In the oilfield arts, a subsurface safety valve (SSSV) is often installed in a well upper completion, as a component of tubing which arrests well flow in the event of an emergency shut-down or blowout. Normally, an SSSV is controlled from a surface location and is actuated via signals transmitted via a control line. However, in the event of any damage to the control line or related malfunction, a complex workover operation is typically required for repairing the control line, in cases, and may even warrant removing and replacing the SSSV itself. Wireless control arrangements have been developed conventionally, but significant reliability issues are often encountered.
This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.
In one aspect, embodiments disclosed herein relate to a subsurface safety valve that includes an outer housing, a flapper valve disposed within the outer housing, and a motor that pivotally displaces the flapper valve. The subsurface safety valve also includes a battery that powers the motor, a turbine that charges the battery and a wireless receiver that, responsive to a received signal, transmits a signal to the motor to pivotally displace the flapper valve.
In one aspect, embodiments disclosed herein relate to a method including: providing a subsurface safety valve having an outer housing; disposing a flapper valve within the outer housing; providing a motor, a battery, a turbine and a wireless receiver; charging the battery with the turbine; powering the motor with the battery; receiving a signal at the wireless receiver; and responsive to the received signal, transmitting a signal to the motor to pivotally displace the flapper valve.
Other aspects and advantages of the claimed subject matter will be apparent from the following description and the appended claims.
Specific embodiments of the disclosed technology will now be described in detail with reference to the accompanying figures. Like elements in the various figures are denoted by like reference numerals for consistency.
In the following detailed description of embodiments of the disclosure, numerous specific details are set forth in order to provide a more thorough understanding of the disclosure. However, it will be apparent to one of ordinary skill in the art that the disclosure may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.
Throughout the application, ordinal numbers (e.g., first, second, third, etc.) may be used as an adjective for an element (i.e., any noun in the application). The use of ordinal numbers is not to imply or create any particular ordering of the elements nor to limit any element to being only a single element unless expressly disclosed, such as using the terms “before”, “after”, “single”, and other such terminology. Rather, the use of ordinal numbers is to distinguish between the elements. By way of an example, a first element is distinct from a second element, and the first element may encompass more than one element and succeed (or precede) the second element in an ordering of elements.
By way of general background in accordance with one or more embodiments,
In accordance with one or more embodiments, the wellbore 120 includes a bored hole that extends from the surface 108 into a target zone of the formation 104, such as the reservoir 102. An upper end of the wellbore 120, terminating at or near the surface 108, may be referred to as the “up-hole” end of the wellbore 120, and a lower end of the wellbore, terminating in the formation 104, may be referred to as the “down-hole” end of the wellbore 120. The wellbore 120 facilitates the circulation of drilling fluids during drilling operations, the flow of hydrocarbon production (“production”) 121 (e.g., oil and gas) from the reservoir 102 to the surface 108 during production operations, the injection of substances (e.g., water) into the formation 104 or the reservoir 102 during injection operations, or the communication of monitoring devices (e.g., logging tools) into the formation 104 or the reservoir 102 during monitoring operations (e.g., during in situ logging operations).
In accordance with one or more embodiments, during operation of the well system 106, the control system 126 collects and records wellhead data 140 for the well system 106. The wellhead data 140 may include, for example, a record of measurements of wellhead pressure (Pwh) (e.g., including flowing wellhead pressure), wellhead temperature (Twh) (e.g., including flowing wellhead temperature), wellhead production rate (Qwh) over some or all of the life of the well 106, and water cut data. Such measurements may be recorded in real-time, to be available for review or use within seconds, minutes, or hours of the condition being sensed (e.g., within one hour). Such real-time data can help an operator of the well 106 to assess a relatively current state of the well system 106, and make real-time decisions regarding development of the well system 106 and the reservoir 102, such as on-demand adjustments in regulation of production flow from the well.
In accordance with one or more embodiments, the well sub-surface system 122 includes a casing installed in the wellbore 120. For example, the wellbore 120 may have a cased portion and an uncased (or “open-hole”) portion. The cased portion may include a portion of the wellbore having casing (e.g., casing pipe and casing cement; see, e.g., 342 in
In accordance with one or more embodiments, the well surface system 124 includes a wellhead 130. The wellhead 130 may include a rigid structure installed at the “up-hole” end of the wellbore 120, at or near where the wellbore 120 terminates at the Earth's surface 108. The wellhead 130 may include structures (called “wellhead casing hanger” for casing and “tubing hanger” for production tubing) for supporting (or “hanging”) casing and production tubing extending into the wellbore 120. Production 121 may flow through the wellhead 130, after exiting the wellbore 120 and the well sub-surface system 122, including, for example, the casing and the production tubing. The well surface system 124 may include flow regulating devices that are operable to control the flow of substances into and out of the wellbore 120. For example, the well surface system 124 may include one or more production valves 132 that are operable to control the flow of production 121. For instance, a production valve 132 may be fully opened to enable unrestricted flow of production 121 from the wellbore 120, the production valve 132 may be partially opened to partially restrict (or “throttle”) the flow of production 121 from the wellbore 120, and production valve 132 may be fully closed to fully restrict (or “block”) the flow of production 121 from the wellbore 120, and through the well surface system 124.
In accordance with one or more embodiments, the wellhead 130 includes a choke assembly. For example, the choke assembly may include hardware with functionality for opening and closing the fluid flow through pipes in the well system 106. Likewise, the choke assembly may include a pipe manifold that may lower the pressure of fluid traversing the wellhead. As such, the choke assembly may include set of high pressure valves and at least two chokes. These chokes may be fixed or adjustable or a mix of both. Redundancy may be provided so that if one choke has to be taken out of service, the flow can be directed through another choke. In some embodiments, pressure valves and chokes are communicatively coupled to the well control system 126. Accordingly, a well control system 126 may obtain wellhead data regarding the choke assembly as well as transmit one or more commands to components within the choke assembly in order to adjust one or more choke assembly parameters.
In accordance with one or more embodiments, the well surface system 124 includes a surface sensing system 134. The surface sensing system 134 may include sensors for sensing characteristics of substances, including production 121, passing through or otherwise located in the well surface system 124. The characteristics may include, for example, pressure, temperature and flow rate of production 121 flowing through the wellhead 130, or other conduits of the well surface system 124, after exiting the wellbore 120.
In accordance with one or more embodiments, the surface sensing system 134 includes a surface pressure sensor 136 operable to sense the pressure of production 121 flowing through the well surface system 124, after it exits the wellbore 120. The surface pressure sensor 136 may include, for example, a wellhead pressure sensor that senses a pressure of production 121 flowing through or otherwise located in the wellhead 130. In some embodiments, the surface sensing system 134 includes a surface temperature sensor 138 operable to sense the temperature of production 121 flowing through the well surface system 124, after it exits the wellbore 120. The surface temperature sensor 138 may include, for example, a wellhead temperature sensor that senses a temperature of production 121 flowing through or otherwise located in the wellhead 130, referred to as “wellhead temperature” (Twh). In some embodiments, the surface sensing system 134 includes a flow rate sensor 139 operable to sense the flow rate of production 121 flowing through the well surface system 124, after it exits the wellbore 120. The flow rate sensor 139 may include hardware that senses a flow rate of production 121 (Qwh) passing through the wellhead 130.
In accordance with one or more embodiments,
In accordance with one or more embodiments, the well cap 200 provides access to wellbore for interventions with wireline, coil tubing, slickline etc. The crown valve 201 is the uppermost valve on wellhead. Typically, the crown valve 201 is closed until there is a need to access the well as described above. The wing valve 202 is for production flow control. In the case of needing to enter a well, this valve would be closed and the master valve would be open. The surface safety valve 203 is typically a hydraulic failsafe close valve located at surface. The surface safety valve 203 used in the event of an issue in the wellbore/surface equipment and for testing. The master valve 204 is the main valve controlling flow from the wellbore. The subsurface safety valve 205 is another safety device located below the surface, e.g., several hundred plus feet below the surface. The subsurface safety valve 205 makes up part of the production tubing and provides an arrangement for safety closure in the case of uncontrolled release of hydrocarbons, such as a kick. Also, the subsurface safety valve 205 may be used as a barrier when testing or needed to perform maintenance on the wellhead.
In accordance with one or more embodiments, the choke valve 208 is used for flow restriction in the event of bleeding down pressure during testing, loss of pressure in the wellbore, temperature management, etc. The upstream pressure transmitter 206 is a pressure/temperature gauge located upstream of choke valve 208 and provides pressure data prior to reaching the choke valve 208. The downstream pressure transmitter 207 is a pressure/temperature gauge downstream of choke valve 208 and provides pressure data after passing the choke valve 208. The plot limit valve 209 is a valve for testing, maintenance and isolation purposes, e.g., if the upstream pressure transmitter 206, downstream pressure transmitter 207, or choke valve 208 were being replaced. The pressure gauge 210 located above the crown valve 201 is for testing each component of the wellhead. As generally treated herein, shut-in wellhead pressure (SIWHP) refers to the initial wellhead pressure from the reservoir as seen at surface and is a base line pressure for testing purposes, and can be measured by the pressure gauge 210. The initial manifold pressure refers to the initial pressure downstream of wellhead and is a base line pressure for testing purposes.
In one or more embodiments, the hydraulic valves and associated gauges are connected as depicted in
In accordance with one or more embodiments, following the first open/close configuration and in the second open/close configuration, the subsurface safety valve, master valve, wing valve, and crown valve are opened with the plot limit valve closed to record the initial shut-in wellhead pressure (SIWHP) using the permanently installed pressure gauge between the well cap and the crown valve. The pressure gauge readings of the permanently installed pressure gauge, the upstream pressure transmitter, and the downstream pressure transmitter are compared with each other to validate gauge accuracy. The gauge readings from the downstream pressure transmitter, the upstream pressure transmitter, and the pressure gauge between the well cap and the crown valve are denoted as DPT, UPT, and PG, respectively. All pressure gauge readings are observed for 10 minutes to record pressure changes, if any. If all three following conditions are true over the 10 minutes period: DPT=SIWHP, UPT=SIWHP, and PG=SIWHP, then the plot limit valve is determined as holding (i.e., no leakage).
Following the second open/close configuration and in the third open/close configuration, the wellhead valve is closed and the plot limit valve is opened to observe all pressure gauge readings for 10 minutes and record pressure changes, if any. If both following conditions are true over the 10 minutes period: UPT=initial manifold pressure=DPT and PG=SIWHP, then the wellhead valve is determined as holding (i.e., no leakage).
Following the third open/close configuration and in the fourth open/close configuration, the crown valve is closed followed by closing the master valve and opening the wellhead valve. If both following conditions are true over the 10 minutes period: UPT=initial manifold pressure=DPT and PG=SIWHP, then the crown valve and the master valve are determined as holding (i.e., no leakage).
Subsequent to the first, second, third and fourth open/close configurations, the crown valve is opened to bleed the pressure to a flare pit. Specifically, PLV and WV are open. MV is closed and CV bleeds the trapped pressure between CV and MV into the flare pit.
The disclosure now turns to working examples of a system and method in accordance with one or more embodiments, as described and illustrated with respect to
Broadly described and contemplated herein, in accordance with one or more embodiments, is a sub-surface safety valve (SSSV) equipped with a downhole energy harvesting system and wireless activation mechanism. Thus, the wireless activation mechanism can be utilized instead of a conventional hard-wired connection involving one or more control lines connected to equipment at a terrestrial surface, while the same can be powered locally to ensure longer-term reliability. Particularly, the SSSV may utilize well production flow to generate electrical power via a built-in turbine, and thereby charge a battery that powers the SSSV assembly.
Also illustrated in
In accordance with one or more embodiments, a suitable turbine 364 may also be mounted at the inner cylindrical surface of housing 352, axially spaced apart from receiver 358, battery 360 and motor 362. Further, a wired connection 366 may be provided to connect the turbine 364 with receiver 358 and battery 360, such that the turbine 364 can charge the receiver 358 and battery 360. In accordance with one or more variants, a wireless charger may be run downhole on an e-line (electric cable) to charge the receiver 358 and/or battery 360 in the event either loses power or becomes drained from inactivity of the turbine 364 (e.g., after a relatively long period of well shut-in).
In accordance with one or more embodiments, as the valve 354 remains open during well production, the uphole flow of reservoir fluid (indicated via the central arrow) will power the turbine 364, and thus permit the turbine 364 to recharge the receiver 358 and battery 360. It should be appreciated that any of a wide variety of possible turbines 364 may be utilized here. The type, size and selection of turbine 364 can be considered on the basis of a wide variety of factors, including predicated well performance and bubble point, in the context of prospective flow regimes.
In accordance with one or more embodiments, the signal to close the valve 354 may be manually transmitted as just noted or may be automatically transmitted. In either case, the signal may be transmitted in response to emergency conditions detected or experienced at the surface or detected or experienced in the wellbore. By way of illustrative example, a surface leak due to a pinhole leak or other physical damage to the flowline (e.g., by errantly performing equipment) may represent such an emergency condition. A resultant pressure drop may then trigger the signal to close the valve 354. Additionally, the valve 354 can be closed manually if used as a barrier, wherein a manually actuated signal can be transmitted from the terrestrial surface.
As such, in accordance with one or more embodiments, a subsurface safety valve having an outer housing is provided (Step 770); this can correspond to the outer housing 352 described and illustrated with respect to
It can be appreciated from the foregoing that, in accordance with one or more embodiments, solutions as broadly contemplated herein can avoid any and all disadvantages normally associated with the use of hard-wired control lines for SSSVs and with powering SSSVs that may otherwise be wirelessly controlled. Workover or other costly interventions can be avoided, especially to the benefit of populated areas with numerous operating wells and associated SSSVs.
In accordance with one or more embodiments, the illustrated computer 885 is intended to encompass any computing device such as a server, desktop computer, laptop/notebook computer, wireless data port, smart phone, personal data assistant (PDA), tablet computing device, one or more processors within these devices, or any other suitable processing device, including both physical or virtual instances (or both) of the computing device. Additionally, the computer 885 may include a computer that includes an input device, such as a keypad, keyboard, touch screen, or other device that can accept user information, and an output device that conveys information associated with the operation of the computer 885, including digital data, visual, or audio information (or a combination of information), or a GUI.
The computer 885 can serve in a role as a client, network component, a server, a database or other persistency, or any other component (or a combination of roles) of a computer system for performing the subject matter described in the instant disclosure. The illustrated computer 885 is communicably coupled with a network 899. In some implementations, one or more components of the computer 885 may be configured to operate within environments, including cloud-computing-based, local, global, or other environment (or a combination of environments).
At a high level, the computer 885 is an electronic computing device operable to receive, transmit, process, store, or manage data and information associated with the described subject matter. According to some implementations, the computer 885 may also include or be communicably coupled with an application server, e-mail server, web server, caching server, streaming data server, business intelligence (BI) server, or other server (or a combination of servers).
The computer 885 can receive requests over network 899 from a client application (for example, executing on another computer 885) and responding to the received requests by processing the said requests in an appropriate software application. In addition, requests may also be sent to the computer 885 from internal users (for example, from a command console or by other appropriate access method), external or third-parties, other automated applications, as well as any other appropriate entities, individuals, systems, or computers.
Each of the components of the computer 885 can communicate using a system bus 887. In some implementations, any or all of the components of the computer 885, both hardware or software (or a combination of hardware and software), may interface with each other or the interface 889 (or a combination of both) over the system bus 887 using an application programming interface (API) 895 or a service layer 897 (or a combination of the API 895 and service layer 897. The API 895 may include specifications for routines, data structures, and object classes. The API 895 may be either computer-language independent or dependent and refer to a complete interface, a single function, or even a set of APIs. The service layer 897 provides software services to the computer 885 or other components (whether or not illustrated) that are communicably coupled to the computer 885. The functionality of the computer 885 may be accessible for all service consumers using this service layer. Software services, such as those provided by the service layer 897, provide reusable, defined business functionalities through a defined interface. For example, the interface may be software written in JAVA, C++, or other suitable language providing data in extensible markup language (XML) format or another suitable format. While illustrated as an integrated component of the computer 885, alternative implementations may illustrate the API 895 or the service layer 897 as stand-alone components in relation to other components of the computer 885 or other components (whether or not illustrated) that are communicably coupled to the computer 885. Moreover, any or all parts of the API 895 or the service layer 897 may be implemented as child or sub-modules of another software module, enterprise application, or hardware module without departing from the scope of this disclosure.
The computer 885 includes an interface 889. Although illustrated as a single interface 889 in
The computer 885 includes at least one computer processor 891. Although illustrated as a single computer processor 891 in
The computer 885 also includes a memory 892 that holds data for the computer 885 or other components (or a combination of both) that can be connected to the network 899. For example, memory 892 can be a database storing data consistent with this disclosure. Although illustrated as a single memory 892 in
The application 893 is an algorithmic software engine providing functionality according to particular needs, desires, or particular implementations of the computer 885, particularly with respect to functionality described in this disclosure. For example, application 893 can serve as one or more components, modules, applications, etc. Further, although illustrated as a single application 893, the application 893 may be implemented as multiple applications 893 on the computer 885. In addition, although illustrated as integral to the computer 885, in alternative implementations, the application 893 can be external to the computer 885.
There may be any number of computers 885 associated with, or external to, a computer system containing computer 885, wherein each computer 885 communicates over network 899. Further, the term “client,” “user,” and other appropriate terminology may be used interchangeably as appropriate without departing from the scope of this disclosure. Moreover, this disclosure contemplates that many users may use one computer 885, or that one user may use multiple computers 885.
Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. § 112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function.