Apparatus and methods for utilizing a downhole deployment valve

A method of drilling a wellbore, comprising:

• assembling a downhole deployment valve (DDV) as part of a casing string, the DDV comprising:
• a housing defining a bore therethrough in communication with a bore of the casing string, and
• a valve member disposed in the housing and moveable between an open position and a closed position, wherein the valve member substantially seals a first portion of the casing bore from a second portion of the casing bore in the closed position;
• running the casing string and the DDV into the wellbore;
• running a drill string into the wellbore and through the casing string bore, the drill string comprising a drill bit disposed at an axial end thereof;
• automatically opening the valve member in response to the drill bit being proximate to the DDV.

A downhole deployment valve (DDV), comprising:

• a housing disposed in a wellbore and defining a bore adapted for passage of tools therethrough;
• a valve member disposed within the housing and movable between an open position and a closed position, wherein the valve member substantially seals a first portion of the bore from a second portion of the bore in the closed position;
• at least one sensor proximate the valve member for sensing a wellbore parameter, the at least one sensor comprising:
• a first pressure sensor in communication with the first bore portion,
• a second pressure sensor in communication with the second bore portion, and
• a tool sensor in communication with the first bore portion;
• and
• a monitoring and control unit (MCU) proximate the housing for automatically opening and closing the valve member based on signals from the at least one sensor,
• wherein the monitoring and control unit includes logic that only opens the valve member when signals from the pressure sensors indicate an equalized pressure differential and a signal from the tool sensor indicates the presence of a tool.

A downhole deployment valve (DDV), comprising:

• a housing disposed in a wellbore and defining a bore adapted for passage of tools therethrough;
• a sleeve axially movable in the housing;
• a flapper disposed within the housing and movable between an open position and a closed position, wherein the flapper substantially seals a first portion of the bore from a second portion of the bore in the closed position;
• at least one sensor proximate the valve member for sensing a wellbore parameter;
• a monitoring and control unit (MCU) proximate the housing for automatically opening and closing the valve member based on signals from the at least one sensor;
• and
• an actuator:
• in communication with the MCU,
• operably coupled to the valve member,
• comprising a motor, and
• operable to move the sleeve between the open position where the sleeve holds the flapper open and the closed position where the sleeve is moved away from the flapper.

A down hole deployment valve (DDV), comprising:

• a housing disposed in a wellbore and defining a bore adapted for passage of tools therethrough;
• a flapper disposed within the housing and movable between an open position and a closed position, wherein the flapper substantially seals a first portion of the bore from a second portion of the bore in the closed position;
• at least one sensor proximate the valve member for sensing a wellbore parameter;
• a monitoring and control unit (MCU) proximate the housing for automatically opening and closing the valve member based on signals from the at least one sensor;
• an actuator in communication with the MCU and operably coupled to the valve member, the actuator comprising a motor;
• a gear hinge rotationally coupled to the flapper, and
• a worm gear engaged with the gear hinge and operably coupled to the motor.

A downhole deployment valve (DDV), comprising:

• a housing disposed in a wellbore and defining a bore adapted for passage of tools therethrough;
• a valve member disposed within the housing and movable between an open position and a closed position, wherein the valve member substantially seals a first portion of the bore from a second portion of the bore in the closed position;
• a tool sensor in communication with the first bore portion, the tool sensor operable to detect a tool within the first bore portion;
• and
• a monitoring and control unit (MCU) in communication with the tool sensor and operable to automatically open the valve member in response to detection of the tool.

A method of drilling a wellbore, comprising:

• running a drill string into the wellbore and through a bore of a casing string, the casing string comprising a valve member moveable between an open position and a closed position, wherein the valve member substantially seals a first portion of the casing bore from a second portion of the casing bore in the closed position;
• automatically opening the valve member when the drill string is proximate to the valve member;
• and
• drilling the wellbore using the drill string.