SYSTEM

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Application No. 17/975728, filed on October 28, 2023, which is incorporated herein by reference in its entirety.

BACKGROUND

[0002] In the resource recovery industry valves are ubiquitous. Valves control fluid flow from a tubular into a formation and from the formation into the tubular. Valves also control fluid pressure acting on various downhole tools. Often times, the valves employ sleeves that are shifted to expose and/or cover ports. The sleeves may be shifted hydraulically, electrically, and/or mechanically. A toe sleeve is a valve that selectively opens at a toe of a well bore to allow fluid communication to an annulus. Often times, the toe sleeve is opened to perform a pressure check prior to fracturing operations.

[0003] A toe sleeve relies on an entire cross-section to house components, including a valve actuator, that relies on pressure cycling and timed delay mechanisms to open the valve. The pressure cycling and time delay mechanisms include pistons, j -tracks, large springs, snap rings, and other precision made components that detract from an overall flow area of the toe sleeve. Further, after cycling a piston to open the valve, spring pressure on the valve may remain. Occasionally, an unintended pressure differential may allow the piston to be inadvertently forced back into the valve by the spring closing the valve. If closed, additional operations will be needed reopen the valve and continue shifting the sleeve. Re-cycling the valve actuator to reopen the valve adds to an overall and usage cost of the toe sleeve.

SUMMARY

[0004] A downhole tool, in accordance with non-limiting example, includes a body including a wall having an outer surface, an inner surface defining a passage, and an opening extending through the wall. The outer surface includes a recess. A sleeve is arranged in the passage and selectively positioned over the opening. A valve actuator module is detachably mounted in the recess. The valve actuator module forms a part of the outer surface and includes a housing having an inlet, an outlet, a valve chamber extending between the inlet and the outlet, a piston arranged in the valve chamber, and an actuator delay mechanism selectively operatively connected to the piston. The actuator delay mechanism includes a spring and a piston sleeve that is selectively conducts pressure from the actuator delay mechanism in a first configuration and allows the piston to move freely relative to the actuator delay mechanism in a second configuration.

[0005] A resource exploration and recovery system, in accordance with a nonlimiting example, includes a surface system and a subsurface system including a system of tubulars. At least one of the system of tubulars includes a downhole tool includes a body including a wall having an outer surface, an inner surface defining a passage, and an opening extending through the wall. The outer surface includes a recess. A sleeve is arranged in the passage and is selectively positioned over the opening. A valve actuator module is detachably mounted in the recess. The valve actuator module forms a part of the outer surface and includes a housing having an inlet, an outlet, a valve chamber extending between the inlet and the outlet, a piston arranged in the valve chamber, and an actuator delay mechanism selectively operatively connected to the piston. The actuator delay mechanism includes a spring and a piston sleeve that selectively conducts pressure from the actuator delay mechanism in a first configuration and allows the piston to move freely relative to the actuator delay mechanism in a second configuration.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:

[0007] FIG. 1 depicts a resource exploration and recovery system including a valve having a modular actuation system, in accordance with a non-limiting example;

[0008] FIG. 2 FIG. 2 depicts a cross-section side view of the valve of FIG. 1 shown as a toe sleeve, in accordance with a non-limiting example;

[0009] FIG. 3 depicts the modular actuation system of the valve of FIG. 2 mounted in recess formed in an outer surface of a tubular, in accordance with a non-limiting example;

[0010] FIG. 4 depicts a partial glass view of a piston of the modular activation system in a fully closed position, in accordance with a non-limiting example;

[0011] FIG. 5 depicts partial glass view of an actuator delay mechanism of the modular actuation system incrementally shifting the piston toward an open position, in accordance with a non-limiting example; [0012] FIG. 6 depicts a partial glass view of the piston further transitioning toward the open configuration, in accordance with a non-limiting example;

[0013] FIG. 7 depicts the glass view of the valve of FIG. 6 without the actuator delay mechanism showing a key member on the piston rotating towards a keyway formed in a piston sleeve, in accordance with a non-limiting example, and

[0014] FIG. 8 depicts the key member having passed through the keyway in the piston sleeve to fully disengage the piston from a valve spring and fully open the valve, in accordance with a non-limiting example.

DETAILED DESCRIPTION

[0015] 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.

[0016] A resource exploration and recovery system, in accordance with an exemplary embodiment, is indicated generally at 10, in FIG. 1. Resource exploration and recovery system 10 should be understood to support well drilling operations, completions, resource extraction and recovery, CO2 sequestration, and/or the like. Resource exploration and recovery system 10 may include a first system 12 which, in some environments, may take the form of a surface system 14 operatively and fluidically connected to a second system 18 which, in some environments, may take the form of a subsurface or downhole system (not separately labeled). Surface system 14 may be on land or supported on a platform at sea.

[0017] Surface system 14 may include a control system 23 that may provide power to, monitor, communicate with, and/or activate one or more downhole operations as will be discussed herein. Surface system 16 may also include additional systems such as pumps, fluid storage systems, cranes, and the like (not shown). Second system 18 may include a casing tubular 30 that extends into a wellbore 34 formed in a formation 36. Casing tubular 30 defines an inner surface 38 of wellbore 34. A tubular string 44, that may be formed from one or more tubulars (not separately labeled), extends from surface system 14 toward a toe 48 of wellbore 34.

[0018] In a non-limiting example, tubular string 44 supports a valve 58 that may take the form of a valve or toe sleeve 60. However, as will become more fully evident herein, valve 58 may be employed in a variety of locations and configurations. For example, valve 58 may be arranged within casing tubular 30 or in an open hole portion (not separately labeled) of wellbore 34. Referring to FIG. 2, valve 58 includes a tubular 66 having a body 68 that extends along a longitudinal axis “A”. Body 68 includes an outer surface 70 and an inner surface 72 that defines a passage 74. An opening 80 extends through body 68 and selectively fluidically connects passage 74 with an area defined outwardly of outer surface 70 such as an annulus (not separately labeled) of wellbore 34. The number and arrangement of opening 80 may vary.

[0019] Body 68 also includes a recess 83 formed in outer surface 70 and an activation passage 86 that extends from recess 83 through body 68 along axis “A”. Activation passage 86 includes a first end portion (not separately labeled) and a second end portion (also not separately labeled). Inner surface 72 includes a shoulder 92 that is defined by a reduced diameter portion (also not separately labeled) of passage 74. As will be detailed more fully herein, shoulder 92 defines a travel stop 94 for valve 58. Valve sleeve 60 is arranged in passage 74. Valve sleeve 60 is selectively shiftable along inner surface 72 as will be detailed herein.

[0020] Valve sleeve 60 includes a first end portion 103, a second end portion 105, and an intermediate portion (not separately labeled) having a shoulder portion 108. Shoulder portion 108 selectively engages with shoulder 92 to limit movement of valve sleeve 60 along axis “A”. Valve sleeve 60 includes an annular recess 113 at first end portion 103. Annular recess 113 forms a skirt (not separately labeled) that is received in a recess portion (also not separately labeled) formed in body 68. Activation passage 86 terminates at the recess portion to deliver an activation fluid to first end 103 of valve sleeve 60. Valve sleeve 60 is detachably fixed in passage 74 by a plurality of frangible dogs, one of which is indicated at 118. A plurality of seals, one of which is indicated at 122 is arranged about valve sleeve 60 and seal against inner surface 72.

[0021] Referring to FIG. 3, a valve actuator module 130 is arranged in recess 83. Valve actuator module 130 defines a section of outer surface 70 and is operable to deliver an actuation force to valve sleeve 60. In the non-limiting example shown and described herein, valve actuator module 130 operates on fluid, but it should be appreciated that other operation principles may also be applied. Valve actuator module 130 is arranged over an inlet passage 132. In the non-limiting example shown, inlet passage 132 may include a frangible disc 135 that establishes a pressure barrier between passage 74 and valve actuator module 130 until a predetermined pressure threshold is met. [0022] In a non-limiting example, valve actuator module 130 includes a housing 140 having an inlet 142 that registers with inlet passage 132 and an outlet 144 that registers with activation passage 86. A valve chamber 146 is disposed between inlet 142 and outlet 144. A first access member 148 is mounted to a first end (not separately labeled) of housing 140 and a second access member 150 is mounted to a second, opposing end (also not separately labeled) of housing 140. Valve chamber 146 includes a first end 152 that is accessible through first access member 148 and a second end 154 that is accessible through second access member 150. First and second access members 148 and 150 allow components of valve module 130 to be replaced for maintenance, tailored to specific application pressures, and the like.

[0023] In a non-limiting example, a valve member 160, shown in the form of a piston 162 is arranged in valve chamber 146. Valve member 160 is shiftable between first end 152 and second end 154 through an actuator delay mechanism 165. In a non-limiting example, actuator delay mechanism 165 takes the form of a J-track member 168 fixed in valve chamber 146. Valve member 160 supports a pin 170 that transitions into and out of a number of slots (not separately labeled) formed in J-track member 168 to incrementally shift piston 162 away from inlet 132 as will be detailed herein. That is, as piston 162 cycles within valve chamber 146, pin 170 transitions along J-track member 168 to eventually expose inlet 142 to outlet 144. The number of slots may vary and could depend on the number of activation pulses desired before valve sleeve 60 is shifted to expose opening 80.

[0024] In a non-limiting example, a first orifice 172 is mounted at first end 152 of valve chamber 146. A second orifice 174 is arranged in valve chamber 146 downstream of first orifice 172. First orifice 172 may be installed through first access member 148. First orifice 172 establishes a selected control pressure that acts upon piston 162. First orifice 172 may be selected based upon a desired pressure acting on piston 162. Second orifice 174 supports an O-ring 176. In a non-limiting example, fluid may be passed through passage 74. The fluid may travel through inlet passage 132 and into valve actuator module 130 via frangible disc 135. The fluid enters first end 152, passes through first orifice 172 and urges piston 162 toward second end 154. As fluid pressure drops, a spring 180 urges piston 162 back toward first end 152 completing a cycle. Continued cycling of piston 162 will eventually expose outlet 144 to inlet 142.

[0025] In accordance with a non-limiting example, piston 162 includes a first end portion 184, a second end portion 186, and an intermediate portion 188 extending between first end portion 184 and second end portion 186. First end portion 184 selectively extends through second orifice 174 and into first orifice 172. As piston 162 transitions toward outlet 144, first end portion 184 passes out from second orifice 174 and first orifice 172 to fluidically connect inlet 142 with activation passage 82. In the non-limiting example shown, pin 170 projects radially outwardly from intermediate portion 188. A first key member 190 (FIG. 7) extends radially outwardly from intermediate portion 188 between pin 170 and second end 186. A second key member 192 is arranged about 180° from first key member 190.

[0026] In a non-limiting example, a piston sleeve 194 is disposed over second end 186 of piston 162. Piston sleeve 194 includes a first sleeve 196, a second sleeve 198 (FIG. 7), and an end surface 200. End surface 200 includes an opening 202 having a first key way 204 that is selectively receptive of first key member 190 and a second key way (not shown) that is selectively receptive of second key member 192. Second end 186 of piston 162 passes through opening 202. Spring 180 engages end surface 200 forcing piston sleeve 194 into contact with first key member 190 and second key member 192 thereby urging piston 162 toward first end 152 of valve chamber 146.

[0027] In a non-limiting example, a device such as a drop ball, a dart, or the like may be introduced into passage 74 and pumped down below toe sleeve 60. Fluid is introduced into tubular string 44 and pressure is increased. When at a selected pressure, the fluid breaks frangible disk 135 and enters into valve actuation module 130 via inlet 142. The fluid passes through first office 172 and acts on valve member 160. Valve member 160 travels toward second end 154 compressing spring 180. As valve member 160 travels in valve chamber 146, pin 170 transitions in J-track member 168. Pressure may then be alleviated thereby allowing spring 180 to bias valve member 160 back towards first end 152. Each application of pressure causes pin 170 to travel in J-track member 168 such a shown in FIGS. 4, 5, and 6. As pin travels in J-track member 168, piston 162 rotates relative to piston sleeve 194 and first and second key members 190 and 192 begin to align with first key way 204 and the second key way respectively as shown in FIG. 7.

[0028] After a select number of pressure cycles such as shown in FIGS. 4, 5, and 6, first and second key members 190 and 190 align with first key way 204 and the second keyway and pin 170 passes through an open track allowing piston 162 to pass through opening 202 and no longer be acted upon by actuator delay mechanism 165. as shown in FIG. 8. In this manner, a change in pressure within valve chamber 146 will not be able to shift piston 162 back into second orifice 174 creating an undesired blockage.

[0029] When piston 162 is clear of second orifice 174 (FIG. 8), fluid passes through valve chamber 146 and into activation passage. Fluid pressure may be increased or simply applied to valve sleeve 60 via activation passage 86. When exposed to a selected pressure, frangible dog(s) 118 shear and valve sleeve 60 shifts within passage 74 until shoulder portion 108 abuts shoulder 92. At this point, opening 80 may be exposed to wellbore 34. Fluid may pass through opening 80 to perform a pressure check on wellbore 34 prior to initiating, for example, a fracking operation.

[0030] Set forth below are some embodiments of the foregoing disclosure:

[0031] Embodiment 1. A downhole tool comprising: a body including a wall having an outer surface, an inner surface defining a passage, and an opening extending through the wall, the outer surface including a recess; a sleeve arranged in the passage and selectively positioned over the opening; and a valve actuator module detachably mounted in the recess, the valve actuator module forming a part of the outer surface and including a housing having an inlet, an outlet, a valve chamber extending between the inlet and the outlet, a piston arranged in the valve chamber, and an actuator delay mechanism selectively operatively connected to the piston, the actuator delay mechanism including a spring and a piston sleeve that selectively conducts pressure from the actuator delay mechanism in a first configuration and allows the piston to move freely relative to the actuator delay mechanism in a second configuration.

[0032] Embodiment 2. The downhole tool according to any prior embodiment, wherein the actuator delay mechanism includes a J-track member operable to incrementally shift the piston away from the outlet based on a number of pressure cycles applied to the valve chamber.

[0033] Embodiment 3. The downhole tool according to any prior embodiment, wherein the housing includes an orifice that is arranged between the inlet and the outlet, the piston including first end that selectively extends into the orifice and a second end that extends through the J-track member.

[0034] Embodiment 4. The downhole tool according to any prior embodiment, wherein the orifice includes a seal element that engages the first end of the piston.

[0035] Embodiment 5. The downhole tool according to any prior embodiment, wherein the J-track member includes a first end portion rotationally fixed in the valve chamber, a second end portion, and an internal passage, the piston sleeve being arranged at the second end portion.

[0036] Embodiment 6. The downhole tool according to any prior embodiment, wherein the J-track member includes a J-track extending between the first and the second end, the piston including a J-track guide extending radially outwardly between the first end and the second end, the J-track guide riding in the J-track to incrementally shift the piston away from the orifice.

[0037] Embodiment 7. The downhole tool according to any prior embodiment, wherein the piston sleeve includes sleeve that extends about the second end of the piston and an end surface including an opening, the second end of the piston extending through the opening.

[0038] Embodiment 8. The downhole tool according to any prior embodiment, wherein the piston includes a key member projecting radially outwardly between the second end and the J-track guide and the opening in the piston sleeve includes a keyway receptive of the key member, the piston being free of the actuator delay mechanism when the key member aligns with the key way.

[0039] Embodiment 9. The downhole tool according to any prior embodiment, wherein the spring acts upon the end surface of the piston sleeve to bias the piston toward the orifice.

[0040] Embodiment 10. The downhole tool according to any prior embodiment, wherein the sleeve defines a toe sleeve.

[0041] Embodiment 11. A resource exploration and recovery system comprising: a surface system; a subsurface system including a system of tubulars, at least one of the system of tubulars includes a downhole tool comprising: a body including a wall having an outer surface, an inner surface defining a passage, and an opening extending through the wall, the outer surface including a recess; a sleeve arranged in the passage and selectively positioned over the opening; and a valve actuator module detachably mounted in the recess, the valve actuator module forming a part of the outer surface and including a housing having an inlet, an outlet, a valve chamber extending between the inlet and the outlet, a piston arranged in the valve chamber, and an actuator delay mechanism selectively operatively connected to the piston, the actuator delay mechanism including a spring and a piston sleeve that selectively conducts pressure from the actuator delay mechanism in a first configuration and allows the piston to move freely relative to the actuator delay mechanism in a second configuration. [0042] Embodiment 12. The resource exploration and recovery system according to any prior embodiment, wherein the actuator delay mechanism includes a J-track member operable to incrementally shift the piston away from the outlet based on a number of pressure cycles applied to the valve chamber.

[0043] Embodiment 13. The resource exploration and recovery system according to any prior embodiment, wherein the housing includes an orifice that is arranged between the inlet and the outlet, the piston including first end that selectively extends into the orifice and a second end that extends through the J-track member.

[0044] Embodiment 14. The resource exploration and recovery system according to any prior embodiment, wherein the orifice includes a seal element that engages the first end of the piston.

[0045] Embodiment 15. The resource exploration and recovery system according to any prior embodiment, wherein the J-track member includes a first end portion rotationally fixed in the valve chamber, a second end portion, and an internal passage, the piston sleeve being arranged at the second end portion.

[0046] Embodiment 16. The resource exploration and recovery system according to any prior embodiment, wherein the J-track member includes a J-track extending between the first and the second end, the piston including a J-track guide extending radially outwardly between the first end and the second end, the J-track guide riding in the J-track to incrementally shift the piston away from the orifice.

[0047] Embodiment 17. The resource exploration and recovery system according to any prior embodiment, wherein the piston sleeve includes sleeve that extends about the second end of the piston and an end surface including an opening, the second end of the piston extending through the opening.

[0048] Embodiment 18. The resource exploration and recovery system according to any prior embodiment, wherein the piston includes a key member projecting radially outwardly between the second end and the J-track guide and the opening in the piston sleeve includes a key way receptive of the key member, the piston being free of the actuator delay mechanism when the key member aligns with the keyway.

[0049] Embodiment 19. The resource exploration and recovery system according to any prior embodiment, wherein the spring acts upon the end surface of the piston sleeve to bias the piston toward the orifice. [0050] Embodiment 20. The resource exploration and recovery system according to any prior embodiment, wherein the sleeve defines a toe sleeve.

[0051] 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” can include a range of ± 8% or 5%, or 2% of a given value.

[0052] 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.

[0053] 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.