Downhole valve

Field of the Invention

The present invention relates to a downhole valve for insertion into a wall of a casing. The downhole valve comprises a housing having a first end and a second end and an inner face and an outer face. Furthermore, the invention relates to a downhole tool for inserting a downhole valve into a wall of a casing and to a downhole system comprising the downhole tool and a driving unit.

Background Art

During production, it may be expedient to change the openings through which oil fluid can enter the casing, thus sealing the existing openings, and create new openings. However, such operations may be very difficult to perform in muddy fluid where visibility is low and the casing is narrow.

One type of opening may be a valve to be inserted at another position in the casing when the oil production zone is sealed off. Thus, there is a need for a simple solution for inserting new valves in the wall of a casing.

Summary of the Invention

It is an object of the present invention to wholly or partly overcome the above disadvantages and drawbacks of the prior art. More specifically, it is an object to provide an improved simple solution for inserting a downhole valve, and thus for a valve which can easily be inserted into the wall of a casing.

The above objects, together with numerous other objects, advantages, and features, which will become evident from the below description, are accomplished by a solution in accordance with the present invention by a downhole valve for insertion into a wall of a casing, comprising:

• - a housing having a first end and a second end as well as an inner face and an outer face,
  
  

  wherein the first end of the housing comprises at least one cutting edge.

In one embodiment, the housing may have an inlet at the first end and an outlet at the second end.

Furthermore, the housing may comprise a valve means for restricting the flow from the inlet to the outlet.

The valve may have an axial extension and an axial direction from the inlet to the outlet.

Moreover, the valve means may comprise a diaphragm.

Additionally, the valve means may comprise a spring acting on a piston.

The aforementioned cutting edge may be arranged as an extension of the outer face.

Also, the cutting edge may extend from the inner face to the outer face.

In addition, the cutting edge may be arranged at an angle in relation to a radial extension from the inner face to the outer face.

Further, the cutting edge may have a meander shape.

Moreover, the housing in cross-section may have a circumference, and the cutting edge may extend partly or fully around the circumference.

The wall of the housing may be made of a metal, such as cemented carbide, tungsten-carbide cobalt, hard metal or widia.

Further, the valve may be an inflow control valve, a gas lift valve, a throttle or a pressure control valve.

Also, the outer face of the housing may be provided with a thread.

The present invention furthermore relates to a downhole tool for inserting a downhole valve into a wall of a casing, comprising:

• at least one downhole valve, and
• a moving means for moving the valve to penetrate the wall of the casing.

In one embodiment, the casing may have an axial extension, and the tool may move the valve so that the axial extension of the valve is transverse to the axial extension of the casing.

In addition, the downhole tool may further comprise a holder for holding the valve.

The holder may comprise a contact surface.

Moreover, the moving means may comprise a piston punching the valve through the casing.

Furthermore, the moving means may screw the valve through the casing.

In addition, the moving means may rotate the valve so that the valve drills itself through the casing.

The downhole tool may further comprise a magazine comprising several valves to be inserted into the wall of the casing.

Additionally, the downhole tool may further comprise a stop means for controlling the moving means so that the valve penetrates the wall of the casing and the second end face is aligned with an inner face of the wall of the casing.

The present invention furthermore relates to a downhole system comprising the downhole tool and a driving unit, such as a downhole tractor, for moving the tool forward in the casing.

Brief Description of the Drawings

The invention and its many advantages will be described in more detail below with reference to the accompanying schematic drawings, which for the purpose of illustration show some non-limiting embodiments and in which

• Fig. 1 shows a downhole valve,
• Fig. 2 shows another embodiment of the valve,
• Fig. 3 shows a downhole tool in a casing,
• Fig. 4 shows a partly cross-sectional view of part of another embodiment of the downhole tool,
• Fig. 5 shows a partly cross-sectional view of part of yet another embodiment of the downhole tool, and
• Fig. 6 shows a partly cross-sectional view of part of yet another embodiment of the tool.

All the figures are highly schematic and not necessarily to scale, and they show only those parts which are necessary in order to elucidate the invention, other parts being omitted or merely suggested.

Detailed description of the invention

Fig. 1 shows a downhole valve 1 for insertion into a wall 2 of a casing 3 in a well in order to let formation fluid into the casing. The valve 1 comprises a housing 4 having a first end 5 and a second end 6. The housing 4 has a cutting edge 9 arranged at the first end 5 of the housing. The housing 4 comprises an inner face 7 and an outer face 8, and in Fig. 1, the cutting edge 9 is arranged as an extension of the outer face 8 so that the outer face 8 terminates in the cutting edge at the first end. The cutting edge 9 has a meander shape when seen from the side. The cutting edge 9 curves up and down and has three tips enabling he valve 1 to cut itself into the wall 2 of the casing 3 when being punched into the casing wall.

The housing 4 has an inlet at the first end 5 of the housing 4 and an outlet at the second end 6 of the housing 4. Inside the housing 4, the valve 1 comprises a valve means providing a valve function and restricting free flow from the inlet to the outlet in an axial direction of the valve 1.

The valve means comprises a diaphragm, a throttle, a spring acting on a piston or the like means providing controlled flow restriction in the axial direction of the valve 1. Thus, the valve 1 may be any kind of valve, such as a flow control valve, a gas lift valve, a throttle or a pressure controlled valve.

As shown in Fig. 2, the valve 1 has two cutting edges 9 which extend from the inner face 7 to the outer face 8, and between the cutting edges, a first end face of the first end 5 of the housing 4 inclines, causing the cutting edges 9 to form a tip of the housing 4. When the valve is punched into the casing wall 2 by pushing the valve from a second 38 end face of the second end 6 of the housing 4, the cutting edges 9 cut through the wall. Each cutting edge 9 extends along the radius from the inner face 7 to the outer face 8. In another embodiment, the cutting edge 9 is arranged at an angle in relation to a radial extension from the inner face 7 to the outer face 8.

When seen in cross-section, as in Fig. 1, the housing 4 has a circumference, and the cutting edge 9 extends fully around the circumference. In Fig. 2, the cutting edge 9 forms only part of the circumference.

In order to be able to cut itself into the casing 3 when used as a punch, the housing wall is made of a metal, such as cemented carbide, tungsten-carbide cobalt, hard metal or widia.

The cutting edge 9 may be part of a bit welded or embedded into the first end 5 of the housing 4.

In another embodiment, the outer face 8 of the housing 4 is provided with a thread, and the valve 1 is screwed into the wall 2 of the casing 3. Hereby the valve 1 is mechanically secured into the wall of the casing 3 and can withstand direct pressure acting on the first end 5.

The valve 1 is inserted in the casing 3 by means of a downhole tool 100 comprising a moving means 12 for moving the valve 1 so that it penetrates the wall 2 of the casing 3, as shown in Fig. 3. The moving means 12 provides a movement transverse to the longitudinal extension of the tool 100 and the axial extension of the casing 3.

As shown in Fig. 4, the moving means 12 comprises a holder 11 for holding the valve 1. The moving means 12 furthermore comprises a piston 13 which is activated by a cylinder 14 and which moves the holder 11 holding the valve 1 through an opening 15 in the tool 100. The opening 15 is sealed by a blocking plate made of e.g. glass breaking when the moving means 12 punches the valve 1 into the casing wall 2.

When the moving means 12 moves the valve 1 towards the wall 2 of the casing 3, a contact surface of the holder 11 abuts the inner face 39 of the casing 3, providing a backstop and a measure of how far the moving means 12 has to punch and/or rotate into the casing wall in order for the second end 6 of the valve 1 to be aligned with the inner face 7 of the casing 3. This serves to ensure that the valve 1 does not extend into the casing 3, thereby decreasing the inner diameter of the casing 3.

In order to move the valve 1 to penetrate the casing wall 2, the moving means 12 comprises a piston 13 punching or pushing the valve 1 through the casing 3.

As shown in Fig. 5, the tool 100 comprises two moving means 12 each moving a valve 1 to penetrate the casing wall 2. The tool 100 comprises an electrical motor 26 for driving a pump 27 providing hydraulic power to the moving means 12, enabling the valve 1 to penetrate the casing wall 2. The moving means 12 may also be driven directly by the motor 26 without the use of hydraulics.

In another embodiment, the tool 100 comprises a magazine 20 holding several valves ready to be inserted into the holder 11, as shown in Fig. 6. When one valve is inserted in a position in the casing 3, the tool 100 moves and the holder 11 is loaded with a second valve from the magazine 20, and when the tool reaches a new position, the second valve is ready to be inserted into the casing wall 2.

While moving the valve 1 to penetrate the casing wall 2, the moving means 12 may also screw the valve 1 through the casing 3.

In another embodiment, the moving means 12 rotates the valve 1 so that the valve 1 drills itself through the casing 3.

The holder 11 acts as a stop means for controlling the moving means 12 to ensure that the valve 1 penetrates the wall 2 of the casing 3 and the second end face is aligned with an inner face 7 of the wall 2 of the casing 3. The tool 100 may also have a separate stop means if the holder 11 is not designed to abut the inner face of the casing 3.

The downhole tool 100 may be connected with a driving unit 22, such as a downhole tractor, for moving the tool forward in the casing 3. The downhole tool 100 and the driving unit 22 together form a downhole system.

By fluid or well fluid is meant any kind of fluid that may be present in oil or gas wells downhole, such as natural gas, oil, oil mud, crude oil, water, etc. By gas is meant any kind of gas composition present in a well, completion, or open hole, and by oil is meant any kind of oil composition, such as crude oil, an oil-containing fluid, etc. Gas, oil, and water fluids may thus all comprise other elements or substances than gas, oil, and/or water, respectively.

By a casing is meant any kind of pipe, tubing, tubular, liner, string etc. used downhole in relation to oil or natural gas production.

In the event that the tool is not submergible all the way into the casing 3, a downhole tractor can be used to push the tool all the way into position in the well. A downhole tractor is any kind of driving tool capable of pushing or pulling tools in a well downhole, such as a Well TractorⓇ.

Although the invention has been described above in connection with preferred embodiments of the invention, it will be evident for a person skilled in the art that several modifications are conceivable without departing from the invention as defined by the following claims.