Apparatus and Method For Remote Actuation of A Downhole Assembly

Abstract

An apparatus and method is disclosed for remotely operating a downhole tool within a wellbore. The wellbore extends from a ground or subsea surface downward into the earth. The apparatus includes a tool having a production assembly with at least one sleeve adapted for movement from a first sleeve position facilitating entry of formation fluids past the sleeve into the wellbore to a second sleeve position that retards entry of formation fluids. The downhole tool may be configured to resume production following fracturing, gravel packing or other operations without the need for additional trips into the well for the purpose of opening production sleeves. A fluid pressure pulse or electromagnetic signal or other signal may be delivered downhole for remote mechanical actuation of the apparatus.

What is claimed is: 
     
         1 . An apparatus for remotely operating a downhole tool within a wellbore, the wellbore extending from a ground or subsea surface downward into the earth, the downhole tool comprising a production assembly having at least one sleeve adapted for movement from a first closed position blocking entry of formation fluids past the sleeve and into the wellbore to a second open position that allows entry of formation fluids, the downhole tool having an internal cavity, the internal cavity being adapted for passage of wellbore fluids, the apparatus comprising:
 (a) a sensor, the sensor being configured to receive transmitted signals and then generate electrical signals responsive to the value of such transmitted signals;   (b) a control module, the control module being adapted for receiving electrical signals from the sensor, the control module further comprising operating instructions representing predetermined parameters, the control module being configured to receive from the sensor signals corresponding to values and to compare such values to predetermined parameters such that when received values exceed predetermined parameters the control module is capable of sending action signals in response; and   (c) a motor configured to receive such action signals from the control module, the motor being adapted for applying force to open or close a sleeve of a production assembly to alter the flow path of formation fluids through the sleeve.   
     
     
         2 . The apparatus of  claim 1  additionally comprising the following:
 (d) a hydraulic system connected to the motor, the hydraulic system further comprising a pump, the pump being configured for applying hydraulic force to control lines, the control lines being operatively engaged to a sleeve of the production assembly to open or close the sleeve, thereby altering the flow path of formation fluids. 
 
     
     
         3 . The apparatus of  claim 1  further wherein the sensor is a pressure sensor, further wherein the pressure sensor is adapted for receiving pressure pulse signals, further comprising a signal generating device positioned remotely from the pressure sensor, the signal generating device being configured to create pressure pulses in a fluid passing through the internal cavity, the pressure pulses having predetermined intensity and time values. 
     
     
         4 . The apparatus of  claim 1  further comprising a battery configured for supplying power to at least one of the following: sensor, control module, motor. 
     
     
         5 . The apparatus of  claim 1  configured for deployment in connection with a multi-zone wellbore completion system having a plurality of production assemblies. 
     
     
         6 . The apparatus of  claim 1  further comprising a shroud and mandrel, the shroud being configured as a conduit for flow of formation fluids among a plurality of production assemblies, further wherein the shroud is configured to be lockable in rotation with the mandrel. 
     
     
         7 . The apparatus of  claim 3  further comprising an additional pressure sensor, wherein the additional pressure sensor is positioned downhole, the additional pressure sensor being configured for measuring changes in pressure due to pressure drop generated by turbulent flow. 
     
     
         8 . The apparatus of  claim 1  wherein the apparatus further comprises a first temperature sensor positioned below the ground or subsea surface, the first temperature sensor being configured to measure temperature, further wherein the control module comprises instructions representing predetermined temperature parameters. 
     
     
         9 . The apparatus of  claim 8  wherein the control module comprises instructions to refrain from sending action signals when the temperature measured by said first temperature sensor is below a predetermined minimum temperature parameter. 
     
     
         10 . The apparatus of  claim 1  wherein the sensor comprises an electromagnetic sensor. 
     
     
         11 . A method for remotely controlling the production flow path of formation fluids through the sleeve of a production assembly in a fluid-containing wellbore, the wellbore extending from a ground or subsea surface downhole into a subterranean formation, the subterranean formation having at least one producing zone, the method of the invention comprising the steps of:
 (a) activating a sensor, the sensor being adapted to receive transmitted signals and generate in response electrical signals correlated to the value of received transmitted signals;   (b) detecting with a control module electrical signals from the sensor, the control module being adapted for receiving signals from the sensor, the control module further comprising operating instructions having predetermined parameters, the control module being configured to receive from the sensor electrical signals;   (c) comparing received signal values to predetermined parameters to determine if measured signal values exceed predetermined parameters, thereby triggering the production of action signals;   (d) sending action signals to a motor, the motor being configured to receive action signals and apply forces which operate on the sleeve in response, and   (e) manipulating the sleeve of the production assembly to alter the flow of formation fluids.   
     
     
         12 . The method of  claim 11  wherein a pumping apparatus generates such transmitted signals in the form of pressure pulses in the fluid within the wellbore, such pressure pulses having certain defined and predetermined intensity and time values, the pulses propagating from a position near the ground or subsea surface through the fluid and into a cavity within the wellbore to a production assembly positioned downhole. 
     
     
         13 . The method of  claim 11 , wherein the motor is operably connected to the sleeve of the production assembly, wherein the manipulating step further comprises activating a hydraulic system connected to the motor, such hydraulic system being configured with a pump that receives forces from the motor, the hydraulic system having hydraulic control lines capable of applying force to the sleeve of the production assembly. 
     
     
         14 . The method of  claim 11  wherein the manipulating step comprises opening the sleeve to facilitate the flow of formation fluids beyond the sleeve and into the production assembly. 
     
     
         15 . The method of  claim 12  wherein, prior to the step of generating pressure pulses, a fracturing fluid is passed through the wellbore and into the subterranean formation, thereby fracturing a first zone of the subterranean formation to form a first fractured zone. 
     
     
         16 . The method of  claim 15  further including the step of gravel packing the first fractured zone following the fracturing step. 
     
     
         17 . The method of  claim 11  wherein the sensor comprises an electromagnetic sensor.