ATUADOR MODULAR, MÉTODO E SISTEMA

Abstract

An actuator including an impulse generation arrangement including an atmospheric pressure chamber, and a valve connected fluidly to the chamber, a prime mover arrangement including a device piston, and a hydrostatic pressure source, and a hydraulic chamber disposed between and fluidically connecting the impulse generation arrangement and the prime mover arrangement. A method for actuating a downhole tool including signaling the trigger in an actuator, opening the atmospheric chamber of the actuator, causing a low pressure pulse in the actuator, and moving the device piston with the pulse. A borehole system including a borehole in a subsurface formation, a string in the borehole, and the actuator disposed within or as a part of the string.

Description

1 / 12 MODULAR ACTUATOR, METHOD AND SYSTEM CROSS-REFERENCE TO RELATED DEPOSIT REQUESTS

[0001] This application claims the benefit of U.S. Application No. 18 / 186604, filed March 20, 2023, which is incorporated herein by reference in its entirety. BACKGROUND

[0002] In the resource recovery and fluid sequestration sectors, there are many different types of tools that require actuation. The tools differ in purpose, construction, material properties, and dimensions. Traditionally, an actuator is a part of the tool since actuators rely on mechanical energy transfer to effect actuation. The included actuators are developed and designed to fit and manage the various dimensions and properties of the parts. As such, the actuators function well but remain unique to each tool. There is little ability to standardize components where the unique characteristics of the tools must be addressed individually. The technology is always seeking efficiency improvements and is therefore open to innovations that support standardization in the sector. SUMMARY

[0003] An embodiment of an actuator including a thrust generating arrangement including an atmospheric pressure chamber and a valve connected in fluid communication to the chamber, a main actuator arrangement including a device piston and a hydrostatic pressure source and a hydraulic chamber disposed between and connecting in fluid communication the thrust generating arrangement and the main actuator arrangement. Petition 870250081688, dated 11 / 09 / 2025, page 12 / 126 2 / 12

[0004] An embodiment of a method for actuating a downhole tool including signaling the trigger on an actuator, opening the atmospheric chamber of the actuator, causing a low-pressure pulse in the actuator and moving the piston of the device with the pulse.

[0005] An embodiment of a well system including a well in an underground formation, a string in the well and the actuator disposed within or as part of the string. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The following descriptions should not be considered limiting in any respect. With reference to the attached drawings, similar elements are numbered similarly:

[0007] Figure 1 is a view of a first embodiment of an actuator that can be configured to be modular;

[0008] Figure 2 is the actuator from Figure 1 showing a flow path with arrows;

[0009] Figure 3 is a second embodiment of an actuator that can be configured to be modular;

[0010] Figure 4 is an enlarged view of a portion of Figure 3;

[0011] Figure 5 is a third embodiment of an actuator that can be configured to be modular;

[0012] Figure 6 is an enlarged view of a portion of Figure 5;

[0013] Figure 7 is a system diagram employing a plurality of the actuators disclosed in this document;

[0014] Figure 8 is a system diagram of another embodiment employing a plurality of the actuators disclosed in this document; and

[0015] Figure 9 is a view of a well system that includes an actuator as revealed here. Petition 870250081688, dated 11 / 09 / 2025, p. 13 / 126 3 / 12 DETAILED DESCRIPTION

[0016] A detailed description of one or more embodiments of the apparatus and method revealed by way of example, but without any limitation with reference to the Figures, is presented here.

[0017] With reference to Figure 1, a first embodiment of an actuator 10 is illustrated. The actuator 10 includes a pulse generation arrangement 12 (one or more components that together create a positive or negative pressure pulse that can be used to perform work), a main actuator arrangement 14, and a hydraulic chamber 16 between the pulse generation arrangement 12 and the main actuator arrangement 14. In embodiments, the hydraulic chamber 16 directly connects the arrangements 12 and 14, and in some embodiments, it exclusively connects the arrangements 12 and 14. In some embodiments, the chamber 16 is configured as a control line, although other structures capable of seamlessly connecting the arrangements 12 and 14 may be contemplated. Each of these conditions may also exist in a single embodiment, as illustrated in Figure 1.The embodiment of Figure 1 operates in a negative pressure paradigm to move a tool or device 20 on demand and according to a signal received by the actuator 10. The signal may be generated on the surface or at another remote location, or it may be generated in the actuator 10 according to a timer or sensor configured to detect temperature or pressure or other well parameter. In embodiments, the signal may be electrical, electromagnetic, acoustic, optical, etc., and is ultimately received at a trigger 22 (of a type known to the industry) that controls a valve 24 connected in fluid communication to a hydrostatic pressure chamber 26 with atmospheric pressure or lower than expected. For efficiency reasons, the term atmospheric chamber will be used hereafter, including in the claims appended to this document, and is intended to mean both a chamber at literal atmospheric pressure (14.7 pounds per second) and a chamber at atmospheric pressure (14.7 pounds per second). Petition 870250081688, dated 11 / 09 / 2025, page 14 / 126 4 / 12 square inch) as well as other pressures lower than the hydrostatic pressure foreseen at the intended target location for use of actuator 10. In Figure 1, the hydraulic chamber 16 can be seen connected to the main actuator 14, which may be a part of the device to be actuated or may be a configuration to move another device. In either case, the main actuator, as illustrated in Figure 1, includes a piston chamber 30 having a piston 32 in it that bifurcates the chamber 30. One end of the chamber 30 is connected to the hydraulic chamber 16 while the other end of the chamber 30 is connected to the hydrostatic pressure, or simply open to the hydrostatic pressure.After actuation of actuator 10, meaning a signal was received at trigger 22 and valve 24 was opened, fluid from hydraulic chamber 16 will be transferred to atmospheric chamber 26, thus creating a negative pressure pulse in hydraulic chamber 16 as the hydraulic fluid flows into atmospheric chamber 26 (see arrows in Figure 2). Due to the negative pressure in chamber 16, the hydrostatic pressure in chamber 30 will cause piston 32 to move towards hydraulic chamber 16 and thus change the physical position of piston 32. With the change in physical position, device 20 will be actuated directly or indirectly. In the case of the illustration in Figure 1, piston 32 is part of a sliding sleeve 34 and therefore is part of a directly actuated device 20.

[0018] With reference to Figures 3 and 4, a second embodiment of an actuator 40 is illustrated. The second embodiment actuates the main booster 14 with positive pressure instead of the negative pressure that the embodiment of Figure 1 uses. When the components are substantially similar to Figure 1, these components will have the same reference numbers. The impulse generation arrangement 42 is, in part, similar to the previous embodiment, but the arrangement 42 also includes a reverse piston booster 44. The booster 44 comprises a reverse piston 46 having a larger sealing area 48 Petition 870250081688, dated 11 / 09 / 2025, page 15 / 126 5 / 12 at one end of the same that is exposed to hydrostatic pressure and a smaller sealing area 50 at one end of the same that is connected to the hydraulic chamber 16. The differences in the sealing areas between 48 and 50 will cause the pressure applied to piston 46 to be amplified in the smaller sealing area 50. This pressure increase above the hydrostatic pressure can be exploited for use in a positive pressure actuation that is initially caused by the same trigger and atmospheric chamber as in Figure 1. It will be recognized that the seal 50 is beyond a fluid intersection 52 with the valve 24, so that the fluid being transferred to the atmospheric chamber 26 is a fluid that is initially disposed around the piston 46 and between the seal 48 and the intersection 52, rather than the fluid that is in the hydraulic chamber 16.Thus, the negative pulse that pulls the piston towards the atmospheric chamber 26 (see arrows 58) does not create a negative pressure in the hydraulic chamber 16, but only causes a pressure increase in the hydraulic chamber 16 equal to the hydrostatic pressure plus the additional force that is created by the negative pressure in the atmospheric chamber 26 pulling the piston 46. The pressure applied to the main impeller 14 is illustrated with arrows 60.

[0019] With reference now to Figures 5 and 6, a third embodiment of the actuator 62 is illustrated. This embodiment is for the impulse generation arrangement 12 and the hydraulic chamber 16, identical to Figure 1, but the actuator 62 adds a subcircuit 64 that also manages the vent fluid of the main actuator arrangement 14. The subcircuit 64 is disposed between the hydraulic chamber 16 and the hydrostatic pressure, but is also configured to operate a closed hydraulic fluid circuit that is connected to the main actuator arrangement 14. Specifically, line 66 is connected to one end of the main actuator arrangement 14 (as illustrated in Figure 1, for example) and line 68 is connected to the other end of the arrangement 14. Petition 870250081688, dated 11 / 09 / 2025, page 16 / 126 6 / 12 (for example, line 66 can be connected where chamber 16 is connected in Figure 1, while line 68 would be connected where arrangement 14 is open to hydrostatic pressure in Figure 1. The reverse is also possible.) Therefore, the pressure in line 66 will push piston 32 towards line 68 and the pressure in line 68 will push piston 32 towards line 66. Returning to subcircuit 64 in Figure 6, it will be recognized that hydraulic chamber 16 is connected at one end 70 of the subcircuit and hydrostatic pressure is available at the other end 72. A piston 74 is arranged in a chamber 76 and sealed to the chamber at seals 78, having the same seal diameter. Piston 74 is also sealed at seal 80 between lines 66 and 68.Consequently, after triggering 22 and opening valve 24, a negative pressure is applied to the hydraulic chamber 16, causing piston 74 to move under the hydrostatic pressure at end 72 on the right of the figure, thus pressurizing the fluid in line 68. This can open or close an actuated device depending on where the pressurized fluid is connected to it. The actuating fluid is conserved by moving from an opposite side of the main actuator 14 back to the subcircuit 64 in line 66. Consequently, the actuating fluid does not need to be expelled.

[0020] Referring again to Figures 1, 2, 3, and 5, it will be recognized that each figure illustrates a housing 82 and a housing coupling 84. This is an additional benefit of the disclosure in this document. Although the configuration of the impulse generation arrangement, the main actuator arrangement, and the hydraulic chamber can be used in a tool in a dedicated manner, the elements of Figures 1, 2, 3, and 5 can also be configured with the housing 82 and the housing coupling 84 to be modular. The housings 82 are universal, and the housing couplings 84 are sized for many different diameter tools and even tools of Petition 870250081688, dated 11 / 09 / 2025, page 17 / 126 7 / 12 different format intended for use in the well. The housing coupling 84 and housing 82 work together to secure the actuator to the end tool. This means that one of the significant disadvantages of the actuators of the prior art is specific and unique to the tools they actuate; the actuators according to this disclosure can be of a modular nature and therefore one actuator can be used for a number of different tools, thus reducing the number of different actuators that must be provisioned. Furthermore, this disclosure allows a number of actuators in modular form to be used on a single tool for multiple actuations, if desired.

[0021] With reference to Figure 7, a system 90 employing a number of actuators 10, 40 or 62 disclosed herein is illustrated. As illustrated, there are two positive pressure actuators 40 or 62 and two negative pressure actuators 10. There may be more or less of each and there may be all negative or all positive actuators. In each case, one actuator will act once to take the actions described above and thus move the end device in one way or another. Additional actuations may be provided by each of the additional actuators. The number of actuators is limited only by the available space. Additionally, and optionally, a compensator with a restricted orifice may be disposed in fluid communication with the hydraulic chamber 16 to allow the pressure in chamber 16 to equalize over time.The actuation would take seconds, while the compensator would bleed for hours, and therefore, the situation of permanent pressure differential between the hydrostatic chamber and the hydraulic chamber 16 can be avoided without impacting the tool's actuation.

[0022] With reference to Figure 8, a similar system 90 is illustrated in which the reversible movement of the end tool is performed with all positive actuators, but wherein a single line switch 96 is incorporated between the hydraulic chamber 16 and the arrangement of Petition 870250081688, dated 11 / 09 / 2025, page 18 / 126 8 / 12 main actuator 14. A single-line switch is a commercially available product and therefore does not require specific discussion. This system will include a fluid restrictor 98, a check valve 100, and a vent 102 to drain all excess fluid into the annular space.

[0023] Each of the components (atmospheric chamber 26, trigger 22, booster 44, subcircuit 64, etc.) of actuators 10, 40 and 62 is modular and can be replaced to alter the overall action in the system. For example, different sealing areas can be used on components to adjust the volume or pressure of the fluid moved in this way. Trigger 22 can be configured to respond to any trigger that an operator may dictate and can also be threaded into housing 82.

[0024] With reference to Figure 9, a well system 110 is illustrated. The system 110 comprises a well 112 in a subsurface formation 114. A string 116 is disposed within the well 112. An actuator 10, 40, 62 as disclosed herein is disposed within or as part of the string 116.

[0025] Below, some modalities of the aforementioned revelation will be presented:

[0026] Embodiment 1: An actuator including a thrust generating arrangement including an atmospheric pressure chamber and a valve connected in fluid communication with the chamber, a main actuator arrangement including a device piston and a hydrostatic pressure source and a hydraulic chamber disposed between and connecting in fluid communication the thrust generating arrangement and the main actuator arrangement.

[0027] Modality 2: The actuator is as in any previous modality, except that the hydraulic chamber directly connects the impulse generation arrangement with the main actuator arrangement. Petition 870250081688, dated 11 / 09 / 2025, page 19 / 126 9 / 12

[0028] Modality 3: The actuator is as in any previous modality, except that the hydraulic chamber connects exclusively the impulse generation arrangement with the main actuator arrangement.

[0029] Mode 4: The actuator as in any previous mode, where the hydraulic chamber is a control line.

[0030] Modality 5: The actuator, as in any previous modality, is a modular, mountable construction with a plurality of distinct and different tools.

[0031] Embodiment 6: The actuator, as in any previous embodiment, additionally comprising a housing coupler configured to fix the actuator to a tool to be actuated.

[0032] Modality 7: The actuator is as in any previous embodiment, except that the impulse generation arrangement is housed in a housing that is configured to attach to the housing coupler.

[0033] Embodiment 8: The actuator as in any previous embodiment, additionally including a reverse piston booster disposed between the hydrostatic pressure source and the piston of the device.

[0034] Modality 9: The actuator as in any previous embodiment, except that the reverse piston booster includes a reverse piston containing pressure areas that cause the reverse piston to increase the pressure of the hydraulic fluid in contact with the piston of the device above a pressure of the hydrostatic pressure acting on the reverse piston.

[0035] Modality 10: The actuator as in any previous embodiment, additionally including a hydraulic subcircuit disposed between the hydrostatic pressure source and the piston of the device.

[0036] Mode 11: The actuator as in any previous mode, except that the subcircuit includes a hydraulic piston which includes Petition 870250081688, dated 11 / 09 / 2025, page 20 / 126 10 / 12 piston areas causing hydraulic fluid pressure to be transferred between the lines.

[0037] Mode 12: The actuator as in any previous mode, with the hydraulic subcircuit comprising a hydrostatic pressure inlet, a trigger outlet, a device fluid vent inlet and a device fluid outlet.

[0038] Modality 13: The actuator as in any previous embodiment, additionally including a compensator arrangement.

[0039] Modality 14: The actuator is as in any previous modality, except that the compensator includes a bleed hole.

[0040] Embodiment 15: A method for actuating a downhole tool including signaling the trigger on an actuator as in any previous embodiment, opening the atmospheric chamber of the actuator, causing a low-pressure pulse in the actuator and moving the piston of the device with the pulse.

[0041] Embodiment 16: The method as in any previous embodiment, including additionally routing the low-pressure pulse to a reverse piston, moving the reverse piston with hydrostatic fluid pressure, and amplifying the pressure in a hydraulic fluid with the reverse piston above the hydrostatic fluid pressure.

[0042] Embodiment 17: The method as in any previous embodiment, including additionally containing hydraulic actuation fluid in a subcircuit that is connected to the main actuator arrangement.

[0043] Mode 18: The method as in any previous mode, including additionally receiving ventilation fluid from an actuated device in the subcircuit.

[0044] Embodiment 19: A well system including a well in an underground formation, a string in the well and an actuator as in any previous embodiment disposed within or as part of the string. Petition 870250081688, dated 11 / 09 / 2025, page 21 / 126 11 / 12

[0045] Modality 20: The system is as in any previous modality, except that the actuator is modular and configured to attach to an external surface of a series of downhole devices.

[0046] The use of the terms a, an, and similar references in the context of describing the invention (especially in the context of the following claims) should be interpreted as encompassing both the singular and the plural, except where otherwise indicated in the present invention or clearly contradicted by the context. Additionally, it should be considered that the terms first, second, and similar in the present invention do not denote any order, quantity, or importance, but are instead used to distinguish one element from another. The terms approximately, substantially, and generally are intended to include the degree of error associated with measuring the specific quantity based on the equipment available at the time of filing. For example, approximately and / or substantially and / or generally includes a range of values ​​of ± 8% of a given value.

[0047] The teachings of this present disclosure can be used in a variety of well operations. These operations may involve the use of one or more treatment agents to treat a formation, the fluids residing in a formation, a wellbore, and / or well equipment such as a production line. 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, signalers, flow improvers, etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, signaler injection, cleaning, acidification, steam injection, water injection, cementing, etc. Petition 870250081688, dated 11 / 09 / 2025, page 22 / 126 12 / 12

[0048] Although 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 alterations may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. Additionally, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its essential scope. Therefore, it is intended that the invention is not limited to the specific embodiment disclosed as the best contemplated mode for carrying out the present invention, but that the invention includes all embodiments that fall within the scope of the claims.Furthermore, in the drawings and description, exemplary embodiments of the invention have been disclosed, and although specific terms may have been employed, they are used, unless otherwise stated, only in a generic and descriptive sense and not for the purpose of limitation; therefore, the scope of the invention is not thus limited. Petition 870250081688, dated 11 / 09 / 2025, page 23 / 126

Claims

1 / 3 CLAIMS 1. Actuator (10, 40, 62) characterized by comprising: an impulse generating arrangement (12, 42) comprising: an atmospheric pressure chamber; and a valve (24) connected in fluid communication with the chamber; a main actuator arrangement (14) comprising: a device piston (32); and a hydrostatic pressure source; and a hydraulic chamber (26) disposed between and connecting in fluid communication the impulse generating arrangement (12, 42) and the main actuator arrangement (14).

2. Actuator (10, 40, 62), according to claim 1, characterized in that the hydraulic chamber (26) directly connects the impulse generation arrangement (12, 42) with the main actuator arrangement (14).

3. Actuator (10, 40, 62), according to claim 1, characterized in that the hydraulic chamber (26) exclusively connects the impulse generation arrangement (12, 42) with the main actuator arrangement (14).

4. Actuator (10, 40, 62), according to claim 1, characterized by being a modular, mountable construction with a plurality of distinct and different tools.

5. Actuator (10, 40, 62), according to claim 4, characterized by additionally including a housing coupler (84) configured to fix the actuator (10, 40, 62) to a tool to be actuated.

6. Actuator (10, 40, 62), according to claim 5, characterized in that the impulse generation arrangement (12, 42) is Petition 870250081688, dated 11 / 09 / 2025, p. 24 / 126 2 / 3 disposed in a housing (82) that is configured to attach to the housing coupler (84).

7. Actuator (40), according to claim 1, characterized by additionally including a reverse piston booster (44) disposed between the hydrostatic pressure source and the piston of the device.

8. Actuator (62), according to claim 1, characterized by additionally including a hydraulic subcircuit (64) disposed between the hydrostatic pressure source and the piston of the device.

9. Actuator (10, 40, 62), according to claim 1, characterized by additionally including a compensator arrangement.

10. Method for actuating a downhole tool, characterized by comprising: signaling the trigger on an actuator (10, 40, 62) as defined in claim 1; opening the atmospheric chamber of the actuator (10, 40, 62); causing a low-pressure pulse in the actuator (10, 40, 62); and moving the piston of the device (32) with the pulse.

11. Method according to claim 10, characterized by further comprising: directing the low pressure pulse to a reverse piston (46); moving the reverse piston (46) with hydrostatic fluid pressure; and amplifying the pressure in a hydraulic fluid with the reverse piston (46) above the hydrostatic fluid pressure.

12. Method according to claim 10, characterized by further comprising: Petition 870250081688, dated 11 / 09 / 2025, page 25 / 126 3 / 3 containing hydraulic actuation fluid in a subcircuit (64) that is connected to the main actuator arrangement (14).

13. Method according to claim 12, characterized by further comprising: receiving ventilation fluid from an actuated device in the subcircuit (64).

14. Well system (110) characterized by comprising: a well (112) in a subsurface formation (114); a string (116) in the well (112); and an actuator (10, 40, 62) as defined in claim 1, disposed within or as part of the string (116).

15. System (110), according to claim 14, characterized in that the actuator is modular and configured to attach to an external surface of a series of downhole devices. Petition 870250081688, dated 11 / 09 / 2025, p. 26 / 126

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