This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.
A blowout preventer (BOP) is installed on a wellhead to seal and control an oil and gas well during various operations. For example, during drilling operations, a drill string may be suspended from a rig through the BOP into a wellbore. A drilling fluid is delivered through the drill string and returned up through an annulus between the drill string and a casing that lines the wellbore. In the event of a rapid invasion of formation fluid in the annulus, commonly known as a “kick,” the BOP may be actuated to seal the annulus and to contain fluid pressure in the wellbore, thereby protecting well equipment positioned above the BOP.
Various features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying figures in which like characters represent like parts throughout the figures, wherein:
One or more specific embodiments of the present disclosure will be described below. These described embodiments are only exemplary of the present disclosure. Additionally, in an effort to provide a concise description of these exemplary embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
Present embodiments are generally directed to systems and methods for the hot isostatic pressing (HIP) fabrication of components for use in the oil field services industry, which may relate generally to any activities (e.g., drilling, producing, monitoring, and/or maintaining) that facilitate access to and/or extraction of natural resources (e.g., hydrocarbons) from the earth. The components may be any of a variety of components for use in equipment, such as pressure-containing and/or pressure-controlling equipment. Present embodiments enable the production of multi-metallic (e.g., bimetallic, trimetallic) components, such as pressure-containing components and/or pressure-controlling components. An example embodiment includes a HIP-fabricated multi-metallic ram of a blowout preventer (BOP). A traditional BOP ram is fabricated using a subtractive manufacturing technique in which a forged block of a particular metal alloy is precisely machined into a complex shape, and then a number of conventional and unconventional heat treatments are performed to impart different material properties to different portions of the part. As used herein, the term metal alloy refers to either a pure metal or a metallic solid solution including a number of different metallic and/or non-metallic chemical elements.
In contrast, present embodiments involve the use of a HIP-fabrication process in which different metal alloys (e.g., different metal alloy powders, different metal alloy boundary layers) are combined and sealed in a canister before being heated and pressurized during a HIP process (e.g., in an autoclave) to form a multi-metallic pressure-controlling component (e.g., a BOP ram). As a result, the different metal alloys are disposed in different portions of the part to impart different material properties to these portions of the part (e.g., higher strength and hardness in a blade area of the ram, higher toughness in the body of the ram). Additionally, a finite (e.g., narrow) diffusion bond forms at the interface between different metal alloys, yielding a dense, seamless pressure-controlling component.
It is presently recognized that the disclosed HIP manufacturing process enables substantially greater freedom of design by enabling the joining of metal alloys that may be chemically incompatible using traditional joining methods (e.g., welding). Additionally, by using different metal alloys in different portions of the part, a greater range of material properties (e.g., strength, toughness, ductility, hardness, corrosion resistance) is available compared to the range of material properties achievable using a traditional, single metal alloy ram with multiple thermal processing steps. Within the HIP manufacturing process, a HIP process chemically bonds powder metal into a solid part under “extreme” temperature and pressure. After the HIP process is complete, the final part may be achieved with reduced processing time, compared with the traditional manufacturing techniques. For example, after the HIP process has been applied to join the metal powders of the multi-metallic part, the final part may be realized with reduced machining time, with little or no welding, and without special heat treatment processes of traditional manufacturing techniques, thereby reducing manufacturing time and cost relative to traditional manufacturing techniques. Furthermore, the disclosed HIP manufacturing process generally provides the capability to efficiently construct pressure-controlling equipment components having a complex shape while avoiding or reducing time-consuming and/or costly complex thermal processing, welding, and/or machining steps.
While the present embodiments are described in the context of a ram of a BOP for a drilling system to facilitate discussion, it should be appreciated that the systems and methods for HIP fabrication of multi-metallic components may be adapted for fabrication of other equipment, such as another component of the BOP for the drilling system and/or another component of another device for any type of system (e.g., drilling system, production system).
With the foregoing in mind,
As shown, a BOP stack 12 may be mounted to a wellhead 14, which is coupled to a mineral deposit 16 via a wellbore 18. The wellhead 14 may include or be coupled to any of a variety of other components such as a spool, a hanger, and a “Christmas” tree. The wellhead 14 may return drilling fluid or mud toward a surface during drilling operations, for example. Downhole operations are carried out by a conduit 20 (e.g., drill string) that extends through a central bore 22 of the BOP stack 12, through the wellhead 14, and into the wellbore 18.
As discussed in more detail below, the BOP stack 12 may include one or more BOPs 24 (e.g., ram BOPs), and component (e.g., rams) of the one or more BOPs 24 may be manufactured using systems and methods for HIP fabrication disclosed herein. To facilitate discussion, the BOP stack 12 and its components may be described with reference to a vertical axis or direction 30, an axial axis or direction 32, and/or a lateral axis or direction 34.
As shown, the BOP 24 includes a bonnet flange 56 surrounding the central bore 22. The bonnet flange 56 is generally rectangular in the illustrated embodiment, although the bonnet flange 56 may have any cross-sectional shape, including any polygonal shape and/or annular shape. Bonnet assemblies 60 are mounted on opposite sides of the bonnet flange 56 (e.g., via threaded fasteners). Each bonnet assembly 60 includes an actuator 62, which may include a piston 64 and a connecting rod 66. The actuators 62 may drive the opposed rams 50 toward one another along the axial axis 32 to reach a closed position in which the opposed rams 50 are positioned within the central bore 22, contact and/or shear the conduit 20 to seal the central bore 22, and/or contact one another to seal the central bore 22.
Each of the opposed rams 50 may include a body section 68 (e.g., ram body), a leading surface 70 (e.g., side, portion, wall) and a rearward surface 72 (e.g., side, portion, wall, rearmost surface). The leading surfaces 70 may be positioned proximate to the central bore 22 and may face one another when the opposed rams 50 are installed within the housing 56. The rearward surfaces 72 may be positioned distal from the central bore 22 and proximate to a respective one of the actuators 62 when the opposed rams 50 are installed within the housing 56. The leading surfaces 70 may be configured to couple to and/or support sealing elements (e.g., elastomer or polymer seals) that are configured to seal the central bore 22 in the closed position, and the rearward surfaces 72 may include an attachment interface 74 (e.g., recess) that is configured to engage with the connecting rod 66 of the actuator 62. The body section 68 also includes lateral surfaces 76 (e.g., walls) that are on opposite lateral sides of the body section 68 and that extend along the axial axis 32 between the leading surface 70 and the rearward surface 72. In
For the pressure-controlling components 26 illustrated in
The metal alloys of the pressure-controlling component 26 (e.g., metal alloys 94, 96, 98) may be selected based on a number of criteria. For example, for the embodiment illustrated in
As such, for the embodiment illustrated in
Additionally, the embodiment of the upper ram 50A illustrated in
It may be appreciated that, for certain embodiments of pressure-controlling components 26, it may be desirable for the diffusion bonds at the boundaries 100 to demonstrate certain features or material properties. For example, in certain embodiments, the strength (e.g., tensile strength, yield strength) at each interface 100 between different metal alloys is greater than the strength of the material that is used to form at least a substantial portion of the body 68. For the embodiment of
In some embodiments, the boundaries 100 that define the diffusion bonds between the different metal alloys of the pressure-controlling components 26 may not be planar boundaries. For example,
In some embodiments, the boundaries that define the diffusion bonds between different metal alloys may be complex and correspond to (e.g., follow, match) one or more contours in the outer surface of the pressure-controlling components 26. For example,
For certain embodiments of the lower ram 50B illustrated in
In certain embodiments, the controller 112 is an electronic controller having electrical circuitry configured to process data from various components of the system 110, for example. In the illustrated embodiment, the controller 112 includes a processor 122 and a memory device 124. The controller 112 may also include one or more storage devices and/or other suitable components. By way of example, the processor 122 may be used to execute software, such as software for controlling the user interface 114, controlling the heat source 118, the pressure source 120, and so forth. Moreover, the processor 122 may include multiple microprocessors, one or more “general-purpose” microprocessors, one or more special-purpose microprocessors, and/or one or more application specific integrated circuits (ASICS), or some combination thereof. For example, the processor 122 may include one or more reduced instruction set (RISC) processors.
The memory device 124 may include a volatile memory, such as random access memory (RAM), and/or a nonvolatile memory, such as read-only memory (ROM). The memory device 124 may store a variety of information and may be used for various purposes. For example, the memory device 124 may store processor-executable instructions (e.g., firmware or software) for the processor 122 to execute, such as instructions for controlling the user interface 114, the heat source 118, the pressure source 120, and so forth. The storage device(s) (e.g., nonvolatile storage) may include read-only memory (ROM), flash memory, a hard drive, or any other suitable optical, magnetic, or solid-state storage medium, or a combination thereof.
The user interface 114 may include suitable input and output devices communicatively coupled to the controller 112. The user interface 114 is configured to receive user input defining parameters of the HIP manufacturing process (e.g., temperature/pressure programs). The controller 112 may store received inputs in the memory device 124 until used by the processor 122 to perform portions of the HIP manufacturing process. During the HIP manufacturing process, information about the state of the controller 112, the heat source 118, the pressure source 120, and measurements from various sensors (e.g., temperature sensors, pressure sensors, displacement sensors) of the HIP manufacturing system 110 may be suitably presented on a display device of the user interface 114.
The canister 116 is generally a sacrificial metal alloy (e.g., steel) container that serves as a mold during the HIP processing. As such, the canister 116 includes an internal cavity that generally corresponds to the shape of the pressure-controlling component 26 being manufactured, although notably larger due to the reduction in volume experienced during HIP process. As discussed below, the canister 116 is designed to receive multiple metal alloy powders, and potentially receive metal alloy foil boundary layers (e.g., nickel foil boundary layers) that are disposed between each layer of distinct metal alloy powder. During HIP processing of the canister 116, the pressure provided by the pressure source 120 and the heat provided by the heat source 118 condenses the materials (e.g., metal alloy powders, boundary layers) within the canister 116 into an integral, dense, multi-metallic pressure-controlling component 26. In certain embodiments, the heat source 118 and the pressure source 120 are integrated into a single element (e.g., an autoclave furnace).
With the foregoing in mind,
For the embodiment illustrated in
Continuing through the embodiment illustrated in
As mentioned, the boundary layer is a thin piece of a metal alloy (e.g., a metallic foil, a flat sheet) that may be disposed between layers of different metal alloy powders to prevent mixing of the powders during placement within the canister prior to carrying out the HIP processing and/or in the part after the HIP processing, which may enable a sharp and well-defined boundary between the different metal alloy powders and/or facilitate bonding. In certain embodiments, the boundary layer may have a composition that is the same as, or similar to, one of the metal alloy powders it separates. In some embodiments, the boundary layer may have a composition that is different than the composition of the metal alloy powders separated by the boundary layer. For example, the boundary layer may serve as a “butter layer” to facilitate the formation of a strong bond between the metal alloy powder layers. That is, the boundary layer may be a metal alloy that is more conducive towards bonding with the first and second metal alloy powders than the first and second metal alloy powders are toward bonding directly with each other. In some embodiments, the actions of blocks 134 and 136 may be repeated to add a third metal alloy, a fourth metal alloy, etc., to the canister 116 as desired.
The actions of blocks 132, 134, and 136 may be better understood by way of
Returning to
In certain embodiments, the materials sealed within the canister 116 may be heated to approximately 1050 to 1100 degrees Celsius, and the hydrostatic pressure within the canister may be approximately 400 to 450 Megapascals. However, any suitable temperature and/or pressure may be utilized to cause formation of the pressure-controlling component 26. For example, in some embodiments, the temperature may be between approximately 900 to 1200, 950 to 1150, or 1000 to 1100 degrees Celsius and/or the pressure may be approximately 300 to 600, 350 to 550, or 400 to 500 Megapascals. In certain embodiments, the temperature and/or the pressure may be varied at different times during HIP processing as part of a temperature/pressure program, for example, with various ramps to increase or decrease the temperature and/or pressure over predefined time windows, and with various holds times during which the temperature and/or pressure are held substantially constant. It may be appreciated that the particular temperatures and pressures used in the HIP process of block 146 may be selected based on the material properties (e.g., melting point, sintering point) of the powder metal alloys and boundary layers disposed within the canister 116. It may be noted that there is a substantial reduction in volume (e.g., between 15 percent and 25 percent, about 20 percent) of the materials disposed within the canister 116 during this HIP process. Upon completion of the HIP process of block 146, the pressure-controlling component 26 is subsequently removed from the canister 116. The resulting pressure-controlling component 26 may have a substantially uniform density (e.g., plus or minus 10 percent, plus or minus 5 percent) and/or the various regions of the component 26 with different metal alloys may be coupled to one another via narrow diffusion bonds. In certain embodiments, the pressure-controlling component 26 may undergo additional processing steps (e.g., machining, welding overlays, thermal treatment) to yield the final part.
The disclosed techniques enable the HIP fabrication of multi-metallic (e.g., bimetallic, trimetallic) pressure-controlling components for pressure-controlling equipment used in oil and gas applications. The disclosed HIP manufacturing process enables multiple, distinct metal alloys to be used to form particular portions of a pressure-controlling component, wherein the different metal alloys can be joined using a single HIP process. Compared with traditional subtractive manufacturing techniques, the disclosed HIP manufacturing process reduces the manufacturing time and cost, enables greater freedom of design in the selection of metal alloys, and enables a broader range of different material properties (e.g., strength, toughness, corrosion resistance) in different portions of the pressure-controlling component. Additionally, the disclosed HIP manufacturing technique can enable the formation of surface layers of metal alloy at thicknesses not achievable using weld-based processes (e.g., inlaying, overlaying, cladding) and using metal alloys that are not conducive to welding-based processes.
While the disclosure may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the following appended claims.
This application is a continuation of U.S. application Ser. No. 17/123,186, filed on Dec. 16, 2020, and entitled “HOT ISOSTATIC PRESSING (HIP) FABRICATION OF MULTI-METALLIC COMPONENTS FOR PRESSURE-CONTROLLING EQUIPMENT,” which is hereby incorporated by reference in its entirety for all purposes.
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Number | Date | Country | |
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Number | Date | Country | |
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Parent | 17123186 | Dec 2020 | US |
Child | 17328438 | US |