Toe Valve Actuation via Segmented Pressure Levels
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Solution Overview
Problem
The existing toe valve designs risk damaging the casing during pressure testing due to the high pressure required to open the valve, which exceeds the pressure used for casing integrity testing, potentially causing unintended valve activation during integrity testing.
Innovation Solution
A downhole tool with a main sleeve and actuator system that moves between blocking and allowing fluid flow in response to different pressure levels, allowing fluid communication without exceeding the pressure used for casing integrity testing, featuring a plurality of sleeves and rings that cooperate to actuate the tool through various positions based on pressure changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pressure of the fluid is increased to a second level (higher than the first level) to move the sliding sleeve from the closed position to the open position, then the toe valve opens successfully, but the casing may be damaged because the second level pressure exceeds the pressure at which the casing integrity is tested
Solution Approach 1:
The actuation process is segmented into multiple stages using different pressure levels. The first pressure level (P1) performs casing integrity testing and partially actuates the valve, while the second pressure level (P2 ≤ P1) completes the valve opening. This segmentation allows the system to achieve full valve actuation without exceeding the casing's pressure tolerance, as the highest pressure applied (P1) is exactly the testing pressure that the casing is designed to withstand.
Solution Approach 2:
The system performs preliminary action by applying the first pressure level (P1) to conduct casing integrity testing and initiate valve actuation before applying the second pressure level (P2). The actuator is partially activated during the integrity testing phase, and the main sleeve begins moving. This preliminary action ensures that the casing is verified to withstand the maximum pressure before completing the valve opening process, preventing unexpected casing failure during subsequent high-pressure actuation.
2Reliability
If the pressure is increased to test casing integrity, then the casing integrity can be confirmed, but the sliding sleeve may inadvertently move to the open position during testing if the pressure exceeds the activation threshold
Solution Approach 1:
The system applies different pressure levels for different functions: the first pressure level (P1) is specifically calibrated for casing integrity testing and partial actuation, while the second pressure level (P2 ≤ P1) is used for completing valve opening. The actuator and main sleeve have localized functional zones where different pressure thresholds trigger different stages of operation. This local quality differentiation ensures that during integrity testing, the pressure remains controlled at P1, which is sufficient to verify casing integrity and initiate actuation but controlled to prevent inadvertent full opening.
3Reliability
If a single high pressure level is used to open the toe valve, then the valve opens reliably, but the device complexity increases and the risk of casing damage increases
Solution Approach 1:
The system uses periodic action by applying pressure in distinct phases: first applying P1 for integrity testing and partial actuation, then applying P2 (≤ P1) for completing the valve opening. The pressure is applied in periods rather than continuously, with clear transitions between pressure levels. This periodic pressure application ensures reliable valve opening through the two-stage process while keeping the pressure control system relatively simple, as it only requires managing two discrete pressure levels rather than complex continuous control.
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 safe and controlled actuation of the downhole tool, preventing casing damage by using pressure levels that are less than or equal to those used for integrity testing, ensuring reliable fluid communication without risking the integrity of the casing.
Implementation Method 1
The actuator is configured to actuate from a first state to a second state in response to application of a first level of pressure, and to a third state in response to application of a second level of pressure
Data Source
AI summary
A downhole tool including a body having one or more openings. A main sleeve is disposed in the body. The main sleeve is configured to move between a first position in which the main sleeve blocks fluid flow through the one or more openings and a second position in which the main sleeve allows fluid flow through the one or more openings. An actuator is disposed in the body. The actuator is configured to actuate from a first state to a second state in response to application of a first level of pressure, and to a third state in response to application of a second level of pressure. Actuating the actuator to the third state causes the main sleeve to move from the first position to the second position, and the second level of pressure is less than or equal to the first level or pressure.