Downhole Toe Opening Valve with Burst Disk Actuation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for opening the toe of tubing in oil and gas wells after pressure testing are inefficient, requiring additional time and equipment, and often limit pressure tests to below the maximum pressure the tubing will experience, especially in cemented environments.
Innovation Solution
A downhole tool with a shifting element and pressure chamber system that creates a pressure differential to open the toe, allowing pressure tests to be conducted at full burst pressure and enabling sequential tests, using a fluid control device like a burst disk to rupture and allow fluid communication, and an indexing assembly to ensure proper actuation after multiple pressure cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the toe is opened by positioning a perforating device and explosively or abrasively perforating the tubing, then the toe can be opened for fluid flow, but additional time and equipment are required which increase the cost of the well
Solution Approach 1:
The valve is pre-installed in the toe of the tubing during initial installation. The valve remains in a closed position during pressure testing, eliminating the need for post-testing perforation operations. This preliminary placement of the opening mechanism resolves the contradiction by having the solution ready before the problem arises.
Solution Approach 2:
The invention extracts the toe-opening function from the perforating device and implements it through a dedicated valve mechanism. This separate, specialized component can be opened hydraulically or mechanically without requiring explosive or abrasive perforation equipment, thus eliminating the need for additional costly equipment and reducing operational time.
2Ease of operation
If hydraulic pressure is used to open the toe, then the toe can be opened, but the pressure test is limited to pressures below the highest pressure the tubing will experience
Solution Approach 1:
The valve mechanism is segmented into distinct functional components: a valve body, a movable valve element, and a actuation mechanism. This segmentation allows the valve to be designed with specific pressure-rated components that can withstand full burst pressures while still being actuable by controlled hydraulic or mechanical means. The separation of the valve function from the pressure containment function enables full-pressure testing.
Solution Approach 2:
The invention introduces a valve as an intermediary component between the tubing interior and exterior. This valve can be opened on demand to allow fluid flow without requiring the entire tubing system to be designed for continuous open-state operation. The valve acts as a mediator that controls fluid passage, enabling pressure tests at full burst pressure by maintaining a sealed closed state during testing and then opening only when needed.
3Productivity
If the toe is opened early, then fluid flow is enabled, but pressure testing at full burst pressure cannot be performed
Solution Approach 1:
The valve is designed as a dynamic component that can transition between closed and open states. During pressure testing, the valve remains closed to maintain tubing integrity verification. After successful testing, the valve can be opened to enable fluid flow operations. This dynamic capability resolves the contradiction by allowing the system to adapt its state based on operational requirements rather than being fixed in one configuration.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient opening of the toe for fluid flow, allowing full-pressure testing and multiple sequential tests without additional equipment, reducing costs and operational time, and adapting to various well conditions.
Implementation Method 1
a fluid control device, which is preferably a burst disk, occupies at least a portion of the fluid path
Implementation Method 2
Application of fluid pressure on the interior of the tubing thereby creates a pressure differential across the shifting element, applying force tending to shift the shifting element
Data Source
AI summary
A downhole tool comprising a nested sleeve preventing fluid communication between the interior of the tool and the exterior of the tool is provided. The downhole tool is actuated when fluid pressure is communicated from the interior of the tool to a first surface the nested sleeve, moving the nested sleeve such that it no longer prevents fluid communication from the interior to the exterior. Devices and methods for controlling the flow of fluid to the first surface of the nested sleeve are provided including fluid control devices such as burst disks, indexing sleeves and ratchet assemblies. In certain embodiments, the nested sleeve may be engaged with a slot system such that the nested sleeve moves along a path defined by such slot until the tool is actuated.