Water Jetting Head for Cutting Stuck Wellhead Gate Valves
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Solution Overview
Problem
Stuck gate valves in wellhead Christmas trees pose a challenge for wellbore accessibility, as conventional milling methods are time-consuming, hazardous, and can lead to safety issues and environmental contamination.
Innovation Solution
A water jetting system is used to cut through stuck gate valves by accelerating water flow through an orifice plate, creating a high-pressure jet that can mill through the valve without physical contact, using only water and no hazardous chemicals or abrasive materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional milling methods are used to remove stuck gate valves, then the valve can be removed, but the process is time-consuming and hazardous
Solution Approach 1:
The patent replaces conventional mechanical milling methods with a water jetting system that uses high-pressure fluid dynamics to cut through stuck gate valves. The water jetting head accelerates water to extremely high velocities (supersonic speeds) to erode and remove the valve material, eliminating the need for mechanical contact and reducing both time and safety hazards associated with traditional milling operations
Solution Approach 2:
The invention utilizes hydraulic principles by employing a high-pressure pump system to generate and deliver water at extreme pressures through a focused jet. The water jetting head converts hydraulic pressure into kinetic energy, creating a high-velocity water stream that can cut through metal valve components rapidly and safely without mechanical contact
2Reliability
If conventional milling methods are used, then the valve can be removed, but environmental contamination and well control incidents may occur
Solution Approach 1:
By replacing mechanical milling with water jetting, the patent eliminates sources of contamination such as metal shavings from milling operations and potential sparks that could cause well control incidents. The water-based system is inherently cleaner and safer for wellbore environments
Solution Approach 2:
The water jetting system creates a controlled, inert cutting environment using water as the cutting medium. This eliminates the risk of explosive atmospheres that can occur with flame-based cutting methods and prevents contamination from oil-based cutting fluids, ensuring a cleaner and safer operation
3Productivity
If water jetting is used to cut the gate valve, then cutting speed increases and safety improves, but specialized equipment is required
Solution Approach 1:
The water jetting head is designed to be deployed within existing wellbore infrastructure, nesting the specialized cutting equipment inside the wellhead Christmas tree structure. The jetting head can be lowered through the wellbore and positioned at the stuck valve location without requiring complete removal of existing equipment
Solution Approach 2:
The water jetting system is designed with multi-functionality to handle various stuck valve scenarios and different wellbore configurations. The same basic jetting head design can be adapted to cut through different materials and valve types, reducing the need for multiple specialized equipment variants
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
The water jetting method provides a faster, safer, and environmentally friendly solution for cutting through stuck gate valves, reducing the risk of well control incidents and minimizing damage to the wellbore and reservoir, while offering cost savings and versatility for cutting various materials.
Implementation Method 1
The orifice plate defines an orifice configured to accelerate a flow rate of the water received at a first flow rate upstream of the orifice plate to a second flow rate, greater than the first flow rate, downstream of the orifice plate
Implementation Method 2
At the second flow rate, the water can mill a gate valve disposed within the wellhead. The jetting port is downstream of the orifice plate. The jetting port is configured to receive the water at the second flow rate and to guide the received water to the gate valve
Data Source
AI summary
A well tool assembly to cut a wellhead gate valve by water jetting includes a water jetting head lowered into a wellhead tree coupled to a wellbore. The head includes a housing, an orifice plate and a jetting port. The housing defines a tubular region to receive water. The orifice plate is positioned within the tubular region downstream of a first end and upstream of a second end of the housing, and defines an orifice to accelerate a flow rate of the water received at a first flow rate upstream of the orifice plate to a second flow rate, greater than the first, downstream of the plate. At the second flow rate, the water can mill a gate valve within the wellhead. The jetting port is downstream of the orifice plate, and can receive the water at the second flow rate and guide the received water to the gate valve.