seal therebetween. The sealing array includes a pair of oppositely disposed backup rings, each defining a primary outer seal member of the sealing array. A pair of rigid cap rings is disposed between the backup rings. Each cap ring has a substantially planar surface and an oppositely disposed surface that engages one of the backup rings to energize the backup rings upon the application of sufficient pressure. The cap rings are sized to form controlled extrusion gaps with both tubular members. An energizing element is disposed between the planar surfaces of the cap rings. The energizing element engages a planar surface of at least one of the cap rings and seals the extrusion gaps associated with the engaged cap ring upon the application of sufficient pressure.

Abstract: A downhole circulating valve includes a generally tubular outer housing having an axially extending internal passageway including an internal seat and at least one generally radially extending opening formed through the housing intersecting the internal seat. A valve element is rotatably disposed within the internal passageway. The valve element has an axially extending internal bore and a head portion disposed at least partially within the internal seat. The head portion includes at least one generally radially extending seal element. The valve element has a first position relative to the housing, wherein the seal element is not aligned with the opening, thereby allowing fluid communication between the opening and the internal passageway.

Abstract: A downhole circulating valve includes a generally tubular outer housing having a generally axially extending internal passageway. At least one generally longitudinally extending circulating passageway is formed through at least a portion of the housing. At least one exterior port and at least one interior port are in fluid communication with the circulating passageway. At least one seal plug is disposed within the circulating passageway. The seal plug has a first position relative to the housing wherein the seal plug is remote from the exterior port and the interior port, thereby allowing fluid flow between the exterior port and the interior port through the circulating passageway. The seal plug has a second position relative to the housing wherein the seal plug is between the exterior port and the interior port and wherein the seal plug forms at least one metal-to-metal seal with the circulating passageway, thereby preventing fluid flow between the exterior port and the interior port.

Abstract: A downhole circulating valve includes a generally tubular outer housing having a generally axially extending internal passageway. At least one generally longitudinally extending circulating passageway is formed through at least a portion of the housing. At least one exterior port and at least one interior port are in fluid communication with the circulating passageway. At least one seal plug is disposed within the circulating passageway. The seal plug has a first position relative to the housing wherein the seal plug is remote from the exterior port and the interior port, thereby allowing fluid flow between the exterior port and the interior port through the circulating passageway. The seal plug has a second position relative to the housing wherein the seal plug is between the exterior port and the interior port and wherein the seal plug forms at least one metal-to-metal seal with the circulating passageway, thereby preventing fluid flow between the exterior port and the interior port.

Abstract: A downhole circulating valve includes a generally tubular outer housing having a generally axially extending internal passageway. At least one generally longitudinally extending circulating passageway is formed through at least a portion of the housing. At least one exterior port and at least one interior port are in fluid communication with the circulating passageway. At least one seal plug is disposed within the circulating passageway. The seal plug has a first position relative to the housing wherein the seal plug is remote from the exterior port and the interior port, thereby allowing fluid flow between the exterior port and the interior port through the circulating passageway. The seal plug has a second position relative to the housing wherein the seal plug is between the exterior port and the interior port and wherein the seal plug forms at least one metal-to-metal seal with the circulating passageway, thereby preventing fluid flow between the exterior port and the interior port.

Abstract: A downhole circulating valve includes a generally tubular outer housing having an axially extending internal passageway including an internal seat and at least one generally radially extending opening formed through the housing intersecting the internal seat. A valve element is rotatably disposed within the internal passageway. The valve element has an axially extending internal bore and a head portion disposed at least partially within the internal seat. The head portion includes at least one generally radially extending seal element. The valve element has a first position relative to the housing, wherein the seal element is not aligned with the opening, thereby allowing fluid communication between the opening and the internal passageway.

Abstract: A downhole circulating valve includes a generally tubular outer housing having an axially extending internal passageway including an internal seat and at least one generally radially extending opening formed through the housing intersecting the internal seat. A valve element is rotatably disposed within the internal passageway. The valve element has an axially extending internal bore and a head portion disposed at least partially within the internal seat. The head portion includes at least one generally radially extending seal element. The valve element has a first position relative to the housing, wherein the seal element is not aligned with the opening, thereby allowing fluid communication between the opening and the internal passageway.

Abstract: Certain aspects and embodiments of the present invention are directed to a subsurface safety valve that can be disposed in a wellbore that is through a fluid-producing formation. The subsurface safety valve can include a closure mechanism, a sleeve, and a control line. The closure mechanism can be positioned in a passageway defined by a tubing string. The closure mechanism can be configured to prevent a flow of fluid to a portion of the passageway that is closer to a surface of the wellbore than the closure mechanism. The sleeve can be positioned in the passageway adjacent to the closure mechanism. The control line can communicate pressure to a piston from a pressure source within an inner diameter of the tubing string, causing the piston to apply a force to the sleeve. The sleeve can open the closure mechanism in response to the force being applied to the sleeve.

Abstract: A sealing array for positioning in an annular space between tubular members to provide a seal therebetween. The sealing array includes a pair of oppositely disposed backup rings, each defining a primary outer seal member of the sealing array. A pair of rigid cap rings is disposed between the backup rings. Each cap ring has a substantially planar surface and an oppositely disposed surface that engages one of the backup rings to energize the backup rings upon the application of sufficient pressure. The cap rings are sized to form controlled extrusion gaps with both tubular members. An energizing element is disposed between the planar surfaces of the cap rings. The energizing element engages a planar surface of at least one of the cap rings and seals the extrusion gaps associated with the engaged cap ring upon the application of sufficient pressure.

Abstract: Systems and methods are provided for treating a wellbore using a loop system to heat oil in a subterranean formation contacted by the wellbore. The loop system comprises a loop that conveys a fluid (e.g., steam) down the wellbore via a injection conduit and returns fluid (e.g., condensate) from the wellbore via a return conduit. A portion of the fluid in the loop system may be injected into the subterranean formation using one or more valves disposed in the loop system. Alternatively, only heat and not fluid may be transferred from the loop system into the subterranean formation. The fluid returned from the wellbore may be re-heated and re-conveyed by the loop system into the wellbore. Heating the oil residing in the subterranean formation reduces the viscosity of the oil so that it may be recovered more easily.

Abstract: Systems and methods are provided for treating a wellbore using a loop system to heat oil in a subterranean formation contacted by the wellbore. The loop system comprises a loop that conveys a fluid (e.g., steam) down the wellbore via a injection conduit and returns fluid (e.g., condensate) from the wellbore via a return conduit. A portion of the fluid in the loop system may be injected into the subterranean formation using one or more valves disposed in the loop system. Alternatively, only heat and not fluid may be transferred from the loop system into the subterranean formation. The fluid returned from the wellbore may be re-heated and re-conveyed by the loop system into the wellbore. Heating the oil residing in the subterranean formation reduces the viscosity of the oil so that it may be recovered more easily.

Abstract: Methods of operating a downhole tool comprise thermally-controlling the tool by sensing a temperature and controlling the tool in response to the sensed temperature. Thermally-controlled downhole tools comprise a control element responsive to a change in temperature that control flow into, out of, or through a wellbore. Methods and systems for servicing a wellbore comprise using a thermally-controlled tool comprising a thermally-controlled valve (TCV) in a wellbore. The TCV includes a valve body comprising an injection port for allowing material to flow into or out of the wellbore and an opening/closing mechanism for regulating flow of the material through the injection port in response to a change in temperature. The valve body may be coupled to a downhole conduit. A plurality of TCV's may be arranged in the wellbore to control the injection of steam into the wellbore or the recovery of oil from the wellbore.

Abstract: A downhole power generator produces electrical power for use by downhole tools. In a described embodiment, a downhole power generator includes a member that is vibrated in response to fluid flow through a housing. Vibration of the member causes a power generating assembly to generate electrical power.