Automated relief valve control system and method
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
E21B-021/08
E21B-034/16
E21B-034/08
E21B-033/068
E21B-034/02
출원번호
US-0886771
(2013-05-03)
등록번호
US-9322243
(2016-04-26)
발명자
/ 주소
Baca, Matthew S.
Witkowski, Brian C.
출원인 / 주소
S.P.M. Flow Control, Inc.
대리인 / 주소
Haynes and Boone, LLP
인용정보
피인용 횟수 :
1인용 특허 :
169
초록▼
A pressure relief valve system for use in a downhole operation may include a pressure relief valve configured to relieve pressure from high pressure tubing extending between a pump and a wellhead, and may include a sensor operably disposed to detect pressure in the high pressure tubing. The pressure
A pressure relief valve system for use in a downhole operation may include a pressure relief valve configured to relieve pressure from high pressure tubing extending between a pump and a wellhead, and may include a sensor operably disposed to detect pressure in the high pressure tubing. The pressure relief valve system also may include a controller having a pressure threshold stored therein. The controller may be configured to receive data from the sensor and compare the detected pressure to the stored pressure threshold. A valve actuation system may be in communication with the pressure relief valve and in communication with the controller. The valve actuation system may be configured to change the state of the pressure relief valve from a closed state to an open state in response to a command signal from the controller.
대표청구항▼
1. A pressure relief valve system for use in a downhole operation, the pressure relief valve system comprising: a pressure relief valve configured to relieve pressure from high pressure tubing extending between a pump and a wellhead;a sensor operably disposed to detect pressure in the high pressure
1. A pressure relief valve system for use in a downhole operation, the pressure relief valve system comprising: a pressure relief valve configured to relieve pressure from high pressure tubing extending between a pump and a wellhead;a sensor operably disposed to detect pressure in the high pressure tubing;a controller having a pressure threshold stored therein, the controller being configured to receive data from the sensor and compare the detected pressure to the stored pressure threshold;a gas source to provide a pressurized gas at a first gas pressure; anda valve actuation system in communication with the gas source, in communication with the pressure relief valve, and in communication with the controller, the valve actuation system being configured to change the state of the pressure relief valve from a closed state to an open state in response to a command signal from the controller, the valve actuation system comprising an output portion connected to the pressure relief valve and containing the pressurized gas at a second gas pressure; wherein the second gas pressure of the pressurized gas contained in the output portion maintains the pressure relief valve in the closed state; and wherein the second gas pressure of the pressurized gas contained in the output portion is less than the first gas pressure of the pressurized gas. 2. The pressure relief valve system of claim 1, wherein the controller is configured to emit the command signal when the controller determines that the detected pressure exceeds the stored pressure threshold. 3. The pressure relief valve system of claim 1, wherein the valve actuation system comprises a dump valve that receives the command signal from the controller. 4. The pressure relief valve system of claim 1, wherein the valve actuation system further comprises: an input portion connected to the gas source and containing the pressurized gas at a third gas pressure; anda reducing valve disposed between the input portion and the output portion, the reducing valve being configured to adjust the second gas pressure of the pressurized gas contained in the output portion based on data from the controller. 5. The pressure relief valve system of claim 4, further comprising: a first pressure transmitter configured to detect the third gas pressure of the pressurized gas contained in the input portion; and a second pressure transmitter configured to detect the second gas pressure of the pressurized gas contained in the output portion. 6. The pressure relief valve system of claim 5, wherein the third gas pressure is equal to the first gas pressure. 7. The pressure relief valve system of claim 4, wherein the third gas pressure is equal to the first gas pressure. 8. The pressure relief valve system of claim 1, wherein the controller is configured to receive an operator input that sets said pressure threshold, the controller also being configured to receive an operator input that sets a reset pressure for the pressure relief valve. 9. The pressure relief valve system of claim 1, wherein the controller is operable via a touch screen interface. 10. The pressure relief valve system of claim 1, wherein the controller is configured to average the detected pressure over an increment of time and compare the average detected pressure to the stored pressure threshold. 11. The pressure relief valve system of claim 1, wherein the controller receives data directly from the sensor. 12. The pressure relief valve system of claim 1, wherein the gas source comprises a nitrogen tank. 13. The pressure relief valve system of claim 1, wherein, when the pressure relief valve is in the closed state, the second gas pressure is about 105-150% of a gas pressure threshold that opens the pressure relief valve. 14. A pressure relief valve system for use in a downhole operation, the pressure relief valve system comprising: a pressure relief valve configured to relieve pressure from high pressure tubing extending between a pump and a wellhead;a sensor operably disposed to detect pressure in the high pressure tubing;a controller having a pressure threshold stored therein, the controller being configured to receive data from the sensor and compare the detected pressure to the stored pressure threshold;a valve actuation system in communication with the pressure relief valve, and in communication with the controller, the valve actuation system being configured to change the state of the pressure relief valve from a closed state to an open state in response to a command signal from the controller;wherein the valve actuation system comprises: an input portion connected to a gas source;an output portion connected to the pressure relief valve; anda reducing valve disposed between the input portion and the output portion, the reducing valve being configured to adjust the pressure in the output portion based on data from the controller;andwherein the valve actuation system comprises a second controller configured to determine a suitable pressure for the output portion, the second controller configured to adjust the reducing valve to achieve the suitable pressure in the output portion. 15. The pressure relief valve system of claim 14, wherein the suitable pressure is about 105-150% of a gas pressure threshold that opens the relief valve. 16. A pressure relief valve system for use in a downhole operation, comprising: a pressure relief valve configured to relieve pressure from high pressure tubing extending between a pump and a wellhead;a sensor operably disposed to detect pressure in the high pressure tubing;a controller having a pressure threshold stored therein, the controller being configured to receive data from the sensor and compare the detected pressure to the stored pressure threshold;a valve actuation system in communication with the pressure relief valve, and in communication with the controller, the valve actuation system being configured to change the state of the pressure relief valve from a closed state to an open state in response to a command signal from the controller;an actuation fluid source in communication with the valve actuation system, the actuation fluid source providing fluid pressurized to maintain the state of the pressure relief valve in a closed state; anda regulator structure carrying the valve actuation system and the actuation fluid source in a single transportable unit. 17. The pressure relief valve system of claim 16, wherein the regulator structure is a skid. 18. The pressure relief valve system of claim 16, wherein the regulator structure comprises: a hose reel carrying a hose extendable between the valve actuation system and the pressure relief valve and configured to place the valve actuation system and the pressure relief valve in fluid communication; anda data cable reel carrying a data cable extendable between the valve actuation system and the controller and configured to place the valve actuation system and the controller in electrical communication. 19. The pressure relief valve system of claim 16, further comprising a user interface in communication with the controller, wherein the regulator structure carries the controller and comprises: a hose reel carrying a hose extendable between the valve actuation system and the pressure relief valve and configured to place the valve actuation system and the pressure relief valve in fluid communication; anda data cable reel carrying a data cable extendable between the controller and the user interface and configured to place the controller and the user interface in electrical communication. 20. A method of controlling a pressure relief valve in a downhole operation, the method comprising: maintaining a pressure relief valve in a closed state with a pressurized gas, comprising: receiving the pressurized gas at a first gas pressure; andreducing the pressure of the pressurized gas from the first gas pressure to a second gas pressure that is less than the first gas pressure; wherein the second gas pressure of the pressurized gas maintains the pressure relief valve in the closed state;detecting, with a pressure sensor disposed adjacent the pressure relief valve, a fluid pressure in a high pressure tube extending between a pump and a wellhead;comparing the detected pressure to a stored fluid pressure threshold;sending a signal to open a dump valve if the detected pressure exceeds the fluid pressure threshold; andopening the dump valve to lower the second gas pressure of the pressurized gas until the pressure relief valve changes from the closed state to the open state. 21. The method of claim 20, comprising: regulating, using a reducing valve, the second gas pressure of the pressurized gas that maintains the pressure relief valve in the closed state; andcontrolling the reducing valve with an electronic controller. 22. The method of claim 21, wherein regulating the second gas pressure of the pressurized gas comprises maintaining the second gas pressure at a pressure about 105-150% of a gas pressure threshold that opens the pressure relief valve. 23. The method of claim 22, comprising changing the second gas pressure of the pressurized gas with the reducing valve in response to changes in the gas pressure threshold. 24. The method of claim 20, wherein, when the pressure relief valve is in the closed state, the second gas pressure is about 105-150% of a gas pressure threshold that opens the pressure relief valve. 25. A method of controlling a pressure relief valve in a downhole operation, the method comprising: maintaining a pressure relief valve in a closed state with a pressurized gas;detecting, with a pressure sensor disposed adjacent the pressure relief valve, a fluid pressure in a high pressure tube extending between a pump and a wellhead;comparing the detected pressure to a stored fluid pressure threshold;sending a signal to open a dump valve if the detected pressure exceeds the fluid pressure threshold;opening the dump valve to lower the pressure of the pressurized gas until the pressure relief valve changes from the closed state to the open state;prompting an operator to enter the fluid pressure threshold;prompting an operator to enter a reset pressure threshold; andclosing the dump valve to increase the pressure of the pressurized gas when the detected fluid pressure is below the reset pressure threshold. 26. A method of controlling a pressure relief valve in a downhole operation, the method comprising: maintaining a pressure relief valve in a closed state with a pressurized gas;detecting, with a pressure sensor disposed adjacent the pressure relief valve, a fluid pressure in a high pressure tube extending between a pump and a wellhead;comparing the detected pressure to a stored fluid pressure threshold;sending a signal to open a dump valve if the detected pressure exceeds the fluid pressure threshold; andopening the dump valve to lower the pressure of the pressurized gas until the pressure relief valve changes from the closed state to the open state;wherein detecting the pressure of fluid comprises:averaging the pressure over an increment of time to obtain the average pressure, and wherein comparing the detected pressure to a fluid pressure threshold comprises comparing the average pressure to the fluid pressure threshold. 27. A pressure relief valve system for a high pressure frac tubing, the pressure relief valve system comprising: a pressure relief valve configured to relieve pressure from the high pressure frac tubing extending between a frac pump and a wellhead;a sensor operably disposed to detect pressure in the high pressure frac tubing;a controller configured to receive a desired pressure threshold, configured to receive data from the sensor representing a detected pressure, and configured to compare the detected pressure to the desired pressure threshold;a valve actuation system in communication with the pressure relief valve and in communication with the controller, the valve actuation system being configured to change the state of the pressure relief valve from a closed state to an open state in response to a command signal from the controller; andan actuation fluid source in fluid communication with the valve actuation system and configured to supply pressurized fluid to the valve actuation system at a first fluid pressure;wherein the valve actuation system is configured to reduce the pressure of the pressurized fluid from the first fluid pressure to a second fluid pressure that is less than the first fluid pressure; andwherein the second fluid pressure of the pressurized fluid maintains the pressure relief valve in the closed state. 28. The pressure relief valve system of claim 27, wherein the valve actuation system is disposed adjacent the pressure relief valve. 29. The pressure relief valve system of claim 27, wherein the valve actuation system comprises: an input portion connected to the actuation fluid source;an output portion connected to the pressure relief valve; anda reducing valve disposed between the input portion and the output portion, the reducing valve being configured to adjust the pressure in the output portion based on data from the controller. 30. The pressure relief valve system of claim 29, wherein the actuation fluid source is a gas source; wherein the pressurized fluid is a pressurized gas;wherein the first and second fluid pressures are first and second gas pressures, respectively, of the pressurized gas;wherein the output portion contains the pressurized gas at the second gas pressure;wherein the reducing valve is configured to adjust the second gas pressure based on the data from the controller; andwherein the input portion contains the pressurized gas at a third gas pressure. 31. The pressure relief valve system of claim 30, wherein the third gas pressure is equal to the first gas pressure. 32. The pressure relief valve system of claim 27, further comprising a user interface configured to receive operator inputs representing the desired pressure threshold from an operator. 33. The pressure relief valve system of claim 32, further comprising a control van, the user interface being disposed in the control van and the valve actuation system being disposed adjacent the pressure relief valve. 34. The pressure relief valve system of claim 27, wherein the actuation fluid source is a gas source. 35. The pressure relief valve system of claim 34, wherein the gas source comprises a nitrogen tank. 36. The pressure relief valve system of claim 27, wherein, when the pressure relief valve is in the closed state, the second fluid pressure is about 105-150% of a fluid pressure threshold that opens the pressure relief valve. 37. A pressure relief valve system for a high pressure frac tubing, the pressure relief valve system comprising: a pressure relief valve configured to relieve pressure from the high pressure frac tubing extending between a frac pump and a wellhead;a sensor operably disposed to detect pressure in the high pressure frac tubing;a user interface configured to receive operator inputs representing a desired pressure threshold from an operator;a controller configured to receive the desired pressure threshold entered at the user interface, configured to receive data from the sensor representing a detected pressure, and configured to compare the detected pressure to the desired pressure threshold;a valve actuation system in communication with the pressure relief valve and in communication with the controller, the valve actuation system being configured to change the state of the pressure relief valve from a closed state to an open state in response to a command signal from the controller;an actuation fluid source in communication with the valve actuation system, the actuation fluid source providing fluid pressurized to maintain the state of the pressure relief valve in a closed state; anda regulator structure carrying the valve actuation system and the actuation fluid source in a single transportable unit. 38. The pressure relief valve system of claim 37, wherein the regulator structure is a skid. 39. The pressure relief valve system of claim 37, wherein the regulator structure comprises: a hose reel carrying a hose extendable between the valve actuation system and the pressure relief valve and configured to place the valve actuation system and the pressure relief valve in fluid communication; anda data cable reel carrying a data cable extendable between the valve actuation system and the controller and configured to place the valve actuation system and the controller in electrical communication. 40. The pressure relief valve system of claim 37, wherein the regulator structure carries the controller and comprises: a hose reel carrying a hose extendable between the valve actuation system and the pressure relief valve and configured to place the valve actuation system and the pressure relief valve in fluid communication; anda data cable reel carrying a data cable extendable between the controller and the user interface and configured to place the controller and the user interface in electrical communication. 41. A pressure relief valve system for high pressure frac tubing, the pressure relief valve system comprising: a pressure relief valve;a sensor configured to detect pressure;a controller configured to receive data from the sensor representing a detected pressure, and configured to compare the detected pressure to a pressure threshold;a valve actuation system configured to be in communication with each of the pressure relief valve and the controller, the valve actuation system being configured to change the state of the pressure relief valve from a closed state to an open state in response to a command signal from the controller; andan actuation fluid source configured to be in fluid communication with the valve actuation system and configured to supply pressurized fluid to the valve actuation system at a first fluid pressure;wherein the valve actuation system is configured to reduce the pressure of the pressurized fluid from the first fluid pressure to a second fluid pressure that is less than the first fluid pressure; andwherein the second fluid pressure of the pressurized fluid is suitable to maintain the pressure relief valve in the closed state. 42. The pressure relief valve system of claim 41, wherein the actuation fluid source is a gas source; wherein the pressurized fluid is a pressurized gas; andwherein the first and second fluid pressures are first and second gas pressures, respectively, of the pressurized gas. 43. The pressure relief valve system of claim 42, wherein the gas source comprises a nitrogen tank. 44. The pressure relief valve system of claim 41, wherein, when the pressure relief valve is in the closed state, the second fluid pressure is about 105-150% of another fluid pressure that opens the pressure relief valve. 45. The pressure relief valve system of claim 41, wherein the valve actuation system comprises: an input portion configured to be connected to the actuation fluid source;an output portion configured to be connected to the pressure relief valve; anda reducing valve configured to be in fluid communication with each of the input and output portions, and configured to adjust the pressure in the output portion based on data from the controller. 46. The pressure relief valve system of claim 45, wherein the actuation fluid source is a gas source; wherein the pressurized fluid is a pressurized gas;wherein the first and second fluid pressures are first and second gas pressures, respectively, of the pressurized gas;wherein the output portion is configured to contain the pressurized gas at the second gas pressure;wherein the reducing valve is configured to adjust the second gas pressure based on the data from the controller; andwherein the input portion is configured to contain the pressurized gas at a third gas pressure. 47. The pressure relief valve system of claim 46, wherein the third gas pressure is equal to the first gas pressure. 48. The pressure relief valve system of claim 46, further comprising: a first pressure transmitter configured to detect the third gas pressure of the pressurized gas; and a second pressure transmitter configured to detect the second gas pressure of the pressurized gas. 49. The pressure relief valve system of claim 41, further comprising a regulator structure carrying the valve actuation system and the actuation fluid source in a single transportable unit. 50. The pressure relief valve system of claim 49, wherein the regulator structure comprises: a hose reel carrying a hose extendable between the valve actuation system and the pressure relief valve and configured to place the valve actuation system and the pressure relief valve in fluid communication; anda data cable reel carrying a data cable extendable between the valve actuation system and the controller and configured to place the valve actuation system and the controller in electrical communication. 51. The pressure relief valve system of claim 41, wherein the controller is configured to emit the command signal when: the pressure threshold is stored in the controller; andthe controller determines that the detected pressure exceeds the pressure threshold. 52. The pressure relief valve system of claim 41, wherein the valve actuation system comprises a dump valve configured to receive the command signal from the controller. 53. The pressure relief valve system of claim 41, wherein the controller is configured to receive an operator input that sets the pressure threshold, the controller also being configured to receive an operator input that sets a reset pressure for the pressure relief valve. 54. The pressure relief valve system of claim 41, wherein the controller is configured to average the detected pressure over an increment of time and compare the average detected pressure to the pressure threshold.
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