Patent Application
20240218747
This disclosure relates to an alignment subsystem having a packoff running tool and a knuckle joint.
Existing hanger pack-off running tools utilizes a solid drill pipe joint (sub) that attaches the pack-off body to the landing drill pipe. The rig floor rotary table is aligned fully with the wellhead below the rotary table. The pack-off is run and landed around the hanger.
In certain aspects, an oil rig system includes a rotary table aligned with a wellhead opening. The rotary table is centered on a first axis. The oil rig system also includes an elevator having flexible links and an alignment subsystem. The alignment subsystem includes a running tool and a knuckle joint. The running tool has a first end and a second end. The running tool is configured to attach to a packoff body. The knuckle joint is attached to the first end of the running tool and is attached to the elevator. The knuckle joint is configured to angularly deflect.
Some system also include the packoff and/or a riser arranged in a wellhead. Some risers are arranged on a second axis and the second axis is parallel to the first axis and is offset from the first axis. Some systems also include a hanger having a landing surface. The hanger can be centered on the second axis.
In some systems, the alignment subsystem is configured to move from a first position to a second position. In the first position, the running tool can be aligned with the first axis. In the second position, the running tool can aligned with a second axis. The second axis is parallel to the first axis and is offset from the first axis. The knuckle joint can be configured to rotate to move the alignment subsystem from the first position to the second position. The knuckle joint can be configured to rotate to move the alignment subsystem from the second position to the first position.
In some systems, knuckle joint has a tensile capacity of about 10,000 psi to about 45,000 psi, a pressure capacity of about 3,000 psi to about 15,000 psi, a torsional capacity of 5,000 ft-lb to about 20,000 ft-lb, and/or a maximum deflection angle of about 5° to about 45°.
Some systems also include a computer system having a controller, one or more processors, a (non-transitory) computer-readable medium storing instructions executable by the one or more processors to perform operations. The operations include receiving deflection data. The deflection data contains at least a deflection angle between about 5° to about 45°. The operations also include transmitting instructions to a transceiver of the knuckle joint. The instructions contain the deflection angle.
In some systems, the elevator includes a series of flexible links and the elevator is configured to flex relative to the first axis. The elevator can have a relaxed position and a flexed position. In some embodiments, in the relaxed position of some, the elevator is arranged on and aligned with the first axis. In some embodiments, in the flexed position, the elevator is angled relative to the first axis. In the flexed position, the flexible can be flexed.
In certain aspects, an alignment subsystem includes a running tool, a knuckle joint, and a computer subsystem. The running tool, configured to attach to a packoff body, has a first end and a second end. The knuckle joint is attached to the first end of the running tool and is attached to an elevator. The knuckle joint is arranged on a first axis and is configured to angularly deflect by an angle. The computer subsystem includes a controller, one or more processors, and a computer-readable medium storing instructions executable by the one or more processors to perform operations. The operations include receiving deflection data. The deflection data contains at least a deflection angle. The operations also include transmitting instructions to a transceiver of the knuckle joint. The instructions contain the deflection angle.
In some systems, the alignment subsystem is configured to move from a first position to a second position. In the first position, the running tool can be aligned with the first axis. In the second position, the running tool can be aligned with a second axis. The second axis is parallel to the first axis and is offset from the first axis. The knuckle joint can be configured to rotate to move the alignment subsystem from the first position to the second position. The knuckle joint can be configured to rotate to move the alignment subsystem from the second position to the first position.
In some systems, knuckle joint has a tensile capacity of about 10,000 psi to about 45,000 psi, a pressure capacity of about 3,000 psi to about 15,000 psi, a torsional capacity of 5,000 ft-lb to about 20,000 ft-lb, and/or a maximum deflection angle of about 5° to about 45°.
The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.
Like reference symbols in the various drawings indicate like elements.
The disclosed system includes an alignment system for adjusting the position of a pack-off tool relative to a rotary table and wellhead. In some configurations, a wellhead and a rotary table are offset, for example centered on two parallel, but offset axes. The offset depends on hole (wellbore) size, rig size, and riser to rotary level. Generally, the offset is between 0.01 inches and 24 inches. In such a configuration, the system can adjust the alignment of the packoff running tool and packoff body (tool) after passing through the rotary table, using a knuckle joint. The knuckle joint connects the pack-off running tool and an elevator of the rig system. In a first position of the alignment subsystem, the knuckle joint is vertical, aligning the packoff running tool on a first axis, on which the rotary table is centered. After passing through the rotary table, the knuckle joint rotates or tilts by a predetermined angle to transition the alignment subsystem into a second position. In the second position, the packoff running tool aligns with a second axis defined by the wellhead. The packoff tool can then be inserted into the wellhead and deliver a packoff to a hanger in the wellhead.
The packoff running tool 152 has a first end 152a and a second end 152b. The first end 152a is attached to the connecting pipe 155 at a fixed angle, for example a 0° angle. In this configuration, the connecting pipe 155 and the pack off running tool 152 are aligned on a single axis, for example the first axis, the second axis, or a different axis. The second end 152b of the packoff running tool 152 is releasably attached to the packoff body 166. When connected, the packoff running tool 152 can translate axially, rotate, or tilt the packoff body 166. The packoff body 166 includes seals 167 that can be actuated to seal the packoff body 166 to the hanger 164 and/or spool 163. In use, the packoff body 166 is run in the wellhead 107 by the packoff running tool 152 and is landed in the hanger 164 at the landing surface 164a.
The knuckle joint 154 attaches to the first end 152a of the running tool by the connecting pipe 155 and attaches to the elevator 156 such that the knuckle joint 154 is arranged between the pack off running tool 152 and the elevator 156. The knuckle joint 154 is angularly deflectable to control the position and angle of the packoff running tool 152 relative to the first axis 108. The knuckle joint 154 has a tensile capacity of about 10,000 psi to about 45,000 psi (e.g., about 5,000 psi to about 150,000 psi). The knuckle joint 154 may have a pressure capacity of about 3,000 psi to about 15,000 psi. The knuckle joint 154 has a torsional capacity of about 5,000 ft-lb to about 20,000 ft-lb (e.g., about 5,000 ft-lb to about 50,000 ft-lb). The knuckle joint 154 has a maximum deflection angle of about 5° to about 45° (e.g., about 5° to about 90°).
The alignment subsystem 102 is configured to move from a first position to a second position, shown with reference to
The alignment subsystem 102 includes position sensors operable to generate and transmit position and/or deflection data indicative of the position of the knuckle joint the elevator, the packoff running tool, the wellbore, the wellbore opening, the rotary table, the opening of the rotary table, the drill string first axis, and/or second axis relative to the alignment subsystem or position sensors. In some sensors, the transmitted data includes the position of any of the knuckle joint, the elevator, the packoff running tool, the wellbore, the wellbore opening, the rotary table, the opening of the rotary table, the drill string first axis, and/or second axis relative to another of the knuckle joint, the elevator, the position of the packoff running tool, the wellbore, the wellbore opening, the rotary table, the opening of the rotary table, drill string first axis, and/or second axis relative to the alignment subsystem or position sensors. In some sensors, the position and/or deflection data includes a predetermined deflection angle determined by a controller of the sensor.
The elevator 156 includes multiple flexible links or a hinge that can deflect the elevator 156 from the first axis 108 or tilt the elevator 156 relative to the first axis 108. Tilting the elevator 156 also tilts any assemblies, subsystems, or components arranged downhole of the elevator 156. The elevator 156 is configured to covey or press the alignment subsystem 102 downwards through the opening 104a of the rotary table 104 and the wellhead 107. The elevator 156 is also configured to covey or pull the alignment subsystem 102 from the wellhead 107 after landing the packoff tool 166.
The system 100 includes a drill pipe 168 attached to the pack off running tool 152 and a computer system 170. The drill pipe 168 assists the elevator 156 in pulling the alignment subsystem into the 107 by acting as a weight. The drill pipe density and/or weight can depend on the string available and/or on the landing weight required per size. The drill pipe has a weight between 1,000 lbs and 45,000 lbs. The computer system 170 includes a controller 172 and at least one processor 174. The computer system 170 is operatively connected to the alignment subsystem 102 and the elevator 156 to control the alignment subsystem 102 and the elevator 156. A computer-readable medium storing instructions is executable by the processors to perform operations (e.g., a non-transitory computer readable medium). The operations include receiving deflection data from the alignment subsystem 102 and transmitting instructions to a transceiver 154a of the knuckle joint 154. The deflection data is indicative of the deflection of the alignment subsystem 102 relative to the first and/or second axis. In some cases, the deflection is relative to a vertical axis. The deflection data may be input manually, determined by the computer system 170, or by the alignment subsystem 102. The operations also include determining a deflection angle that would realign the alignment subsystem 102 with the first and/or second axis. The instructions sent by the computer system 170 to the knuckle joint 154 contain the predetermined deflection angle. In some system, the alignment subsystem includes the computer system.
A method for operating an alignment subsystem with a knuckle joint is described herein. The method is described with reference to the system 100 however, the method can be used with any applicable system. Initially, the drill pipe 168 is at least partially inserted into the hanger 164. The drill pipe 168, alignment subsystem 102, and elevator 156 are aligned with the first axis 108. The first axis 108 is defined by the opening 104a of the rotary table 104. The second axis 110, defined by the wellhead 107, is parallel and offset from the first axis 108, such that the opening 104a of the rotary table 104 and the opening 106 of the wellhead 107 overlap, but do not align. The offset d between the first and second axis is about 2 inches to about 8 inches. Some offsets are, for example, about 1 inch to about 10 inches, about 4 inches to about 24 inches, about 4 inches to about 12 inches, about 4 inches to about 8 inches, about 5 inches to about 24 inches, about 6 inches to about 24 inches, about 8 inches to about 24 inches, about 10 inches to about 24 inches, about 12 inches to about 24 inches, about 18 inches to about 24 inches, about 6 inches to about 12 inches, about 6 inches to about 18 inches, about 12 inches to about 16 inches, greater than 1 inch, greater than 2 inches, greater than 3 inches, greater than 4 inches, greater than 5 inches, greater than 6 inches, greater than 7 inches, greater than 8 inches, greater than 9 inches, greater than 10 inches, greater than 11 inches, greater than 12 inches, greater than 18 inches, or greater than 24 inches.
The elevator runs the alignment subsystem 102, packoff tool 166, and drill pipe 168 downhole, in a first direction, past the rotary table 104. The weight of the drill pipe 168 assists the elevator 156 in moving the alignment subsystem 102 and the packoff running tool 152 in the first downhole direction. After the first end 152a of the packoff running tool 152 passes the rotary table 104, the links of the elevator may be hydraulically adjusted to radially move the alignment subsystem 102, packoff tool 166, and drill pipe 168. Some elevator links are electronically or manually adjusted. The links continue to flex or tilt until the knuckle joint 154 is arranged on the second axis 110. The computer system can control the deflection of the links. The links then lock to hold the elevator 156 in the flexed position. Deflection data can be generated by the alignment subsystem or by the computer system. The deflection data include the angle of deflection experienced by the alignment subsystem due to the flex of the links. The deflection data also include a predetermined deflection angle that would align the alignment subsystem with the second axis. The knuckle joint 154 receives, from the computer system 170, instructions containing the predetermined deflection angle. The knuckle joint 154 is electrically or manually adjusted to deflect at the predetermined angle. The predetermined angle may be between about 0.10 and about 900 to center the pack-off body on the second axis. For example, the predetermined angle may be between about 0.1° to about 90°, about 1 to about 10°, about 0.1° to about 0.5°, about 0.1° to about 1°, about 0.5° to about 15°, about 100 to about 15°, about 100 to about 20°, about 150 to about 20°, about 150 to about 45°, about 100 to about 90°, about 150 to about 30°, about 10 to about 30°, about 10 to about 20°, about 0.10 to about 20°, about 0.10 to about 30°, about 5° to about 45°, about 300 to about 90°, about 300 to about 60°, about 10 to about 70°, about 5° to about 25°, about 3° to about 9°, about 4° to about 16°, or about 2° to about 900 relative to the second axis. The knuckle joint 154 is locked at the predetermined angle so that the alignment subsystem 102 is aligned with the second axis 110 and insertable into the opening 106 of the wellhead 107.
The elevator 156 conveys the alignment subsystem 102 into the wellhead until the packoff tool 166 reaches the landing surface of the hanger 164. The packoff tool 166 engages seals 167 with the hanger 164 and spool 163 to attach the packoff body 166 to the hanger 164 and spool 163. The packoff tool 166 is disengaged from the packoff running tool 152 and the packoff running tool 152 can be removed with the drill pipe.
The elevator 156 conveys the alignment subsystem 102 into the wellhead until the packoff tool 166 reaches the landing surface of the hanger 164. The packoff tool 166 engages seals 167 with the hanger 164 and spool 163 to attach the packoff body 166 to the hanger 164 and spool 163. The packoff tool 166 is disengaged from the packoff running tool 152 and the packoff running tool 152 can be removed with the drill pipe.
To remove the alignment subsystem 102 from the wellhead, the elevator 156 conveys the alignment subsystem 102 in a second, uphole direction. The second direction is opposite the first direction. The knuckle joint 154 holds the deflection angle until the second end 152b of the packoff running tool 152 exits the riser 162 of the wellhead 107. The knuckle joint 154 and links are returned to the starting angles (e.g., 0°) and are realigned with the first axis 110. The elevator then conveys the alignment subsystem 102 in the second direction so that the second end 152b of the packoff running tool 152 exits the opening 104a of the rotary table 104. The alignment subsystem 102 can then be removed or adjusted by an operator. After use, the pack-off running tool can be removed and/or redressed for future reuse.
In some system include a different tool or sub-system that lands equipment into the wellhead or wellbore. For example, rather than or in addition to a packoff tool, the system can include landing test plugs and/or hangers. The system can operate similarly to the system 100 to identify an offset and realign the tool or sub-system manually or via a computer sub-system (automatically).
In some systems, the knuckle joint tilts as the links in the elevator are flexed. For example, the knuckle joint may move or tilt at the same rate as the links of the elevator so that the drill pipe remains parallel to the first axis and/or second axis.
While the system has been described as an electronic or automated system, some systems are semimanual or fully manual. For example, such a system can be manually adjusted by an operator. In such a system, the drill pipe is at least partially inserted into the hanger. The drill pipe, alignment subsystem, and elevator are aligned with the first axis, defined by the opening of the rotary table. The second axis, defined by the wellhead, is parallel and offset from the first axis, such that the opening of the rotary table and the opening of the wellhead overlap, but do not align. The offset d between the first and second axis is about 0.01 inches to about 24 inches (e.g., about or greater than 3 inches, e.g., about 3 inches to about 12 inches, e.g., about 4 inches).
The elevator runs the alignment subsystem, packoff tool, and drill pipe downhole, in a first direction, past the rotary table. The weight of the drill pipe assists the elevator in moving the alignment subsystem and the packoff running tool in the first downhole direction. After the first end of the packoff running tool passes the rotary table, an operator flexes the links of the elevator to radially move the alignment subsystem, packoff tool, and drill pipe. The links continue to flex or tilt until the operator sees knuckle joint is arranged in the center of the wellhead, on the second axis. The links then lock to hold the elevator in the flexed position.
Next, the packoff running tool, drill pipe, and alignment subsystem are run further downhole so that the packoff running tool abuts the wellhead or a riser in the wellhead. The packoff running tool, drill pipe, and alignment subsystem continue downhole applying more pressure to the packoff running tool and drill pipe until the knuckle joint flexes to release the force. The knuckle joint will continue to flex until the pack off running tool is aligned with the opening of the well head. The elevator or operator conveys the alignment subsystem into the wellhead until the packoff tool reaches the landing surface of the hanger. The packoff tool engages seals with the hanger and spool to attach the packoff body to the hanger and spool. The packoff tool is disengaged from the packoff running tool and the packoff running tool can be removed.
In some cases, the predetermined angle of the knuckle is measured, calculated, and preset by an operator. In such an embodiment, the operator measures the offset between the rotary table and the wellhead and calculates the required deflection angle of the knuckle joint. The operator then manually adjusts the knuckle joint to the calculated deflection angle and locks the knuckle joint, for example by using pins. In this system, the knuckle joint includes a locking sub-system comprising a locking pin and a recess in the knuckle joint for receiving a locking pin. The locking pin, when inserted into the knuckle joint, structurally locks the knuckle joint at an angle. An angle of deflection relative to an axis defined by the drill string or elevator links may be determined by position sensors in the knuckle joint and/or an alignment sub-system. The angle of deflection can be displayed on a screen or connected display to assist the operator in manually adjusting the knuckle joint to the measured, calculated, or predetermined angle. At this stage the links of the elevator are aligned with the first axis and the packoff running tool is tilted at the calculated angle and aligned with the second axis.
In systems where the string assembly is “made up” or assembled, the operator connects components of the string assembly at connection points to form the string assembly. In the system with a pack-off running tool, the operator makes up or connects the knuckle joint of the string assembly to the pack-off running tool. The operator then runs the pack off running tool, flexing the links of the elevator so that the packoff running tool, drill pipe, and alignment subsystem align with the first axis and pass through the opening of the rotary table. After the packoff running tool passes the rotary table, the operator realigns the links on the first axis so that the packoff running tool, drill pipe, and alignment subsystem are aligned with the second axis.
The elevator or operator conveys the alignment subsystem into the wellhead until the packoff tool reaches the landing surface of the hanger. The packoff tool engages seals with the hanger and spool to attach the packoff body to the hanger and spool. The packoff tool is disengaged from the packoff running tool and the packoff running tool can be removed.
In some embodiments, the system comprises a first knuckle joint and a second knuckle joint. The system, automatically via the controller or manually via the operator, may prompt each knuckle joint to rotate so that the pack off running tool aligns with the first axis and/or the second axis.
A number of embodiments have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope. Accordingly, other embodiments are within the scope of the following claims.
