PDF valve

[0002] This application is a continuation-in-part of U.S. patent application Ser. No. 09/836,755 filed Apr. 17, 2001, assigned to the Assignee of the present invention.

[0003] 1. Field of the Invention

[0004] The present invention relates generally to valve devices that may be used in the construction of oil and gas wells. More specifically, the present invention relates to an improved pressure and differential-fill (PDF) valve used to position and cement casing into a wellbore.

[0005] 2. Setting of the Invention

[0006] Differential-fill float and cementing assemblies employ a flow regulation valve in the casing string to permit forward circulation through the casing string and to automatically control the filling of the casing string with drilling fluid as the casing string is lowered into a well. Admitting regulated amounts of drilling fluid into the casing as it is being lowered into the wellbore reduces the suspended weight of the casing string, allows the casing to sink through the drilling fluid, prevents the casing from collapsing and reduces hydraulic ram forces against the subsurface formation. Once the casing is lowered into the proper position in the wellbore, a cement slurry is pumped through the casing string and cementing assembly into the annulus between the casing and the borehole. During this cementing process, the valving in the cementing assembly is remotely reconfigured to form a backpressure (check) valve for the purpose of preventing back-flow of the cement slurry pumped into the annulus. A complete description of differential-fill float and cementing equipment of the type with which the present invention may be employed may be found in U.S. Pat. No. 4,729,432 (herein, the “'432 patent”). The '432 patent, belonging to the Assignee of the present application, is incorporated herein for all purposes.

[0007] The differential-fill operation of the assembly described in the '432 patent is provided by a differential pressure valve comprised of a small, pivoting flapper valve “piggybacked” on the flapper gate of a larger flapper check valve. The differential pressure valve and the flapper check valve cooperate to prevent back-flow of drilling fluid from the well into the casing until the differential pressure valve opens. The small flapper valve opens to permit a regulated amount of well fluid to flow into the casing through a flow passage in the gate of the check valve. A controlled strength spring constructed of hard spring-steel biases the small flapper valve to its closed position preventing back-flow of drilling fluid into the casing. When the differential pressure between the drilling fluid in the wellbore and that in the casing is sufficiently great, the spring bias is overcome and the small flapper valve pivots open to admit drilling fluid into the casing. The flapper spring closes the small flapper valve automatically when fluid admitted into the casing reduces the pressure differential below that required to open the valve. The flapper spring imposes a great deal of stress on the flapper hinge pin, requiring usage of a relatively large, high strength steel pin as the hinge pin.

[0008] After the casing has been cemented into the well, the differential-fill and cementing assembly must be milled or drilled out of the casing string. This removal process is facilitated by constructing the assembly with materials that are easily milled or cut by the drill bit. Brass and aluminum are commonly employed in the construction of the major structural components of the differential-fill and cementing equipment.

[0009] The springs used to regulate the opening of the regulating valves used in the differential-fill portions of the assembly are often provided by heavy coiled springs constructed of relatively hard spring-steel. The high strength steel flapper hinge pins and the steel springs, such as the pins and springs used for the small flapper valve of the '432 patent, are very difficult for a polycrystalline diamond compact (PDC) bit to mill or drill out of the casing.

[0010] A feature of the assembly of the present invention is that a differential pressure poppet valve is centrally located in the differential-fill equipment and is moved along its central axis, parallel to the direction of fluid back-flow, as it travels between opened and closed positions. The poppet valve of the assembly operates without pivoting into and out of the centerline area of the flow stream and eliminates the need for a heavy steel hinge pin as is required for the flapper closure member of the prior art. The axial movement of the poppet valve maintains symmetrical flow past the valve to improve fluid flow regulation and minimize erosion of the valve components, which is particularly important where the components are constructed of plastics and/or composite materials. As compared with a standard piggybacked flapper arrangement, the configuration of the poppet valve and its placement on the flapper gate of the differential pressure valve of the present invention contribute to an increase in the flow passage dimensions through the differential-fill equipment when the flapper gate is fully opened.

[0011] When the invention is employed as a differential-fill valve for lowering casing into drilling fluid, the major structural components and the pressure regulating biasing spring of the differential-fill valve may be constructed of plastics and/or composite materials to facilitate the milling or drilling up of the valve. A leaf spring constructed of composite material may be employed to impose the biasing closing force on a poppet valve mounted in the flapper gate of the differential pressure valve. Elimination of a flapper valve as a regulating component of the differential-fill valve eliminates the need for a heavy steel hinge pin. In a preferred embodiment, the poppet valve, poppet valve biasing element, flapper valve and flapper hinge pin may be constructed of composite materials and/or plastics.

[0012] The regulating poppet valve feature of the present invention may be used in a combination, differential-fill and cementing assembly that is first used to automatically fill the casing as the casing is lowered into a wellbore and then is remotely reconfigured from the well surface to conduct a cement slurry from the casing into the annulus between the casing and the wellbore. The differential pressure valve also functions to provide a backpressure check valve to prevent back-flow of the cement slurry into the casing once the cement slurry has been pumped into the annulus. The major structural components of the assembly, including the pressure regulating spring of the differential fill valve, may be constructed of composite materials and/or plastics to facilitate the milling or drilling up of the assembly after the casing has been cemented into the wellbore.

[0013] As used herein, the term “composite materials” is intended to mean a combination of two or more materials (reinforcing elements, fillers, and composite matrix binder), differing in form or composition on a macro scale. Constituents of composite materials retain their identities; that is, they do not dissolve or merge completely into one another although they act in concert. Normally, the components of composite materials can be physically identified and exhibit an interface between one another.

[0014] From the foregoing, it will be appreciated that a major objective of the present invention is to provide a poppet valve in the closure element of a differential pressure valve that permits improved regulation of a back-flow of fluid through the valve while minimizing turbulent fluid flow and valve erosion through the poppet valve.

[0015] An object of the present invention is to provide a subsurface fluid flow regulating valve in which the regulating portions of the valve are smoothly contoured and symmetrically oriented about a central axis and are moved in a direction parallel to the regulated fluid flow to improve flow regulation, minimize fluid turbulence and minimize erosion of the valve components.

[0016] A related object of the present invention is to provide a biasing spring constructed of a composite material that is sufficiently strong to bias the closure member of a regulating valve against the opening force of a pressurized fluid to maintain a predetermined pressure differential between the pressurized fluid and the area regulated by the valve.

[0017] Another important object of the present invention is to provide a regulating valve that can be easily drilled out of a casing string by a PDC bit.

[0018] Yet another object of the present invention is to provide a combination differential-fill and cementing valve assembly constructed primarily of plastics and/or composite materials whereby the assembly may be easily drilled out of a casing string with a PDC bit. A related object of the invention is to eliminate the need for a heavy steel flapper hinge pin in the regulating portions of the cementing valve assembly.

[0019] The foregoing objects, features and advantages of the present invention, as well as others, will be more fully appreciated and better understood by reference to the following drawings, specification and claims.

[0020] FIG. 1 is a vertical sectional view of a float collar assembly having a differential-fill and cementing assembly of the present invention illustrated in a casing string as the assembly appears during the lowering of the casing string through the drilling fluid in a wellbore;

[0021] FIG. 1A is an end view illustrating details of a piggybacked poppet valve on a flapper gate of a regulating valve of the present invention;

[0022] FIG. 1B is an end view of a modified piggybacked poppet valve on a flapper gate of a regulating valve of the present invention;

[0023] FIG. 1C is a side view of the poppet valve illustrated in FIG. 1B;

[0024] FIG. 2 is a vertical sectional view of the float collar assembly of FIG. 1 illustrating the disabling of the regulating differential-fill valve and the activation of a back pressure valve before a cement slurry is to be pumped through the float collar assembly; and

[0025] FIG. 3 is a vertical sectional view of the float collar assembly of FIG. 1 illustrating the float collar assembly fully opened and converted to a back pressure valve for the introduction of a cement slurry through the float collar assembly.

[0026] A combination differential-fill and cementing assembly including a poppet valve constructed in accordance with the teachings of the present invention is indicated generally in FIG. 1 as a regulating float collar assembly 10. The float collar assembly 10 is illustrated threadedly connected in a casing string between a casing joint 11 and a casing joint 12. The collar assembly includes a steel tubular body 14 within which the back pressure and differential pressure valves are carried.

[0027] The valve components of the float collar assembly 10 are retained in place within the collar assembly body 14 by easily drilled bonding material 15. An annular seating ring 17 of plastic or composite material at the top of the bonding material 15 functions as a plug seat and receives a setting ball 50 (FIG. 2) introduced into the casing string from the well surface and used to convert the float collar assembly from differential-fill to a backpressure or float valve.

[0028] The valving of the float collar assembly 10 includes an upper, tubular, back-flow valve housing 18 secured at its lower end to a tubular, regulating flow valve housing 19. A flapper valve gate 20, illustrated locked back in the upper housing 18, is unlocked when the valve is converted to its cementing function. The valve gate 20, when unlocked, functions as a backpressure valve that pivots between open and closed positions to permit one-way, downward flow of fluids through the float collar assembly.

[0029] A lightweight coiled spring 21 encircles a hinge pin 22 from which the flapper gate 20 pivots. The spring 21 provides a bias force tending to move the flapper gate 20 toward its closed position. Within the regulating flow valve housing 19, a differential pressure regulating valve, indicated generally at 23, regulates the flow of fluids upwardly through the float collar assembly 10 during the lowering of the casing into the drilling fluid.

[0030] As may best be described by reference to FIGS. 1 and 1A, the differential pressure regulating valve 23 includes a flapper valve with a flapper gate 24 having a central flow passage 25. The flapper valve gate 24 is biased to its closed position by a lightweight coil spring 26 encircling a hinge pin 27 from which the gate is pivoted. An annular sealing section 24aof the flapper gate 24 seats against a mating sealing surface 19aformed at the base of the regulating flow valve housing 19.

[0031] The flow passage opening 25 through the flapper gate is controlled with a piggybacked poppet valve assembly carried on the flapper gate 24. The poppet valve assembly includes a symmetrically formed, smoothly contoured closure element 28 with a stem 29 that extends centrally and axially from the closure element. A leaf spring 30, secured to the valve stem 29 with a nut 31, biases the poppet valve toward its closed position sealing the flow passage 25. The mounting of the closure element 28 in the regulating valve 23 and the connection with the leaf spring 30 constrain the closure element of the poppet valve assembly to move linearly in a direction along the central axis of the closure element 28, parallel to the linear flow of fluids through the float sleeve 10.

[0032] The leaf spring 30 imposes a strong biasing force that maintains the flow passage closed against the differential pressure acting across the closed poppet valve 28. The spring force determines the pressure differential required to open the flow passage and thus regulates the fluid level in the casing string above the float collar assembly 10.

[0033] The valve closure element 28 of the poppet valve included in the control valve 23 is centrally positioned axially within the flow passage 25 extending through the flapper gate 24. The movement of element 28 is coaxial with the float collar assembly and is parallel to the direction of fluid flow through the valve. The closure element 28 forms a symmetrical, smoothly continuous element centralized in the flow path of the drilling fluid entering the casing. The design and central placement of the control element 28 cooperates with the centralized flow passage opening 25 in the flapper valve gate 24 and the direct axial force applied by the leaf spring 30 to minimize turbulence in the drilling fluid flow and to more closely regulate the pressure response for opening and closing the poppet valve. The dimensions and placement of the leaf spring 30 on the flapper gate 24 also contribute to the symmetrical flow pattern to further minimize flow turbulence. The result is a reduction in the differential erosion in the sealing elements of the poppet valve and a corresponding improvement in the flow regulation of the valve.

[0034] During the time the casing is being lowered into the wellbore; the back pressure valve gate 20 is locked open by a control sleeve indicated generally at 35. The control sleeve 35 operates as a valve change mechanism to change the function of the assembly 10. In its initial position within the float collar assembly 10, the sleeve 35 traps the flapper gate 20 to hold it in its open position within a recess 36 formed in the back-flow housing 18. The sleeve 35 is temporarily secured against axial motion by shear pins 37 extending from a support ring 38 anchored to the top of the regulating valve housing 19.

[0035] As will be described hereinafter, the sleeve 35 is shifted axially downwardly by a setting ball to change the function of the regulating float collar assembly 10. Circumferentially spaced collet fingers 40 extend upwardly at the top end of the sleeve 35 to form a ball catching receptacle. To this end, fingers 40 are equipped with internal, radially developed shoulder sections 42 extending radially inwardly from each of the collet fingers to collectively form a receiving seat for the setting ball. Circumferential gaps 44 between adjacent collet fingers 40 and between the shoulder projections 42 are filled and sealed with an elastomeric sealing material indicated at 45. The sealed sleeve shoulders and collet slots provide a continuous seat that cooperates with the setting ball to seal the flow passage through the float collar assembly 10.

[0036] In operation, after the casing string has been lowered into the desired position within the wellbore, a setting ball 50 is positioned in the casing and pumped down to the float collar assembly 10. As indicated in FIG. 2, the ball 50 passes through the central flow passage of the float collar assembly 10 and seats on the collet shoulder projections 42 where it seals the central opening through the sleeve 35. When a sufficiently high-pressure differential is exerted across the seated ball, the shear pins 37 sever and release the sleeve 35 from the support ring 38. The differential pressure acting across the seated ball 50 drives the sleeve 35 axially downwardly. The initial downward movement of the sleeve 35 frees the flapper gate 20, permitting it to pivot toward its closed position.

[0037] With reference to FIG. 3, as the sleeve 35 moves axially downwardly, the bottom 35aof the sleeve engages the control valve 23 and pivots it into its fully open position. The downward travel of the sleeve is terminated when an external sleeve shoulder 52 engages an internal housing shoulder 53 to prevent further downward movement of the sleeve within the housing. At this lowermost position of sleeve travel, illustrated in FIG. 3, the control valve 23 is fully opened.

[0038] The continued application of a pressure differential across the ball 50 seated in the sleeve seat radially outwardly deforms the collet shoulder projections 42 and the collet fingers 40 sufficiently to allow passage of the ball 50. The radial deformation of the collet fingers permits the ball 50 to move past the sleeve seat and travel through the float collar assembly 10 to the bottom of the casing.

[0039] The cement slurry used to cement casing into the wellbore is pumped through the float collar assembly when the float collar assembly 10 is in the float valve configuration illustrated in FIG. 3. In this float valve configuration, fluids pumped into the casing may flow freely through the float collar assembly 10 in a downward direction into the wellbore. Reverse flow, in a direction toward the well surface, is prevented by the back pressure operation of the flapper valve gate 20.

[0040] With the exception of the tubular body 14, the float collar assembly 10 described in FIGS. 1 through 3 herein is preferably constructed entirely of plastics and/or composite materials. By way of example rather than limitation, the back-flow valve housing 18 and regulating flow valve housing 19 may be constructed of a suitable thermoset phenolic plastic. The flapper valve gates 20 and 24, shear pins 37, control sleeve 35 and poppet closure element 28 may be constructed of a suitable composite of fiberglass fibers and resin. The hinge pins 22 and 27 may also be formed from a suitable composite of fiberglass and resin. The elastomeric material used to seal, the openings between the collet fingers 40 may be a nitrile rubber or other suitable sealing material. The hinge springs 21 and 26 may also be made of a suitable resilient composite material that provides the minimal biasing force required to return the flapper valve into the flow stream.

[0041] While springs constructed of composite materials are preferable, the springs 21 and 26 may be constructed from a relatively soft, resilient steel metal. Because the springs are of relatively small volume as compared with the hard, large volume, spring steel components employed to bias the control valve in conventional cement equipment, the resistance to a PDC bit is not excessive. The function of the springs 21 and 26 is merely to urge the flapper gates into the flow path of the fluid and, as contrasted with the springs employed to bias regulating valves, the springs need not overcome an opening force exerted by the fluid or pressure differential. The light springs 21 and 26 may thus be constructed of any suitable materials that provide a sufficient biasing force to move the flapper gates into the flow string provided such materials are not a significant obstacle to removal by a PDC bit.

[0042] FIGS. 1B and 1C illustrate a modified piggybacked poppet valve 128 of the present invention mounted on a flapper valve gate 124. The gate 124 and poppet 128 occupy less space and employ less material than the flapper gate and poppet arrangement illustrated in Figure 1A. A leaf spring 130 extends laterally across the annular sealing section 124aof the flapper gate. The connection of the leaf spring 130 to the closure element 128 reduces the profile of the gate and poppet valve assembly to minimize the space required in the float collar when the gate 125 is fully opened.

[0043] It will be appreciated that, while the differential-fill float valve device of the present invention has been described herein in detail as a collar, it may be configured either as a collar or as a casing shoe device. Moreover, it will also be understood that the invention may be included in each of multiple collars connected in a single string, or, in each of a collar and shoe connected in a single string, or in each of multiple collars and a shoe connected in a single casing string. Use of multiple valves in a single string allows an increase in the differential pressure required to admit fluid into the casing string thereby reducing the amount of drilling fluid admitted into the pipe during its placement in the wellbore.

[0044] It will also be understood that while various components of the preferred forms of the invention have been described as being constructed of composites and plastics, any of the components of the invention may be constructed from any suitable easily drillable material, including metal. Aluminum, for example, is a suitable metal for various components of the valve of the present invention. The primary requirement for the materials of construction is that they be easily drillable and have adequate mechanical strength to perform their intended functions.

[0045] The flapper gate 125 pivots about a hinge pin 124b. The leaf spring 130 connects to a stem 129 screwed into the closure element 128. The spring 130 is held to the stem by a slotted screw head 131.

[0046] Various preferred forms of the present inventions have been described in detail herein, it may be appreciated however, that many changes, additions and deletions may be made to the described embodiments without departing from the spirit and scope of the inventions, which are more fully defined in the following claims.