Tubing Spool With Independent Annulus Flow Control
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Solution Overview
Problem
Current methods for transitioning between tubing and annulus operations in wellheads are time-consuming and expensive, and lack a back pressure valve (BPV) to isolate the annulus production/injection flow path, posing safety hazards.
Innovation Solution
A wellhead assembly with a tubing spool featuring a body with two channels, one for the tubing string and another for the annulus, each with independent flow control valves and back pressure valves to facilitate safe and independent control of fluid flow between the tubing and annulus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional wellhead operations are used to transition between tubing and annulus operations, then the well can be operated, but significant time and expense are required for equipment transitions and installations
Solution Approach 1:
The wellhead assembly is segmented into separate, independently controllable flow paths for tubing and annulus operations. Each flow path has its own set of valves and control mechanisms, allowing simultaneous or independent operation without requiring equipment transitions. This segmentation eliminates the need to shut down and reconfigure equipment when switching between tubing and annulus operations.
Solution Approach 2:
The wellhead assembly is designed with multi-functional capabilities to handle both tubing and annulus operations through a single integrated structure. The assembly includes multiple flow paths, valves, and connections that can accommodate different operational modes (tubing production, annulus injection, annulus production) without requiring additional equipment or major reconfigurations.
2Reliability
If traditional wellhead operations are used without back pressure valves, then the well can be operated, but safety hazards exist due to inability to isolate annulus production/injection flow paths
Solution Approach 1:
The flow paths are segmented into isolated sections with back pressure valves positioned at strategic locations to create independent, isolatable zones. This segmentation allows any section to be sealed off from the rest of the system, enabling safe maintenance, pressure control, and emergency shutdown without affecting other parts of the wellhead assembly.
Solution Approach 2:
Back pressure valves act as intermediary control elements between different flow paths and pressure zones. These valves provide intermediate control capability, allowing operators to regulate pressure and flow between sections independently, thereby enhancing safety without requiring complete system shutdown or complex external intervention.
3Productivity
If traditional wellhead operations are used, then equipment can be installed, but expensive workover equipment and facility connections must be brought in and installed
Solution Approach 1:
The wellhead assembly incorporates universal, multi-functional components that can handle multiple operational scenarios (tubing production, annulus injection, annulus production, workover operations) through a single integrated design. This eliminates the need to install separate, expensive workover equipment and facility connections for different operational modes, as the assembly can be reconfigured in-place.
Solution Approach 2:
The wellhead assembly is pre-configured with all necessary flow paths, valves, and connections during initial installation to accommodate future operational needs. This preliminary action includes installing back pressure valves, multiple flow control valves, and redundant connections that enable both tubing and annulus operations from the outset, avoiding the need for costly retrofits or workover equipment installations later.
Data Source
AI summary
A tubing spool of a wellhead assembly can include a body having a body cavity, a first channel, and a second channel disposed therein, where the body cavity is configured to receive a tubing hanger used to couple to and suspend a tubing string, where the first channel is configured to be in communication with a tubing string cavity within the tubing string, where the second channel is configured to be in communication with an annulus located between the tubing string and a production casing, and where the first channel and the second channel are each configured to facilitate flow of at least one of a plurality of fluids in either direction independently of each other. The tubing spool can also include a first back pressure valve disposed within the first channel and a second back pressure valve disposed within the second channel.