HIGH-FLOW SENSITIVE INSERTION SAFETY VALVE, INSENSITIVE TO WELL PRESSURE

Abstract

An insertion valve (238) configured for installation, at least partially, in a safety valve (236) in a borehole (120) comprising a flow orifice (362) disposed on the exterior of the insertion valve, a poppet (354) configured to control fluid flow through the flow orifice, an upper piston rod (344U) disposed upstream of the poppet configured to move the poppet beyond at least a portion of the flow orifice, and a chamber (564) disposed downstream of the poppet comprising a chamber pressure (567), and a lower piston rod (344L) coupled to the poppet, wherein the lower piston rod is configured to exert a chamber piston force on the poppet. (Shortcut Figure: Figure 1)

Description

Title of the invention: High flow rate insertion safety valve insensitive to well pressure

[0001] REFERENCE TO RELATED APPLICATIONS

[0002] This is a non-provisional application claiming priority from U.S. Provisional Patent Application No. 63 / 598,410, filed November 13, 2023.

[0003] CONTEXT

[0004] The oil and gas industry may use boreholes as fluid conduits to access subterranean deposits of various fluids and minerals that may include hydrocarbons. A drilling operation may be used to construct the fluid conduits capable of producing hydrocarbons lying in the subterranean formations. The borehole may be constructed, in increments, as tapered sections, which extend sequentially into a subterranean formation.

[0005] A safety valve may be installed to prevent the unwanted flow of fluids (e.g., oil, gas, etc.) from a reservoir, through the borehole, and to the surface. The safety valve may be "normally closed," such that a flapper (or other component thereof) is subjected to a passive, uncontrolled, and / or constant force (e.g., via a torsion spring) to bring the flapper into the closed position. Thus, to open the safety valve, an active control (e.g., a hydraulic piston) is required to counteract the constant force applied to the flapper. Thus, in an emergency situation, the hydraulic pressure on the flapper can be quickly removed (if it has not already been removed) and the safety valve will automatically close by its own mechanism. Therefore, flow from the reservoir will cease, and the emergency situation at the surface can be adequately managed.

[0006] BRIEF DESCRIPTION OF THE DRAWINGS

[0007] These drawings illustrate certain aspects of some examples of the present disclosure and should not be construed as limiting or defining the disclosure.

[0008] [Fig. 1] is a diagram of an example drilling environment.

[0009] [Fig.2A] is a diagram of an insertion valve approaching a safety valve in a borehole.

[0010] [Fig.2B] is a diagram of an insertion valve partially penetrating a safety valve.

[0011] [Fig.2C] is a diagram of an insertion valve installed in a safety valve, prior to removal of the drill string.

[0012] [Fig.2D] is a diagram of an insertion valve installed in a safety valve with fluid flow.

[0013] [Fig.3A] is a diagram of an insertion valve installed in a safety valve.

[0014] [Fig.3B] is a sectional view of an upstream-oriented insertion valve.

[0015] [Fig.4A] is a diagram of an insertion valve in the closed position.

[0016] [Fig.4B] is a diagram of an insertion valve in the open position.

[0017] [Fig.5] is a diagram of an example chamber showing the forces exerted on a piston disposed therein.

[0018] [Fig.6A] is a diagram of an insertion valve with a chamber in the closed position.

[0019] [Fig.6B] is a diagram of an insertion valve with one chamber in the open position. DETAILED DESCRIPTION

[0020] — Overview and Advantages —

[0021] Generally, this application discloses one or more embodiments of methods and systems for an insertion valve, installed in an insertion valve, that provide improved fluid flow and control.

[0022] In boreholes, a safety valve may be installed to prevent the unwanted flow of fluids (e.g., oil, gas, etc.) from a reservoir to the surface through the borehole. The safety valve may be "normally closed," such that a flapper (or other component thereof) is subjected to a passive, uncontrolled, and / or constant force (e.g., via a torsion spring) to bring the flapper into the closed position. Thus, to open the safety valve, active control is required to counteract the constant force applied to the flapper (e.g., via a hydraulic piston). Thus, in an emergency situation, the hydraulic pressure on the flapper can be quickly removed (if it has not already been removed) and the safety valve will automatically close by its own mechanism.Therefore, the flow from the reservoir will cease and the emergency situation on the surface can be managed properly.

[0023] However, as the safety valve is repeatedly opened and closed (e.g., via a hydraulic piston), the internal components of the safety valve may "wear out" and no longer operate as efficiently as intended. Specifically, the flapper (or other closing mechanism) of the safety valve may not close completely (e.g., the spring may have lost part of its original spring force). of its ability to maintain tension). Therefore, fluids can flow partially around the valve, even when the safety valve is "closed". Such performance is not desirable because the uncontrolled flow of fluids from a reservoir, even if minimal, can aggravate an emergency situation at the surface.

[0024] When a safety valve is no longer able to properly control the flow of fluid from a tank, an insertion valve can be installed inside the safety valve, in parallel, to restore proper control of the tank fluid. However, there are several disadvantages to using an insertion valve.

[0025] A first disadvantage of an insertion valve is that the flow rate from the borehole is reduced because the additional components of the insertion valve consume the volume of the flow path within the original safety valve. A second disadvantage is that insertion valves are often equipped with similar spring and poppet mechanisms that are subject to the same wear as the original safety valve. Furthermore, at certain depths, it becomes impractical or even impossible to manufacture a spring capable of overcoming the hydrostatic head (due to the weight of the liquid column in the borehole). A third disadvantage is that conventional insertion valves (as well as other types of valves) often have complicated designs and hydraulic control mechanisms requiring the addition of several seals, each of which is subject to wear and leakage.

[0026] The present document provides an insertion valve that allows for greater fluid flow than conventional insertion valves by allowing fluid to flow around the closure mechanism and then into the internal volume of the insertion valve. The piston that controls the closure is constructed to be aligned and centered with the closure mechanism. In addition, the piston (and corresponding hydraulic controls) is placed upstream of the closure mechanism, thereby reducing the number of hydraulic seals installed in the insertion valve.

[0027] — [Fig.l] —

[0028] [Fig.l] is a diagram of an exemplary drilling environment. The drilling environment 100 may include a platform 102 that supports the derrick 104 and the crown block 106 to enable the use of the travel block 108 to raise and lower the upper drive 110 and the drill string 112. The upper drive 110 supports and rotates the drill string 112 as it is lowered through the wellhead 114. In turn, the drill bit 116 (disposed on the bottom hole assembly 118 at the end of the drill string 112) may create the borehole 120. Each of these components is described below.

[0029] The platform 102 is a structure that may be used to support one or more other components of the drilling environment 100 (e.g., the derrick 104). The platform 102 may be designed and constructed from suitable materials (e.g., concrete) capable of resisting forces applied by other components (e.g., the weight and counterforces experienced by the derrick 104). In any embodiment, the platform 102 may be constructed to provide a uniform surface for drilling operations in the drilling environment 100.

[0030] The derrick 104 is a structure that can support, contain, and / or facilitate the operation of one or more pieces of drilling equipment. In any embodiment, the derrick 104 can provide support to the crown block 106, the travel block 108, and / or any portion connected to (and including) the drill string 112. The derrick 104 can be constructed from any suitable material (e.g., steel) to provide the necessary strength to support these components.

[0031] The crown block 106 is one or more simple machines that may be rigidly attached to the derrick 104 and include a set of pulleys (e.g., a "block"), threaded (e.g., "passed") with a drilling line (e.g., a steel cable), to provide a mechanical advantage. The crown block 106 may be disposed vertically above the travel block 108 and threaded with the same drilling line.

[0032] The travel block 108 is one or more simple machines that can be movably attached to the derrick 104 and include a set of pulleys, threaded with a drill line, to provide a mechanical advantage. The travel block 108 may be disposed vertically below the crown block 106, where the crown block 106 is threaded with the same drill line. In any embodiment, the travel block 108 may be mechanically coupled to the drill string 112 (e.g., via the top drive 110) and allow the drill string 112 (and / or any component thereof) to be lifted from (and out of) the borehole 120. Both the crown block 106 and the travel block 108 may utilize a series of parallel pulleys (e.g.,in a "hoist" type arrangement) to achieve a significant mechanical advantage, allowing the drill string to support greater loads (compared to a configuration that uses non-parallel tension). The travel block 108 can move vertically (e.g., up or down) within the derrick 104 by extending and retracting the drill string.

[0033] The upper drive 110 is a machine that may be configured to rotate the drill string 112. The upper drive 110 may be attached to the travel block 108 and configured to travel vertically within the derrick. 104 (e.g., with the displacement block 108). In any embodiment, rotation of the drill string 112 (caused by the upper drive 110) may allow the drill string 112 to excavate the borehole 120. The upper drive 110 may use one or more motors and gear mechanisms to rotate the drill string 112. In any embodiment, a rotary table (not shown) and a "Kelly" drive (not shown) may be used in addition to or instead of the upper drive 110.

[0034] The drill string 112 is a machine that may be used to excavate the borehole 120 and / or collect data about the borehole 120 and the surrounding geology. The drill string 112 may include one or more drill rods, the bottom hole assembly 118, and one or more repeaters 122 disposed thereon. The drill string 112 may rotate (e.g., via the top drive 110) to form and deepen the borehole 120 (e.g., via the drill bit 116) and / or via one or more motors attached to the drill string 112.

[0035] The wellhead 114 is a machine that may include one or more pipes, plugs, and / or valves to provide pressure control of the contents of the borehole 120 (e.g., when connected to a well (not shown)). In any embodiment, during drilling, the wellhead 114 may be equipped with a blowout preventer (not shown) to prevent the flow of high-pressure fluids (in the borehole 120) from escaping to the surface in an uncontrolled manner. The wellhead 114 may be equipped with other ports and / or sensors to monitor pressures within the borehole 120 and / or facilitate drilling operations.

[0036] The drill bit 116 is a machine that may be used to cut, scrape, and / or crush (i.e., break up) materials in the ground (e.g., rocks, soil, clay, etc.). The drill bit 116 may be disposed at the forward end of the drill string 112 and the downhole assembly 118. In any embodiment, the drill bit 116 may include one or more cutting edges (e.g., hardened metal tips, surfaces, blades, protrusions, etc.) to form a geometry that helps loosen the materials from the ground and crush them into smaller quantities. In any embodiment, the drill bit 116 may be rotated and forced into (i.e., pushed against) the ground material to cause the cutting, scraping, and crushing action. Rotations of the drill bit 116 may be caused by the top drive 110 and / or one or more motors located on the drill string 112 (e.g., on the bottom hole assembly 118).

[0037] The downhole assembly 118 is a machine that may be equipped with one or more tools for creating, structuring, and maintaining the borehole 120, as well as one or more tools for measuring the surrounding environment (e.g., in-process measurement). drilling (MWD), logging while drilling (LWD). In any embodiment, the bottom hole assembly 118 may be disposed at (or near) the end of the drill string 112 (e.g., in the most "downstream" portion of the borehole 120).

[0038] Non-limiting examples of tools that may be included in the downhole assembly 118 include a drill bit 116, casing tools (e.g., a displacement tool), a plug tool, a mud motor, a drill collar (thick-walled steel pipes that provide weight and rigidity to aid in the drilling process), actuators (and the pistons attached thereto), a steering system, and any measurement tools (e.g., sensors, probes, particle generators, etc.)

[0039] Further, the downhole assembly 118 may include a telemetry subsystem for maintaining a communication link with the surface (e.g., possibly via repeaters 122 and transducers 124 to the information processing system 130). These telemetry communications may be used to (i) transfer tool measurement data from the downhole assembly 118 to the surface receivers, and / or (ii) receive controls (from the surface) at the downhole assembly 118 (e.g., for operation of one or more tools in the downhole assembly 118).

[0040] Non-limiting examples of techniques for transferring measurement data from the tool (to the surface) include mud pulse telemetry and through-wall acoustic signaling. For through-wall acoustic signaling, one or more repeaters 122 may detect, amplify, and retransmit signals from the downhole assembly 118 to the surface (e.g., to the information processing system 130), and vice versa, from the surface (e.g., from the information processing system 130) to the downhole assembly 118.

[0041] The borehole 120 is a hole in the ground that may be formed by the drill string 112 (and one or more of its components). The borehole 120 may be partially or fully covered with a casing to protect the surrounding ground from the contents of the borehole 120 and, conversely, to protect the borehole 120 from the surrounding ground.

[0042] The repeater 122 is a device that can be used to receive and send signals from one component of the drilling environment 100 to another component of the drilling environment 100. As a non-limiting example, the repeater 122 can be used to receive a signal from a tool in the downhole assembly 118 and send that signal to the transducer 124 (or directly to the information processing system 130). Two or more repeaters 122 can be used together, in series, so that a signal from or to the downhole assembly 118 can be relayed by two or more repeaters 122 before reaching its destination.

[0043] The transducer 124 is a device that may be configured to convert non-digital data (e.g., vibrations, other analog data) into a digital form suitable for the information processing system 130. As a non-limiting example, one or more transducers 124 may convert the signals between mechanical and electrical forms, allowing the information processing system 130 to receive the signals from a telemetry subsystem on the downhole assembly 118, and conversely, to transmit a downlink signal to the telemetry subsystem on the downhole assembly 118. In any embodiment, the transducer 124 may be located at the surface and / or in any portion of the drill string 112 (e.g., as part of the downhole assembly 118).

[0044] The pump 126 is a machine that can be used to circulate the drilling fluid 128 in the borehole 120. In one or more embodiments, the pump 126 circulates the drilling fluid 128 from a reservoir, through a supply pipe, to the derrick 104, into the drill string 112, through the drill bit 116 (through ports, not shown), up through the borehole 120 in a ring around the drill string 112, and back to the reservoir. In any embodiment, any type of pump 126 can be used (e.g., centrifugal, gear, etc.) that is powered by any suitable means (e.g., electricity, fuel, etc.).

[0045] The drilling fluid 128 is a liquid that can be pumped through the drill string 112 and the borehole 120 to collect drill cuttings, debris, and / or other ground material at the end of the borehole 120 (e.g., the volume most recently drilled by the drill bit 116). Further, the drilling fluid 128 can conductively cool the drill bit 116 (and / or the bottom hole assembly 118). In any embodiment, the drilling fluid 128 can circulate via the pump 126 and be filtered to remove unwanted debris.

[0046] The information processing system 130 is a hardware computer system that can be operatively connected to the drill string 112 (and / or other various components of the drilling environment). In any embodiment, the information processing system 130 can use any form of wired and / or wireless communication to send and / or receive data to and / or from other components of the drilling environment 100. In any embodiment, the information processing system 130 can receive a digital telemetry signal, demodulate the signal, display the data (e.g., via a visual output device), and / or store the data. In any embodiment, the information processing system 130 can send a signal (with data) to one or more components of the drilling environment 100 (e.g., to control one or more tools of the downhole assembly 118).

[0047] In any embodiment, the information processing system 130 may be used to perform various steps, methods, and techniques disclosed herein (e.g., by executing software). In any embodiment, the information processing system 130 may include one or more processors, a cache, memory, storage, and / or one or more peripherals. Two or more of these components may be operatively connected by a system bus that allows data to be transferred between these components.

[0048] — [Fig.2A]-2D —

[0049] [Fig.2A] is a diagram of an insertion valve approaching a safety valve in a borehole. [Fig.2B] is a diagram of an insertion valve partially penetrating a safety valve. [Fig.2C] is a diagram of an insertion valve installed in a safety valve, prior to removal of the drill string. [Fig.2D] is a diagram of an insertion valve installed in a safety valve with fluid flow.

[0050] The safety valve 236 is a fail-safe valve that prevents uncontrolled and / or unwanted flow of fluids from a reservoir up the borehole 120. The safety valve 236 may be equipped with a spring-loaded poppet that can be forced open (e.g., via a hydraulic piston) and allow the flow of fluids. When not held open, the poppet tends toward the "closed" position and prevents the flow of fluids up the borehole 120. In any embodiment, the safety valve 236 is installed within a casing of the borehole 120.

[0051] The flapper of a safety valve 236 may wear over time (e.g., due to repeated opening and closing) and not close completely, such that some fluids may leak through the flapper even when it is not held open. To better control the flow of fluids when the safety valve 236 becomes leaking, the insertion valve 238 may be installed in the safety valve to better control the flow of fluids into the borehole 120.

[0052] The insertion valve 238, like the safety valve 236, is a fail-safe valve that prevents the uncontrolled and / or unwanted flow of fluids from a reservoir up the borehole 120. However, unlike the safety valve 236, the insertion valve 238 is configured to be installed within the safety valve 236. In any embodiment, the insertion valve 238 may be installed within the safety valve 236 using a cable and / or any other apparatus capable of releasably holding and lowering the insertion valve 238. A Once the insertion valve 238 is installed in the safety valve 236, the cable (and / or other device) can be detached from the insertion valve 238.

[0053] The hydraulic control line 250 is a pipe, tube, and / or other conduit that carries hydraulic fluid. In any embodiment, the hydraulic control line 250 carries the hydraulic fluid between the surface and the hydraulic control port 448 (the insertion valve 238 may be in hydraulic contact with the hydraulic control line 250, generally). In any embodiment, hydraulic fluid may be pumped (i.e., hydraulic flow 466) through the hydraulic control line 250, through the hydraulic control port 448, and into the upper piston bore 346U. In turn, the hydraulic fluid pumped into the upper piston bore 346U moves the piston rod 344 toward the poppet 354.

[0054] Fluid flow 264 is the movement of fluid (e.g., oil, gas, etc.) from a reservoir upward through the borehole 120, into and through the insertion valve 238, and to the surface. Fluid flow 264 may be controlled (e.g., prevented, slowed, allowed) by one or more valves (e.g., safety valve 236, insertion valve 238, wellhead 114).

[0055] — [Fig.3A]-3B —

[0056] [Fig.3A] is a diagram of an insertion valve installed in a safety valve. [Fig.3B] is a sectional view of an upstream-facing insertion valve.

[0057] The piston rod 344 is a rigid structure used to transmit force and / or pressure to another body. In any embodiment, the movement of the piston rod 344 may be hydraulically controlled (e.g., from the hydraulic control port 448 and the hydraulic control line 250). As shown in [Fig. 4A], the piston rod 344 may be used to transmit force to the valve 354. In any embodiment, the piston rod 344 may move at least partially within the piston bore 346. The piston rod 344 may include one or more larger diameter sections that are used to isolate the volumes around the different sections of the piston rod 344 (within the piston bore 346). In any embodiment, the piston rod 344 may move along the translation axis 462.

[0058] The piston bore 346 is generally a volume that surrounds at least a portion of the piston rod 344. In any embodiment, the piston bore 346 includes one or more volumes (e.g., the upper piston bore 346U, the lower piston bore 346L) that are isolated from the volumes that surround the piston bore 346 (e.g., the internal volume of the insertion valve 238). The piston seal 451 may divide the piston bore 346 into two internal volumes isolated from each other (e.g., the upper piston bore 346U, the lower piston bore 346L).

[0059] The upper piston bore 346U is the volume in which the piston rod 344 can move and is fluidly connected to the hydraulic control port 448. The piston seal 451 may separate the volume of the upper piston bore 346U on one side. In any embodiment, the upper piston bore 346U is isolated from the internal volume of the insertion valve 238 and therefore may have a different pressure within the volume (i.e., that of the hydraulic control port 448).

[0060] The lower piston bore 346L is the volume in which the piston rod 344 can move. In one or more embodiments, the lower piston bore 346L is in fluid contact with the internal volume of the insertion valve 238. Alternatively, in one or more embodiments, the lower piston bore 346L may be isolated from the internal volume of the insertion valve 238 by one or more piston seals (not shown). The piston seal 451 may separate the volume of the lower piston bore 346L on one side from the upper piston bore 346U.

[0061] The valve 354 is a rigid body that can be configured to control (i.e., to "open" or "close") the insertion valve 238 in the "open position" and "closed position," respectively. In any embodiment, the poppet 354 moves within the internal volume of the insertion valve 238 past the flow port 362. When the poppet 354 is in the “open position” (as shown in [Fig. 3A] and [Fig. 4B]), the poppet 354 is moved further downstream (by the piston rod 344), allowing the flow of fluid 264 through the flow port 362. When the poppet 354 is in the “closed position” (as shown in [Fig. 4A]), the poppet 354 may be pressed against the poppet seat 460, thereby preventing the flow of fluid 264 from the borehole into the insertion valve 238. In any embodiment, the poppet 354 may move along the translation axis 462.

[0062] The centralizing rod 356 is a rigid body, attached to the valve 354, which is used to keep the valve 354 aligned with the piston rod 344 and the insertion valve 238, generally. The centralizing rod 356 may slide through an opening (e.g., a hole) at the downstream end of the insertion valve 238. The opening through which the centralizing rod 356 moves may be long enough to prevent the valve 354 (and the centralizing rod 356) from pivoting away from the translation axis 462. In any embodiment, the centralizing rod 356 may move along the translation axis 462.

[0063] The flow port 362 is a hole in the insertion valve 238 that allows the flow of fluid 264 when the flapper 354 is in the "open" position. In one or more embodiments, the flow port 362 is disposed outside the insertion valve 238. The insertion valve 238 may have one or more ports flow ports 362 disposed around the circumference of the body. When the insertion valve 238 is in the "closed" position, the flow port 362 is exposed to the underside (or side) of the flapper 354 and the flow of fluid 264 is prevented because there is no passage between the underside of the insertion valve 238 and the internal volume of the insertion valve 238.

[0064] — [Fig.4A]-4B —

[0065] [Fig.4A] is a diagram of an insertion valve in the closed position. [Fig.4B] is a diagram of an insertion valve in the open position.

[0066] The hydraulic control port 448 is an opening and / or passage through which hydraulic fluid can be pumped (e.g., from the hydraulic control line 250). In any embodiment, the hydraulic control port 448 may be integrated with the insertion valve 238 (e.g., drilled) with an exposed hole on an exterior surface of the body. The exposed hole may be connected to the hydraulic control line 250 to allow passage of hydraulic fluids from the hydraulic control line 250 to the hydraulic control port 448. At the other end, the hydraulic control port 448 opens into the upper piston bore 346U.

[0067] The piston seal 451 is a device that surrounds the piston rod 344 and may have a larger diameter. In any embodiment, the piston seal 451 serves to isolate the piston bore 346 into two volumes (e.g., the upper piston bore 346U versus a lower volume). Thus, in any embodiment, the upper piston bore 346U may be filled with pressurized hydraulic fluid because the piston seal 451 prevents (or limits) the leakage of hydraulic fluid into the internal volume of the insertion valve 238. Conversely, the internal volume of the insertion valve 238 may be filled with pressurized fluids (e.g., oil) and the piston seal 451 prevents (or limits) the flow of pressurized fluid into the upper piston bore 346U.

[0068] The compression spring 458 (i.e., the "spring") is a machine that provides constant tension between two bodies. In any embodiment, the compression spring 458 may operate by tending toward an extended state while allowing elastic compression. Thus, when compressed, the compression spring 458 exerts an outward force (i.e., tension) on the bodies that exert inward forces (i.e., compression) on the compression spring 458. In any embodiment, the compression spring 458 may be used to assist the poppet 354 into the poppet seat 460 and maintain force thereon (e.g., the compression spring 458 exerts an "upward force" on the poppet 354). In any embodiment, the compression spring 458 may be centered about the translation axis 462.

[0069] The valve seat 460 is a structure in the internal volume of the insertion valve 238 that forms a seal with the valve 354. In any embodiment, the valve seat 460 may take the form of a conical wall whose geometry is complementary to at least a portion of the valve 354. Thus, when the valve 354 is coupled to the valve seat 460, a seal is formed between the corresponding geometries that sufficiently prevents the flow of fluid 264.

[0070] The translation axis 462 is the axis along which the piston rod 344, the valve 354, and the centralizing rod 356 can move. In any embodiment, the translation axis 462 may be centered (or relatively close) within the insertion valve 238.

[0071] Hydraulic flow 466 is the flow of hydraulic fluid between the piston bore 346 and the surface via the hydraulic control port 448 and the hydraulic control line 250. Hydraulic flow 466 may be manually controlled at the surface (e.g., by an operator) to initiate movement of the piston rod 344 and poppet 354 to open the insertion valve 238. Hydraulic flow 466 may be in either direction depending on the pressure pumped into the hydraulic control line 250. When hydraulic fluid is pumped into the hydraulic control line 250, hydraulic flow 466 passes from the surface to the upper piston bore 346U. When pressure is released in the hydraulic control line 250 (i.e., pumping is stopped and hydraulic fluid is allowed to return to the surface), hydraulic flow 466 passes from the upper piston bore 346U to the surface.

[0072] — [Fig.5] —

[0073] [Fig.5] is a diagram of an example chamber showing the forces exerted on a piston located inside.

[0074] The chamber 564 is a volume that may be in fluid contact with the piston rod 344 and its internal piston surfaces (e.g., the inwardly facing piston surface X 570X and piston surface Z 570Z). In any embodiment, the chamber 564 may be "precharged" and filled with a gas (or gas-liquid combination) to maintain a (relatively) constant chamber pressure 567. The chamber 564 may include two openings, through which the piston rod 344 may be disposed. The two openings of the chamber 564 (through which the piston rod 344 is disposed) may have dimensions each corresponding to the piston surface X 570X and the piston surface Z 570Z, respectively. Further, each opening of the chamber 564 may include one or more piston seals 451.

[0075] Chamber pressure 567 is the pressure within chamber 564. In one or more embodiments, chamber pressure 567 may be lower, equal to or greater than the surrounding pressure 568. The chamber pressure may be set (e.g., controlled, charged, etc.) to a predefined value (e.g., an absolute pressure of 1,000 psi) and then disposed at the desired location (e.g., downhole 120 as part of the insertion valve 238). In embodiments where the chamber pressure 567 is different (i.e., higher or lower) than the surrounding pressure 568 and the piston surface area X 570X is different (i.e., higher or lower) than the piston surface area Z 570Z, a force from the chamber piston (along the translation axis 462) will exist on the piston rod 344 due to the pressure and surface area difference (i.e., the pressure difference and the surface area difference).

[0076] The surrounding pressure 568 is a pressure outside and / or around at least a portion of the chamber 564. In one or more embodiments, the surrounding pressure 568 may be less than, equal to, or greater than the chamber pressure 567. In one or more embodiments, the volume surrounding the insertion valve 238 may be the internal volume of the borehole 120 (or any casing thereof). Thus, the surrounding pressure 568 may be caused by and equal to the hydrostatic pressure (i.e., the "hydrostatic head") in the borehole 120 at the depth at which the insertion valve 238 is placed. As a non-limiting example, at a depth of 3,000 feet below a liquid with a density of 150 pounds per cubic foot (pcf), there is a hydrostatic head of approximately 3,140 pounds per square inch (psi).

[0077] The piston surface area, in general, is the exposed surface area of ​​the piston rod 344 in a given volume. In one or more embodiments, the piston surface area is equal to the projected surface area orthogonal to the translation axis 462. Thus, adding texture or cutting the piston rod 344 at a non-orthogonal angle would not increase the piston surface area, as only the projected surface area determines the piston surface area. In one or more embodiments, two piston surfaces may be identical on opposite sides of a piston seal 451. Alternatively, a piston rod 344 may have two different piston surfaces (e.g., as illustrated in [Fig. 5] with piston surface X 570X and piston surface Z 570Z).

[0078] The piston surface X 570X is a piston surface located on one side of the piston rod 344. In the example illustrated in [Fig.5], the piston surface X 570X is arranged on the left side of the chamber 564. The piston surface X 570X may be greater or less than the piston surface Z 570Z.

[0079] The piston surface Z 570Z is a piston surface located on one side of the piston rod 344. In the example illustrated in [Fig.5], the piston surface X 570X is arranged on the right side of the chamber 564. The piston surface Z 570Z may be greater or less than the piston surface X 570X.

[0080] Due to the geometry of the chamber 564 and the piston rod 344 disposed therein, a chamber piston force (along the translation axis 462) is applied to the piston rod 344 whenever (i) the chamber pressure 567 is not equal to the surrounding pressure 568, and (ii) the piston area X 570X is not equal to the piston area Z 570Z. In general, the chamber piston force exerted on the piston rod 344 (and thus exerted by the piston rod 344 on anything coupled to it) can be described by the following equation (with "left" being negative and "right" being positive):

[0081] Chamber piston force = (piston area A - piston area B) x (surrounding pressure - chamber pressure)

[0082] As a first non-limiting example, consider a scenario in which: a. The piston area X 570X is 3 in2, b. The piston area of ​​the Z 570Z is 1.5 in2, c. The surrounding pressure 568 is 3,000 psi, and d. The chamber pressure 567 is 3,200 psi.

[0083] Thus: has. Fnet= (3 in2 - 1.5 in2) x (3000 psi - 3200 psi) b. Fnet= (1.5 in2) x (-200 psi) c. Fnet= -300 1b = 300 1b to the “left”

[0084] As a second non-limiting example, consider a scenario in which: a. The piston area X 570X is 2 in2, b. The piston area of ​​Z 570Z is 1 in2, c. The surrounding pressure 568 is 5,000 psi, and d. The chamber pressure 567 is 50 psi.

[0085] Thus: has. Fnet= (2 in2 - 1 in2) x (5000 psi - 50 psi) b- Fnet= (1 in2) x (4.950 psi) c. Fnet= 4.950 1b = 4.950 1b to the “right”

[0086] Thus, depending on (i) the difference (magnitude and direction) between the chamber pressure 567 and the surrounding pressure 568, and (ii) the difference (magnitude and direction) between the piston surface X 570X and the piston surface Z 570Z, the magnitude and direction of the force applied to the piston rod 344 can be controlled.

[0087] As shown in [Fig.5], the chamber piston force can be considered to be in a "left" (negative) direction or in a "right" (negative) direction. » (positive). Similarly, in the context of [Fig.6A]-6B, the chamber piston force can be considered as a “downward chamber piston force” or an “upward chamber piston force”, depending on the direction of the resultant chamber piston force.

[0088] — [Fig.6A]-6B —

[0089] [Fig.6A] is a diagram of an insertion valve with a chamber in the closed position. [Fig.6B] is a diagram of an insertion valve with a chamber in the open position.

[0090] The exemplary embodiments of the insertion valve 238 shown in [Fig. 6A]-6B, may be similar to those shown in [Fig. 4A]-4B with the addition of a chamber 564 in the downstream portion of the insertion valve 238. The description of the similar components shown in [Fig. 6A]-6B to those described in [Fig. 4A]-4B are omitted below. In addition, several components of the chamber 564 described in [Fig. 6A]-6B operate similarly to the chamber 564 described in [Fig. 5], and the description of these components is also omitted. Thus, only the description of the newly introduced components is included below.

[0091] In one or more embodiments, when two or more piston rods 344 are disposed within the insertion valve 238, one piston rod 344 may be designated as "upper," "upstream," "lower," "downstream," etc. to provide comparative positioning relative to the other piston rod 344. As shown in [Fig. 6A]-6B, the lower piston rod 344L may be coupled to the centralizing rod 356, while the upper piston rod 344U may be coupled to the poppet 354.

[0092] The upper piston rod 344U is a piston rod (e.g., piston rod 344) disposed further upstream than the lower piston rod 344L. In one or more embodiments, the upper piston rod 344U may be coupled to the valve 354. Further, the forces exerted on and movement of the upper piston rod 344U may be controlled, at least partially, by the pressures in the hydraulic control line 250.

[0093] The lower piston rod 344L is a piston rod (e.g., piston rod 344) disposed further downstream than the upper piston rod 344U. In one or more embodiments, the lower piston rod 344L may be coupled to the centralizing rod 356. Further, the forces exerted on and movement of the lower piston rod 344L may be controlled, at least partially, by the chamber pressure 567. In one or more embodiments, the piston surfaces exposed at each end of the lower piston rod 344L are different (e.g., the upstream piston surface 570U is different from the upstream piston surface 570U). downstream 570D). The lower piston rod 344L can pass, at least partially, through the chamber 564.

[0094] The upstream piston surface 570U is a piston surface on the upstream side of the lower piston rod 344L. In one or more embodiments, the upstream piston surface 570U may be exposed to the surrounding pressure 568 on the side coupled to the centralizing rod 356. Further, the upstream piston surface 570U may be exposed to the chamber pressure 567, within the chamber 564, in an opening upstream of the chamber 564. As shown in [Fig. 6A]-6B, the upstream piston surface 570U is shown to be larger than the downstream piston surface 570D, however a person of ordinary skill in the art, having the benefit of this detailed description, would understand that the downstream piston surface 570D may be larger than the upstream piston surface 570U depending on the desired functionality of the insertion valve 238.

[0095] The downstream piston surface 570D is a piston surface on the downstream side of the lower piston rod 344L. In one or more embodiments, the downstream piston surface 570D may be exposed to the surrounding pressure 568 toward the downstream side of the insertion valve 238, in an opening of the chamber 564. Further, the downstream piston surface 570D may be exposed to the chamber pressure 567, within the chamber 564, in an opening downstream of the chamber 564.

[0096] In one or more embodiments, a "surface area difference" is the two-dimensional surface area difference between a first piston surface (e.g., the upstream piston surface 570U) and a second piston surface (e.g., the downstream piston surface 570D). Similarly, a "pressure difference" is the pressure difference between a first pressure (e.g., the chamber pressure 567) and a second pressure (e.g., the surrounding pressure 568).

[0097] In one or more embodiments, the addition of the chamber 564 to the insertion valve 238 allows the insertion valve 238 to be used at greater depths. As a non-limiting example, the compression spring 458 may be limited to a maximum size due to the impracticality of installing a compression spring 458 that is larger and / or capable of exerting a greater upward force on the valve 354. When the insertion valve 238 is installed below a certain depth, the maximum force exerted by the compression spring 458 may be less than the force necessary to hold the valve 354 closed. In other words, the installation depth of the insertion valve 238 (without the chamber 564) may be limited, because the hydrostatic head of the liquid prevents the compression spring 458 from closing the valve 354.Thus, in such cases, chamber 564 may be provided to exert an additional upward force on poppet 354 (via lower piston rod 344L).

[0098] Conversely, in another non-limiting example, at certain depths, higher pressures from the formation may prevent the valve 354 from opening because too much pressure is applied to the downstream side of the insertion valve 238 (in the closed state). In such cases, the chamber 564 may be installed to exert additional downward force on the valve 354 (via the lower piston rod 344L).

[0099] In any embodiment where the depth and pressures of the insertion valve 238 are, at least in large part, known, the chamber 564 (and its components) can be sized and constructed (e.g., by selecting the upstream piston surface 570U, the downstream piston surface 570D, and the chamber pressure 567). When properly sized, the chamber 564 can largely neutralize any unwanted additional force acting on the poppet 354, thereby bringing the chamber piston force on the poppet 354 into a desirable range. When within this desirable range, the insertion valve 238 can be opened and closed via the upper piston rod 344U by pressure changes in the hydraulic control line 250 (to the upper piston bore 346U). Thus, an operator at the surface can open and close the insertion valve 238, as desired, using the hydraulic control line 250.

[0100] — Solutions and improvements —

[0101] The methods and systems described above are an improvement over current technology because the methods and systems provide an insertion valve that improves fluid flow and control.

[0102] Generally, when a safety valve fails to properly control the flow of fluid from a tank, an insertion valve can be installed inside the safety valve, in parallel, to restore proper control of the tank fluid. However, insertion valves suffer from reduced flow rates, components that wear in the same manner as the safety valve, depth restrictions, and complicated designs that are subject to increased maintenance and failure.

[0103] As discussed herein, there is an insertion valve that allows for greater fluid flow than conventional insertion valves by allowing fluid to flow around the closure mechanism and then into the internal volume of the insertion valve. The piston that controls the closure is constructed in-line and centered with the closure mechanism to provide a simplified design with better control. In addition, the piston (and corresponding hydraulic controls) is placed upstream of the closure mechanism, thereby reducing the number of hydraulic seals installed in the insertion valve. In addition, the piston may be exposed to the internal volume of the insertion valve, at both ends, to neutralize the effect of pressure on the piston. A pressure chamber can be installed to counterbalance the forces of a spring mechanism and allow the insertion valve to be controlled at greater depths.

[0104] Other embodiments include a safety valve with a chamber to further neutralize any unwanted forces acting on the insertion valve. The addition of a chamber allows the net forces acting on the insertion valve (and its poppet) to be brought into a desired range. Since the forces on the insertion valve can be designed in advance, the insertion valve can be controlled via the hydraulic control line already present.

[0105] — Declarations —

[0106] The systems and methods may include any of the various features disclosed herein, including one or more of the following statements.

[0107] Statement 1. An insertion valve configured to be installed, at least partially, in a safety valve in a borehole, comprising a flow port disposed on an exterior of the insertion valve, a poppet configured to control a flow of fluid through the flow port, an upper piston rod, disposed upstream of the poppet, configured to move the poppet past at least a portion of the flow port; a chamber, disposed downstream of the poppet, comprising a chamber pressure; a lower piston rod coupled to the poppet, wherein the lower piston rod is configured to exert a chamber piston force on the poppet.

[0108] Statement 2. The insertion valve according to statement 1, wherein the lower piston rod comprises an upstream piston surface and a downstream piston surface.

[0109] Statement 3. The insertion valve according to statement 2, wherein the chamber piston force exerted by the lower piston rod is caused by an area difference between the upstream piston surface and the downstream piston surface; a pressure difference between the chamber pressure and the surrounding pressure.

[0110] Statement 4. The insertion valve according to statement 3, wherein the surrounding pressure is caused by a hydrostatic head in the borehole.

[0111] Statement 5. The insertion valve according to statement 4, wherein the chamber pressure is lower than the surrounding pressure.

[0112] Statement 6. The insertion valve according to statement 5, wherein the upstream piston area is smaller than the downstream piston area, whereby the chamber piston force on the poppet is a downward force of the chamber piston.

[0113] Statement 7. The insertion valve according to one of statements 5 to 6, wherein the upstream piston area is larger than downstream piston area, which makes that the force of the chamber piston on the valve is an upward force of the chamber piston.

[0114] Statement 8. The insertion valve according to one of statements 4 to 7, wherein the chamber pressure is greater than the surrounding pressure.

[0115] Statement 9. The insertion valve according to statement 8, wherein the upstream piston area is smaller than the downstream piston area, whereby the chamber piston force on the poppet is an upward force of the chamber piston.

[0116] Statement 10. The insertion valve according to one of statements 8 to 9, wherein the upstream piston area is larger than the downstream piston area, whereby the chamber piston force on the poppet is a downward force of the chamber piston.

[0117] Statement 11. The insertion valve according to one of statements 3 to 10, wherein the insertion valve further comprises a spring configured to exert an upward force on the flapper.

[0118] Statement 12. The insertion valve according to one of statements 3 to 11, wherein the insertion valve is in hydraulic contact with a hydraulic control line.

[0119] Statement 13. The insertion valve according to statement 12, wherein the movement of the upper piston rod can be controlled by pressure in the hydraulic control line.

[0120] Statement 14. The insertion valve according to statement 13, wherein the addition of hydraulic pressure to the hydraulic control line causes the flapper to move downhole.

[0121] Statement 15. The insertion valve according to one of statements 13-14, wherein removal of hydraulic pressure from the hydraulic control line causes the flapper to move up the hole.

[0122] Statement 16. An insertion valve installed in a surrounding pressure, comprising a poppet configured to control a flow of fluid through a flow orifice; an upper piston rod coupled to the poppet and configured to move the poppet past at least a portion of the flow orifice; a lower piston rod coupled to the poppet and configured to exert a chamber piston force on the poppet, wherein the lower piston rod passes, at least in part, through a chamber.

[0123] Statement 17. The insertion valve according to statement 16, wherein a chamber pressure, in the chamber, causes the force of the chamber piston.

[0124] Statement 18. The insertion valve according to statement 17, wherein the lower piston rod comprises an upstream piston surface and a downstream piston surface.

[0125] Statement 19. The insertion valve according to statement 18, wherein the chamber piston force exerted by the lower piston rod is caused by an area difference between the upstream piston surface and the downstream piston surface; a pressure difference between the chamber pressure and the surrounding pressure.

[0126] Statement 20. The insertion valve according to statement 19, wherein the insertion valve is in hydraulic contact with a hydraulic control line.

[0127] — General remarks —

[0128] Since it is not possible to disclose all conceivable forms of the technology described herein, the figures, examples, and description provided herein disclose only a limited number of potential embodiments. A person of ordinary skill in the art will understand that many potential variations or modifications can be made to the embodiments explicitly disclosed, and that such alternative embodiments remain within the scope of the broader technology. Thus, the scope should be limited only by the appended claims. Further, the compositions and methods are described in terms of "comprising," "containing," or "including" various components or steps; the compositions and methods may also "consist essentially of" or "consist of" various components and steps.Certain technical details, known to those of ordinary skill in the relevant art, may be omitted for the sake of brevity and to avoid cluttering the description of novel aspects.

[0129] For brevity, descriptions of similarly named components may be omitted if a description of that similarly named component exists elsewhere in the application. Thus, any component described with respect to a specific figure may be equivalent to one or more like-named components shown or described in another figure, and each component incorporates the description of each like-named component provided in the application (unless explicitly stated otherwise). The description of a component should be construed as an optional embodiment—one that may be implemented in addition to, in conjunction with, or instead of an embodiment of a like-named component described for any other figure.

[0130] — Lexicographical remarks —

[0131] As used herein, ordinal adjectives (e.g., first, second, third, etc.) are used to distinguish elements and do not create an order among them. For example, a “first element” is distinct from a “second element,” but the “first element” may come after (or before) the “second element” in an ordering of elements. Thus, an ordering of elements exists only if an ordering terminology is expressly provided (e.g., “before,” “between,” “after,” etc.) or if a type of “order” is expressly provided (e.g., “chronological,” “alphabetical,” “ by size", etc.) Furthermore, the use of ordinal numbers does not preclude the existence of other elements. For example, a "table with a first leg and a second leg" is a table with two or more legs (e.g., two legs, five legs, thirteen legs, etc.). A maximum quantity of elements exists only if explicit language is used to limit the upper bound (e.g., "two or fewer", "five exactly", "nine to twenty", etc.). Similarly, the singular use of an ordinal number does not imply the existence of another element. For example, a "first threshold" may be the only threshold and therefore does not require the existence of a "second threshold".

[0132] As used herein, the term "operational connection" (or "operationally connected") refers to the direct or indirect connection between devices that enables the transmission of data. For example, the term "operationally connected" may refer to a direct connection (e.g., a direct wired or wireless connection between devices) or an indirect connection (e.g., multiple wired and / or wireless connections between any number of other devices connecting the operatively connected devices).

[0133] As used herein, the term "machine" means any set of components assembled to form a tool, structure, or other apparatus. A set of components may be grouped together and referred to as a single "machine" based on the functionality of the machine enabled by the combination of the components. By way of non-limiting example, a "car engine" is a machine assembled from the components of an engine block, one or more pistons, a camshaft, etc., which, when combined, enable the conversion of chemical energy into mechanical energy. In addition, a machine may be constructed using one or more other machines.By way of non-limiting example, an automobile may be an assembly of an engine, a drive train and a steering system, each an independent machine, but assembled to form a larger machine, singularly called an "automobile", the function of which is to provide transportation.

[0134] As used herein, "ascending" means in an "upstream" direction and "downstream" means in a "downstream" direction. Further, the term "upstream" refers to a surface of the borehole that is closer to the surface (when navigating the borehole) than a surface "downstream" of the borehole. In other words, although a borehole may vary in depth and move (relatively) closer to the surface, a section is only considered "upstream" along the path of the borehole.

Claims

Claims

1. An insertion valve (238) configured to be installed, at least partially, in a safety valve (236) in a borehole (120), comprising: a flow port (362) disposed externally of the insertion valve; a poppet (354) configured to control fluid flow through the flow port; an upper piston rod (344U), disposed upstream of the poppet, configured to move the poppet past at least a portion of the flow port; and a chamber (564), disposed downstream of the poppet, comprising: a chamber pressure (567); and a lower piston rod (344L) coupled to the poppet, wherein the lower piston rod is configured to exert a chamber piston force on the poppet.

2. The insertion valve of claim 1, wherein the lower piston rod comprises: an upstream piston surface (570U); and a downstream piston surface (570D).

3. The insertion valve of claim 2, wherein the chamber piston force exerted by the lower piston rod is caused by: an area difference between the upstream piston surface and the downstream piston surface; and a pressure difference between the chamber pressure and the surrounding pressure.

4. The insertion valve of claim 3, wherein the surrounding pressure is caused by a hydrostatic head in the borehole.

5. The insertion valve of claim 4, wherein the chamber pressure is lower than the surrounding pressure, and wherein the upstream piston area is smaller than the downstream piston area, whereby the force of the chamber piston on the poppet is a downward force of the chamber piston.

6. The insertion valve of claim 4, wherein the chamber pressure is lower than the surrounding pressure, and wherein the upstream piston area is greater than the downstream piston area, so the chamber piston force on the poppet is an upward chamber piston force.

7. The insertion valve of claim 4, wherein the chamber pressure is greater than the surrounding pressure, and wherein the upstream piston area is smaller than the downstream piston area, whereby the force of the chamber piston on the poppet is an upward force of the chamber piston.

8. The insertion valve of claim 4, wherein the chamber pressure is greater than the surrounding pressure, and wherein the upstream piston area is greater than the downstream piston area, whereby the force of the chamber piston on the poppet is a downward force of the chamber piston.

9. The insertion valve of claim 3, wherein movement of the upper piston rod is controllable by pressure in a hydraulic control line in hydraulic contact with the insertion valve.

10. The insertion valve of claim 9, wherein adding hydraulic pressure to the hydraulic control line causes the flapper to move downstream.

11. The insertion valve of claim 9, wherein removing hydraulic pressure from the hydraulic control line causes the upstream poppet to move.

12. An insertion valve (238) installed in a pressure environment (568), comprising: a poppet (354) configured to control fluid flow through a flow port (362); an upper piston rod (344U) coupled to the poppet and configured to move the poppet past at least a portion of the flow port; and a lower piston rod (344L) coupled to the poppet and configured to exert a chamber piston force on the poppet, the lower piston rod passing, at least partially, through a chamber (364).

13. The insertion valve of claim 12, wherein a chamber pressure (567), in the chamber, causes the force of the chamber piston.

14. The insertion valve of claim 13, wherein the lower piston rod comprises: an upstream piston surface (570U); and a downstream piston surface (570D).

15. The insertion valve of claim 14, wherein the chamber piston force exerted by the lower piston rod is caused by: an area difference between the upstream piston surface and the downstream piston surface; and a pressure difference between the chamber pressure and the surrounding pressure.

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