US20080135235A1 - Downhole well valve having integrated sensors - Google Patents

Abstract

A valve includes a tubular valve housing, a valve seat, a valve element and a sensor. The valve seat is located in a central passageway of the housing and defines a first portion of the central passageway above the valve seat and a second portion of the central passageway below the valve seat. The valve element controls flow through the valve seat. The sensor is fixed to the housing to measure an attribute that is indicative of a state of the valve.

Description

BACKGROUND
• The invention generally relates to a well valve that has integrated sensors.
• A typical well includes various valves for such purposes as isolating formations, safeguarding against blow out conditions and regulating flows. In this regard, a typical well may include choke or sleeve valves for purposes of regulating production; safety valves that fail in the closed position for purposes of preventing a blow out; and formation isolation valves, which may be used to isolate formations after drilling before completion operations can be finished. The valves of a typical well may be remotely operated from the surface using a variety of different communication media, such as hydraulic control lines, electrical wires and well fluid.
SUMMARY
• In an embodiment of the invention, a valve includes a tubular valve housing, a valve seat, a valve element and a sensor. The valve seat is located in a central passageway of the housing and defines a first portion of the central passageway above the valve seat and a second portion of the central passageway below the valve seat. The valve element controls flow through the valve seat. The sensor is fixed to the housing to measure an attribute that is indicative of a state of the valve.
• In another embodiment of the invention, a system includes a string, a valve and a sensor. The valve controls a flow between a portion of the central passageway of the string located above the valve and a portion of the central passageway of the string located below the valve. The sensor is mounted near the valve to measure an attribute that is indicative of a state of the valve.
• In yet another embodiment of the invention, a technique that is usable with a well includes providing a valve in a central passageway of a tubular member in the well to regulate a flow through the central passageway. The technique also includes using at least one sensor to monitor an attribute that is indicative of a state of the valve.
• Advantages and other features of the invention will become apparent from the following drawing, description and claims.
BRIEF DESCRIPTION OF THE DRAWING
• FIG. 1 is a schematic diagram of a formation isolation valve according to an embodiment of the invention.
• FIG. 2 is a schematic diagram illustrating a sensor architecture for use with a valve according to an embodiment of the invention.
• FIGS. 3 and 4 are schematic diagrams illustrating sensors to detect the position of a valve operator according to embodiments of the invention.
• FIG. 5 is a flow diagram depicting a technique to use sensors to verify valve position and sealing according to an embodiment of the invention.
• FIG. 6 is a flow diagram depicting a technique to use one or more sensors to verify a state of a valve according to an embodiment of the invention.
• FIG. 7 is a flow diagram depicting a technique to use one or more sensors to verify an integrity of a valve according to an embodiment of the invention.
• FIG. 8 is a flow diagram depicting a technique to use one or more sensors to determine a number of operations of an operator of the valve according to an embodiment of the invention.
• FIG. 9 is a flow diagram depicting a technique to use sensors to evaluate performance of a valve according to an embodiment of the invention.
DETAILED DESCRIPTION
• Referring toFIG. 1, an embodiment of a formation isolation valve (FWV) (also called a “barrier valve”)10 in accordance with the invention, controls access to a particular formation below the valve. In this regard, theFIV10 permits a string, such as anexemplary string30, to pass through theFIV10 to the region beneath theFIV10 when theFIV10 is in an open state (as depicted inFIG. 1). When theFIV10 is in a closed state, theFIV10 seals off communication between the region below the valve and the region above the FIV. An annular region, orannulus11, which is located between an exterior surface of theFIV10 and aproduction tubing9 of the well may be sealed off by a packer (not shown inFIG. 1).
• As described herein, the FIV10 includesvarious sensors50,52,54,56,60,64 and66, which measure various attributes of the well and theFIV10. Indications of these attributes are communicated to the surface of the well for purposes of verifying downhole conditions, the performance of theFIV10 and the FIV's state, as further described below. Thesensors50,52,54,56,60,64 and66 are generally fixed to ahousing19 of theFIV10, in accordance with some embodiments of the invention, which means thevalves50,52,54,56,60,64 and/or66 may be, for example, integral with thehousing19 or may be located inside thehousing19.
• It is noted that the FIV10 is described herein for purposes of describing an exemplary downhole valve in accordance with embodiments of the invention. However, it is understood that valves other than an FIV valve may incorporate sensors in accordance with other embodiments of the invention. For example, aball element22 of the FIV10 may be replaced with another valve element, such as a flapper element, in accordance with other embodiments of the invention. Regardless of the particular valve element, the valve element controls flow through a valve seat of the valve to control fluid communication between a first portion of a central passageway of the valve above the valve seat and a second portion of the central passageway of the valve below the valve seat. Furthermore, mechanisms other than those described herein may be used to control theFIV10, in accordance with other embodiments of the invention. Thus, in accordance with other embodiments of the invention, the FIV10 may be replaced by an FIV of a different design or another type of valve, such as a sleeve valve, choke, safety valve, etc.
• It is noted that the well in which the FIV10 is deployed may be used in a subterranean well or a subsea well, depending on the particular embodiment of the invention. Additionally, in accordance with other embodiments of the invention, the FIV10 may be located outside of a production tubing.
• When the FIV10 is first set in place downhole, theball element22 may be opened (or alternatively, run into the wellbore) to permit thestring30 to pass through. Alternatively, the FIV10 may be run with thestring30 already included through theball element22. Thestring30 may include a gravel packing tool to perform gravel packing operations downhole. After the gravel packing operations are complete, thestring30 may be withdrawn from the well.
• In some embodiments of the invention, after the gravel packing operation is complete, the ball element (or other type of closure mechanism)22 is closed. In this regard, thestring30 may include a shifting tool16 (near a lower end of the string30) to physically close theball element22. More specifically, after the lower end of thestring30 is retracted above theball element22, a profiledsection17 of the shiftingtool16 may be used to engage theFIV10 so that theFIV10 may be operated in a manner to cause theball element22 to close. After thestring30 is withdrawn from the well and the gravel packing operations are complete, pressure tests may then be performed downhole. At the conclusion of the pressure tests, annulus pressure may be used to reopen theball element22.
• Thus, in general, for purposes of example, theball element22 may be closed by action of a shifting (or other mechanical method)tool16 and may be opened via pressure in the annulus (or other hydraulic or mechanical method)11.
• For purposes of preventing unintentional opening and closing of theball element22, the FIV10 includes twoindex mechanisms15 and20, in accordance with some embodiments of the invention. Theindex mechanism15 is pressure-actuated via the pressure in theannulus11 and prevents the unintentional opening of theball element22 without the occurrence of a predetermined number of pressurization/de-pressurization cycles. Theindex mechanism20 is actuated via physical contact between the shiftingtool16 and theFIV10 and prevents the unintentional closing of theball element22 without a predetermined pattern of engagement. Without theindex mechanism20, movement of the shiftingtool16 or movement of thestring30 itself may unintentionally engage the closing mechanism of theFIV10 to close theball element22 to prematurely close, a condition that may cause thestring30 to become jammed in theball element22, thereby preventing removal of thestring30 from the well.
• The FIV10 may include one or more valve operators for purposes of opening and closing theball element22. For the particular embodiment depicted inFIG. 1 and described herein, theFIV10 includes two such valve operators: anoperator mandrel12 and a ballvalve operator mandrel14. It is noted that depending on the particular embodiment of the invention, the valve may include a single operator or may include more than two valve operators. Thus, other variations are possible and are within the scope of the appended claims.
• Theoperator mandrel12 is constructed to move up (as an example) in response to applied tubing pressure (i.e., pressure in the central passageway of the production string16) and move down when the pressure is released. The travel of theoperator mandrel12 is limited by theindex mechanism15 until a predetermined number of cycles occur in which the tubing pressure increases and then decreases. After the predetermined number of cycles, theindex mechanism15 permits themandrel12 to travel downwardly to contact acollet actuator13 that is connected to the ballvalve operator mandrel14. This contact causes downward travel of theball valve operator14, a movement that operates theball element22 to cause theball element22 to open.
• For purposes of closing theball element22 via the shiftingtool16, theprofile17 of the shiftingtool16 engages thecollet actuator13 to force the collet actuator up and down. On each upward stroke, thecollet actuator13 disengages from themandrel14. When themandrel14 moves up by a sufficient distance, the ballvalve operator mandrel14 closes theball element22. However, the upward travel of the ballvalve operator mandrel14 is limited by theindex mechanism20 until the shiftingtool16 forces thecollet actuator13 up and down for a predetermined number of cycles. After the cycles occur, themandrel14 engages with thecollet actuator13 on the downstroke of theactuator13 and remains engaged with theactuator13 on the upstroke, thereby permitting the shiftingtool16 to lift the mandrel up for a sufficient distance to close theball element22.
• More details regarding theFIV10 that is depicted inFIG. 1 may be found in U.S. Pat. No. 6,662,877, entitled “FORMATION ISOLATION VALVE,” which granted on Dec. 16, 2003, is commonly assigned to the same assignee as the present application and is hereby incorporated by reference in its entirety.
• Referring toFIG. 2, in accordance with some embodiments of the invention, thesensors50,52,54,56,60,64 and66 form part of aintegrated sensor architecture90 for the well. In this regard, thesensors50,52,54,56,60,64 and66 may be connected to atelemetry interface92 for purposes of communicating measured data from thesensors50,52,54,56,60,64 and66 to a surface dataacquisition system computer110. Thesurface computer110 may be connected to thetelemetry interface92 via aserial bus96 in accordance with some embodiments of the invention. However, it is noted that in other embodiments of the invention, other telemetry techniques may be used for purposes of communicating the sensor measurements uphole. Furthermore, in other embodiments of the invention, eachsensor50,52,54,56,60,64 and66 may be connected directly to theserial bus96 and thus, may include its own telemetry interface, in accordance with some embodiments of the invention.
• It is noted that the downhole equipment may include additional sensors that are not associated with the valve, which are represented byreference numeral100. For example, other downhole components, such as packers, may include sensors that communicate data to the well surface, as well as additional sensors that are located downhole for purposes of measuring various temperatures, pressures, etc.
• In accordance with some embodiments of the invention, one or more of the sensors of theFIV10 may be used to measure the tubing condition both above and below theball element22. Thus, referring toFIG. 5 in conjunction withFIG. 1, in accordance with some embodiments of the invention, atechnique150 includes measuring (block152) static and dynamic well attributes above and below theball element22. These measurements may be used to verify valve position and the condition of the valve sealing, pursuant to block154.
• As a more specific example, in accordance with some embodiments of the invention, thesensor50 may be used, for example, to measure the pressure in theproduction string16 above theball element22; and the pressure or temperature (as examples) above theball element22, and thesensor52 may be used to measure the pressure or temperature (as examples) below theball element22. As shown inFIG. 1, in accordance with some embodiments of the invention, thesensors50 and52 may be integrated with and thus, may be mounted to apressure housing19 of theFIV10.
• Referring toFIG. 6 in conjunction withFIG. 1, as another example, one ormore sensors50,52,54,56,60,64 and66 of theFIV10 may be used for purposes of determining whether theball element22 is fully opened, fully closed or at an intermediate position. In this regard, pursuant to atechnique170, the position(s) of the valve's operators are measured (block174), and these measurements are used (block178) to verify whether theFIV10 is fully opened or fully closed.
• As a more specific example, in accordance with some embodiments of the invention, thesensor54 measures a position of thevalve operator mandrel14. As shown, thesensor54 may be integrated into thehousing19, in accordance with some embodiments of the invention. Many possible embodiments of thesensor54 are possible and are within the scope of the appended claims. As examples,FIG. 3 depicts an embodiment of thesensor54, which includes acoil80, which is integrated in thehousing19 for purposes of measuring the position of the ballvalve operator mandrel14. In this regard, when the ballvalve operator mandrel14 is allowed to move downwardly by theindex mechanism20 and thus, open theball valve element22, the flux path of thecoil80 changes due to the presence of the lower end of themandrel14, which indicates the fully open state.
• As another example of a possible embodiment of the invention, the lower end of thevalve operator14 may include aprotrusion86, which resides in aslot84 of thehousing19, as depicted inFIG. 4. In this regard, when theprotrusion86 reaches the end of theslot84, contact may be made with an electrical/electronic switch (not shown inFIG. 4) to indicate opening of theball valve element22.
• It is noted thatFIGS. 3 and 4 depict two of the many possible embodiments of a sensor to detect the position of a valve operator in accordance with the many different and possible embodiments of the invention. Thus, other mechanical, electrical and optical devices may be used to detect and verify the position of a valve operator, in accordance with the many possible embodiments of the invention.
• Referring toFIG. 1, thesensor56 may be used for purposes of detecting when theball valve element22 is in its fully closed position. In this regard, in accordance with some embodiments of the invention, thesensor56 may be integrated with thepressure housing19 and located at a position above thecollet actuator mandrel13, when theball element22 is open. However, when theindex mechanism20 allows thecollet actuator mandrel13 to move upwardly to fully close theball valve element22, thesensor56 provides an indication of the detection of this position. Thesensor56 may have a similar design to thesensor54 and thus, may take on any of the forms described above for thesensor54, in accordance with the many different possible embodiments of the invention.
• Referring toFIG. 7 in conjunction withFIG. 1, in accordance with some embodiments of the invention, atechnique180 includes using one or more sensors to measure attributes (pressures and temperatures, for example) of control fluids, pursuant to block182. Thus, for thespecific FIV10 that is described herein, one or more sensors may be used for purposes of measuring a pressure (as an example) of fluid that is communicated through theproduction string16. Due to these measurements, the measurements may then be used (block186) to verify the integrity of theFIV10. Thus, one or more sensors may measure the pressure and/or temperature of the annulus, tubing pressure or control lines, as applicable to the particular valve being used. The sensors provide the data to invalidate or validate whether the applied pressures from the surface are being communicated to the valve to cause the intended operation(s) to occur.
• As yet another example of the application of sensors to a downhole valve, atechnique190 may be used for purposes of measuring the operational position of a valve operating mechanism. In this regard, referring toFIG. 8 in conjunction withFIG. 1, in accordance with some embodiments of the invention, atechnique190 includes measuring the number of operations of a valve operator at a valve, pursuant to block194. These measurements are then used, pursuant to block196 to verify the state of the valve. Thus, due to the inclusion of theindex mechanisms15 and20, a number of mechanical and/or pressure cycles may be used for purposes of opening and closing theball valve element22. In this regard, as described above, the shiftingtool16 may be used to close the valve via a number of up and down mechanical cycles; and tubing pressure may be used via a number of pressurization/de-pressurization cycles for purposes of opening the valve. It may be challenging at the surface of the well to verify whether the number of mechanical or pressurization cycles have been performed, as the operator at the surface of the well may lose count of the number of mechanical or pressurization cycles; sufficient mechanical movement or pressurization/de-pressurization, etc. did not occur to account for a particular cycle; etc.
• Because one or more sensors are used to measure the operations at the valve, the number of cycles may then be accurately determined at the surface. As a more specific example, in accordance with some embodiments of the invention, theFIV10 may include asensor64 that measures the position of theoperator mandrel12. In this regard, on each pressure cycle, the position of themandrel12 may incrementally change, and this position may be detected by thesensor64, which is embedded in thepressure housing19 below the lower end of theoperator mandrel12. Thesensor64 may have a similar design to thesensors54 and56 discussed above. Additionally, thesensor66 may be located above the upper end of thecollet actuator13 for purposes of counting cycles of theactuator13. In this regard, on each mechanical cycle induced by action of the shiftingtool16, thesensor66, which is embedded in thepressure housing19, verifies when thecollet actuator13 reaches the uppermost point of travel for each cycle.
• Referring toFIG. 9 in conjunction withFIG. 1, in accordance with embodiments of the invention described herein, all of the above-describedsensors50,52,54,56,60,64 and66 may be used in general to evaluate the integrity of the well by comparing measurements with predicted or previously-performed measurements associated with a valve that performs as intended. More specifically, atechnique200 may include measuring attributes of a valve and well, pursuant to block204, such as measuring the attributes disclosed herein with thesensors50,52,54,56,60,64 and66. The measurements are then compared (block208) with known or predicted measurements and then corrected action may be taken (block212) based on the comparison. For example, secondary or contingency tools may be run downhole and/or operated based on the results of the comparison. In this regard, using this comparison, downhole obstructions, debris accumulations, particular friction adders and other downhole issues, which may potentially interfere with the proper operation of theFIV10, may be identified. Thus, by monitoring the signals provided by thesensors50,52,54,56,60,64 and66, the control facility at the surface of the well may be assured of the proper operation of theFIV10 and enhance the ability to troubleshoot the entire well system.
• While terms of orientation and direction, such as “up,” “down,” “vertical,” etc. have been used for reasons of convenience to describe exemplary embodiments of the invention, it is understood that such directions and orientations are not necessary in order to practice the claimed invention. For example, in accordance with other embodiments of the invention, theoperator mandrel12 may be constructed to move down in response to applied tubing pressure and move up when the pressure is released. As another example, a valve in accordance with embodiments of the invention may be located in a lateral wellbore. Thus, many variations are contemplated and are within the scope of the appended claims.
• While the present invention has been described with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention.

Claims (22)

1. A valve, comprising:

a tubular valve housing having a central passageway;

a valve seat located in the central passageway to define a first portion of the central passageway above the valve seat and second portion of the central passageway below the valve seat;

a valve element to control flow through the valve seat; and

a sensor fixed to the housing to measure an attribute indicative of a state of the valve.

2. The valve ofclaim 1, wherein the sensor is integrally mounted to the housing.

3. The valve ofclaim 1, wherein the sensor is located within the housing.

4. The valve ofclaim 1, wherein the sensor measures at least one of a temperature and a pressure.

5. The valve ofclaim 1, wherein the sensor is adapted to measure at least one of an annulus pressure and a tubing pressure.

6. The valve ofclaim 1, wherein the sensor is adapted to measure a pressure associated with an internal pressure chamber of the valve.

7. The valve ofclaim 1, wherein the sensor is part of at least two sensors adapted to indicate a state of the valve element.

8. The valve ofclaim 1, wherein the valve comprises a safety valve.

9. The valve ofclaim 1, wherein the valve comprises a formation isolation valve.

10. A system comprising:

a string comprising a central passageway;

a valve to control a flow between a portion of the central passageway of the string located above the valve and a portion of the central passageway of the string located below the valve; and

a sensor mounted near the valve to measure an attribute indicative of a state of the valve.

11. The system ofclaim 10, wherein the valve comprises a housing and the string is mounted to the housing.

12. The system ofclaim 10, wherein the valve comprises a valve seat located in the central passageway to define the portion of the central passageway above the valve and the portion of the central passageway below the valve.

13. The system ofclaim 10, wherein the sensor measures a pressure of a pressurized chamber of the valve.

14. The system ofclaim 10, wherein the sensor indicates whether the valve is in an open state or a closed state.

15. The system ofclaim 10, wherein the valve comprises a formation isolation valve.

16. The system ofclaim 10, wherein the valve comprises a safety valve.

17. A method usable with a well, comprising:

providing a valve in a central passageway of a tubular member in the well to regulate a flow through the central passageway; and

using at least one sensor to monitor an attribute indicative of a state of the valve.

18. The method ofclaim 17, wherein the using comprises using said at least one sensor to measure at least one of a pressure and a temperature associated with the valve.

19. The method ofclaim 17, wherein the using comprises using said at least one sensor to measure conditions indicative of whether the valve is in an open state or a closed state.

20. The method ofclaim 17, wherein the using comprises using said at least one sensor to measure a pressure of a pressurized chamber of the valve.

21. The method ofclaim 17, further comprising:

connecting said at least one sensor to a sensor bus that extends to the surface of the well.

22. The method ofclaim 17, wherein the valve comprises one of a formation isolation valve and a safety valve.

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