Remote well servicing systems and methods

Embodiments of the present disclosure include a remote well servicing system including a control unit and a remote servicing manifold. The control unit further includes a service fluid source and a control system. The remote servicing manifold further includes a fluid input line coupled to the service fluid source, a fluid output line couplable to a well component, and a valve coupled to the fluid input line and the fluid output line, wherein the valve, when actuated, places the fluid input line in fluid communication with the fluid output line and permits delivery of a service fluid from the service fluid source to the well component. The remote servicing manifold also includes a control line coupling the valve and the control system wherein the control system controls actuation of the valve via the control line.

BACKGROUND

1. Field of the Invention

The present disclosure relates to servicing well equipment. More particularly, the present disclosure relates to systems and methods of remotely providing a service fluid to one or more well components via a remote servicing manifold.

2. Description of Related Art

Certain hydrocarbon production related operations, such as hydraulic fracturing, utilize well equipment that is made up of many parts. One example is a hydraulic fracturing tree, which has many valves. These valves may need to be greased or lubricated from time to time to ensure proper function and maximum operational life, Typically, this process is carried out manually by an operator at the well site. As such, the operator has to travel to the well site and manually make and break the valve fittings in order to grease the valve. This process is time consuming and costly.

SUMMARY

Applicants recognized the problems noted above herein and conceived and developed embodiments of systems and methods, according to the present disclosure, for remotely providing a service fluid to one or more well components via a remote servicing manifold.

In an embodiment, a remote well servicing system includes a remote servicing manifold, which includes a fluid input line couplable to a service fluid source, a fluid output line couplable to a well component, a valve coupled to the fluid input line and the fluid output line, wherein the valve, when actuated, places the fluid input line in fluid communication with the fluid output line and permits delivery of a service fluid from the service fluid source to the well component, and a control line coupled to and controlling actuation of the valve.

In another embodiment, a remote well servicing system includes a control unit and a remote servicing manifold. The control unit further includes a service fluid source and a control system. The remote servicing manifold further includes a fluid input line coupled to the service fluid source, a fluid output line couplable to a well component, and a valve coupled to the fluid input line and the fluid output line, wherein the valve, when actuated, places the fluid input line in fluid communication with the fluid output line and permits delivery of a service fluid from the service fluid source to the well component. The remote servicing manifold also includes a control line coupling the valve and the control system, wherein the control system controls actuation of the valve via the control line.

In another embodiment, a method of remotely servicing a well component includes supplying a service fluid to a remote servicing manifold, actuating a valve on the remote servicing manifold, thereby permitting flow of the service fluid, and delivering the service fluid from the remote servicing manifold to a well component.

DETAILED DESCRIPTION

The foregoing aspects, features, and advantages of the present disclosure will be further appreciated when considered with reference to the following description of embodiments and accompanying drawings. In describing the embodiments of the disclosure illustrated in the appended drawings, specific terminology will be used for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms used, and it is to be understood that each specific term includes equivalents that operate in a similar manner to accomplish a similar purpose.

When introducing elements of various embodiments of the present disclosure, the articles “a”, “an”, “the”, and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including”, and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Any examples of operating parameters and/or environmental conditions are not exclusive of other parameters conditions of the disclosed embodiments. Additionally, it should be understood that references to “one embodiment”, “an embodiment”, “certain embodiments”, or “other embodiments” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, reference to terms such as “above”, “below”, “upper”, “lower”, “side”, “front”, “back”, or other terms regarding orientation or direction are made with reference to the illustrated embodiments and are not intended to be limiting or exclude other orientations or directions.

Embodiments of the present disclosure include systems and methods for remotely monitoring and/or servicing a well, such as providing a service fluid without operator intervention at the well site. An example application of the present disclosure includes greasing well assemblies during hydrocarbon drilling and development operations, such as during hydraulic fracturing or when the wells are producing and under pressure. Doing so can reduce failures of the well assembly and the operation. The systems and techniques of the present disclosure may be used for a wide variety of wells and well operations, and is particularly advantageous for wells that are not easily accessible by operators, such as remote land wells, dry offshore wells, and unmanned platforms, where regular servicing can increase operational life.

FIG. 1is a schematic view of a remote well servicing system100, in accordance with an example embodiment of the present disclosure. The system100includes a control unit102and a remote servicing manifold104. Generally, in many applications of the present disclosure, the manifold104selectively delivers a service fluid from the control unit102to one or more well components105of a well106. The control unit102may include a control system108and a service fluid source110, The control system108controls at least some aspects of the remote well servicing system100, The service fluid source110may be any suitable type of vessel or reservoir for holding a service fluid. The service fluid may be any type of fluid that may be used to service a well component from time to time. For example, the service fluid source110may be a grease or lubricant storage container.

The control system108may include one or more processors and/or controllers for carrying out its control functions, including controlling the manifold104. The control system108may also include a control panel112or interface through which an operator can interact with the control system108, such as to input control commands or receive output information. The control panel112may be located on the control unit102, as illustrated inFIG. 1. Alternatively, the control panel112can be a part of a remote controller such as a pendant controller or a digital controller. As an example, the control panel112can be configured for touch screen operations and allow for straightforward and intuitive operation of the remove servicing operation. The control panel112can communicate via wires or wirelessly. Non-exhaustive wireless examples include wireless interne or telemetry, radio, microwave, ultrasonic, or infrared. In some embodiments, the control panel112may include a tablet computer, smart phone, personal computer, and the like, that allow for interaction with the control system112at one or more offsite locations.

The control unit102may be in the form of a wheeled mobile operation center or grease skid. Additional equipment may be located on the control unit that facilitation other operations, such as hydraulic fracturing. The control unit102may also include various other system components and control capabilities used to operate and monitor well equipment. Such components may include accumulators, hydraulic, electric, and pneumatic actuators, torque wrenches, pressure pumps, and various meters and visual indicators. Such components may be used to perform certain services at the well106, such as diagnostic operations, as well as measuring temperature, pressure, oil and gas ratio, water content, and chemical tracers at the well106.

The remote servicing manifold104is located away from the control unit102, For example, in some applications, the manifold104is located twenty-five to one hundred feet from the control unit102. However, in other example applications, the manifold104may be closer to or farther from the control unit102. The manifold104includes a fluid input for receiving a service fluid and a control input for receiving a control signal. In some example embodiments, the fluid input is coupled to the service fluid source110at the control unit102via a supply line114and service fluid is delivered to the manifold104from the service fluid source110through the supply line114. There may be a check valve coupled to the supply line114to prevent back flow. In some embodiments, the control input is coupled to the control system108at the control unit102via one or more control lines116. The control lines116may include electrical lines, optical lines, pneumatic lines, and the like, and any combination thereof.

The manifold104includes one or more fluid outputs from which the service fluid can be delivered to one or more well components105through respective delivery lines116. There may be one or more check valves coupled to the delivery line116to prevent back flow. In certain example applications, the manifold104may be located five to fifty feet away from the well106. However, in some other example applications, the manifold104may be located closer to or farther from the well106. The control system108controls delivery of service fluid from the manifold to each of the well components105by selectively actuating respective valves within the manifold via the control lines116. Delivery of service fluid to each of the well components105may be independently controlled. Alternatively, service fluid may be delivered to all or a subset of the well components simultaneously.

FIG. 2is a diagram representation of a remote well servicing system200, according to example embodiments of the present application. In one or more such embodiments, the system200includes a control unit202and a plurality of remote servicing manifolds204. The control unit202supplies service fluid to the manifolds204via supply lines214and controls the manifolds204via control lines216. There may be control lines216and supply lines214connecting the control unit202directly to each manifold204. Alternatively or additionally, there may be control lines216and/or supply lines214between manifolds204. In such embodiments, service fluid and/or control signals may be communicated to one of the manifolds204via another manifold204rather than directly from the control unit202, For example, such a configuration may be advantageous in an application where one manifold204is physically located between the control unit202and another manifold204. Delivering control signals and/or service fluid to the farther manifold204via the closer manifold204rather than directly from the control unit204may reduce the number or length of lines required.

In the embodiment illustrated inFIG. 2, a manifold204can provide service fluid to a plurality of well components on the same well206as well as to well components on a plurality of wells206, as represented by each individual supply line218. Additionally, one well206may receive service fluid from multiple manifolds204. In some embodiments, the same service fluid may be provided to each of the manifolds204. In some other embodiments, the control unit202may provide different types of services fluids to different manifolds204. The control unit202may also provide different types of service fluids to the same manifold204. This embodiment may be particularly useful for applications in which different well components require different service fluids.

FIG. 3Ais a block diagram of a remote well servicing system300, illustrating a control unit302coupled to three remote servicing manifolds304with electro-pneumatic valve control, which are coupled to three wells306, respectively, in accordance with example embodiments of the present disclosure. The control unit302includes at least one service fluid source310and may include a pump320for pumping the service fluid from the fluid source310to the manifolds304. The service fluid is communicated from the control unit302to the manifold304via a supply line314. The control unit302further includes an electrical controller322and a pneumatic source324that together control actuation of individual valves within the manifolds304that permit delivery of the service fluid to respective well components at the wells306. The electrical controller322delivers electrical control signals to the manifold304via an electrical control line316aand the pneumatic source delivers an air supply to the manifold304via a pneumatic control line316b. Based on actuation of the valves in the manifolds, service fluid is selectively delivered to respective well components via fluid delivery lines318. Thus, an operator or program can select to which well components) to provide service fluid. In some example embodiments, for each well component to which the manifold304provides service fluid, the manifold304includes a valve actuation system350, as illustrated inFIG. 3B.

With reference toFIG. 3B, the valve actuation system350includes an electrical actuator such as a solenoid326which is controlled by an electrical signal from the electrical control line316a. Upon actuation of the solenoid326, a pneumatic actuator328receives air pressure from the pneumatic control line316band opens a valve, such as a needle valve330. The needle valve is also coupled to the service fluid supply line314and the delivery line such that when open, the needle valve permits delivery of the service fluid to the well component305. Alternatively, the needle valve330is coupled to a reservoir of service fluid within the manifold304and controls flow of service fluid from the reservoir to the well component305via the delivery line318. In some embodiments, there is a valve actuation system350for every well component to which the manifold304is configured to deliver service fluid. In some other embodiments, one valve actuation system350may be configured to deliver service fluid to multiple well components305simultaneously.

FIG. 4Ais a block diagram of a remote well servicing system400, illustrating a control unit402, three remote servicing manifolds404with fully pneumatic valve control, and three wells406, in accordance with example embodiments of the present disclosure. The control unit402includes at least one service fluid source410and may include a pump420for pumping the service fluid from the fluid source410to the manifolds404. The service fluid is communicated from the control unit402to the manifold404via a supply line414. The control unit402further includes a pneumatic controller424that controls actuation of valves within the manifolds404by sending pneumatic signals through pneumatic control lines416. Based on actuation of the valves in the manifolds, service fluid is selectively delivered to well components via respective fluid delivery lines418. Thus, an operator or program can select which well component(s) to provide service fluid to. In some embodiments, the manifold includes a valve actuation system450for each well component405to which the manifold404provides service fluid, as illustrated inFIG. 4B, in accordance in one or more embodiments. In one or more embodiments, the valve actuation system450includes a pneumatically valve430that is coupled to the delivery line418and permits flow of service fluid to the well component through the delivery line418upon actuation. The valve430can be selectively actuated via the pneumatic control line416to permit fluid communication between the supply line414and the delivery line418to deliver the service fluid to the well component405. In some embodiments, there is a valve act nation system450for every well component405to which the manifold504is configured to deliver service fluid. In some other embodiments, one valve actuation system450may be configured to deliver service fluid to multiple well components405simultaneously.

FIG. 5is a block diagram of a another embodiment of a remote well servicing system500similar to the remote well servicing system300ofFIG. 3, with the addition of a pressure boosting station560at the manifold504. The pressure boosting station560increases the pressure of the service fluid in the delivery line518to facilitate delivery of the service fluid to the well506. The pressure boosting station may include a well service fluid reservoir562with a pump564such that the service fluid can be pumped through the delivery line518at a sufficient pressure to ensure delivery of the service fluid to the well. This may be particularly advantageous in application in which there is wellbore pressure acting against delivery of the service fluid or if the well506is at a great distance from or a higher altitude than the manifold504. Similarly,FIG. 6is a block diagram of a another embodiment of a remote well servicing system600similar to the remote well servicing system400ofFIG. 4, with the addition of a pressure boosting station660at the manifold604.

FIG. 7is a block diagram of a remote well servicing system700with pressure relief, in accordance with example embodiments of the present disclosure. The well servicing system700includes a control unit702which provides service fluid to a remote servicing manifold704via a supply line714and also controls a pneumatic valve in the manifold via a pneumatic control line716. The manifold704then delivers the service fluid to a well706via a delivery line upon actuation of the pneumatic valve. During operation, it may be the case there is a high pressure trapped within the pneumatic control line716, the supply line714, or the delivery line718, such as after closing the valve after a servicing process. As such, bleed lines770may be coupled to the pneumatic control line716, the supply line714, and/or the delivery line718. These may be multiple individual bleed lines770or one joined bleed line770. In certain embodiments, the bleed lines770are each coupled to a relief valve772that can be used to control release of pressure in the respective lines714,716,718. The bleed lines770may empty into a collection tank for disposal. In some embodiments, the relief valves772may be controlled automatically based on a predetermined protocol such when pressure within a respective line exceeds a certain threshold. Specifically, this may be carried out electronically using a pressure sensor and controller that reads the pressure sensor and controls the relief valve772accordingly. This may also be carried out purely mechanically by using a relief valve772that s configured to trigger open upon being subject to a certain set-point pressure. Alternatively, the relief valves772can be controlled remotely or manually by an operator when needed.

Embodiments of the present disclosure provide a remote well servicing system that allows for servicing of well components, such as applying a servicing fluid, to be carried out without interrupting other well operations or the need to assemble or disassembly any equipment, and without on-site operator intervention.

The foregoing disclosure and description of the disclosed embodiments is illustrative and explanatory of the embodiments of the invention. Various changes in the details of the illustrated embodiments can be made within the scope of the appended claims without departing from the true spirit of the disclosure. The embodiments of the present disclosure should only be limited by the following claims and their legal equivalents.