Patent Grant
11851985
This disclosure relates generally to fluid flow control within a subterranean well and in particular, to subsurface safety valves located downhole within the subterranean well.
In hydrocarbon production, a wellbore is drilled into a hydrocarbon-rich geological formation. After the wellbore is partially or completely drilled, a completion system is installed to secure the wellbore in preparation for production or injection. The completion system can include casing cemented in the wellbore to help control the well and maintain well integrity, and a production tubing positioned within the casing through which oil, gas, or other produced fluids can flow from the producing formation to the surface.
A wireline-retrievable subsurface safety valve can be installed within a nipple assembly installed on the production tubing, some distance below the surface. The subsurface safety valve can be configured to close in the event of an emergency or other condition, thereby preventing flow of fluid though the production tubing.
Certain aspects of the subject matter herein can be implemented as a well system. The system includes a production tubing string configured to be disposed within a wellbore at least partially filled with a wellbore fluid and a nipple assembly connected to the production tubing string. The nipple assembly includes a main body with a central bore configured to receive a hydraulically operated wireline-retrievable subsurface safety valve (WLSSSV and a pressure chamber open to the central bore via a sidewall port. The pressure chamber is thereby configured to receive a volume of wellbore fluid from the central bore via the sidewall port as the nipple assembly is disposed within the wellbore prior to receipt of the WLSSSV in the central bore. The nipple assembly configured such that the sidewall port is in fluid communication with a pressure inlet port of the WLSSSV when the WLSSSV is received and releasably locked in the central bore. The nipple assembly also includes an electrically operated piston assembly comprising a motor operable to drive a piston in response to an electric signal, thereby decreasing the volume of the pressure chamber and generating an increase in hydraulic pressure of the wellbore fluid at the pressure inlet port of the WLSSSV when the WLSSSV is releasably locked in the central bore. The system also includes an electric cable configured to convey the electric signal from a surface location to the motor.
An aspect combinable with any of the other aspects can include the following features. The WLSSSV can be configured to, when releasably locked in the central bore, switch, in response to a force resulting from the increase in a hydraulic pressure at the pressure inlet port overcoming a biasing force of a spring connected to a closure member of the WLSSV, from a closed state in which the closure member blocks fluid flow through the production tubing string to an open state in which the closure member does not block fluid flow through the production tubing string. A movement of the piston in response to an electric signal change can increase the volume in the pressure chamber, thereby causing a decrease in hydraulic pressure at the inlet port such that the biasing force of the spring drives the closure member of the WLSSSV from the open state to the closed state.
An aspect combinable with any of the other aspects can include the following features. The electric signal change can be a cessation of an electric current.
An aspect combinable with any of the other aspects can include the following features. The electric signal can be a first control signal and the electric signal change can be a receipt by the motor of a second control signal transmitted to the nipple assembly.
An aspect combinable with any of the other aspects can include the following features. The piston can be a cylindrical piston.
An aspect combinable with any of the other aspects can include the following features. The piston can be or can include a bellows.
Certain aspects of the subject matter herein can be implemented as a nipple assembly configured to be connected to a production tubing string disposed in a wellbore at least partially filled with a wellbore fluid. The nipple assembly includes a main body with a central bore configured to receive a hydraulically operated wireline-retrievable subsurface safety valve (WLSSSV) and a pressure chamber open to the central bore via a sidewall port. The pressure chamber is thereby configured to receive a volume of wellbore fluid from the central bore via the sidewall port as the nipple assembly is disposed within the wellbore prior to receipt of the WLSSSV in the central bore. The nipple assembly is configured such that the sidewall port is in fluid communication with a pressure inlet port of the WLSSSV when the WLSSSV is received and releasably locked in the central bore. The nipple assembly further includes an electrically operated piston assembly comprising a motor operable to drive a piston in response to an electric signal, thereby decreasing the volume of the pressure chamber and generating an increase in hydraulic pressure of the wellbore fluid at the pressure inlet port of the WLSSSV when the WLSSSV is releasably locked in the central bore.
An aspect combinable with any of the other aspects can include the following features. The WLSSSV can be configured to, when releasably locked in the central bore, switch, in response to a force resulting from the increase in a hydraulic pressure at the pressure inlet port overcoming a biasing force of a spring connected to a closure member of the WLSSV, from a closed state in which the closure member blocks fluid flow through the production tubing string to an open state in which the closure member does not block fluid flow through the production tubing string. A movement of the piston in response to an electric signal change can increase the volume in the pressure chamber, thereby causing a decrease in hydraulic pressure at the inlet port such that the biasing force of the spring drives the closure member of the WLSSSV from the open state to the closed state.
An aspect combinable with any of the other aspects can include the following features. The electric signal can be a first control signal and the electric signal change can be a receipt by the motor of a second control signal transmitted to the nipple assembly.
An aspect combinable with any of the other aspects can include the following features. The nipple assembly can be configured to be attached to an electric cable configured to convey the electric signal to the nipple assembly from a surface location.
Certain aspects of the subject matter herein can be implemented as a method. The method includes connecting a nipple assembly to a production tubing string. The nipple assembly includes a main body with a central bore configured to receive a hydraulically operated wireline-retrievable subsurface safety valve (WLSSSV), a pressure chamber open to the central bore via a sidewall port, and an electrically operated piston assembly comprising a motor operable to drive a piston in response to an electric signal, thereby decreasing a volume of the pressure chamber. The method further includes disposing in a wellbore the production tubing string with the nipple assembly attached thereto, thereby permitting wellbore fluid to enter the pressure chamber via the sidewall port. The method further includes, after the production string and nipple assembly are disposed in the wellbore, lowering the WLSSSV downhole such that the WLSSSV is received and releasably locked in the central bore and the sidewall port is in fluid communication with a pressure inlet port of the WLSSSV. The method further includes, after the WLSSSV is received and releasably locked in the central bore, transmitting the electric signal to the motor, thereby generating an increase in hydraulic pressure of the wellbore fluid at the pressure inlet port of the WLSSSV.
An aspect combinable with any of the other aspects can include the following features. The WLSSSV can switch, in response to a force resulting from the increase in a hydraulic pressure at the pressure inlet port overcoming a biasing force of a spring connected to a closure member of the WLSSV, from a closed state in which the closure member blocks fluid flow through the production tubing string to an open state in which the closure member does not block fluid flow through the production tubing string. A movement of the piston can be in response to an electric signal change increases the volume in the pressure chamber, thereby causing a decrease in hydraulic pressure at the inlet port such that the biasing force of the spring drives the closure member of the WLSSSV from the open state to the closed state.
An aspect combinable with any of the other aspects can include the following features. The electric signal change can be a cessation of electric current to the motor.
An aspect combinable with any of the other aspects can include the following features. The electric signal can be a first control signal and the electric signal change is receipt by the motor of a second control signal. The method can further include transmitting the second control signal to the motor.
An aspect combinable with any of the other aspects can include the following features. The piston can be a cylindrical piston.
An aspect combinable with any of the other aspects can include the following features. The piston can be or can include a bellows.
An aspect combinable with any of the other aspects can include the following features. The electric signal can be transmitted to the motor via an electric cable configured to convey the electric signal from a surface location.
Wireline-retrievable subsurface safety valves (SSSVs) installed within nipple assemblies on production tubing can provide a fail-safe mechanism for preventing fluid flow through the production tubing in the event of an emergency or other condition. The opening and closing of the valves can be controlled by the application and removal of hydraulic pressure carried from a surface facility through a hydraulic control line strapped to the external surface of the production tubing to the nipple, which is then conveyed to the valve therein. However, such hydraulic control lines can be fragile and prone to corrosion or leakage, resulting in premature valve closure or other potentially hazardous or undesirable conditions, decreasing operational efficiency, and increasing well cost.
In accordance with an embodiment of the present disclosure, an improved system and method for deploying and operating a wireline-retrievable SSSV is disclosed. In some embodiments, the system can include a nipple assembly connected to a production tubing string. The nipple assembly can include a main body with a central bore there-though, the central bore fluidically connected to the production tubing string and configured to receive a wireline-retrievable subsurface safety valve (WLSSSV). The system can include an electric actuator assembly configured to open the WLSSSV by mechanically generating an increase in hydraulic pressure in response to an electric signal conveyed from a surface location to the nipple assembly. In some embodiments, the hydraulic pressure that operates the WLSSV is from wellbore fluid that fills a pressure chamber within the nipple assembly as the nipple assembly and production tubing string are lowered downhole. In such embodiments, in other words, it is the wellbore fluid itself that provides the hydraulic pressure, rather than a hydraulic fluid conveyed downhole (via, for example, a hydraulic line conduit). Thus, in some embodiments, the nipple assembly of the present disclosure can provide for operation of a standard hydraulically actuated WLSSSV without the necessity of conveying a dedicated hydraulic fluid downhole to the nipple assembly to operate the WLSSSV. The method and system of the present disclosure can provide a simple and more efficient system that can minimize the risk of hydraulic line corrosion or leakage, thus reducing costs, reducing environmental and safety risks, and increasing production. Furthermore, proper downhole operation of the SSSV can be monitored and problems more easily and efficiently identified using embedded pressure sensors within the actuator assembly.
Production tubing string 112 is positioned within casing string 110 and provides a passageway through which produced fluid 108 from production zone 114 of subterranean zone 104 can reach the surface 106. A production packer 116 anchors and isolates the bottom of the production tubing string. When disposed in wellbore 102, production tubing string 112 can be partially or completely filled with wellbore fluid.
The inner surface of casing string 110 and the outer surface 118 of production tubing 112 define (or partially define) the tubing-casing annulus (TCA) 120. Wellbore fluid 122 fills or substantially fills the volume of the TCA 120 and the inner bore of production string 110. Wellbore fluid 122 can be or can include produced fluids 108 (produced from subterranean zone 104, such as oil, gas, and/or water), drilling fluids, completion fluids, or other fluids, and can include or can be a mixture of diesel, brine, or other fluid or particulate component. Well system 100 further includes a wellhead assembly 130 which can include hangers for casing string 110 and production tubing string 112 and can include various valves, spools, pressure gauges and chokes to regulate and control production of produced fluids 108 from wellbore 102. Produced fluids 108 can be flowed from wellhead assembly 130 via a production line (not shown) or other conveyance towards pipelines or other surface treatment, gathering, or conveyance facilities.
Well system 100 also includes a landing nipple assembly 150 connected to production tubing string 112, configured to receive and hold a WLSSSV. As described in greater detail below, the WLSSSV can include a closure member (such as a flapper or ball valve) that permits fluid flow through the central bore when in an open position (thus permitting fluid to flow in an uphole direction through production tubing 112) and that prevents fluid flow through the central bore when in a closed state (thus preventing fluid flow in an uphole direction through production tubing 112). Landing nipple assembly 150 is described in greater detail in reference to
Nipple assembly 150 includes an actuator assembly 160 on or within landing nipple assembly 150 that includes electrical actuators configured to apply hydraulic pressure from wellbore fluids to operate the WLSSSV. Actuator assembly 160 is described in greater detail in reference to
In some embodiments, control module 164 is on a surface location at the wellsite proximate to wellhead assembly 130 and other wellsite equipment. In other embodiments, control module 164 can be remote from the wellsite and/or positioned at a subsurface or downhole location. In some embodiments, control module 164 can be part of and/or in communication with other remote or wellsite monitoring and control system such as a supervisory control and data acquisition (SCADA) system. In some embodiments, control module 164 is a portable system.
In some embodiments, control module 164 can be (or can include) a computer system that comprises one or more processors, and a computer-readable medium (for example, a non-transitory computer-readable medium) storing computer instructions executable by the one or more processors to perform operations that can include, for example, controlling actuator 160, monitoring hydraulic pressure applied to the WLSSSV, and others.
It will be understood that actuator assembly 160 can be disposed on main body 200, which can include embodiments wherein actuator assembly 160 is disposed on an outer surface of nipple assembly 150 such that actuator assembly 160 protrudes from nipple assembly 150 into TCA 120 (as shown in
Referring to
In the illustrated embodiment, pressure chamber 318a is open to the central bore 202 via sidewall port 210 (see
In the illustrated embodiment, piston 320a is a cylindrical piston. In response to an electric signal from electric cable 162, as shown in
Because in some embodiments, as described above, the nipple assembly is configured such that pressure chamber 318a fills with wellbore fluid as the nipple assembly and production tubing string are lowered downhole, it is in such embodiments it is the wellbore fluid itself that provides the hydraulic pressure at the pressure inlet port of the WLSSSV. Thus, in some embodiments, the nipple assembly of the present disclosure can provide for operation of a standard hydraulically actuated WLSSSV without the necessity of conveying (whether via a hydraulic fluid conduit or within a volume carried within the nipple assembly) a dedicated hydraulic fluid downhole to the nipple assembly to operate the WLSSSV.
In some embodiments, a change in the electric signal can trigger or permit piston 320a to move in a direction that increases the volume in pressure chamber 318a and causing a decrease in hydraulic pressure at the inlet port, thus (for example) allowing the WLSSSV to switch back from the open state to the closed state. Such switch from the open state to the closed state can be, for example, movement of the closure member of the WLSSSV driven at least in part by the biasing force of the spring. In some embodiments, the electric signal change can be in the form of a partial or complete cessation of electric current, caused by (for example) a well control event or other trigger acting on (or damaging or destroying) the surface control module, such that the nipple assembly and WLSSSV are part of a “fail-safe” system, closing the production tubing string against fluid flow in the event of a catastrophic event or other circumstance in which well closure is desirable. In some embodiments, the electric signal change can be a second electric signal sent to the motor triggering the return piston movement (i.e., a second signal sent at an appropriate time after the (first) initial signal that opens the valve, when closure of the valve is necessary or desirable).
Spring 328a is connected to piston 320a and is pulled to an extended position as motor 322a drives piston 320a. The extension of spring 328a provides a biasing force such that, if the driving force from motor 322a is reduced or is eliminated (for example, in response to the electric signal change described above), the biasing force of spring 328a pulls piston 320a back to the starting position, thus reducing or eliminating the hydraulic pressure applied through pressure outlet 306a.
Actuator assembly 160a further includes a sensor module 340a including a pressure sensor 342a whereby pressure in pressure chamber 318a can be monitored to ensure proper operation of actuator 160a and the WLSSSV system. (for example, by indicating to the operator whether sufficient pressure is being generated by actuator assembly 160a to open the WLSSSV, and/or whether a decrease in pressure is sufficient to cause closure of the WLSSSV). In some embodiments, actuator assembly can also include other suitable sensors such as temperature sensor 344a.
In response to an electric signal from cable 162, as shown in
Similar to actuator assembly 160a of
As step 406, after the production string and nipple assembly are disposed in the wellbore, a WLSSSV is lowered downhole such that the WLSSSV is received and releasably locked in the central bore and the sidewall port is in fluid communication with a pressure inlet port of the WLSSSV.
At step 408, the operator transmits an electric signal to actuator assembly 160 that triggers the application of hydraulic pressure of the wellbore from the actuator assembly into the pressure inlet port of the WLSSSV, as described above and as illustrated in
At step 410, the operator can use pressure readings from the pressure sensor within the actuator assembly to confirm whether the pressure applied to the WLSSSV is being maintained, thus confirming proper valve opening. If at step 410 the sensor readings indicate that pressure is not being maintained as expected, then at step 412 troubleshooting operations can commence. If at step 414 the troubleshooting operations are successful, then the method can return to step 408 for additional pressure testing. If at step 414 the troubleshooting is not successful, then the WLSSSV can at step 416 be pulled from the nipple and at step 418 repaired or replaced, thus returning to step 406.
Returning to step 410, if the pressure readings are maintained indicating proper valve opening, then, at step 420, production fluid (such as water, oil, and/or gas) can flow through the production tubing. The valve can remain open and production can continue so long as no well control event or other event or circumstance in which valve closure is necessary or desired occurs (shown as the return arrow at step 442).
If at step 442 a well control event or other event or circumstance in which valve closure is necessary or desired occurs, then the method proceeds to step 424 in which the electric an electric signal change (such as a cessation of an electric current or a control signal) initiates a decrease in the pressure applied to the WLSSSV, triggering its closure. Such closure is illustrated in
The term “uphole” as used herein means in the direction along the production tubing or the wellbore from its distal end towards the surface, and “downhole” as used herein means the direction along a tubing string or the wellbore from the surface towards its distal end. A downhole location means a location along the tubing string or wellbore downhole of the surface.
A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. For example, example operations, methods, or processes described herein may include more steps or fewer steps than those described. Further, the steps in such example operations, methods, or processes may be performed in different successions than that described or illustrated in the figures. Accordingly, other implementations are within the scope of the following claims.
| Number | Name | Date | Kind |
|---|---|---|---|
| 6102828 | MacKenzie | Aug 2000 | A |
| 6619388 | Dietz | Sep 2003 | B2 |
| 6719057 | Johansen | Apr 2004 | B2 |
| 7967074 | Lake | Jun 2011 | B2 |
| Number | Date | Country |
|---|---|---|
| 2244942 | Feb 2005 | CA |
