Remote launch system for activating downhole tool and related method

Abstract

The present disclosure describes a system for launching an activation device to a frac tree, to a frac tree including the system, and to a method of remotely launching an activation device into a frac tree. The activation device is pneumatically conveyed through a pneumatic line between a loading station located remotely from the frac tree, to a staging valve system adapted to connect to the frac tree. The staging valve system stages the activation device from a low pressure zone above the staging valve system to a high pressure zone in the frac tree.

1 . A system for launching an activation device to a frac tree, comprising:
 a loading station for the activation device, the loading station being located remotely from the frac tree;   a staging valve system adapted to connect to the frac tree for staging the activation device from a low pressure zone above the staging valve system to a high pressure zone in the frac tree;   a pneumatic line connected to the loading station for delivering the activation device to the staging valve system; and   an air source to impart air pressure within the pneumatic line to pneumatically convey the activation device through the pneumatic line from the loading station to the staging valve system.   
     
     
         2 . The system of  claim 1 , wherein the pneumatic line is tubular, and wherein the system further comprises a carrier for pneumatically conveying the activation device in the pneumatic line, the carrier having a generally cylindrical body, at least one closed end, and one or more circumferential seals carried on an outer surface of the carrier to support the carrier within the pneumatic line and to pneumatically convey the carrier through the pneumatic line when air pressure from the air source is imparted on the closed end of the carrier. 
     
     
         3 . The system of  claim 2 , further comprising:
 a launch housing connected to the staging valve system, the launch housing having a housing inlet and a housing outlet and a launch passageway extending between the housing inlet and the housing outlet, the launch passageway being shaped and sized to accommodate the activation device for delivery from the housing inlet to the housing outlet, the housing outlet being axially aligned with, and connected to, the staging valve system; and   the pneumatic line being connected to the housing inlet of the launch housing such that the activation device and the carrier are pneumatically conveyed through the pneumatic line from the loading station for discharging the activation device from the carrier to the housing inlet for delivery via the launch passageway and the housing outlet to the staging valve system.   
     
     
         4 . The system of  claim 2 , further comprising:
 a vented adaptor located in the pneumatic line between the loading station and the staging valve system for discharging the activation device from the carrier for delivery to the staging valve system.   
     
     
         5 . The system of  claim 3 or 4 , wherein the carrier is adapted to carry the activation device within the cylindrical body, with the closed end of the carrier being rear facing toward the air source, and a front end of the carrier being open to discharge the activation device hands free from the carrier, for gravity delivery to the staging valve system. 
     
     
         6 . The system of  claim 5 , wherein both ends of the carrier are closed, and the carrier is adapted to push the activation device ahead of the carrier in the pneumatic line to discharge the activation device hands free from the carrier, for gravity delivery to the staging valve system. 
     
     
         7 . The system of any one of  claims 1-6 , wherein the pneumatic line comprises a flexible hose in one or more sections, one or more pipe sections joined to one or more flexible hose sections, or one or more curved pipe sections joined to one or more linear pipe or hose sections. 
     
     
         8 . The system of any one of  claims 3-7 , wherein the air source is located rearwardly of the loading station with controls to switch between imparting air pressure in the pneumatic line and imparting vacuum pressure in the pneumatic line, whereby imparting vacuum pressure in the pneumatic line after the activation device is discharged returns the carrier to the loading station. 
     
     
         9 . The system of any one of  claims 3-8 , further comprising a stop located at the housing inlet of the launch housing or at the vented adaptor to stop the carrier and to discharge the activation device from the carrier. 
     
     
         10 . The system of  claim 9 , wherein the launch housing or the vented adaptor includes one or more vents to vent air pressure. 
     
     
         11 . The system of  claim 9 or 10 , wherein:
 the activation device has a generally cylindrical body with a length dimension, and with a forward end which first enters the housing inlet of the launch housing or the vented adaptor;   the launch passageway of the launch housing or a passageway of the vented adaptor is a generally radial passageway with a radial dimension less than the length dimension of the activation device, and having sidewalls to guide the activation device through the vented adaptor passageway or to the housing outlet with the forward end first arriving, generally axially aligned with the housing outlet or with the passageway of the vented adaptor.   
     
     
         12 . The system of  claim 11 , including the launch housing, wherein the housing inlet and outlet are arranged such that a center axis of the housing inlet and a center axis of the housing outlet are either axially aligned, or intersect at an angle between 90 and 180 degrees, such as between 125 and 180 degrees, or between 135 and 160 degrees. 
     
     
         13 . The system of any one of  claims 3-12 , wherein the loading station includes a sealed loading port with an open position for loading the activation device and the carrier into the pneumatic line, and a closed position to seal the pneumatic line at the loading port. 
     
     
         14 . The system of any one of  claims 3-13 , wherein the staging valve system includes a first valve member, a second valve member adapted to connect to the frac tree, and a pressure isolation passageway between the first and second valve members, wherein the first and second valve members and the pressure isolation passageway are axially aligned one with another and with an axial passageway of the frac tree, and permit passage of the activation device through the staging valve system to the frac tree. 
     
     
         15 . The system of  claim 14 , wherein the staging valve system further comprises a wing valve connecting to the pressure isolation passageway for introducing fluid under pressure to the pressure isolation passageway for launching the activation device through the staging valve system, and for releasing pressure from the staging valve system. 
     
     
         16 . The system of  claim 14 , wherein the staging valve system further comprises:
 a valved pressure equalizing line fluidly connecting a frac head of the frac tree to the pressure isolation passageway to use frac stream pressure to pressurize the pressure isolation passageway for launching the activation device through the staging valve system; and   a bleed off valve connecting to the pressure isolation passageway for releasing pressure from the staging valve system.   
     
     
         17 . The system of any one of  claims 1-13 , further comprising one or more position indicators, sensors and/or cameras to provide signals, images or information relating to one or more of location of the activation device, pressure, and valve position to monitor progression of the activation device at one or more locations at, within or between the loading station and the staging valve system. 
     
     
         18 . A method of remotely launching an activation device into a frac tree, comprising:
 a) providing a loading station for the activation device located remotely from the frac tree;   b) providing a staging valve system adapted to connect to the frac tree for staging the activation device from a low pressure zone above the staging valve system to a high pressure zone in the frac tree;   c) providing a pneumatic line connected to the loading station for delivering the activation device to the staging valve system;   d) loading an activation device at the loading station into the pneumatic line; and   e) pneumatically conveying the activation device through the pneumatic line from the loading station to the staging valve system.   
     
     
         19 . The method of  claim 18 , wherein pneumatically conveying of the activation device through the pneumatic line is with a carrier pneumatically sealed in the pneumatic line. 
     
     
         20 . The method of  claim 19 , further comprising:
 providing a launch housing for connecting to the staging valve system, the launch housing having a launch passageway extending from a housing inlet to a housing outlet, and the launch passageway being shaped and sized to accommodate the activation device for delivery from the housing inlet to the housing outlet;   providing the pneumatic line between the loading station and the housing inlet; and   pneumatically conveying the activation device with the carrier through the pneumatic line and discharging the activation device from the carrier to the housing inlet of the launch housing, such that the activation device is delivered via the launch passageway and the housing outlet to the staging valve system.   
     
     
         21 . The method of  claim 19 , further comprising
 providing a vented adaptor in the pneumatic line between the loading station and the staging valve system for discharging the activation device from the carrier for delivery to the staging valve system;   providing the pneumatic line between the loading station and the staging valve system; and   pneumatically conveying the activation device with the carrier through the pneumatic line to the vented adaptor and discharging the activation device from the carrier for delivery of the activation device to the staging valve system.   
     
     
         22 . The method of  claim 20 or 21 , wherein:
 the pneumatic line is tubular;   the carrier has a generally cylindrical body, at least one closed end, and carries one or more circumferential seals on an outer surface of the carrier to support the carrier within the pneumatic line and to pneumatically convey the carrier though the pneumatic line when air pressure from the air source is imparted on the closed end of the carrier.   
     
     
         23 . The method of  claim 22 , wherein the carrier carries the activation device within the cylindrical body, with the closed end of the carrier being rear facing toward the air source, and a front end of the carrier being open to discharge the activation device hands free from the carrier for gravity delivery to the staging valve system. 
     
     
         24 . The method of  claim 22 , wherein both ends of the carrier are closed and the carrier pushes the activation device ahead of the carrier to discharge the activation device hands free from the carrier for gravity delivery to the staging valve system. 
     
     
         25 . The method of any one of  claims 20-24 , wherein the air source includes controls to switch between imparting air pressure in the pneumatic line or imparting vacuum pressure in the pneumatic line, and wherein the method further comprises imparting a vacuum pressure in the pneumatic line after the activation device is discharged to return the carrier to the loading station. 
     
     
         26 . The method of any one of  claims 20-25 , wherein the pneumatic line comprises a flexible hose in one or more sections, one or more pipe sections joined to one or more flexible hose sections, or one or more curved pipe sections joined to one or more linear pipe or hose sections. 
     
     
         27 . The method of any one of  claims 20-26 , wherein the loading station includes a sealed loading port with an open position for loading the activation device and the carrier, and a closed position to seal the pneumatic line at the loading port. 
     
     
         28 . The method of any one of  claims 20-27 , wherein the staging valve system comprises a first valve member, a second valve member and a pressure isolation passageway between the first and second valve members, and wherein the method further comprises:
 staging the activation device though the first valve member, through the pressure isolation passageway, and then through the second valve member, wherein the first and second valve members and the pressure isolation passageway are axially aligned one with another and with an axial passageway of the frac tree.   
     
     
         29 . The method of claim  29 , wherein the staging comprises:
 i. opening the first valve member from an initially closed position to allow the activation device to be launched through the first valve member to the pressure isolation passageway between the first and second valve members and closing the first valve member;   ii. with the second valve member in an initially closed position, pressurizing the pressure isolation passageway; and   iii. opening the second valve member to allow the activation device to be launched from the pressure isolation passageway through the second valve member to the axial passageway of the frac tree and closing the second valve member.   
     
     
         30 . The method of  claim 29 , wherein step ii. includes opening an initially closed wing valve into the pressure isolation passageway and introducing fluid into the pressure isolation passageway to provide a fluid pressure at or above the fluid pressure of the axial passageway of the frac tree, and either closing the wing valve before opening the second valve member, or leaving the wing valve open to continue introducing fluid into the pressure isolation passageway after the second valve member is opened to assist in launching the activation device into the axial passageway of the frac tree. 
     
     
         31 . The method of  claim 29 , wherein step ii. includes fluidly connecting a valved pressure equalizing line between a frac head of the frac tree and the pressure isolation passageway to use frac stream pressure to pressurize the pressure isolation passageway for launching the activation device through the staging valve system, and providing a bleed off valve connecting to the pressure isolation passageway for releasing pressure from the staging valve system. 
     
     
         32 . The method of any one of  claims 28-31 , wherein the steps d), e) and the staging step are repeated for launching each subsequent one of a plurality of activation devices. 
     
     
         33 . The method of claim any one of  claims 28-32 , which further comprises providing one or more position indicators, sensors and/or cameras to provide signals, images or information relating to one or more of location of the activation device, pressure and valve position to monitor progression of the activation device at one or more locations at, within or between the loading station and the staging valve system. 
     
     
         34 . The method of any one of  claims 20-33 , wherein the method further comprises providing a stop at the housing inlet of the launch housing or at the vented adaptor to stop the carrier and to discharge the activation device from the carrier. 
     
     
         35 . The method of  claim 34 , further comprising venting the launch housing or the vented adaptor. 
     
     
         36 . The method of  claim 35 , wherein the activation device has a generally cylindrical body with a length dimension and with a forward end which first enters the housing inlet of the launch housing or the vented adaptor, and wherein the launch passageway of the launch housing or a passageway of the vented adaptor is a generally radial passageway with a radial dimension less than the length dimension of the activation device, and having sidewalls to guide the activation device through the vented adaptor passageway or to the housing outlet with the forward end first arriving, generally axially aligned with the housing outlet or with the passageway of the vented adaptor. 
     
     
         37 . The method of  claim 36 , including the launch housing, wherein the housing inlet and the housing outlet are arranged with a center axis of the housing inlet and a center axis of the housing outlet either axially aligned, or intersecting at an angle between 90 and 180 degrees, such as between 125 and 180 degrees, or between 135 and 160 degrees. 
     
     
         38 . A frac tree including the system of any one of  claims 1-17  connected into the frac tree.