Patent Application
20240125205
Safety valves (e.g., including subsurface safety valves (SSSVs)) are well known in the oil and gas industry and provide one of many failsafe mechanisms to prevent the uncontrolled release of subsurface production fluids, should a wellbore system experience a loss in containment. Typically, safety valves comprise a portion of a tubing string, the entirety of the safety valve being set in place during completion of a wellbore. Although a number of design variations are possible for safety valves, the vast majority are flapper-type valves that open and close in response to longitudinal movement of a flow tube.
Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
In the drawings and descriptions that follow, like parts are typically marked throughout the specification and drawings with the same reference numerals, respectively. The drawn figures are not necessarily, but may be, to scale. Certain features of the disclosure may be shown exaggerated in scale or in somewhat schematic form and some details of certain elements may not be shown in the interest of clarity and conciseness. The present disclosure may be implemented in embodiments of different forms. Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure, and is not intended to limit the disclosure to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed herein may be employed separately or in any suitable combination to produce desired results. Moreover, all statements herein reciting principles and aspects of the disclosure, as well as specific examples thereof, are intended to encompass equivalents thereof. Additionally, the term, “or,” as used herein, refers to a non-exclusive or, unless otherwise indicated.
Unless otherwise specified, use of the terms “connect,” “engage,” “couple,” “attach,” or any other like 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.
Unless otherwise specified, use of the terms “up,” “upper,” “upward,” “uphole,” “upstream,” or other like terms shall be construed as generally away from the bottom, terminal end of a well, regardless of the wellbore orientation; likewise, use of the terms “down,” “lower,” “downward,” “downhole,” “downstream,” or other like terms shall be construed as generally toward the bottom, terminal end of a well, regardless of the wellbore orientation. Use of any one or more of the foregoing terms shall not be construed as denoting positions along a perfectly vertical or horizontal axis. Unless otherwise specified, use of the term “subterranean formation” shall be construed as encompassing both areas below exposed earth and areas below earth covered by water, such as ocean or fresh water.
The present disclosure has acknowledged that offshore wells are being drilled at ever increasing water depths and in environmentally sensitive waters, and thus safety valves (e.g., including subsurface safety valves (SSSVs)) are necessary. The present disclosure has further acknowledged that safety valves have inherent problems. For instance, the present disclosure has recognized that the operational lifespan of traditional safety valve is less than optimal, whether they completely quit working or alternatively begin to leak. In such situations where the safety valves completely stop working or alternatively begin to leak, the tubing string that the safety valves are coupled to must be pulled out of hole, coupled to a new working safety valve, and then returned within the wellbore, which is an expensive and time consuming process. Alternatively, a secondary wireline retrievable safety valve may be insert within the wellbore, but they tend to have their own problems.
Based, at least in part, on the foregoing acknowledgments and recognitions, the present disclosure has developed a retrievable safety valve insert (e.g., tubing string independent retrievable safety valve insert). The retrievable safety valve insert, in at least one embodiment, may be run in hole in two or more steps. For example, an outer housing, lock mandrel and safety valve insert of the retrievable safety valve insert may be first run in hole. Thereafter, a secondary opening prong may be run in hole, and for example coupled with a bore flow management actuator of the failed safety valve. In at least one embodiment, when coupled with the bore flow management actuator of the failed safety valve, the secondary opening prong is configured to move with the bore flow management actuator to: 1) hold the valve body closure mechanism of the failed safety valve in the valve body open state and allow the safety valve insert closure mechanism of the retrievable safety valve insert to remain in the outer housing closed state when the bore flow management actuator is in an uphole state; or 2) hold the valve body closure mechanism in the valve body open state and hold the safety valve insert closure mechanism in the outer housing open state when the bore flow management actuator is in a downhole state. The process of inserting the retrievable safety valve insert within the wellbore is a much less expensive and much less time consuming process (e.g., can eliminate the need for a workover unit) than is currently necessary when pulling the tubing string, as discussed above.
Safety valves according to the disclosure may include hydraulic and/or electric actuation. For example, in at least one embodiment, a hydraulic actuator is coupled to the bore flow management actuator to move the bore flow management actuator, and thus the secondary opening prong, from the uphole state to the downhole state. In at least one other embodiment, an electric actuator is coupled to the bore flow management actuator to move the bore flow management actuator, and thus the secondary opening prong, from the uphole state to the downhole state.
A safety valve according to the disclosure may also have increased failsafe ability as compared to other safety valves. Failsafe may be defined as a condition in which the safety valve or associated control system may be damaged and the safety valve (e.g., including the retrievable safety valve insert) retains the ability to close. In some examples, the safety valve may fail in a closed position (e.g., closed state), thus ensuring that wellbore fluids and pressure are contained. In another example, the safety valve (e.g., including the retrievable safety valve insert) may fail while in an open position (e.g., flow state), but closes automatically (e.g., using one or more springs) when a hydraulic and/or electrical connection to the surface is damaged or severed without any additional external input.
The safety valve 170, or at least a portion thereof, may be interconnected in conduit 140 (e.g., in line with conduit) and positioned in the wellbore 130. Although the well system 100 is depicted in
The safety valve 170, in at least one embodiment, may include a retrievable safety valve insert. The retrievable safety valve insert, in at least one embodiment, may include an outer housing including an outer housing central bore extending axially through the outer housing, the outer housing central bore operable to convey subsurface production fluids there through, and a lock mandrel having a lock mandrel profile extending radially outward from the outer housing, the lock mandrel profile movable between a radially retracted state and a radially expanded state configured to engage with an end sub profile of an end sub. The retrievable safety valve insert may further include a safety valve insert closure mechanism coupled to the outer housing proximate a downhole end of the outer housing central bore, the safety valve insert closure mechanism movable between an outer housing closed state and an outer housing open state. In at least one embodiment, the safety valve 170 further includes a secondary opening prong coupled to a bore flow management actuator of the safety valve 170. Accordingly, the safety valve 170 may employ movement of the bore flow management actuator to slide the secondary opening prong to open and/or close the safety valve insert closure mechanism of the retrievable safety valve insert. While the embodiment of
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The retrievable safety valve insert 200 may further include a lock mandrel 220. In at least one embodiment, the lock mandrel 220 has a lock mandrel profile 225 extending radially outward from the outer housing 210, the lock mandrel profile 225 movable between a radially retracted state (e.g., not shown) and a radially expanded state (e.g., shown) configured to engage with the end sub profile of the end sub. In at least one embodiment, the lock mandrel 220 includes a sliding wedge 230, the sliding wedge 230 operable to engage the lock mandrel profile 225 to move the lock mandrel profile 225 from the radially retracted state to the radially expanded state. The lock mandrel 220, in at least this one embodiment, further includes a deployment profile 235 located along an inner surface of the lock mandrel 220, the deployment profile 235 operable to deploy the retrievable safety valve insert 200 within the end sub, as well as move the lock mandrel profile 225 from the radially retracted state to the radially expanded state to engage the end sub profile of the end sub.
The retrievable safety valve insert 200, in the illustrated embodiment, further includes a safety valve insert closure mechanism 240 coupled to the outer housing 210 proximate a downhole end of the outer housing central bore 215. The safety valve insert closure mechanism 240, in the illustrated embodiment, is movable between an outer housing closed state (e.g., as shown) and an outer housing open state (e.g., not shown). The safety valve insert closure mechanism 240, in the illustrated embodiment of
In the illustrated embodiment of
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The secondary opening prong 300, in accordance with at least one embodiment, further includes a secondary opening prong profile 320. The secondary opening prong profile 320, in one or more embodiments, is configured to engage with a related bore flow management actuator profile (e.g., not shown) in a bore flow management actuator of a safety valve. When the secondary opening prong profile 320 is engaged with the bore flow management actuator profile, any movement of the bore flow management actuator moves the secondary opening prong 300, as will be further discussed below.
In at least one embodiment, the secondary opening prong 300 comprises metal. In yet another embodiment, the secondary opening prong 300 comprises any other materials suitable for downhole use, including various plastics and/or polymers.
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The safety valve 400, in one or mor embodiments, further includes a valve body closure mechanism 420 coupled to the valve body 410 proximate a downhole end of the valve body central bore 415. The valve body closure mechanism 420, in accordance with one embodiment, is configured to move between a valve body closed state (e.g., as shown) and a valve body open state (e.g., not shown). In at least one embodiment, the valve body closure mechanism 420 includes a safety valve flapper valve 422 that engages with a safety valve flapper seat 424. The valve body closure mechanism 420, in one or more embodiments, may additionally include a bias spring 426, the bias spring 426 configured to bias the valve body closure mechanism 420 towards the valve body closed state.
The safety valve 400, in one or more embodiments, may further include a bore flow management actuator 430 disposed in the valve body central bore 415, the bore flow management actuator 430 configured to slide to move the valve body closure mechanism 420 between the valve body closed state (e.g., as shown) and the valve body open state (e.g., not shown). In the embodiment of
In at least one embodiment, the bore flow management actuator 430 includes a bore flow management actuator profile 435 located along an inner surface thereof. As will be discussed further below, the bore flow management actuator profile 435 may be used to engage with a secondary opening prong profile of a secondary opening prong. Further to the embodiment of
The safety valve 400, in one or more embodiments, may further include one or more springs 450 coupled to the bore flow management actuator 430, the one or more springs 450 configured to return the bore flow management actuator 430 to the uphole state when the actuator 440 loses power, or the power is cut to the actuator 440. Nevertheless, other embodiments exist wherein only a single spring is employed.
The safety valve 400, in the illustrated embodiment, additionally includes an end sub 460 coupled to a downhole end of the valve body 410. In one or more embodiments, the end sub 460 includes an end sub profile 465 along an inner surface thereof. As will be discussed in greater detail below, the end sub profile 465 is operable to engage with a related lock mandrel profile of the retrievable safety valve insert that may be included therein.
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Aspects Disclosed Herein Include:
A. A retrievable safety valve insert, the retrievable safety valve insert including: 1) an outer housing including an outer housing central bore extending axially through the outer housing, the outer housing central bore operable to convey subsurface production fluids there through; 2) a lock mandrel having a lock mandrel profile extending radially outward from the outer housing, the lock mandrel profile movable between a radially retracted state and a radially expanded state configured to engage with an end sub profile of an end sub; and 3) a safety valve insert closure mechanism coupled to the outer housing proximate a downhole end of the outer housing central bore, the safety valve insert closure mechanism movable between an outer housing closed state and an outer housing open state.
B. A safety valve, the safety valve including: 1) a valve body defining a valve body central bore extending through the valve body, the valve body central bore operable to convey subsurface production fluids there through; 2) a valve body closure mechanism coupled to the valve body proximate a downhole end of the valve body central bore; 3) a bore flow management actuator disposed in the valve body central bore, the bore flow management actuator configured to slide to move the valve body closure mechanism between a valve body closed state and a valve body open state; 4) an end sub coupled to a downhole end of the valve body, the end sub including an end sub profile along an inner surface thereof; and 5) a retrievable safety valve insert coupled to the end sub, the retrievable safety valve insert including: a) an outer housing including an outer housing central bore extending axially through the outer housing, the outer housing central bore operable to convey the subsurface production fluids there through; b) a lock mandrel having a lock mandrel profile extending radially outward from the outer housing, the lock mandrel profile movable between a radially retracted state and a radially expanded state engaged with the end sub profile of the end sub; and c) a safety valve insert closure mechanism coupled to the outer housing proximate a downhole end of the outer housing central bore, the safety valve insert closure mechanism movable between an outer housing closed state and an outer housing open state.
C. A well system, the well system including: 1) a wellbore extending through one or more subterranean formations; 2) production tubing disposed in the wellbore; and 3) a safety valve disposed in line with the production tubing, the safety valve including: a) a valve body defining a valve body central bore extending through the valve body, the valve body central bore operable to convey subsurface production fluids there through; b) a valve body closure mechanism coupled to the valve body proximate a downhole end of the valve body central bore; c) a bore flow management actuator disposed in the valve body central bore, the bore flow management actuator configured to slide to move the valve body closure mechanism between a valve body closed state and a valve body open state; d) an end sub coupled to a downhole end of the valve body, the end sub including an end sub profile along an inner surface thereof; and e) a retrievable safety valve insert coupled to the end sub, the retrievable safety valve insert including: i) an outer housing including an outer housing central bore extending axially through the outer housing, the outer housing central bore operable to convey the subsurface production fluids there through; ii) a lock mandrel having a lock mandrel profile extending radially outward from the outer housing, the lock mandrel profile movable between a radially retracted state and a radially expanded state engaged with the end sub profile of the end sub; and iii) a safety valve insert closure mechanism coupled to the outer housing proximate a downhole end of the outer housing central bore, the safety valve insert closure mechanism movable between an outer housing closed state and an outer housing open state.
D. A method for assembling and operating a safety valve, the method including: 1) positioning a safety valve within a wellbore extending through one or more subterranean formations, the safety valve disposed in line with production tubing located within the wellbore, the safety valve including: a) a valve body defining a valve body central bore extending through the valve body, the valve body central bore operable to convey subsurface production fluids there through; b) a valve body closure mechanism coupled to the valve body proximate a downhole end of the valve body central bore; c) a bore flow management actuator disposed in the valve body central bore, the bore flow management actuator configured to slide to move the valve body closure mechanism between a valve body closed state and a valve body open state; and d) an end sub coupled to a downhole end of the valve body, the end sub including an end sub profile along an inner surface thereof; 2) actuating the bore flow management actuator to slide the valve body closure mechanism from the valve body closed state to the valve body open state; and 3) positioning a retrievable safety valve insert withing the wellbore below the valve body closure mechanism after actuating the bore flow management actuator, the retrievable safety valve insert including: a) an outer housing including an outer housing central bore extending axially through the outer housing, the outer housing central bore operable to convey the subsurface production fluids there through; b) a lock mandrel having a lock mandrel profile extending radially outward from the outer housing, the lock mandrel profile movable between a radially retracted state and a radially expanded state engaged with the end sub profile of the end sub; and c) a safety valve insert closure mechanism coupled to the outer housing proximate a downhole end of the outer housing central bore, the safety valve insert closure mechanism movable between an outer housing closed state and an outer housing open state.
Aspects A, B, C and D may have one or more of the following additional elements in combination: Element 1: wherein the safety valve insert closure mechanism is a flapper valve configured to engage with a safety valve insert flapper seat positioned in the outer housing. Element 2: further including one or more seals positioned about the outer housing between the lock mandrel profile and the safety valve insert closure mechanism. Element 3: further including a deployment profile located along an inner surface of the lock mandrel, the deployment profile operable to deploy the retrievable safety valve insert within the end sub, as well as move the lock mandrel profile from the radially retracted state to the radially expanded state to engage the end sub profile of the end sub. Element 4: wherein the bore flow management actuator has a bore flow management actuator profile located along an inner surface thereof, and further including a secondary opening prong including a secondary opening prong profile located within the valve body central bore, the secondary opening prong profile coupled with the bore flow management actuator profile. Element 5: wherein the secondary opening prong is configured to move with the bore flow management actuator to: hold the valve body closure mechanism in the valve body open state and allow the safety valve insert closure mechanism to remain in the outer housing closed state when the bore flow management actuator is in an uphole state; or hold the valve body closure mechanism in the valve body open state and hold the safety valve insert closure mechanism in the outer housing open state when the bore flow management actuator is in a downhole state. Element 6: wherein a hydraulic actuator is coupled to the bore flow management actuator to move the bore flow management actuator from the valve body closed state and the valve body open state. Element 7: wherein an electric actuator is coupled to the bore flow management actuator to move the bore flow management actuator from the valve body closed state and the valve body open state. Element 8: further including one or more springs coupled to the bore flow management actuator, the one or more springs configured to return the bore flow management actuator to the valve body closed state when an actuator coupled to the bore flow management actuator loses power. Element 9: wherein the safety valve insert closure mechanism is a flapper valve configured to engage with a safety valve insert flapper seat positioned in the outer housing. Element 10: further including one or more seals positioned about the outer housing between the lock mandrel profile and the safety valve insert closure mechanism. Element 11: further including a deployment profile located along an inner surface of the lock mandrel, the deployment profile operable to deploy the retrievable safety valve insert within the end sub, as well as move the lock mandrel profile from the radially retracted state to the radially expanded state to engage the end sub profile of the end sub. Element 12: wherein positioning the retrievable safety valve insert includes coupling the lock mandrel profile with the end sub profile of the end sub. Element 13: further including coupling a secondary opening prong with the bore flow management actuator after positioning the retrievable safety valve insert withing the wellbore. Element 14: wherein the bore flow management actuator has a bore flow management actuator profile located along an inner surface thereof and the secondary opening prong includes a secondary opening prong profile located along an outer surface thereof, and further wherein coupling the secondary opening prong with the bore flow management actuator includes coupling the secondary opening prong profile with the bore flow management actuator profile. Element 15: wherein coupling the secondary opening prong with the bore flow management actuator occurs after allowing the bore flow management actuator to return to the valve body closed state. Element 16: wherein the secondary opening prong is configured to move with the bore flow management actuator to: hold the valve body closure mechanism in the valve body open state and allow the safety valve insert closure mechanism to remain in the outer housing closed state when the bore flow management actuator is in an uphole state; or hold the valve body closure mechanism in the valve body open state and hold the safety valve insert closure mechanism in the outer housing open state when the bore flow management actuator is in a downhole state. Element 17: further including re-actuating the bore flow management actuator after coupling the secondary opening prong with the bore flow management actuator, the secondary opening prong moving to a downhole state to hold the valve body closure mechanism in the valve body open state and hold the safety valve insert closure mechanism in the outer housing open state. Element 18: wherein the retrievable safety valve insert is a first retrievable safety valve insert, and further including removing the first retrievable safety valve insert from the wellbore and then positioning a second retrievable safety valve insert withing the wellbore below the valve body closure mechanism.
Those skilled in the art to which this application relates will appreciate that other and further additions, deletions, substitutions and modifications may be made to the described embodiments.
