This disclosure relates to wellbore chemical injection and specifically to injection from a surface of the wellbore through a wellhead.
Wellbore operations utilize well tools installed within a wellbore formed in a subterranean zone (e.g., a formation, a portion of a formation, multiple formations). Fluids (e.g., drilling mud) used during wellbore formation or hydrocarbons (e.g., petroleum, natural gas, combinations of them) produced through the wellbore after formation and completion can corrode the well tools. Chemicals, such as corrosion inhibitors, scale inhibitors, emulsion preventive inhibitors, asphaltene inhibitor, to name a few, can be injected from a surface of the wellbore into the wellbore (e.g., into a wellbore-tubing annulus) to minimize such corrosive effect of fluids that flow through the wellbore. The chemicals can be injected using a chemical injection assembly that is installed at the surface of the wellbore. The chemical injection assembly can be fluidically coupled to the wellhead, specifically to the wellhead to inject the chemicals through a tubing spool, which is a component of the wellhead.
This disclosure relates to wellbore chemical injection flange system through tubing spool side outlet port.
Certain aspects of the subject matter described here can be implemented as a wellbore chemical injection assembly. The assembly includes an extension flange including a first end and a second end opposite the first end. The extension flange defines a flange bore between the first end and the second end. The first end can be fluidically coupled to a tubing spool inlet of a wellhead installed at a surface of a wellbore formed through a subterranean zone. The second end can be fluidically coupled to a chemical reservoir from which chemical is injected through the flange bore into the tubing spool. The assembly includes a mandrel positioned within the extension flange. A portion of the mandrel resides within the flange bore. A remainder of the mandrel extends out of the extension flange. The mandrel defines an interior opening spanning an axial length of the mandrel. The assembly includes outer coupling threads formed on an outer surface of the remainder of the mandrel. The outer coupling threads can removably mate with counterpart threads in the tubing spool inlet. The assembly includes inner coupling threads formed on an inner surface of a portion of the interior opening. The assembly includes a valve assembly removably seated in the interior opening. The valve assembly includes valve coupling threads on an outer surface of the valve assembly. The valve coupling threads can removably mate with the inner coupling threads formed on the inner surface of the portion of the interior opening.
An aspect combinable with any other aspect includes the following features. The valve assembly includes a valve seat seated in the interior opening. The valve assembly includes multiple check valves installed in the valve seat. The multiple check valves can permit flow of the chemical in one direction through the interior opening and prevent flow of the chemical in the opposite direction.
An aspect combinable with any other aspect includes the following features. An inner diameter of the portion of the interior opening with the inner coupling threads is greater than an inner diameter of the remainder of the mandrel with the outer coupling threads.
An aspect combinable with any other aspect includes the following features. The valve seat includes a first segment and a second segment. An outer diameter of the first segment is greater than an outer diameter of the second segment. The first segment is seated in the portion of the interior opening with the greater inner diameter. The second segment is seated in the portion of the interior opening with the smaller inner diameter.
An aspect combinable with any other aspect includes the following features. The multiple check valves are installed in the second segment.
An aspect combinable with any other aspect includes the following features. The outer coupling threads form a metal-to-metal seal with the tubing spool inlet.
An aspect combinable with any other aspect includes the following features. The outer coupling threads are Sharp Vee threads or ACME threads.
An aspect combinable with any other aspect includes the following features. The flange bore is oriented parallel to a flow of the chemical into the tubing spool inlet.
Certain aspects of the subject matter described here can be implemented as a method. A valve assembly is installed in an interior opening that spans an axial length of a mandrel by removably mating valve coupling threads on an outer surface of a first segment of the valve assembly with inner coupling threads on an inner surface of a portion of the interior opening. The mandrel with the valve assembly is positioned within a flange bore defined between a first end and a second, opposite end of the extension flange. A portion of the mandrel resides within the flange bore and a remainder of the mandrel extends out of the extension flange. Outer coupling threads are formed on an outer surface of the remainder of the mandrel. The outer coupling threads formed on the outer surface of the remainder of the mandrel are coupled with counterpart threads in a tubing spool inlet of a wellhead installed at a surface of a wellbore formed through a subterranean zone. Chemicals are injected through the mandrel and the valve assembly into the wellbore through the tubing spool inlet.
An aspect combinable with any other aspect includes the following features. A chemicals leaks in the valve seat is determined. In response to determining the chemicals leak in the valve seat, injecting the chemicals through the mandrel and the valve assembly is ceased. The valve assembly is removed from the interior opening by de-coupling the valve coupling threads with the inner coupling threads while retaining the mandrel within the flange bore.
An aspect combinable with any other aspect includes the following features. A chemicals leak is determined in the flange bore. In response to determining the chemicals leak in the flange bore, injecting the chemicals through the mandrel and the valve assembly is ceased. The mandrel is removed through the flange bore while retaining the valve assembly within the interior opening while retaining the flange bore in place.
An aspect combinable with any other aspect includes the following features. To couple the outer coupling threads formed on the outer surface of the remainder of the mandrel with counterpart threads in the tubing spool inlet, the flange bore is oriented parallel to a flow of the chemical into the tubing spool inlet.
An aspect combinable with any other aspect includes the following features. The valve assembly includes a valve seat and multiple check valve that can permit flow of the chemical in one direction through the interior opening and prevent flow of the chemical in the opposite direction. The valve seat is seated in the interior opening. The plurality of check valves are installed in the valve seat.
An aspect combinable with any other aspect includes the following features. An inner diameter of the portion of the interior opening with the inner coupling threads is greater than an inner diameter of the remainder of the mandrel with the outer coupling threads. The valve seat includes a first segment and a second segment. An outer diameter of the first segment is greater than an outer diameter of the second segment. The first segment is seated in the portion of the interior opening with the greater inner diameter. The second segment is seated in the portion of the interior opening with the smaller inner diameter.
An aspect combinable with any other aspect includes the following features. The plurality of check valves are seated in the second segment.
Certain aspects of the subject matter described here can be implemented as a wellbore chemical injection system. The system includes a chemical reservoir storing chemicals to be injected into a wellbore formed in a subterranean zone through a wellhead installed at a surface of the wellbore. The wellhead includes a tubing spool having a tubing spool inlet that can receive the chemicals from the chemical reservoir. The system includes a flowline fluidically coupled to the chemical reservoir. The flowline can flow the chemicals from the chemical reservoir to the tubing spool inlet. The system includes a wellbore chemical injection assembly. The assembly includes an extension flange including a first end and a second end opposite the first end. The extension flange defines a flange bore between the first end and the second end. The first end can be fluidically coupled to a tubing spool inlet of a wellhead installed at a surface of a wellbore formed through a subterranean zone. The second end can be fluidically coupled to a chemical reservoir from which chemical is injected through the flange bore into the tubing spool. The assembly includes a mandrel positioned within the extension flange. A portion of the mandrel resides within the flange bore. A remainder of the mandrel extends out of the extension flange. The mandrel defines an interior opening spanning an axial length of the mandrel. The assembly includes outer coupling threads formed on an outer surface of the remainder of the mandrel. The outer coupling threads can removably mate with counterpart threads in the tubing spool inlet. The assembly includes inner coupling threads formed on an inner surface of a portion of the interior opening. The assembly includes a valve assembly removably seated in the interior opening. The valve assembly includes valve coupling threads on an outer surface of the valve assembly. The valve coupling threads can removably mate with the inner coupling threads formed on the inner surface of the portion of the interior opening.
The details of one or more implementations of the subject matter described in this specification are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims.
Like reference numbers and designations in the various drawings indicate like elements.
Hydrocarbons entrapped in subsurface reservoirs flow from the reservoirs through the subterranean zone into the wellbore formed in the subterranean zone. Wellbore equipment are installed within the wellbore to produce the hydrocarbons to the surface. The fluids, e.g., high saline formation brines, various mixtures of oil and mixtures of gas (such as natural gas, hydrogen sulfide, carbon dioxide) that flow into the wellbore through the subterranean zone are extremely corrosive. The wellbore equipment, e.g., tubulars, packers, and the like, can be adversely impacted by the long-term contact with such fluids. For example, the equipment can corrode, or scales or sludges can build up on the equipment or both. The adverse impact on the wellbore equipment, in turn, can impact well production, well integrity, surface production facilities and the like. The adverse impact of the wellbore fluids can be reduced by flowing (i.e., injecting or pumping) chemical inhibitors into the wellbore. The chemicals can be pumped from a surface of the wellbore continuously to downhole locations, specifically to the area of the designed target depth.
This disclosure describes a wellbore chemical injection assembly with an extension flange that can be coupled to a tubing spool inlet of a wellhead of a wellbore formed in a subterranean zone. In some implementations, the assembly includes a mandrel with a thread profile that can be coupled to a counterpart thread profile formed in the tubing spool inlet. The mandrel is installed within the extension flange. The extension flange is a flange that has a similar/same type of pressure rating and connection type for a gate valve connection. The extension flange is designed and constructed to swallow mandrel/seat together while also allowing the injection valve to pass through. The extension flange allows increasing the space between the gate valve and tubing spool side outlet flange.
A valve seat is installed within the mandrel, and a valve set including check valves is installed within the valve seat. The assembly is fluidically coupled to the wellhead such that the mandrel forms a metal-to-metal seal with the tubing spool inlet (e.g., a side outlet port), and the valve seat forms a fluidic seal within the mandrel. Chemicals can be injected into the wellhead through the extension flange. If a leak is detected at the tubing spool inlet-mandrel interface, then the assembly can be detached from the wellhead at the mandrel, and the mandrel alone can be replaced. If a leak is detected in the valve seat-mandrel interface, then the valve seat alone can be replaced. If the injection valve leaks, then the injection valve can be replaced. All these replacements can be done directly if wellhead does not have any positive pressure or can be done through VR plug lubricator systems if the well is under pressure.
In some implementations, the assembly includes an extension flange with an inlet formed on a flange wall (i.e., a side wall that connects an inlet and an outlet). An extension member extends from the flange wall inlet away from the flange wall. A valve seat is installed within the extension member, and a valve set including check valves is installed within the valve seat. In this implementation, there is no thread connection for the valve seat. Instead, the valve seat are included in the body of the chemical injection flange. The flange body has three different sized seats (threads). Each check valve can be installed or removed independently. Deeper check valve seat is smaller in size (near the flange main inner bore). Outer check valve is comparatively bigger. The assembly is fluidically coupled to the wellhead such that chemicals can be injected through the tubing spool inlet. In particular, the chemicals are injected in a direction that is transverse to the end-to-end opening within the extension flange. If a leak is detected in the valve seat-extension member interface, then the valves can be replaced.
Implementations of the subject matter described in this disclosure can improve efficiency and safety of wellbore chemical injection operations by deploying internal fail safe systems. The techniques described here are mechanical solutions that can be deployed with lesser resource consumption compared to smart solutions that implement pneumatic, hydraulic or electrical actuators. The techniques can also increase well integrity in instances that do not require chemical injection from the surface for a duration of time. The arrangement allows chemical injection while keeping side outlet barriers in place and in closed position, while keeping side outlet gate valves in closed position. The arrangement of the valve seat allows easy removal of valves to perform operations such as killing the well, injecting high density brine fluid or performing higher rate injection operations. The assembly can serve as a barrier that facilitates replacing gate valves on the side outlet of the tubing spool. Replacing the mandrel can be performed using valve removal (VR) lubricators.
At the surface, a wellhead can be installed to deploy wellbore equipment (including the production tubing 104, the packers 112, etc.) within the wellbore 100, and also to serve as a connection point for surface equipment. The wellhead can include a wellhead 116, which is a network of fluidic inlets, outlets and flow control equipment (such as valves) to which the wellbore injection assembly 102 is fluidically coupled. In particular, the assembly 102 can be fluidically coupled to an inlet formed in a tubing spool 118 of the wellhead 116. A control line 120 (e.g., a tubing or a pipe) extends from the tubing spool 118 to a downhole location that is downhole of the inlet to the production tubing 104. For example, the control line 120 can pass through an annulus formed by the production tubing 104 and the casing installed in or inner wall of the wellbore 100, and through the packers 112. Chemicals can be injected from the surface of the wellbore 100 through the control line 120 to the downhole location. The injected chemicals are flowed in an uphole direction (arrows 122) by the hydrocarbons and swept into the production tubing 104. As the chemicals flow towards the surface, the chemicals contact the wellbore equipment (such as the inner walls of the production tubing 104) to prevent, reduce or reverse the adverse effects mentioned earlier.
As described later, the assembly 102 and the tubing spool inlet are coupled using valve removal (VR) plugs. The VR plugs have an American Petroleum Institute (API) Sharp Vee VR profile (called “Sharp Vee”) profile that is rated for pressures between 3,000 pounds per square inch (psi) and 10,000 psi. Tubing spools have API standard VR plug profiles. VR plugs do not stay in installed positions in the side outlet ports at all times. In some situations, the VR plugs can be installed and kept in the wellhead. If the VR standard VR plug is installed, they fully isolate the side outlet port.
In some implementations, the wellbore chemical injection assembly 102 can be fluidically coupled to the top tubing spool 118 between the gate valve 310c and an inlet to the tubing spool 118. In alternative implementations, the assembly 102 can be fluidically coupled between the gate valves 310c and 310d, or the gate valves 310c and 310d can be fluidically coupled between the assembly 102 and the tubing spool inlet.
Chemicals flowed using the pump 206 (
The assembly 102 includes a mandrel/valve seat sub-assembly 412 that includes a mandrel 414 and a valve seat 416. The mandrel 414 is coupled to the tubing spool side outlet port (VR plug profile) negating any direct contact between mandrel/valve seat and extension flange 402. In particular, a portion of the mandrel 414 resides within the flange bore 408. A remainder of the mandrel 414 extends out of the extension flange 402, e.g., past the first end 404. The extension flange 402 covers the mandrel 414.
Outer coupling threads 418 are formed on an outer surface of the portion of the mandrel 414 that extends out of the flange bore 408 past the first end 404. The outer coupling threads 418 can removably mate with counterpart threads in the tubing spool inlet. By removably couple, it is meant that, when portion of the mandrel 404 with the outer coupling threads is inserted into the portion of the tubing spool inlet with the counterpart threads, the mandrel 404 and the tubing spool inlet form a seal, e.g., a metal-to-metal seal or similar seal that fluidically seals the outer surface of the mandrel 404 to the inner surface of the tubing spool inlet. For example, the outer coupling and counterpart threads can be API standard Sharp Vee threads or ACME threads.
To reverse the mating, the mandrel 414 can be pulled out of the tubing spool inlet, e.g., using a VR plug lubricator system, which can remove the mandrel even when the connection is under fluidic pressure. A VR lubricator system is used to replace valves such as a side outlet valve, annular valve or wing valve on the tubing spool of a wellhead. The VR lubricator system is mounted on the outlet flange of the gate valve (e.g., the gate valve 312d) and operated to install/remove the VR plug through the extension flange bore. The VR lubricator system can be operated hydraulically or manually. The VR lubricator system includes a cylinder and an internal rod. The VR lubricator system works by exerting pressure into the cylinder causing the rod to move inward or outward like a hydraulic piston.
In some implementations, the length segment of the interior opening with the smallest inner diameter can also have the outer coupling threads 418 on the outer surface. Conversely, the length segment of the interior opening with the largest inner diameter can have no threads formed on the outer surface. Instead, that length segment can have inner coupling threads 422 formed on an inner surface of the interior opening 420. In the schematic shown in
The valve 424 can further define an interior opening 428 through which injected chemicals can flow into the tubing spool inlet. Multiple valves (e.g., two check valves 430a, 430b (also shown in
During operation, if a chemicals leak is detected in the valve 424, then the injection of chemicals through the mandrel and the valve assembly is ceased, e.g., by turning off the HP pump 206 (
The extension flange 604 defines an inlet 612 on the flange wall 610. For example, the inlet 612 can be a through opening from an outer surface of the flange wall 610 to the interior opening (i.e., the flange bore 611) defined by the extension flange 604. In some implementations, the inlet 612 is formed equidistantly from the first end 604 and the second end 604. In some implementations, the inlet 612 can be nearer to one end than the other.
An extension member 612 is attached to the flange wall 610 at the inlet 612. For example, the extension member 612 can be a tubular structure made of the same material as the flange wall 610. The tubular structure can be attached (e.g., welded or manufactured directly into the flange body) to the flange wall 610 at the inlet 612 at a non-zero angle (e.g., substantially perpendicular or other non-zero angle) with respect to the flange wall 610. Like the flange bore 611 of the extension flange 604, the extension member 612 also defines an interior opening 616.
In some implementations, the interior opening 616 can have a uniform inner diameter along an axial length of the interior opening 616. In some implementations, the axial length of the extension member 614 can define a through opening of increasing inner diameter from the inlet 612 towards an end 618 of the extension member 614. The end 618 is configured to be fluidically coupled to a chemical reservoir (e.g., the chemical reservoir 202 (
As shown in
In some implementations, the multiple valves are sized differently to seal the through opening 614 of increasing diameter. For example, an outer diameter of each of the multiple valves can be different and can be sized to match an inner diameter of the location in the through opening 614 in which the respective valve is installed. In implementations in which the through opening 616 is sized to have a decreasing inner diameter along the axial length from the inlet 612 to the end 618, the outer diameter of the valve 620 can be sized so that the valve 620 can be seated near the inlet 612 where an inner diameter of the through opening 614 is the narrowest. The outer diameter of the valve 622 can be greater than that of the valve 620, and the outer diameter of the valve 624 can be greater than that of the valve 622. In this manner, each valve can be sized to be seated to seal along an axial length of the extension member 614.
In implementations in which the through opening 616 has a uniform inner diameter along its length from the inlet 612 to the end 618, a valve 626 can be installed within the through opening 616, for example, in a manner similar to which the valve 424 (
In the arrangement of
In some implementations, the valve 626 is installed in the through opening of the extension member 614. The valve 626 has increasing inner diameters from the inlet 612 towards the end 616 of the extension member 616. The multiple valves are installed in the flange body. During operation, if a chemicals leak is detected in the valve 626, then the injection of chemicals through the extension member 614 is ceased, e.g., by turning off the HP pump 206 (
Thus, particular implementations of the subject matter have been described. Other implementations are within the scope of the following claims.
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