Downhole electric valve with electrohydraulic actuator

Abstract

The invention relates to the oil and gas production industry. An electric valve for installation in a borehole as a part of downhole tubing comprises a hollow cylindrical housing (1) with circulating ports (6), and a movable closure sleeve (4) which is disposed inside the housing and is capable of linear movement between an open position and a closed position in response to a signal arriving via a communication channel. The movable closure sleeve (4) is directly connected to a plunger (10) equipped with a return spring (5). The housing (1) has at least one hermetically sealed compartment containing an electric linear actuator (2) having a plunger (9) that is hydraulically connected to the plunger (10) of the closure sleeve (4). The ratio of the cross-sectional area of the plunger (10) of the closure sleeve to the cross-sectional area of the plunger (9) of the electric linear actuator (2) is directly proportional to the ratio of the force required to move the movable closure sleeve (4) into the open position to the force generated by the electric linear actuator (2), and is inversely proportional to the ratio of the stroke magnitude of the movable closure sleeve (4) to the stroke magnitude of the plunger (9) of the electric linear actuator. The result is an increase in the operating reliability of the electric valve.

Description

[0001] Well solenoid valve with electrohydraulic drive

[0002] Field of technology

[0003] The invention relates to the oil and gas production industry, namely to underground well equipment, in particular to well solenoid valves for performing work on killing, developing, flushing, hydraulic fracturing of a productive formation, subsequent monitoring and regulation of the inflow (injection) to increase oil or gas recovery.

[0004] State of the art

[0005] A downhole electric valve for fluid production or injection is known from the prior art (US20190316440A1, published October 17, 2019). The device can operate in aggressive downhole conditions and consists of a sliding valve, an electric motor, and a controller. The device can also be equipped with pressure and temperature sensors. The sliding valve is a small-diameter shutoff element that enables hydraulic communication between the tubular and annular space to monitor and regulate inflow (injection). The device is controlled from the surface via an electric cable laid along the wellbore. A disadvantage of the device is its design, as the small diameter of the shutoff element prevents it from operating at high fluid flow rates.

[0006] A solenoid valve for hydraulic fracturing is known from the prior art (EA 202100164 A1, published November 30, 2022). The device consists of a solenoid valve housing containing a sealed electronics compartment and a movable part. The solenoid valve housing is a hollow cylindrical body with circulation holes, and the movable part is a hollow cylindrical shutter with radial holes, which is coaxially located within the solenoid valve housing and is movable along the axis of the solenoid valve housing. The design of the solenoid valve's shutter mechanism, in which the total area of ​​the valve's side holes is no less than the valve's flow cross-sectional area, enables hydraulic communication between the tubular and annular space for both hydraulic fracturing (HF) and for monitoring and regulating inflow (injection).The solenoid valve's moving part is driven by a geared motor via a screw pair. A drawback of this device is the low reliability of the electric drive. Due to the specific design of the device, the geared motor is located between the valve casing and the valve bore, imposing strict geometric limitations on the diameter of the geared part. Consequently, the small-diameter geared motor is forced to overcome enormous torques when moving the valve, exerting forces of up to several tons.

[0007] Also known from the prior art is a solenoid valve (RU2777043 C1, published August 1, 2022) for installation in a well as part of well pipes. The valve is designed to control fluid flow between the space inside the pipes and the space behind the pipes at the valve location. The valve has a hollow cylindrical body with openings and a sleeve with openings located inside, along with an electric motor. The sleeve is designed to move between the open and closed positions in response to a signal received via a remote communication channel. A disadvantage of this device is the lack of a gearbox between the electric motor and the movable sleeve, which imposes operational limitations on the opening / closing force of the valve.

[0008] Disclosure of invention

[0009] The objective of the invention is to create a new downhole solenoid valve with an electrohydraulic drive and a movable valve sleeve through which fluid flows, which ensures the possibility of reliable operation of the device in high-flow oil or gas production wells, as well as in injection wells; performing work on killing, development, flushing, and hydraulic fracturing of the productive formation; during further operation of the well, to serve as a device for controlling the fluid inflow in the production well or the fluid injection profile in the injection well.

[0010] The technical result of the claimed invention is the expansion of the operational capabilities (expansion of the scope of application) of the downhole solenoid valve while simultaneously increasing its reliability.

[0011] The stated objective and the required technical result when using the invention are achieved by a new solenoid valve for installation in a well as part of well pipes. The solenoid valve is designed to control the flow of fluid between the space inside the pipes and the space behind the pipes at the location of the valve, comprising a hollow cylindrical body with circulation holes, a movable valve sleeve located within the body, designed to be linearly moved between an open position and a closed position in response to a signal received via a communication channel, wherein the movable valve sleeve is directly connected to a piston equipped with a return spring, and the body has at least one sealed compartment with an electric linear drive having a piston hydraulically connected to the piston of the valve sleeve,wherein the ratio of the cross-sectional area of ​​the piston of the shutter sleeve to the cross-sectional area of ​​the piston of the electric linear drive is directly proportional to the ratio of the force required to move the movable shutter sleeve to the open position to the force developed by the linear electric drive and inversely proportional to the ratio of the stroke of the movable shutter sleeve to the stroke of the piston of the electric linear drive.

[0012] In a particular embodiment of the invention, the total area of ​​the circulation openings of the housing is at least equal to the cross-sectional area of ​​the internal space of the shutter sleeve.

[0013] In a particular embodiment of the invention, the communication channel is a wired channel or a wireless channel.

[0014] In a particular embodiment of the invention, the solenoid valve is additionally equipped with temperature and / or pressure and / or composition and / or flow sensors to control the flow of fluid into or from the well or any possible combination thereof.

[0015] In a particular embodiment of the invention, the solenoid valve is configured to respond to changes provided by at least one sensor.

[0016] In a particular embodiment of the invention, the solenoid valve is additionally provided with at least one through channel for transit control lines, located along its axis while maintaining the tightness of the internal space of the valve.

[0017] In a particular embodiment of the invention, the solenoid valve additionally has a seat for fixing an anti-sand filter at the inlet of the circulation openings of the housing.

[0018] A distinctive feature of the invention is the expansion of the downhole valve's operational capabilities while simultaneously increasing operational reliability through a new design of an electrohydraulic downhole valve, which has at least one electric linear actuator that transmits control to a sliding valve sleeve via hydraulic fluid within a sealed circuit. When the linear electric actuator's piston extends, the hydraulic fluid pressure within the valve's sealed circuit increases, exerting pressure on the sliding valve sleeve piston, causing it to move and, consequently, opening the valve.This configuration allows the hydraulic fluid to perform a dual function, namely, to act as a lubricant for the moving elements of the solenoid valve, in particular the piston of the linear drive and the sliding valve sleeve, increasing the reliability of their operation, and as a medium for transmitting pressure in the movement system.

[0019] In the new valve configuration, the ratio of the cross-sectional area of ​​the valve sleeve piston to the cross-sectional area of ​​the electric linear actuator piston is directly proportional to the ratio of the force required to open the valve sleeve to the force generated by the electric linear actuator, and inversely proportional to the ratio of the valve sleeve stroke to the electric linear actuator piston stroke. This configuration enables the required force to open the valve sleeve with minimal force generated by the electric linear actuator(s). Furthermore, the wide range of possible cross-sectional area to piston stroke ratios allows for the optimal selection of the electric linear actuator's opening force reduction ratio.Typically, the greatest opening forces are required when the valve must be opened due to a large pressure differential between the annulus and the internal space, or when the valve has been idle for a long time, requiring peak forces to move the valve sleeve. The new valve design allows the sliding valve sleeve to be opened without equalizing the pressure in the annulus and internal space, ensuring guaranteed valve opening even if the sliding valve sleeve becomes stuck, thereby increasing the valve's operational capabilities and reliability.

[0020] The additional ability to move the sliding valve sleeve to intermediate positions between open and closed significantly expands the valve's adjustment range within wellbore tubing when operating in inflow (injection) control and regulation mode. These features are essential and interrelated, creating a stable set of essential attributes sufficient to achieve the stated objective and obtain the required technical result.

[0021] Brief description of the drawings

[0022] The details, features, and advantages of the present invention are explained by the following description of embodiments of the claimed technical solution using specific examples of implementation shown in Figs. 1-4, which, however, are not the only possible ones, but demonstrate the possibility of achieving the required technical result.

[0023] Fig. 1 shows an electrohydraulic valve in the open position.

[0024] Fig. 2 shows a cross-section of the valve shown in Fig. 1 along line B.

[0025] Fig. 3 shows the electrohydraulic valve in the closed position.

[0026] Fig. 4 shows a cross-section of the valve shown in Fig. 3 along line G.

[0027] The following positions are designated by numbers in the figures: 1 - solenoid valve body; 2 - electric linear drive, designed to control the position of the shutter sleeve 4 of the solenoid valve by creating excess pressure of the hydraulic fluid 8 in the annular chamber A; 3 - a sealed entry designed to hermetically connect the electric cable to the device; 4 - a movable shutter sleeve, combined with a piston 10; 5 - a return spring designed to return the sleeve 4 to the position in which the valve is closed; 6 - circulation holes of the solenoid valve body; 7 - seals; 8 - hydraulic fluid, designed to act on the piston 10 of the sleeve 4 during operation of the electric drives 2; 9 - linear drive piston; 10 - piston of the shutter sleeve; 11 - electric cable; 12 - circulation holes of the movable shutter sleeve.

[0028] Implementation of the invention

[0029] Various design and operating features of the valve are detailed below with reference to the drawings. It should be understood that the detailed description below, including the drawings and operating examples, is illustrative and not limiting.

[0030] A new solenoid valve for installation in a well as part of well pipes, configured to control the flow of fluid between the space inside the pipes and the space behind the pipes at the location of the valve, comprises a hollow cylindrical body 1 with circulation openings 6, a movable shutter sleeve 4 located inside the body with openings 12, configured to allow both complete and discrete (partial) linear movement between the open position and the closed position in response to a signal received via a communication channel (Fig. 1, 3). In this case, the total area of ​​the circulation openings 6 of the body 1 is at least equal to the cross-sectional area of ​​the internal space of the shutter sleeve 4.

[0031] Within the internal space of the valve body 1, there is at least one sealed compartment with an electric linear actuator 2 having a piston 9. The actuator 2 is connected to a sealed entry 3, which provides a hermetically sealed connection of the electric cable 11 to the valve (Fig. 1, 3). In this case, it is possible to implement a wireless communication channel (not shown in the drawings), when the solenoid valve composition additionally includes a battery for powering the actuator 2 and a system for activating the actuator 2, based, for example, on control via RFID tags.

[0032] Piston 9 is hydraulically connected to piston 10 of valve sleeve 4. The hydraulic connection is provided by hydraulic fluid 8, the distribution of which in the closed and open positions of the valve is shown in detail in Figs. 1-4. Hydraulic fluid 8 is the medium for transmitting pressure during the movement of pistons 9 and 10 in the closed, open, or intermediate positions of the valve. Simultaneously, hydraulic fluid 8 functions as a lubricant for the moving elements of the solenoid valve.

[0033] Piston 10 of valve sleeve 4 is equipped with sealing elements 7 and a return spring 5, which ensures the closed position of valve sleeve 4 in the absence of excess pressure in Chamber A and Chamber B of the valve (Fig. 1, 3). The parameters of spring 5, pistons 9 and 10, the stroke and diameter of pistons 9 and 10 themselves are selected based on the specific operating conditions of the equipment in the well.

[0034] The configuration of the solenoid valve body 1 allows for additional temperature and / or pressure and / or composition and / or flow sensors to monitor fluid inflow into or out of the wellbore in any possible combination. The relative positioning and interconnection of at least one sensor and the valve are such that the valve is capable of promptly responding to signals received from the sensor (not shown in the drawings). The configuration of the solenoid valve body 1 additionally allows for a through-channel for transit control lines (not shown in the drawings), which is located along the valve axis while maintaining the seal of the solenoid valve's internal compartments, including the one filled with hydraulic fluid 8.

[0035] The configuration of the housing 1 of the solenoid valve allows for an additional seat for the secure fixation of an anti-sand filter (not shown in the drawings) at the inlet of the circulation openings 6 of the housing 1. In the inflow control mode, this filter is capable of cutting off sand fractions from entering the intra-tube space of the solenoid valve, which leads to a noticeable reduction in the wear of the sealing units 7 of the sliding valve sleeve 4.

[0036] The solenoid valve in the example of implementation shown in Figs. 1-4 operates as follows. In the closed position of the electrohydraulic valve, all linear electric drives 2 are in the position with retracted pistons 9. In this case, in Chamber A and Chamber B there is no excess pressure of hydraulic fluid 8, and the movable shutter sleeve 4 is in the closed position due to the action of the spring 5, when the openings 6 of the housing 1 are disconnected from the openings 12 of the shutter sleeve 4. When a control signal to open the valve is received from the surface via the electric cable 11, the pistons 9 of the linear electric drives 2 extend, creating excess pressure in Chambers A and B. Under the action of excess pressure, the movable shutter sleeve 4 moves to the open position, squeezing the spring 5, and the hydraulic fluid 8 flows from Chamber B to Chamber A. In the open position, the openings 6 of the housing 1 are completely (Fig.3) or partially (not shown in the drawings) aligned with the openings 12 of the valve sleeve 4. When a control signal is received from the surface via the electric cable 11 to close the valve, the pistons 9 of the linear electric drives 2 are retracted to their original position, while the excess pressure in Chambers A and B is removed, and the system returns to its original position.

[0037] The present invention allows for many different applications, modifications or changes without going beyond the scope of protection as defined by independent claim 1 of the invention.

[0038] In addition, the equipment and materials, including hydraulic fluid, used to implement the present invention, as well as the shapes and sizes of individual components, can be selected to be most suitable for meeting the specific requirements.

Claims

FORMULA 1. An electric valve for installation in a well as part of well pipes, configured to control the flow of fluid between the space inside the pipes and the space behind the pipes at the location of the valve, comprising a hollow cylindrical body (1) with circulation holes (6), a movable shutter sleeve (4) located inside the body, configured to move linearly between an open position and a closed position in response to a signal received via a communication channel, wherein the movable shutter sleeve (4) is directly connected to a piston (10) provided with a return spring (5), and the body (1) has at least one sealed compartment with an electric linear drive (2) having a piston (9) hydraulically connected to the piston (10) of the shutter sleeve (4), wherein the ratio of the cross-sectional area of ​​the piston (10) of the shutter sleeve to the cross-sectional area of ​​the piston (9) of the electric linear drive (2) is directly proportional to the ratio of the force,required to move the movable shutter sleeve (4) into the open position to the force developed by the linear electric drive (2) and inversely proportional to the ratio of the stroke of the movable shutter sleeve (4) to the stroke of the piston (9) of the electric linear drive.

2. The solenoid valve according to claim 1, in which the total area of ​​the circulation openings of the housing is at least equal to the cross-sectional area of ​​the internal space of the valve sleeve.

3. The solenoid valve according to claim 1, wherein the communication channel is a wired channel or a wireless channel.

4. The solenoid valve according to item 1, which is additionally equipped with temperature and / or pressure and / or composition and / or flow sensors for monitoring the flow of fluid into or out of the well or any possible combination thereof.

5. The solenoid valve according to paragraph 1 and paragraph 5, which is configured to respond to changes provided by at least one sensor.

6. The solenoid valve according to item 1, which is additionally provided with at least one through channel for transit control lines, located along its axis while maintaining the tightness of the internal space of the valve.

7. The solenoid valve according to item 1, which additionally has a seat for fixing the sand filter at the inlet of the circulation openings of the housing.

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