The present invention relates to a valve assembly and relative method for controlling extraction wells under emergency conditions, in particular, it relates to a valve assembly for the management of extraction wells, such as, for example wells for the extraction of hydrocarbons (petroleum and/or gas), under emergency conditions arising from uncontrolled eruption of the well (blow-out) or from transitory overpressures coming from the reservoir formation (kick).
The growing tendency of the Oil & Gas industry to explore in offshore areas at increasing depths, as a result leads to the necessity of guaranteeing a continuous improvement in the safety level for wellheads on sea or ocean bottoms at depths close to 4000 meters; the capacity and effectiveness of intervening in the case of emergencies at these depths represents a necessity and challenge for the future which is orienting technique towards security solutions that integrate the current capacities of blow-out preventers (BOPS) installed on the production crosses and existing safety valves inside the wellhead.
At present, blow-out preventers are devices installed redundantly for guaranteeing an effective intervention in the case of emergencies.
The main functions of BOPs are to control the volumes of well fluid, center the drill pipes, close and seal the well. Two categories of BOPs can be mainly distinguished: annular and ram. Whereas annular devices adopt a control element of the volume of fluids and closing of the well having an annular form, ram devices implement a gate or guillotine mechanism made of metallic or elastomeric material capable of exerting a closing and hydraulic sealing action with or without the presence of tubular material inside the valve. Particular BOPs called “shear rams” can induce shear stress on the tubular materials engaged in the valve body of the BOP so as to shear them and obtain the desired results.
A well-eruption prevention system is normally composed of a series of redundant BOPs which exploit various functioning systems (annular and ram) to ensure a greater effectiveness. The intervention times of BOPs generally range from tens of seconds to minutes thanks to dedicated actuations and hydraulic controls.
Although the barrier formed by BOPs represents a significant safety means with respect to emergency events, some limits on their functioning can be detected.
The capacity of shearing drill pipes engaged in BOPs is limited and does not comprise the shearing of joining components between the rods (tool joints) having a larger thickness and diameter with respect to the rods themselves. The BOPs must be maintained and the seals substituted at the end of the drilling operations. In the case of shearing with systems that induce shear stress (shear rams), the cutting action on the drill pipe is exerted so as to guarantee the separation of the two sections of rod and the subsequent closing of the well if the rod is in a centered position with respect to the passage pipe of the valve. In cases where the drill string is compressed by the pressure of the well or is diverted laterally, its shearing risks to be incomplete or with a deformed residual material which does not allow the subsequent closing phase of the well through the sealing element. The passage of the cutting elements provides that the rod is sheared after a complete crushing of the section which only occurs in the central part of the rod.
The area of the tool joint, subjected to the action of the cutting elements, tends to break with reduced crushing and with unforeseeable fracture lines; consequently some metal debris may remain entrapped, blocking the stroke of the shearing elements and thus preventing the closing of the well.
The objective of the present invention is to provide a valve that overcomes the drawbacks of the known art, allowing the well to be closed even after a possible ineffective intervention of the BOPs.
According to the present invention, a safety valve for extraction wells of hydrocarbons is provided, which allows the tubular drilling material possibly present in the safety valve to be cut and the closing of the well with a hydraulic-seal.
According to the present invention, a safety valve for extraction wells of hydrocarbons is provided, that is capable of exerting the shearing action of the tubular material with a higher capacity than conventional BOPs, considering the worst stress conditions created in correspondence with the wellhead, currently not contemplated by said BOPs. In particular, the safety valve according to the invention is capable of severing a wide range of tubular elements in its interior, among which: casings having an outer diameter preferably ranging from 1″ to 20″, with a wall thickness preferably up to about 20 mm, drill pipes having an external diameter preferably ranging from 1″ to 10″, with a wall thickness preferably up to about 20 mm and tool joints having an external diameter preferably ranging from 1″ to 10″, with a wall thickness preferably up to about 40 mm.
A first object of the present invention therefore relates to a safety valve assembly AV comprising a valve body 2 in which there is a passage duct 24, preferably straight, configured to be passed through by a production and/or drilling line designed for containing and transporting, through a tubular element 26, extraction fluids or other fluids to be extracted from an underground reservoir, said valve assembly AV being provided with a punch 4 sliding linearly in a controlled mode along the axis A2 which intersects the longitudinal axis of the pipe A1 and a counter-punch 3, positioned diametrically opposite to the punch 4, sliding linearly in a controlled mode along said axis A2, said valve assembly AV being characterized in that the counter-punch 3 is configured so as to have a hollow part suitable for slidingly receiving the section of tubular material and the punch 4 in its interior, in the linear movement during the shearing operation, so as to create two different shearing planes.
A second object of the present invention relates to an extraction well comprising the valve assembly AV object of the present invention, as described hereunder.
A further object of the present invention relates to a method for managing an extraction well under emergency conditions, comprising the valve assembly AV, as described hereunder.
Further characteristics of the invention are indicated in the dependent claims, which are an integral part of the present description.
The characteristics and advantages of the present invention will appear evident from the following description of a non-limiting embodiment example, with reference to the figures of the enclosed drawings, in which:
With reference in particular to
In particular, the safety-valve assembly AV is configured to allow the passage of a tubular element 26, typically metallic, at least partially contained inside the well and oriented in the same axial direction as the well itself. The tubular element 26 is internally hollow and is designed for containing and transporting fluids and other substances extracted through the well, among which, for example, hydrocarbons (petroleum or natural gas), water, mud, rock debris and/or soil debris. The safety-valve assembly AV is operated by a remote power and control system 300 which can be installed either at a drill construction site (in the case of on-shore drillings), or on the sea bottom (in the case of off-shore drillings), at a predefined distance from the well. The technical characteristics of the safety-valve assembly AV, as will be better explained hereunder, are such as to not require maintenance during the operating life of the safety-valve assembly AV itself. The remote power and control system 300, however, can be removed to effect either programmed or occasional maintenance. In the case of off-shore drillings, the electric and hydraulic connections 400 between the remote power and control system 300 and the safety-valve assembly AV can be effected by means of an underwater ROV (“remotely operated vehicle”) 500, using connectors called “ROV-mateable connectors”.
In the present description, the expressions “lower” and “upper” respectively indicate positions closer to and further away from the reservoir in which the extraction well is operated.
With reference to
The safety-valve assembly AV is characterized in that the punch 4 and counter-punch 3 are configured so as to allow the counter-punch 3 to slidingly receive the punch 4 in its interior in order to create two different shearing planes; the counter-punch 3 being configured so as to have a hollow part suitable for receiving the section of tubular material and the punch 4 in the linear motion during the shearing operation.
The tubular elements 26 can be so-called casings, production tubings or pipe strings comprising drill pipes and tool joints (in technical jargon).
In a preferred embodiment of the invention, the punch 4 and the counter-punch 3 have a “V”-shaped configuration in the part which comes into contact with the tubular element 26 so as to exert a centering function of the above-mentioned tubular element when said punches engage the tubular element.
In a preferred embodiment, the punch 4 and the counter-punch 3 are actuated by means of respective hydraulic pistons 9 and 10.
In a further preferred embodiment, the punch 4 and the counter-punch 3 are controlled in the operative phases through the respective position sensors 13 and 14.
As can be seen from
In order to make the shearing process more effective, in a preferred embodiment, the valve assembly AV can be provided with an upper incision system which incises the surface of the tubular element 26, said notches contained in an upper incision plane IS, parallel to the upper cutting plane TS, lying above TS at a maximum distance preferably ranging from 0.1 mm to 10 mm from TS measured in the direction of the axis A1.
In a further preferred embodiment, the valve assembly AV can be provided with a lower incision system which incises the surface of the tubular element 26, said notches contained in a lower incision plane II, parallel to the lower cutting plane TI, lying below TI at a maximum distance preferably ranging from 0.1 mm to 10 mm from TI measured in the direction of the axis A1.
For this purpose, at least one engraver 7 for each cutting plane TS and TI is mounted on the valve assembly AV; the engravers are configured with cutter-holder bars 11, preferably having a rectangular section, sliding linearly along axes substantially orthogonal to the axis A1 and lying on incision planes IS, II. The cutters 28 are installed on the cutter-holder bars 11. The valve body 2 is designed with cavities 23 suitable for the passage of the engravers 7, enabling contact of the cutters 28 with the surface of the tubular element 26.
In a preferred embodiment, the engravers produce incisions preferably having a triangular form on the surface of the tubular element 26, said incisions having a penetration depth preferably ranging from 0.1 mm to 5 mm.
In a preferred embodiment of the invention, the valve assembly AV is provided with six engravers for each cutting plane, upper and lower, said engravers having a specular arrangement with respect to the plane comprising the axis A1 and the axis A2.
In a preferred embodiment, the engravers 7 are actuated by means of respective hydraulic pistons 8. In a further preferred embodiment, the engravers 7 are controlled in the operative phases by means of the respective position sensors 12.
In a preferred embodiment of the invention, the punch 4 is configured for incising the surface of the tubular element 26 on the plane TS; in a further preferred configuration of the invention, the punch 4 is configured for incising the surface of the tubular element 26 on the plane TI.
In a preferred embodiment of the invention, the counter-punch 3 is configured for incising the surface of the tubular element 26 on the plane IS; in a further preferred configuration of the invention, the counter-punch 3 is configured for incising the surface of the tubular element 26 on the plane II.
In a preferred embodiment of the invention, the force that can be impressed on the tubular element 26 by the punch 4 and the counter-punch 3 preferably ranges from 30,000 kN to 40,000 kN; the force expressed by each engraver 7 preferably ranges from 3,000 kN to 10,000 kN.
In a preferred embodiment of the invention, the seals 31 of the stems 30 of the hydraulic pistons 8,9 and 10 are protected from well fluids by means of elastic bellows 6, preferably metallic or made of PTFE. The elastic bellows 6 allow small movements of the relative pistons. Said movements, set at regular time intervals (in the order of 1-2 months), are useful for lubricating the seals 31, preventing sticking and ensuring the necessary reliability over a long time period (explorative phase and production phase of the well). In the case of actuation of the valve, the force of the pistons 8, 9 or 10 shears the fixing elements of the bellows 6 to the stems 30, which then continue their stroke for exerting specific functions.
In a preferred embodiment of the invention, the chambers 21 and 22 of the closing collar 5 and volumes confined by the protection bellows 6 are filled with an inert fluid and kept at the same pressure as the well fluids which pass through the valve body 2 by means of pressure-compensating devices 16, 17. The use of pressure-compensating devices is also envisaged for the protection bellows 6 installed for protecting the seals of the stems 30 of the hydraulic pistons 8 of the engravers 7. This system allows the seals to be isolated from the well fluids, avoiding damage to the protection bellows 6.
With reference to
Once the closing position has been reached, the closing collar 5 is blocked in the sealing position by means of one or more blocking pins 19, so as to keep said closing collar 5 in abutment on the sealing recess 18 situated in the punch 4 also in the absence of hydraulic pressure. The blocking pins 19 are pushed into corresponding grooves in the closing collar 5 by means of one or more corresponding springs 20 and, when the movement of said collar is required, the blocking pins 19 are withdrawn by means of hydraulic pressure exerted through the specific circuit which, as it advantageously communicates with said pins, allows them to be withdrawn overcoming the force of the springs 20. The pressurization of the chamber 22, positioned between the passage duct 24 and the outer surface of the closing collar 5, allows the downward sliding movement of the closing collar 5 which becomes disengaged from the recess 18. The hydraulic chambers 21 and 22 do not communicate with each other.
In a preferred embodiment of the invention, the valve assembly AV is designed for being installed on a seabed submerged by a water head up to 4,000 m deep.
With reference to
The actuation of the safety valve is of the reversible type to allow the restoration of the well if this is possible.
The re-opening process of the valve assembly AV comprises the following phases:
It can therefore be seen that the safety valve for wells for the extraction of hydrocarbons according to the present invention achieves the objectives previously indicated, obtaining numerous advantages, among which:
The safety valve for wells for the extraction of hydrocarbons of the present invention thus conceived, can in any case undergo numerous modifications and variants, all included in the same inventive concept; furthermore, all the details can be substituted by technically equivalent elements. In practice, the materials used, as also the forms and dimensions can vary according to technical requirements.
The protection scope of the invention is therefore defined by the enclosed claims.
Number | Date | Country | Kind |
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MI2014A001830 | Oct 2014 | IT | national |
Filing Document | Filing Date | Country | Kind |
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PCT/IB2015/058156 | 10/22/2015 | WO | 00 |