Downhole actuation apparatus
The downhole actuation apparatus uses hydraulic pressure to remotely actuate downhole components, addressing the need for mechanical intervention by providing efficient and resettable actuation of wellbore tools.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- WEATHERFORD TECHNOLOGY HOLDINGS LLC
- Filing Date
- 2026-01-20
- Publication Date
- 2026-07-30
AI Technical Summary
Existing wellbore tools require mechanical intervention for remote actuation of downhole components, which may be undesirable in certain circumstances.
A downhole actuation apparatus utilizing a hydraulic fluid reservoir, actuator sleeve, and pressure-operated actuator assembly to remotely actuate downhole components, such as valves, without mechanical tools, by increasing pressure within a throughbore to displace hydraulic fluid and move the actuator sleeve.
Provides quick and reliable actuation of downhole components, offering an alternative to mechanical tools and enabling controlled, one-time actuation with the ability to reset for repeated use.
Smart Images
Figure US2026011762_30072026_PF_FP_ABST
Abstract
Description
M&C PA991453W0- 1 - DOWNHOLE ACTUATION APPARATUS FIELD
[0001] The present disclosure relates to a downhole actuation apparatus and a method for providing downhole actuation.BACKGROUND
[0002] Wellbores are drilled through subterranean formations for hydrocarbon exploration and recovery. Numerous tools and equipment may be utilised in the wellbore that require remote actuation, e.g., requiring a sleeve or the like within the wellbore to be moved between positions. Mechanical intervention tools, such as shifting tools, may be run into the wellbore to provide remote actuation of such downhole components. However, in certain circumstances, it may be desirable to provide actuation of the component without using mechanical tools.SUMMARY
[0003] An aspect of the present disclosure relates to a downhole actuation apparatus comprising:a housing defining a throughbore;an actuator sleeve disposed within the housing and moveable between a first position and a second position; andan actuator assembly configured to move the actuator sleeve from the first position to the second position, the actuator assembly comprising:a fluid reservoir configured to receive a hydraulic fluid;a barrier piston in pressure communication with the throughbore of the housing and configured to displace hydraulic fluid from the fluid reservoir; andan actuator piston configured to be moved by the hydraulic fluid displaced from the fluid reservoir, wherein the actuator piston is axially coupled to the actuator sleeve.
[0004] The actuation apparatus may be configured to actuate a downhole component (e.g., a device, mechanism, etc.) within a wellbore. The downhole component may comprise any component that may be remotely operated to transition between different configurations. In some examples, the downhole component may comprise a valve member. The valve member may comprise a ball valve, a flapper valve, etc. The valve member may be an isolation valve, e.g., for use in a production well. The downhole component may comprise a linkage system, such as a yoke mechanism, configured to convert linear motion of the actuator sleeve into rotational motion of the valve member.
[0005] The actuation apparatus may be operated by increasing a pressure within the throughbore of the housing to actuate the downhole component. In this respect, the actuation apparatus may be defined as a pressure operated downhole actuation apparatus. The pressure within the throughbore of the housing may be increased, for example, by operating a pump at surface to build up pressure against a downhole component (e.g., a closed valve member) positioned downhole of the actuationM&C PA991453W0- 2 -apparatus, or by providing a flow restriction within the wellbore to create a back pressure, etc. The actuation apparatus may provide for quick and reliable actuation of downhole components within the wellbore, e.g., without requiring mechanical tools.
[0006] The terms “uphole” and “downhole” are used herein with respect to a longitudinal axis of the actuation apparatus and an intended direction of deployment. The actuation apparatus (e.g., the housing) may be cylindrical. The actuation apparatus (e.g., the housing) may be elongate.
[0007] The actuator sleeve may be configured to actuate the downhole component by moving from the first position to the second position (e.g., in a downhole direction). The actuator sleeve may be configured to engage (e.g., push) the downhole component during a stroke of the actuator sleeve from the first position to the second position. The actuator sleeve may be defined as a ram sleeve. In some examples, the actuator sleeve may be configured to engage a shifting sleeve associated with the downhole component. The shifting sleeve may be configured to be operated mechanically, e.g., by a shifting tool, to actuate the downhole component. As such, in addition to actuation by the actuator assembly, the downhole component may be configured to be mechanically actuated. The mechanical actuation may provide an alternative or contingency mode of actuation of the downhole component, or may be used as partof an operational protocol, e.g., in combination with the actuation apparatus.
[0008] The actuation apparatus (e.g., the actuator assembly) may comprise a removable barrier configurable between a blocking configuration and an open configuration. In the blocking configuration, the removable barrier may be configured to prevent hydraulic fluid from being displaced from the fluid reservoir. In the open configuration, the removable barrier may be configured to permit hydraulic fluid to be displaced from the fluid reservoir. The removable barrier may be configured to move from the blocking configuration to the open configuration upon the fluid pressure within the throughbore exceeding an activation pressure. The removable barrier may comprise a rupture disc, shearable member, etc. When the removable barrier is in the open configuration, the hydraulic fluid may communicate movement of the barrier piston to the actuator piston.
[0009] The actuation apparatus (e.g., the actuator assembly) may comprise a flow regulator. The flow regulator may be configured to regulate (e.g., reduce) a flowrate of the hydraulic fluid displaced from the fluid reservoir. The flow regulator may be configured to regulate (e.g., reduce) a flowrate of the hydraulic fluid delivered to the actuator piston. In some examples, the flow regulator may be configured to regulate (e.g., reduce) a pressure of the hydraulic fluid displaced from the fluid reservoir. The flow regulator may be configured to regulate (e.g., reduce) a pressure of the hydraulic fluid delivered to the actuator piston. In this respect, the flow regulator may be defined as a pressure regulator. The flow regulator may provide the ability to reduce a flowrate of the fluid within the throughbore to a lower flowrate for delivering to the actuator piston. The flow regulator may provide the ability to reduce a pressure of the fluid within the throughbore, e.g., which may be elevated aboveM&C PA991453W0- 3 -the activation pressure, to a lower pressure for delivering to the actuator piston. The flow regulator may permit a pressure of the hydraulic fluid acting on the actuator piston to be built up gradually. The flow regulator may facilitate a low pressure differential across the actuator piston, e.g., providing for a controlled actuation force of the actuator sleeve. The flow regulator may comprise any suitable regulator, such as a flow restrictor, a valve, a pressure adjuster, etc.
[0010] The actuation apparatus (e.g., the actuator assembly) may comprise a flow passage extending between the fluid reservoir and the actuator piston. The flow passage may comprise a channel (e.g., a cylindrical channel) formed through the housing (e.g., formed through a wall of the housing) or between two components, e.g., tubular components. In some examples, the flow passage may comprise a drilled bore formed through the housing (e.g., formed through a wall of the housing). The hydraulic fluid may be configured to flow through the flow passage from the fluid reservoir to the actuator piston. The removable barrier when in the blocking configuration may close the flow passage to the fluid reservoir. When the removable barrier is in the open configuration, the removable barrier may open the flow passage to the fluid reservoir.
[0011] At least one of the removable barrier and the flow regulator may be disposed within the flow passage. The removable barrier may be positioned at a first (uphole) axial end of the flow passage, e.g., towards the fluid reservoir. The flow regulator may be positioned at a second (downhole) axial end of the flow passage, e.g., towards the actuator piston. Alternatively, the removable barrier may be positioned at the second (downhole) axial end, and the flow regulator may be positioned at the first (uphole) axial end. Alternatively, the removable barrier and the flow regulator may be positioned at some other location within the flow passage.
[0012] The actuation apparatus (e.g., the actuator assembly) may define a first piston bore. The first piston bore may be annular. The first piston bore may be defined radially between the housing and a mandrel extending within the housing. The first piston bore may be defined axially between first and second axial shoulders of the housing. The barrier piston may be disposed within the first piston bore. The barrier piston may be annular. The barrier piston may define a first piston chamber on a first (uphole) axial end of the barrier piston. The first piston chamber may be in fluid communication with the throughbore of the housing, e.g., via an inlet port through the mandrel. The barrier piston may define a second piston chamber on a second (downhole) axial end of the barrier piston. The second piston chamber may define the fluid reservoir. The first piston chamber and the fluid reservoir may be annular.
[0013] The actuation apparatus (e.g., the actuator assembly) may be configured such that a pressure within the fluid reservoir equals a pressure within the throughbore of the housing. The barrier piston may be configured to float within the first piston bore to balance pressure between the first piston chamber and the fluid reservoir. In this respect, the barrier piston may be defined as a balance piston. The barrier piston may be configured to prevent fluid from the throughbore mixingM&C PA991453W0- 4 -with the hydraulic fluid within the fluid reservoir, thus ensuring the fluid moved through the actuator assembly does not contain fluid or debris from the throughbore that could affect operation of the actuator assembly. The barrier piston may comprise a seal arrangement configured to seal between the first piston chamber and the fluid reservoir.
[0014] The fluid reservoir may comprise the hydraulic fluid. The hydraulic fluid may be substantially incompressible. In some examples, the hydraulic fluid may comprise an oil-based fluid. In other examples, the hydraulic fluid may comprise a water-based fluid.
[0015] The actuation apparatus (e.g., the actuator assembly) may comprise a second piston bore. The second piston bore may be annular. The second piston bore may be defined radially between the housing and the actuator sleeve. The second piston bore may be defined axially between third and fourth axial shoulders of the housing. The actuator piston may be disposed within the second piston bore. The actuator piston may be annular.
[0016] The actuator piston may define a third piston chamber on a first (uphole) axial end of the actuator piston. The actuator piston may define a fourth piston chamber on a second (downhole) axial end of the actuator piston. At least one of the third and fourth piston chambers may be defined as a pressure control chamber. At least one of the third and fourth piston chambers may comprise a gas. At least one of the third and fourth piston chambers may be an atmospheric chamber (e.g., comprising air at atmospheric conditions). At least one of the third and fourth piston chambers may comprise a gas, such as nitrogen, charged at a predetermined pressure. In other examples, the fourth piston chamber may be exposed to annulus pressure, such that fluid within the fourth piston chamber may be displaced into the annulus as the actuator piston moves the actuator sleeve to the second position. The third and fourth piston chambers may be annular.
[0017] The flow regulator may be configured to regulate (e.g., reduce) a flowrate of the hydraulic fluid received within the third piston chamber. The flow regulator may be configured to regulate (e.g., reduce) a pressure of the hydraulic fluid received within the third piston chamber.
[0018] The flow passage may define an inlet opening on the second axial shoulder. The flow passage may define an outlet opening on the third axial shoulder. The flow passage may extend between the inlet opening and the outlet opening.
[0019] When the removable barrier is in the open configuration, the hydraulic fluid from the fluid reservoir may flow through the flow passage and into the third piston chamber. The hydraulic fluid may be delivered into the third piston chamber to create a pressure differential across the actuator piston. Once the pressure differential is sufficiently high (e.g., to overcome friction associated with the actuator sleeve), the actuator sleeve may begin to move from the first position to the second position. As the actuator piston moves to the second position, the barrier piston may continue to move under the fluid pressure of the throughbore to maintain pressure on the hydraulic fluid being displaced from the fluid reservoir.M&C PA991453W0- 5 -
[0020] The actuator piston may comprise a first seal member. The actuator sleeve may comprise a second seal member. The first and second seal members may be configured to seal between the third and fourth piston chambers. As will be described in more detail below, the first and second seal members may be configured to provide a disconnect function of the actuation apparatus.
[0021] The actuator piston may be coupled to the actuator sleeve to move the actuator sleeve from the first position to the second position. In some examples, the actuator piston may be releasably coupled to the actuator sleeve via a releasable connection. The releasable connection may be configured to be released when the actuator sleeve is moved into the second position. The actuator sleeve may be released from the actuator piston to disconnect the actuator sleeve from the actuator assembly. In this respect, the actuation apparatus may be defined as providing a one-time actuation function.
[0022] The releasable connection may comprise one or more keys (e.g., dogs, snap rings, etc.) provided on one of the actuator piston and the actuator sleeve. The releasable connection may comprise one or more grooves (e.g., circumferential grooves) formed on the other of the actuator piston and the actuator sleeve. The one or more grooves may be configured to receive the one or more keys. The one or more grooves may extend around at least a portion of a circumference of the other of the actuator piston and the actuator sleeve.
[0023] The one or more keys may be configured to move out of the one or more grooves when the actuator sleeve is moved into the second position. The one or more grooves may comprise a ramp profile for driving the one or more keys out of the one or more grooves when the actuator sleeve is moved into the second position. The housing may comprise a recess portion for receiving the one or more keys when the actuator sleeve is moved into the second position. When the one or more keys are received in the recess portion of the housing, the actuator piston may become axially coupled to the housing.
[0024] Once the actuator sleeve has been released from the actuator piston, the actuator sleeve may be axially moveable relative to the actuator piston. As such, the actuator sleeve may be moved from the second position back to the first position while the actuator piston remains axially coupled to the housing. When the actuator sleeve is returned to the first position, the second seal member of the actuator sleeve may unseat from the actuator piston. This may open a flow path between the third and fourth piston chambers, allowing hydraulic fluid from the third piston chamber to pass into the fourth piston chamber, e.g., removing any pressure differential across the actuator piston and therefore disconnecting the actuator piston from the actuator assembly.
[0025] The housing may comprise one or more housing subs. The one or more housing subs may be threaded together to form the housing. In some examples, a first housing sub may define the first piston bore and the fluid reservoir. A second housing sub may define the flow passage andM&C PA991453W0- 6 -the second piston bore. A third housing sub may comprise the downhole component to be actuated, e.g. a valve member.
[0026] The housing may comprise first and second (e.g., male and female) connectors at first and second (e.g., uphole and downhole) axial ends of the apparatus for connection to a tubing string, e.g., a completion string.
[0027] The actuation apparatus may comprise one or more fill ports to permit hydraulic fluid to be delivered into the fluid reservoir. The actuation apparatus may comprise one or more fill ports to permit fluid (e.g., air or other gas, such as nitrogen) to be delivered into the third and fourth piston chambers. The fill ports may be plugged at surface (e.g., via one or more screw plugs) prior to the actuation apparatus being run downhole.
[0028] In some examples, the actuation apparatus may be resettable. For example, once the actuation apparatus has been used to actuate a downhole component, and the actuator sleeve has been released from the actuator piston (as described above), the apparatus may be retrieved to surface and reset for a subsequent use. For instance, the screw plugs may be removed to permit the barrier piston and the actuator piston to be reset, the removable barrier to be replaced, the third and fourth piston chambers to be emptied and filled with atmospheric air, and / or the fluid reservoir to be emptied and filled with hydraulic fluid, such that the apparatus may be used for a repeated application.
[0029] Another aspect of the present disclosure relates to a downhole valve assembly comprising:a housing defining a throughbore;an actuator sleeve disposed within the housing and moveable between a first position and a second position; andan actuator assembly configured to move the actuator sleeve from the first position to the second position, the actuator assembly comprising:a fluid reservoir configured to receive a hydraulic fluid;a barrier piston in pressure communication with the throughbore of the housing and configured to displace hydraulic fluid from the fluid reservoir; andan actuator piston configured to be moved by the hydraulic fluid displaced from the fluid reservoir, wherein the actuator piston is axially coupled to the actuator sleeve; and a valve member configured to be actuated by movement of the actuator sleeve from the first position to the second position.
[0030] The valve member may comprise a ball valve, a flapper valve, etc. The valve member may be or comprise an isolation valve, e.g., for use in a production well. The valve member may be positioned downhole of the actuation apparatus.M&C PA991453W0- 7 -
[0031] The actuator sleeve may be configured to engage (e.g., push) the valve member during a stroke of the actuator sleeve from the first position to the second position.
[0032] The downhole valve assembly may comprise a shifting sleeve configured to move the valve member between open and closed positions. The shifting sleeve may be configured to be operated mechanically, e.g., by a shifting tool, to actuate the valve member. The actuator sleeve (e.g., an engagement portion of the actuator sleeve) may be configured to engage the shifting sleeve (e.g., an upper setting profile of the shifting sleeve) to actuate the valve member.
[0033] As such, in addition to actuation by the actuator assembly, the valve member may be configured to be mechanically actuated by the shifting tool. The mechanical actuation may provide an alternative or contingency mode of actuation of the valve member, or may be used as part of an operational protocol, e.g., in combination with the actuator assembly. The mechanical actuation may be performed by engaging a shifting tool with one or more shifting profiles of the shifting sleeve to move the shifting sleeve. The valve member may be mechanically actuated before and / or after being actuated by the actuator assembly.
[0034] The downhole valve assembly may comprise a linkage system, such as a yoke mechanism, configured to convert linear motion of the shifting sleeve into rotational motion of the valve member.
[0035] An aspect of the present disclosure relates to a downhole actuation apparatus comprising:a housing defining a throughbore;an actuator sleeve disposed within the housing and moveable between a first position and a second position; andan actuator assembly configured to move the actuator sleeve from the first position to the second position.
[0036] The actuator assembly may comprise a fluid reservoir. The fluid reservoir may be configured to receive a hydraulic fluid. The fluid reservoir may comprise the hydraulic fluid.
[0037] The actuator assembly may comprise a barrier piston in pressure communication with the throughbore of the housing and configured to displace hydraulic fluid from the fluid reservoir.
[0038] The actuator assembly may comprise an actuator piston configured to be moved by the hydraulic fluid displaced from the fluid reservoir.
[0039] The actuator piston may be axially coupled to the actuator sleeve.
[0040] Another aspect of the present disclosure relates to a method for providing downhole actuation in a wellbore, the method comprising:M&C PA991453W0- 8 - positioning a downhole actuation apparatus in the wellbore, the downhole actuation apparatus comprising a housing defining a throughbore, an actuator sleeve disposed within the housing, and an actuator assembly;increasing a fluid pressure within the throughbore to bias a barrier piston of the actuator assembly against a fluid reservoir of the actuator assembly;displacing hydraulic fluid from the fluid reservoir to create a pressure differential across an actuator piston of the actuator assembly, wherein the actuator piston is axially coupled to the actuator sleeve; andmoving the actuator sleeve from a first position to a second position.
[0041] The method may comprise preventing the hydraulic fluid from being displaced from the fluid reservoir until a fluid pressure within the throughbore exceeds an activation pressure. The method may comprise increasing the fluid pressure within the throughbore to exceed the activation pressure.
[0042] The method may comprise regulating (e.g., reducing) a pressure of the hydraulic fluid displaced from the fluid reservoir. The method may comprise regulating (e.g., reducing) a pressure of the hydraulic fluid delivered to the actuator piston. The method may comprise regulating (e.g., reducing) a flowrate of the hydraulic fluid displaced from the fluid reservoir. The method may comprise regulating (e.g., reducing) a flowrate of the hydraulic fluid delivered to the actuator piston.
[0043] The method may comprise flowing the hydraulic fluid from the fluid reservoir to the actuator piston via a flow passage.
[0044] The method may comprise moving the actuator sleeve from the first position to the second position to actuate a downhole component (e.g., a valve member). The method may comprise engaging the actuator sleeve with the downhole component to actuate the downhole component. The method may comprise engaging the actuator sleeve with a shifting sleeve of the downhole component to actuate the downhole component.
[0045] The method may comprise releasing the actuator piston from the actuator sleeve when the actuator sleeve is moved into the second position. The method may comprise axially coupling the actuator piston to the housing when the actuator sleeve is moved into the second position.
[0046] The method may comprise moving the actuator sleeve from the second position back to the first position while the actuator piston remains axially coupled to the housing. The method may comprise unseating a seal member of the actuator sleeve from the actuator piston, e.g., to disconnect the actuator piston from the actuator assembly.
[0047] Another aspect of the present disclosure relates to a method for actuating a downhole valve assembly in a wellbore, the method comprising:M&C PA991453W0- 9 - positioning a tubular string in the wellbore comprising the downhole valve assembly, the downhole valve assembly comprising a housing defining a throughbore, an actuator sleeve disposed within the housing, an actuator assembly, and a valve member;moving the valve member from an open position to a closed position using a shifting tool; increasing a fluid pressure within the throughbore to bias a barrier piston of the actuator assembly against a fluid reservoir of the actuator assembly;displacing hydraulic fluid from the fluid reservoir to create a pressure differential across an actuator piston of the actuator assembly, wherein the actuator piston is axially coupled to the actuator sleeve; andmoving the actuator sleeve from a first position to a second position to move the valve member from the closed position to the open position.
[0048] The method may comprise preventing the hydraulic fluid from being displaced from the fluid reservoir until a fluid pressure within the throughbore exceeds an activation pressure. The method may comprise building up pressure within the throughbore against the closed valve member to exceed the activation pressure.
[0049] The method may comprise regulating (e.g., reducing) a pressure of the hydraulic fluid displaced from the fluid reservoir. The method may comprise regulating (e.g., reducing) a pressure of the hydraulic fluid delivered to the actuator piston. The method may comprise regulating (e.g., reducing) a flowrate of the hydraulic fluid displaced from the fluid reservoir. The method may comprise regulating (e.g., reducing) a flowrate of the hydraulic fluid delivered to the actuator piston.
[0050] The method may comprise flowing the hydraulic fluid from the fluid reservoir to the actuator piston via a flow passage.
[0051] The method may comprise engaging the actuator sleeve with the valve member to move the valve member from the closed position to the open position. The method may comprise engaging the actuator sleeve with a shifting sleeve of the valve member to move the valve member from the closed position to the open position.
[0052] The method may comprise releasing the actuator piston from the actuator sleeve when the actuator sleeve is moved into the second position. The method may comprise axially coupling the actuator piston to the housing when the actuator sleeve is moved into the second position.
[0053] The method may comprise moving the actuator sleeve from the second position back to the first position while the actuator piston remains axially coupled to the housing. The method may comprise unseating a seal member of the actuator sleeve from the actuator piston, e.g., to disconnect the actuator piston from the actuator assembly.
[0054] The method may comprise closing the valve member with the shifting tool after the valve member has been moved to the open position by the actuator sleeve.M&C PA991453W0- 10 -
[0055] The tubular string may be or comprise a completion string.
[0056] Features defined in relation to one aspect may be provided in combination with any other aspect.BRIEF DESCRIPTION OF THE DRAWINGS
[0057] These and other aspects of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0058] Figure 1 is a schematic illustration of an example wellbore including a downhole actuation apparatus and a downhole isolation valve;
[0059] Figure 2 is an isometric cutaway view of the downhole actuation apparatus;
[0060] Figure 3 is an isometric cutaway view of the downhole isolation valve;
[0061] Figure 4 is a cross-sectional view of the downhole actuation apparatus and downhole isolation valve, wherein the downhole actuation apparatus is in an inactive configuration and the downhole isolation valve is in an open configuration;
[0062] Figure 5 is a cross-sectional view of the downhole actuation apparatus and downhole isolation valve, wherein a shifting tool has mechanically moved the downhole isolation valve into a closed configuration;
[0063] Figure 6 is a cross-sectional view of the downhole actuation apparatus and the downhole isolation valve, wherein the downhole actuation apparatus has been moved into an active configuration thereby moving the downhole isolation valve into the open configuration;
[0064] Figure 7 is a cross-sectional view of the downhole actuation apparatus and downhole isolation valve, wherein the downhole actuation apparatus has been moved into a disconnected configuration and the downhole isolation valve has been mechanically moved back into the closed configuration; and
[0065] Figure 8 is a cross-sectional view of the downhole actuation apparatus and downhole isolation valve, wherein the downhole isolation valve has been moved into the open configuration by the shifting tool while the downhole actuation apparatus remains in the disconnected configuration.DETAILED DESCRIPTION OF THE DRAWINGS
[0066] Aspects of the present disclosure relate to a downhole actuation apparatus and method for providing downhole actuation. Multiple applications may be possible and may facilitate actuation of any component requiring remote operation to transition between different configurations within the wellbore. However, for the purposes of providing an exemplary application, the following description relates to the actuation of a valve member within the wellbore.M&C PA991453W0- 11 -
[0067] Figure 1 is a schematic illustration of a wellbore 10 comprising a downhole actuation apparatus 12 and a downhole isolation valve 14 (which, in other examples, may be any other downhole component requiring actuation). The illustration of Figure 1 is highly schematic and it should be appreciated that the wellbore 10 may be of another configuration. The wellbore 10 extends from a wellhead 16 at a surface level 18 (e.g., the seabed or ground level, depending on whether the wellbore 10 is located onshore or offshore) to a subterranean formation 20 containing hydrocarbons 21. In this example, the wellbore 10 deviates from vertical to horizontal in the subterranean formation 20. However, the wellbore 10 may be entirely vertical or deviate in another manner than horizontal.
[0068] A completion string 22 coupled to the wellhead 16 extends through the wellbore 10 into the subterranean formation 20. The isolation valve 14 is provided in a lower part of the completion string 22 below a packer 24. The isolation valve 14 may be opened to allow fluid flow through the completion string 22 to and from surface. When closed, the isolation valve 14 isolates the lower part of the completion string 22 from surface.
[0069] As will be described in more detail below, in one example application the isolation valve 14 may be run into the wellbore 10 in an open position, mechanically closed with a shifting tool and then re-opened in response to an increase in tubing pressure within the completion string 22, e.g., above the downhole actuation apparatus 12. In some examples, the isolation valve 14 may be run into the wellbore 10 in an open position with lower completion equipment. An operator may perform lower completion activities, such as stimulation, setting of hangers, etc., before closing the isolation valve 14 with a wash-pipe shifting tool. The lower completion may be pressure tested to ensure well integrity. An operator may then run an upper completion, using the isolation valve 14 as a well barrier, and set other equipment, such as packers, etc. Once completed, an operator may remotely open the isolation valve 14 by using the downhole actuation apparatus 12, and the downhole isolation valve 14 may remain functional as a mechanical valve that may be opened and closed using a shifting tool as required.
[0070] The downhole actuation apparatus 12 is shown in more detail in Figures 2 and 4. The apparatus 12 comprises a housing 26 defining a throughbore 28, extending parallel with a longitudinal axis 31 of the apparatus 12, an actuator sleeve 30 disposed within the housing 26 and moveable between a first position and a second position, and an actuator assembly 32 configured to move the actuator sleeve 30 from the first position to the second position. The actuator assembly 32 comprises an annular fluid reservoir 34 containing a hydraulic fluid and an annular barrier piston 36 in pressure communication with the throughbore 28. The barrier piston 36 is configured to displace hydraulic fluid from the fluid reservoir 34 through a flow passage 44. An annular actuator piston 38 is axially coupled to the actuator sleeve 30 via a set of dogs 40 received within one or more circumferential grooves 42 of the actuator sleeve 30. The housing 26 comprises first and second end connectors 45, 47 for connecting within the completion string 22. In the present example, theM&C PA991453W0- 12 -housing 26 is formed of several housing subs threaded together. However, in other examples, the housing 26 may be a unitary structure.
[0071] The apparatus 12 comprises a first annular piston bore and a second annular piston bore. The first piston bore is defined radially between the housing 26 and a mandrel 46 extending within the housing 26, and is disposed axially between first and second axial shoulders 63, 65 of the housing 26. The second piston bore is defined radially between the housing 26 and the actuator sleeve 30, and is disposed axially between third and fourth axial shoulders 67, 69 of the housing 26.
[0072] The barrier piston 36 is disposed within the first piston bore to define a first annular piston chamber 48 on a first (uphole) axial end of the barrier piston 36, and a second annular piston chamber on a second (downhole) axial end of the barrier piston 36, the second piston chamber defining the fluid reservoir 34. The first piston chamber 48 is in fluid communication with the throughbore 28 of the housing 26 via an inlet port 50 through the mandrel 46, and is therefore in communication with tubing pressure. A first seal arrangement 52 is provided on the barrier piston 36 and is configured to seal between the fluid reservoir 34 and the first piston chamber 48. The barrier piston 36 is configured to float within the first piston bore to balance pressure between the first piston chamber 48 and the fluid reservoir 34.
[0073] The actuator piston 38 is disposed within the second piston bore to define a third annular piston chamber 54 on a first (uphole) axial end of the actuator piston 38, and a fourth annular piston chamber 56 on a second (downhole) axial end of the actuator piston 38. The third and fourth piston chambers 54, 56 are atmospheric chambers, comprising a gas (e.g., air at atmospheric conditions). A second seal arrangement, including first and second seal members 58, 60, is provided to seal between the third and fourth piston chambers 54, 56. The first seal member 58 is disposed on the actuator piston 38 and the second seal member 60 is disposed on the actuator sleeve 30. The housing 26 comprises an end sealing arrangement 49 for sealing between the fourth piston chamber 56 and the throughbore 28 of the housing 26. The flow passage 44, formed by a drilled bore through a wall of the housing 26, axially extends between the fluid reservoir 34 and the third piston bore 54.
[0074] Figure 3 is an isometric cutaway view of the downhole isolation valve 14, which comprises a ball valve 68 and a mechanically operated tool, e.g., a shifting sleeve 70, for mechanically moving the ball valve 68 between open and closed positions. In the present example, the actuator sleeve 30 comprises an engagement portion 72 for engaging an upper setting profile 74 of the shifting sleeve 70 when the actuator sleeve 30 is moved to the active configuration. The shifting sleeve 70 comprises internal shifting profiles 76 to permit a shifting tool to engage the shifting sleeve 70 to mechanically move the ball valve 68 between open and closed positions by moving the shifting sleeve 70 between uphole and downhole positions. However, in other examples, other types of shifting sleeve may be used. The ball valve 68 comprises a linkage system, such as a yoke mechanism, configured to convert linear motion of the shifting sleeve 70 into rotational motion of theM&C PA991453W0- 13 -ball valve 68 about an axis transverse to the longitudinal axis 31 of the apparatus 12 between open and closed positions.
[0075] Figures 2 and 4 illustrate the actuator assembly 32 in an inactive configuration. In this configuration, a removable barrier, in the form of a rupture disc 78, is configured to prevent hydraulic fluid from being displaced from the fluid reservoir 34, thus preventing fluid communication between the fluid reservoir 34 and the third piston chamber 54. The rupture disc 78 is configured to rupture when the fluid pressure within the throughbore 28 (and therefore the fluid pressure within the fluid reservoir 34) exceeds an activation pressure.
[0076] A first fill port 62 is formed through the housing 26 for delivering hydraulic fluid into the fluid reservoir 34. A second fill port 64 is formed through the housing 26 for delivering air (or other gas) into the flow passage 44 and the third piston chamber 54. A third fill port 66 is formed through the housing 26 for delivering air (or other gas) into the fourth piston chamber 56. The fill ports 62, 64, 66 may be closed at surface via one or more screw plugs before the apparatus 12 is run downhole. After the actuation apparatus 12 has been used, the apparatus 12 may be retrieved to surface and the screws removed to permit the apparatus 12 to be reset for a repeated use. For example, once the actuation apparatus 12 has been used, the apparatus 12 may be retrieved to surface and the screw plugs removed to permit the barrier piston 36 and the actuator piston 38 to be reset, the rupture disc 78 to be replaced, the third and fourth piston chambers 54, 56 to be emptied and filled with atmospheric air (or another compressible fluid), and / or the fluid reservoir 34 to be emptied and filled with hydraulic fluid, such that the apparatus can perform a repeated use. In other examples, the third fill port 66 may be exposed to an annulus between the housing 26 and the wellbore 10, such that fluid within the fourth piston chamber 56 may be displaced into the annulus as the actuator piston 38 moves the actuator sleeve 30 to the second position.
[0077] A flow regulator 82 is configured to regulate (e.g., reduce) a flowrate of the hydraulic fluid displaced from the fluid reservoir 34 and delivered into the third piston chamber 54. The flow regulator 82 may comprise any suitable regulator, such as a flow restrictor, a valve, a pressure adjuster, etc. The flow regulator 82 may permit a volume of the hydraulic fluid received within the third piston chamber 54 to be built up gradually, thereby facilitating a low pressure differential across the ball valve 68 during opening and ensuring a more controlled operation of the ball valve 68. In this example, the flow regulator 82 is positioned at a downhole end of the flow passage 44 and the rupture disc 78 is positioned at an uphole end of the flow passage 44. However, in other examples, the position of the flow regulator 82 and rupture disc 78 may be reversed. In such examples, after the rupture disc 78 has ruptured, an initial volume of hydraulic fluid built up behind the rupture disc 78 may flow into the third piston chamber 54. The flow regulator 82 may then function to regulate the flowrate of the remaining hydraulic fluid from the fluid reservoir 34 into the third piston chamber 54.M&C PA991453W0- 14 -
[0078] Figure 5 schematically illustrates a shifting tool 43 positioned within the shifting sleeve 70 and having moved the shifting sleeve 70 in an uphole direction 35, thereby closing the ball valve 68. The actuator assembly 32 has remained in the first position. When an operator desires to use the actuator assembly 32 to open the ball valve 68, fluid pressure within the throughbore 28 of the housing 26 is increased, e.g., via operating a pump at surface to build up pressure behind the closed ball valve 68. This increase in fluid pressure is communicated to the first piston chamber 48 via the inlet port 50, which in turn causes the barrier piston 36 to be biased against the fluid reservoir 34, increasing a pressure of the hydraulic fluid within the fluid reservoir 34. Once the pressure within the throughbore 28 (and therefore the fluid pressure within the fluid reservoir 34) exceeds the activation pressure, the rupture disc 78 ruptures permitting the hydraulic fluid within the fluid reservoir 34, charged at tubing pressure, to flow through the flow passage 44 and into the third piston chamber 54.
[0079] Figure 6 illustrates the actuator assembly 32 in the active configuration, where the rupture disc 78 has ruptured allowing the fluid pressure within the throughbore 28 to move the barrier piston 36 to displace hydraulic fluid from the fluid reservoir 34. As such, the hydraulic fluid has flown through the flow passage 44 and entered into the third piston chamber 54 creating a pressure differential across the actuator piston 38. Once the pressure differential is sufficiently high to overcome any friction associated the actuator sleeve 30, the actuator piston 38 moves in a downhole direction 37 driving the actuator sleeve 30 into the second position. The barrier piston 36 has continued to move in a downhole direction 37 under the fluid pressure of the throughbore 28 to maintain pressure on the hydraulic fluid. The engagement portion 72 of the actuator sleeve 30 has engaged the upper setting profile 74 of the shifting sleeve 70, moving the shifting sleeve 70 in a downhole direction 37 and opening the ball valve 68. With the actuator sleeve 30 in the second position, the set of dogs 40 have ramped out of the groove 42 and have been received within an annular recess 80 of the housing 26, axially coupling the actuator piston 38 to the housing 26 and permitting axial movement of the actuator sleeve 30 relative to the actuator piston 38.
[0080] Figure 7 illustrates the actuator assembly 32 in a disconnected configuration, where the shifting tool 43 has moved the shifting sleeve 70 uphole to mechanically close the ball valve 68. The upper setting profile 74 of the shifting sleeve 40 has engaged the engagement portion 72 of the actuator sleeve 30, and moved the actuator sleeve 30 and the second seal member 60 in an uphole direction 35. In Figure 7, the barrier piston 36 is illustrated to have moved in an uphole direction 35, e.g., due to a reduction in tubing pressure. However, this may not always be the case. In the disconnected configuration, the second seal member 60 has unseated from the actuator piston 38 such that a flow path between the third and fourth piston chambers 54, 56 has opened allowing hydraulic fluid to pass into the fourth piston chamber 56, removing any pressure differential across the actuator piston 38. This disconnects the actuator piston 38 from the actuator assembly 32. In this respect, the apparatus 12 may be defined as providing a one-shot actuation function. However,the shifting tool 43 can still be used to mechanically open and close the ball valve 68 as required prior to and after using the actuator assembly 32. For example, Figure 8 illustrates the ball valve 68 having moved back into an open position by the shifting tool 43 while the actuator assembly 32 remains in the disconnected configuration.
Claims
M&C PA991453W0- 16 - CLAIMS:
1. A downhole actuation apparatus comprising:a housing defining a throughbore;an actuator sleeve disposed within the housing and moveable between a first position and a second position; andan actuator assembly configured to move the actuator sleeve from the first position to the second position, the actuator assembly comprising:a fluid reservoir configured to receive a hydraulic fluid;a barrier piston in pressure communication with the throughbore of the housing and configured to displace hydraulic fluid from the fluid reservoir; andan actuator piston configured to be moved by the hydraulic fluid displaced from the fluid reservoir, wherein the actuator piston is axially coupled to the actuator sleeve.
2. The downhole actuation apparatus of claim 1, comprising a removable barrier configurable between a blocking configuration configured to prevent hydraulic fluid from being displaced from the fluid reservoir, and an open configuration configured to permit hydraulic fluid to be displaced from the fluid reservoir.
3. The downhole actuation apparatus of claim 2, wherein the removable barrier is configured to move from the closed position to the open position upon a pressure within the throughbore exceeding an activation pressure.
4. The downhole actuation apparatus of any preceding claim, comprising a flow regulator configured to regulate a flowrate of the hydraulic fluid displaced from the fluid reservoir.
5. The downhole actuation apparatus of any preceding claim, wherein the actuator assembly comprises a flow passage extending between the fluid reservoir and the actuator piston.
6. The downhole actuation apparatus of claim 5, when dependent on claims 2 and 4, wherein at least one of the removable barrier and the flow regulator is disposed within the flow passage.
7. The downhole actuation apparatus of any preceding claim, comprising a first piston bore defined radially between the housing and a mandrel extending within the housing, wherein the barrier piston is disposed within the first piston bore.M&C PA991453W0- 17 - 8. The downhole actuation apparatus of claim 7, wherein the barrier piston defines a first piston chamber on a first axial end of the barrier piston, and a second piston chamber on a second axial end of the barrier piston, the first piston chamber in fluid communication with the throughbore of the housing and the second piston chamber defining the fluid reservoir.
9. The downhole actuation apparatus of claim 8, wherein the barrier piston is configured to float within the first piston bore to balance pressure between the first piston chamber and the fluid reservoir.
10. The downhole actuation apparatus of any preceding claim, comprising a second piston bore defined radially between the housing and the actuator sleeve, wherein the actuator piston is disposed within the second piston bore.
11. The downhole actuation apparatus of claim 10, wherein the actuator piston defines a third piston chamber on a first axial end of the actuator piston, and a fourth piston chamber on a second axial end of the actuator piston, at least one of the third and fourth piston chambers comprising a gas.
12. The downhole actuation apparatus of any preceding claim, wherein the actuator sleeve is axially coupled to the actuator piston via a releasable connection.
13. The downhole actuation apparatus of claim 12, wherein the releasable connection is configured to be released when the actuator sleeve is moved into the second position.
14. The downhole actuation apparatus of claim 12 or 13, wherein the releasable connection comprises a key provided on one of the actuator piston and the actuator sleeve, and a groove formed on the other of the actuator piston and the actuator sleeve for receiving the key.
15. The downhole actuation apparatus of claim 14, wherein the housing comprises a recess portion for receiving the key when the actuator sleeve is in the second position.
16. The downhole actuation apparatus of any one of claims 11 to 15, wherein the actuator piston comprises a first seal member, the actuator sleeve comprises a second seal member, and wherein the first and second seal members are configured to seal between the third and fourth piston chambers.M&C PA991453W0- 18 - 17. The downhole actuation apparatus of claim 16, wherein the second seal member is configured to disengage from the actuator piston when the actuator sleeve is released from the actuator piston and returned to the first position.
18. A downhole valve assembly comprising:the downhole actuation apparatus of any preceding claim; anda valve member configured to be actuated by movement of the actuator sleeve from the first position to the second position.
19. The downhole valve assembly of claim 18, comprising a shifting sleeve configured to move the valve member between an open position and a closed position, wherein the shifting sleeve is configured to be operated mechanically.
20. The downhole valve assembly of claim 19, wherein the actuator sleeve is configured to engage the shifting sleeve when the actuator sleeve is moved from the first position to the second position.
21. A method for providing downhole actuation in a wellbore, the method comprising:positioning a downhole actuation apparatus in the wellbore, the downhole actuation apparatus comprising a housing defining a throughbore, an actuator sleeve disposed within the housing, and an actuator assembly;increasing a fluid pressure within the throughbore to bias a barrier piston of the actuator assembly against a fluid reservoir of the actuator assembly;displacing hydraulic fluid from the fluid reservoir to create a pressure differential across an actuator piston of the actuator assembly, wherein the actuator piston is axially coupled to the actuator sleeve; andmoving the actuator sleeve from a first position to a second position.
22. The method of claim 21, comprising preventing hydraulic fluid from being displaced from the fluid reservoir until a fluid pressure within the throughbore exceeds an activation pressure.
23. The method of claim 21 or 22, comprising regulating a pressure of the hydraulic fluid displaced from the fluid reservoir.
24. The method of any one of claims 21 to 23, comprising moving the actuator sleeve from the first position to the second position to actuate a downhole component.M&C PA991453W0- 19 - 25. A downhole valve assembly comprising:a housing defining a throughbore;an actuator sleeve disposed within the housing and moveable between a first position and a second position; andan actuator assembly configured to move the actuator sleeve from the first position to the second position, the actuator assembly comprising:a fluid reservoir configured to receive a hydraulic fluid;a barrier piston in pressure communication with the throughbore and configured to displace hydraulic fluid from the fluid reservoir; andan actuator piston configured to be moved by the hydraulic fluid displaced from the fluid reservoir, wherein the actuator piston is axially coupled to the actuator sleeve; and a valve member configured to be actuated by movement of the actuator sleeve from the first position to the second position.
26. A method for actuating a downhole valve in a wellbore, the method comprising:positioning a tubular string in the wellbore comprising a downhole valve assembly, the downhole valve assembly comprising a housing defining a throughbore, an actuator sleeve disposed within the housing, an actuator assembly, and a valve member;moving the valve member from an open position to a closed position using a shifting tool; increasing a fluid pressure within the throughbore to bias a barrier piston of the actuator assembly against a fluid reservoir of the actuator assembly;displacing hydraulic fluid from the fluid reservoir to create a pressure differential across an actuator piston of the actuator assembly, wherein the actuator piston is axially coupled to the actuator sleeve; andmoving the actuator sleeve from a first position to a second position to move the valve member from the closed position to the open position.