Wellhead Control Line Hanger for Safety Valve Deployment
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Solution Overview
Problem
Operators in the field development face challenges when a surface control subsurface safety valve (SCSSV) stops functioning due to a blocked or damaged control line, requiring costly and time-consuming well workovers or the deployment of velocity valves that may not meet integrity requirements, and there is a need for a solution to install a safety valve and alternate control line without these expenses.
Innovation Solution
The Weatherford Damaged Control Line (WDCL) Safety Valve system uses a control line hanger that supports and communicates hydraulic fluid to a downhole safety valve, allowing for the installation of a new control line without hot tapping the wellhead, using various arrangements such as spools, replacement master valves, and adjustable sleeves to accommodate different wellhead configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If operators perform a full-scale workover to replace the control line, then the safety valve function is restored, but the operation becomes time-consuming and expensive
Solution Approach 1:
The invention separates the control line replacement into distinct segments: the existing control line is isolated at the wellhead using a spool and hanger assembly, while only the downhole portion needs replacement. This allows the safety valve to be serviced without requiring complete tubing removal or full workover operations, significantly reducing downtime while restoring safety valve function.
Solution Approach 2:
The invention introduces a control line hanger and spool assembly as intermediary components at the wellhead. These components provide a isolation point that allows the control line to be disconnected and replaced downhole without affecting the entire well system. The hanger acts as a mediator between the existing wellhead infrastructure and the new control line configuration.
2Reliability
If operators install a velocity or dome charged subsurface controlled safety valve downhole, then the control line issue is bypassed, but the valve may not meet integrity requirements and production is reduced
Solution Approach 1:
The invention replicates the original surface-controlled safety valve configuration by installing a new control line that connects to the existing SCSSV downhole. Instead of replacing the valve type, the system copies the original control architecture, maintaining the same integrity standards and production capabilities while addressing the damaged control line issue.
3Ease of manufacture
If operators use a control line hanger system with spools and sleeves, then installation can be done without hot tapping the wellhead, but the device complexity increases
Solution Approach 1:
The control line hanger assembly is designed as a universal interface that can be adapted to various wellhead configurations without requiring custom hot tapping operations. The spool and hanger components provide standardized connection points that work with different wellhead types, simplifying the installation process while managing complexity through modular, multi-functional design.
Data Source
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AI summary
There is provided a wellhead component (50, 60) installing above a casing hanger on a wellhead (10), the wellhead component (50, 60) having a first bore (52, 62) and having at least one lock screw (55, 65) disposing in a side of the first bore (52, 62). The wellhead component (50, 60) has a first port (56, 66) communicating from the first bore (52, 62) to outside the component (50, 60). A control line hanger (100) installs at least partially in the first bore (52, 62) of the wellhead component (50, 60). At least one lock screw (55, 65) engages the control line hanger (100) when installed therein. The control line hanger (100) has a tubular body (101) defining a second bore (102) from a first end to a second end, the tubular body (101) having a second port (106) with an inlet and an outlet, the inlet communicating with the first port (56, 66) on the component (50, 60). The control line hanger also has a connector (110) supported on the second end of the tubular body (101) and coupled to a control line (120), the connector having one or more flutes communicating with the second bore, the connector having a conduit connecting the outlet of the second port with the control line (120) coupled to the connector.