System and method for toe valve

Abstract

A system includes a valve cartridge, including a body defining a fluid flow path extending from an oil inlet to an oil outlet. The oil inlet is configured to be fluidly coupled to a volume disposed about a piston. The oil inlet is configured to receive oil from the volume disposed about the piston and direct the oil along the flow path. The toe valve cartridge further includes a first membrane disposed along the flow path, downstream of the oil inlet. The first membrane is configured to rupture when exposed to a pressure and a second membrane disposed along the flow path, downstream of the first membrane. The valve cartridge is configured to direct the oil along the flow path, through the ruptured first membrane, through the ruptured second membrane, and out of the valve cartridge via the oil outlet.

Description

 system and method for toe valveCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. entitled “Welded ATM chamber Toe Valve with Mechanical Override,” filed March 13, 2024, the disclosure of which is incorporated herein by reference in its entirety.BACKGROUND

[0002] The present disclosure relates generally to downhole tooling for hydraulic fracturing (“fracking”), and more specifically to a welded atmosphere (ATM) chamber toe valve with mechanical override.

[0003] In a variety of well applications, a toe valve may be positioned along a downhole tool to enable selective communication between a wellbore and the surrounding reservoir via circumferential flow ports. In a multistage stimulation, for example, a toe valve may be run at the toe of the housing in a closed position. The toe valve is then actuated to open the circumferential flow ports to provide communication between the interior of the downhole tool and the surrounding reservoir. This allows an operator to run perforation guns, plugs, and other tools via wireline in a horizontal section of the wellbore by pumping fluids down through the housing string. The pumped fluids push the tool or tools along the wellbore before exiting the housing through the flow ports of the toe valve. Toe valves are typically installed during completion of the well and are actuated by pressurizing the well when production begins. If the toe valve experiences downhole conditions for an extended period of time prior to actuation, the toe valve may not actuate at the designed pressure. In some cases, the pressure to actuate the toe valve may exceed pressure ratings for some downhole components. Accordingly, new toe valve designs are needed. BRIEF DESCRIPTION

[0004] In certain embodiments, a system includes a valve cartridge, including a body defining a fluid flow path extending from an oil inlet to an oil outlet. The oil inlet is configured to be fluidly coupled to a volume disposed about a piston. The oil inlet is configured to receive oil from the volume disposed about the piston and direct the oil along the flow path. The valve cartridge further includes a first membrane disposed along the flow path, downstream of the oil inlet. The first membrane is configured to rupture when exposed to a pressure and a second membrane disposed along the flow path, downstream of the first membrane. The valve cartridge is configured to direct the oil along the flow path, through the ruptured first membrane, through the ruptured second membrane, and out of the toe valve cartridge via the oil outlet.

[0005] In other embodiments, a method includes pressurizing a borehole defined by a housing, wherein a piston is disposed within the borehole. Pressurizing the borehole causes the piston to pressurize oil in an annular volume disposed between the piston and the housing, flowing the oil through an oil inlet of a valve cartridge and along a flow path defined by a body of the valve cartridge, and applying a pressure above a threshold pressure to a first membrane along the flow path of the valve cartridge, downstream of the oil inlet. The pressure above the threshold pressure causes the first membrane to rupture. The method further includes applying a pressurized oil from the ruptured first membrane to a second membrane along the flow path of the valve cartridge, downstream of the first membrane. The pressurized oil causes the second membrane to rupture. The method also includes flowing the oil to an oil outlet of the valve cartridge. The oil outlet is downstream of the second membrane.

[0006] In other embodiments, a system including a piston, a volume disposed about the piston. The volume is configured to reserve oil. The volume is fluidly coupled to an oil inlet. The system further includes a valve cartridge, including a body defining a fluid flow path extending from the oil inlet to an oil outlet. The oil inlet is configured to receive oil from the volume disposed about the piston and direct the oil along the flow path, a first membrane disposed along the flow path, downstream of the oil inlet. The first membrane is configured to rupture when exposed to a pressure above a threshold pressure, a second membrane disposed along the flow path, downstream of the first membrane. The second membrane is configured to rupture when exposed to the pressure above the threshold pressure. The valve cartridge is configured to direct the oil along the flow path, through the ruptured first membrane, through the ruptured second membrane, and out of the valve cartridge via the oil outlet.DRAWINGS

[0007] These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

[0008] FIG. 1 illustrates an example of a fracking system in a geologic environment, in accordance with the present disclosure;

[0009] FIG. 2 is a schematic of a welded ATM toe-valve cartridge in the fracking system of FIG. 1, in accordance with the present disclosure;

[0010] FIG. 3 is a detailed schematic of the welded ATM toe-valve cartridge of FIG. 2, in accordance with the present disclosure; and

[0011] FIG. 4 is a flowchart illustrating a method of operation of the welded ATM toe valve cartridge of FIGS. 2 and 3, in accordance with the present disclosure.DETAILED DESCRIPTION

[0012] One or more specific embodiments of the present disclosure will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers’ specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0013] When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Any examples of operating parameters and / or environmental conditions are not exclusive of other parameters / conditions of the disclosed embodiments.

[0014] As used herein, the terms “connect”, “connection”, “connected”, “in connection with”, and “connecting” are used to mean “in direct connection with” or “in connection with via one or more elements;” and the term “set” is used to mean “one element” or “more than one element.” Further, the terms “couple”, “coupling,” “coupled”, “coupled together”, and “coupled with” are used to mean “directly coupled together” or “coupled together via one or more elements.” As used herein, the terms "up" and "down"; "upper" and "lower"; "top" and "bottom"; and other like terms indicating relative positions to a given point or element are utilized to more clearly describe some elements. Commonly, these terms relate to a reference point at the surface from which drilling operations are initiated as being the top point and the total depth being the lowest point, wherein the well (e.g., wellbore, borehole) is vertical, horizontal or slanted relative to the surface.

[0015] Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and / or within less than 0.01% of the stated amount. As another example, in certain embodiments, the terms “generally parallel” and “substantially parallel” or “generally perpendicular” and “substantially perpendicular” refer to a value, amount, or characteristic that departs from exactly parallel or perpendicular, respectively, by less than or equal to 15 degrees, 10 degrees, 5 degrees, 3 degrees, 1 degree, or 0.1 degree.

[0016] FIG. 1 shows an example of a geologic environment 120. In Figure 1, the geologic environment 120 may be a sedimentary basin that includes layers (e.g., stratification) that include a reservoir 121 and that may be, for example, intersected by a fault 123 (e.g., or faults). As an example, the geologic environment 120 may be outfitted with any of a variety of sensors, detectors, actuators, etc. For example, equipment 122 may include communication circuitry to receive and / or to transmit information with respect to one or more networks 125. Such information may include information associated with downhole equipment 124, which may be equipment to acquire information, to assist with resource recovery, etc. Other equipment 126 may be located remote from a well site and include sensing, detecting, emitting or other circuitry. Such equipment may include storage and communication circuitry to store and to communicate data, instructions, etc. As an example, one or more pieces of equipment may provide for measurement, collection, communication, storage, analysis, etc. of data (e.g., for one or more produced resources, etc.). As an example, one or more satellites may be provided for purposes of communications, data acquisition, geolocation, etc. For example, Figure 1 shows a satellite in communication with the network 125 that may be configured for communications, noting that the satellite may additionally or alternatively include circuitry for imagery (e.g., spatial, spectral, temporal, radiometric, etc.).

[0017] FIG. 1 also shows the geologic environment 120 as including equipment 127 and 128 associated with a well that includes a substantially horizontal portion that may intersect with one or more fractures 129. For example, consider a well in a shale formation that may include natural fractures, artificial fractures (e.g., hydraulic fractures) or a combination of natural and artificial fractures. As an example, a well may be drilled for a reservoir that is laterally extensive. In such an example, lateral variations in properties, stresses, etc. may exist where an assessment of such variations may assist with planning, operations, etc. to develop the reservoir (e.g., via fracturing, injecting, extracting, etc.). As an example, the equipment 127 and / or 128 may include components, a system, systems, etc. for fracturing, seismic sensing, analysis of seismic data, assessment of one or more fractures, injection, production, etc. As an example, the equipment 127 and / or 128 may provide for measurement, collection, communication, storage, analysis, etc. of data such as, for example, production data (e.g., for one or more produced resources). As an example, one or more satellites may be provided for purposes of communications, data acquisition, etc.

[0018] FIG. 2 is a schematic of a welded ATM toe-valve cartridge 150 in the housing 146 of a downhole tool 152, which may be disposed within the well 148 shown in FIG. 1. For purposes of discussion, reference may be made to an axial direction or axis 154, a radial direction or axis 156, and a circumferential direction or axis 158 relative to a central axis 160 of the downhole tool 152. The axial direction 154 may align with the central axis 160 of the downhole tool 152 such that the circumferential axis 158 aligns with the general geometry of the borehole in which the downhole tool 152 sits. With the welded ATM toe valve cartridge 150, the downhole tool 152 may include a piston 162 disposed within an annular chamber 164 prefilled with clean oil and an optional shifting sleeve 166.

[0019] The piston 162 may be hydraulically locked until an operator initiates or triggers the piston 162. The chamber 164 may maintain vacuum pressure before an operator triggers the downhole tool 152 from the surface. To trigger actuation of the ATM toe-valve cartridge 150, the borehole is pressurized, pushing the piston 162 in the axial direction 154, causing the piston 162 (e.g., via a stopping edge 170) to increase pressure on the oil in the vacuum pressure chamber 164. When the pressure on the oil in the vacuum pressure chamber 164 exceeds a threshold value, two membranes (shown in FIG. 3) in the ATM toe-valve cartridge 150 rupture, allowing the oil in the vacuum pressure chamber 164 to flow into the oil inlet 168 of the ATM toe-valve cartridge 150 and out of the vacuum pressure chamber 164. As the oil in the vacuum pressure chamber 164 is directed into the oil inlet 168 of the ATM toe-valve cartridge 150, the piston 162 moves in the axial direction 154 towards the shifting sleeve 166.

[0020] The shifting sleeve 166 may include one or more windows 172 spaced circumferentially around the central axis 160 of the shifting sleeve 166 proximate to the piston 162. There may be one or more windows 172 based on the size of the windows 172, the fluid the downhole tool 152 is expected to direct from the borehole in which the downhole tool 152 resides to the surface. In some embodiments, there may be one or more windows 172 proximate to each other in the axial direction 154 as well as circumferentially. As the piston 162 moves, the piston 162 may shift the shifting sleeve 166 in the axial direction. When the piston 162 has shifted such that the stopping edge 170 meets the oil inlet 168, the windows 172 may align with the frac ports 176. The frac ports 176 may include surface-side frac ports 176a, which may be frac ports 176 located on the side of the downhole tool 152 closer to the surface. The frac ports 176 may also include center-side frac ports 176b, which may be frac ports 176 located on the side of the downhole tool 152 farthest from the surface. There may be a surface-side frac port 176a on each axial side of the windows 172 (e.g., upstream and downstream), and a center-side frac port 176b on each axial side (e.g., upstream and downstream) such that each surface-side frac port 176a corresponds to a center-side frac port 176b. As such, when the windows 172 align with multiple surface-side frac ports 176a and multiple center-side frac ports 176b, the windows 172 may provide a flow path 178 for any fracking material (e.g., fluid) to flow through the center-side frac ports 176b and / or the surface-side frac ports 176a, into the borehole, and up to the surface. In embodiments in which there are multiple windows placed axially proximate to each other, there may be more than two corresponding surface-side frac ports 176a and center-side frac ports 176b such that there are three or more flow paths through the frac ports 176a, 176b into the borehole.

[0021] The shifting sleeve 166 may also include one or more temporary retention members 174. The temporary retention members may be a spring energized c-ring that is radially flexible configured to hold the piston 162 in place relative to the shifting sleeve 166. In another embodiment, the retention member may comprise a snap ring, shear pins, or any other retention device. Specifically, the temporary retention members may constrain axial motion of the shifting sleeve 166 when the downhole tool 152 is in one configuration or another (e.g., open configuration or closed configuration). As such, once the operator triggers the external pressure on the piston 162 and the piston 162 travels downstream to the shifting sleeve 166, the temporary retention members 174 may hold the piston 162 in place relative to the shifting sleeve 166. Conversely, the temporary retention members 174 may also hold the piston 162 in place relative to the shifting sleeve 166 before the operator triggers the external pressure on the piston 162. The temporary retention members may be positioned such that, when latched, the temporary retention members 174 maintain the position of the windows 172 in alignment with the surface-side frac ports 176a and / or the center-side frac ports 176b such that the fracking material may follow the flow path 178 to the surface.

[0022] The downhole tool 152 may also include one or more seals 180 positioned along the piston 162 and shifting sleeve 166 axially. The seals 180 may assist the piston 162 and shifting sleeve 166 with maintaining their relative positions in the downhole tool 152 and their relative pressures, as well as the pressure in the vacuum pressure chamber 164, until the operator initiates or triggers the piston 162. The seals 180 may be pressure balanced

[0023] In some embodiments, the shifting sleeve 166 of the downhole tool 152 may include an annular groove 182. The annular groove 182 may be a shifting profile on the inner surface of the shifting sleeve 166. As such, the annular groove 182 may be shaped for engaging the shifting tool to mechanically shift the shifting sleeve 166. The annular groove 182 may be beneficial to force the ATM toe-valve cartridge 150 open in a situation in which pressure in the ATM toe-valve cartridge 150 or chamber 164 is incorrect to open the ATM toe-valve cartridge 150. As such, the annular groove 182 may mechanically override the chamber 164 to force the shifting sleeve 166 open and provide adequate pressure for the ATM toe-valve cartridge 150 to drain the oil from the chamber 164.

[0024] The ATM toe-valve cartridge 150 may be supported in the wellbore via a support structure 184. The support structure 184 may be a metallic wall. The support structure 184 may be part of the housing 146 of the wellbore. In some embodiments, the ATM toe-valve cartridge 150 may be welded to the support structure 184. Once the oil from the chamber 164 reaches a threshold pressure, membranes in the ATM toe-valve cartridge 150 (shown in FIG. 3) rupture, opening a flow path through the ATM toe-valve cartridge 150. Oil in the vacuum pressure chamber 164 is pushed through the oil inlet 168 and through the ATM toe-valve cartridge 150 by the stopping edge 170 of the piston and exit through the annulus 186. The innerworkings of the ATM toe-valve cartridge 150 is described below in relation to FIG. 3.

[0025] FIG. 3 is a schematic of the welded ATM toe-valve cartridge. As described above, the ATM toe-valve cartridge 150 may be coupled to the support structure 184. As such, the coupling points of the ATM toe-valve cartridge 150 to the support structure 184 may be the one or more welded seams 198. The one or more welded seams 198 may couple the individual components of the ATM toe valve cartridge 150 together. Specifically, the welded seams 198 may couple the first membrane 202 to the ATM pressure chamber 204, and the welded seams 198 may couple the ATM pressure chamber 204 to the second membrane 206. The welded seams 198 may provide adequate support to the first membrane 202 and second membrane 206 such that the membranes may remain coupled to the cartridge under high pressures, such that the first membrane 202 and second membrane 206 may rupture rather than uncouple from the ATM toe valve cartridge 150. There may be as many welded seams 198 as are needed to securely fasten the components of the ATM toe-valve cartridge 150 together. The welded seams may be generated by an electron beam welding machine, which may weld the ATM toe valve cartridge 150 to the housing 146 and pressurize the ATM toe-valve cartridge 150 and / or the ATM pressure chamber 204 to vacuum pressure during the welding process.

[0026] When the oil exits the chamber 164 and enters the oil inlet 168, the oil may flow along a flow path 200 in the inner diameter and exert pressure on the first membrane 202 due to the pressure in the chamber 164 applied by the piston 162. The first membrane 202 may be a rupture disc configured to rupture at a first threshold pressure suitable for the downhole tool 152. For example, the first membrane 202 may rupture upon reaching a pressure of 13,000 psi or greater. In some embodiments, the first membrane 202 may rupture upon reaching a pressure of 14,000 psi or greater. In other embodiments, the first membrane 202 may rupture upon reaching a pressure of 15,000 psi or greater.

[0027] Once the first membrane 202 ruptures, the oil may enter the atmosphere (ATM) pressure chamber 204. The ATM pressure chamber 204 may be a volume held at atmospheric pressure until the first membrane 202 ruptures. When the first membrane 202 ruptures, the pressure may equalize between the ATM pressure chamber 204 and the oil inlet 168. Upon the rupturing of the first membrane 202, the pressure from the chamber 164 may affect the ATM pressure chamber 204 and the second membrane 206 disposed axially downstream of the first membrane 202. As the oil enters the ATM pressure chamber 204, it may flow towards multiple parallel flow ports 216 disposed in the ATM pressure chamber 204 downstream of the first membrane 202. When the oil reaches the parallel flow ports 216, the oil may exit the parallel flow ports 216 to exert pressure on the second membrane 206.

[0028] The second membrane 206 may act as a hermetically sealed check valve. Similar to the first membrane 202, the second membrane 206 may be configured to rupture at a second pressure suitable for the downhole tool 152. In some embodiments, the pressure suitable to rupture the second membrane 206 may be the same pressure suitable to rupture the first membrane 202. In other embodiments, the pressure suitable to rupture the second membrane 206 may be different than the pressure suitable to rupture the first membrane 202. The second membrane 206 may rupture upon reaching a pressure of 13,000 psi or greater. In some embodiments, the second membrane 206 may rupture upon reaching a pressure of 14,000 psi or greater. In other embodiments, the second membrane 206 may rupture upon reaching a pressure of 15,000 psi or greater.

[0029] The second membrane 206 may be configured to bend and pull away from its initial location, shearing or tearing the second membrane 206. In its initial position, the second membrane 206 may be supported in the ATM pressure chamber 204 by one or more support holes 208. The support holes 208 may be configured to maintain the integrity of the ATM pressure chamber 204 until the pressure in the ATM pressure chamber 204 is great enough to shear open the second membrane 206. When first membrane 202 ruptures, pressure may come from inside the ATM pressure chamber 204 and pushes the second membrane 206 open to escape to annulus of downhole tool. Once the second membrane 206 ruptures, the pressure in the ATM pressure chamber 204 may direct the oil out of the downhole tool through the oil outlet 210 and through the annulus.

[0030] In some embodiments, a needle 212 or other sharp edge may be located axially downstream of the second membrane 206. The needle 212 may be any sharp material configured to shear open the second membrane 206, rather than support the second membrane 206. The needle 212 may be advantageous in instances in which there is debris near the second membrane 206 which may act as a support for the second membrane 206. When debris is located such that the debris supports the second membrane 206, the needle 212 may assist the pressure exerted on the second membrane 206 from within the ATM pressure chamber 204 in shearing open the second membrane 206. Further, the outer diameter side of the ATM toe valve cartridge 150 may be greased to prevent cement from reaching the second membrane 206.

[0031] The ATM toe valve cartridge 150 may include members 214. Member 214a forms the oil inlet 168 and defines part of the flow path 200, member 214b forms the flow path between the first membrane 202 and the second membrane 206, and member 214c forms the oil outlet 210. These members 214 may sandwich the first membrane 202, second membrane 206, and ATM pressure reference 204 between the members 214 such that the oil flows through the member 214a forming the oil inlet 168, ruptures the first membrane 202, flows into the ATM pressure chamber 204 in the second member 214b, and ruptures the second membrane 206 before the oil flows through the member 214c that forms the oil outlet 210. The members 214 may be coupled to their respective membranes via welded seams 198. These members 214 may be machined from a single block, 3D printed, or a combination thereof.

[0032] The first membrane 202 and second membrane 206 may be formed from materials designed to rupture at the desired pressure. In some embodiments, the membranes may be formed from stainless steel, polyamide, polysulfone, aluminaI, or any other material suitable for rupturing at the desired pressure. In some embodiments, the first membrane and second membrane may be formed of different materials. This may be suitable based on the amount of expected debris, the desired rupture pressure, construction costs, and the like. In some embodiments, one or more of the membranes may be this walls machined into the members 214 during construction of the ATM toe valve cartridge 150. The walls may be configured to rupture at a pressure suitable for the downhole tool.

[0033] FIG. 4 is a flowchart illustrating a method 250 of operation of the welded ATM toe valve cartridge shown in FIGS. 2 and 3. The operation described herein may be used to transition a well from the construction / completion phase to the fracking / production phase using the ATM toe-valve cartridge.

[0034] In block 252 of method 250, the system may pressurize a borehole defined by a housing 146. The operator may pressurize the borehole using a trigger or other initiator located at the surface above the borehole. Upon pressurizing the borehole, the hydraulically locked piston may begin to move downstream towards the shifting sleeve. As the piston moves downstream, the stopping edge of the piston may begin to exert pressure on the chamber prefilled with oil, which is held at vacuum pressure.

[0035] In block 254 of method 250, the system may flow the oil through an inlet of a toe valve cartridge and along a flow path defined by a body of the toe valve cartridge. As the stopping edge of the piston exerts pressure on the oil in the prefilled chamber held at vacuum pressure, the oil in the chamber may move into the inlet of the toe valve cartridge and up through the flow path within the toe valve cartridge. As the stopping edge of the piston moves further downstream, the pressure along the flow path of defined by the body of the toe valve cartridge increases.

[0036] In block 256 of method 250, the system may apply a second pressure to a first membrane along the flow path of the toe valve cartridge. As the oil and pressure reach the first membrane, which is disposed downstream of the oil inlet, the pressure exerted on the first membrane reaches the pressure at which the first membrane is configured to rupture. As discussed above, that second pressure may be greater than or equal to 13,000 psi, 14,000 psi, 15,000 psi, or any other pressure. Specifically, the second pressure may be any pressure the configured to suit the design of the downhole tool.

[0037] Once the first membrane ruptures, the oil may enter the ATM pressure chamber, which is maintained at atmospheric pressure until the first membrane is ruptured, after which the pressure upstream and downstream of the first membrane may equalize. The oil may continue to flow along the flow path, which may continue through the ATM chamber and downstream to the second membrane as the stopping edge of the piston continues to move downstream towards the oil inlet, continuing to exert pressure on the oil in the chamber and cartridge.

[0038] In block 258 of method 250, the system may apply a third pressure to a second membrane along the flow path of the toe valve cartridge. As the oil and pressure reach the second membrane, which is disposed downstream of the first membrane along the flow path, the pressure exerted on the second membrane should be approximating the pressure at which the second membrane is configured to rupture. As discussed above, that third pressure may be greater than or equal to 13,000 psi, 14,000 psi, or 15,000 psi. Specifically, the third pressure may be any pressure the configured to suit the design of the downhole tool.

[0039] The second membrane may be supported by one or more support holes, which may provide adequate support to assist the second membrane in rupturing at the desired third pressure. In some embodiments, a needle (e.g., sharp object) may be positioned downstream of the second membrane along the flow path of the toe valve cartridge to assist the second membrane in rupturing at the desired third pressure.

[0040] At block 260 of method 250, the system may flow the oil to an oil outlet at the outer diameter of the toe valve cartridge. Once the second membrane ruptures, the pressure within the ATM pressure chamber and which is exerted on the oil by the stopping edge of the piston may direct the oil through the ruptured second membrane and to the oil outlet of the toe valve cartridge. The oil outlet may be disposed downstream from the second membrane along the flow path of the toe valve cartridge. After reaching the oil outlet, the oil may exit the downhole tool through the annulus connecting the oil outlet to the surface.

[0041] A system includes a valve cartridge, including a body defining a fluid flow path extending from an oil inlet to an oil outlet. The oil inlet is configured to be fluidly coupled to a volume disposed about a piston. The oil inlet is configured to receive oil from the volume disposed about the piston and direct the oil along the flow path. The valve cartridge further includes a first membrane disposed along the flow path, downstream of the oil inlet. The first membrane is configured to rupture when exposed to a pressure and a second membrane disposed along the flow path, downstream of the first membrane. The valve cartridge is configured to direct the oil along the flow path, through the ruptured first membrane, through the ruptured second membrane, and out of the toe valve cartridge via the oil outlet.

[0042] The system of the preceding clause, further comprising a membrane puncturing device disposed downstream of the second membrane, wherein the membrane puncturing device comprises a sharp edge or point configured to puncture the second membrane when the second membrane deflects toward the sharp edge or point in response to being exposed to the pressure.

[0043] The system of any preceding clause, wherein the body includes a first member that includes the oil inlet and defines the flow path between the oil inlet and the first membrane, a second member that defines the flow path between the first membrane and the second membrane, wherein the second member comprises a pressure reference chamber, and a third member that includes the oil outlet and defines the flow path between the second membrane and the oil outlet.

[0044] The system of any preceding clause, wherein the first membrane is sandwiched between the first member and the second member, and wherein the second membrane is sandwiched between the second member and the third member.

[0045] The system of any preceding clause, wherein the first member and the second member are coupled to one another via a first welded seam, and wherein the second member and the third member are coupled to one another via a second welded seam.

[0046] The system of any preceding clause, wherein the second member defines multiple parallel flow paths and is configured to direct the oil into the multiple parallel flow paths wherein the multiple parallel flow paths comprises a structure configured to support the second membrane to prevent the second membrane rupturing when exposed to pressure on an oil outlet.

[0047] A method includes pressurizing a borehole defined by a housing, wherein a piston is disposed within the borehole. Pressurizing the borehole causes the piston to pressurize oil in an annular volume disposed between the piston and the housing, flowing the oil through an oil inlet of a valve cartridge and along a flow path defined by a body of the valve cartridge, and applying a pressure above a threshold pressure to a first membrane along the flow path of the valve cartridge, downstream of the oil inlet. The pressure above the threshold pressure causes the first membrane to rupture. The method further includes applying a pressurized oil from the ruptured first membrane to a second membrane along the flow path of the valve cartridge, downstream of the first membrane. The pressurized oil causes the second membrane to rupture. The method also includes flowing the oil to an oil outlet of the valve cartridge. The oil outlet is downstream of the second membrane.

[0048] The method of any preceding clause, wherein the oil flowing out of the annular volume and pressurizing the borehole causes the piston to actuate within the housing, causing the piston to make contact with and actuate a shifting sleeve disposed within the housing, and causing one or more windows of the shifting sleeve to align with one or more frac ports of the housing.

[0049] The method of the preceding clause wherein the borehole further contains a shifting sleeve.

[0050] The method of any preceding clause, wherein applying the pressurized oil to the second membrane causes the second membrane to deflect and come into contact with a sharp edge or point that ruptures the second membrane.

[0051] The method of any preceding clause, wherein the oil flowing out of the annular volume and pressurizing the borehole causes the piston to actuate within the housing, causing the piston to vent into a formation.

[0052] The method of any preceding clause, wherein the piston is further configured to open communication with one or more frac ports.

[0053] The method of any preceding clause, including directing the oil through multiple parallel flow paths upstream of the second membrane.

[0054] The method of any preceding clause, wherein the valve cartridge is welded to the housing via electron beam welding.

[0055] The method of any preceding clause, wherein a first member, a second member, and a third member are combined and machined from a single block, 3D printed, or a combination thereof.

[0056] A system including a piston, a volume disposed about the piston. The volume is configured to reserve oil. The volume is fluidly coupled to an oil inlet. The system further includes a valve cartridge, including a body defining a fluid flow path extending from the oil inlet to an oil outlet. The oil inlet is configured to receive oil from the volume disposed about the piston and direct the oil along the flow path, a first membrane disposed along the flow path, downstream of the oil inlet. The first membrane is configured to rupture when exposed to a pressure above a threshold pressure, a second membrane disposed along the flow path, downstream of the first membrane. The second membrane is configured to rupture when exposed to the pressure above the threshold pressure. The valve cartridge is configured to direct the oil along the flow path, through the ruptured first membrane, through the ruptured second membrane, and out of the valve cartridge via the oil outlet.

[0057]

[0058] The system of the preceding clause, further including a shifting sleeve disposed at least partially downstream of the piston.

[0059] The system of any preceding clause, further including a membrane puncturing device disposed downstream of the second membrane. The membrane puncturing device comprises a sharp edge or point configured to puncture the second membrane when the second membrane deflects toward the sharp edge or point in response to being exposed to the pressure above the threshold pressure.

[0060] The system of the preceding clause, further including one or more latches configured to maintain a position of the piston relative to the shifting sleeve.

[0061] The system of the preceding clause, wherein the shifting sleeve houses one or more windows, wherein the one or more windows are aligned with two frac ports when the volume disposed about the piston is evacuated.

[0062] The system of any preceding clause, wherein the volume disposed about the piston is configured to hold oil under vacuum.

[0063] While only certain features have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the disclosure.

[0064] The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for (perform)ing (a function)…” or “step for (perform)ing (a function)…”, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f).      

Claims

1. A valve cartridge, comprising:a body defining a fluid flow path extending from an oil inlet to an oil outlet, wherein the oil inlet is configured to be fluidly coupled to a volume disposed about a piston, wherein the oil inlet is configured to receive oil from the volume disposed about the piston and direct the oil along the flow path;a first membrane disposed along the flow path, downstream of the oil inlet, wherein the first membrane is configured to rupture when exposed to a pressure; anda second membrane disposed along the flow path, downstream of the first membrane, wherein the second membrane is configured to rupture when exposed to the pressure; wherein the valve cartridge is configured to direct the oil along the flow path, through the ruptured first membrane, through the ruptured second membrane, and out of the valve cartridge via the oil outlet.

2. The system of claim 1, further comprising a membrane puncturing device disposed downstream of the second membrane, wherein the membrane puncturing device comprises a sharp edge or point configured to puncture the second membrane when the second membrane deflects toward the sharp edge or point in response to being exposed to the pressure. 3. The system of claim 1, wherein the body comprises:a first member that comprises the oil inlet and defines the flow path between the oil inlet and the first membrane;a second member that defines the flow path between the first membrane and the second membrane, wherein the second member comprises a pressure reference chamber; anda third member that comprises the oil outlet and defines the flow path between the second membrane and the oil outlet.

4. The system of claim 3, wherein the first membrane is sandwiched between the first member and the second member, and wherein the second membrane is sandwiched between the second member and the third member.

5. The system of claim 3, wherein the first member and the second member are coupled to one another via a first welded seam, and wherein the second member and the third member are coupled to one another via a second welded seam.

6. The system of claim 3, wherein the second member defines multiple parallel flow paths and is configured to direct the oil into the multiple parallel flow paths wherein the multiple parallel flow paths comprises a structure configured to support the second membrane to prevent the second membrane rupturing when exposed to pressure on an oil outlet.

7. A method, comprising: pressurizing a borehole defined by a housing, wherein a piston is disposed within the borehole, wherein pressurizing the borehole causes the piston to pressurize oil in an annular volume disposed between the piston and the housing; flowing the oil through an oil inlet of a valve cartridge and along a flow path defined by a body of the valve cartridge; applying pressure above a threshold pressure to a first membrane along the flow path of the valve cartridge, downstream of the oil inlet, wherein the pressure above the threshold pressure causes the first membrane to rupture; applying a pressurized oil from the ruptured first membrane to a second membrane along the flow path of the valve cartridge, downstream of the first membrane, wherein the pressurized oil causes the second membrane to rupture; and flowing the oil to an oil outlet of the valve cartridge, wherein the oil outlet is downstream of the second membrane.

8. The method of claim 7, wherein the borehole further contains a shifting sleeve.

9. The method of claim 7, wherein applying the pressurized oil to the second membrane causes the second membrane to deflect and come into contact with a sharp edge or point that ruptures the second membrane.

10. The method of claim 7, wherein the oil flowing out of the annular volume and pressurizing the borehole causes the piston to actuate within the housing, causing the piston to vent into a formation.

11. The method of claim 7, wherein the piston is further configured to open communication with one or more frac ports.

12. The method of claim 7, comprising directing the oil through multiple parallel flow paths upstream of the second membrane.

13. The method of claim 7, wherein the valve cartridge is welded to the housing via electron beam welding.

14. The method of claim 7, wherein a first member, a second member, and a third member are combined and machined from a single block, 3D printed, or a combination thereof.

15. A system, comprising: a piston; a volume disposed about the piston, wherein the volume is configured to reserve oil and wherein the volume is fluidly coupled to an oil inlet; anda valve cartridge, comprising:a body defining a fluid flow path extending from the oil inlet to an oil outlet, wherein the oil inlet is configured to receive oil from the volume disposed about the piston and direct the oil along the flow path;a first membrane disposed along the flow path, downstream of the oil inlet, wherein the first membrane is configured to rupture when exposed to a pressure above a threshold pressure; anda second membrane disposed along the flow path, downstream of the first membrane, wherein the second membrane is configured to rupture when exposed to the pressure above the threshold pressure;wherein the valve cartridge is configured to direct the oil along the flow path, through the ruptured first membrane, through the ruptured second membrane, and out of the valve cartridge via the oil outlet.

16. The system of 15, further comprising a shifting sleeve disposed at least partially downstream of the piston.

17. The system of claim 15, further comprising a membrane puncturing device disposed downstream of the second membrane, wherein the membrane puncturing device comprises a sharp edge or point configured to puncture the second membrane when the second membrane deflects toward the sharp edge or point in response to being exposed to the pressure above the threshold pressure.

18. The system of claim 15, further comprising one or more latches configured to maintain a position of the shifting sleeve relative to a housing.

19. The system of claim 15, wherein the shifting sleeve houses one or more windows, wherein the one or more windows are aligned with one or more frac ports when the volume disposed about the piston is evacuated.

20. The system of claim 15, wherein the volume disposed about the piston is configured to hold oil under vacuum.  

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