Downhole Cross Flow Prevention During Well and Power Shutdown
A system and method for automatically preventing cross flow in a subterranean well during a shutdown event includes a plurality of downhole control valves located within the subterranean well. An energy storage device releases a stored energy during a shutdown event. A primary fail device is a normally close, fail open device that moves to a primary open position during a shutdown event, providing a portion of the stored energy to each of the plurality of downhole control valves during a shutdown event. The portion of the stored energy delivered to each of the plurality of downhole control valves is sufficient to move each of the plurality of downhole control valves to a valve closed position.
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1. Field of the Disclosure
The present disclosure relates in general to the control of subterranean wells, and more particularly to automatically preventing downhole cross-flow of fluids in subterranean multizone intelligent completion wells.
2. Description of the Related Art
The production of oil and gas in multilateral or multizone wells typically requires the use of various valves and other downhole equipment commonly known as intelligent completions. For example, an inflow control valve (ICV) assembly can be inserted into the well bore, and can include an inflow valve 28 that regulates the flow of fluid through the bore. The communication of commands from an operator at the surface to such valves and other downhole equipment is important to production control of the well.
In some current multizone intelligent wells with inflow from multiple zones, only the surface valves and subsurface safety valves are closed during well shut down. The downhole valves remain open and will have cross flow between zones during the period of shutdown. The downhole control valves do not have a mechanism to automatically close and some current auto-close features available for such valves are subject to potential failures. In addition, adding automatic features downhole can be difficult to install, service, and replace.
During well shutdown, with some currently available systems, because the downhole valves will remain open, there will be cross flow from higher pressure zone to lower pressure zone through the downhole valve. This crossflow could affect reserves management and ultimately reduce overall recovery from the well.
SUMMARY OF THE DISCLOSUREEmbodiments of this disclosure provide systems and methods for automatically shutting down selected downhole control valves with elements that are located at the surface. Features of this disclosure can be added to the surface system, can be compatible with currently available intelligent completions, can be used with hydraulic or electric operated valves The system is operated during power failure or well shut in. Closing downhole valves will prevent downhole cross flow during shut in period. In certain embodiments of this disclosure, one or more of the downhole control valves can remain in an open position and remaining downhole valves closed to allow the well to be produced through the open valves at re-start of production so that no excess start-up operation is required at time of well start up. Once the well is stable, the closed downhole control valves can be opened in a traditional known manner, such as through supervisory control and data acquisition (SCADA).
In an embodiment of this disclosure, a system for automatically preventing cross flow in a subterranean well during a shutdown event includes a plurality of downhole control valves located within the subterranean well. The system also includes an energy storage device, the energy storage device releasing a stored energy during a shutdown event. The system further includes a primary fail device, the primary fail device being a normally close, fail open device that moves to a primary open position during a shutdown event, providing a portion of the stored energy to each of the plurality of downhole control valves during a shutdown event. The portion of the stored energy delivered to each of the plurality of downhole control valves is sufficient to move each of the plurality of downhole control valves to a valve closed position.
In alternate embodiments, the system includes a secondary fail device. The secondary fail device can be a normally open, fail close device that moves to a secondary closed position during a shutdown event. The secondary fail device can be associated with a one or more of the downhole control valves and prevent such downhole control valves from moving to a valve closed position when the portion of the stored energy is provided to each of the plurality of downhole control valves and each of the other of the plurality of downhole control valves is moved to a valve closed position.
In certain alternate embodiments, the energy storage device can be an accumulator and the plurality of downhole control valves are hydraulic valves. Each downhole control valve can be a hydraulically operated valve and the secondary fail device can be a valve that is positioned to prevent a pressure media from traveling from the one of the downhole control valves when the secondary fail device is in a secondary closed position. In alternate embodiments, the energy storage device can be an electric storage device and the plurality of downhole control valves are electrically activated devices.
In other alternate embodiments, the energy storage device, primary fail device, and secondary fail device can be located at an earth's surface outside of the subterranean well. Each downhole control valve can be associated with a separate zone of the subterranean well and in the valve closed position, each downhole control valve restricts the flow of fluids into and out of the separate zone associated with such downhole control valve.
In other embodiments of the current disclosure, a system for automatically preventing cross flow in a subterranean well during a shutdown event includes a plurality of downhole control valves located within the subterranean well. An accumulator is associated with each of the plurality of downhole control valves, the accumulator storing a pressure media. The system also includes a primary fail device, the primary fail device being a valve that moves to a primary open position during a shutdown event, releasing a portion of the pressure media to the close side of each of the plurality of downhole control valves during a shutdown event. The system further includes a secondary fail device, the secondary fail device being a valve that moves to a secondary closed position during a shutdown event. The secondary fail device is associated with one of the downhole control valves and prevents such one of the downhole control valves from moving to a valve closed position when the portion of the pressure media is provided to each of the plurality of downhole control valves and each of the other of the plurality of downhole control valves is moved to a valve closed position.
In alternate embodiments, the accumulator, primary fail device, and secondary fail device can be located at an earth's surface outside of the subterranean well. Each downhole control valve can be associated with a separate zone of the subterranean well and in the valve closed position, each downhole control valve can restrict the flow of well fluids into and out of the separate zone associated with such downhole control valve. A control fluid return line can be associated with an open side of each of the plurality of downhole control valves and provide a fluid flow path for a trapped pressure control fluid media to exit the open side of the downhole control valve as the downhole control valve moves to a valve closed position. The secondary fail device can be positioned in the surface panel between the open side of the one of the downhole control valves and the fluid return vent line so that in the secondary closed position, the secondary fail device prevents the trapped control fluid pressure media from exiting the open side of the one of the downhole control valves.
In yet other embodiments of the current disclosure, a method for automatically preventing cross flow in a subterranean well during a shutdown event includes locating a plurality of downhole control valves located within the subterranean well. During a shutdown event, a portion of a stored energy is provided to each of the plurality of downhole control valves. The portion of the stored energy is sufficient to move each of the plurality of downhole control valves to a valve closed position. The stored energy is released from an energy storage device with a primary fail device, the primary fail device being a normally close, fail open device that moves to a primary open position during a shutdown event.
In alternate embodiments the method also includes preventing one of the plurality of downhole control valves from moving to a valve closed position during a shutdown event with a secondary fail device. The secondary fail device can be a normally open, fail close device associated with a one or more of the downhole control valves that moves to a secondary closed position during a shutdown event, so that the one or more of the downhole control valves remains in a valve open position and each of the other of the plurality of downhole control valves is moved to a valve closed position.
In certain alternate embodiments, the energy storage device can be an electric storage device and the plurality of downhole control valves can be electrically activated devices. In such an embodiment, the step of releasing a stored energy from an energy storage device includes releasing a portion of stored electric energy to each of the plurality of downhole control valves during a shutdown event. In other alternate embodiments, the energy storage device is an accumulator and the primary fail device and the secondary fail device are hydraulic valves. In such embodiments, the step of releasing a stored energy from an energy storage device includes releasing a portion of a pressure media to a close side of each of the plurality of downhole control valves during a shutdown event.
In yet other alternate embodiments, the method includes providing a fluid flow path for a trapped pressure media to exit an open side of the downhole control valve as the downhole control valve moves to a valve closed position, with a fluid return line associated with the open side of each of the plurality of downhole control valves. The secondary fail device can be positioned between the open side of the downhole control valves and the fluid return line, preventing the trapped pressure media from exiting the open side of the downhole control valves with the secondary fail device when the secondary fail device is in the secondary closed position. The energy storage device, primary fail device, and secondary fail device can be located at earth's surface outside of the subterranean well. Each downhole control valve can be associated with a separate zone of the subterranean well so that in the valve closed position, each downhole control valve restricts the flow of fluids into and out of the separate zone associated with such downhole control valve.
In still other alternate embodiments, fluid from the subterranean well can be produced through the one or more of the downhole control valves during normal production. After a shutdown event, the primary fail device can be moved to a primary closed position, and the secondary fail device can be moved to a secondary open position. At least one of the other of the plurality of downhole control valves can be moved to the valve open position to restart production from desired zones and the energy storage device can be recharged.
So that the manner in which the above-recited features, aspects and advantages of the invention, as well as others that will become apparent, are attained and can be understood in detail, a more particular description of the invention briefly summarized above may be had by reference to the embodiments thereof that are illustrated in the drawings that form a part of this specification. It is to be noted, however, that the appended drawings illustrate only preferred embodiments of the invention and are, therefore, not to be considered limiting of the invention's scope, for the invention may admit to other equally effective embodiments.
The Specification, which includes the Summary of Disclosure, Brief Description of the Drawings and the Detailed Description of the Preferred Embodiments, and the appended Claims refer to particular features (including process or method steps) of the invention. Those of skill in the art understand that the invention includes all possible combinations and uses of particular features described in the Specification. Those of skill in the art understand that the invention is not limited to or by the description of embodiments given in the Specification. The inventive subject matter is not restricted except only in the spirit of the Specification and appended Claims.
Those of skill in the art also understand that the terminology used for describing particular embodiments does not limit the scope or breadth of the invention. In interpreting the Specification and appended Claims, all terms should be interpreted in the broadest possible manner consistent with the context of each term. All technical and scientific terms used in the Specification and appended Claims have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs unless defined otherwise.
As used in the Specification and appended Claims, the singular forms “a”, “an”, and “the” include plural references unless the context clearly indicates otherwise. As used, the words “comprise,” “has,” “includes”, and all other grammatical variations are each intended to have an open, non-limiting meaning that does not exclude additional elements, components or steps. Embodiments of the present invention may suitably “comprise”, “consist” or “consist essentially of” the limiting features disclosed, and may be practiced in the absence of a limiting feature not disclosed. For example, it can be recognized by those skilled in the art that certain steps can be combined into a single step.
Spatial terms describe the relative position of an object or a group of objects relative to another object or group of objects. The spatial relationships apply along vertical and horizontal axes. Orientation and relational words including “uphole” and “downhole”; “above” and “below” and other like terms are for descriptive convenience and are not limiting unless otherwise indicated.
Where the Specification or the appended Claims provide a range of values, it is understood that the interval encompasses each intervening value between the upper limit and the lower limit as well as the upper limit and the lower limit. The invention encompasses and bounds smaller ranges of the interval subject to any specific exclusion provided.
Where reference is made in the Specification and appended Claims to a method comprising two or more defined steps, the defined steps can be carried out in any order or simultaneously except where the context excludes that possibility. Looking at
In the example embodiment of
The flow of fluid through the ICV assembly 22 can be regulated by downhole control valve 28 within the ICV assembly 22. When downhole control valve 28 is open, fluid can freely pass through the ICV assembly 22. Conversely, when downhole control valve 28 is closed, fluid is restricted from passing through the ICV assembly 22. The position of downhole control valve 28 (valve open, valve closed, or valve partially open) can be controlled by an operator at the earth's surface 14. By manipulating the position of downhole control valve 28, the operator can control how much fluid passes through the ICV assembly 22 towards the top of the well 10. Each downhole control valve 28 can be associated with a separate zone or region of well 10 so that when a downhole control valve 28 is in the valve closed position, such downhole control valve 28 restricts the flow of fluids into and out of the separate zone associated with such downhole control valve 28.
In the example embodiment of
Turning to
Cross flow prevention system 30 is shown in the example of
Looking at
In the example of
As pressure media is delivered to close side 28a of each of the plurality of downhole control valves 28, an open line 58 associated with open side 28b of each of the plurality of downhole control valves 28 will provide a fluid flow path for trapped pressure media within open side 28b to exit open side 28b as the downhole control valve 28 moves to a valve closed position. The trapped pressure media will return to fluid reservoir 34.
In an alternate embodiment, primary fail device 40 can be a gate that closes to allow power stored within batteries of energy storage device 32 to be delivered to electrically operated downhole control valves 28.
Looking at the example embodiment of
In alternate embodiments, secondary fail device 50 can be a gate that is part of an electrical operated valve system. During a shutdown event, the gate of secondary fail device 50 will open, causing the circuit associated with one of the downhole control valves 28 to be incomplete so that such downhole control valve 28 cannot be signaled to move to the closed position.
Looking at both
In an example of operation, in order to produce fluids from well 10 through ICV assemblies 22, an operator can open downhole control valves 28. To open downhole control valves 28, pressure media can be pumped from fluid reservoir 34 with pump and motor assembly 36 to open side 28b of downhole control valves 28. Pressure media can be pumped through open control valves 56 to open lines 58 to reach open side 28b of downhole control valves 28. This moves the piston in the ICV 28 in the open direction and pushes the control fluid to surface through close line 42. This control fluid is vented to the tank through devices 50 and line 48. Valve 46 in closed position stops this fluid from going to the pump line. Open control valves 56 can be normally closed valves that are kept in a closed position during normal operations and opened when downhole control valves 28 are to be moved to a valve open position. When pumping pressure media to open side 28b of downhole control valves 28, close line valve 46, which is normally open, can be closed so that close delivery line 42 is blocked and pressure media from the pump 36 will not reach close side 28a of downhole control valves 28 during the operation to open the ICVs 28. Return line valve 60, which is normally open, will be closed while pumping pressure media to open side 28b of downhole control valves 28 so that pressure media being used to fill open side 28b will not instead return through return line valve 60 to fluid reservoir 34. Device 50 in line 58 will be in the closed position while opening the downhole valves 28.
As downhole control valves 28 are opening, pressure media trapped in close side 28a of downhole control valves 28 can exit close side 28a and return to fluid reservoir 34 by way of one of the secondary fail devices 50 and return line 48. During normal operating conditions, secondary fail devices 50 are in a secondary open position. During the operation to open the ICVs 28, it is acceptable for the fluid in close side 28a to flow through close delivery line 42 and secondary fail device 50, return line 48 to reach the fluid reservoir 34.
After downhole control valves 28 are opened, close line valve 46 can be returned to its normal open position, open control valves 56 can be returned to their normal closed positions, and return line valve 60 can be returned to its normal open position. Secondary fail device 50 will be brought to an open position. A number of pressure gauges 62 can be used to monitor the pressure within varies flow lines of the cross flow prevention system 30. During normal operating conditions, energy storage device 32 is charged and primary fail device 40 is in a closed position. Fluids can be produced from well 10 from a number of zones through ICV assemblies 22.
During a shutdown event, the power or force retaining primary fail device 40 in a primary closed position will be cut off and primary fail device 40 will move to a primary open position. Device 50 in line 42 will also move from a primary open position to close position. This will allow the stored energy of energy storage device 32 to be released and be delivered to close side 28a of each downhole control valve 28. Such energy will be sufficient to move downhole control valves 28 to the valve closed position. The control fluid displaced from the valves during the closing operation will return to surface through control lines 58.
In certain embodiments, no secondary fail device 50 is included in the return lines 58 that will block the path of pressure media returning to fluid reservoir 34. In such an embodiment, all of the downhole control valves 28 will move to a valve closed position and production of fluids from, and injection of fluids into, all zones of well 10 will be stopped.
In the example embodiment of
After the shutdown event, in order to resume normal operation of well 10, primary fail device 40 can be returned to the primary closed position. Secondary fail devices 50 can be returned to the secondary open position. During well start up well 10 can continue to be produced from the open zones that is associated with the downhole control valve 28 that is in the valve open position. This will expedite the start of production after shut down by reducing the number of steps required to return the well 10 to normal operating conditions. Once the flow is stable, the other zones can be remotely opened by moving at least one of the downhole control valves 28 to the valve open position, and the downhole control valves 28 can otherwise be opened and closed as deemed appropriate by the operator. Energy storage device 32 can be recharged and cross flow prevention system 30 is then ready to operate during a subsequent shutdown event.
Embodiments described herein, therefore, are well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims.
Therefore as described herein, during operation, surface control panel 52 has three distinct operating conditions. In a first operating condition, normal well production is undertaken with multiple downhole control valves 28 in the open position. Accumulator 32 is charged, primary fail device 40 is closed, and all secondary fail devices 50 are in an open position. This is a waiting period with no valves moving and the system is waiting for a trigger to close one or more downhole control valves 28.
In a second operating condition, a trigger such as, for example, a power failure, to close one or more downhole control valves occurs. As a result of the trigger, primary fail device 40 is open and secondary fail devices 50 are closed. Pressure is applied through the close delivery line 42. This causes the selected downhole valves 28 that are associated with open return line valves 60 to close to and selected downhole control valves 28 that are associated with secondary fail devices 50, which are in a closed position, to remain open.
In a third operating condition, the opening of downhole control valves 28 through providing pressure through open control valves 56 and open lines 58 is undertaken. Close line valve 46 and return line valve 60 are closed. Secondary fail device 50 associated with open line 58 will be closed while secondary fail device 50 associated with close delivery line 42 will be in an open position
Claims
1. A system for automatically preventing cross flow in a subterranean well during a shutdown event, the system comprising:
- a plurality of downhole control valves located within the subterranean well;
- an energy storage device, the energy storage device releasing a stored energy during the shutdown event; and
- a primary fail device, the primary fail device being a normally close, fail open device that moves to a primary open position during the shutdown event, providing a portion of the stored energy to each of the plurality of downhole control valves during the shutdown event, the portion of the stored energy delivered to each of the plurality of downhole control valves being sufficient to move each of the plurality of downhole control valves to a valve closed position.
2. A system in accordance with claim 1, further comprising a secondary fail device, the secondary fail device being a normally open, fail close device that moves to a secondary closed position during the shutdown event, the secondary fail device being associated with a one of the downhole control valves and preventing such one of the downhole control valves from moving to the valve closed position when the portion of the stored energy is provided to each of the plurality of downhole control valves and each of the other of the plurality of downhole control valves is moved to the valve closed position.
3. A system in accordance with claim 2, wherein the energy storage device is an accumulator and the plurality of downhole control valves are hydraulic valves.
4. A system in accordance with claim 2, wherein the energy storage device is an electric storage device and the plurality of downhole control valves are electrically activated devices.
5. A system in accordance with claim 2, wherein the energy storage device, primary fail device, and secondary fail device are located at an earth's surface outside of the subterranean well.
6. A system in accordance with claim 2, wherein each downhole control valve is a hydraulically operated valve and the secondary fail device is a valve that is positioned to prevent a pressure media from traveling from the one of the downhole control valves when the secondary fail device is in the secondary closed position.
7. A system in accordance with claim 1, wherein each downhole control valve is associated with a separate zone of the subterranean well and in the valve closed position, each downhole control valve restricts a flow of fluids into and out of the separate zone associated with such downhole control valve.
8. A system for automatically preventing cross flow in a subterranean well during a shutdown event, the system comprising:
- a plurality of downhole control valves located within the subterranean well;
- an accumulator associated with each of the plurality of downhole control valves, the accumulator storing a pressure media;
- a primary fail device, the primary fail device being a valve that moves to a primary open position during the shutdown event, releasing a portion of the pressure media to the close side of each of the plurality of downhole control valves during the shutdown event; and
- a secondary fail device, the secondary fail device being a valve that moves to a secondary closed position during the shutdown event, the secondary fail device being associated with one of the downhole control valves and preventing such one of the downhole control valves from moving to a valve closed position when the portion of the pressure media is provided to each of the plurality of downhole control valves and each of the other of the plurality of downhole control valves is moved to the valve closed position.
9. A system in accordance with claim 8, wherein the accumulator, primary fail device, and secondary fail device are located at an earth's surface outside of the subterranean well.
10. A system in accordance with claim 8, wherein each downhole control valve is associated with a separate zone of the subterranean well and in the valve closed position, each downhole control valve restricts a flow of fluids into and out of the separate zone associated with such downhole control valve.
11. A system in accordance with claim 8, further comprising a fluid return line associated with an open side of each of the plurality of downhole control valves and providing a fluid flow path for a trapped pressure media to exit the open side of the downhole control valve as the downhole control valve moves to the valve closed position.
12. A system in accordance with claim 11, wherein the secondary fail device is positioned between the open side of the one of the downhole control valves and the fluid return line so that in the secondary closed position, the secondary fail device prevents the trapped pressure media from exiting the open side of the one of the downhole control valves.
13. A method for automatically preventing cross flow in a subterranean well during a shutdown event, the method comprising:
- locating a plurality of downhole control valves located within the subterranean well; and
- during the shutdown event, providing a portion of a stored energy to each of the plurality of downhole control valves, the portion of the stored energy being sufficient to move each of the plurality of downhole control valves to a valve closed position, the stored energy being released from an energy storage device with a primary fail device, the primary fail device being a normally close, fail open device that moves to a primary open position during the shutdown event.
14. A method in accordance with claim 13, further comprising preventing one of the plurality of downhole control valves from moving to the valve closed position during the shutdown event with a secondary fail device, the secondary fail device being a normally open, fail close device associated with a one of the downhole control valves that moves to a secondary closed position during the shutdown event, so that the one of the downhole control valves remains in a valve open position and each of the other of the plurality of downhole control valves is moved to the valve closed position.
15. A method in accordance with claim 14, wherein the energy storage device is an electric storage device and the plurality of downhole control valves are electrically activated devices, and wherein the step of releasing the stored energy from the energy storage device includes releasing a portion of stored electric energy to each of the plurality of downhole control valves during the shutdown event.
16. A method in accordance with claim 14, wherein the energy storage device is an accumulator and the primary fail device and the secondary fail device are hydraulic valves, and wherein the step of releasing the stored energy from the energy storage device includes releasing the portion of a pressure media to a close side of each of the plurality of downhole control valves during the shutdown event.
17. A method in accordance with claim 14, further comprising providing a fluid flow path for a trapped pressure media to exit an open side of the downhole control valve as the downhole control valve moves to the valve closed position with a fluid return line associated with the open side of each of the plurality of downhole control valves.
18. A method in accordance with claim 17, wherein the secondary fail device is positioned between the open side of the one of the downhole control valves and the fluid return line, the method further comprising preventing the trapped pressure media from exiting the open side of the one of the downhole control valves with the secondary fail device when the secondary fail device is in the secondary closed position.
19. A method in accordance with claim 14, further comprising locating the energy storage device, primary fail device, and secondary fail device at an earth's surface outside of the subterranean well.
20. A method in accordance with claim 14, further comprising after the shutdown event:
- moving the primary fail device to a primary closed position;
- moving the secondary fail device to a secondary open position;
- moving at least one of the other of the plurality of downhole control valves to the valve open position; and
- recharging the energy storage device.
21. A method in accordance with claim 13, further comprising associating each downhole control valve with a separate zone of the subterranean well so that in the valve closed position, each downhole control valve restricts a flow of fluids into and out of the separate zone associated with such downhole control valve.
Type: Application
Filed: May 14, 2015
Publication Date: Nov 17, 2016
Applicant: Saudi Arabian Oil Company (Dhahran)
Inventor: Suresh Jacob (Trivandrum)
Application Number: 14/712,095