To control pressure and flow during drilling or production of hydrocarbon wells, operators may install a choke at the wellhead. Chokes generally include an inlet, an outlet, and some form of internal restriction between the inlet and outlet that maintains backpressure on the well and limits flow through the choke.
With adjustable chokes, the internal restriction is commonly a movable valve gate disposed within the choke between the inlet and the outlet. The valve gate is movable by an actuator between at least a fully open and a fully closed position. In the fully open position, flow between the inlet and the outlet is minimally restricted by the valve gate. In the fully closed position, on the other hand, the valve gate seats against a valve seat, blocking all flow through the choke. Although the fully open and fully closed positions define the full stroke of the valve gate, adjustable chokes typically permit positioning of the valve gate in intermediate positions between the fully opened and fully closed positions. When in an intermediate position, the valve gate partially limits flow through the choke while maintaining backpressure on the well. By changing the position of the valve gate to different intermediate positions, an operator can throttle flow through the valve and adjust backpressure on the well to fit drilling or production requirements.
Repositioning of the valve gate within the choke is typically accomplished by an actuator coupled to the valve gate by a valve stem. In some chokes, the actuator is a valve wheel, crank handle, or other manually operated structure. Other chokes may be equipped with actuators driven by hydraulic, pneumatic, electric, or other types of power and responsive to commands from a control system.
Chokes are commonly designed with the choke outlet being substantially perpendicular to the choke inlet and the valve gate arranged such that the valve gate moves along a path that is co-axial with the choke outlet. In such an arrangement, fluid pressure at the leading face of the valve gate is minimized as is the resulting axial load placed on the valve gate, valve stem, and actuator. As a result, during normal operating conditions, smaller and more cost-effective valve components may be used than if the valve gate were aligned otherwise.
Chokes are typically designed to withstand loading associated with normal operating conditions, but upset conditions in which operating conditions exceed their normal range may occur. For example, a downstream blockage or a failure of a downstream pressure relief or control valve may cause an increase in downstream pressure that exerts increased load on the valve gate, valve stem, and actuator. If the rise in downstream pressure is sufficient, the load may exceed the designed strength of the choke components, causing one or more of the components to fail.
Despite the resulting safety issues and downtime for such failures being undesirable, operators may find it impractical or cost prohibitive to install chokes capable of withstanding a full range of potential upset conditions. As a result, instead of opting for a potentially over-sized or over-designed choke, operators may find desirable a choke designed to fail in a predictable, controlled, and safe manner and that once failed, can be brought back into operation with minimal downtime.
A more complete understanding of the present embodiments and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like reference numbers indicate like features.
While embodiments of this disclosure have been depicted and described and are defined by reference to exemplary embodiments of the disclosure, such references do not imply a limitation on the disclosure, and no such limitation is to be inferred. The subject matter disclosed is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those skilled in the pertinent art and having the benefit of this disclosure. The depicted and described embodiments of this disclosure are examples only, and not exhaustive of the scope of the disclosure.
The present disclosure relates generally to chokes and specifically to valve stems for use in chokes.
Illustrative embodiments of the present invention are described in detail herein. In the interest of clarity, not all features of an actual implementation may be described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation specific decisions must be made to achieve the specific implementation goals, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of the present disclosure.
To facilitate a better understanding of this disclosure, the following examples of certain embodiments are given. In no way should the following examples be read to limit, or define, the scope of the claims.
Chokes, such as choke 100, are generally used to control back pressure and flow in a system. For example, chokes may be installed at a wellhead of a hydrocarbon-producing well to maintain backpressure on the well and control the amount of hydrocarbons produced from the well. Chokes, such as choke 100, generally operate by permitting high pressure fluid to enter the inlet 104, flow through the body 102, and exit the outlet 106. Valve gate 110, or a similar restriction, is disposed within the choke to restrict flow between the inlet 104 and the outlet 106.
The valve gate 110 may be stroked within the body 102 between an open position, as depicted in
The valve gate 110 may be positioned in intermediate positions between the open position and the closed position such that the valve gate 110 partially restricts flow between the inlet 104 and the outlet 106. By varying the position of the valve gate 110 within the body 102, the degree of restriction created by the valve gate 110 and the resultant pressure drop and flow reduction across the choke 100 may be adjusted. Specifically, moving the valve gate 110 towards the open position reduces the restriction created by the valve gate 110, thereby reducing backpressure and increasing fluid flow through the outlet 106. Conversely, moving the valve gate 110 towards the closed position increases the restriction created by the valve gate 110, increasing backpressure and decreasing flow through the outlet 106.
The valve gate 110 is stroked between the first and the second position by an actuator 114 coupled to the valve gate 110 by a valve stem 108 that transmits motion of the actuator 114 to the valve gate 110. The actuator 114 may be any suitable actuator for moving the valve stem 108. For example, in manually actuated chokes, the actuator may be a handwheel, handle, crank, or similar manually operated structure for moving the valve stem 108. Alternatively, the actuator may include a drive mechanism for moving the valve stem 108 and may be actuated by hydraulic, pneumatic, electrical, or any other suitable type of power.
By way of example,
During operation, fluid pressure at a leading face 118 of the valve gate 110 generates forces on the valve gate 110 towards the open position. When in the open position, as depicted in
When the valve gate 110 is in the closed position, as depicted in
As depicted in
Although a co-axial arrangement of the valve gate 110 and the outlet 106 minimizes axial loading during normal operating conditions when downstream pressure is relatively low, blockages in downstream piping, failure of downstream relief valves, and other abnormal conditions may cause an increase in downstream pressure. If the increase is sufficiently high, an overpressure event in which the resulting axial load exceeds the design strength of choke components may occur, causing the components to become damaged or catastrophically fail.
Under normal operating conditions, the restriction within the choke 100 created by the valve gate 110 maintains backpressure upstream of the choke 100. However, in downstream overpressure conditions, the restriction created by the valve gate 110 instead creates backpressure downstream of the choke 100. Because of this increase in downstream pressure, the axial load on the valve stem 108 may also increase during downstream overpressure conditions.
As previously discussed, backpressure maintained by the choke 100 may be reduced by moving the valve gate 110 towards the open position. As a result, one method of reducing damage to the actuator and other choke components from a downstream overpressure event is to permit movement of the valve gate 110 towards the open position when a downstream overpressure event occurs. Doing so reduces the restriction within the choke created by the valve gate 110, allowing downstream backpressure to escape upstream and reducing axial loading of the valve stem 108.
An alternative method of reducing the axial load on the valve gate 110 and actuator stem 120 during an overpressure event is to retract the valve gate 110 into a position in which the valve gate rests against the housing or other fixed valve components. Doing so transfers some of the axial load experienced by the valve gate 110 and actuator stem 120 to stronger valve components.
An overpressure event may also cause the valve seat 112 to retract with the valve gate 110. This retraction may be an unintended result of the overpressure event or the valve seat 112 may be configured to retract during an overpressure event. In certain embodiments, the valve seat 112 may be shaped such that in the retracted position, the valve seat 112 maintains a seal against both the valve gate 110 and the outlet 106, preventing fluid from travelling upstream of the valve 100. Accordingly, a retracting valve seat may be implemented in applications in which backflow to upstream equipment is undesirable.
As depicted in
Generally, during normal operating conditions, the shear screws 124A, 124B, and 124C maintain the operator stem 120 in a first position partially within a recess defined by the stroke limit nut 122 and the actuator stem 116. This first position is illustrated in
The shear screws 124A, 124B, and 124C are selected such that when an overpressure event occurs, the shear screws 124A, 124B, and 124C shear, permitting retraction of the operator stem 120 into the recess. Because the operator stem 120 is coupled to the valve gate 110, retraction of the operator stem 120 into the recess also moves the valve gate 110 towards the open position, reducing axial loading on the valve stem 108 by relieving downstream backpressure or by transferring the axial loading to other valve components, as previously discussed.
Shearing of the shear screws 124A, 124B, and 124C and the effect of shearing on positioning of components of the valve stem 108 is illustrated by comparing
Operation of valve stems in accordance with this disclosure are further explained by referring to
In accordance with this disclosure,
Although
Returning to
Referring now to
During operation of chokes in accordance with this disclosure, downstream pressure exerts a force on the valve gate. The force on the valve gate is transferred as an axial load on the operator stem 220, through the shear screws 224A, 224B, and 224C to the stroke limit nut 222, and to the actuator stem 216. Due to the coupling of the operator stem 220 to the stroke limit nut 222 by the shear screws 224A, 224B, and 224C, axial loads applied to the operator stem 220 result in shear stresses on each of the shear screws 224A, 224B, and 224C.
If the axial load and therefore the resulting shear stress on the shear screws 224A, 224B, and 224 is sufficiently high, the shear screws 224A, 224B, and 224C will shear, permitting retraction of the operator stem 220 further into the recess 226, as depicted in
During shearing, the threaded portions 230A, 230B, and 230C and/or the unthreaded portions 232A, 232B, and 232C may become deformed or develop burrs or similar rough edges that obstruct movement of the operator stem 220 into the recess 226. To reduce the likelihood of such obstructions, clearance may be provided in the shear screw bores such that the unthreaded portions 232A, 232B, and 232C of the shear screws drop into the shear screw bores after shearing. The shear screw bores may include a beveled entrance to guide the unthreaded portions 232A, 232B, and 232C into the shear screw bores. Alternatively or in addition to the beveled entrance, the diameter of recess 226 may be such that clearance exists between the walls of the recess 226 and the operator stem 220 when the operator stem retracts into the recess 226.
After a downstream overpressure event resulting in shearing of the shear screws has occurred, the valve stem must be repaired before the choke can be returned to service. Repair of the valve stem generally involves removing the valve stem from the choke, removing the portions of the sheared shear screws from the stroke limit nut and the operator stem, installing new shear screws, and then replacing the valve stem within the choke.
The steps to remove the valve stem from the choke are not within the scope of this disclosure and will vary based on the specific arrangement of the choke and its components. However, removal of the valve stem from the choke generally involves partial disassembly of the choke to permit access and removal of the valve stem. Disassembly and replacement of the valve stem may also require decoupling the valve stem from the actuator and decoupling of the operator stem from the valve gate.
Repair further requires decoupling of the stroke limit nut and operator stem. This may occur after the valve stem has been removed from the choke or as part of the disassembly process. Because the shear screws coupling the stroke limit nut to the operator stem have been sheared, disassembly of the stroke limit nut and operator stem generally involves sliding the operator stem out of the recess. Once the valve stem and stroke limit nut are separated, the portions of the shear screws retained in the stroke limit nut and the operator stem may be removed. Threaded portions of the shear screws retained in the stroke limit nut after shearing may be removed from the stroke limit nut by backing out the threaded portion using a screwdriver, hex key, or other appropriate tool for counter-rotating the threaded portion. One of ordinary skill in the art would appreciate that the shear screws may be designed to be driven or removed by any tool suitable for driving or removing screws or bolts. Preferably, the shear screws include heads having standard shapes and sizes, permitting installation and removal using standard, readily available tools.
The unthreaded portions of the shear screw may simply fall out of the shear screw bores when the operator stem is separated from the stroke limit nut. However, in some cases the unthreaded portions of the shear screws may be deformed as they are sheared, causing them to become stuck within the shear screw bores. Depending on the nature of the deformation, the unthreaded portion may be removed by inserting a screwdriver or other tool into the shear screw bore and prying the unthreaded portion out of the shear screw bore. However, doing so may not be possible or may not be possible without damaging the operator stem. As an alternative, and as depicted in
Once the sheared shear screws have been removed, the valve stem can be reassembled by reinserting the operator stem into the stroke limit nut such that the shear screw bores align with the shear screw locations of the stroke limit nut. Once aligned, the operator stem can be recoupled to the stroke limit nut by installing a new set of shear screws using a screwdriver, hex key, or other appropriate tool for rotating the shear screws.
Although the previously discussed embodiments depict valve stems having three shear screws, embodiments according to this disclosure are not limited to three-shear-screw configurations. Any number or arrangement of shear screws may be used to secure the stroke limit nut to the operator stem provided that the shear screws are sufficiently strong to withstand shear stresses applied to the shear screws during normal operating conditions and selected to shear when an overpressure event occurs. The particular quantity and shear strength of the shear screws used in any embodiment will be dependent on the specific operating conditions under which the choke is to be used and the strength of other choke components to be protected during overpressure conditions. For example, if a threaded section of the valve stem is particularly susceptible to damage during overpressure events, the quantity and strength of the shear screws may be selected such that the combined shear strength of the shear screws is lower than that of the threaded section. As a result, during an overpressure event, the shear screws will shear before the threaded section is damaged.
One of ordinary skill having the benefit of this disclosure would appreciate that embodiments disclosed herein may be incorporated in new chokes or may be used to retrofit existing chokes. For example, valve stems in an existing choke may be replaced with valve stems in accordance with this disclosure. Similarly, valve stems of embodiments disclosed herein may also be removed and reused in multiple valves over the useful life of the valve stem. Incorporation of embodiments disclosed herein into existing valves may require modification or alteration of the existing choke to accommodate valve stems in accordance with this disclosure, but any such modifications would be within the abilities of one skilled in the art having the benefit of this disclosure.
Although numerous characteristics and advantages of embodiments of the present invention have been set forth in the foregoing description and accompanying figures, this description is illustrative only. Changes to details regarding structure and arrangement that are not specifically included in this description may nevertheless be within the full extent indicated by the claims.
Filing Document | Filing Date | Country | Kind |
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PCT/US2014/071934 | 12/22/2014 | WO | 00 |