Wellbore pressure insensitive hydraulic piston configuration
A tubing pressure insensitive and hydrostatic pressure insensitive control system includes a housing, a hydraulic piston sealingly disposed in the housing via a first seal set, and a balance piston sealingly disposed in the housing via, at least, a second seal set and a third seal set, the balance piston comprising a through-piston communication port. The housing includes a control pressure chamber associated with the hydraulic piston, and a balance pressure chamber associated with the balance piston. The system also includes a control line from the housing to surface, the control line being in fluid communication with the control pressure chamber, and a balance line from the housing to the surface, the balance line being in fluid communication with the balance pressure chamber.
1. A tubing pressure insensitive and hydrostatic pressure insensitive control system, comprising:
a housing;
a hydraulic piston sealingly disposed in the housing via a first seal set;
a balance piston sealingly disposed in the housing via, at least, a second seal set and a third seal set, wherein the hydraulic piston and the balance piston are sequentially movable;
wherein the housing comprises a control pressure chamber associated with the hydraulic piston, and a balance pressure chamber associated with the balance piston, and wherein the balance piston comprises a through piston communication port allowing for fluid communication between the balance pressure chamber and an area in the housing between the hydraulic piston and the balance piston;
a control line from the housing to surface, the control line being in fluid communication with the control pressure chamber; and
a balance line from the housing to the surface, the balance line being in fluid communication with the balance pressure chamber.
2. The tubing pressure insensitive and hydrostatic pressure insensitive control system of claim 1 , wherein the first seal set holds pressure between a control line pressure of the control line and a balance line pressure of the balance line.
3. The tubing pressure insensitive and hydrostatic pressure insensitive control system of claim 1 , wherein the second and third seal sets hold pressure between a wellbore pressure and a balance line pressure of the balance line.
4. The tubing pressure insensitive and hydrostatic pressure insensitive control system of claim 2 , wherein the second and third seal sets hold pressure between a wellbore pressure and the balance line pressure.
5. The tubing pressure insensitive and hydrostatic pressure insensitive control system of claim 1 , wherein the first seal set is exposed to the control pressure chamber.
6. The tubing pressure insensitive and hydrostatic pressure insensitive control system of claim 5 , wherein the second and third seal sets are exposed to a wellbore pressure and the balance pressure chamber.
7. The tubing pressure insensitive and hydrostatic pressure insensitive control system of claim 6 ,
wherein resulting forces on the second and third seal sets from the well bore pressure and the balance pressure chamber act in opposite directions.
8. The tubing pressure insensitive and hydrostatic pressure insensitive control system of claim 7 , wherein the resulting forces are of substantially equal magnitude and partially or fully cancel each other out.
9. The tubing pressure insensitive and hydrostatic pressure insensitive control system of claim 1 , wherein the balance piston isolates a well bore pressure from the balance pressure chamber and establishes tubing pressure insensitivity.
10. The tubing pressure insensitive and hydrostatic pressure insensitive control system of claim 1 , wherein the balance piston is face fit or otherwise coupled with the hydraulic piston in the housing.
11. A system, comprising:
the tubing pressure insensitive and hydrostatic pressure insensitive control system of claim 1 ; and
a safety valve, comprising:
a tubular member having a longitudinal bore therethrough;
a flapper pivotably mounted to the tubular member and movable between an open position in which the longitudinal bore is unblocked and a closed position in which the longitudinal bore is blocked;
a flow tube configured to move the flapper between the open position and the closed position, the flow tube comprising:
a shoulder; and
a power spring disposed around the flow tube and attached to the shoulder,
wherein the power spring biases the flow tube away from the flapper,
wherein the housing of the tubing pressure insensitive and hydrostatic pressure insensitive control system defines an opening through which the balance piston is operably connected to the flow tube.
12. The system of claim 11 , wherein a pressure differential between the control pressure chamber and the balance pressure chamber controls actuation of the safety valve.
13. The system of claim 11 ,
wherein, when a pressure differential across the first seal set is higher than an opposing force of the power spring, the hydraulic piston moves the flow tube within the longitudinal bore, thereby moving the flapper into the open position, and
wherein, when control pressure in the control pressure chamber is bled to zero or below balance pressure in the balance pressure chamber, the flapper is moved toward the closed position by the power spring.
14. A method of controlling a safety valve comprising a flow tube actuating a flapper; and a power spring that biases the flow tube away from the flapper, the method comprising:
applying control pressure into the control pressure chamber of the tubing pressure insensitive and hydrostatic pressure insensitive control system of claim 1 via the control line from surface to actuate the hydraulic piston;
balancing hydrostatic forces on the hydraulic piston from the control line with a balance line to the surface;
isolating well bore pressure from the balance pressure chamber and establishing tubing pressure insensitivity using the balance piston,
wherein the housing of the tubing pressure insensitive and hydrostatic pressure insensitive control system defines an opening through which the balance piston is operably connected to the flow tube; and
establishing a pressure differential across the first seal set in the control pressure chamber to actuate the safety valve, thereby moving the flapper into an open position.
15. The method of claim 14 , further comprising:
bleeding the control pressure in the control pressure chamber to below a balance pressure in the balance pressure chamber; and
moving the flapper toward a closed position by the power spring.
16. The method of claim 14 , wherein the establishing step further comprises the control pressure in the control pressure chamber overcoming a balance pressure in the balance pressure chamber and a power spring force of the power spring.