SYSTEM AND METHOD FOR ACTUATING TOOLS DOWNHOLE

Abstract

A technique facilitates actuation of a downhole tool in a well string. The downhole tool may be actuated hydraulically via the controlled flow of a hydraulic fluid under pressure to the downhole tool through a port. Flow of the pressurized fluid through the port is controlled by a barrier member which may be opened by a plunger working in cooperation with the barrier member. Movement of the plunger is controlled by selectively increasing the pressure acting on the plunger through, for example, actuation of an expansion device or other suitable device.

Description

BACKGROUND

In a variety of well related applications, downhole tools are actuated to perform desired functions. For example, packers, valves, and other downhole tools may be selectively actuated at specific times during a downhole procedure and/or at specific locations within a wellbore. Several types of mechanisms have been employed to enable actuation of the tool at the desired time and/or location.

For example, rupture discs and other shear mechanisms have been employed to control actuation of one or more downhole tools. However, such mechanisms often limit the number of tools that can be operated in a predetermined sequence. Additionally, these types of mechanisms can be difficult to use in applications and environments in which the maximum pressures available are limited. Intelligent triggering devices also have been used to control the selective actuation of downhole tools based on signals delivered to the intelligent triggering devices. In various environments and applications, however, some of these types of devices can be difficult to use or unreliable. Explosive materials also have been employed to open flow paths downhole. However, components with explosive materials can be difficult to ship or transport to a well site due, at least in part, to governmental regulations on handling and transporting such materials.

SUMMARY

Embodiments of the claimed system or methodology may comprise the use of a downhole tool in a well string. The downhole tool may be actuated via the controlled flow of a fluid, e.g. a hydraulic fluid, under pressure to the downhole tool through a port. Flow of the pressurized fluid through the port is controlled by a barrier member which may be opened by a plunger working in cooperation with the barrier member. Movement of the plunger is controlled by selectively increasing the pressure acting on the plunger through, for example, actuation of a gas generating device or other suitable device.

BRIEF DESCRIPTION OF THE DRAWINGS

Certain embodiments of the disclosure will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements. It should be understood, however, that the accompanying drawings only illustrate various implementations described herein and are not meant to limit the scope of various technologies described herein. The drawings are as follows:

FIG. 1 is a schematic illustration of a well system deployed in a wellbore in which the well system comprises a downhole tool that may be selectively actuated by a tool actuation system, according to an embodiment of the disclosure;

FIG. 2 is a schematic illustration of an embodiment of the tool actuation system illustrated in FIG. 1, according to an embodiment of the disclosure;

FIG. 3 is a schematic illustration of another embodiment of the tool actuation system coupled to a downhole tool, according to an embodiment of the disclosure; and

FIG. 4 is a schematic illustration of another embodiment of the tool actuation system, according to an embodiment of the disclosure.

DETAILED DESCRIPTION

In the following description, numerous details are set forth to provide an understanding of some illustrative embodiments of the present invention. However, it will be understood by those skilled in the art that various embodiments of the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.

As described herein, a tool actuation system may be utilized with a variety of downhole tools to provide dependable actuation of one or more downhole tools in a variety of well related applications. By way of example, the tool actuation system may be used in cooperation with different types of downhole valves, packers, and other downhole tools which are actuated by a fluid, e.g. a hydraulic fluid, under pressure. In many applications, such downhole tools may be actuated by the pressure of well fluid. The tool actuation system is designed to selectively control the flow of high pressure well fluid to the desired downhole tool or tools.

According to one embodiment, the tool actuation system comprises a barrier member, e.g. a pressure membrane/rupture disc or valve, which blocks flow of pressurized actuating fluid to a downhole tool. A plunger is movably mounted within a housing and is oriented to transition the barrier member. For example, the plunger may be positioned to open a valve or to impact a rupture disc in a manner which fractures or weakens the rupture disc. The plunger is driven by expansion of a suitable material within an expansion chamber, and the suitable expansion material may comprise a gas generating energetic material. However, the plunger and the expansion material are uniquely designed so the system falls within the US Department of Transportation (DOT) “Not Regulated” class. The design enables shipping of the product without labeling the product as explosive and without subjecting the product to the shipping restrictions required with respect to explosive devices.

Expansion of the selected material within the expansion chamber is initiated by an initiator device which may be designed to receive signals from an uphole location, e.g. a surface location. A variety of techniques and types of systems may be employed to communicate signals downhole to the initiator device to selectively initiate opening of the port and flow of pressurized actuating fluid to the downhole tool or tools. By way of example, the signals may be transmitted via cable-to-surface systems, electromagnetic telemetry systems, acoustic telemetry systems, wireline systems, coiled tubing with wireline systems, coiled tubing with fiber optic systems, drilling and measurement systems (e.g. mud pulse or electromagnetic telemetry systems), or other suitable telemetry systems. Additionally, the tool actuation system may comprise a plurality of trigger systems, e.g. a plurality of plungers, which cooperate with corresponding barrier members to enable repeated closing and opening of the port for repeated downhole tool actuations.

Referring in general to FIGS. 1 and 2, a well system 20 is illustrated as employing an embodiment of a downhole tool actuation system 22 which is able to selectively actuate a downhole tool 24. By way of example, downhole tool 24 may comprise a packer, a flow valve, or a variety of other downhole tools that are actuated by pressurized fluid. In many applications, the downhole tool or tools 24 may be hydraulically actuated by well fluid or by another hydraulic fluid delivered downhole along an appropriate conduit or other flow passage.

In the example illustrated, well system 20 comprises a downhole equipment assembly 26 which incorporates downhole tool 24. The downhole equipment assembly 26 may comprise a bottom hole assembly, a well completion assembly, or other types of downhole equipment selected according to the specific well operation being conducted. The downhole equipment assembly 26 may be delivered downhole along a wellbore 28 from a surface location 30 via a suitable conveyance 32. Depending on the well application, conveyance 32 may comprise production tubing, coiled tubing, cable, wireline, slick line, or other suitable conveyances.

The downhole tool actuation system 22 comprises a downhole portion 34 which may be referred to as the trigger system. The downhole portion 34 is selectively operated to control flow of actuating fluid to downhole tool 24 based on signals received from a control system 36. In some embodiments, downhole portion 34 operates to open a port 38 which allows high pressure well fluid to flow into downhole tool 24 from an annulus 40 surrounding the downhole tool 24. The high pressure well fluid serves to actuate downhole tool 24 by shifting the downhole tool to a desired operational configuration. However, port 38 may be positioned to control flow through hydraulic control lines, through an interior of conveyance 32, or through other suitable features to selectively enable flow of actuating fluid to downhole tool 24.

In the example illustrated, control system 36 is positioned at a surface location 30, however the control system also may be positioned at remote locations or at both remote and well site locations. In some applications, the control system 36 may be manually operated while in other applications the control system 36 is partially or fully automated to act upon the occurrence of specific parameters detected downhole or at other locations. If the control system 36 is automated, the control may be conducted from a downhole location in certain applications. In the example illustrated, however, control system 36 is coupled to downhole portion 34 by a suitable communication line 42 which may be a hard wired or wireless communication line. Depending on the well application, a variety of telemetry systems may be employed for conveying signals between control system 36 and downhole portion 34. By way of example, signals/commands may be transmitted via acoustic telemetry (e.g. mud pulse telemetry), electromagnetic telemetry, seismic telemetry (e.g. air guns, detonation sources, or impact sources positioned at the surface), radio frequency telemetry (e.g. RF tag telemetry systems), electrically conductive path systems from surface or subsurface (e.g. wireline or control line type systems), or combinations of the telemetry systems.

Depending on the specific well application and on the type of telemetry system employed to convey signals downhole, the downhole portion 34 may have various configurations. As illustrated in greater detail in FIG. 2, for example, the downhole portion 34 may comprise a barrier member 44 which initially blocks flow of actuating fluid through port 38. By way of example, the barrier member 44 comprises a valve or a pressure membrane, e.g. a rupture disc. In the embodiment illustrated, a plunger member 46 is positioned and oriented to engage barrier member 44. Plunger member 46 is movably, e.g. slidably, mounted within a surrounding housing 48, such as a cylindrical housing. Movement of plunger member 46 with respect to barrier member 44 serves to selectively transition the barrier member 44 to a flow position which allows flow of actuating fluid through port 38 to actuate downhole tool 24. For example, plunger member 46 may be moved to transition a valve or to fracture a rupture disc so that actuating fluid may freely flow through port 38.

Plunger member 46 is moved by an expansion device 50 which may be in the form of a gas generating device. In the example illustrated, expansion device 50 is a gas generating device having an expansion chamber 52 in which gases are rapidly expanded to drive the plunger member 46 which, in turn, opens port 38. The expansion device 50 comprises an expansion material 54 disposed in expansion chamber 52, and the expansion material 54 may be in the form of a gas generating energetic material, e.g. a pyrotechnic material. The expansion material 54 rapidly expands upon initiation of the desired reaction by an initiator device 56 which receives command signals from control system 36 via communication line 42. As described above, the communication line 42 may be wired or wireless and it may carry a variety of signals depending on the type of telemetry system employed in the downhole tool actuation system 22.

However, the expansion device 50 is designed as a DOT “Not Regulated” class device to facilitate handling and transport of the device. Specifically, expansion device 50 is designed (and the expansion material 54 and/or plunger member 46 are selected) such that the expansion device 50 and overall tool system meet the testing criteria required for such devices. In this example, the testing criteria include assessing the expansion material 54 and/or the component containing the expansion material 54, e.g. expansion chamber 52, to ensure the component/materials are not ruptured or fragmented. The criteria further comprise ensuring the surface temperature in the vicinity of the expansion device 50 containing the expansion material 54 does not exceed 100° C. and ensuring the device provides little or no smoke generation. Additionally, the criteria require that the audible report from initiation of the expansion material does not exceed 150 dB when measured with an ANSI type 1 sound level meter placed not more than 1 meter away or does not exceed 140 dB when measured with an ANSI type 2 sound level meter placed not more than 1 meter away from the expansion material 54. Furthermore, the criteria require that no mechanical movement of more than 1 meter occurs in any direction as result of initiation of the expansion material 54, e.g. movement of plunger member 46. The structure of plunger member 46 and expansion chamber 52, the amount and type of expansion material 54, and the overall arrangement of the expansion device 50 and downhole tool 24, as described and illustrated herein, are designed within these criteria.

Accordingly, use of gas generating energetic material 54 to push the plunger member 46 facilitates the handling, transport, and implementation of the actuation system 22. By utilizing the gas generating energetic material 54 in the manner described, the overall actuation system 22 also avoids generation of fragments and/or release of hot gases. The amount of gas generating energetic material 54 and the design of plunger member 46 is selected to enable classification of the system and components as Not Regulated materials, as described above. This allows the expansion device 50 and other components of the actuation system to be shipped by standard commercial carriers. Consequently, the handling, transport, and implementation of such devices are substantially improved and simplified.

Referring generally to FIG. 3, an embodiment of the downhole portion 34 of downhole tool actuation system 22 is illustrated as coupled to downhole tool 24. In this embodiment, communication line 42 is a wireless communication line and the telemetry system is an acoustic, pressure pulse type telemetry system. Control system 36 controls the delivery of pressure pulses down hole through wellbore 28 along, for example, annulus 40. The pressure pulses are received by initiator device 56 which comprises a pressure sensor 58 designed to detect a series of pressure pulses that represent a signature associated with activation of expansion material 54 within expansion chamber 52.

The pressure sensor 58 works in cooperation with a battery 60 and an electronics module 62. The battery 60 is configured to supply electrical energy to electronics module 62 which, in turn, is designed to interpret the series of pressure pulses detected by pressure sensor 58. If a predetermined series of pressure pulses is detected by electronics module 62, the electronics module outputs an activation signal via appropriate communication lines 64, e.g. conductors, to initiate the expansion, e.g. gas generation, of expansion material 54 in expansion device 50. By way of example, the communication lines 64 may deliver an appropriate current, spark, chemical, or other signal to initiate the rapid expansion within expansion chamber 52. It should be noted that battery 60 may be replaced with other electric energy supplies, such as capacitors or electric supply lines routed downhole. Additionally, the electronics module 62 may comprise a variety of electronics modules, including processor-based modules. An example of one type of battery and electronics module which can be employed in the illustrated embodiment is described in U.S. Pat. No. 7,510,001.

Rapid expansion of expansion material 54 drives plunger member 46 along an interior of housing 48. By way of example, housing 48 may have a cylindrical interior 66 which serves as a cylinder along which the plunger member 46 slides to transition barrier member 44. In the embodiment illustrated, barrier member 44 comprises a valve 68 coupled to plunger member 46 by a coupling mechanism 70. As plunger member 46 is forced along interior 66, the coupling mechanism 70 transitions valve 68 from a closed position to an open position which allows the flow of hydraulic actuating fluid through port 38. Valve 68 may comprise a variety of valve types, including sliding sleeve valves and ball valves. As with the previously described embodiments, the expansion device 50, along with expansion material 54/plunger member 46, is designed as a DOT Not Regulated class device to facilitate handling and transport.

Referring generally to FIG. 4, an alternate embodiment of the downhole portion 34 of tool actuation system 22 is illustrated. In this embodiment, barrier member 44 comprises a pressure membrane 72, e.g. a rupture disc, which initially prevents flow of actuating fluid through port 38. The port 38 may be positioned in a wall of housing 48. The plunger member 46 comprises an impact member 74 oriented to impact pressure membrane 72 when expansion material 54 expands and forces plunger member 46 to move along the interior of housing 48. By way of example, the impact member 74 may have a pointed end which impacts and fractures the pressure membrane 72 to allow flow of actuating fluid through port 38 and along a conduit 76 to downhole tool 24. Alternatively, the impact member 74 and plunger member 46 may be designed to sufficiently weaken pressure membrane 72 upon impact to allow the pressure of the actuating fluid to remove the barrier and enable flow to downhole tool 24.

In the example illustrated in FIG. 4, expansion material 54 may again be a gas generating energetic material located within expansion chamber 52. The initiator device 56 is located adjacent expansion device 50 and is designed to selectively initiate the expansion of expansion material 54 upon receipt of an activating command signal through communication line 42. The expansion of material 54 then drives plunger member 46 along the interior of housing 48 until impact member 74 impacts the pressure membrane 38 and opens a flow pathway to allow flow of pressurized fluid through port 38 to the downhole tool 24. In this latter embodiment, the expansion device 50 is again constructed as a DOT Not Regulated class device.

The specific configuration of the downhole tool actuation system 22 and its downhole portion 34 may be adjusted according to the parameters of a given well application and/or environment. The type of expansion material 54 may be selected according to the temperatures, pressures, environmental conditions, and/or system conditions related to the well operation being conducted. Also, the configuration of the plunger member, initiator device, electronics module, housing, barrier member, control system, communication/telemetry system, all may be adjusted or interchanged according to the needs of a given application.

Additionally, other mechanisms may be combined with, used in cooperation with, or employed as an alternative to the mechanisms described above for selectively transitioning the barrier member 44 to an open flow condition. In some embodiments, the barrier member may initially be weakened or combined with a weakening material, e.g. a chemical, designed to degrade the barrier member. For example, the pressure membrane may be selectively exposed to corrosive or reactive materials which deconstruct the membrane. Thus, the plunger member 46 may be used in cooperation with a variety of chemicals or other features designed to weaken or otherwise alter the pressure membrane or other type of barrier member 44 to facilitate opening of the flow port.

Although only a few embodiments of the present invention have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this invention. Accordingly, such modifications are intended to be included within the scope of this invention as defined in the claims.

Claims

1. A system for use in a well, comprising:

a downhole tool to be actuated by pressure exerted by well fluid; and

a downhole tool actuation system, comprising: an inlet port in communication with the well fluid; a pressure sensor for receiving one or more pressure pulses; an electronics module in communication with the pressure sensor, wherein the electronics module processes the one or more pressure pulses to detect a command for actuating the downhole tool; an expansion device having an expansion chamber for expansion of a gas generating energetic material, wherein the audible report from initiation of the expansion device does not exceed 150 dB as measured on an ANSI type I sound level meter placed not more than 1 meter away; a plunger disposed in a housing and in communication with the expansion device, wherein the plunger is constrained to movement of not more than 1 meter in any direction; and a barrier positioned to block flow through the inlet port such that actuation of the expansion device drives the plunger into the barrier to enable flow through the inlet port.

2. The system as recited in claim 1, wherein the plunger is figured to rupture the barrier.

3. The system as recited in claim 1, wherein the barrier comprises a rupture disc.

4. The system as recited in claim 1, wherein the plunger is configured to weaken the barrier.

5. The system as recited in claim 1, wherein the expansion device locates the gas generating energetic material in the housing.

6. The system as recited in claim 1, wherein the downhole tool comprises a flow valve.

7. The system as recited in claim 1, wherein the housing comprises the inlet port to enable exposure of the downhole actuation tool to actuating pressure of the well fluid after the plunger engages the barrier.

8. A method for actuating a tool downhole, comprising:

positioning the tool in a well string, the tool being hydraulically actuatable by a hydraulic fluid;

locating a barrier member to block flow of the hydraulic fluid through a port to the tool;

orienting a plunger between the barrier member and an expansion device containing a gas generating energetic material in a manner such that any audible report from initiation of the gas generating energetic material is less than 140 dB as measured by an ANSI type 2 sound level meter positioned at a distance of less than 1 meter and such that initiation of the gas generating energetic material provides no mechanical movement of more than 1 meter; and

coupling the expansion device to an initiator device able to receive signals from uphole regarding actuation of the gas generating energetic material.

9. The method as recited in claim 8, further comprising sending a signal downhole to the initiator device to actuate the expansion device and drive the plunger into the barrier member.

10. The method as recited in claim 8, further comprising locating a rupture disc in the port.

11. The method as recited in claim 8, wherein orienting comprises slidably orienting the plunger in a cylindrical housing adjacent the barrier.

12. The method as recited in claim 9, wherein sending the signal downhole comprises sending an acoustic signal downhole to the initiator device.

13. The method as recited in claim 9, wherein sending the signal downhole comprises sending an electromagnetic signal downhole to the initiator device.

14. The method as recited in claim 9, wherein sending the signal downhole comprises sending a seismic telemetry signal downhole to the initiator device.

15. The method as recited in claim 9, wherein sending the signal downhole comprises sending a radiofrequency signal downhole to the initiator device.

16. The method as recited in claim 8, further comprising forming the expansion device with the gas generating energetic material located in an internal expansion chamber.

17. The method as recited in claim 8, further comprising hydraulically actuating the tool with well fluid.

18. A method of constructing and actuatable downhole tool system, comprising:

providing a port in communication with a downhole tool which may be hydraulically actuated;

positioning a barrier member to selectively block flow of fluid through the port;

orienting a plunger member to selectively transition the barrier member in a manner which allows flow of actuating fluid through the port to actuate the downhole tool;

locating an expansion chamber adjacent the plunger member;

placing an expansion material in the expansion chamber, the expansion material being selectively expandable to drive the plunger member to transition the barrier member; and

simplifying transportability of the actuatable downhole tool system by: ensuring the expansion chamber is not ruptured; maintaining temperature in the area surrounding the expansion material to a temperature that does not exceed 100° C.; minimizing the audible report from initiation of the expansion material to less than 150 dB as measured by an ANSI type 1 sound level meter at not more than 1 meter away; and limiting mechanical movement due to initiation of the expansion material to less than 1 meter.

19. The method as recited in claim 18, wherein positioning the barrier member comprises positioning a valve.

20. The method as recited in claim 18, wherein positioning the barrier member comprises positioning a rupture disc.