Patent ID: 12247850

To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements disclosed in one implementation may be beneficially utilized on other implementations without specific recitation.

DETAILED DESCRIPTION

Aspects of the present disclosure relate to obstruction detector assemblies, systems, and related methods for detecting obstructions along oil and gas equipment. In one implementation, an obstruction detector assembly includes a driver housing having an internal chamber and a plurality of fastener openings. The obstruction detector assembly includes a driver stem disposed at least partially in the internal chamber of the driver housing. The driver stem is movable partially out of the internal chamber of the driver housing. The obstruction detector assembly includes a driver head disposed outside of the driver housing and coupled to the driver stem. In one implementation, movement of the driver stem and the driver head is used to detect obstructions (such as a wireline) in a wellhead structure. In one implementation, movement of the driver stem and the driver head is used to detect obstructions (such as sand) in a valve.

The disclosure contemplates that terms such as “couples,” “coupling,” “couple,” and “coupled” may include but are not limited to welding, interference fitting, and/or fastening such as by using bolts, threaded connections, pins, and/or screws. The disclosure contemplates that terms such as “couples,” “coupling,” “couple,” and “coupled” may include but are not limited to integrally forming. The disclosure contemplates that terms such as “couples,” “coupling,” “couple,” and “coupled” may include but are not limited to direct coupling and/or indirect coupling, such as indirect coupling through components such as links.

FIG.1is a schematic isometric view of a wellhead system100having a plurality of wellhead structures101,102at a wellsite, according to one implementation.FIG.1shows two wellhead structures101,102. Each wellhead structure101,102is fluidly connected to a respective well. Each wellhead structure101,102includes a respective first valve assembly111,121and a respective second valve assembly112,122. A respective fracture header118,128couples the respective first valve assembly111,121to the respective second valve assembly112,122.

Each respective first valve assembly111,121includes a first manifold valve113,123coupled to a second manifold valve114,124. Each second manifold valve114,124is coupled to the respective fracture header118,128. Each respective second valve assembly112,122includes a first frac valve115,125coupled to a second frac valve116,126. Each second frac valve116,126is coupled to the respective fracture header118,128. A respective swab valve119,129is coupled to each respective fracture header118,128. Each first valve assembly111,121includes, respectively, a first bottom block131and a second bottom block141. Each second valve assembly112,122includes a respective adaptor flange132,142that is configured to couple to the respective well.

Each of the wellhead structures101,102is configured to couple to a pump manifold, such as a frac manifold, to pump operations fluids (such as frac fluids and/or acids) downhole into the wells.

The present disclosure contemplates that additional wellhead structures can be included to fluidly connect to additional wells. Spools180(three are shown), such as trunk lines, are coupled to and between the wellhead structures101,102. In one embodiment, which can be combined with other embodiments, a wellbore treatment operation using the wellhead system100shown inFIG.1may further include connecting each wellhead structure101,102to a respective well. The wellbore treatment operation may further include connecting each bottom block131,141to the snake spool assemblies180. Each bottom block131,141is a manifold header. A flange181of each spool180is coupled to each respective bottom block131,141.

The wellbore treatment operation may further include pumping treatment fluid through the spools180, sequentially through wellhead structures101,102, and into each well. The wellbore treatment operation may include sequentially pumping treatment fluid into each well such that the treatment fluid is pumped into each well in turn, one well at a time. The wellbore treatment operation may further include closing the first manifold valve113or123and the second manifold valve114or124of the wellhead structure101or102associated with wells that are not to receive the treatment fluid, and opening the first manifold valve113or123and the second manifold valve114or124of the wellhead structure101or102associated with the well that is to receive the treatment fluid. The wellbore treatment operation may further include closing the first manifold valve113or123and the second manifold valve114or124of the wellhead structure101or102associated with the well that received the treatment fluid, and opening the first manifold valve113or123and the second manifold valve114or124of the wellhead structure101or102associated with another well that is to receive the treatment fluid. The wellbore treatment operation may thus include using the sequential closing and opening of the first manifold valve113or123and the second manifold valve114or124of each wellhead structure101,102to direct the treatment fluid into each well sequentially.

Each second valve assembly112,122includes a respective obstruction detector assembly201coupled between the respective swab valve119,129and the respective fracture header118,128. Each obstruction detector assembly201can be the obstruction detector assembly201shown inFIGS.2-4as further described below.

FIG.2is a schematic isometric top view of an obstruction detector assembly201, according to one implementation.FIG.3is a schematic isometric bottom view of the obstruction detector assembly201shown inFIG.2, according to one implementation. The obstruction detector assembly201includes a ring flange210. The ring flange210includes a first outer surface211, a second outer surface212, and a plurality of fastener openings213extending from the first outer surface211to the second outer surface212. The ring flange210includes a central opening214, a first inner surface215, a second inner surface216, and an inner circumferential recess217separating the first inner surface215and the second inner surface216.

FIG.4is a schematic bottom cross-sectional view of the obstruction detector assembly201shown inFIGS.2and3, along Section4-4shown inFIG.2, according to one implementation. The obstruction detector assembly201includes a driver housing220coupled to the ring flange210and having an internal chamber221. The obstruction detector assembly201includes a driver stem231disposed at least partially in the internal chamber221of the driver housing220. The driver stem231is movable partially out of the internal chamber221. The obstruction detector assembly201includes a driver head232disposed outside of the driver housing220and coupled to the driver stem231. The driver head232is disposed in the inner circumferential recess217and is movable into and out of the central opening214of the ring flange210.

In the implementation shown inFIG.4, the driver head232includes an arcuate plate233coupled to the driver stem231through an end block234. The arcuate plate233may be a gate. The arcuate plate233includes an inner face235having an inner radius of curvature IR1that is within a difference of 5% or less relative to an outer radius R1of the central opening214of the ring flange210. The arcuate plate233includes an outer face236having an outer radius of curvature OR1that is within a difference of 5% or less relative to an outer radius R2of the inner circumferential recess217of the ring flange210. The arcuate plate233includes a plurality of openings237A-237E extending from the inner face235and to the outer face236.

The end block234of the driver head232includes an outer shoulder239having an outer diameter OD1that is larger than an outer diameter OD2of the driver stem231. The outer diameter OD1of the outer shoulder239is larger than an opening238formed in the ring flange210. The driver stem231is disposed through the opening238formed in the ring flange210.

The obstruction detector assembly201includes a piston head241disposed in the internal chamber221of the driver housing220. The piston head241is movable along an inner surface222of the driver housing220. The driver rod231is coupled to the piston head241through a piston rod242and a piston cap243.

The obstruction detector assembly201includes a detector stem251coupled to the driver stem231through the piston head241, the piston cap243, and the piston rod242. The obstruction detector assembly201includes a target252coupled to the detector stem251, a mount plate253coupled to the driver housing220, a first switch254mounted to the mount plate253, and a second switch255mounted to the mount plate253and spaced from the first switch254. Each of the first switch254and the second switch255is a magnetic proximity switch configured to measure the target252(e.g. sense the proximity of the target252relative to the first and second switches254,255). The target252may be a magnet. In one embodiment, which can be combined with other embodiments, the mount plate253is a bracket, such as an L-shaped bracket.

The driver housing220includes a sleeve223, a first end ring224coupled (e.g., fastened) to the sleeve223and disposed about the detector stem251, and a second end ring225coupled (e.g., threaded) to the sleeve223and disposed about the driver stem231. The obstruction detector assembly201includes a plurality of fluid openings226A,226B formed in the first end ring224, and a plurality of hydraulic lines227A,227B fluidly connected to the plurality of fluid openings226A,226B.

The obstruction detector assembly201includes one or more biasing elements228(one is shown inFIG.4) disposed in the internal chamber221of the driver housing220and configured to bias the piston head241, the driver stem231, and the detector stem251away from the ring flange210. In the implementation shown inFIG.4, the biasing element228is a spring. In one embodiment, which can be combined with other embodiments, the one or more biasing elements228are disposed between the piston cap243and the second end ring225. The one or more biasing elements228bias the piston head241, the driver stem231, and the detector stem251away from the ring flange210.

The ring flange210is configured to couple to one of the wellhead structures101,102. The plurality of fastener openings213of the ring flange210are sized and spaced to align with a plurality of fastener openings of the fracture headers118,128and a plurality of fastener openings of the swab valves119,129of the wellhead structures101,102.

A plurality of fasteners149(shown inFIG.1) are disposed through the fastener openings of the respective swab valves119,129, through the fastener openings213of the respective ring flanges210, through the fastener openings of the respective fracture headers118,128, through fastener openings of the respective second frac valves116,126, and through fastener openings of the respective first frac valves115,125.

A hydraulic fluid H1is supplied to the internal chamber221through the fluid openings226A,226B above the piston241(e.g. the side of the piston241opposite the one or more biasing elements228) to extend the driver stem231and the driver head232. The force of the hydraulic fluid H1applied to the piston head241moves the piston head241toward the ring flange210and against the force of the one or more biasing elements228. The one or more biasing elements228are compressed between the piston cap243and the second end ring225as the piston head241moves to extend the driver stem231and the driver head232into the ring flange210. The hydraulic fluid H1is exhausted from the internal chamber221through the fluid openings226A,226B to retract the driver stem231and the driver head232. The force of the one or more biasing elements228are used retract the driver stem231and the driver head232as the hydraulic fluid H1is exhausted from the internal chamber221. One or more openings259are formed in the sleeve223to expose a portion of the internal chamber221to ambient air. An atmospheric pressure applied to the piston head241using the ambient air facilitates retracting the piston head241away from the ring flange210. In one embodiment, which can be combined with other embodiments, fluid (such as fluid from the well) flowing through the wellhead structure101or102can apply a pressure to the arcuate plate233and/or the end block234to facilitate retracting the arcuate plate233and the driver stem231.

During an obstruction detection operation, the arcuate plate233of the driver head232is extended toward the central opening214of the ring flange210. If an obstruction, such as a wireline260(shown in broken lines inFIG.4), is disposed in the central opening214, then the arcuate plate233will contact the wireline260and stop the detector stem251. The stoppage of the detector stem251stops the target252before the target252reaches the second switch255, which indicates to a controller290that there is the obstruction260disposed in the internal volume214. The detection of the obstruction260in the internal volume214can indicate that the obstruction is in the respective first valve assembly111,121or second valve assembly112,122. Based on the detection of the obstruction, the controller290can control the respective valves of the first valve assembly111,121or second valve assembly112,122such that the respective valves do not close to engage the obstruction. If the target252reaches the second switch255, then a determination is made that the central opening214of the ring flange210is clear of obstructions. The first switch254and/or the second switch255generate one or more signals that the controller290uses to determine an obstructed condition or an unobstructed condition for the ring flange210. The controller290determines an obstruction status of the ring flange210in an automated manner, reducing the amount of manual operation needed from operations personnel.

The controller290is in communication with the first switch254and the second switch255to detect movement of the target252. The controller290is in communication with one or more fluid sources292,293to control the supply of the hydraulic fluid H1to the driver housing220, and to control the exhausting of the hydraulic fluid H1from the driver housing220. One or more vacuum sources may be used in relation to the hydraulic fluid H1. The controller290controls the extending and retracting of the driver stem231, the detector stem251, the target252, the piston head241, and the driver head232. The controller290uses the first and second switches254,255to detect movement of the target252and determine if any obstruction is in the central opening214of the ring flange210. As shown inFIG.1, the controller290is in communication with the valve assemblies111,112,121,122to actuate (e.g. open and close) any one or more of the valves113-116,123-126,119,129.

The controller290can include instructions (such as software) stored on a memory that, when executed by a processor, control the operations of the wellhead structures101,102and the obstruction detector assembly201. The instructions of the controller290can use simple automation module for internet explorer (SAMI) automation software. In one embodiment, which can be combined with other embodiments, the instructions of the controller290(when executed by the processor) cause the operations702,704,706,708of the method700to be conducted.

The first switch254and the second switch255are spaced from each other by a distance D1that is greater than the outer radius R1of the central opening214. In one embodiment, which can be combined with other embodiments, the distance D1is equal to or greater than a diameter (which is double the outer radius R1) of the central opening214. In one embodiment, which can be combined with other embodiments, the distance D1is lesser than a diameter (which is double the outer radius R2) of the inner circumferential recess217.

In a retracted position (shown inFIG.4) where the outer shoulder239abuts against the ring flange210, the piston rod242is spaced from the second end ring225by a distance D2. In one embodiment, which can be combined with other embodiments, the distance D2is greater than the diameter (which is double the outer radius R1) of the central opening214and lesser than the diameter (which is double the outer radius R2) of the inner circumferential recess217. The distance D2facilitates allowing the arcuate plate233to traverse the central opening214to contact any obstruction, and facilitates stopping the arcuate plate233before the arcuate plate abuts against a circumferential inner surface266defined by the inner circumferential recess217. The distance D1facilitates the target252stopping before reaching the second switch255if the arcuate plate233contacts and stops against an obstruction in the central opening214. The distance D1facilitates the target252reaching the second switch255if the arcuate plate233traverses past the central opening214without contacting an obstruction in the central opening214.

FIG.5is a schematic plan view of a valve system510coupled to a solids separator502, according to one implementation. The valve system510and the solids separator502are part of a separation system500. The valve system510is disposed along a first outlet line503coupled to the solids separator502. A second outlet line504is coupled to the solids separator502.

The solids separator502is configured to separate solids (such as sand) from fluids (such as oil or gas). The separated solids exit the solids separator502through the second outlet line504. The separated fluids exit the solids separator502through the first outlet line503. The second outlet line504includes one or more valves521,522(two are shown). A first valve521is a ball valve. The first valve521can be a relief valve or an excess flow valve. A second valve522is an angle valve.

The first outlet line503includes one or more valves511,512(two are shown). A first valve511can be an indicator valve that indicates flow. A second valve512can be a choke valve. The first outlet line503also includes a first fail open valve513, a second fail open valve514, and a fail close valve515, all positioned between the first and second valves511,512. An obstruction detector assembly501is coupled to each of the first valve511and the second valve512.

FIG.6is a schematic partial view of the obstruction detector assembly501coupled to the second valve512shown inFIG.5, according to one implementation. The obstruction detector assembly501is similar to the obstruction detector assembly201shown inFIGS.2-4, and includes one or more of the aspects, features, components, and/or properties thereof. In the implementation shown inFIG.6, the obstruction detector assembly501omits the arcuate plate233and the ring flange210.

The second valve512is a choke valve. The second valve512includes an inlet passage532, a seat passage533, and an outlet passage534. A head536of a valve stem535is configured to abut against a seat537of a valve housing531and move away from the seat537to open the second valve512. The driver stem231and the end block234are configured to move into the seat passage533to detect one or more obstructions such as solids (for example sand) in the seat passage533. The present disclosure contemplates that the obstruction detector assembly501can be oriented to detect obstruction(s) in the inlet passage532, obstruction(s) in the outlet passage534, and/or obstruction(s) adjacent the head536in a head chamber538.

The sleeve223of the driver housing220includes a plurality of fastener openings541sized and spaced to align with a plurality of valve fastener openings542of the valve housing531. One or more expandable packing rings543A-543C are disposed about the driver stem231.

In the implementation shown inFIG.6, the controller290is in communication with the second valve512and the obstruction detector assembly501to determine if an obstruction (such as sand) is disposed in the second valve512. The controller290is also in communication with the second valve512to control actuation of the second valve512open and closed, such as by moving the valve stem535. The instructions of the controller290can use simple automation modules for internet explorer (SAMI) automation software that controls the operation of the second valve512using one or more operational parameters. In one embodiment, which can be combined with other embodiments, the one or more operational parameters include a measured flow rate, a measured pressure, and/or other measured parameters of fluid flowing through the second valve512. The controller290determines an obstruction status of the second valve512in an automated manner, reducing the amount of manual operation needed from operations personnel.

FIG.7is a schematic block diagram view of a method700of determining an obstruction status of oil and gas equipment, according to one implementation. Operation702includes extending a driver stem toward an internal volume of a piece of equipment. In one embodiment, which can be combined with other embodiments, the piece of equipment is a flange ring coupled to a wellhead structure. In one embodiment, which can be combined with other embodiments, the piece of equipment is a valve housing of a valve, such as a choke valve. In one embodiment, which can be combined with other embodiments, the driver stem is moved by supplying a hydraulic fluid into an internal chamber of a driver housing. The driver stem is partially disposed in the internal chamber of the driver housing.

Operation704includes moving a detector stem in a direction away from a first switch and toward a second switch spaced from the first switch. The detector stem is coupled to the driver stem. In one embodiment, which can be combined with other embodiments, the detector stem is disposed partially in the internal chamber of the driver housing. In one embodiment, which can be combined with other embodiments, the movement of the driver stem in operation702and the movement of the detector stem in operation704occur simultaneously.

Operation706includes determining if a target coupled to the detector stem reaches the second switch. If the target stops before reaching the second switch, then a determination is made that there is an obstruction disposed in the internal volume of the piece of equipment, and a determination is made that the piece of equipment has an obstructed condition. In one embodiment, which can be combined with other embodiments, the obstruction is a wireline or sand. If the target reaches the second switch, then a determination is made that the internal volume of the piece of equipment is clear of obstructions, and a determination is made that the piece of equipment has an unobstructed condition.

Operation708includes retracting the driver stem away from the internal volume of the piece of equipment. In one embodiment, which can be combined with other embodiments, the detector stem is moved by supplying a hydraulic fluid into an internal chamber in which the detector stem is partially disposed.

Benefits of the present disclosure include detecting obstructions in oil and gas equipment in an automated manner; reduced amounts of manual labor; reduced expenditures of resources; reduced costs; streamlined operational speeds; and reduced or eliminated probabilities of damage to oil and gas equipment (such as wirelines and valves).

It is contemplated that one or more of the aspects disclosed herein may be combined. Moreover, it is contemplated that one or more of these aspects may include some or all of the aforementioned benefits. As an example, the present disclosure contemplates that one or more aspects, features, operations, components, and/or properties of the wellhead system100, the obstruction detector assembly201, the separation system500, the obstruction detector assembly501, and/or the method700may be combined. For example, one or more of the operations described for the wellhead system100and the obstruction detector assembly201can be combined with one or more of the operations702,704,706,708described for the method700and/or one or more of the operations described for the separation system500and the obstruction detector assembly501.

It will be appreciated by those skilled in the art that the preceding embodiments are exemplary and not limiting. It is intended that all modifications, permutations, enhancements, equivalents, and improvements thereto that are apparent to those skilled in the art upon a reading of the specification and a study of the drawings are included within the scope of the disclosure. It is therefore intended that the following appended claims may include all such modifications, permutations, enhancements, equivalents, and improvements. The disclosure also contemplates that one or more aspects of the embodiments described herein may be substituted in for one or more of the other aspects described. The scope of the disclosure is determined by the claims that follow.