Autonomous systems and methods for wellbore intervention

Abstract

An autonomous intervention system configured to perform an intervention operation in a wellbore comprises a tool housing having a tool storage compartment configured to house an intervention tool. A valve arrangement permits selective communication of tools and fluid between the tool housing and the wellbore. The intervention system is configured to move in response to an activation event between a tool storage configuration in which the tool housing is isolated from the wellbore by the valve arrangement and an activated configuration in which the valve arrangement is open and the tool housing communicates with the wellbore to permit deployment of the intervention tool by a tool deployment arrangement.

Claims

1. An autonomous intervention system for a wellbore, the intervention system comprising: a tool housing configured to house an intervention tool for deployment into the wellbore; a tool deployment arrangement for deploying the intervention tool into the wellbore, wherein the tool deployment arrangement comprises a conveyance for transporting the intervention tool into and/or retrieving the intervention tool from the wellbore and a winch configured to pay out and/or reel in the conveyance, and wherein the intervention system is configurable between a tool storage configuration in which the tool housing is isolated from the wellbore and an activated configuration in which the tool housing communicates with the wellbore and permits deployment of the intervention tool by the tool deployment arrangement; and a controller configured to permit autonomous control of operation of the intervention system between the tool storage configuration and the activated configuration to facilitate deployment of the intervention tool into the wellbore, wherein the controller is configured to activate the intervention system in response to a predetermined activation event, so as to reconfigure the intervention system from the tool storage configuration to the activated configuration.

2. The intervention system of claim 1, wherein the activation event comprises at least one of: a fluid flow rate; a time event; a pressure event; and/or a temperature event.

3. The intervention system of claim 1, wherein the tool housing comprises a lubricator.

4. The intervention system of claim 1, wherein the tool housing is configured for location on a wellhead of the wellbore.

5. The intervention system of claim 1, further comprising a well valve arrangement wherein the well valve arrangement is configured to: prevent fluid communication between the tool housing and the wellbore and/or a well valve arrangement of the wellbore when the intervention system defines the tool storage configuration; and/or permit fluid communication between the tool housing and the wellbore and/or the well valve arrangement when the intervention system defines the activated configuration.

6. The intervention system of claim 1, wherein the tool deployment arrangement comprises a pulley.

7. The intervention system of claim 1, further comprising, operatively associated with, or provided in combination with, a drive arrangement.

8. The intervention system of claim 7, wherein the drive arrangement comprises an electric motor.

9. The intervention system of claim 1, further comprising a support arrangement, the support arrangement comprising a support mast.

10. The intervention system of claim 1, comprising a monitoring arrangement.

11. The intervention system of claim 10, further comprising a sensor arrangement configured to obtain information relating to a condition in the wellbore and/or a condition of the intervention system.

12. The intervention system of claim 1, further comprising a communication arrangement.

13. The intervention system of claim 1, further comprising a power supply for supplying to the intervention system.

14. The intervention system of claim 13, wherein the power supply comprises comprise one or more battery.

15. The intervention system of claim 1, further comprising an energy capture device arrangement.

16. The intervention system of claim 1, further comprising a sealing system operatively associated with the conveyance, the sealing system configured to prevent leakage between the tool housing and the conveyance.

17. A well system comprising: the intervention system of claim 1; and a wellbore.

18. A method comprising: providing an intervention system for a wellbore, the intervention system comprising: a tool housing configured to house an intervention tool for deployment into the wellbore; a tool deployment arrangement for deploying the intervention tool into the wellbore, wherein the tool deployment arrangement comprises a conveyance for transporting the intervention tool into and/or retrieving the intervention tool from the wellbore and a winch configured to pay out and/or reel in the conveyance, and wherein the intervention system is configurable between a tool storage configuration in which the tool housing is isolated from the wellbore and an activated configuration in which the tool housing communicates with the wellbore and permits deployment of the intervention tool by the tool deployment arrangement; and a controller configured to permit autonomous control of operation of the intervention system between the tool storage configuration and the activated configuration to facilitate deployment of the intervention tool into the wellbore; activating the intervention system from the tool storage configuration to the activated configuration, wherein the controller is configured to activate the intervention system in response to a predetermined activation event, so as to reconfigure the intervention system from the tool storage configuration to the activated configuration; and operating the tool deployment arrangement to deploy the intervention tool into the wellbore.

19. The intervention system of claim 1, wherein the conveyance comprises at least one of: a conductor line; a wireline, an E-Line; a slickline; and coiled tubing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) These and other aspects will now be described, by way of example only, with reference to the accompanying drawings, in which:

(2) FIGS. 1 and 2 show an intervention system according to a first embodiment;

(3) FIG. 3 shows an enlarged view of a valve arrangement of the intervention system shown in FIGS. 1 and 2;

(4) FIG. 4 shows an enlarged view of a stuffing box of the intervention system shown in FIGS. 1 and 2;

(5) FIG. 5 shows an enlarged view of part of a monitoring arrangement of the intervention system shown in FIGS. 1 and 2;

(6) FIG. 6 shows a cut-away view of a tool housing of the intervention system, showing an intervention tool of the intervention system shown in FIGS. 1 and 2;

(7) FIG. 7 shows a flowchart of an intervention method using the intervention system shown in FIGS. 1 and 2;

(8) FIGS. 8 and 9 show an intervention system according to a second embodiment;

(9) FIG. 10 shows an enlarged view of a valve arrangement of the intervention system shown in FIGS. 8 and 9;

(10) FIG. 11 shows an enlarged view of a stuffing box of the intervention system shown in FIGS. 8 and 9;

(11) FIG. 12 shows an enlarged view of a winch unit of the intervention system shown in FIGS. 8 and 9;

(12) FIG. 13 shows a cut-away view of a tool housing of the intervention system, showing an intervention tool of the intervention system shown in FIGS. 8 and 9;

(13) FIG. 14 shows a flowchart of an intervention method using the intervention system shown in FIGS. 8 and 9;

(14) FIG. 15 shows an exemplary intervention tool for use in the intervention system shown in FIGS. 1 and 2 and/or the intervention system shown in FIGS. 8 and 9; and

(15) FIG. 16 shows a well system according to an embodiment.

DETAILED DESCRIPTION OF THE INVENTION

(16) Referring first to FIGS. 1 to 2 of the accompanying drawings, there is shown an intervention system 10, the intervention system 10 configured to perform an intervention operation in a wellbore 12.

(17) In the illustrated embodiment, the wellbore 12 is land-based having a wellhead valve arrangement in the form of a Christmas tree 14 disposed on a wellhead 16.

(18) The intervention system 10 is configured to deploy an intervention tool 18 (shown in FIG. 6) into the wellbore 12 and in the illustrated embodiment the intervention tool 18 comprises a paraffin wax removal tool for cleaning paraffin deposits from the wellbore 12 and associated infrastructure and equipment. However, it will be recognized that the intervention system 10 may be configurable to perform a number of different intervention operations using a suitable intervention tool.

(19) As shown in FIGS. 1 and 2, the intervention system 10 comprises a tool housing in the form of a lubricator 20. In the illustrated embodiment, the lubricator 20 comprises a stand of three connected heavy wall tubing sections, the interior of the lubricator 20 defining a tool storage compartment 21 (shown in FIG. 5) configured to house the intervention tool 18.

(20) As shown in FIGS. 1 and 2, the lubricator 20 is coupled to and disposed on top of the Christmas tree 14. A valve arrangement 22—which in the illustrated embodiment forms part of the lubricator 20—permits selective communication of tools and fluid between the lubricator 20 and the Christmas tree 14 (or between the lubricator 20 and the wellbore 12 where no Christmas tree 14 is provided).

(21) As shown in FIGS. 2 and 3, the valve arrangement 22 has an upper control valve 24 and a lower control valve 26. In the illustrated embodiment, the valve arrangement 22 has an upper valve 24 and a lower valve 26 which can be controlled independently. The valve arrangement 22 provides a dual barrier between the lubricator 20 and the wellhead valve arrangement 14, and permits an upper valve 28 of the Christmas tree 14 to be maintained in an open condition.

(22) The intervention system 10 is configurable between a tool storage configuration in which the tool housing 20 is isolated from the wellbore 12 by the valve arrangement 22 and an activated configuration in which the valve arrangement 22 is open and the tool housing 20 communicates with the Christmas tree 14 and the wellbore 12 to permit deployment of the intervention tool 18 by a tool deployment arrangement 30, as will be described below.

(23) The tool deployment arrangement 30 is provided for deploying the intervention tool 18 into the wellbore 12. The tool deployment arrangement 30 comprises a conveyance in the form of wireline 32 which is coupled to the intervention tool 18 and which extends through an upper end portion of the lubricator 20 via stuffing box 34—in the illustrated embodiment a dual chamber stuffing box—to ensure pressure integrity of the tool housing 20 and monitors any fluid/gas wire bypass. An enlarged view of the stuffing box 34 is shown in FIGS. 4 and 5.

(24) The tool deployment arrangement further comprises pulleys 36,38 for supporting the wireline 32. In the illustrated embodiment shown in FIG. 1, pulley 36 is disposed on the tool housing 20 above the stuffing box 34 and pulley 38 is tied to wellhead 16, although it will be recognized that the pulleys 36,38 may be disposed at other suitable locations.

(25) A winch 40 is provided and is operatively coupled to a drive 42 which in the illustrated embodiment takes the form of a direct drive electric motor. In use, the drive 42 rotates the winch 40 in order to pay out the wireline 32 when it is desired to deploy the intervention tool 18 into the wellbore 12 and reel in the wireline 32 when it is desired to retrieve the intervention tool 18 from the wellbore 12.

(26) As shown in FIG. 2, in the illustrated embodiment a control desk 44 permits manual interface with the intervention system 10 by an onsite operative, where desired.

(27) A power supply arrangement which in the illustrated embodiment takes the form of a battery unit 46 supplies power to the system 10. Power conduit 48 supplies power from the battery unit 46 to the drive 42 and winch 40. Power conduit 50 supplies power from the battery unit 46 to the valve arrangement 22. Power to the power supply arrangement 46 in the illustrated embodiment is provided by an energy capture arrangement—represented generally by 52—including an energy capture device which in the illustrated embodiment takes the form of a solar panel 54.

(28) The intervention system 10 further comprises a controller 56 in the form of a programmable logic controller (PLC) configured to permit autonomous control of operation of the intervention system 10. It will be recognized that the controller 56, or parts of the controller 56, may be located at any suitable location, for example but not exclusively on the lubricator 20 or at the wellhead 16.

(29) A support arrangement in the form of support mast 58 supports the Christmas tree 14 and the lubricator 20.

(30) A monitoring arrangement is provided. In the illustrated embodiment, the monitoring arrangement comprises a flow sensor 60 and a pressure sensor 62. However, it will be recognized that in other embodiments the intervention system 10 may comprise one or other of the flow sensor 60 and the pressure sensor 62, or other sensors alone or in combination. The monitoring arrangement also comprises a visual monitoring system in the form of a camera 64 which in the illustrated embodiment is disposed on the support mast 58. In use, the camera 64 facilitates remote visual monitoring of the tool deployment arrangement.

(31) A communication arrangement—in the illustrated embodiment a transceiver 66—is provided for communicating information to a remote location 68 either directly or as shown via satellite 70. In use, the transceiver 66 communicates information obtained by the monitoring arrangement to the remote location 68. In the illustrated embodiment, the transceiver 66 is configured for two-way communication; permitting commands to be sent to the intervention system 10.

(32) Operation of the intervention system 10 will now be described with reference to FIGS. 1 to 7 of the accompanying drawings.

(33) The intervention system 10 is initially disposed in the tool storage configuration with the intervention tool 18 disposed in the tool storage compartment 21 of the lubricator 20. In this configuration, the upper and lower control valves 24,26 are configured in their closed configurations, thereby providing a dual barrier between the lubricator 20 and the Christmas tree 14/wellbore 12. As described above, the provision of the dual barrier beneficially permits the upper control valve 28 of the Christmas tree 14 to be maintained in an open configuration.

(34) As illustrated in FIG. 7, on identifying that an activation event has occurred (e.g. the sensor detecting that the well flow rate has dropped below a threshold valve) the controller 56 will reconfigure the intervention system 10 from the well storage configuration to the activated configuration to permit deployment of the intervention tool 18 into the wellbore 12 by opening the lower and upper control valves 24,26.

(35) In the illustrated embodiment, the lower control valve 26 is opened first and then the upper control valve 24. However, it will be recognized that in some instances the upper control valve 26 may be opened first or the valves may be opened simultaneously.

(36) The monitoring arrangement monitors the intervention system to ensure that the control valves 24, 26 have opened correctly and that pressure integrity has been maintained.

(37) The controller 56 then activates the electric motor and winch of the tool deployment arrangement to pay out the wireline and deploy the intervention tool 18 into the wellbore 12 to perform the intervention operation.

(38) In the illustrated embodiment, the intervention operation comprises running a paraffin wax removal tool into the wellbore 12 to remove paraffin wax deposits from the wellbore 12 and associated infrastructure and equipment.

(39) On completion of the intervention operation, the controller 56 activates the electric motor and winch of the tool deployment arrangement to reel in the wireline and the coupled intervention tool 18 until the intervention tool 18 has been retrieved into the lubricator 20.

(40) The controller 56 then reconfigures the intervention system 10 from the activated configuration to the tool storage configuration by closing the upper and lower control valves 24,26.

(41) Well pressure may then be vented from the lubricator 20.

(42) It should be understood that embodiments described herein are merely exemplary and that various modifications may be made thereto without departing from the scope of the invention.

(43) For example, and referring now to FIGS. 8 to 14 of the accompanying drawings, there is shown an intervention system 110 according to a second embodiment. The intervention system 110 is similar to the intervention system 10 and like components of the system 110 to those of the system 10 are represented by like numerals incremented by 100.

(44) As in the intervention system 10, the intervention system 110 is configured to permit an intervention operation to be carried out on a wellbore 112, the wellbore 112 also being land-based and having a wellhead valve arrangement in the form of a Christmas tree 114 disposed on wellhead 116.

(45) The intervention system 110 is configured to deploy an intervention tool 118 (shown in FIG. 13) into the wellbore 112 and in the illustrated embodiment the intervention tool 118 comprises a paraffin wax removal tool for cleaning paraffin deposits from the wellbore 112 and associated infrastructure and equipment. However, it will be recognized that the intervention system 110 may be configurable to perform a number of different intervention operations using a suitable intervention tool.

(46) As in the intervention system 10, the intervention system 110 comprises a tool housing in the form of a lubricator 120. In the illustrated embodiment, the lubricator 120 comprises a stand of three connected heavy wall tubing sections, the interior of the lubricator 120 defining a tool storage compartment 121 (shown in Figure) configured to house the intervention tool 118. As shown in FIG. 8, the lubricator 120 is coupled to and disposed on top of the Christmas tree 114.

(47) A valve arrangement 122—which in the illustrated embodiment forms part of the lubricator 120—permits selective communication of tools and fluid between the lubricator 120 and the Christmas tree 114 (or between the lubricator 120 and the wellbore 112 where no Christmas tree 114 is provided).

(48) As shown in FIGS. 9 and 10, the valve arrangement 122 has an upper control valve 124 and a lower control valve 126. In the illustrated embodiment, the valve arrangement 122 has an upper valve 124 and a lower valve 126 which can be controlled independently. The valve arrangement 122 provides a dual barrier between the lubricator 120 and the Christmas tree 114, and permits an upper valve 128 of the Christmas tree 114 to be maintained in an open condition.

(49) The intervention system 110 is configurable between a tool storage configuration in which the lubricator 120 is isolated from the wellbore 112 by the valve arrangement 122 and an activated configuration in which the valve arrangement 122 is open and the lubricator 120 communicates with the Christmas tree 114 and the wellbore 112 to permit deployment of the intervention tool 118 by a tool deployment arrangement 130, as will be described below.

(50) The tool deployment arrangement 130 is provided for deploying the intervention tool 118 into the wellbore 112. The tool deployment arrangement 130 comprises a conveyance in the form of wireline 132 which is coupled to the intervention tool 118 and which extends through an upper end portion of the lubricator 120 via stuffing box 134—in the illustrated embodiment a dual chamber stuffing box 134—to ensure pressure integrity of the tool housing 20 and monitors any fluid/gas wire bypass. An enlarged view of the stuffing box 134 is shown in FIGS. 11 and 12.

(51) In the intervention system 110, the tool deployment arrangement 130 comprises a single pulley 136 which is disposed on the tool housing 120 above the stuffing box 134.

(52) A winch 140 is provided and is operatively coupled to a drive 142 which in the illustrated embodiment takes the form of a direct drive electric motor. In use, the drive 142 rotates the winch 140 in order to pay out the wireline 132 when it is desired to deploy the intervention tool 118 into the wellbore 112 and reel in the wireline 132 when it is desired to retrieve the intervention tool 118 from the wellbore 112.

(53) In the system 110, it can be seen that the winch 140 and the drive 142 are disposed on the lubricator 120. This provides a more compact system having a smaller footprint than the system 10.

(54) A power supply arrangement which in the illustrated embodiment takes the form of a battery unit 146 supplies power to the system 110. Power conduit 148 supplies power from the battery unit 146 to the drive 142 and winch 140. Power conduit 150 supplies power from the battery unit 146 to the valve arrangement 122. Power to the power supply arrangement 146 in the illustrated embodiment is provided by an energy capture arrangement—represented generally by 152—including an energy capture device which in the illustrated embodiment takes the form of a solar panel 154.

(55) The intervention system 110 further comprises a controller 156 in the form of a programmable logic controller (PLC) configured to permit autonomous control of operation of the intervention system 110. It will be recognized that the controller 156, or parts of the controller 156, may be located at any suitable location, for example but not exclusively on the lubricator 120 or at the wellhead 116.

(56) A monitoring arrangement is provided. In the illustrated embodiment, the monitoring arrangement comprises a flow sensor 160 and a pressure sensor 162. However, it will be recognized that in other embodiments the intervention system 110 may comprise one or other of the flow sensor 160 and the pressure sensor 162, or other sensors alone or in combination.

(57) A communication arrangement—in the illustrated embodiment a transceiver 166—is provided for communicating information to a remote location 168 either directly or as shown via satellite 170. In use, the transceiver 166 communicates information obtained by the monitoring arrangement to the remote location 168. In the illustrated embodiment, the transceiver 166 is configured for two-way communication; permitting commands to be sent to the intervention system 110.

(58) Operation of the intervention system 110 will now be described with reference to FIGS. 8 to 14 of the accompanying drawings.

(59) The intervention system 110 is initially disposed in the tool storage configuration with the intervention tool 118 disposed in the tool storage compartment 121 of the lubricator 120. In this configuration, the upper and lower control valves 124,126 are configured in their closed configurations, thereby providing a dual barrier between the lubricator 120 and the Christmas tree 114/wellbore 112. As described above, the provision of the dual barrier beneficially permits the upper control valve 128 of the Christmas tree 114 to be maintained in an open configuration.

(60) As illustrated in FIG. 14, on identifying that an activation event has occurred (e.g. the sensor 160 detecting that the well flow rate has dropped below a threshold valve) the controller 156 will reconfigure the intervention system 110 from the well storage configuration to the activated configuration to permit deployment of the intervention tool 118 into the wellbore 112 by opening the lower and upper control valves 124,126.

(61) In the illustrated embodiment, the lower control valve 126 is opened first and then the upper control valve 124. However, it will be recognized that in some instances the upper control valve 126 may be opened first or the valves may be opened simultaneously.

(62) The monitoring arrangement monitors the intervention system to ensure that the control valves 124, 126 have opened correctly and that pressure integrity has been maintained.

(63) The controller 156 then activates the electric motor and winch 140 of the tool deployment arrangement 130 to pay out the wireline 132 and deploy the intervention tool 118 into the wellbore 112 to perform the intervention operation.

(64) In the illustrated embodiment, the intervention operation comprises running a paraffin wax removal tool into the wellbore 112 to remove paraffin wax deposits from the wellbore 112 and associated infrastructure and equipment.

(65) On completion of the intervention operation, the controller 156 activates the electric motor and winch 140 of the tool deployment arrangement 130 to reel in the wireline 132 and the coupled intervention tool 118 until the intervention tool 118 has been retrieved into the lubricator 120.

(66) The controller 156 then reconfigures the intervention system 110 from the activated configuration to the tool storage configuration by closing the upper and lower control valves 124,126.

(67) Well pressure may then be vented from the lubricator 120.

(68) As described above, the intervention systems 110 is configured to deploy and/or retrieve an intervention tool 118 into and/or from the wellbore 112 in order to perform an operation. An exemplary intervention tool 118 is shown in FIG. 15. It will be recognized that the intervention tool 118 may also be used as the intervention tool 18 in the intervention system shown in FIGS. 1 and 2.

(69) As shown, the intervention tool 118 comprises a connector arrangement—which in the illustrated embodiment takes the form of a rope socket 172 and a thread connector 174—for connecting the intervention tool 118 to the wireline 132. The intervention tool 118 further comprises a mandrel 176—in the illustrated embodiment a jar rod—and an end cap 178. A cutter, shown generally at 180, is disposed on the mandrel 176 and is coupled to the mandrel 176 so as to be axially moveable relative to the mandrel 176. In the illustrated embodiment, the cutter 180 comprises one or more wire cutter elements 182. In use, movement of the cutter 180 relative to the mandrel 176 acts to remove paraffin deposits or other solids or residues from the wellbore 112.

(70) Beneficially, embodiments of the intervention system permit wellbore integrity to be managed and production maintained safely and efficiently while at the same time permitting intervention operations, such as paraffin wax cleaning operations for example, to be carried out autonomously. Moreover, embodiments of the intervention system may reduce the environmental impact on the surrounding environment, for example reducing the requirement for large and heavy vehicles; reduce carbon emissions, and noise. Vehicle fleet management and personnel costs may also be reduced.

(71) A well system 1010 according to an embodiment is shown in FIG. 16 of the accompanying drawings. As shown, the well system 1000 comprises a plurality of wellbores 1012, a first intervention system 1010 operatively associated with a first of the wellbores 1012 and a second intervention system 1100 operatively associated with a second of the wellbores 1012. The intervention systems 1010, 1110 may be of the same configuration or different configurations. For example, in the illustrated embodiment, the first intervention system 1010 corresponds to the intervention system 10 while the second intervention system 1110 corresponds to the intervention system 110.

(72) In the illustrated embodiment, the intervention systems 1010,1110 each have their own power supply in the form of battery units 1046,1146, controller 1056,1156 and energy capture arrangement 1052,1152. However, it will recognized that the intervention systems 1010,1110—in particular but not exclusively those relating to wellbores from the same field—may be coupled to a common power supply, energy capture arrangement and/or controller.

(73) Similarly, the intervention systems 1010,1110 each have their own communication arrangement 1066,1166 for communicating information to a remote location 1068 either directly or as shown via satellite 1070.

(74) Beneficially, embodiments of the well system 1000 permit wellbore integrity to be managed and production maintained safely and efficiently while at the same time permitting intervention operations, such as paraffin wax cleaning operations for example, to be carried out autonomously. Moreover, embodiments of the well system 1000 may reduce the environmental impact on the surrounding environment, for example reducing the requirement for large and heavy vehicles; reduce carbon emissions, and noise. Vehicle fleet management and personnel costs may also be reduced.

(75) As described above, it should be understood that embodiments described herein are merely exemplary and that various modifications may be made thereto without departing from the scope of the invention.

(76) For example, while in the described embodiments the systems and methods are directed to the removal of paraffin wax from a wellbore and associated infrastructure and equipment, it will be understood that the systems and methods may be used to perform any suitable intervention operation, including not exclusively well logging operations.