Downhole valve for production or injection

Abstract

The present disclosure provides a valve assembly comprising a valve section, a power section, and an electronics section. The valve assembly is configured to mate with a tubing sub (and/or mandrel) inserted in-line with a tubing string inserted into a wellbore. The valve allows for injection into or production from the tubing string. The valve assembly comprises an electric motor and a motor controller permitting fine control over the valve, as well as sensors which measure various parameters, such as fluid flow, valve position, pressure, temperature, and/or water cut. A cable connects the valve assembly to the surface and provides power and data telemetry and allows control of the valve assembly with a remote electronic signal. Multiple valve assemblies may be provided at spaced intervals along the tubing string and individually monitored and/or controlled by a remote location. Also disclosed is a method for operation of such valve assemblies.

What is claimed is: 
     
         1 . A downhole valve for controlling fluid flow, comprising:
 a motor adapted to provide rotational movement of a motor shaft;   a position sensor coupled to the motor and adapted to determine a rotation position of the motor;   a linear actuator coupled to the motor and adapted to convert the rotational movement of a drive shaft to an axial movement in an axial direction;   a valve assembly comprising:
 an inlet and an outlet; and 
 a flow control member positioned between the inlet and the outlet of the valve assembly, the flow control member coupled to the linear actuator; 
   a motor controller coupled to the motor and adapted to control axial movement of the flow control member in the axial direction between the inlet and the outlet;   wherein the motor controller is further adapted to control the axial movement of the flow control member in a continuously variable mode such that the flow control member linearly moves in the axial direction to a plurality of continuously variable positions between a fully closed position and a fully open position; and   a valve seat and wherein the flow control member comprises a sealing portion positioned against the valve seat in the fully closed position.   
     
     
         2 . The downhole valve of  claim 1 , wherein the linear actuator is threadably engaged with a portion of the flow control member. 
     
     
         3 . The downhole valve of  claim 1 , wherein the linear actuator is threadably engaged with a portion of a connecting shaft, wherein the connecting shaft is coupled to the motor and the linear actuator. 
     
     
         4 . The downhole valve of  claim 1 , wherein the linear actuator comprises a worm gear or ball screw. 
     
     
         5 . The downhole valve of  claim 1 , wherein the linear actuator comprises at least one drive shaft. 
     
     
         6 . The downhole valve of  claim 1 , wherein the linear actuator comprises a male spline and a female spline. 
     
     
         7 . The downhole valve of  claim 1 , wherein the flow control member is a dart. 
     
     
         8 . The downhole valve of  claim 1 , wherein the flow control member is a valve plug. 
     
     
         9 . The downhole valve of  claim 1 , wherein the flow control member comprises a moveable barrier. 
     
     
         10 . The downhole valve of  claim 1 , wherein the flow control member is moveable to close and open the valve assembly. 
     
     
         11 . The downhole valve of  claim 1 , wherein the flow control member is adapted to block the inlet and outlet to control fluid flow through the valve assembly. 
     
     
         12 . The downhole valve of  claim 1 , further comprising a connecting shaft coupled to the linear actuator. 
     
     
         13 . The downhole valve of  claim 12 , wherein the connecting shaft comprises at least one spline. 
     
     
         14 . The downhole valve of  claim 12 , wherein the connecting shaft comprises a drive shaft. 
     
     
         15 . The downhole valve of  claim 12 , wherein the motor controller is adapted to control the axial movement of the flow control member such that the connecting shaft causes the flow control member to linearly move in the axial direction. 
     
     
         16 . The downhole valve of  claim 1 , further comprising a gearhead coupled to the motor shaft and adapted to provide a rotational movement of the flow control member. 
     
     
         17 . The downhole valve of  claim 1 , further comprising at least one spline coupled to the motor shaft and adapted to provide a rotational movement of the flow control member. 
     
     
         18 . The downhole valve of  claim 1 , further comprising
 a valve sub having a substantially cylindrical primary bore and a sub port and adapted to be in fluid communication with a production tubing of an oil well;   wherein the inlet of the valve assembly is positioned substantially perpendicular to the substantially cylindrical primary bore and in fluid communication with the sub port; and   wherein the downhole valve is adapted to control fluid flow between the sub port and the inlet of the valve assembly.   
     
     
         19 . The downhole valve of  claim 18 , wherein the downhole valve is adapted to control fluid flow in a bidirectional mode in any of a first direction from the inlet of the valve assembly to the sub port and a second direction from the sub port to the inlet of the valve assembly. 
     
     
         20 . A method of operating a downhole control valve comprising:
 providing a valve assembly having a plurality of continuously variable positions between a fully open position and a fully closed position;   providing a control signal to the valve assembly;   controlling a fluid flow through the valve assembly;   wherein the providing of the control signal comprises:
 rotating a motor; 
 rotating a drive shaft coupled to the motor; 
 actuating a linear actuator coupled to the drive shaft; and 
 producing an axial movement of a flow control member coupled to the linear actuator and positioning the flow control member to a predetermined one of the plurality of continuously variable positions. 
   
     
     
         21 . The method of  claim 20 , further comprising rotating a gearhead, wherein the gearhead is coupled to the motor and the linear actuator, wherein the gearhead comprises at least one drive spline. 
     
     
         22 . The method of  claim 20 , further comprising sensing a rotational position of the motor and positioning the flow control member based on the rotational position. 
     
     
         23 . The method of  claim 20 , further comprising
 coupling the valve assembly to a production tubing string in a well; and   controlling a fluid flow between the production tubing string and an annulus.   
     
     
         24 . The method of  claim 20 , wherein the controlling a fluid flow between the production tubing string and an annulus is any of controlling the fluid flow from the production tubing string to the annulus and controlling the fluid flow from the annulus to the production tubing string. 
     
     
         25 . The method of  claim 20 , further comprising
 sensing at least one parameter; and   adjusting the flow control member to a different predetermined one of the plurality of continuously variable positions based on the at least one parameter.   
     
     
         26 . The method of  claim 25 , further comprising determining a flow rate through the valve assembly based on the at least one parameter. 
     
     
         27 . The method of  claim 25 , further comprising determining a flow rate through the valve assembly based on the at least one parameter. 
     
     
         28 . A method of controlling the production of a well comprising:
 coupling a plurality of remotely controlled valves at predetermined locations along a length of a production tubing disposed in the well;   selectively controlling at least one of the plurality of remotely controlled valves to one of a plurality of continuously variable positions between a fully closed position and a fully open position;   controlling a fluid flow between the production tubing and an annulus;   sensing at least one parameter; and   selectively adjusting at least one of the plurality of remotely controlled valves to a different predetermined one of the plurality of continuously variable positions based on the at least one parameter.   
     
     
         29 . The method of  claim 28 , wherein the fluid flow is an annulus injection fluid, the method further comprising:
 providing the annulus injection fluid into the annulus; and   controlling the fluid flow of the annulus injection fluid from the annulus to the production tubing through at least one of the plurality of remotely controlled valves.   
     
     
         30 . The method of  claim 28 ,wherein the fluid flow is a tubing injection fluid, the method further comprising:
 providing the tubing injection fluid into the production tubing; and   controlling the fluid flow of the tubing injection fluid from the production tubing to the annulus through at least one of the plurality of remotely controlled valves.   
     
     
         31 . The method of  claim 28 , further comprising
 providing an injection rate any of the annulus injection fluid and the tubing injection fluid;   wherein the at least one parameter is any of a bottom hole tubing pressure, a bottom hole annulus pressure, a pressure sensed at any of the plurality of remotely controlled valves, a surface tubing pressure and a surface annulus pressure; and   controlling the fluid flow of any of the annulus injection fluid and the tubing injection fluid based on the injection rate and the at least one parameter by selectively adjusting at least one of the plurality of remotely controlled valves to a predetermined one of the plurality of continuously variable positions.   
     
     
         32 . A well production system comprising:
 a well having a wellbore;   a casing positioned in the wellbore;   a production tubing positioned within the casing and defining an annulus therebetween;   a plurality of remotely controlled valves positioned at predetermined locations along the production tubing, wherein each of the plurality of remotely controlled valves comprises
 a motor adapted to provide rotational movement of a motor shaft; 
 a position sensor coupled to the motor and adapted to determine a rotation position of the motor; 
 a linear actuator coupled to the motor and adapted to convert the rotational movement of a drive shaft to an axial movement in an axial direction; 
 a valve assembly comprising:
 an inlet and an outlet; and 
 a flow control member positioned between the inlet and the outlet of the valve assembly, the flow control member coupled to the linear actuator; 
 
 at least one sensor adapted to sense at least one environmental parameter; 
 a motor controller coupled to the motor and adapted to control axial movement of the flow control member in a continuously variable mode such that the flow control member linearly moves in the axial direction to a plurality of continuously variable positions between a fully closed position and a fully open position; and 
 wherein the motor controller is adapted to control the flow control member based at least in part on the at least one environmental parameter.