VALVE CONTROL SYSTEM FOR A WELL TESTER

Abstract: A hydraulic control system, for controlling a retainer valve (19) in an underwater well test system, is contained in a housing (20) in the test string above the retainer valve (19). The control system and valve are operated by a surface control manifold (29) via control conduits (23,24) extending between the manifold (19) and control system housing (20). The system provides opening and closing and very quick closure of the retainer valve (19) by eliminating the requirement for closing pressure to be conducted through a long conduit from the surface and by utilizing well pressure to close the valve and lock the valve closed. The system includes, within the housing (20), two pilot valves (35,37), check valves (39,39a,39b) and a pressure accumulator (31).

Description: The present invention relates to a hydraulic control system for controlling the operation of a valve, especially a retainer valve in an underwater well test system. US-A-4,693,315 to Frank H. Taylor discloses a well test system which includes a hydraulically controlled retainer valve in the upper section of the test pipe string. An electro/hydraulic control system for controlling remotely located valves is disclosed in US-A-4,636,934 to which reference should be made for further details. This elaborate system controls a number of remote valves in a well test system for underwater wells. The control system also measures various well parameters and analyzes the measurements for preprogrammed considerations to control remotely located valves for optimum operation of the test system. Retainer valves are used above a subsea test tree in the upper section of the string of pipe lowered into a well to conduct formation evaluating flow tests. Before starting test operations in a well, the retainer valve is usually closed to seal pressure from above and permit all test string connections from the retainer valve to surface to be pressure tested. After pressure testing, retainer valves are reopened to permit flow through the test string while testing. The primary function of the retainer valve is to close before the upper section of the test string is quickly disconnected from the rest of the test string during emergency conditions. The closed retainer valve retains water polluting liquids in the upper test string section and prevents discharge of these liquids into surrounding water. The closed retainer valve also prevents discharge of pressurized fluids downward from the upper test string section on disconnect with possible resulting rapid jet assisted upward movement of the string section which could cause injury or property damage. Previous hydraulic control systems included control conduits connected to a pressure source on the surface. These conduits extended from the surface pressure source possibly thousands of feet downwardly to conduct pressured fluid to valves in well test strings to open or close the valves as required during well test operations. Because of the long lengths and small size of these conduits, along with high viscosity off pressurized control liquids pumped through the conduits, liquids in sufficient quantities necessary to close or open hydraulically operated valves require long periods of time to travel from surface to a valve and operate the valve. As retainer valves are sometimes closed because of emergency conditions which develop during well testing, quick closure is very desirable. According to the present invention, there is provided a hydraulic control system for controlling a retainer valve in a test pipe string having an upper section and lower section in a well, said hydraulic control system comprising: (i) a control system housing in said test pipe string; and (ii) control system means in said housing for conducting pressure from said test pipe string to said valve for quickly closing it, said control system means including means for sensing reduced pressure in said test pipe string above a said retainer valve when closed and locked, and for locking said retainer valve to allow fluids to be pumped through said retainer valve and said test pipe string into said well, said control system means comprising: (a) a first normally closed pilot valve of the three-way, two-position type, having an actuating pilot portion for opening this valve and a spring loaded pilot portion for closing this valve, (b) a second normally open pilot valve of the three-way, two-position type, having an actuating pilot portion for closing this valve and a spring loaded pilot portion for opening this valve, (c) a remote pressure source, (d) a first flow passage between the pressure source and the first port of the first pilot valve, with a first check valve allowing flow from the first pilot valve to the pressure source, (e) a second flow passage between the retainer valve and a second port of the first pilot valve, which second port is connected with the first port of the first pilot valve when the latter is in the normally closed position, the passage being for closing the retainer valve and locking it closed, (f) a third flow passage between the second port of the first pilot valve and the actuating pilot portion of the second pilot valve, for closing said second pilot valve, (g) an accumulator, (h) a fourth flow passage between the interior of the upper section of said test pipe string in said well and the third port of the first pilot valve, (i) a fifth flow passage between the accumulator and the actuating pilot portion of the first pilot valve, (j) a sixth flow passage between the actuating pilot portion of the first pilot valve and the third port of the first pilot valve, in which passage a second check valve allowing flow from the accumulator to the third port of the first pilot valve, is provided, (k) a seventh, flow passage connecting the part of the first flow passage between the pressure source and the first check valve on the one hand, with the part of the sixth flow passage between the accumulator and the second check valve, the seventh flow passage having a third check valve allowing flow from the pressure source to the accumulator and the actuating pilot portion of the first pilot valve, (l) an eighth flow passage between the pressure source and: the spring loaded pilot portions of the first and the second pilot valves, the third port of the second pilot valve, (m) a ninth flow passage between the retainer valve and the second port of the second pilot valve, which in the normally open position of this valve is connected to the third port of this valve, this passage providing for the opening of the retainer valve, (n) a tenth flow passage between the first port of the second pilot valve and the exterior of the system control housing. The retainer valve controlled by the invention control system is preferably a ball type valve rotated between open and closed positions by a longitudinally movable pressure responsive piston similar to the valve show, in US-A-4,522,370 to Noack and Rathie. This valve is internally biased toward open position and when closed, continuous application of closing pressure hydraulically locks the valve closed. When not locked, the force of high pressure above the closed valve ball in this valve will force the ball downwardly and open to permit kill fluids to be pumped downwardly through the retainer valve and test string into the well. The hydraulic control system of this invention provides quick closure of a hydraulically operated valve by eliminating the long control conduit from surface which usually delivers pressurized closing fluid to the valve. The downhole control system can utilize well pressure in the test string to close the valve. The invention control system provides the operator with the capability of opening the retainer valve by pressurizing fluid in a first opening control conduit at the surface and closing the retainer valve to seal pressure from above by pressurizing fluid in a second closing control conduit at the surface as required. One embodiment of the control system of the present invention provides a quick retainer valve closure by manually opening a shut-off valve at surface to transmit a pressure pulse from a high pressure accumulator down a conduit to close a pilot valve in a control housing in the test string. The closed pilot valve directs well pressure from the test string through flow passages in the housing and conduits to close the retainer valve and lock the valve closed. The control system of the invention utilizes a number of pilot valves, pilot operated check valves and an accumulator housed in the downhole control housing and numerous flow passages in the control housing and conduits to open, close and lock or quick close and lock the retainer valve closed. This control system embodiment also provides pressure monitoring of conduits from surface, quick automatic closure of the retainer valve, reopening of the retainer valve or pumping kill fluids through the retainer valve into the well before reopening. When the retainer valve is open, the control system monitors the control conduits to surface for pressure loss. The control system will sense loss of pressure in damaged control conduits and will automatically operate the retainer valve to quickly close and hydraulically lock the valve closed. When the valve closes, well pressure is trapped in the control housing accumulator. This pressure is utilized later to operate the control system to reopen the retainer valve. The automatically closed valve may be pumped open with high pressure above the valve and killing fluid may be pumped through the valve and test string into the well to kill the well. After pumping kill fluid or re-establishing control line integrity after automatic retainer valve closure, the control system may be operated to reopen the retainer valve. The control conduits are connected to a pressure source on the surface, extend down the annulus between the test string and riser and are connected into control circuitry in the housing near the retainer valve in the upper test string section. The valve opening and closing conduits extend from the control housing to the retainer valve and the housing control circuitry is in pressure communication with the well test string and liquids in the riser annulus. The control system of this invention may be used to control any similar hydraulically operated valve. Among the features which can be provided by the valve control system of the present invention are: (i) the system can operate and unlock the retainer valve after closing on reduction of pressure above the retainer valve; (ii) the system can, after closing the retainer valve, permit killing fluids to be pumped down the test string through the retainer valve into the well; (iii) the system can monitor pressure in control conduits from surface when the valve is open and automatically utilize well pressure to quickly close a valve in the well pipe string on loss of pressure in the control conduits; (iv) the system can utilize well pressure for quickly closing the valve; (v) the system housed in a well pipe string does not require pressurized fluid to be pumped long distances from the surface for closing a valve; (vi) the system can, after operating to close a valve, initiate valve reopening; and (vii) the system also may initiate disconnect of a subsea test tree in the well test string. In order that the invention may be more fully understood, reference is made to the accompanying drawings, wherein: FIG. 1 is a schematic drawing showing an underwater well on which well testing is being performed. The testing equipment includes a retainer valve controlled by a hydraulic control system of this invention. Fig. 2 is a schematic drawing of a hydraulic valve control system showing the valve open. This system is not in accordance with the present invention but is given to assist in an understanding thereof. Fig. 3 is a drawing of the control system of Fig. 2, which has been operated to close the valve. FIG. 4 is a schematic drawing of the embodiment of the hydraulic valve control system of this invention snowing the valve open. FIG. 5 is a drawing of the control system of FIG. 4, which has been operated to close the valve. FIG. 1 shows an underwater well on which well tests are being performed. A floating vessel or platform 10 is positioned over an underwater wellhead 11. The wellhead includes a blowout preventer 12 on which is mounted a riser pipe 13. A string of casing 14 extends downwardly from the wellhead into the well bore hole and includes a landing shoulder 15. A derrick 16 on the vessel has been used to lower a string of test pipe 17, having an upper section 17a and a lower section 17b, into the well forming an annulus 18 between the upper test pipe string and riser pipe. The upper test pipe section includes a retainer valve 19 and a retainer valve control system housing 20. The upper section of the test string may be disconnected from the lower test string section by operating subsea test tree 21 to disconnect the upper tree section 21a from lower tree section 21b if required during well testing operations. A fluted hanger 22 has landed on casing landing shoulder 15 and is supporting the weight of the test string and blowout preventer 12 has been closed to seal around the test string. Control conduits 23, 24 and 25 (if used) are encased in umbilical 26 which is reeled on reel 27 on deck 28 of the vessel. These control conduits are connected into the control system housing and an hydraulic pressure source 29 also on the vessel deck. First and second Conduits 23 and 24 extend from the housing to the retainer valve and conduit 25 may if desired extend from the housing to the subsea test tree. It should be obvious to those skilled in well testing and control system art that the control system could be housed in the retainer valve body and first and second conduits 23 and 24 between the control system housing and the retainer valve would not be required. The pressure source contains pumps, valves, a control fluid reservoir and gauges for providing pressurized fluid in the control conduits and operating the control system and retainer valve as required for testing the well. FIG. 2 shows schematically an embodiment of a hydraulic system wherein pressure source 29 includes a pump 30, an accumulator 31 and a directional control valve 32 (shown in the off position). Valve 32 has an outlet 32a. The pump is used to pressurize the accumulator and pressure from the pump may be admitted selectively through valve 33 into first conduit 23 and the control system for opening retainer valve 19 or through valve 34 into second conduit 24 and the control system for closing the retainer valve and sustaining pressure on the closed retainer valve, locking it closed. Within control system housing 20 is a three-way two-position normally open pilot valve 35 and a number of internal flow passages 36(a-d). Conduit 25 extends from the accumulator through the directional control valve in the control manifold and internal flow passages to valve 35 in the control housing. Conduit 25 may be extended from the control housing to a subsea test tree in the test string if desired, to conduct pressurized fluid to the test tree for initiating disconnect of the tree. To open retainer valve 19, using the hydraulic control system shown in FIG. 2, the system should be filled with fluid, valves 32, 33 and 34 closed and pump 30 operated to pressurize accumulator 31. To close the retainer valve, pump 30 should be operated and valve 34 opened to pump fluid down possibly very long second conduit 24 through housing internal flow passage 36a, valve 35 and internal passage 36b, back into second conduit 24 into and under retainer valve piston 19a to move the piston upwardly, compressing retainer valve opening spring 19b and closing the valve. Sustained pressure in second conduit 24 will hold the retainer valve closed. If quick closure of the retainer valve is desired, directional control valve 32 is pushed to open as shown in FIG. 3, permitting pressurized accumulator 31 to discharge into control conduit 25 and transmit a pressure pulse quickly down to and through control housing passage 36c to valve 35. This pressure pulse shifts valve 35 to a position closing internal flow passage 36a and connecting flow passage 36d from inside upper test string section 17a with flow passage 36b and second conduit 24 between retainer valve 19 and control housing 20. Higher well pressure in string section 17a now flows a short distance through passage 36d, valve 35, passage 36b and second conduit 24 into the retainer valve and closes the valve. Continuous application of closing pressure on retainer valve piston 19a will hold or "lock" the retainer valve closed. If desired, a conduit 25 may be connected between housing internal passage 36c and the subsea test tree so the pressure pulse from the accumulator will not only operate the retainer valve to close but will also ready the subsea test tree for disconnect. With the retainer valve closed and locked, the subsea test tree may be disconnected and the closed retainer valve will retain pressurized liquids in the test string. If disconnect is not required, but it is now desirable to pump kill fluids down the test string, pressure in conduit 25 and internal flow passage 36c must be reduced to near zero by positioning valve 32 so pressure may vent through outlet 32a in valve 32. If subsea test tree disconnect or pumping kill fluids is not required, the retainer valve may be reopened to continue well test operations by positioning valve 32 to reduce conduit 25 and passage 36c. Now, pressurized fluid from pump 30 and/or accumulator 31 should be admitted into first control conduit 23 through valve 33 to move retainer valve piston 19a downwardly opening the retainer valve. Another form of a hydraulic control system which is in accordance with the present invention is shown in FIG.4. This control system is housed in control system housing 20 with first and second conduits 23 and 24 extending from pressure source 29 on the platform deck to the control housing. First and second control conduits 23 and 24 extend from the control housing to the retainer valve and conduit 25 may if desired extend from the pressure source to subsea test tree 21. In this system, the only purpose conduit 25 serves is to initiate disconnect of the subsea test tree. The hydraulic pressure source 29 for this invention form contains a pump, a control fluid reservoir and valves for selectively admitting pressurized fluid into first and second conduits 23, 24 and 25 to operate the control system and retainer valve as required for well testing operations. Pressurizing fluid in first conduit 23 on the deck will operate the control system of FIG. 4 to move retainer valve piston 19a downwardly, opening the retainer valve. Pressurizing fluid in second conduit 24 will move the retainer valve piston upwardly to close the retainer valve 19 as shown in FIG. 5. Sustained pressure in second conduit 24 will retain or lock the retainer valve closed. Within control system housing 20 of FIG. 4 is a three-way two-position normally open pilot valve 35, a three-way two-position normally closed pilot valve 37, an isolator 38, a small volume accumulator 31, a number of check valves 39 and a number of internal flow passages 40. Valve 35 has an outlet 35a which is in communication with internal passage 40a and the annulus 18 of FIG. 1 exterior of the valve. Internal flow passage 40b communicates between the inside of upper test pipe section 17a and isolator 38. Resilient seal 38b on isolator floating piston 38a sealingly separates control fluid in the control system from well fluid in the test pipe and prevents contamination of the control system fluid by well fluids containing crude hydrocarbons, basic sediments or water. The isolator piston is free to "float" as urged by pressures in internal passages 40b and 40f. Control conduit 25 may extend, if desired, from pressure source 29 through housing internal passage 40c and conduit 25, from the system housing to the subsea test tree 21, to conduct pressurized fluid to the test tree to initiate disconnecting the tree. Obviously, passage 40c would not be required if conduit 25 is not used. To open the retainer valve using the control system of FIG. 4, the control system is filled with fluid, pressure is bled from second conduit 24 and first conduit 23 is pressurized from pressure source 29. This pressure is transmitted through internal passage 40d in system housing 20, to and through pilot valve 35, internal passage 401 and first conduit 23 to move piston 19a downwardly opening the retainer valve. The control system of FIG. 4 may be operated to utilize well pressure in upper test pipe section 17a, when greater than any pressure applied in second conduit 24 from pressure source 29, to close the retainer valve when pressure in first conduit 23 is bled off. Higher pressure from upper test pipe section 17a in passage 40b has been transmitted through isolator 38 into passage 40f, closing check valve 39b. Source pressure in second conduit 24 is now transmitted through internal housing passage 40e into passage 40f, through check valve 39a into passage 40g and passage 40h, charging accumulator 31 and moving pilot valve 37 to open position. Higher pressure in passage 40f may now cause flow through passage 40i, through open valve 37 into 40j and 40k to the pilot of valve 35, back into second conduit 24 and under piston 19a, urging it upwardly toward retainer valve closed position. Pressure on the pilot valve 35 moves valve 35 to a position where any pressure in passage 401 and first conduit 23 above piston 19a urging the piston downwardly toward retainer valve open position is exhausted through valve outlet 35a into annulus 18. When pressure in passage 40k and second conduit 24 below piston 19a is high enough to overcome spring 19b, piston 19a moves upwardly closing the retainer valve as shown in FIG. 5. Sustained pressure in second conduit 24 locks valve 19 closed. If conduit 25 has been extended from pressure source 29 through system housing passage 40c to subsea test tree 21, conduit 25 may be pressurized to initiate disconnect of the test tree and upper string section 17a may be disconnected from, lower string section 17b if required. In a situation where the well pressure in upper test pipe section 17a is zero or less than pressure that can be applied in second conduit 24 by pressure source 29 for closing the retainer valve, pressure is bled from first conduit 23 and pressure in second conduit 24 is transmitted through 40e, into 40f and check valve 39a, into 40g and through check valve 39b, into but not through isolator 36. Pressure in 40g and 40h charges accumulator 31 and moves valve 37 open, permitting pressure from 40f in 40i to flow through open valve 37 into 40j and 40k to second conduit 24 and the pilot for valve 35. Pressure in 40k moves valve 35 to a position exhausting pressure in passage 401 and first conduit 23 through valve outlet 35a into annulus 18. Pressure in 40k and second conduit 24 moves piston 19a upwardly closing the retainer valve. If desired, the retainer valve may now be reopened by bleeding off pressure in second conduit 24 and increasing pressure in first conduit 23 at the pressure source. As pressure in first conduit 23 approaches the pressure stored in accumulator 31, valve 37 is repositioned closed by pressure from first conduit 23 plus spring force, permitting pressure in second conduit 24, passages 40k and 40j to flow through valve 37, check valve 39, passage 40e and second conduit 24 and be bled off through pressure source 29 on the deck. When pressure in conduit 40k has been reduced to almost equal pressure in conduit 40d, valve 35 is repositioned open, permitting flow from first conduit 23 into passage 40d, through the valve into passage 401 and first conduit 23 into the retainer valve, urging the piston toward valve open position. Increasing pressure above piston 19a and reducing pressure below piston 19a has moved the piston downwardly reopening the retainer valve as shown in FIG. 4. The valve control system of FIG. 4 additionally provides automatic closure for an open retainer valve by well fluids and pressure in the upper test pipe section. If first and second control conduits 23 and 24 are damaged or cut and pressure in these conduits is reduced to the hydrostatic pressure at depth, lower pressure in first conduit 23 permits the charge pressure in accumulator 31 to reposition valve 37 and allows flow from inside upper pipe section 17a through passage 40b to move isolator piston 38a and cause flow into passages 40f and 40i, through the valve into passages 40j and 40k, into conduit 24 under piston 19a urging the piston upwardly to close the retainer valve. Pressurized fluid in passage 40k and valve 35 retains pilot valve 35 in a position so that control fluid displaced by upward movement of the piston may flow through first conduit 23, passage 401, valve 35 and be exhausted to annulus 18 through outlet 35a and passage 40a, as the piston moves upwardly closing the retainer valve and locking the valve closed. The retainer valve will remain closed and locked as long as the pressure in pipe section 17a is maintained. At this time, it may be desirable to pump killing fluid downwardly through the retainer valve and test pipe string into the well to maintain pressure control of the well or control first and second conduits 23 and 24 may be repaired and the retainer valve reopened as previously described. If pumping killing fluid is desired, pressure in upper pipe section 17a must be reduced to permit accumulator 31 to discharge through passages 40h, 40g, valve 39b and passage 40f into isolator 38 to reduce pressure in passage 40h on valve 37's pilot to allow valve 37's spring to reposition valve 37 closed, so pressure under piston 19a may be vented through valve 37, check valve 39, passage 40e and second conduit 24 to the pressure source. Now, pressure is increased in upper test pipe section 17a. Flow into passage 40b cannot induce flow through isolator 38 into passages 40f and 40i as check valve 39b and valve 37 are closed. As the retainer valve controlled by the invention control systems is of the type which may be moved downwardly and rotated to open position when closing pressure acting on piston 19a is removed and on application of higher pressure above the closed retainer valve. Increased pressure in upper test pipe section 17a to above the pressure in the lower test pipe section acts on the retainer ball valve to move it down-wardly and open, permitting killing fluids to be pumped down the upper test pipe section through the retainer valve and down the test pipe string into the well. After repairing or replacing first and second control conduits 23 and 24, the retainer valve may be reopened as previously described to continue well testing operations.

Claims: A hydraulic control system for controlling a retainer valve (19) in a test pipe string (17) having an upper section (17a) and lower section (17b) in a well, said hydraulic control system comprising: (i) a control system (20) housing in said test pipe string (17); and (ii) control system means in said housing (20) for conducting pressure from said test pipe string (17) to said valve (19) for quickly closing it, said control system means including means for sensing reduced pressure in said test pipe string above a said retainer valve when closed and locked, and for locking said retainer valve to allow fluids to be pumped through said retainer valve and said test pipe string into said well, said control system means comprising: (a) a first normally closed pilot valve (37) of the three-way, two-position type, having an actuating pilot portion for opening this valve and a spring loaded pilot portion for closing this valve, (b) a second normally open pilot valve (35) of the three-way, two-position type, having an actuating pilot portion for closing this valve and a spring loaded pilot portion for opening this valve, (c) a remote pressure source (29), (d) a first flow passage (40e,24) between the pressure source (29) and the first port of the first pilot valve (37), with a first check valve (39) allowing flow from the first pilot valve to the pressure source, (e) a second flow passage (40j,24) between the retainer valve (19) and a second port of the first pilot valve (37), which second port is connected with the first port of the first pilot valve (37) when the latter is in the normally closed position, the passage being for closing the retainer valve and locking it closed, (f) a third flow passage (40k) between the second port of the first pilot valve (37) and the actuating pilot portion of the second pilot valve (35), for closing said second pilot valve, (g) an accumulator (31), (h) a fourth flow passage (40b,40i) between the interior of the upper section of said test pipe string in said well and the third port of the first pilot valve (37), (i) a fifth flow passage (40h) between the accumulator (31) and the actuating pilot portion of the first pilot valve (37), (j) a sixth flow passage (40g,40f,40i) between the actuating pilot portion of the first pilot valve (37) and the third port of the first pilot valve, in which passage a second check valve (39b) allowing flow from the accumulator (31) to the third port of the first pilot valve, is provided, (k) a seventh flow passage connecting the part of the first flow passage (40e,24) between the pressure source (29) and the first check valve (39) on the one hand, with the part of the sixth flow passage (40g) between the accumulator (31) and the second check valve (39b), the seventh flow passage having a third check valve (39a) allowing flow from the pressure source to the accumulator and the actuating pilot portion of the first pilot valve (37), (1) an eighth flow passage (23,40d) between the pressure source (29) and: the spring loaded pilot portions of the first (37) and the second (35) pilot valves, the third port of the second pilot valve (35), (m) a ninth flow passage (23,40l) between the retainer valve (19) and the second port of the second pilot valve (35), which in the normally open position of this valve is connected to the third port of this valve, this massage providing for the opening of the retainer valve (19), (n) a tenth flow passage (40a) between the first port of the second pilot valve (35) and the exterior (18) of the system control housing. A system according to claim 1, further including test tree means (21) in the test pipe string below the retainer valve (19) for disconnecting the upper pipe section (17a) from the lower pipe section (17b) and a conduit (25) extending between the pressure source (29) and housing (20) and extending between said housing (20) and said tree (21). A system according to claim 1 or 2, wherein: (a) first control conduit (23) extends between the pressure source (29) and the control system housing (20) and between said system housing (20) and the retainer valve (19), for opening the retainer valve (19); and (b) second control conduit (24) extends between said pressure source (29) and said housing (20) and between said housing (20) and said retainer valve (19), for closing said valve and locking said valve closed. A system according to claim 1, 2 or 3, wherein the control system means further includes an isolator (38) between the inside of the upper test string section (17a) and the second check valve (39b).

Inventors: NOACK, TIMOTHY J., SCHWENDEMANN, KENNETH L.
Applicants: HALLIBURTON COMPANY
Application year: 1989
Main classification: E21B34
IPC codes: E21B34