Remotely Actuated Valve for Rapid Well Control

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Solution Overview

Problem

Existing well control methods during cementing operations are inadequate, particularly when the shoe with a one-way valve fails to prevent blowouts, and the use of plugs or balls can be too slow in critical situations, as seen in the Macondo well incident, where rapid well control is essential to prevent damage and injury.

Innovation Solution

A remotely actuated valve is integrated near the lower end of the tubular string, which can be triggered by surface signals, such as mud pulses, to quickly shut off the string and prevent pressure surges without the need for introducing a ball or plug, utilizing a sensor and processor system for rapid operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a shoe with a one-way valve is used to control cement flow, then cement can be pumped out through the lower end, but the valve may not be sufficient to hold back an incipient blowout

Engineering Contradiction:

Improvewell control capabilityVSAvoidblowout risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A remotely actuated valve is introduced as an intermediary device between the surface control system and the wellbore. This valve can be activated by surface personnel to provide an additional barrier against blowouts, working in conjunction with the shoe's one-way valve to enhance overall well control reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The remotely actuated valve is positioned and ready for immediate activation before a blowout occurs. By having the valve pre-installed and capable of remote activation, the system can respond rapidly to developing situations without requiring time-consuming interventions like dropping balls or plugs into the string.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If plugs or balls are pumped down to secure a position for well control, then pressure differential can be used to control the well, but the response time is too slow in critical situations

Engineering Contradiction:

Improvewell control capabilityVSAvoidresponse time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The manual intervention process of dropping and landing balls or plugs is replaced with a remotely actuated valve system that can be controlled from the surface. This substitution eliminates the time delay associated with pumping down and positioning plugs, allowing for immediate well control when needed.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The valve is pre-positioned in the tubular string and can be activated immediately through remote signaling. This preliminary preparation eliminates the need for time-consuming operations of pumping down and landing plugs, enabling rapid response to well control situations.

Inventive Principle:

Principle #10Preliminary action

3Speed

If a remotely actuated valve is integrated near the lower end of the tubular string, then rapid well control can be achieved, but the device complexity increases

Engineering Contradiction:

Improveresponse speedVSAvoidvalve actuation system

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

A sensor acts as an intermediary between the mud pulse signal from the surface and the valve actuation mechanism. The sensor detects the presence of a ball or plug and triggers the valve to close automatically, providing rapid response while maintaining relatively simple system architecture through the use of this intermediary detection and signaling component.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution enables rapid well control by ensuring the valve can close quickly to prevent hydrocarbon escape and pressure surges, enhancing safety and reducing the risk of damage and injury during cementing operations, even in deep water environments where conventional methods may fail.

Implementation Method 1

triggered by surface signals, such as mud pulses, to quickly shut off the string

Methodology Applied

Scientific EffectMud pulse detection:

Data Source

PatentUS10125572B2Casing or liner barrier with remote interventionless actuation feature

Publication Date: 2018.11.13 BAKER HUGHES CO

AI summary

A tubular string is run into a wellbore with a remotely actuated valve near a lower end adjacent a cementing shoe. The valve is triggered to operate without intervention such as by mud pulses generated at the surface and recognized by a sensor linked to a processor adjacent the valve to trigger the valve to close. Alternative actuation systems are envisioned for the valve that is located near the cementing shoe.