Downhole Sleeve Tool

Abstract

A downhole sleeve tool is provided that includes cartridge sub and a ported sub defining a central bore and one or more sleeve ports therethrough. There is a piston sleeve valve movably positionable within the ported sub to selectively block communication between the central bore and the one or more sleeve ports. The cartridge sub has an inlet port and an outlet port. There is an at least one cartridge assembly disposed in a cartridge bore formed in a sidewall of the cartridge sub.

Description

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0001] Not applicableBACKGROUNDFIELD OF THE DISCLOSURE

[0002] The present disclosure relates generally to a downhole sleeve tool for use in a wellbore. Some embodiments pertain to a sleeve tool in the form of an initiator sleeve for use in or with a workstring.BACKGROUND OF THE DISCLOSURE

[0003] An oil or gas well includes a wellbore extending into a subterranean formation at some depth below a surface (e.g., Earth’s surface), and is usually lined with a tubular, such as casing, to add strength to the well.

[0004] Production treatment or stimulation of the formation may be necessary to fracture the formation and provide passage of hydrocarbons to the wellbore, from which it can be brought to the surface and produced. Fracturing of formations via horizontal wellbores traditionally involves pumping a stimulant fluid through either a cased or open hole section of the wellbore and into the formation to fracture the formation and produce hydrocarbons therefrom.

[0005] In some circumstances frac strings are deployed in cased wellbores, in which case perforations are provided in the cemented in system to allow stimulation fluids to travel through the fracing tool and the perforated cemented casing to stimulate the formation beyond. In other cases, fracing is conducted in uncased, open holes.

[0006] In the case of multistage fracing, multiple frac valve tools are used in a sequential order to frac sections of the formation, typically starting at a toe end of the wellbore and moving progressively towards a heel end of the wellbore. A toe valve is a particular valve located at the toe end of a frac string. It is the first valve on the string to open and to allow communication between an interior of the frac string and the formation beyond.

[0007] Toe valves, also called toe-initiator sleeves (or other common nomenclature), are sometimes designed to open only after a specific number of pressure cycles once specific values have been applied. Once opened, the flow path can be used to either stimulate the formation for production or simply to allow the multistage frac bottom hole assembly (BHA) of choice to be pumped downhole. The completion string can be cemented or not inside the well-bore.

[0008] Toe sleeves often lack the ability to multi-cycle test. Of the devices that might operate with some success, there tend to be known difficulties with reliability. For example, the sleeve may have a test cartridge that is prone to failure because the design is too complex (tight clearances, dimensions too hard to machine, etc.).

[0009] There is a need is a downhole tool or device suitable to provide multi-cycle operability and reliability.SUMMARY

[0010] Embodiments of the disclosure pertain to a downhole sleeve tool that may include one or more of: a lower sub defining or having a central bore and one or more sleeve ports therethrough; a piston valve slidably positionable within the lower sub to selectively block communication between the central bore and the one or more sleeve ports; an upper sub connectable to the lower sub and sharing a central bore therewith, said upper sub defining an inlet port, one or more communication ports and an outlet port and comprising one or more cartridge assemblies each housed in a cartridge bore of the upper sub. The cartridge bore may be in wall of the upper sub. The upper sub may be referred to as a cartridge sub or sleeve, which may be disposed between the lower sub and a top sub.

[0011] Any of such cartridge assemblies may include one or more of: a shear housing or shear member housing, which may be (movably) disposed in the cartridge bore. There may be a shear piston movably disposed in the shear housing. There may be a shear member (such as a pin or the like) disposed between the shear housing and the shear piston. The shear member need not be limited to something that can shear, and instead may be any kind of deformable device suitable to change configuration upon a change in pressure. In a first configuration, the shear member may be unbroken, and may be configured to facilitate keeping the shear piston in a corresponding first configuration.

[0012] Any cartridge assembly may include another movable member proximate the shear member, such as in the first configuration. The movable member may be a (movable) valve stem or rod. There may be a bias member disposed around and / or engaged with the valve stem in a manner that facilitates holding the valve stem in the first configuration.

[0013] The valve stem may be at least partially disposed within a valve housing or body. The bias member may be disposed between an end of the valve stem and a corresponding end of the valve body.

[0014] The shear member or deformable device may be configured to break or otherwise move. Moving, deforming, breaking, etc. of the deformable device by fluid pressure (such as from the central bore), and release or bleed of fluid pressure may allow the valve stem to move, thereby allowing passage of fluid to one or more subsequent cartridge assemblies via a communications port, or allows passage of fluid to thereby shift the valve to allow communication between the central bore and the one or more sleeve ports.

[0015] Other embodiments of the disclosure may pertain to a downhole sleeve tool or tool assembly that include a cartridge sub. The cartridge sub may be a downhole sleeve tool. The sub may include a sidewall having a cartridge bore. There may be an at least one cartridge device or assembly disposed in the cartridge bore.

[0016] Any cartridge of the disclosure may have a first cartridge assembly configuration that prevents fluid communication through the cartridge assembly, and a second assembly configuration that does not prevent fluid communication through the cartridge assembly. The second assembly configuration may occur upon a pressure reduction or bleed down.

[0017] The cartridge sub may be coupled with a ported sub. The ported sub may have one or more ports, which may be selectively blocked by a sliding sleeve. The ported sub may have a first ported sub configuration where the ports are blocked. There may be a second ported sub configuration whereby the one or more ports are not blocked by the sliding sleeve. In aspects, the second ported sub configuration may not occur until the sleeve tool is in the second assembly configuration.

[0018] Any sleeve tool of the disclosure may have a plurality of cartridge assemblies. For example, there may be a second cartridge assembly. The second assembly may be configured for fluid communication in series with the cartridge assembly. Fluid may be prevented from passing to the second cartridge assembly unless the cartridge assembly is in the second assembly configuration.

[0019] Any cartridge assembly of the disclosure may have one or more cartridge devices or units. For example, the cartridge assembly may include first cartridge unit and a second cartridge unit. The units may be coupled in parallel (fluid communication).

[0020] Any cartridge assembly of the disclosure may include one or more of: a piston housing; a piston disposed within the housing; a valve stem comprising a valve stem end proximate the movable piston, and a valve stem tip; and / or a valve body disposed at least partially around the valve stem, the valve body comprising a valve body end and a stem tip bore. There may be a bias member disposed around the valve stem, and positioned between the valve stem end and the valve body end.

[0021] In the first assembly configuration the valve stem tip may be disposed within the stem tip bore. In the second assembly configuration the valve stem tip need not be disposed within the stem tip bore, which may thus open a flow path and provide fluid communication through the assembly.

[0022] Any cartridge assembly of the disclosure may include usage of a breakable member. The breakable member may be in a single piece, unbroken form, and may be disposed through one or both of the piston housing and the piston in the first assembly configuration. The breakable member may be broken into at least two pieces in the second assembly configuration.

[0023] In aspects, the first assembly configuration may include the moveable piston in a first piston configuration. The first assembly configuration may include the valve stem in a first valve configuration. The second assembly configuration may include the movable piston in a second piston configuration. The second assembly configuration may include the valve stem in a second valve configuration.

[0024] Other embodiments herein pertain to a method of opening a downhole sleeve tool. The method may include the step of providing a downhole sleeve tool. The sleeve tool may include one or more of: a lower sub with one or more sleeve ports therethrough; a piston valve slidably positionable within the lower sub to selectively block communication with the wellbore and the tubestring; a cartridge sub or sleeve connectable to the lower sub and sharing a central bore therewith, said cartridge sub configured with or having an inlet port, one or more communication ports and an outlet port. One or more cartridge assemblies may be housed in a respective cartridge bore formed in a wall of the cartridge sub.

[0025] The method may include the step of pressurizing a first cartridge of said downhole tool to break or move a deformable member with fluid pressure from the central bore; releasing fluid pressure to allow movement of a valve stem; allowing passage of fluid to one or more subsequent cartridge assemblies via a communications port, or allowing passage of fluid to an uphole end of the piston valve to thereby shift the valve to allow communication between the central bore and the one or more sleeve ports.

[0026] The cartridge sub may include an at least one fluid communication port; and an outlet port. The upper sub may have a sidewall. There may be a cartridge bore formed within the sidewall. There may be a cartridge assembly disposed within the cartridge bore.

[0027] The downhole sleeve tool may include a second cartridge assembly. In aspects, the fluid may enter the second cartridge assembly after the stem moves to a second position or configuration. An at least one of the cartridge assembly and the second cartridge assembly may have a longitudinal cartridge axis. The downhole sleeve tool may have a respective longitudinal sleeve axis. The longitudinal cartridge axis may be (substantially) orthogonal to the longitudinal sleeve axis. Orthogonal is meant to include a reasonable tolerance for precision, but need not be exactly mathematical orthogonal.

[0028] The downhole tool sleeve may include an upper atmospheric chamber proximate an uphole end of the piston valve. The upper atmospheric chamber may be in fluid communication with the outlet port. The piston valve may be hydraulically balanced until the upper atmospheric chamber is pressurized with fluid transferred from the outlet port. In aspects, the fluid may enter a pressure chamber of the cartridge from the inlet port in order to act on a working surface. The pressure chamber may be sealingly isolated from fluid communication with any other part of the cartridge bore until the deformable member deforms or breaks. One or more seals or o-rings on the cartridge sleeve may be configured to prevent fluid pressure from entering another atmospheric chamber.

[0029] Embodiments herein pertain to a downhole system that may use a downhole sleeve tool of the disclosure. Other embodiments herein pertain to a method that may use a downhole sleeve tool of the disclosure. For example, method may include using or otherwise disposing a workstring into the wellbore. The workstring may include the downhole sleeve tool. The workstring may have an inner bore and an outer annulus therearound.

[0030] The method may include increasing pressure in the inner bore from a first pressure to a second pressure, the second pressure may be sufficient to exceed a set point. The second pressure may be sufficient to move or facilitate moving the downhole sleeve tool from a closed tool configuration to a second tool configuration.

[0031] The method may include reducing the second pressure to a next pressure that is lower than the second pressure. Reducing the pressure may allow or facilitate the downhole sleeve tool ability to move to an open tool configuration.

[0032] In aspects, the downhole sleeve tool may be an assembly that includes a cartridge sub and a ported sub. In the closed tool configuration, at least some fluid from the inner bore may be prevented from passing through the ported sub into the outer annulus. In the open tool configuration, fluid from the inner bore need not be prevented from passing through the ported sub into the outer annulus (e.g., the ported sub is opened). In operation, the method may include re-increasing the pressure to a sufficient amount to move the ported sub from a closed ported sub configuration to an open ported sub configuration.

[0033] The method may include disposing cement into the outer annulus.

[0034] These and other embodiments, features and advantages will be apparent in the following detailed description and drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0035] For a more detailed description of the present disclosure, reference will now be made to the accompanying drawings, wherein:

[0036] FIG. 1A shows a partial side view of a system having a workstring configured with a downhole sleeve tool in a sleeve closed position according to embodiments of the disclosure;

[0037] FIG. 1B shows a cross-sectional side view of the workstring with the downhole sleeve tool according to embodiments of the disclosure;

[0038] FIG. 1C shows a cross-sectional side view of a system having a workstring configured with a downhole sleeve tool in a sleeve opened position according to embodiments of the disclosure;

[0039] FIG. 2A shows a slightly rotated longitudinal side see-through view of a downhole sleeve tool (sometimes cartridge sleeve or sub), the sleeve tool having one or more cartridge assemblies according to embodiments of the disclosure;

[0040] FIG. 2B shows a lateral view of an end of the sleeve tool of FIG. 2A according to embodiments of the disclosure;

[0041] FIG. 2C shows a partial silhouetted longitudinal side cross-sectional view of a downhole sleeve tool having one or more cartridge assemblies according to embodiments of the disclosure;

[0042] FIG. 2D shows a partial silhouetted longitudinal side view of a downhole sleeve engaged with a one or mor subs, the sleeve having one or more cartridge assemblies according to embodiments of the disclosure;

[0043] FIG. 3A shows a longitudinal side view of a downhole sleeve tool according to embodiments of the disclosure;

[0044] FIG. 3B shows a lateral cut view of the sleeve tool of FIG. 3A showing a side cross-sectional side view of a cartridge according to embodiments of the disclosure;

[0045] FIG. 3C shows a side cross-sectional side view of the cartridge of FIG. 3B undergoing a pressure cycle (via fluid pressure) according to embodiments of the disclosure;

[0046] FIG. 3D shows a side cross-sectional view of the cartridge of Figure B moved to an intermediate or broke pin / rod position according to embodiments of the disclosure; and

[0047] FIG. 3E shows a side cross-sectional view of the cartridge of Figure B moved to a pressure release position during a pressure-down or bleed down portion of the pressure cycle according to embodiments of the disclosure.DETAILED DESCRIPTION

[0048] Herein disclosed are novel apparatuses, systems, and methods that pertain to downhole tools usable for wellbore operations, and aspects (including components) related thereto, the details of which are described herein.

[0049] Embodiments of the present disclosure are described in detail with reference to the accompanying Figures. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, such as to mean, for example, “including, but not limited to…”. While the disclosure may be described with reference to relevant apparatuses, systems, and methods, it should be understood that the disclosure is not limited to the specific embodiments shown or described. Rather, one skilled in the art will appreciate that a variety of configurations may be implemented in accordance with embodiments herein.

[0050] Although not necessary, like elements in the various figures may be denoted by like reference numerals for consistency and ease of understanding. Numerous specific details are set forth in order to provide a more thorough understanding of the disclosure; however, it will be apparent to one of ordinary skill in the art that the embodiments disclosed herein may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description. Directional terms, such as “above,”“below,”“upper,”“lower,”“front,”“back,”“right”, “left”, “down”, etc., may be used for convenience and to refer to general direction and / or orientation, and are only intended for illustrative purposes only, and not to limit the disclosure.

[0051] Connection(s), couplings, or other forms of contact between parts, components, and so forth may include conventional items, such as lubricant, additional sealing materials, such as a gasket between flanges, PTFE between threads, and the like. The make and manufacture of any particular component, subcomponent, etc., may be as would be apparent to one of skill in the art, such as molding, forming, press extrusion, machining, or additive manufacturing. Embodiments of the disclosure provide for one or more components to be new, used, and / or retrofitted.

[0052] Numerical ranges in this disclosure may be approximate, and thus may include values outside of the range unless otherwise indicated. Numerical ranges include all values from and including the expressed lower and the upper values, in increments of smaller units. As an example, if a compositional, physical or other property, such as, for example, molecular weight, viscosity, melt index, etc., is from 100 to 1,000, it is intended that all individual values, such as 100, 101, 102, etc., and sub ranges, such as 100 to 144, 155 to 170, 197 to 200, etc., are expressly enumerated. It is intended that decimals or fractions thereof be included. For ranges containing values which are less than one or containing fractional numbers greater than one (e.g., 1.1, 1.5, etc.), smaller units may be considered to be 0.0001, 0.001, 0.01, 0.1, etc. as appropriate. These are only examples of what is specifically intended, and all possible combinations of numerical values between the lowest value and the highest value enumerated, are to be considered to be expressly stated in this disclosure.

[0053] Embodiments herein may be described at the macro level, especially from an ornamental or visual appearance. Thus, a dimension, such as length, may be described as having a certain numerical unit, albeit with or without attribution of a particular significant figure. One of skill in the art would appreciate that the dimension of “2 centimeters” may not be exactly 2 centimeters, and that at the micro-level may deviate. Similarly, reference to a “uniform” dimension, such as thickness, need not refer to completely, exactly uniform. Thus, a uniform or equal thickness of “1 millimeter” may have discernable variation at the micro-level within a certain tolerance (e.g., 0.001 millimeter) related to imprecision in measuring and fabrication.

[0054] The drawings are not necessarily to scale and in some instances proportions may have been exaggerated or silhouetted in order to more clearly depict certain features. One or more sleeve or sub devices may be depicted in isolation; however, one of skill would appreciate any such sleeve or sub may be readily coupled with other components for operational / wellbore use.Terms

[0055] The term “connected” as used herein may refer to a connection between a respective component (or subcomponent) and another component (or another subcomponent), which can be fixed, movable, direct, indirect, and analogous to engaged, coupled, disposed, etc., and can be by screw, nut / bolt, weld, and so forth. Any use of any form of the terms “connect”, “engage”, “couple”, “attach”, “mount”, etc. or any other term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described.

[0056] The term “fluid” as used herein may refer to a liquid, gas, slurry, multi-phase, etc. and is not limited to any particular type of fluid such as hydrocarbons.

[0057] For some embodiments, a material of construction may include a composition of matter designed or otherwise having the inherent characteristic to react or change integrity or other physical attribute when exposed to certain wellbore conditions, such as a change in time, temperature, water, heat, pressure, solution, combinations thereof, etc. Heat may be present due to the temperature increase attributed to the natural temperature gradient of the earth, and water may already be present in existing wellbore fluids. The change in integrity may occur in a predetermined time period, which may vary from several minutes to several weeks. In aspects, the time period may be about 12 to about 36 hours.

[0058] The term “fracing” or “frac operation” as used herein may refer to fractionation of a downhole well that has already been drilled. The same may also be referred to and interchangeable with the terms facing operation, fractionation, hydrofracturing, hydrofracking, fracking, hydraulic fracturing, frac, and so on. A frac operation may be land or water based.

[0059] The present testable toe-initiator sleeve may be used as part of a completion string, in order to create a flow path for the fluid from inside the string to the formation outside (or vice versa), after a specific number of pressure cycle tests at specific values have been applied. Once opened, the flow path can be used to stimulate the formation for production.

[0060] A downhole sleeve tool in or having a component in a configuration may be analogous to a position. For example, a first configuration may be analogous or identical to a first position, with the words usable interchangeably.

[0061] Referring now to FIGS. 1A, 1B, and FIG. 1C together, a partial side view of a system having a workstring configured with a downhole sleeve tool in a sleeve closed position, a cross-sectional side view of the workstring with the downhole sleeve tool, and a cross-sectional side view of a system having a workstring configured with a downhole sleeve tool in a sleeve opened position, respectively, according to embodiments of the disclosure, are shown. One of skill would appreciate the views of FIGS. 1A-1C may be partial in nature. The downhole system 100 (and accompanying device(s)) with a downhole sleeve tool 102 may be coupled with, and axially and / or longitudinally movable, at least partially, with respect to each other. The sleeve tool 102 may be a cartridge sub or sleeve.

[0062] The system 100 may include a wellbore 116 formed in a subterranean formation 110 with a tubular 114 disposed therein. In an embodiment, the tubular 114 may be a workstring, such as casing (e.g., casing, hung casing, casing string, tubestring, etc.) (which may be cemented), and the like. The workstring 114, shown only in part here, may be run from the surface to any desired depth within the wellbore 116. As such, the workstring 114 may be used to position or run a downhole sleeve assembly 101 into and through the wellbore 116 to a desired location. The workstring 114 may include downhole sleeve tool assembly 101 coupled therewith.

[0063] As shown, the downhole sleeve tool assembly 101 may be a toe-initiator sleeve device. The sleeve tool 102 may be part of the sleeve sub assembly 101, which may also include or have other components coupled therewith, namely an upper sub or collar 104, a lower sub or collar 106, and the like, which may be integral to or coupled together.

[0064] There may be a ported sub 105 disposed between the upper sub 104 and the lower sub 106. As shown here, the ported sub 105 may be coupled between the sleeve tool 102 and the lower sub 106. A sliding or piston sleeve 118 may be engaged with and disposed within the ported sub 105. In aspects, the sliding sleeve 118 may be sealingly engaged with the ported sub 105 in a manner that prevents fluid flow out of the sleeve 118, such as in a first or original configuration.

[0065] The sleeve tool 102 may have hydraulic valving or network. that by means of applied (internal) hydraulic or fluid pressure communicated via one or more communication or sidewall ports 127 or flow paths to one or more cartridges 108. Establishing pressure flow to at least one of the cartridges 108 may facilitate the sleeve tool 102 to cycle through a respective number of adjustable pressure cycles before the sliding sleeve 118 opens (e.g., to a second or opened configuration shown in FIG. 1C). The paths 127 et al. may be machine or otherwise formed within the tool 102, even if not clearly depicted within the Figures.

[0066] Opening the sleeve 118 may entail the assembly 101 moving from a first configuration to a second configuration. In analogous manner, opening the sleeve 118 may entail moving the sleeve 118 from a first sleeve position 156a to a second sleeve position 156b. The cartridge(s) 108 etc. may be held in place, such as via a retention plate, fasteners, etc. and the like.

[0067] Operation of the tool 102 corresponds to a sequence of pressure changes, usually associated with a test or pressure cycle. That is, a first pressure is increased to a second pressure higher than the first pressure, which may be referred to as a pressure-up or the like. Although not necessary, the second pressure may be high enough to cause a failure or other type of action that permits the sleeve tool be movable to an open configuration that permits transfer of fluid F therethrough.

[0068] In a first configuration, the sliding sleeve 118 may be a (primary) barrier for fluid F from transferring from an inner assembly bore 122 of the assembly 101 to access the wellbore 116 or formation 110 via sleeve ports 120. The assembly bore 122 may include respective bores of components of the assembly 101.

[0069] When the sleeve tool 120 is run-in to or positioned at a desired location via the workstring 114, pressure testing for the system 100 may be initiated or cycled. At a first position or configuration, the sliding sleeve 118 may be in a state of hydraulic balance. In embodiments, difference in hydraulic areas may be provided between an uphole end 118a of the sliding sleeve 118, and a downhole end 118b. This difference in hydraulic areas may facilitate or generate a positive force up-hole suitable to keep the sliding sleeve 118 closed with fluid F in the bore 122.

[0070] To prevent the sleeve 118 from inadvertent movement or shifting, one or more securing members (such as shear shrews) 128 may be used to connect the sleeve 118 with the ported sub 105. The securing member(s) 128 may have a predetermined failure or break point. For example, the securing member(s) 128 may fail (e.g., shear) when a chamber (not viewable here) is flooded with sufficient fluid to pass chamber into flow path 126 (shown via dotted line as an illustration). As such, force (pressure) may act on the uphole end 118a to overcome (break, shear, etc.) the securing members 128. One of skill would appreciate members 128 need not be required.

[0071] Thereafter, the sleeve 118 may move or shift (e.g., downhole), thereby opening (by no longer blocking) sleeve ports 120. Fluid F may be transferred through the hydraulic passages of the sleeve tool 102. Shifting the sleeve 118 to open the ports 120 may be the assembly 101 moved to a second configuration (or the sleeve 118 moved to a second sleeve configuration).

[0072] The passages (e.g., 127) of the sleeve tool 102 may be inaccessible unless or until a rupture portion 130a of a rupture device 130 is broken or otherwise removed. The rupture device 130 may be broken once the pressure of fluid F exceeds a (predetermined) set point of the device 130. When the rupture device is broken, fluid may flow from the bore 122 into the passages 127, and toward the cartridge 108.

[0073] The downhole system 100 may include one or more stages. Any such individual stage may have the exact same or comparable machined features, parts, and functionality, and may be connected (such as in series) by a number of communication ports.

[0074] Referring now to FIGS. 2A, 2B, 2C, and FIG. 2D together, a slightly rotated longitudinal side see-through view of a downhole sleeve tool (sometimes cartridge sleeve or sub), the sleeve tool having one or more cartridge assemblies, a lateral view of an end of the sleeve tool, a partial silhouetted longitudinal side cross-sectional view of a downhole sleeve tool having one or more cartridge assemblies, and a partial silhouetted longitudinal side view of a downhole sleeve engaged with a one or mor subs, the sleeve having one or more cartridge assemblies, respectively, according to embodiments of the disclosure, are shown. One of skill would appreciate the views of FIGS. 2A-2D may be partial in nature, or have some transparency or silhouette in order to depict internals.

[0075] A downhole sleeve tool 202 (and accompanying components) may be useable with downhole systems of the present disclosure (e.g., downhole system 100, etc.). The tool 202 may be referred to as a cartridge sub or sleeve 202, which may be used with a workstring, top sub, lower sub, etc. As such, the downhole sleeve tool 202 may be like that of other sleeve tools described herein (e.g., 102, etc.), and thus similarities only discussed in brevity, with differences, if any, discernable to one of ordinary skill in the art. The tool 202 may have or be coupled with a ported section or sub 205 (shown only in partial simplified block form; see also 105) as part of a sleeve tool assembly (e.g., 101). The tool 202 may be coupled or associated with a top sub 204 (shown only in partial simplified block form) and a lower or bottom sub (e.g., 106).

[0076] FIGS. 2A-2D together show a first pressure cycle or pressure increase (or fluid F) may communicate (e.g., fluid communication) directly with the fluid inside of a sleeve tool bore 222a. The fluid F may feed to a first cartridge assembly 208 / 208a via an inlet path 227 formed in a sidewall of the sleeve tool 202. Initial feed into the inlet path 227 may be blocked or obstructed by a pressure sensitive device 230, such as a rupture disk or the like. The rupture portion 230a of the device 230 may be exposed to the inner bore 222a. A cartridge of the present disclosure may be interchangeably or analogously referenced as a cartridge or cartridge assembly 208.

[0077] As shown here, there may be a first cartridge assembly 208a and a second cartridge assembly 208b. Any cartridge assembly 208 may include one or more cartridge units or devices 228. The assemblies 208a, 208b may be arranged in series or parallel. Series may facilitate multi-cycle testing; parallel may facilitate redundancy.

[0078] After breach of the device 230, fluid F (or the inlet fluid Fi) may be communicated from the bore 222a to the first assembly 208a (or respective unit 228) via an inlet port and path. In operation, after a first or proceeding stage has been pressured up in a first pressure test or cycle, fluid (such as intermediate fluid Fx) may be allowed to travel to a next assembly (e.g., 208a to 208b) or another stage. The intermediate fluid Fx is akin to fluid F, Fi, but understood to be what exits the assembly 208a once the assembly 208a moves from a first assembly configuration to a second assembly configuration. One of skill would appreciate reference to a change in configuration as being comparable or equivalent to a change in position, and thus used interchangeably.

[0079] The next stage or cycle may involve travel of fluid via a second communication port (e.g., 229, etc.) to a second stage of pressure testing. Alternatively, the first stage or any stage may serve as the last stage after which pressurized fluid flows to access the upper atmospheric chamber via a final communication port 226 (see also 126, FIG. 1A), also called an outlet port or path. This outlet 226 may facilitate or trigger the shift or movement of a sleeve valve 218 from a first sleeve valve configuration to a second sleeve valve configuration. The first sleeve valve configuration may be a closed sleeve configuration (156a), and the second sleeve valve configuration may be an open sleeve configuration (156b).

[0080] In aspects, fluid may travel to a second or subsequent stage via a downstream communication port. A second or additional pressure test may be performed until the second stage is functioned, allowing fluid to move to any next or subsequent stage.

[0081] To ease manufacturing, any paths (e.g., 227, 229, 226, etc.) may be machined open into the sidewall. In order to maintain pressure, the paths may be plugged with a suitable cap (plug, etc.) 270.

[0082] Fluid travel may be prevented unless and until at least the first assembly 208a has a change in configuration (such as release of an inner valve stem). The change in configuration may not occur until after a first pressure release or bleed down occurs, which coincides with release or movement of the valve stem to reveal a previously blocked flow port. Pressure cycles may be repeated as may be desired.

[0083] Referring now to FIGS. 3A, 3B, 3C, 3D, and FIG. 3E together, a longitudinal side view of a downhole sleeve tool, a lateral cut view of the sleeve tool showing a side cross-sectional view of a cartridge, a side cross-sectional view of the cartridge undergoing a pressure cycle (via fluid pressure), a side cross-sectional view of the cartridge moved to an intermediate or broke pin / rod position, a side cross-sectional view of the cartridge moved to a pressure release position (such as during a pressure-down or bleed down portion of a pressure cycle), respectively, according to embodiments of the disclosure, are shown.

[0084] The components and functionality of the cartridge assembly 308 may be exact or comparable to those discussed herein (e.g., 208, etc.), with any differences discernable to one of skill in the art. The arrangement and operation any cartridges 308 may be associated with any ‘sub’ or collar (e.g., top sub 104, FIG. 1A). Any cartridge 308 may be disposed or arranged in relation to one another and in relation to an (upper) atmospheric chamber.

[0085] The cartridge(s) may facilitate use or ability for an adjustable number of pressure cycles that may be used or applied to a downhole sleeve tool before the tool (102) opens. Such a sleeve tool (102, 202, etc.) may be moved from a first or closed configuration to a second or open configuration. Any pressure cycle may include increasing a first pressure to a second pressure, and then reducing the second pressure to a reduced or lowered pressure. Although it may be the case, it is not required that the first pressure be the same as the reduced or lowered pressure, as pressure values would be known to change or fluctuate.

[0086] Generally, each stage or cartridge assembly 308 may have or be associated with a cartridge bore 332 formed inside of any sub, such as in a sub sidewall 334. In operation, the cartridge assembly 308 may be disposed (inserted) in the cartridge bore 332 (in isolation or part of a cartridge system), and thereby form or create one or more sealed chambers in a first assembly configuration.

[0087] The sealed chamber(s) may include a pressure chamber 336 and one or more atmospheric chambers 338. As shown here, there may be a first (shear) atmospheric chamber 338 and a second (valve) chamber 340. In assembly, run-in, first assembly configuration, etc. the atmospheric chambers 338, 340 may either or both be separated or isolated by or from the pressure chamber 336. This may be prior to initiation of any pressure cycle.

[0088] A communication port or flowpath 327 (with path end 327a) may be in fluid communication with the pressure chamber 336, and may be configured to bring or facilitate introduction of pressurized fluid F into the pressure chamber 336. In the case of the first stage or assembly configuration, fluid F may enter the pressure chamber 336 from a first communication port 327, such as shown by way of example in FIG. 3B. In the case of any subsequent stages, fluid may be introduced into the pressure chamber 336 from subsequent communications ports, connecting earlier stages to subsequent stages.

[0089] The atmospheric chamber 340 of one stage may be able to be opened into fluid communication with a pressure chamber 336 of a subsequent stage via a subsequent communications path or port(s). Alternatively, in the case of a last stage or cartridge assembly, the respective atmospheric chamber 340 may be opened in fluid communication into communication with the upper atmospheric chamber (e.g., between the tool 102 and the sliding sleeve 118, FIG. 1B) via an outlet communications port 326 (which may also be formed in sidewall 334, although illustrated here in dotted line form). Established fluid communication of a valve atmospheric chamber of one stage with either the pressure chamber of the following stage or the atmospheric chamber may allow for setting of the number of pressure cycles as may be desired.

[0090] A retention plate 342 may be installed or formed on an end of the cartridge assembly 308 and assists in restricting movement of the cartridge 308. In an embodiment, the retention plate 342 may be a separate component that may be affixed to the upper sub via one or more screws (242a), or other well-known fasteners.

[0091] As shown, the cartridge assembly 308 may include a movable (shear) member or piston 344 with a (shear) member or piston housing 346, which may be positioned or disposed over at least a portion of the piston 344. There may be a deformable or breakable member 354, which may be disposed through one or both of the piston housing 346 and the piston 344. The deformable member 354 coupled with the housing 346 and the piston 344. The member 354 may be positioned orthogonal or perpendicular to cartridge long axis 309. The cartridge axis 309 may be orthogonal or perpendicular to a tool long axis (124, FIG. 1B).

[0092] The piston housing 346 and the piston 344 may have respective bores 346a and 344a for the deformable member 354 to fit therein. The deformable member 354 may be a force or pressure sensitive device, such as a shear member or pin. The deformable member 354 may be configured with a predetermined failure point 354a, such as a groove. As such, the force or pressure for which the deformable member 354 may fail (e.g., break) may be predetermined or calculated. Other comparable devices may be used.

[0093] The cartridge assembly 308 may include a suitable bias or movable member 348 disposed or positioned (at least partially) around a valve member or stem 350. While not limited, the bias member 348 may be a spring or comparable. The bias member 348 may be kept in a preloaded compressed (energized) state between an abutting valve end 347 of the valve 350 and an abutting valve end 345 of a valve body or sleeve 352. The bias member 348 may bias the stem 350 into engagement with the piston 344 in a first assembly configuration, which may coincide with a pressure cycle that has yet to occur (and thus no or insufficient fluid F flows into pressure chamber 332).

[0094] The first assembly configuration may include the piston 344 in a first piston configuration 361a. The first assembly configuration may include the valve stem 350 in a first valve configuration 351a. The first assembly configuration may include the valve stem 350 in (biased) engagement with the piston 344, shown by way of example in FIG. 3B. The first assembly configuration may occur when the deformable member 354 has not been deformed or broken, such that the fluid (pressure) F has either not been introduced into the chamber 332 (because device [130, etc.] has yet to break or rupture, or the pressure has yet to exceed a setpoint of member 354). The first assembly configuration may be a run-in or unenergized configuration.

[0095] In this first configuration, passage of fluid F through the assembly 308 may be prevented due to the presence of valve stem tip 350a (sealingly / movingly) disposed within valve body tip bore 352a. As a result, fluid F may not pass out of the assembly 308 via outlet ports 360 or path 326, and instead pressure may build within the pressure chamber 332.

[0096] FIG. 3C shows the assembly 308 moving from the first assembly configuration to an intermediate or next assembly configuration, whereby pressure of fluid F may exert against stem end 347 and / or against the deformable member 354. Pressure against the stem end 347 may result in at least some compression of the bias member 348. The stem 350 may cease moving at a point where stem shoulder 350b contacts body shoulder 352a, at which point stem tip 350a may still be disposed within the tip bore 352b.

[0097] As FIG. 3D shows, eventually the deformable member 354 may break from sufficient pressure of fluid F, which may result in release and movement of the piston 344 from the first piston configuration 361a to a second piston configuration 361b. Of note, even though a piston release event may have occurred, passage of fluid F out of the assembly 308 may still be prevented to due pressure holding the valve stem 350 in place (and thus tip 350a may still remain in bore 352b).

[0098] Once the (high) pressure up cycle is completed, the cycle may next include a bleed off or pressure release, whereby the stem 350 is no longer held in place by pressure, and instead the bias member 354 may urge the stem 350 in direction of arrow A. In the bleed off, after a pressure cycle (sufficient to break or deform member 354) occurs, the valve stem 350 may now move from the first valve configuration 351a to a second valve configuration 351b, as shown in FIG. 3E.

[0099] FIG. 3E thus shows the assembly 308 in a second assembly configuration, whereby the stem tip 350a is no longer within bore 352b, and a flow path through the assembly is opened. In this second assembly or open configuration, in the event of any subsequent pressure cycle the fluid (F, Fx, Fo, etc.) may pass freely through the assembly 308, out ports 360, and into pathway 326 / 329.

[0100] The second assembly configuration may include the piston 344 in the second piston configuration 361b and / or may include the valve stem 350 in the second valve configuration 351b. The second valve configuration 351b may facilitate fluid communication between the pressure chamber 332 and outlet ports 360. In an analogous manner the second assembly configuration may include fluid communication between the pressure chamber 332 and ports 360.

[0101] One or more compressible members, seals, O-rings, etc. 355a, 355b, 355c, may be used to sealingly and fluidly isolate pressure chambers. There may be one or more backup or support rings 356 present with any respective members. Any ring 356 may be made of any suitable durable material, such as plastic (e.g., polyetheretherketone). The members 355a / b / c may be made of any suitable pliable material, such as rubber. Other components of the tool 302 may be made of any suitable material for downhole conditions, such as metal.Operation

[0102] Any sleeve tool of embodiments used herein may be used in an analogous manner. Generally the sleeve tool may be used in or with a workstring, such as a casing string. Although the string may be made of subs, collars, stands, etc., it may just as well be the case that one or more of the same are integral to each other.

[0103] Be that as it may, the sleeve tool may generally be part of a sleeve tool assembly that includes a ported sleeve or sub. The typical use of the sleeve tool would be to undergo one or more pressure cycles, whereby a sufficient amount of pressure at some point results in the sleeve tool moving from a closed configuration to an open configuration, which point the ported sub may be moved from a respective closed configuration to an open configuration.

[0104] It may be the case that the sleeve tool has but a single cartridge assembly with a single cartridge device; embodiments herein are not meant to be limited by the dual device and / or dual assembly configuration show by non-limiting example in the Figures.

[0105] It would usually be the case that the wellbore is cemented (or comparable) around the workstring, including at the toe, such that pressure in the inner string bore is isolated from an outer annulus or area around or external to the workstring.

[0106] Pressure in the workstring may be at a first pressure, which may be too low to have any interaction or effect on the sleeve tool. In a first test, which may be a first pressure cycle, the first pressure may be increased to a second pressure, as may be desired. Any pressure between the first pressure and the second pressure may be sufficient to break the breakable member of the cartridge device.

[0107] One or more devices may be in parallel with the cartridge device, which may be beneficial for added redundancy for the sleeve tool. That is, each of such devices may experience the pressure increase at the same time, and in the event one device might fail (i.e., the breakable member does not break for some reason), a redundant device will. Only one device of the cartridge assembly needs to function correctly in order for the cartridge assembly to function correctly.

[0108] At this point, at least one cartridge device / assembly may be movable to an open configuration from its initial closed configuration. That is, upon bleed down or pressure reduction, such as reducing from the second pressure to another pressure that is lower than the second pressure, a bias member within the device may now be able to move a piston, which opens a flow passage within the assembly.

[0109] During a next pressure cycle, fluid (pressure) may now pass freely through the cartridge assembly either to a next cartridge assembly in series with the first assembly, or to the ported sub. Having a second cartridge assembly in series with the first assembly may provide multi-cycle functionality to the sleeve tool. There may be any number of cartridge assemblies in parallel as desired, including zero (i.e., the sleeve tool need only have a single cartridge assembly)

[0110] Any cartridge may be installed in a horizontal manner (orientation) with respect to the vertical nature of the sleeve (or associated workstring). The use of a horizontal configuration may make it easier to insert or replace the cartridge without having to remove or disconnect portions of the workstring from one another.

[0111] In the embodiments presented, fluid inside the toe initiator sleeve may be prevented from accessing the first communication port either by plugging it with plug device, such as a shear mechanism or by the use of a rupture disk. The plug device may be configured and sized to break at desired pressure values above known threshold, such as the absolute cementing pressure. Once breached, the plug device may now allow fluid into the pressure chamber (such as of the first stage).

[0112] The deform or break mechanism may include a shear pin and a shear piston, or the like. The activation (shear, break, etc.) value may be adjusted and / or pre-determined for different applications. Regardless of what device may be used, activation may occur. For example, when the predetermined pressure value reaches the set point, the mechanism may fail (e.g., the shear feature may shear). This facilitates the eventual opening of the ported sub, and fluid communication established between inside and outside the workstring.Advantages

[0113] Embodiments of the disclosure may provide for compact downhole sleeve tool design capable of withstanding high pressures and temperatures in a small envelope (large inside dia. and small outside dia.). This means there may be a “two-layered” sleeve design, which may provide for an essential feature.

[0114] Embodiments herein may provide for a modular design that allows for fast set-up changes. The pressure cartridges may easily be accessible and interchanged without having to remove any major component(s). The upper (or top) and lower (or bottom) subs may be replaced without affecting any of the atmospheric chambers.

[0115] Other advantages provide for a frac port opening that may be adjusted without difficulty to vary from matching the sleeve ID to the desired restricted size.

[0116] The piston valve may be beneficially kept form prematurely opening (on top of members coupling it to the housing) by a force imbalance generated by simply exposing the sleeve to internal pressure. As such, a positive force (proportional with the internal pressure) across this component is biasing the sleeve closed.

[0117] Embodiments herein may provide for short and compact design due to the tangential (or orthogonal, perpendicular, offset, etc.) orientation of the cartridge / stage bores. There may be a sufficient number of pressure cartridge capable of a large number of set-ups to match the customer requirements.

[0118] While preferred embodiments of the disclosure have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of the disclosure. The embodiments described herein are exemplary only, and are not intended to be limiting. Many variations and modifications of the disclosure disclosed herein are possible and are within the scope of the disclosure. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations. The use of the term "optionally" with respect to any element of a claim is intended to mean that the subject element is required, or alternatively, is not required. Both alternatives are intended to be within the scope of the claim. Use of broader terms such as comprises, includes, having, etc. should be understood to provide support for narrower terms such as consisting of, consisting essentially of, comprised substantially of, and the like.

[0119] Accordingly, the scope of protection is not limited by the description set out above but is only limited by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated into the specification as an embodiment of the present disclosure. Thus, the claims are a further description and are an addition to the preferred embodiments of the present disclosure. The inclusion or discussion of a reference is not an admission that it is prior art to the present disclosure, especially any reference that may have a publication date after the priority date of this application. The disclosures of all patents, patent applications, and publications cited herein are hereby incorporated by reference, to the extent they provide background knowledge; or exemplary, procedural or other details supplementary to those set forth herein.

Claims

1. A downhole sleeve tool comprising: a cartridge sub comprising a sidewall having a cartridge bore, and an at least one cartridge assembly disposed in the cartridge bore,wherein the cartridge assembly has a first assembly configuration that prevents fluid communication through the cartridge assembly, and a second assembly configuration that does not prevent fluid communication through the cartridge assembly, andwherein the second assembly configuration occurs upon a pressure reduction or bleed down.

2. The downhole sleeve tool of claim 1, wherein the cartridge sub is coupled with a ported sub, wherein the ported sub comprises a plurality of ports that are blocked by a sliding sleeve in a first ported sub configuration, and wherein in a second ported sub configuration the plurality of ports are not blocked by the sliding sleeve.

3. The downhole sleeve tool of claim 2, wherein the second ported sub configuration does not occur until the cartridge assembly is in the second assembly configuration.

4. The downhole sleeve tool of claim 1, the downhole sleeve tool further comprising a second cartridge assembly configured for fluid communication in series with the cartridge assembly, and wherein fluid is prevented from passing to the second cartridge assembly unless the cartridge assembly is in the second assembly configuration.

5. The downhole sleeve tool of claim 1, the cartridge assembly comprising a first cartridge unit in parallel fluid communication with a second cartridge unit.

6. The downhole sleeve tool of claim 5, the first cartridge unit further comprising: a piston housing;a movable piston disposed within the housing;a valve stem comprising a valve stem end proximate the movable piston, and a valve stem tip;a valve body disposed at least partially around the valve stem, the valve body comprising a valve body end and a stem tip bore; anda bias member disposed around the valve stem, and positioned between the valve stem end and the valve body end,wherein in the first assembly configuration the valve stem tip is disposed within the stem tip bore.

7. The downhole sleeve tool of claim 6, wherein in the second assembly configuration the valve stem tip is not disposed within the stem tip bore.

8. The downhole sleeve tool of claim 1, the cartridge assembly further comprising: a piston housing;a movable piston disposed within the housing;a valve stem comprising a valve stem end proximate the movable piston, and a valve stem tip;a valve body disposed at least partially around the valve stem, the valve body comprising a valve body end and a stem tip bore; anda bias member disposed around the valve stem, and positioned between the valve stem end and the valve body end,wherein in the first assembly configuration the valve stem tip is disposed within the stem tip bore.

9. The downhole sleeve tool of claim 8, wherein in the second assembly configuration the valve stem tip is not disposed within the stem tip bore.

10. The downhole sleeve tool of claim 9, wherein a breakable member in a single piece, unbroken form is disposed through both of the piston housing and the piston in the first assembly configuration.

11. The downhole sleeve tool of claim 10, wherein the breakable member is broken into at least two pieces in the second assembly configuration.

12. The downhole sleeve tool of claim 7, wherein the first assembly configuration comprises the moveable piston in a first piston configuration, and wherein the first assembly configuration comprises the valve stem in a first valve configuration.

13. The downhole sleeve tool of claim 12, wherein the first assembly configuration comprises the valve stem in biased engagement with the movable piston.

14. The downhole sleeve tool of claim 13, wherein the second assembly configuration comprises the movable piston in a second piston configuration, and wherein the second assembly configuration comprises the valve stem in a second valve configuration.

15. The downhole sleeve tool of claim 1, wherein the sidewall comprises an inlet fluid path and an outlet fluid path in fluid communication with the cartridge assembly.

16. The downhole sleeve tool of claim 15, wherein a rupture device is disposed in the sidewall, and in a first sleeve tool configuration the rupture device prevents fluid from transferring from an inner bore of a workstring into the inlet fluid path.

17. A downhole sleeve tool comprising: a cartridge sub comprising a sidewall having a cartridge bore, and an at least one cartridge assembly disposed in the cartridge bore, the cartridge sub further comprising: a piston housing;a movable piston disposed within the housing;a valve stem comprising a valve stem end proximate the movable piston, and a valve stem tip;a valve body disposed at least partially around the valve stem, the valve body comprising a valve body end and a stem tip bore; anda bias member disposed around the valve stem, and positioned between the valve stem end and the valve body end,wherein the cartridge assembly has a first assembly configuration that prevents fluid communication through the cartridge assembly, and a second assembly configuration that does not prevent fluid communication through the cartridge assembly, wherein in the first assembly configuration the valve stem tip is disposed within the stem tip bore.

18. The downhole sleeve tool of claim 17, wherein the second assembly configuration occurs upon a pressure reduction or bleed down, wherein the cartridge sub is coupled with a ported sub, wherein the ported sub comprises a plurality of ports that are blocked by a sliding sleeve in a first ported sub configuration, and wherein in a second ported sub configuration the plurality of ports are not blocked by the sliding sleeve.

19. A downhole sleeve tool assembly comprising: a cartridge sub comprising a sidewall having a cartridge bore, and an at least one cartridge assembly disposed in the cartridge bore; anda ported sub comprising a plurality of ports blocked by a sliding sleeve in a first ported sub configuration,wherein the cartridge assembly has a first assembly configuration that prevents fluid communication through the cartridge assembly, and a second assembly configuration that does not prevent fluid communication through the cartridge assembly,wherein in a second ported sub configuration the plurality of ports are not blocked by the sliding sleeve, andwherein the second ported sub configuration does not occur until the cartridge assembly is moved at least temporarily to the second assembly configuration.

20. The downhole sleeve tool of claim 19, wherein the sidewall comprises an inlet fluid path and an outlet fluid path in fluid communication with the at least one cartridge assembly, wherein a rupture device is disposed in the sidewall, and wherein in a first sleeve tool configuration the rupture device prevents fluid from transferring from an inner bore of a workstring into the inlet fluid path.

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