U.S. patent application number 16/886665 was filed with the patent office on 2020-09-17 for method of intervention in a failed deep-set subsurface safety valve in a deepwater or ultra-deepwater subsea well using a light intervention vessel.
The applicant listed for this patent is Tejas Research & Engineering, LLC. Invention is credited to Thomas G. Hill, JR., Jason C. Mailand, Case Nienhuis.
Application Number | 20200291750 16/886665 |
Document ID | / |
Family ID | 1000004883580 |
Filed Date | 2020-09-17 |
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United States Patent
Application |
20200291750 |
Kind Code |
A1 |
Hill, JR.; Thomas G. ; et
al. |
September 17, 2020 |
METHOD OF INTERVENTION IN A FAILED DEEP-SET SUBSURFACE SAFETY VALVE
IN A DEEPWATER OR ULTRA-DEEPWATER SUBSEA WELL USING A LIGHT
INTERVENTION VESSEL
Abstract
A method of intervention in a failed deep-set tubing-retrievable
subsurface safety valve disposed in a deepwater or ultra-deepwater
subsea well uses a deep-set wireline-retrievable subsurface safety
valve that may be deployed via wireline into the failed deep-set
tubing-retrievable subsurface safety valve. The deep-set
wireline-retrievable subsurface safety valve has a closure
actuation mechanism that is disposed below the closure device. In
addition, the closure actuation mechanism includes a
pressure-balanced piston that is exposed to wellbore fluids on both
distal ends of the piston, thereby allowing the piston to actuate
the closure device in deepwater and ultra-deepwater wells with
significant hydrostatic head in the control line. Advantageously,
the method does not require re-completion of the well and a light
intervention vessel may be used as the platform for performing the
intervention, rather than a conventional drilling rig or platform,
substantially reducing non-productive down-time, lost profits, and
costs associated with resuming production.
Inventors: |
Hill, JR.; Thomas G.; (The
Woodlands, TX) ; Mailand; Jason C.; (The Woodlands,
TX) ; Nienhuis; Case; (Conroe, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Tejas Research & Engineering, LLC |
The Woodlands |
TX |
US |
|
|
Family ID: |
1000004883580 |
Appl. No.: |
16/886665 |
Filed: |
May 28, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16378740 |
Apr 9, 2019 |
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16886665 |
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16386624 |
Apr 17, 2019 |
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16378740 |
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62779121 |
Dec 13, 2018 |
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62718737 |
Aug 14, 2018 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 34/105 20130101;
E21B 34/14 20130101; E21B 34/16 20130101; E21B 2200/04
20200501 |
International
Class: |
E21B 34/16 20060101
E21B034/16; E21B 34/10 20060101 E21B034/10; E21B 34/14 20060101
E21B034/14 |
Claims
1. A method of intervention in a failed deep-set tubing-retrievable
subsurface safety valve disposed in a deepwater or ultra-deepwater
subsea well comprising: cutting or grinding a radial port in an
interior facing portion of the failed deep-set tubing retrievable
subsurface safety valve with an e-line wireline-deployable
communication tool to communicate a hydraulic chamber housing of
the failed deep-set tubing-retrievable subsurface safety valve; and
running in a deep-set wireline-retrievable subsurface safety valve
into a central lumen of the failed tubing-retrievable subsurface
safety valve, wherein the deep-set wireline-retrievable subsurface
safety valve comprises a closure actuation mechanism disposed below
a closure device, and wherein the actuation mechanism comprises a
pressure-balanced piston exposed to wellbore fluids on both distal
ends of the piston.
2. The method of claim 1, further comprising: disposing a light
intervention vessel on a well site.
3. The method of claim 1, further comprising: facilitating wireline
access from a light intervention vessel to the subsea well
comprising the failed tubing-retrievable subsurface safety
valve.
4. The method of claim 3, wherein wireline access is provided by a
riser-based system.
5. The method of claim 3, wherein wireline access is provided by a
riser-less system.
6. The method of claim 3, wherein the wireline access is provided
by a coiled-tubing system.
7. The method of claim 1, further comprising: locking out the
failed deep-set tubing-retrievable subsurface safety valve with a
wireline-deployable lockout tool.
8. The method of claim 1, further comprising: running in the
wireline-deployable communication tool into an interior of the
failed deep-set tubing-retrievable subsurface safety valve.
9. The method of claim 1, further comprising: landing the deep-set
wireline retrievable subsurface safety valve within a no-go
shoulder or other profile of the failed tubing-retrievable
subsurface safety valve.
10. The method of claim 1, further comprising: locking the deep-set
wireline retrievable subsurface safety valve into place at a
location within the failed deep-set tubing-retrievable subsurface
safety valve that facilitates communication.
11. The method of claim 1, further comprising: providing hydraulic
actuation fluid from a surface-controlled pump system to the
deep-set wireline-retrievable subsurface safety valve via the
communicated hydraulic chamber housing of the failed
tubing-retrievable subsurface safety valve.
12. The method of claim 11, wherein the surface-controlled pump
system provides hydraulic actuation fluid to a wet tree that is
fluidly connected to a control line that is fluidly connected to
the hydraulic chamber housing of the failed tubing-retrievable
subsurface safety valve.
13. The method of claim 1, wherein the closure device of the
deep-set wireline retrievable subsurface safety valve comprises an
equalization system configured to equalize pressure across the
closure device to facilitate opening the deep-set wireline
retrievable subsurface safety valve.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 16/378,740, filed on Apr. 9, 2019, which
claims the benefit of, or priority to, U.S. Provisional Patent
Application Ser. No. 62/779,121, filed on Dec. 13, 2018, both of
which are hereby incorporated by reference in their entirety.
[0002] This application is a continuation-in-part of U.S. patent
application Ser. No. 16/386,624, filed on Apr. 17, 2019, which
claims the benefit of, or priority to, U.S. Provisional Patent
Application Ser. No. 62/718,737, filed on Aug. 14, 2018, both of
which are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0003] While the oil and gas industry has drilled more than 14,000
deepwater subsea wells, in the aftermath of the Macondo incident in
the Gulf of Mexico off the southeastern coast of Louisiana and the
Montara incident in the Timor Sea off the northern coast of
Australia, the International Association of Oil and Gas Producers
("OGP") formed the Global Industry Response Group ("GIRG") to
investigate these and other incidents around the world and develop
recommendations to the industry. In 2011, the GIRG published their
recommendations in a report entitled Deepwater Wells: Global
Industry Response Group Recommendations ("Report No. 463"). In
Report No. 463, the GIRG recommends that "operators maintain a
permanently applied minimum of two well barriers when the well is
capable of discharging hydrocarbons or other fluids to the surface
or external environment. . . . During drilling, completion, and
abandonment phases of a well we regard a [blowout preventer] BOP as
a barrier for the purposes of such a policy even when operated in
the open position--if the BOP and associated procedures meet the
operator's policy in . . . configuration and certification;
redundancy for the operations being undertaken; function and
pressure testing; and operational controls to use the BOP to shut
in the well." See Section 1.1 of Report No. 463. As such, operators
consider the subsea blowout preventer ("SSBOP") one of the
permanently applied well barriers and typically install a
surface-controlled tubing-retrievable subsurface safety valve as
the second permanently applied well barrier.
[0004] A subsurface safety valve is a failsafe device deployed
downhole to prevent catastrophic failure by shutting-in a well when
other means of control are compromised or lost. During initial
completion operations, while the drilling rig is still on the well
site, a tubing-retrievable type of subsurface safety valve is run
into the well as part of the production tubing. The term
tubing-retrievable means the subsurface safety valve is deployed as
an integrated part of, and is only retrievable by pulling, the
production tubing. During production operations, typically after
the drilling rig has left the well site, the tubing-retrievable
subsurface safety valve is hydraulically actuated into the open, or
producing, state permitting production flow towards the surface.
When the operator wants to halt production, the hydraulic pressure
in the control line is sufficiently reduced or removed and the bias
spring automatically closes the tubing-retrievable subsurface
safety valve, preventing further production flow. In the event of a
failure or other contingency, tubing-retrievable subsurface safety
valves are designed to fail safely in the closed position to
prevent further production flow. To that end, subsurface safety
valves require the affirmative application of hydraulic pressure in
the control line that is sufficient to overcome the bias spring,
influenced by pressure at the setting depth, to open a
unidirectional flapper or valve and controllably permit the flow of
production fluids toward the surface. When the hydraulic pressure
in the control line is sufficiently reduced or removed,
intentionally or otherwise, the bias spring causes the flapper or
valve to automatically close, thereby safely preventing any further
production flow.
[0005] As tubing-retrievable subsurface safety valves were being
set deeper in the well due to their use in deeper water, the valves
had difficulty operating due to the hydrostatic head in the control
line, which eviscerated the failsafe protection they were intended
to provide. As such, tubing-retrievable subsurface safety valves
were modified to provide additional biasing force to balance the
increased hydrostatic head in the control line. These deep-set
tubing-retrievable subsurface safety valves include additional
biasing means, such as, gas-charged chambers described in, for
example, U.S. Pat. Nos. 4,252,197, 4,660,646, 4,976,317, and
5,310,004, or balance lines described in, for example, U.S. Pat.
Nos. 6,003,605 and 7,392,849 that provide additional biasing force
to the biasing spring. In general, the additional biasing means are
designed to offset the hydrostatic head in the control line so that
the operating pressures within the control line remain relatively
low, such that the subsurface safety valve may be actuated at depth
and fully close as intended when the hydraulic pressure in the
control line is sufficiently reduced or removed.
BRIEF SUMMARY OF THE INVENTION
[0006] According to one aspect of one or more embodiments of the
present invention, a method of intervention in a failed deep-set
tubing-retrievable subsurface safety valve disposed in a deepwater
or ultra-deepwater subsea well includes cutting or grinding a
radial port in an interior facing portion of the failed deep-set
tubing retrievable subsurface safety valve with an e-line
wireline-deployable communication tool to communicate a hydraulic
chamber housing of the failed deep-set tubing-retrievable
subsurface safety valve. The method further includes running in a
deep-set wireline-retrievable subsurface safety valve into a
central lumen of the failed tubing-retrievable subsurface safety
valve. The deep-set wireline-retrievable subsurface safety valve
includes a closure actuation mechanism disposed below a closure
device. The actuation mechanism includes a pressure-balanced piston
exposed to wellbore fluids on both distal ends of the piston.
[0007] Other aspects of the present invention will be apparent from
the following description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 shows the deployment of a conventional deep-set
tubing-retrievable subsurface safety valve in a deepwater or
ultra-deepwater subsea well.
[0009] FIG. 2 shows a conventional deep-set tubing-retrievable
subsurface safety valve.
[0010] FIG. 3 shows a light intervention vessel disposed on a well
site of a failed tubing-retrievable subsurface safety valve
disposed in a deepwater or ultra-deepwater subsea well in
accordance with one or more embodiments of the present
invention.
[0011] FIG. 4A shows communication of the failed deep-set
tubing-retrievable subsurface safety valve in accordance with one
or more embodiments of the present invention.
[0012] FIG. 4B shows a radial cutout formed in an interior facing
surface of the failed deep-set tubing-retrievable subsurface safety
valve providing access to the hydraulic chamber (not independently
shown) in accordance with one or more embodiments of the present
invention.
[0013] FIG. 5 shows a block diagram of a deep-set wireline
retrievable subsurface safety valve for a failed deep-set
tubing-retrievable subsurface safety valve in accordance with one
or more embodiments of the present invention.
[0014] FIG. 6 shows a bottom facing perspective view of a portion
of a deep-set wireline-retrievable subsurface safety valve in
accordance with one or more embodiments of the present
invention.
[0015] FIG. 7 shows an exploded view of a portion of a deep-set
wireline-retrievable subsurface safety valve in accordance with one
or more embodiments of the present invention.
[0016] FIG. 8A shows a cross-sectional view of a portion of a
deep-set wireline-retrievable subsurface safety valve in accordance
with one or more embodiments of the present invention.
[0017] FIG. 8B shows a cross-sectional view of a portion of
deep-set wireline-retrievable subsurface safety valve disposed
within a failed deep-set tubing-retrievable safety valve with a
ball valve in a closed state preventing flow in accordance with one
or more embodiments of the present invention.
[0018] FIG. 8C shows a cross-sectional view of a portion of a
deep-set wireline-retrievable subsurface safety valve disposed
within a failed deep-set tubing-retrievable subsurface safety valve
with a ball valve in an opened state permitting production flow in
accordance with one or more embodiments of the present
invention.
[0019] FIG. 8D shows a detailed portion of a cross-sectional view
of a portion of a deep-set wireline-retrievable subsurface safety
valve disposed within a failed deep-set tubing-retrievable
subsurface safety valve with a ball valve in an opened state
permitting flow in accordance with one or more embodiments of the
present invention.
[0020] FIG. 9A shows a detailed portion of a perspective view of a
ball valve of a deep-set wireline-retrievable subsurface safety
valve on seat in accordance with one or more embodiments of the
present invention.
[0021] FIG. 9B shows a detailed portion of a perspective view of a
ball valve of a deep-set wireline-retrievable subsurface safety
valve off seat under actuation pressure in accordance with one or
more embodiments of the present invention.
[0022] FIG. 10A shows a cross-sectional view of a closure device,
such as, for example, ball of a deep-set wireline-retrievable
subsurface safety valve in a closed state in accordance with one or
more embodiments of the present invention.
[0023] FIG. 10B shows a cross-sectional view of a closure device,
such as, for example, ball of a deep-set wireline-retrievable
subsurface safety valve in an open state in accordance with one or
more embodiments of the present invention.
[0024] FIG. 11 shows a light intervention vessel performing a
method of intervention in a failed deep-set tubing-retrievable
subsurface safety valve in a deepwater or ultra-deepwater subsea
well in accordance with one or more embodiments of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] One or more embodiments of the present invention are
described in detail with reference to the accompanying figures. For
consistency, like elements in the various figures are denoted by
like reference numerals. In the following detailed description of
the present invention, specific details are set forth in order to
provide a thorough understanding of the present invention. In other
instances, well-known features to one of ordinary skill in the art
are not described to avoid obscuring the description of the present
invention. For purposes of clarity, as used herein, top, upper, or
above refer to a portion or side that is closer, whether directly
or in reference to another component, to the surface above a
wellbore and bottom, lower, or below refer to a portion or side
that is closer, whether directly or in reference to another
component, to the bottom of the wellbore.
[0026] FIG. 1 shows the deployment 100 of a conventional deep-set
tubing-retrievable subsurface safety valve 105 in a deepwater or
ultra-deepwater subsea well 110. In offshore operations, a bottom
founded, semi-submersible, drillship, or other floating drilling
rig 115 is floated onto the well site to drill a subsea well 110 to
recover oil or gas reserves disposed below the seafloor 120. In
deepwater applications, the water depth, W.sub.Depth, may be in a
range between 3,500 and 5,000 feet. In ultra-deepwater
applications, the water depth, W.sub.Depth, may be greater than
5,000 feet. The total vertical depth of the wellbore 110 may extend
many thousands of feet below the seafloor 120.
[0027] During drilling and pre-production operations, a marine
riser system 125 facilitates fluid communication between drilling
rig 115 and subsea well 110. An SSBOP 135 is disposed above a
subsea wellhead, or wet tree, 130 disposed above subsea well 110.
The wellhead 130 is in fluid communication with production tubing
140 disposed within the interior of wellbore 110. In this way, a
central lumen is formed that fluidly connects drilling rig 115 to
the interior of wellbore 110 for the deployment of drilling
equipment and other tools (not shown). During initial completion
operations, deep-set tubing-retrievable subsurface safety valve 105
is deployed as an integrated part of production tubing 140,
typically disposed within 200 feet of the hanger (not independently
illustrated) of the wet tree 130. After completion, drilling rig
115 is moved off the well site and a Floating Production and
Storage Offloading ("FPSO") vessel (not shown) is typically brought
in to fluidly connect to the wet tree 130 to facilitate production
activities. The FPSO (not shown) typically includes a surface-based
control system (not shown) that communicates hydraulic actuation
fluid through the wet tree 130 to the deep-set tubing-retrievable
subsurface safety valve 105 via the control line (not shown). When
the operator wishes to start production, the surface-based control
system (not shown) provides hydraulic pressure in the control line
(not shown) that overcomes the resistance of the biasing means (not
shown), causing the flapper (not shown) or valve (not shown) to
open, permitting production flow towards the surface. The
production fluids may be directed from the wet tree 130 to a
storage tank (not shown) on the FPSO (not shown) for storage and
delivery.
[0028] FIG. 2 shows a conventional deep-set tubing-retrievable
subsurface safety valve 105 well-known in the art. A conventional
deep-set tubing-retrievable subsurface safety valve 105 such as,
for example, the valve shown and described in U.S. Pat. No.
5,310,004, may be deployed as part of the production tubing (e.g.,
140 of FIG. 1) and disposed in a subsea well (e.g., 110 of FIG. 1).
The valve 105 is typically set at a depth within the valve's
fail-safe setting depth. The fail-safe setting depth is the maximum
true vertical depth at which the valve may be set and expected to
properly close under worst-case hydrostatic conditions.
[0029] As described in U.S. Pat. No. 5,310,004, valve 105 includes
a central lumen 202 that extends from distal end to distal end and
a flapper 204 connected to a lower portion of a housing 206 by a
pivot pin 208. Valve 105 allows end-to-end communication through
the central lumen 202 when flapper 204 is in the open position and
prevents flow when flapper vale 204 is in the default closed
position. Valve 105 includes a piston 210 and a cylinder 212 that
are connected to a flow tube 214. To open valve 105, the
application of hydraulic pressure, via the control line (not
shown), to the top side of piston and cylinder assembly 216 causes
flow tube 214 to move downward, forcing flapper 204 off of valve
seat 218, opening valve 105 to production flow therethrough. In the
absence of sufficient hydraulic pressure, biasing means, such as
biasing spring 220 and a pressurized gas chamber 222, are biased to
push flow tube 214 in an upward direction, thereby releasing
flapper 204 to close valve 105. Spring 220 acts between a shoulder
224 on housing 206 and a shoulder 226 on flow tube 214. Pressurized
gas chamber 222 includes a plurality of tubing coils 228 containing
pressurized nitrogen.
[0030] As a failsafe, piston 210 includes a second piston 232 that
is telescopically positioned in an end of first piston 210. The
second piston 232 includes a first end 234 and a second end 236,
where the second end 236 has a larger cross-sectional area than the
first end 234. The first end 234 and second end 236 each sealably
engage first piston 210 by seals 238 (not shown) and 240 (not
shown). Seal 238 seals a smaller cross-sectional area than larger
seal 240. The first piston 210 includes a hydraulic fluid
passageway 242 that extends from a first side of the hydraulic
piston and cylinder assembly 216 to the first end 234 of the second
piston 232 and acts against seal 240. The second end 236 of second
piston 232 is exposed to the gas pressure in chamber 222. Because
the cross-sectional area of the second end 236 of second piston 232
has a larger seal area 240 than seal area 238 of first end 234,
second piston 232 will remain in engagement in the end of first
piston 210 with a lower gas pressure acting on second end 236
compared with hydraulic actuation fluid acting on first end 234.
However, if gas pressure is lost, and unable to overcome the
hydrostatic head of the hydraulic actuation fluid in the control
line (not shown), the force of the gas pressure acting on second
end 236 of the second piston 232 decreases allowing the hydrostatic
pressure of the hydraulic fluid acting on the first end 234 to push
the second piston 232 out of piston 210, thereby balancing the
hydrostatic actuation fluid forces on piston 210, such that biasing
spring 220 may close valve 105 safely. One of ordinary skill in the
art will appreciate that the conventional deep-set
tubing-retrievable subsurface safety valve described herein is
merely exemplary and there are other designs, however, each of
which relies on additional biasing means to assist in closing the
valve against the increased hydrostatic head encountered in
deep-set applications.
[0031] In the aftermath of the Deepwater Horizon incident, the use
of deep-set tubing retrievable subsurface safety valves increased
dramatically. While various original equipment manufacturers claim
that deep-set tubing-retrievable subsurface safety valves are
capable of reliable operation at substantial depth, until recently,
their actual performance in deepwater and ultra-deepwater wells was
not well characterized. Unfortunately, data from the field suggests
that deep-set tubing retrievable subsurface safety valves have a
substantially higher failure rate than that of conventional
tubing-retrievable subsurface safety valves, resulting in
non-commanded closures and other critical failure modes.
Specifically, high-profile failures have shed light on the
substantial risk these deep-set valves pose in deepwater and
ultra-deepwater applications. In a litigation matter filed in the
United States District Court for the Southern District of Texas,
styled Hess Corporation.RTM. v. Schlumberger Technology
Corporation.RTM. (case 4:16-CV-03415), Hess filed suit against
Schlumberger for damages resulting from the alleged failure of
Schlumberger's deep-set tubing retrievable subsurface safety valves
deployed offshore. Hess purchased five (5) deep-set
tubing-retrievable subsurface safety valves from Schlumberger for
use in subsea wells in the Outer Continental Shelf of the Gulf of
Mexico. As of the date of the complaint, three (3) of the five (5)
deep-set tubing-retrievable subsurface safety valves deployed in
deepwater subsea wells failed. According to Hess, this has resulted
in significant production losses, costs associated with pulling and
replacing the failed valves, costs associated with restoring
production capabilities, property loss and damage, and deferred
production costs associated with schedule delays on subsequent
producer and injector wells. The subsea wells at issue were drilled
in approximately 4,300 feet of water, with the wells themselves
having an approximate total vertical depth of approximately 25,000
feet. These wells produced between 2,000 and 16,500 barrels of oil
per day, before being shut-in by non-commanded valve closure and
potentially other failure modes. In quantifying the substantial
costs incurred due to these failures, Hess complained that, with
respect to a single subsea well, it took 64 days and cost
approximately $60 million dollars to restore production operations,
exclusive of lost profits.
[0032] The issues complained of in the above-noted litigation
highlight a longstanding problem in the industry that threatens the
financial viability and overall feasibility of deepwater and
ultra-deepwater plays. While tubing-retrievable subsurface safety
valves are required in deepwater and ultra-deepwater applications,
unfortunately, when they fail, the well must be re-completed in a
time-consuming and expensive process that requires floating a
drilling rig back onto the well site, pulling the production
tubing, replacing the failed tubing-retrievable subsurface safety
valve, and re-deploying the production tubing with the replaced
tubing-retrievable subsurface safety valve. In addition to the
substantial costs associated with the above-noted re-completion
activities, profits lost for the duration of these operations are
substantial. As noted in the real-world example, the frequency of
failure of deep-set tubing-retrievable subsurface safety valves and
the substantial time and cost required to re-complete a well
jeopardize the safety of operations and many operators are shying
away from such deepwater and ultra-deepwater plays, where a
significant amount of oil and gas reserves are known to exist.
[0033] In a failed conventional, not deep-set, tubing-retrievable
subsurface safety valve set at a shallower depth, typically less
than 3,500 feet, one avenue for proceeding is to deploy a
conventional wireline-retrievable subsurface safety valve within
the failed tubing-retrievable subsurface safety valve. The
wireline-retrievable subsurface safety valve may be run into the
well on a lock that locates the wireline-retrievable subsurface
safety valve within a desired location of the failed
tubing-retrievable subsurface safety valve. The
wireline-retrievable subsurface safety valve typically includes
packing elements that isolate the hydraulic chamber that was
previously used to control the now failed tubing-retrievable
subsurface safety valve. The process of opening up the original
hydraulic actuation pathway of the failed tubing-retrievable
subsurface safety valve for use with the wireline-retrievable
subsurface safety valve is referred to as communication. Once
communication has been achieved, a surface-controlled pump system
may pump hydraulic actuation fluid through the hydraulic chamber of
the failed tubing-retrievable subsurface safety valve to the
hydraulic chamber of the wireline-retrievable subsurface safety
valve to hydraulically actuate the wireline-retrievable subsurface
safety valve in a similar manner to that of the failed
tubing-retrievable subsurface safety valve.
[0034] While the wireline-retrievable subsurface safety valve
potentially reduces the flow rate of production fluids, it allows
such wells to continue to produce after failure of the
tubing-retrievable subsurface safety valve without the attendant
costs of recompleting the well. Similar to the tubing-retrievable
subsurface safety valve, the conventional wireline-retrievable
subsurface safety valve is a failsafe device that fails in the
closed state such that production flow is halted whenever hydraulic
actuation pressure is sufficiently reduced or removed. As such, the
conventional wireline-retrievable subsurface safety valve requires
the positive application of hydraulic actuation pressure to open a
flapper or valve to permit production flow through the subsurface
safety valve. In the event of a failure or catastrophic event, once
the hydraulic actuation is lost, the energy stored in a power
spring disposed above the flapper of the wireline-retrievable
subsurface safety valve causes the subsurface safety valve to
close, thereby safely halting production flow.
[0035] Notwithstanding, conventional wireline-retrievable
subsurface safety valves cannot be used in deepwater and
ultra-deepwater subsea wells. The depth at which conventional
wireline-retrievable subsurface safety valves may be deployed is
constrained by the ability to provide sufficient hydraulic
activation pressure at the setting depth. Conventional
wireline-retrievable subsurface safety valves require the
application of hydraulic actuation pressure to compress a bias
spring disposed above the flapper or valve to controllably open the
valve when production flow towards the surface is desired. If the
conventional wireline-retrievable subsurface safety valve is
deployed at a depth that exceeds the ability of the hydraulic
actuation to overcome the hydrostatic head in the control line, the
conventional wireline-retrievable subsurface safety valve cannot be
opened, thereby preventing production flow.
[0036] Further, conventional wireline-retrievable subsurface safety
valves require a bias spring disposed above the flapper or valve
that is capable of storing sufficient energy to offset the
increased hydrostatic head in the control line, at the setting
depth, such that it can reliably fail in the closed state. However,
this is not feasible because the size of the bias spring disposed
above the flapper or valve is physically constrained by the inner
diameter of the wireline-retrievable subsurface safety valve
itself. Since the conventional wireline-retrievable subsurface
safety valves require an inner diameter capable of fluidly
communicating production flow, the amount of space above the
flapper or valve is physically constrained, thereby limiting the
amount of energy capable of being stored in the bias spring and, as
a consequence, substantially limiting the depth at which the
conventional wireline-retrievable subsurface safety valve may be
set, typically much shallower than 3,500 feet.
[0037] As such, the current state of the art in the industry is to
deploy a SSBOP and deep-set tubing-retrievable subsurface safety
valve as a permanently installed two barrier system for deepwater
and ultra-deepwater subsea wells. When the tubing-retrievable
subsurface safety valve fails, for whatever reason, the operator
must undertake a complex, time-consuming, and expensive process to
re-complete the well in an attempt to resume production operations.
As noted above, a drilling rig must be brought onto the well site,
the production tubing must be pulled, the failed deep-set
tubing-retrievable subsurface safety valve must be replaced, the
production tubing must be run back into the well, and the well must
be completed with a wellhead or wet tree.
[0038] Accordingly, in one or more embodiments of the present
invention, a method of intervention in a failed deep-set
tubing-retrievable subsurface safety valve disposed in a deepwater
or ultra-deepwater subsea well does not require re-completion of
the well and substantially reduces non-productive down-time, lost
profits, and costs associated with resuming production.
Advantageously, the production tubing, including the failed
deep-set tubing-retrievable subsurface safety valve do not have to
be pulled, dramatically simplifying operations and reducing costs.
A light intervention vessel may be used as the platform for
performing the intervention, rather than a conventional drilling
rig or platform, substantially expediting operations and reducing
costs typically associated with floating a large drilling rig back
onto the well site. A deep-set wireline-retrievable subsurface
safety valve may be deployed via wireline into the failed deep-set
tubing-retrievable subsurface safety valve, where the deep-set
wireline-retrievable subsurface safety valve has a closure
actuation mechanism that is disposed below the closure device. In
addition, the closure actuation mechanism includes a
pressure-balanced piston that is exposed to wellbore fluids on both
distal ends of the piston, thereby allowing the piston to actuate
the closure device in deepwater and ultra-deepwater wells with
significant hydrostatic head in the control line.
[0039] FIG. 3 shows a light intervention vessel 305 disposed on a
well site 310 of a failed tubing-retrievable subsurface safety
valve (e.g., 105 of FIG. 1 and FIG. 2) disposed in a deepwater or
ultra-deepwater subsea well (e.g., 110 of FIG. 1) in accordance
with one or more embodiments of the present invention. While the
use of light intervention vessels for different reasons is
well-known in the art, such vessels 305 may be used with one or
more methods of the claimed invention to facilitate deepwater or
ultra-deepwater intervention in failed tubing-retrievable
subsurface safety valves. Light intervention vessels 305 are small,
dynamically positioned, and monohulled vessels that are capable of
being disposed on the wellsite 310 much faster than large
semi-submersible, drillship, or other large drilling rigs or
platforms (e.g., 115 of FIG. 1). Once disposed on the wellsite 310,
light intervention vessel 305 facilitates wireline access to the
subsea well (e.g., 110 of FIG. 1) where the failed
tubing-retrievable subsurface safety valve (e.g., 105 of FIG. 1 and
FIG. 2) is disposed. In certain embodiments, wireline access may be
provided by a riser-based system (not shown). In other embodiments,
wireline access may be provided by a coiled-tubing-based 315
system. In still other embodiments, wireline access may be provided
by a slickline-based 315 system. In still other embodiments,
wireline access may be provided by wireline-based 315 system. One
of ordinary skill in the art will recognize that any system that
provides wireline access such that communication tools may be
deployable, and a deep-set wireline retrievable subsurface safety
valve (not shown) may be landed, within the failed deep-set tubing
retrievable subsurface safety valve (e.g., 105 of FIG. 1 and FIG.
2) may be used in accordance with one or more embodiments of the
present invention.
[0040] In certain embodiments, a robotically operated vehicle
("ROV") 320 may be tethered to an ROV umbilical 325 to observe and
assist in the intervention operations taking place at or near the
seafloor 120. After wellbore access is achieved, a
wireline-deployable lockout tool (not shown) is run into the
wellbore (e.g., 110 of FIG. 1) to lock out the failed deep-set
tubing-retrievable subsurface safety valve (e.g., 105 of FIG. 1 and
FIG. 2). In certain embodiments, a deformation type of lockout tool
(not shown) may be used. Deformation-type lockout tools locate a
positive shoulder of a known-location, such as, for example, a
no-go shoulder or profile, often located in the top sub of the
tubing-retrievable subsurface safety valve (e.g., 105 of FIG. 1 and
FIG. 2). Downward jarring on the tool engages the flowtube (e.g.,
214 of FIG. 2) of the failed deep-set tubing-retrievable subsurface
safety valve (e.g., 105 of FIG. 1 and FIG. 2), causing the flowtube
(e.g., 214 of FIG. 2) to shift downward causing the flapper (e.g.,
204 of FIG. 2) or valve (not shown) to open. Simultaneously, prongs
or specially adapted hammers (not shown) protrude from the
deformation-type lockout tool (not shown) and deform the flowtube
(e.g., 214 of FIG. 2) permanently opening the flapper (e.g., 204 of
FIG. 2). In some applications, the flowtube (e.g., 214 of FIG. 2)
may be stuck such that it cannot be moved. In such circumstances, a
cylindrical metal coil (not shown) may be deployed with the lockout
tool and deposited in or near the flapper (e.g., 204 of FIG. 2)
housing to permanently open the flapper (e.g., 204 of FIG. 2). Once
locked out, the failed deep-set tubing-retrievable subsurface
safety valve (e.g., 105 of FIG. 1 and FIG. 2) is locked into the
open state, such that fluids are freely communicated through the
tubing-retrievable subsurface safety valve.
[0041] FIG. 4A shows communication of the failed deep-set
tubing-retrievable subsurface safety valve 105 in accordance with
one or more embodiments of the present invention. It is well-known
in the art that you must communicate a failed subsurface safety
valve in order to operate the insertable valve. However, a deep-set
wireline-retrievable subsurface safety valve deployed in deepwater
and ultra-deepwater subsea wells present special challenges because
communication of failed deep-set tubing-retrievable subsurface
safety valves (e.g., 105) has never been attempted or accomplished
to date. The objective here is the same as that used in
non-deepwater subsea wells, namely, to locate within the failed
deep-set tubing retrievable subsurface safety valve 105 a location
(e.g., 410) where a communication pathway may be opened with the
hydraulic chamber (not shown) of the failed tubing-retrievable
subsurface safety valve 105 such that hydraulic actuation fluids
(not shown) may flow from the hydraulic chamber (not shown) of the
failed tubing-retrievable subsurface safety valve 105 into to the
hydraulic pathway of the deep-set wireline retrievable subsurface
safety valve (not shown). A wireline-deployable communication tool
405 may be run into an interior diameter of the failed deep-set
tubing-retrievable subsurface safety valve 105 and powered by an
electric or e-line (not shown). As shown in the figure, the
communication tool 405 may be lowered into the failed deep-set
tubing-retrievable subsurface safety 105 and precisely located by
locating off of a lock profile or no-go shoulder or a distance from
a closed flapper (not shown).
[0042] Once properly located, the communication tool 405 may be
turned on to remove material and form a radial cutout 410 that
intersects at least one piston hole in the hydraulic chamber (not
shown) of the failed deep-set tubing-retrievable subsurface safety
valve 105, thereby establishing communication to enable operation
of an insert valve, such as a deep-set wireline-retrievable
subsurface safety valve (not shown). Continuing, FIG. 4B shows a
radial cutout 410 formed in an interior facing surface of the
failed deep-set tubing-retrievable subsurface safety valve 105
providing access to the hydraulic chamber (not independently shown)
in accordance with one or more embodiments of the present
invention. In certain embodiments, the method of intervention
further includes cutting or grinding a radial port in an interior
facing portion of the failed deep-set tubing-retrievable subsurface
safety valve with a wireline-deployable communication tool to
communicate a hydraulic chamber (not independently illustrated) of
the failed deep-set tubing-retrievable subsurface safety valve.
Prior to running in the deep-set wireline-retrievable subsurface
safety valve, other tools may be used to clear obstructions, polish
the surfaces, or take other actions to facilitate landing the
deep-set wireline-retrievable subsurface safety valve in a manner
that minimizes damage and increases the likelihood of success.
[0043] FIG. 5 shows a block diagram of a deep-set wireline
retrievable subsurface safety valve 500 for a failed deep-set
tubing-retrievable subsurface safety valve (e.g., 105 of FIG. 1 and
FIG. 2) in accordance with one or more embodiments of the present
invention. A deep-set wireline retrievable subsurface safety valve
500 must be capable of being deployed in failed deep-set
tubing-retrievable subsurface safety valve (e.g., 105 of FIG. 1 and
FIG. 2) in a deepwater or ultra-deepwater subsea well and provide
failsafe protection like any other subsurface safety valve.
Specifically, the deep-set wireline retrievable subsurface safety
valve must be capable of opening the flapper, valve, or closure
device 510 upon application of hydraulic actuation pressure from
the surface and fully closing when the hydraulic actuation pressure
is sufficiently reduced or removed or other contingency arises. In
order to achieve this functionality in deepwater and
ultra-deepwater subsea wells, where existing wireline-retrievable
subsurface safety valves are not capable of operating, the closure
actuation mechanism 520 is disposed below the closure device 510
and the closure device 510 includes a pressure equalization
feature.
[0044] Once communication is complete, a deep-set
wireline-retrievable subsurface safety valve 500 is run into a
central lumen of the failed deep-set tubing-retrievable subsurface
safety valve (e.g., 105 of FIG. 1 and FIG. 2). The closure
actuation mechanism 520 of the deep-set wireline retrievable
subsurface safety valve 500 may be disposed below the closure
device 510. In certain embodiments, the closure actuation mechanism
520 comprises a pressure-balanced piston (not shown) that is
exposed to wellbore fluids on both sides, or exposed distal ends,
of the piston. Because closure actuation mechanism 520 is
pressure-balanced and the energy to close the valve 500 is stored
below the closure device 510, the closing ability of valve 500 is
tubing pressure insensitive, and capable of reliable operation at
depth. In addition, closure device 510 comprises an equalization
feature that equalizes pressure across the closure device to
facilitate opening the valve 500 regardless of the hydrostatic head
at the setting depth in deepwater or ultra-deepwater.
[0045] For purposes of illustration, an embodiment of a deep-set
wireline-retrievable subsurface safety valve 500 is described
herein. However, one of ordinary skill in the art, having the
benefit of this disclosure, will appreciate that other designs that
meet the above-noted requirements may be used in accordance with
one or more embodiments of the present invention and their usage is
contemplated by one or more methods of the claimed invention. FIG.
6 shows a bottom facing perspective view of a portion of a deep-set
wireline-retrievable subsurface safety valve 500 in accordance with
one or more embodiments of the present invention. In one or more
embodiments of the present invention, a deep-set
wireline-retrievable subsurface safety valve 500 may include a
locking mechanism (not shown) to secure deep-set
wireline-retrievable subsurface safety valve 500 within an inner
diameter of a failed deep-set tubing retrievable subsurface safety
valve (e.g., 105), an upper packing housing (not shown), an upper
packing element (not shown) that may create an upper hydraulic seal
on an annulus between the deep-set wireline-retrievable subsurface
safety valve 500 above a hydraulic fluid intake port 608, and a
spacer 604. One of ordinary skill in the art will recognize that
the upper packing housing (not shown) and the upper packing element
(not shown) may be substantially similar to that of lower packing
housing 624 and lower packing element 620 described in more detail
herein. Spacer 604 may include the hydraulic fluid intake port 608
that connects an exterior of spacer 604 to a central lumen, or
passageway, disposed therein and have a length to dispose the
hydraulic fluid intake port 608 below a flapper or valve (not
shown) of the failed deep-set tubing-retrievable subsurface safety
valve (e.g., 105) in which the deep-set wireline-retrievable
subsurface safety valve 500 is disposed. The hydraulic fluid intake
port 608 receives surface-injected hydraulic actuation fluid (not
shown) from the annulus surrounding the safety valve 500 when
deployed within the failed deep-set tubing-retrievable subsurface
safety valve (e.g., 105). Deep-set wireline-retrievable subsurface
safety valve 500 may also include lower packing element 620 to
create a lower hydraulic seal on the annulus between deep-set
wireline-retrievable subsurface safety valve 500 and the failed
deep-set tubing-retrievable subsurface safety valve (e.g., 105)
below hydraulic fluid intake port 608 and the flapper or valve (not
shown) of the failed deep-set tubing-retrievable subsurface safety
valve (e.g., 105), a lower packing housing 624, a seat housing 644,
a plurality of flow ports 648 disposed about the seat housing 644,
a hydraulic chamber housing 630, a spring housing 690, and a nose
cap 698.
[0046] FIG. 7 shows an exploded view of a portion of a deep-set
wireline-retrievable subsurface safety valve 500 in accordance with
one or more embodiments of the present invention. In one or more
embodiments of the present invention, deep-set wireline-retrievable
subsurface safety valve 500 may include a spacer 604 having a
hydraulic fluid intake port 608 and a plurality of O-rings 612 and
616 that seal the connection between a lower packing housing 624
and spacer 604. A lower packing element 620 covers a portion of
lower packing housing 624 and a plurality of double O-rings 628 and
632 seal the connection interface between the lower packing housing
624 and seat housing 644. A hard seat 636 and a soft seat 640
partially receive a ball 652, which is one type of closure device
(e.g., 510 of FIG. 5) contemplated herein. Seat housing 644 may
include a plurality of flow ports 648. One or more setting screws
654 may be disposed within ball 652. Deep-set wireline-retrievable
subsurface safety valve 500 may also include an upper retention
screw 656, an upper power seal 660, a plurality of double O-rings
664 and 668 that seal the connection interface between hydraulic
chamber housing 672 and seat housing 644, a double O-ring 676 that
seals the connection interface between hydraulic chamber housing
672 and spring housing 690, a power piston 680, an intermediate
power seal 684, an intermediate retention screw 686, a spring ring
687, a power spring 689, a lower retention screw 692, a lower power
seal 694, a double O-ring 696 that seals the connection interface
between spring housing 690 and nose cap housing 698, and a nose cap
plug 699, discussed in more detail herein.
[0047] FIG. 8A shows a cross-sectional view of a portion of a
deep-set wireline-retrievable subsurface safety valve 500 in
accordance with one or more embodiments of the present invention.
Spacer 604 may include a central lumen through which wellbore
fluids (not shown) may flow when ball 652 valve is moved off soft
seat 640. A lower packing housing 625 may connect to spacer 604 and
may include a first hydraulic fluid passage 610 to align with
hydraulic fluid intake port 608 of spacer 604. When hydraulic
actuation fluid (not shown) is injected from the surface (not
shown), hydraulic actuation fluid (not shown) may flow into the
hydraulic fluid intake port 608, through first hydraulic fluid
passage 610 that traverses the hydraulic seal formed by the upper
packing element (not shown) and lower packing element 620 into a
second hydraulic fluid passage 611 and a third hydraulic fluid
passage 613. If sufficient hydraulic actuation pressure is
provided, the hydraulic fluid exerts a downward force on a piston
shoulder chamber 681 that causes power piston 680 to move down and
compress power spring 689, thereby moving ball 652 off soft seat
640 (not shown).
[0048] Continuing, FIG. 8B shows a cross-sectional view of a
portion of deep-set wireline-retrievable subsurface safety valve
500 disposed within a failed deep-set tubing-retrievable safety
valve 105 with a ball 652 valve in a closed state preventing flow
in accordance with one or more embodiments of the present
invention. In one or more embodiments of the present invention,
deep-set wireline-retrievable subsurface safety valve 500 may be
landed within a no-go shoulder profile of failed deep-set
tubing-retrievable safety valve 105 (which is locked open and
communicated prior to landing). A locking mechanism (not shown) may
be used to secure deep-set wireline-retrievable subsurface safety
valve 500 to failed deep-set tubing-retrievable subsurface safety
valve 105. An upper packing (not shown) and lower packing 620 may
create a hydraulic seal in an annulus surrounding a portion of the
deep-set wireline-retrievable subsurface safety valve 500. A
hydraulic fluid intake port 608 may receive hydraulic fluid in the
annulus surrounding the deep-set wireline-retrievable subsurface
safety valve 500 within the hydraulic seal from an FPSO disposed on
a surface (not shown) of a body of water (not shown). The hydraulic
actuation fluid (not shown) may be communicated via first hydraulic
fluid passage 610, second hydraulic fluid passage 611, and third
hydraulic fluid passage 613 disposed below the hydraulic seal to a
piston shoulder chamber 681 and, if sufficient hydraulic actuation
pressure is provided, may exert a downward force on piston shoulder
chamber 681 that causes power piston 680 to move down and compress
a power spring 689 disposed within an a gas chamber. A ball 652
valve may be disposed above the hydraulic chamber and may be
connected to power piston 680. Absent sufficient hydraulic
actuation pressure, power spring 689 uncompresses and ball 652 is
moved fully on soft seat 640 and hard seat 636, thereby preventing
formation fluids (not shown) from flowing toward the surface (not
shown) through deep-set wireline-retrievable subsurface safety
valve 500.
[0049] Power spring 689 may be disposed within a gas chamber formed
by spring housing 690, intermediate power seal 684, hydraulic
chamber housing 672, lower power seal 684, and nose cap housing
698. The gas chamber may be voided, filled with air, or charged
with one or more gases, including potentially, nitrogen, although
nitrogen charging is not required to uncompress power spring 689 at
deepwater or ultra-deepwater depths. While upper power seal 660 and
lower power seal 694 are in communication with production tubing
pressure, both seals have the same diameter and are disposed on
opposing ends of power piston 680. As such, their pressure areas
are the same and the forces acting on the power piston 680
effectively cancel each other out, thus power piston 680 is said to
be pressure balanced. As such, power spring 689 may not be
sensitive to production tubing pressure. Thus, the hydraulic
actuation pressure required to compress power spring 689 may be
substantially less than the production tubing pressure and when
that actuation pressure is sufficiently reduced or removed, power
spring 689 does not require nitrogen charging to uncompress and
fully close deep-set wireline-retrievable subsurface safety valve
500 at a deepwater or ultra-deepwater depths.
[0050] Continuing, FIG. 8C shows a cross-sectional view of a
portion of a deep-set wireline-retrievable subsurface safety valve
500 disposed within a failed deep-set tubing-retrievable subsurface
safety valve 105 with a ball 652 valve in an opened state
permitting production flow in accordance with one or more
embodiments of the present invention. As previously discussed,
failed deep-set tubing-retrievable subsurface safety valve 105 has
been communicated (not shown) and flapper 204 is locked open.
Deep-set wireline-retrievable subsurface safety valve 500 has been
landed within a no-go shoulder or internal landing profile (not
shown) of failed deep-set tubing-retrievable subsurface safety
valve 105 and locked (not shown) or otherwise secured to failed
deep-set tubing-retrievable subsurface safety valve 105. An upper
packing (not shown) element forms an upper hydraulic seal in the
annulus between deep-set wireline-retrievable subsurface safety
valve 500 and failed deep-set tubing-retrievable subsurface safety
valve 105. Lower packing element 620 forms a lower hydraulic seal
in the annulus between deep-set wireline-retrievable subsurface
safety valve 500 and failed deep-set tubing-retrievable subsurface
safety valve 105. The upper and lower hydraulic seals form a
hydraulic seal. Hydraulic fluid (not shown) may be injected from
the surface (not shown) via the puncture (not shown) into the
annulus surrounding the deep-set wireline-retrievable subsurface
safety valve 500 disposed between the upper and lower hydraulic
seals. The injected hydraulic fluid (not shown) in the annulus
enters the hydraulic fluid intake port 608 and flows through first
hydraulic fluid passage 610, second hydraulic fluid passage 611,
and third hydraulic fluid passage 613 to a piston shoulder chamber
681.
[0051] Continuing, FIG. 8D shows a detailed portion of a
cross-sectional view of a portion of a deep-set
wireline-retrievable subsurface safety valve 500 disposed within a
failed deep-set tubing-retrievable subsurface safety valve 105 with
a ball 652 valve in an opened state permitting flow in accordance
with one or more embodiments of the present invention. As shown in
the detailed view, power piston 680 may be connected on a first
distal end to ball 652 by one or more set screws 653 and on a
second distal end to a nose cap housing (e.g., 698 of FIG. 8C).
Power piston 680 may extend through hydraulic chamber housing 672.
Spring ring 687 may be disposed on a top distal end of power spring
689. Upper power seal 660 may seal an annulus surrounding power
piston 680 and an upper portion of hydraulic chamber housing 672.
Upper power seal retainer 656 may retain upper power seal 660 in
place. Intermediate power seal 684 may seal an annulus surrounding
power piston 680 and a lower portion of hydraulic chamber housing
672. Intermediate power seal retainer 686 may retain intermediate
power seal 684 in place. As such, any pressure trapped between
upper power seal 660 and intermediate power seal 684 forces power
piston 680 down. If the hydraulic actuation fluid (not shown) is
provided at the actuation pressure or higher, hydraulic fluid
enters third hydraulic fluid passage 613 and piston shoulder
chamber 681, forcing power piston 680 down, compressing power
spring 689, and moving ball 652 off soft seat 640 and hard seat
636. When ball 652 is off soft seat 640, formation fluids in the
annulus between spring housing 690 and production tubing 691 enter
deep-set wireline-retrievable subsurface safety valve 500. A
plurality of flow ports 648 may allow fluid communication from the
annulus surrounding the deep-set wireline-retrievable subsurface
safety valve 500 below the hydraulic seal into a central lumen of
the deep-set wireline-retrievable subsurface safety valve 500 that
is exposed when ball 652 is moved off soft seat 640.
[0052] FIG. 9A shows a detailed portion of a perspective view of a
ball 652 valve of a deep-set wireline-retrievable subsurface safety
valve 500 on seat 640 in accordance with one or more embodiments of
the present invention. Absent sufficient hydraulic actuation
pressure, first hydraulic fluid passage (not shown), second
hydraulic fluid passage 611, third hydraulic fluid passage 613, and
piston shoulder chamber 681 may be voided. Continuing, FIG. 9B
shows a detailed portion of a perspective view of a ball 652 valve
of a deep-set wireline-retrievable subsurface safety valve 500 off
seat 640 under actuation pressure in accordance with one or more
embodiments of the present invention. When sufficient actuation
pressure is applied, hydraulic fluid may be injected from the
surface (not shown) into a hydraulic fluid intake port (not shown)
and communicated via a first hydraulic fluid passage (not shown)
disposed within the lower packing housing (not shown) to second
hydraulic fluid passage 611 disposed within seat housing 644.
Second hydraulic fluid passage 611 may communicate hydraulic fluid
to third hydraulic fluid passage 613 of hydraulic chamber housing
672. Third hydraulic fluid passage 613 may communicate hydraulic
fluid to piston shoulder chamber 681.
[0053] FIG. 10A shows a cross-sectional view of a closure device,
such as, for example, ball 652 of a deep-set wireline-retrievable
subsurface safety valve 500 in a closed state in accordance with
one or more embodiments of the present invention. When deep-set
wireline-retrievable subsurface safety valve 500 is in the closed
state, ball 652 is on seat 636, thereby preventing production flow
through flow ports 648. When the operator wishes to open valve 500,
hydraulic actuation pressure is communicated via the control line
(not shown). As it begins to pressure up, production fluids 1005
may flow through flow ports 648 and into equalization ports 1010 to
dart ports 1020 and then to the other side of closure device 652
via insert 1040 and insert equalization ports 1030. Over time, this
has the effect of equalizing the pressure from below the closure
device 652 with the pressure above closure device 652, thereby
equalizing the pressure across it. Continuing, FIG. 10B shows a
cross-sectional view of a closure device, such as, for example,
ball 652 of a deep-set wireline-retrievable subsurface safety valve
500 in an open state in accordance with one or more embodiments of
the present invention. As the hydraulic actuation pressure
increases, and the pressure across the closure device 652 is
equalized, closure device 652 moves off seat hard 636 and soft seat
640, thereby enabling production flow through flow ports 648.
[0054] FIG. 11 shows a light intervention vessel 305 performing a
method of intervention in a failed deep-set tubing-retrievable
subsurface safety valve 105 in a deepwater or ultra-deepwater
subsea well 110 in accordance with one or more embodiments of the
present invention. When a deep-set tubing-retrievable subsurface
safety valve 105 disposed in a deepwater or ultra-deepwater well
fails, for whatever reason, a light intervention vessel 305 may be
brought onto the well site. The light intervention vessel 305 may
establish access to the interior of the production tubing 140
disposed within subsea well 110 via a coiled-tubing, slickline, or
wireline system. A wireline-deployable lockout tool or tools may be
run in to an interior of the failed tubing-retrievable subsurface
safety valve 105 to facilitate locking out the failed valve 105 in
the open position. A wireline-deployable communication tool (not
shown) may be run into the interior of the failed deep-set
tubing-retrievable subsurface safety valve 105. The communication
tool may be precisely located to facilitate communicating the
failed valve 105. In certain embodiments, the communication tool
may cut or grind a radial port into an interior facing portion of
the failed deep-set tubing retrievable subsurface safety valve 105
to communicate a hydraulic chamber housing of the failed deep-set
tubing-retrievable subsurface safety valve and potentially prepare
the failed valve 105 to receive the deep-set wireline retrievable
subsurface safety valve 500 (not shown).
[0055] Once locked out and communicated, a deep-set wireline
retrievable subsurface safety valve 500 (not shown) may be run into
a central lumen of the failed tubing-retrievable subsurface safety
valve 105. The deep-set wireline-retrievable subsurface safety
valve 500 (not shown) may be landed within a no-go shoulder or
other profile of the failed tubing-retrievable subsurface safety
valve 105. Once landed, the deep-set wireline-retrievable
subsurface safety valve 500 (not shown) may be locked into place at
a location within the failed tubing-retrievable subsurface safety
valve 105 that facilitates communication with the hydraulic chamber
of the failed tubing-retrievable subsurface safety valve 105. Once
installed, an FPSO 1100 may provide hydraulic actuation fluid from
a surface-controlled pump system to the deep-set
wireline-retrievable subsurface safety valve via a conduit that
fluidly connects the wet tree 130 to the control line (not shown)
of the failed deep-set tubing-retrievable subsurface safety valve
105. Because deep-set wireline-retrievable subsurface safety valve
500 (not shown) includes a closure actuation mechanism that is
disposed below the closure device, where the actuation mechanism
includes a pressure-balanced piston that is exposed to wellbore
fluids on both distal ends of the piston, and the closure device
includes an equalization system that equalizes pressure across the
closure device to facilitate opening, the deep-set
wireline-retrievable subsurface safety valve is capable of
operation at deepwater and ultra-deepwater depths.
[0056] Advantages of one or more embodiments of the present
invention may include one or more of the following:
[0057] In one or more embodiments of the present invention, method
of intervention in a failed deep-set tubing-retrievable subsurface
safety valve disposed in a deepwater or ultra-deepwater subsea well
does not require re-completion of the well and substantially
reduces non-productive downtime, lost profits, and costs associated
with resuming production. Advantageously, the production tubing,
including the failed deep-set tubing-retrievable subsurface safety
valve, does not have to be pulled, dramatically simplifying
operations and reducing costs.
[0058] In one or more embodiments of the present invention, method
of intervention in a failed deep-set tubing-retrievable subsurface
safety valve disposed in a deepwater or ultra-deepwater subsea well
may use a light intervention vessel rather than a conventional
drilling rig, substantially expediting operations and reducing
costs.
[0059] In one or more embodiments of the present invention, method
of intervention in a failed deep-set tubing-retrievable subsurface
safety valve disposed in a deepwater or ultra-deepwater subsea well
uses a deep-set wireline-retrievable subsurface safety valve having
a closure actuation mechanism disposed below a closure device.
[0060] In one or more embodiments of the present invention, method
of intervention in a failed deep-set tubing-retrievable subsurface
safety valve disposed in a deepwater or ultra-deepwater subsea well
uses a deep-set wireline-retrievable subsurface safety valve having
an actuation mechanism including a pressure-balanced piston that is
exposed to wellbore fluids on both distal ends of the piston,
thereby allowing the piston to actuate the closure device in
deepwater and ultra-deepwater subsea wells with significant
hydrostatic head.
[0061] In one or more embodiments of the present invention, method
of intervention in a failed deep-set tubing-retrievable subsurface
safety valve disposed in a deepwater or ultra-deepwater subsea well
uses a deep-set wireline-retrievable subsurface safety valve having
a closure device that includes equalization means configured to
equalize pressure across the closure device to facilitate opening
the closure device.
[0062] In one or more embodiments of the present invention method
of intervention in a failed deep-set tubing-retrievable subsurface
safety valve disposed in a deepwater or ultra-deepwater subsea well
establishes surface-control by communicating the hydraulic chamber
housing of the failed deep-set tubing retrievable subsurface safety
valve with the hydraulic chamber of the wireline-retrievable
subsurface safety valve.
[0063] While the present invention has been described with respect
to the above-noted embodiments, those skilled in the art, having
the benefit of this disclosure, will recognize that other
embodiments may be devised that are within the scope of the
invention as disclosed herein. Accordingly, the scope of the
invention should be limited only by the appended claims.
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