Method and apparatus for smooth bore toe valve

• US 9,476,282 B2
• Filed: 06/24/2013
• Issued: 10/25/2016
• Est. Priority Date: 06/24/2013
• Status: Active Grant

• Current Assignee: Innovex Downhole Solutions, Inc.
• Original Assignee: Team Oil Tools LP (Innovex Downhole Solutions, Inc.)
• Inventors: Anton, Kenneth J., Harris, Michael J.
• Primary Examiner(s): Gay, Jennifer H
• Assistant Examiner(s): GRAY, GEORGE STERLING
• Application Number:
  US13/924,828
• Publication Number:
  US 20140374096A1
• Time in Patent Office: 1,219 Days
• US Class Current: 1/1
• CPC Class Codes: E21B 2200/06 Sleeve valves
• CPC Class Codes: E21B 33/13 Methods or devices for cementing, for plugging holes, crevices or the like
• CPC Class Codes: E21B 34/063 Valve or closure with destructible element, e.g. frangible disc E21B34/103 takes precedence
• CPC Class Codes: E21B 34/10 operated by control fluid supplied from outside the borehole
• CPC Class Codes: E21B 34/102 with means for locking the closing element in open or closed position E21B34/105 and E21B34/108 take precedence
• CPC Class Codes: E21B 34/108 with time delay systems, e.g. hydraulic impedance mechanisms

Abstract

A smooth bore toe valve includes a first sub defining a through bore and a fluid flow path through a wall thereof; a second sub; a housing mechanically engaged with the first and second subs to define a valve cavity axially between the first and second subs and to define a chamber radially between the first and second subs and the housing, the housing further defining a plurality of openings in a wall thereof; and a sleeve disposed within the chamber between the housing and the first and second subs to close the openings and, upon application of fluid pressure horn the through bore through the fluid this path, open the openings to fluid flow from the valve cavity to the exterior of the housing. A method for using such a valve is also disclosed.

Claims

1. A smooth bore toe valve, comprising:

a first sub defining a portion of a through bore and including a fluid flow path through a wall of the first sub;

a second sub defining another portion of the through bore, the second sub being spaced axially apart from the first sub, such that an annular valve cavity is defined axially between the first and second subs and extending from the through bore;

a housing mechanically engaged with the first and second subs, wherein a chamber is at least partially defined radially between the first and second subs and the housing, the housing further defining one or more openings; and

a sleeve disposed at least partially within the chamber, the sleeve being movable from a closed position to an open position,

wherein, when the sleeve is in the closed position, the sleeve extends across the annular valve cavity, provides an extension of the through bore between the first and second subs, and prevents fluid communication from the through bore to the one or more openings,

wherein the one or more openings fluidly communicate with the through bore via the valve cavity when the sleeve is in the open position, and

wherein the sleeve is movable in response to an application of fluid pressure from the through bore through the fluid flow path.

2. The smooth bore toe valve of claim 1, wherein the first sub defines a first recess in an outer diameter of one end thereof, the second sub defines a second recess in an outer diameter of one end thereof, and the chamber comprises the first and second recesses when closed by the housing.

3. The smooth bore toe valve of claim 2, wherein the housing is at least partially disposed in the first and second recesses.

4. The smooth bore toe valve of claim 1, wherein the fluid flow path comprises an aperture.

5. The smooth bore toe valve of claim 1, wherein the mechanical engagement between at least one of the first and second subs and the housing is a threaded engagement.

6. The smooth bore toe valve of claim 1, further comprising a pressure barrier disposed in the fluid flow path.

7. The smooth bore toe valve of claim 6, wherein the pressure barrier comprises a rupture disk, a check valve, or a pressure relief valve.

8. The smooth bore toe valve of claim 1, wherein at least one of the first and second subs comprises a coupling, a pupjoint, a thread crossover, or a combination thereof.

9. The smooth bore toe valve of claim 1, wherein the openings comprise an oval geometry.

10. The smooth bore toe valve of claim 1, further comprising a body lock ring, wherein the body lock ring is mechanically engaged with the second sub and the sleeve, to lock the sleeve in the open position.

11. The smooth bore toe valve of claim 1, further comprising means for locking the sleeve in the open position.

12. The smooth bore toe valve of claim 1, wherein the first sub is oriented uphole of the second sub.

13. The smooth bore toe valve of claim 1, wherein the first sub is oriented downhole of the second sub.

14. The smooth bore toe valve of claim 1, wherein the fluid flow path communicates with the through bore and extends at least partially radially outward therefrom.

15. The smooth bore toe valve of claim 1, wherein the first and second subs are only connected together by the housing.

16. The smooth bore toe valve of claim 1, wherein the sleeve in the closed position forms a radially inner-most structure across the valve cavity and defines a portion of the through bore.

17. The smooth bore toe valve of claim 1, wherein a radially-inner, axial end of the first sub is beveled, or a radially-inner, axial end of the second sub is beveled, or both.

18. The smooth bore toe valve of claim 1, wherein the first sub comprises a first recess receiving an end of the housing, a second recess receiving the sleeve when the sleeve is in the closed position, and a shoulder between the first and second recesses that is configured to block the sleeve.

19. The smooth bore toe valve of claim 18, wherein the second sub comprises a first recess receiving another end of the housing, a second recess defining at least a portion of the chamber, and a shoulder configured to block the sleeve.

20. A method for opening a toe valve, comprising:

deploying the toe valve into a well, the toe valve comprising;

a first sub comprising a wall and defining a portion of a through bore and a fluid flow path through the wall;

a second sub defining another portion of the through bore, the second sub being spaced axially apart from the first sub, such that an annular valve cavity is defined axially between the first and second subs and extending from the through bore;

a housing mechanically engaged with the first and second subs, wherein a chamber is at least partially defined between the housing and the second sub, the housing defining one or more openings located between the valve cavity and an exterior of the housing; and

a sleeve disposed within the chamber, the sleeve being movable from a closed position to an open position,

wherein, when the sleeve is in the closed position, the sleeve extends across the annular valve cavity, provides an extension of the through bore between the first and second subs, and prevents fluid communication from the through bore to the one or more openings via the valve cavity, and

wherein, when the sleeve is in the open position, the one or more openings fluidly communicate with the through bore via the valve cavity and with the exterior of the housing, the sleeve being movable in response to an application of fluid pressure from the through bore through the fluid flow path; and

producing a differential pressure across the sleeve to move the sleeve from the closed position to the open position.

21. The method of claim 20, wherein producing the differential pressure includes applying a pressure of between about 0 psi and about 20,000 psi to the toe valve.

22. The method of claim 20, further comprising performing a cementing operation before opening the toe valve.

23. A method of actuating a toe valve, the method comprising:

creating a fluid pressure in the toe valve to create a pressure differential across a sleeve of the toe valve,

wherein the sleeve is disposed in a chamber defined between a first sub, a second sub, and a housing of the toe valve, and is movable from a closed position where the sleeve blocks fluid flow from a bore of the toe valve to one or more openings defined in the housing, to an open position where the sleeve permits flow through the one or more openings,

wherein an annular valve cavity is defined axially between the first sub and the second sub and extends from the bore to the one or more openings, and when the sleeve is in the closed position, the sleeve extends across the annular valve cavity and provides an extension of the bore between the first and second subs, and

wherein the fluid pressure ruptures a pressure barrier located in a fluid flow path defined in the first sub of the toe valve such that fluid pressure communicates past the ruptured pressure barrier, through the fluid flow path and to the sleeve, wherein the fluid pressure causes the sleeve to move from the closed position to the open position; and

flowing fluid through the bore and a valve cavity between the first and second subs, and into a well.

24. The method of claim 23, wherein the sleeve is configured to translate axially relative to the first sub and the second sub, and inside the housing when moving from the closed position to the open position.

25. The method of claim 23, wherein, when the sleeve is in the closed position, the sleeve is disposed at least partially between the first sub, the second sub, and the housing, and spans the valve cavity, preventing fluid communication from the valve cavity to the one or more openings.

26. The method of claim 23, wherein, when the sleeve is in the open position, the one or more openings provide fluid communication between the valve cavity and the well.