ACTUATOR FOR A SEPARATE DOWNHOLE TOOL, METHOD AND SYSTEM

Abstract

An actuator for a separate downhole tool, including an electric linear actuator, a latch driven by the linear actuator and configured to interact with and operate a movable component of the separate tool. A subsurface safety valve system, including a subsurface safety valve having a flow tube, the valve lacking an operable actuator, and an actuator runnable into the valve, the actuator latchable to the valve to operate the flow tube. A method for controlling a well including installing a subsurface safety valve in a tubing string at a target location in a borehole of the well, the subsurface safety valve lacking an actuator, running an actuator to the valve, engaging the actuator with the valve, and operating the valve with the actuator. A borehole system including a borehole in a subsurface formation, a string in the borehole, and an actuator disposed within or as a part of the string.

Description

BACKGROUND

In the resource recovery and fluid sequestration industries tools are used that require actuation. There are many considerations that dictate size and cost of such tools. The art is always seeking alternatives.

SUMMARY

An embodiment of an actuator for a separate downhole tool, including an electric linear actuator, a latch driven by the linear actuator and configured to interact with and operate a movable component of the separate tool.

An embodiment of a subsurface safety valve system, including a subsurface safety valve having a flow tube, the valve lacking an operable actuator, and an actuator runnable into the valve, the actuator latchable to the valve to operate the flow tube.

An embodiment of a method for controlling a well including installing a subsurface safety valve in a tubing string at a target location in a borehole of the well, the subsurface safety valve lacking an actuator, running an actuator to the valve, engaging the actuator with the valve, and operating the valve with the actuator.

An embodiment of a borehole system including a borehole in a subsurface formation, a string in the borehole, and an actuator disposed within or as a part of the string.

BRIEF DESCRIPTION OF THE DRAWINGS

The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:

FIG. 1 is a schematic view of a first embodiment of an actuator for a separate downhole tool as disclosed herein;

FIG. 2 is an end view of the actuator of FIG. 1;

FIG. 3 is a schematic view of a second embodiment of an actuator for a separate downhole tool as disclosed herein;

FIG. 4 is a schematic view of the first embodiment engaged with a separate downhole tool; and

FIG. 5 is a view of a borehole system including the actuator for a separate downhole tool as disclosed herein.

DETAILED DESCRIPTION

A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.

Referring to FIGS. 1-3, an actuator 10 for a separate downhole tool 11 is illustrated. What is meant by a “separate downhole tool” is a tool that is not a part of the actuator nor is the actuator a part of the tool in the manufactured state. Rather the tool is separate from the actuator and in some embodiments does not have an actuator at all. In other embodiments, the tool may have its own actuator in an initial state but the actuator 10 would be used to replace the original actuator and yet still actuate the same original components of the tool rather than being, for example a replacement tool such as a wireline retrievable safety valve. In an embodiment, the tool is a subsurface safety valve that may be surface controlled. This is illustrated in the Figures but it is to be understood that the actuator 10 disclosed herein could be used with other tools as well and this disclosure is not intended to limit the contemplation of the actuator 10 to only safety valves.

Actuator 10 includes a linear actuator 12 that is electrically responsive. It is meant by this statement that an electrical signal is used to initiate the linear actuator. This may be, in one embodiment by an inductive coupling between the separate tool and the actuator 10, or other electrical connection. It may also be by battery power (including battery power that is supplemented or recharged through the electrical connection, inductive or otherwise).

Still referring to FIG. 1, the actuator 10 includes a housing 14, within which the linear actuator 12 is disposed. In an embodiment, the linear actuator 12 may be a motor 16 and screw 18 but also may be other linear movement devices that are responsive to electrical signals such as a linear motor, a solenoid, etc. Since these two alternative linear actuators look substantially the same as the motor 16 and screw 18 in a schematic drawing, it is intended that the drawing FIG. 1 also be understood to represent these embodiments.

In an embodiment, the housing 14 is configured as a telescopic structure with a first part 20 and a second part 22 that is sealed to the first part 20 with seals 24 and is slidable relative to the first part 20. The second part 22, then may also include at least a part of a latch 26. Since it is often desirable to maintain linear actuators in a clean environment, a chamber 28 defined within the first and second parts of the housing 14, and within which is located the linear actuator 12, may be filled with a clean liquid (such as hydraulic fluid) or atmospheric air or other gas. Embodiments may also include a pressure compensation configuration 30 such as a diaphragm or a piston to manage pressure and or temperature differentials to which the actuator is exposed during use.

Operably connected to the screw 18 (or other linear construction) is a follower 32, which may be a ball nut or roller screw or similar. The follower 32 is movable linearly (longitudinally of the actuator 10) based upon input from screw 18 and is connected, if only by contact, to the second part 22 of housing 14. The second part 22, then is movable relative to the first part 20 based upon movement of the follower 32 on the screw, pursuant to rotation of the motor 16. Accordingly, pursuant to an electrical signal provided to the motor 16, the follower 32 and second part 22 may be displaced relative to the first part 20. The latch 26, being connected to the second part 22 will also move. The latch 26 may in some embodiments directly connect to the separate tool 11 (see FIG. 3) at recess 38 (or the latch may have the recess and the tool 11 have the projection) or may form a part of a connection that also includes a collet 34 (illustrated in FIG. 1, with the same caveat as to the male versus female configurations). The collet 34 is deflected into engagement with the separate tool 11 at recess 38 and locked in that position by the portion of latch 26 that is connected to the second part 22. The collet 34 is supported on the actuator 10 by frame 36 extending radially outwardly from the housing 14. It should be understood that separate tool 11 is schematically illustrated in FIGS. 1-3 as only a flow tube 40 portion of the tool 11. It should be appreciated that the rest of the tool 11 is contemplated as are different tools that could benefit from the actuator 10. One embodiment of a separate tool 11 with the actuator 10 engaged therein is illustrated in FIG. 4.

Referring to FIG. 4, the actuator 10 is illustrated already landed and engaged with separate tool 11. Separate tool 11, in the illustration is a subsurface safety valve. While the disclosure hereof is not limited to separate tools 11 being safety valves, it does serve as a good example. The tool 11 includes a housing 50 that supports a flapper 52, a flow tube 40, and a power spring 54. The flow tube 40 is configured with the recess 38 therein (that may of course be reversed with regard to the male or female configuration). What is noticeably absent is an actuator in this tool 11. Normally, there would be some kind of actuator in the housing 50 that moves the flow tube 40 on demand. This might be a hydraulic system or might be an electrical system but according to the prior art, it would be a part of tool 11 and housed in the housing 50. In an embodiment of the system that is described herein, such an actuator in the housing 50 is not needed. This can reduce complexity and cost during the build of the original completion and may increase the flow bore for operations that do not require operation of the tool 11. It is also well to note that the actuator 10 described herein merely needs a way to engage the tool 11 (the recess 38 in some embodiments) and hence could also be used as a remediative device for tools 11 that actually did have an actuator housed by housing 50 ab initio but has since stopped working.

Still referring to FIG. 4, some embodiments will be provisioned with an inductive coupler 56 housed by housing 50 (in an embodiment a valve inductive coupler). The inductive coupler 56 is configured to communicate with an actuator inductive coupler 58 to power the actuator 10, charge a battery 60 of the actuator 10 or both. It will be appreciated that FIG. 4 uses the embodiment of FIG. 1 with regard to the engagement with the tool 11 but the embodiment of FIG. 3 could be substituted. FIG. 4 provides further insight to the system as well since a flow path 62 for borehole fluids 64 is illustrated. It will be noted by those of skill in the art that the actuator 10 is located in an inside diameter flow path 66 of the housing 50 and related tubing string. This is an impediment to through tubing operations but is not an impediment to fluid flow. Rather the fluid 64 may flow around the actuator 10 with very little restriction and hence very little pressure drop, if any.

Referring to FIG. 5, a borehole system 70 is schematically illustrated. The system 70 comprises a borehole 72 in a subsurface formation 74. A string 76 is disposed within the borehole 72. In generally the string 76 may include a tool 11 that lacks an actuator (or perhaps suffers with an actuator that has ceased functioning) and includes a feature for engagement with an actuator 10 such as the recess 38 of flow tube 40 discussed above. The system further includes an actuator 10 disposed within or as a part of the string 76 disclosed herein. In use, the previously installed tool 11 is in need of actuation and the actuator 10 is run to engagement therewith on wireline or similar. The actuator 10 is engaged with the tool 11 and an electrical signal is fed to the actuator wither through the wireline or through the inductive coupling discussed above or via battery in the actuator 10 or nearby. Upon the signal being delivered to the actuator 10, the latch 26 (referring back to FIG. 4) is urged to move and moves some component of the tool 11, which in some cases would be the flow tube 40. Upon loss of signal, whether by design or fortuity, the tool 11 may revert to its original condition. This may be a fail safe condition and in the case of a safety valve this would occur based upon the power spring 54 urging the flow tube 40 to a position that does not force flapper 52 open. In embodiments, the linear actuator 12 may be backdrivable or there may be a failsafe signal to automatically reverse the direction of movement of the latch in the event a loss of the primary open signal is lost.

Set forth below are some embodiments of the foregoing disclosure:

Embodiment 1: An actuator for a separate downhole tool, including an electric linear actuator, a latch driven by the linear actuator and configured to interact with and operate a movable component of the separate tool.

Embodiment 2: The actuator as in any prior embodiment, wherein the linear actuator comprises a motor and screw.

Embodiment 3: The actuator as in any prior embodiment, further comprising a follower connected to the screw and to the latch.

Embodiment 4: The actuator as in any prior embodiment, wherein the linear actuator is a linear motor.

Embodiment 5: The actuator as in any prior embodiment, further comprising a housing, within which is disposed the linear actuator.

Embodiment 6: The actuator as in any prior embodiment, wherein the housing defines a chamber, the chamber being filled with clean fluid.

Embodiment 7: The actuator as in any prior embodiment, wherein the housing includes a pressure compensation configuration.

Embodiment 8: The actuator as in any prior embodiment, wherein the actuator further includes a collet, the collet being selectively deflectable into contact with the moveable component of the separate tool.

Embodiment 9: The actuator as in any prior embodiment, further comprising an inductive coupling connected to the motor.

Embodiment 10: The actuator as in any prior embodiment, further comprising a battery.

Embodiment 11: The actuator as in any prior embodiment, wherein the movable component is a flow tube of a subsurface safety valve.

Embodiment 12: A subsurface safety valve system, including a subsurface safety valve having a flow tube, the valve lacking an operable actuator, and an actuator runnable into the valve, the actuator latchable to the valve to operate the flow tube.

Embodiment 13: The system as in any prior embodiment, wherein the valve includes a valve inductive coupler.

Embodiment 14: The system as in any prior embodiment, wherein the actuator includes an actuator inductive coupler that is in magnetic field communication with the valve inductive coupler when the actuator is latched to the valve.

Embodiment 15: The system as in any prior embodiment, wherein the actuator includes a battery.

Embodiment 16: A method for controlling a well including installing a subsurface safety valve in a tubing string at a target location in a borehole of the well, the subsurface safety valve lacking an actuator, running an actuator to the valve, engaging the actuator with the valve, and operating the valve with the actuator.

Embodiment 17: The method as in any prior embodiment, wherein the engaging includes locking a collet into the valve with the actuator.

Embodiment 18: The method as in any prior embodiment, further including inductively powering the actuator while engaged with the valve.

Embodiment 19: The method as in any prior embodiment, further including flowing fluid around the actuator while engaged with the valve.

Embodiment 20: A borehole system including a borehole in a subsurface formation, a string in the borehole, and an actuator as in any prior embodiment, disposed within or as a part of the string.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms “about”, “substantially” and “generally” are intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” and/or “substantially” and/or “generally” includes a range of ±8% of a given value.

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 borehole, and/or equipment in the borehole, 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 the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited.

Claims

1. An actuator for a separate downhole tool, comprising:

an electric linear actuator;

a latch driven by the linear actuator and configured to interact with and operate a movable component of the separate tool.

2. The actuator as claimed in claim 1, wherein the linear actuator comprises a motor and screw.

3. The actuator as claimed in claim 2, further comprising a follower connected to the screw and to the latch.

4. The actuator as claimed in claim 1, wherein the linear actuator is a linear motor.

5. The actuator as claimed in claim 1, further comprising a housing, within which is disposed the linear actuator.

6. The actuator as claimed in claim 5, wherein the housing defines a chamber, the chamber being filled with clean fluid.

7. The actuator as claimed in claim 6, wherein the housing includes a pressure compensation configuration.

8. The actuator as claimed in claim 1, wherein the actuator further includes a collet, the collet being selectively deflectable into contact with the moveable component of the separate tool.

9. The actuator as claimed in claim 1, further comprising an inductive coupling connected to the motor.

10. The actuator as claimed in claim 1, further comprising a battery.

11. The actuator as claimed in claim 1, wherein the movable component is a flow tube of a subsurface safety valve.

12. A subsurface safety valve system, comprising:

a subsurface safety valve having a flow tube, the valve lacking an operable actuator; and

an actuator runnable into the valve, the actuator latchable to the valve to operate the flow tube.

13. The system as claimed in claim 12, wherein the valve includes a valve inductive coupler.

14. The system as claimed in claim 13, wherein the actuator includes an actuator inductive coupler that is in magnetic field communication with the valve inductive coupler when the actuator is latched to the valve.

15. The system as claimed in claim 13, wherein the actuator includes a battery.

16. A method for controlling a well comprising:

installing a subsurface safety valve in a tubing string at a target location in a borehole of the well, the subsurface safety valve lacking an actuator;

running an actuator to the valve;

engaging the actuator with the valve; and

operating the valve with the actuator.

17. The method as claimed in claim 16, wherein the engaging includes locking a collet into the valve with the actuator.

18. The method as claimed in claim 16, further including inductively powering the actuator while engaged with the valve.

19. The method as claimed in claim 16, further including flowing fluid around the actuator while engaged with the valve.

20. A borehole system comprising:

a borehole in a subsurface formation;

a string in the borehole; and

an actuator as claimed in claim 1, disposed within or as a part of the string.