Patent Grant
9127526
Not applicable.
Not applicable.
Not applicable.
Wellbores are sometimes drilled into subterranean formations that contain hydrocarbons to allow for the recovery of the hydrocarbons. Once the wellbore has been drilled, various servicing and/or completion operations may be performed to configure the wellbore for the production of the hydrocarbons. Various wellbore servicing equipment components may be used during the servicing and/or completion operations, for example, to perform a servicing operation, completion operation, or combinations thereof. Many servicing and/or completion operations utilize relatively high pressures and/or relatively high fluid velocities, thereby requiring that one or more of such wellbore servicing equipment components be subjected to such high fluid pressures and/or high fluid velocities, for example, during the performance of such servicing or completion operations. As such, a sudden flow stoppage or blockage, whether intended or unintended, may result in an increase in pressure (e.g., an “over-pressuring” situation) which may be experienced by the equipment and may damage and/or render unsuitable for further use (e.g., unsafe) any such wellbore servicing equipment components (e.g., fluid conduits or “iron,” pumps, wellheads, manifolds, or any other related equipment). Moreover, such over-pressuring situations may pose substantial safety risks to personnel. As such, there is a need for dealing with such over-pressuring situations.
Disclosed herein is a wellbore servicing system, the system comprising at least one wellbore servicing equipment component, wherein a flow path extends from the wellbore servicing system component into a wellbore penetrating a subterranean formation, and a pressure control system in fluid communication with the flow path, wherein the pressure control system comprises a relief path configured to communicate fluid through the pressure control system, a pressure control device configured to permit fluid communication between the flow path and the relief path upon experiencing a pressure and/or a differential pressure of at least a predetermined pressure threshold, and a first valve disposed within the relief path, wherein the first valve is configured to actuate from an open configuration to a closed configuration.
Also disclosed herein is a method of servicing a wellbore, the method comprising providing a flow path between a wellbore servicing system and a wellbore penetrating a subterranean formation, wherein a pressure control system comprising a pressure control device and a relief path is in fluid communication with the flow path, wherein the pressure control system is configured to control fluid communication between the flow path and the relief path, communicating a fluid via the flow path, and upon experiencing a pressure and/or a differential pressure of at least a predetermined pressure threshold within the flow path, allowing fluid to be communicated from the flow path through the relief path, wherein the pressure control device permits fluid communication from the flow path to the relief path within about 0.10 seconds of experiencing the pressure and/or the differential pressure of at least the predetermined pressure threshold.
These and other features will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings and claims.
For a more complete understanding of the present disclosure and the advantages thereof, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description:
In the drawings and description that follow, like parts are typically marked throughout the specification and drawings with the same reference numerals, respectively. The drawing figures are not necessarily to scale. Certain features of the invention may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness.
Unless otherwise specified, any use of any form of the terms “connect,” “engage,” “couple,” “attach,” or any other term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ”. Reference to up or down will be made for purposes of description with “up,” “upper,” or “upward,” meaning toward the surface of the wellbore and with “down,” “lower,” or “downward,” meaning toward the terminal end of the well, regardless of the wellbore orientation. Reference to in or out will be made for purposes of description with “in,” “inner,” or “inward” meaning toward the center or central axis of the wellbore, and with “out,” “outer,” or “outward” meaning toward the wellbore tubular and/or wall of the wellbore. Reference to “longitudinal,” “longitudinally,” or “axially” means a direction substantially aligned with the main axis of the wellbore and/or wellbore tubular. Reference to “radial” or “radially” means a direction substantially aligned with a line from the main axis of the wellbore, a wellbore tubular, and/or an element generally outward. The various characteristics mentioned above, as well as other features and characteristics described in more detail below, will be readily apparent to those skilled in the art with the aid of this disclosure upon reading the following detailed description of the embodiments, and by referring to the accompanying drawings.
Disclosed herein are embodiments of devices, systems, and methods utilized to quickly and efficiently dissipate excessive pressures within a wellbore servicing system, for example, which may occur during the performance of a wellbore servicing operation (e.g., an over-pressuring situation). In an embodiment, the devices, systems, and/or methods disclosed herein may be effective to protect one or more wellbore servicing equipment components (for example, surface equipment, such as pumps, manifolds, or mixers; equipment associated with a wellbore, such as wellheads, work strings, casing strings, or production strings; various downhole equipment; flow lines or conduits; or combinations thereof) from damage that may result upon exposure to excessive pressures (e.g., an over-pressuring situation).
The wellbore 120 may extend substantially vertically away from the earth's surface 160 over a vertical wellbore portion, or may deviate at any angle from the earth's surface 160 over a deviated or horizontal wellbore portion. Alternatively, portions or substantially all of the wellbore 120 may be vertical, deviated, horizontal, and/or curved. In some instances, a portion of the pipe string 140 may be secured into position within the wellbore 120 in a conventional manner using cement 170; alternatively, the pipe string 140 may be partially cemented in the wellbore 120; alternatively, the pipe string 140 may be uncemented in the wellbore 120; alternatively, all or a portion of the pipe string 140 may be secured using one or more packers (e.g. mechanical or swellable packers, such as SWELLPACKER isolation systems, commercially available from Halliburton Energy Services). In an embodiment, the pipe string 140 may comprise two or more concentrically positioned strings of pipe (e.g., a first pipe string such as jointed pipe or coiled tubing may be positioned within a second pipe string such as casing cemented within the wellbore). It is noted that although one or more of the figures may exemplify a given operating environment, the principles of the devices, systems, and methods disclosed may be similarly applicable in other operational environments, such as offshore and/or subsea wellbore applications.
In the embodiment of
In an embodiment, the wellbore servicing system 100 is generally configured to communicate (e.g., introduce) a fluid (e.g., a wellbore servicing fluid) into wellbore 120, for example, at a rate and pressure suitable for the performance of a desired wellbore servicing operation. In an embodiment, the wellbore servicing system 100 comprises at least one wellbore servicing system equipment component. Turning to
Returning to
In an embodiment, for example, in the embodiment of
In an embodiment, for example, as illustrated in
In such an embodiment, the relief valve 124 may be configured to relieve pressure within the flow path 195 when fluid pressure increases to or beyond a threshold pressure (e.g., when the relief valve experiences a given activation or “pop-off” pressure). For example, the relief valve may be configured such that pressure in excess of such a threshold pressure is allowed to flow out of the flow path via the relief valve. The relief valve 124 may comprise any suitable type and/or configuration thereof, examples of which include, but are not limited to, a pop-off valve and a bypass valve. As will be appreciated by one of skill in the art upon viewing this disclosure, relief valves 124 generally comprise mechanical devices.
In an embodiment, the check valve 126 may be configured to allow fluid communication therethrough in a first direction and to prohibit fluid movement in a second direction. For example, in the embodiment of
In an alternative embodiment, the wellbore servicing system 100 may be fluidicly connected to the wellhead 180 without a check valve (e.g., check valve 126) or a relief valve (e.g., relief valve 124). For example, in such an alternative embodiment, the check valve 126 and the relief valve 124 may be absent from the flow path 195 between the wellbore servicing system 100 and the wellhead 180.
Referring again to
In an alternative embodiment, the pressure control system 108 may be in fluid communication with the flow path 195 at a suitable alternative location. For example, in an embodiment, the pressure control system 108 may be in fluid communication with the flow path 195 at a position (e.g., denoted “B” in
Also, while the embodiment of
In an embodiment, the pressure control system 108 may be generally configured to quickly relieve pressure within the flow path 195 when fluid pressure increases to at least a pressure threshold (e.g., when the pressure control system 108 or a component thereof experiences a pressure of at least a predetermined activation threshold). In an embodiment, the pressure control system 108 may also be configured to retain control of the wellbore and associated servicing equipment, for example, to control the escape of fluids from the flow path 195. For example, in an embodiment, the pressure control system 108 may be configured so as to allow pressure (e.g., fluid, such as a wellbore servicing fluid and/or produced fluids such as hydrocarbons) to be discharged therefrom and, following the pressure discharge, to recover control of the wellbore and associated equipment such that the wellbore and associated equipment (e.g., flow path 195) does not remain open for more than a predetermined duration. In an embodiment as will be disclosed herein, the pressure control system 108 may be effective to protect the integrity of the flow path 195 (e.g., including one or more of the components of the wellbore servicing system 100, the wellhead 180, the pipe string 140, the wellbore servicing apparatus 150, or combinations thereof), for example, by ensuring that no component of the flow path 195 experiences a pressure in excess of the pressure threshold. In an embodiment, the pressure threshold (e.g., above which, the pressure control system 108 will discharge any excess pressure) may be selected by one of skill in the art upon viewing this disclosure but, generally, is a pressure less than the maximum pressure for which one or more of the components along the flow path is rated (e.g., the maximum pressure for which a tubular or iron is rated). For example, in an embodiment, the pressure threshold may be about 1,000 psi., alternatively, about 2,500 psi., alternatively, about 5,000 psi., alternatively, about 7,500 psi., alternatively, about 10,000 psi, alternatively, about 15,000 psi., alternatively, about 20,000 psi., alternatively, about 25,000 psi, alternatively, about 30,000 psi., alternatively, about 35,000 psi., alternatively, about 40,000 psi., alternatively, about 45,000 psi., alternatively, about 50,000 psi.
For example, in an embodiment, the pressure control system 108 may relieve (e.g., discharge) excess pressures within the flow path 195, thereby safeguarding (e.g., prohibiting) one or more components of the wellbore servicing system 100 (or any other component in fluid communication such as shown in
As will be disclosed herein, the configuration of the pressure control system 108 may vary depending upon factors including, but not limited to, the intended servicing operation being performed, the intended flow-rate of fluids within the flow path 195, the intended pressures within the flow path 195, and the position at which the pressure control system 108 is incorporated within the flow path 195.
Referring to
In an embodiment, the pressure control device 310 may be generally configured to permit fluid communication between the flow path 195 and a relief path 196 when the differential pressure across the pressure control device 310 reaches a predetermined threshold. For example, in an embodiment, the pressure control device 310 may permit fluid communication between the flow path 195 and the relief path 196 when the differential pressure across the pressure control device 310 increases to at least the pressure threshold. In an embodiment, the change in differential pressure across the pressure control device 310 may be associated with (e.g., substantially with) a change in pressure within the flow path 195. For example, the pressure within the relief flow path 196 may be relatively constant and the pressure within the flow path 195 may vary (e.g., during the movement of fluids therethrough), so that an increase in the differential pressure across the pressure control device 310 may be substantially the result of an increase in pressure within the flow path 195. For example, the pressure within the relief path may be about atmospheric/ambient pressure. As such, the differential pressure across the pressure control device may be about equal to (e.g., approximately) the pressure threshold. For example, in an embodiment, the differential in pressure at which the pressure control device is configured to allow fluid communication to the relief flow path 196 may be about 1,000 psi., alternatively, about 2,500 psi., alternatively, about 5,000 psi., alternatively, about 7,500 psi., alternatively, about 10,000 psi, alternatively, about 15,000 psi., alternatively, about 20,000 psi., alternatively, about 25,000 psi, alternatively, about 30,000 psi., alternatively, about 35,000 psi., alternatively, about 40,000 psi., alternatively, about 45,000 psi., alternatively, about 50,000 psi. In an alternative embodiment, the pressure control device may be configured to permit fluid communication between the flow path 195 and a relief path 196 when the absolute pressure within the flow path 195 reaches the pressure threshold.
In an embodiment, the pressure control device 310 be actuated (e.g., so as to allow fluid communication) upon experiencing a pressure differential across the pressure control device 310 of at least the pressure threshold. In an embodiment, the pressure control device 310 may be configured so as to initially seal and/or separate the flow path 195 from the relief path 196. In an embodiment, the pressure control device 310 may be characterized as a fast-acting device. For example, such a fast-acting device may refer to a device that will be actuated (e.g., so as to allow fluid communication) instantaneously, alternatively, substantially instantaneously, upon experiencing the pressure threshold. For example, in an embodiment the pressure control device 310 (e.g., a fast-acting device) may be actuated (e.g., so as to communicate fluid) in less than or equal to about 0.01 seconds from experiencing the pressure threshold, alternatively, within about 0.02 secs., alternatively, about 0.03 secs., alternatively, about 0.04 secs., alternatively, about 0.05 secs., alternatively, about 0.06 secs., alternatively, about 0.07 secs., alternatively, about 0.08 secs., alternatively, about 0.09 secs., alternatively, about 0.10 secs.
In an embodiment, the pressure control device 310 may comprise a burst disc or rupture disc. For example, in such an embodiment, the pressure control device 310 (i.e., a burst disc or rupture disc) may be configured to break, puncture, perforate, shear, fragment, disintegrate, explode, implode, tear or combinations thereof upon experiencing a pressure or pressure differential of at least the pressure threshold. In such an embodiment, upon actuation (e.g., breaking, puncturing, perforating, shearing, fragmenting, disintegrating, exploding, imploding, tearing, or combinations thereof), the pressure control device 310 may cease to block fluid movement from the flow path 195 to the relief path 196. For example, the pressure control device 310 (i.e., the burst disc or rupture disc) may be initially configured to block fluid movement via the relief path 196. Upon actuation, the pressure control device may break or fragment into small pieces which may pass through and out of the relief path 196, thereby no longer blocking the relief path 196 and permitting fluid communication between the flow path 195 and the relief path 196. In such an embodiment, the burst or rupture disc may be formed from a suitable material. Examples of such materials include, but are not limited to, ceramics, glass, graphite, plastics, metals and/or alloys (such as carbon steel, stainless steel, or Hastelloy®), deformable materials such as rubber, or combinations thereof.
In an additional or alternative embodiment, the pressure control device 310 may comprise a cap releasably engaged within the relief path 196. For example, the cap may be retained within the relief path 196 by a circumferential lip disposed over a rim. Alternatively, the cap may be retained within the relief path 196 by engaging a groove or shoulder within the relief path 196. In such an embodiment, the cap may be configured to release the relief path 196, for example, by bending, expanding, contracting, warping, or otherwise deforming, upon experiencing a pressure or pressure differential of at least the pressure threshold. For example, the pressure control device 310 (i.e., cap) may initially block fluid communication via the relief path 196, for example, by engaging the relief path 196. Upon, actuating (e.g., breaking, bending, expanding, contracting, warping, or deforming) the pressure control device 310 (i.e., the cap) may disengage the relief path (e.g., a rim, shoulder, or groove), thereby no longer blocking fluid communication via the relief path 196 and permitting fluid communication between the flow path 195 and the relief path 196. In such an embodiment, the cap may be formed from a suitable material. Examples of such materials include, but are not limited to, metals and/or metal alloys, polymeric materials, such as various plastics, natural or synthetic rubbers, ceramics, or combinations thereof.
In another additional or alternative embodiment, the pressure control device 310 may comprise a hinged assembly, for example, a flapper assembly. For example, in such an embodiment, the pressure control device may comprise a plate (e.g., the flapper) pivotably attached (e.g., via one or more arm and hinge mechanisms) within the relief path 196 such that the plate (e.g., flapper) may block fluid communication from the flow path 195 to the relief path 196 or such that the plate may pivot substantially out of the relief path 196, for example, so as to not block fluid communication from the flow path 195 to the relief path 196. For example, the plate may initially block fluid communication between the flow path 195 and the relief path 196. In an embodiment, the plate may be initially retained in the initial position by one or more frangible members, such as shear pins. In such an embodiment, the pressure control device 310 may be configured such that, upon experiencing a pressure or pressure differential of at least the pressure threshold, the frangible member(s) is sheared and/or broken, thereby allowing the plate (e.g., the flapper) to rotate out of the relief path 196. Upon actuating, the plate may be configured so as to rotate out of the relief path 196, thereby no longer blocking fluid communication via the relief path 196 and permitting fluid communication between the flow path 195 and the relief path 196.
Additionally or alternatively, in an embodiment, the pressure control device 310 may comprise a relief valve, for example, as similarly disclosed with reference to relief valve 124 disclosed herein. For example, in such an embodiment, the pressure control device may comprise a spring-loaded, hydraulically-loaded, or pneumatically-loaded relief valve, such as a poppet type valve.
In an embodiment, the pressure control device 310 may further comprise one or more sensors, electronic circuitry, and/or actuators, generally configured to monitor a parameter (e.g., pressure) and to actuate the pressure control device 310 in response to sensing a pressure within the flow path 195 of at least the pressure threshold. In such an embodiment, the sensor, electronic circuitry, and/or actuators may comprise a single integrated component, alternatively, the sensor, electronic circuitry, and/or actuators may comprise two or more distributed components. In such an embodiment, when actuated, the actuator may be configured to cause actuation of another component of the pressure control device (e.g., such as a burst or rupture disc, a cap, and/or a flapper plate), as disclosed herein. For example, upon sensing the pressure threshold, the actuator may cause a burst or rupture disc to break, or a shear pin to break.
In an embodiment, the sensor may comprise any suitable sensor (e.g., a transducer) capable of detecting a predetermined parameter and communicating with electronic circuitry to command the pressure control device 310 to actuate. For example, in an embodiment, the sensor may comprise a pressure sensor capable of detecting when the differential pressure across the pressure control device 310 and/or the pressure within the flow path 195 reaches the pressure threshold and transmitting a signal (e.g., via an electrical current) to electronic circuitry to actuate the pressure control device 310. In an embodiment, the electronic circuitry may be configured to receive a signal from the sensor, for example, so as to determine if the sensor has experienced a predetermined pressure, and, upon a determination that such a pressure has been experienced, to output an actuating signal to the pressure control device 310 and/or to an actuator. In an embodiment, the electronic circuitry may comprise any suitable configuration, for example, comprising one or more printed circuit boards, one or more integrated circuits, one or more discrete circuit components, one or more microprocessors, one or more microcontrollers, one or more wires, an electromechanical interface, a power supply and/or any combination thereof. In an embodiment, the actuator may comprise any suitable type or configuration. For example, the actuator may comprise a punch configured so as, upon actuation, to rupture a burst disc. For example, the actuator may be driven by a magnet or an explosive change.
In an embodiment, the first valve 314 is disposed along and/or within the relief path 196 and is generally configured to selectively block fluid communication through the relief path 196, for example, to actuate from an open configuration to a closed configuration. For example, in an embodiment, the first valve 314 may be configured to block fluid communication via (e.g., to seal), alternatively, to substantially block fluid communication via, the relief path 196. For example, the first valve may be configured to prevent and/or stop fluid communication through the relief path 196, for example, by obstructing all or substantially all of the cross-section of the relief path 196. In an embodiment, for example, as shown in
In an embodiment, the first valve 314 may comprise a suitable type and/or configuration of valve. Examples of suitable types and configurations of such a valve include, but are not limited to, a gate valve, a ball valve, a globe valve, a choke valve, a butterfly valve, a pinch valve, a disc valve, the like, or combinations thereof. One of ordinary skill in the art, upon viewing this disclosure, will appreciate that various types and configurations of valves may be used as the first valve 314.
In an embodiment, the first valve 314 may be configured to actuate hydraulically, pneumatically, electrically (e.g., via the operation of a solenoid and/or a motor), manually, or combinations thereof. In an embodiment, and as will be disclosed herein, the first valve 314 may initially be provided in an open configuration (e.g., such that fluid communication is allowed therethrough).
In an embodiment, the first valve 314 may be configured to actuate upon the communication of fluid between the flow path 195 and the relief path 196, for example, upon actuation of the pressure control device 310, as disclosed herein. For example, in an embodiment, a sensor 322 exposed to the relief path 196 may be configured to sense one or more parameters, such as the presence of fluid, the presence of fluid flow, pressure, or combinations thereof, and may output a signal causing the first valve 314 to actuate (e.g., to transition from open to closed). For example, the sensor 322 may be linked (e.g., via a wired or wireless connection) to a control system 324 which may be configured to control the first valve 314. For example, the sensor 322 may comprise a flow switch, a pressure switch, or the like. In an alternative embodiment, the sensor 322 may output a signal (e.g., an alarm, a buzzer, or a siren) to alert an operator as to the communication of fluid via the relief path 196, for example, such that the operator may manually operate (e.g., close) the first valve 314. In another alternative embodiment, a sensor 322 may be absent and the first valve 314 may be manually actuated, for example, by rotating a wheel to actuate the first valve 314.
In an embodiment, the first valve 314 may be configured to actuate (e.g., to transition from the open configuration to the closed configuration) at a controlled rate. In such an embodiment, the first valve 314 may be configured to actuate (e.g., from fully open to fully closed) over a suitable duration, for example, a duration of from about 1 second to about 120 secs, alternatively, from about 2 secs. to about 90 secs., alternatively, from about 4 secs. to about 60 secs., alternatively, from about 5 secs. to about 45 secs. beginning approximately concurrent with fluid communication through the relief path (e.g., upon actuating of the pressure control device 310).
Not intending to be bound by theory, the rate at which the first valve 314 is configured to close may be dependent upon one or more factors including, but not limited to, length of the flow path (e.g., the distance from the pressure control system 108 into the wellbore 120). As will be disclosed herein, a sudden flow stoppage (e.g., at the wellhead, within the wellbore, or at any other location along the flow path 195) may result in a pressure-wave (a relatively high-pressure wave traveling within the flow path 195). For example, closing the first valve 314 too quickly could result in a water hammer pressure wave due to the sudden stoppage of fluid moving through the relief path 196. Again not intending to be bound by theory, in an embodiment, the greater the length of the flow path 195, the slower the first valve 314 may be configured to actuate, for example, so as to allow more time for the dissipation of such a pressure wave. For example, actuating (e.g., closing) the first valve 314 before such a pressure wave could be dissipated could cause the pressure wave to be trapped within the flow path 195, thereby causing damage to one or more components thereof.
Continuing to refer to
In an embodiment, the flow restrictor 312 may comprise a choke, for example, a non-regulating choke or a fixed choke. For example, the flow restrictor 312 may comprise a diameter (e.g., a cross-sectional flow area) that generally decreases (e.g., a throat) in the direction of fluid flow (e.g., decreases moving generally downstream). In an embodiment, the flow restrictor 312 may decrease the pressure of a fluid moving within the relief path 196 from the pressure control device 310 to the first valve 314. In an additional or alternative embodiment, the flow restrictor 312 may comprise a fluidic diode. In such an embodiment, the fluidic diode may operate similarly to a choke. Not intending to be bound by theory, the flow restrictor 312 may decrease the pressure of a fluid moving via the relief path 196 such that the pressure of the fluid is substantially decreased prior to reaching the first valve 314, for example, such that the moving fluid does not damage (e.g., abrade) the first valve 314 as the first valve 314 closes, for example, as will be disclosed herein. For example, in an embodiment the flow restrictor 312 may be configured such that the pressure of a fluid moving via the relief path 196 at a location downstream from the flow restrictor 312 is less than about 95% of the volume/amount of the pressure of the fluid at a location upstream from the flow restrictor 312, alternatively, less than about 90%, alternatively, less than about 85%, alternatively, less than about 80%, alternatively, less than about 75%.
Continuing to refer to
In an embodiment, the second valve 316 may be configured such that the second valve 316 is not fully actuated (e.g., does not reach the closed position) until after the first valve 314 has been fully actuated (e.g., until after the first valve 314 has been fully closed). For example, in an embodiment, the second valve 316 may be configured to actuate (e.g., to transition from open to closed) at a different rate relative to the first valve 314, to begin actuating later than the first valve 314, or combinations thereof. For example, the second valve 316 may be configured to actuate at a slower rate relative to the first valve 314. In such an embodiment, even if the first valve 314 and the second valve 316 are actuated (e.g., begin to transition from open to closed) substantially simultaneously, the first valve 314 may be fully actuated (e.g., closed) prior to the second valve 316 being fully actuated (e.g., closed). In such an embodiment, the second valve 316 may be configured to actuate (e.g., from fully open to fully closed) over a suitable duration, for example, a duration of from about 1 second to about 240 secs., alternatively, from about 2 secs. to about 120 secs., alternatively, from about 4 secs. to about 90 secs., alternatively, from about 5 secs. to about 60 secs.
Additionally or alternatively, the second valve 316 may be configured to be actuated (e.g., begin to transition from open to closed) after the first valve 314 is at least partially actuated (e.g., closed), for example, after the first valve 314 is at least about ¼ actuated, alternatively, at least about ½ actuated, alternatively, at least about ¾ actuated, alternatively, about fully actuated. Additionally or alternatively, the second valve 316 may be configured to actuate upon receipt of a signal, for example, from the sensor 322 (e.g., via the operation of the control system 324), for example, as similarly disclosed herein with respect to the first valve 314. In such an embodiment, the second valve may be configured to begin actuation after a suitable delay period, for example, a delay of about 1 sec., alternatively, about 2 secs., alternatively, about 3 secs., alternatively, about 4 secs., alternatively, about 5 secs., alternatively, about 10 secs., alternatively, about 15 secs., alternatively, about 20 secs., alternatively, about 30 secs.
Continuing to refer to
In an embodiment, any fluid(s) may initially be absent, or substantially absent, from the pressure control apparatus 108 (e.g., the relief path 196 and the relief space 131). For example, the relief path 196 and relief space 131 may initially comprise a dry or void (of fluid) space. In an embodiment, at least a portion of the relief path 196 may have a generally downward slope, for example, toward the relief space 131, such that fluid may readily flow into the relief space with the assistance of gravity.
Referring to
As noted above, in the embodiment of
Referring to
Referring again to
In an embodiment, for example, as illustrated in the embodiment of
In an embodiment, the pressure control system 108 comprises a second valve 316. In such an embodiment, the second valve 316 may generally comprise a second movable sleeve, for example, as disclosed herein with reference to the first valve 314. For example, the second sleeve may be disposed over the first sleeve; alternatively, within the first sleeve. Alternatively one of the first or second sleeves may be disposed within the pipe string 140 and the other disposed around the pipe string 140. Various suitable additional and/or alternative sleeve configurations may be appreciated by one of skill in the art upon viewing this application.
In an embodiment, a pressure control system, such as the pressure control system 108 disclosed herein, may be employed in the performance of a wellbore servicing operation. In such an embodiment, a wellbore servicing method may generally comprise the steps of providing a wellbore servicing system (for example, the wellbore servicing system 100 disclosed herein), providing a flow path (for example, flow path 195, disclosed herein) comprising a pressure control system (e.g., the pressure control system 108 disclosed herein), and introducing a fluid into the wellbore 120 via the flow path. In an embodiment, the wellbore servicing method may further comprise allowing a pressure of at least a pressure threshold to dissipate from the flow path, and reestablishing control of the flow path.
In an embodiment, providing the wellbore servicing system may comprise transporting one or more wellbore servicing equipment components, for example, as disclosed herein with respect to
In an embodiment, providing a flow path (for example, flow path 195 disclosed herein) comprising a pressure control system 108 may comprise assembling the wellbore servicing system 100, coupling the wellbore servicing system 100 to the wellbore 120, providing a pipe string within the wellbore, or combinations thereof. For example, in an embodiment, one or more wellbore servicing equipment components may be assembled (e.g., fluidicly coupled) so as to form the wellbore servicing system 100, for example, as illustrated in
In an embodiment, providing the flow path 195 comprising a pressure control system 108 may also comprise fluidicly coupling the pressure control system 108 to the flow path, incorporating the pressure control system 108 within the flow path 195, or combinations thereof. For example, in an embodiment, the pressure control system 108 may be fluidicly connected, for example, as disclosed with respect to
In an embodiment, (for example, when the flow path 195 has been provided) a fluid may be introduced into the wellbore via the flow path 195. In an embodiment, the fluid may comprise a wellbore servicing fluid. Examples of a suitable wellbore servicing fluid include, but are not limited to, a fracturing fluid, a perforating or hydrajetting fluid, an acidizing fluid, the like, or combinations thereof. Additionally, in an embodiment, the wellbore servicing fluid may comprise a composite fluid, for example, having two or more fluid components which may be communicated into the wellbore separately (e.g., via two or more different flow paths). The wellbore servicing fluid may be communicated at a suitable rate and pressure for a suitable duration. For example, the wellbore servicing fluid may be communicated at a rate and/or pressure sufficient to initiate or extend a fluid pathway (e.g., a perforation or fracture) within the subterranean formation 130 and/or a zone thereof.
In an embodiment, for example, as shown in
In an embodiment, the wellbore servicing method further comprises allowing a pressure of at least the pressure threshold to dissipate from the flow path 195. For example, while undesirable, it is possible that the pressure (e.g., fluid pressure) within some portion of the flow path 195 may reach and/or exceed a desired pressure threshold, for example, as disclosed herein, for example, an “over-pressuring” situation. Such an over-pressuring situation may result for one or more of many reasons, for example, failure or malfunction of wellbore servicing equipment, such as a pump failing to disengage or a valve failing to open or close, an unexpected obstruction within the flow path 195, unexpected pressures from the formation encountered during the performance of a servicing operation, or various other reasons. Regardless of the reason for such an over-pressuring situation, upon the occurrence of such an event, the pressure within the flow path 195 may rise very quickly. For example, because the high pressure and high flow-rate fluids utilized during the performance of a wellbore servicing operation, the possibility exists that the pressures within the flow path 195 may increase very rapidly. For example, in an embodiment, upon the occurrence of such an event, the pressure within the flow path may increase at a rate of greater than about 500 psi/sec., alternatively, greater than about 1,000 psi/sec., alternatively, greater than about 2,000 psi/sec., alternatively, greater than about 4,000 psi/sec., alternatively, greater than about 6,000 psi/sec., alternatively, greater than about 8,000 psi/sec., alternatively, greater than about 10,000 psi/sec, for example, as may vary dependent upon one or more of volume, rigidity of constraints and fluid compressibility, Bulk Modulus, or combinations thereof.
In an embodiment, upon experiencing a pressure or pressure differential, as disclosed herein, of at least the pressure threshold, the pressure control system 108 may be configured to allow at least a portion of the pressure within the flow path 195 to be released. For example, upon experiencing a pressure or pressure differential of at least the pressure threshold, the pressure control device 310 may be configured to allow fluid to be communicated out of the flow path 195 and via the relief path 196. For example, where the pressure control device 310 comprises a burst (or rupture) disc, the burst disc may break, shatter, burst, separate, or otherwise allow fluid to be communicated therethrough (e.g., into the relief path 196). Not intending to be bound by theory, because the pressure control device 310 may comprise a fast-acting device, the pressure within the flow path 195 may be released prior to the pressure rising to an unsafe and/or unintended level. As such, wellbore servicing equipment components (e.g., one or more components of the wellbore servicing system 100) may never experience unsafe, damaging, or otherwise unintended pressures. As will be appreciated by one of skill in the art upon viewing this disclosure, the pressure threshold (e.g., at which the pressure control device 310 is intended to allow fluid communication) may be selected at a pressure less than the pressure which is desired to not be experienced (e.g., a pressure “safety” margin). For example, the pressure threshold may be selected so as to allow a margin of about 100 psi, alternatively, about 150 psi, alternatively, about 200 psi, alternatively, about 250 psi, alternatively, about 300 psi, alternatively, about 400 psi, alternatively, about 500 psi, alternatively, about 1,000 psi, alternatively, about 2,000 psi, alternatively, any other desired differential.
In an embodiment, upon the pressure control device 310 allowing fluid communication from the flow path 195 to the relief path 196, fluid may be communicated via the relief path 196 and into the relief space 131. For example, in an embodiment where the pressure control system 108 is configured for placement at the surface of the formation (e.g., as disclosed with reference to
In an embodiment, the wellbore servicing method may also comprise reestablishing control of the flow path. For example, as disclosed herein, upon experiencing an over-pressuring event, the pressure control system 108 (particularly, the pressure control device 310, for example, a burst disc) is actuated so as to release and/or dissipate pressure (e.g., fluid) from the flow path 195. For example, upon actuation of the pressure control system 108 (i.e., the pressure control device 310), the flow path 195 (e.g., via the relief path 196, which is in fluid communication with the flow path 195) is effectively open, thereby allowing fluid within the flow path 195 to escape. As will be appreciated by one of skill in the art upon viewing this disclosure, control of the flow path 195 (e.g., and therefore, the wellbore 120) must be reestablished, for example, such that fluid(s) from the wellbore 120 and/or the formation 130 do not escape uncontrollably therefrom. In an embodiment, reestablishing control of the flow path 195 may comprise actuating the first valve 314, for example closing the first valve 314.
In an embodiment, and as disclosed herein, the first valve 314 may be configured to close at a controlled rate, for example, so as to avoid a pressure wave becoming trapped within the flow path 195. In an embodiment, the first valve 314 may be closed at a rate so as to allow such a pressure wave to be dissipated. As disclosed herein, the first valve 314 may be actuated (e.g., closed) hydraulically, pneumatically, electrically (e.g., via the operation of a solenoid and/or a motor), manually, or combinations thereof and such actuation may comprise an automated function (e.g., as a function of a sensor, such as sensor 322 and/or a control system, such as control system 324), alternatively, a manual function, alternatively, combinations thereof.
In an embodiment, as the first valve 314 is actuated (e.g., closed), fluid communication via the relief path 196 may be reduced. Not intending to be bound by theory, because of the relatively high pressures, high flow-rates, and/or abrasive nature of the fluid(s) being communicated via the flow path 195 and the relief path 196, the first valve 314 may be abraded or damaged during the actuation (closing) thereof, for example, by the movement of an abrasive fluid moving therethrough at a high pressure and a high rate while the first valve 314 is closed. For example, the movement of fluid through the first valve 314 while the first valve 314 is being closed may cut, abrade, or perforate small flow channels through a portion of the first valve 314.
In an embodiment, reestablishing control of the flow path 195 may further comprise actuating the second valve 316, for example closing the second valve 316. For example, as disclosed herein, the second valve 316 may be configured such that the second valve 316 is not fully actuated (e.g., does not reach the closed position) until after the first valve 314 has been fully actuated (e.g., until after the first valve 314 has been fully closed). Again not intending to be bound by theory, because the second valve 316 is not fully actuated until after the first valve 314 has been fully actuated, the flow-rate and pressure of the fluid within the relief path 196 at the second valve 316 (e.g., at the time when the second valve 316 is actuated) may be substantially lessened. As such, the movement of fluid through the second valve 316 (e.g., at a substantially lower pressure and/or pressure, relative to the fluid moved through the first valve 314, as disclosed herein) will not damage (e.g., abrade or cut) the second valve 316, thereby allow the second valve 316 to fully contain the relief path 196 and, thereby, the flow path 195. For example, closing the second valve 316 may provide absolute containment of fluid within the flow path 195, for example, if the first valve 314 fails due to erosion while being closed.
In an embodiment, a pressure control system, for example, the pressure control system 108 disclosed herein, and/or systems or methods utilizing the same, may be advantageously employed in the performance of a wellbore servicing operation. As disclosed herein, a pressure control system may be effective to protect one or more wellbore servicing equipment components from unexpected and/or unintended increases in fluid pressure (e.g., pressure spikes or over-pressuring events) and, as such, prevent the occurrence of any yield to such components.
Particularly, a pressure control system, as disclosed herein, may be effective to relieve or dissipate pressure where conventional means of pressure control would be ineffective. For example, conventionally, various combinations of relief valves (e.g., pop-off valves, as referenced herein) and/or check valves have been employed to alleviate excess pressure. However, such conventional means may not be capable of reacting quickly enough (e.g., not capable of actuating fast enough) to respond to a sudden increases in pressure in order to protect the equipment and equipment operators. As disclosed herein, because of the high pressures and flow rates utilized in wellbore servicing operations, it is possible that pressures within a flow path could increase to levels to damage equipment and/or personnel before such excess pressures could be relieved. Particularly, and not intending to be bound by theory, because such conventional pressure control means (i.e., relief valves, such as pop-off valves) generally comprise mechanical (biased or spring-loaded devices), a delay in time may be experienced between when an excess pressure was experienced and when that pressure might be relieved. As disclosed herein, the pressure control system 108 is configured to react quickly and, thereby, to relieve pressures so as to prohibit wellbore servicing equipment components from experiencing such pressures and, thereby, to protect the equipment and the equipment operators.
The following are nonlimiting, specific embodiments in accordance with the present disclosure:
A first embodiment, which is a wellbore servicing system, the system comprising:
at least one wellbore servicing equipment component, wherein a flow path extends from the wellbore servicing system component into a wellbore penetrating a subterranean formation; and
a pressure control system in fluid communication with the flow path, wherein the pressure control system comprises:
A second embodiment, which is the wellbore servicing system of the first embodiment, wherein the wellbore servicing equipment component comprises a mixer, a pump, a wellbore services manifold, a storage vessel, or combinations thereof.
A third embodiment, which is the wellbore servicing system of one of the first through the second embodiments, wherein the pressure control device comprises a rupture disc.
A fourth embodiment, which is the wellbore servicing system of the third embodiment, wherein, upon experiencing the pressure and/or the differential pressure of at least the predetermined pressure threshold, the rupture disc is configured to break, puncture, perforate, shear, fragment, disintegrate, explode, implode, tear, or combinations thereof.
A fifth embodiment, which is the wellbore servicing system of one of the first through the fourth embodiments, wherein the pressure threshold is in a range from about 1,000 psi to about 30,000 psi.
A sixth embodiment, which is the wellbore servicing system of one of the first through the fifth embodiments, wherein the pressure control device configured to permit fluid communication in less than or equal to about 0.10 seconds of experiencing the pressure and/or the differential pressure of at least the predetermined pressure threshold.
A seventh embodiment, which is the wellbore servicing system of one of the first through the sixth embodiments, wherein the first valve comprises a gate valve, a ball valve, a globe valve, a choke valve, a butterfly valve, a pinch valve, a disc valve, the like, or combinations thereof.
An eighth embodiment, which is the system of one of the first through the seventh embodiments, wherein the first valve comprises a sleeve, wherein the sleeve is slidably disposed about or within a pipe string.
A ninth embodiment, which is the wellbore servicing system of one of the first through the eighth embodiments, wherein the pressure control system further comprises a flow restrictor, wherein the flow restrictor is configured to decrease the pressure of a fluid communication along the relief path from the pressure control device to the first valve.
A tenth embodiment, which is the wellbore servicing system of the ninth embodiment, wherein the flow restrictor comprises a choke, a fluidic diode, or combinations thereof.
An eleventh embodiment, which is the wellbore servicing system of one of the first through the tenth embodiments, wherein the pressure control system further comprises a second valve disposed within the relief path downstream from the first valve, wherein the second valve is configured to actuate from an open configuration to a closed configuration.
A twelfth embodiment, which is the wellbore servicing system of one of the first through the eleventh embodiments, wherein the pressure control system further comprises a relief space, wherein the relief path is in fluid communication with the relief space.
A thirteenth embodiment, which is the wellbore servicing system of the twelfth embodiment, wherein the relief space comprises a tank, a vessel, a wellbore, an annular space within a wellbore, a second wellbore, a portion of the subterranean formation, or combinations thereof.
A fourteenth embodiment, which is the wellbore servicing system of one of the first through the thirteenth embodiments, wherein at least a portion of the pressure control system is disposed at the surface of the subterranean formation.
A fifteenth embodiment, which is the wellbore servicing system of one of the first through the fourteenth embodiments, wherein at least a portion of the pressure control system is disposed within the wellbore.
A sixteenth embodiment, which is the wellbore servicing system of the fifteenth embodiment, wherein the pressure control system is integrated within a pipe string disposed within the wellbore.
A seventeenth embodiment, which is a method of servicing a wellbore, the method comprising:
providing a flow path between a wellbore servicing system and a wellbore penetrating a subterranean formation, wherein a pressure control system comprising a pressure control device and a relief path is in fluid communication with the flow path, wherein the pressure control system is configured to control fluid communication between the flow path and the relief path;
communicating a fluid via the flow path; and
upon experiencing a pressure and/or a differential pressure of at least a predetermined pressure threshold within the flow path, allowing fluid to be communicated from the flow path through the relief path, wherein the pressure control device permits fluid communication from the flow path to the relief path within about 0.10 seconds of experiencing the pressure and/or the differential pressure of at least the predetermined pressure threshold.
An eighteenth embodiment, which is the method of the seventeenth embodiment, wherein the fluid is communicated from the relief path to a relief space.
A nineteenth embodiment, which is the method of one of the seventeenth through the eighteenth embodiments, further comprising closing a first valve, wherein the first valve is positioned along the relief path.
A twentieth embodiment, which is the method of the nineteenth embodiment, further comprising closing a second valve, wherein the second valve is positioned along the relief path downstream from the first valve.
A twenty-first embodiment, which is the method of the twentieth embodiment, wherein closing the first valve, closing the second valve, or both occurs manually.
A twenty-second embodiment, which is the method of the twentieth embodiment, wherein closing the first valve, closing the second valve, or both occurs automatically as a result of fluid communication via the relief path.
While embodiments of the invention have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of the invention. The embodiments described herein are exemplary only, and are not intended to be limiting. Many variations and modifications of the invention disclosed herein are possible and are within the scope of the invention. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, Rl, and an upper limit, Ru, is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=Rl+k*(Ru−Rl), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . 50 percent, 51 percent, 52 percent, . . . 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. Use of the term “optionally” with respect to any element of a claim is intended to mean that the subject element is required, or alternatively, is not required. Both alternatives are intended to be within the scope of the claim. Use of broader terms such as comprises, includes, having, etc. should be understood to provide support for narrower terms such as consisting of, consisting essentially of, comprised substantially of, etc.
Accordingly, the scope of protection is not limited by the description set out above but is only limited by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated into the specification as an embodiment of the present invention. Thus, the claims are a further description and are an addition to the embodiments of the present invention. The discussion of a reference in the Detailed Description of the Embodiments is not an admission that it is prior art to the present invention, especially any reference that may have a publication date after the priority date of this application. The disclosures of all patents, patent applications, and publications cited herein are hereby incorporated by reference, to the extent that they provide exemplary, procedural or other details supplementary to those set forth herein.
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