The present invention relates generally to a subsea CCD that is used to seal a wellbore and cut any drill pipe in the wellbore. More specifically, the present invention relates to a locking mechanism that locks the two cutters in a closed position. The moving parts of the system operate the locking mechanism to securely lock and unlock in a sequence thereby allowing the safe operation of opening and closing of the CCD. The present invention also teaches an override tool that is capable of operating the locking mechanism utilizing an ROV in case the hydraulics of the CCD are no longer available. The CCD may be referred to herein generically as a subsea pipe cutter.
U.S. application Ser. No. 15/806,919 filed Nov. 8, 2017 is incorporated herein by reference. U.S. application Ser. No. 15/806,919 filed Jul. 12, 2017 is incorporated herein by reference. U.S. Pat. No. 9,732,576 issued Aug. 15, 2017 is also incorporated herein by reference.
Surface and subsea pipelines are subject to high pressure fluid flows. During operation, shear rams, gates or other subsea sealing/cutting devices may be utilized to safely shear a pipe or other physical objects present in the wellbore. The term subsea pipe cutter may be referred generically to as BOP shear rams, dual gate valves, dual gates and/or other devices utilized to shear pipe and seal a subsea well. Cutters may be referred to as the gates or the shear rams. To ensure well safety, it is paramount to utilize a device to consistently and reliably cut a pipe and other physical objects in the wellbore to avoid potential catastrophic blowouts, spills, or other dangerous situations that may arise which are inherent in the pipeline operations.
Wells may be repeatedly sealed during normal operations such as workovers to fix any associated problems that have arisen or due to inclement weather whereby changes in tide, wind, and the like may cause damage to the pipe, rigs, equipment, or personnel. A system that is able to seal a well and cut pipe or other objects is essential to the proper function of drilling operations.
It is often desirable that position indicators are incorporated on all actuators. The position indicators show valve position (open/close and full travel) for observation by a diver/ROV. For some standards where the actuator incorporates ROV override, the position indicator should be visible from the working ROV.
In some cases, standards for original equipment suppliers (OEMs) are specified. For example they may require that rams equipped with hydraulic ram locks should automatically engage and maintain a preload on removal of actuator closing and/or locking pressures. In this case, ram locking devices may be required to be designed to maintain preload to affect a seal under the following conditions: can repeatedly maintain a wellbore pressure seal after removing the actuator closing and/or locking pressures at room temperature, minimum and maximum design temperatures, and as a function of time; maintain a closing pressure margin (e.g., typically 25%) above that required to effect a seal; for pipes and slip rams, maintain a closing pressure margin (e.g., typically 25%) above that required to prevent slippage at maximum-rated hang-off load for rams located in the WCP (Well Control Package), allow for unlatch and re-latch of the EDP (Emergency Disconnect Package) without loss of preload. Single failures of the ram lock mechanisms shall not result in loss of functionality. Once the cutting device is closed, it may be required that means be used to prevent internal pressure inside the cutting device from opening the cutters of the cutting device to allow fluid flow through the bore that extends through the cutting device.
The standards do not state a mechanism to implement the regulations or the sequences required to achieve them. Therefore, there is a need for such a specific system and procedure to meet these standards.
Accordingly, those of skill in the art will appreciate the present invention that provides the locking mechanisms, a sequence of operation for the locking mechanisms and an override tool that is able to work with the locking mechanisms to open and close the valves remotely.
One possible object of the present invention is to provide a hydraulically actuated locking mechanism for a pipe cutting system.
Another possible object of the present invention is to provide an override tool that may be deployed and utilized to operate a pipe cutting system in the event the pipe cutting device cannot be controlled under standard operating conditions. The override tool will also be able to access the otherwise hydraulically locking and unlocking mechanism of the cutters. So if the hydraulic system of the cutting/sealing device is no longer operational due to a blowout or the like, the override tool is able to operate the locking mechanism.
Yet still another object of the present invention is to provide a sequence of operation that may be utilized to lock and unlock a locking mechanism on a pipe cutting/sealing system wherein, upon the proper sequence of operation, the pipe cutting system may then be opened or closed.
These and other objects, features, and advantages of the present invention will become clear from the figures and description given hereinafter. It is understood that the objects listed above are not all inclusive and are only intended to aid in understanding the present invention, not to limit the bounds of the present invention in any way.
One general aspect includes a locking mechanism for a subsea pipe cutter comprising a subsea pipe cutter housing. First and second cutters are connected to respective first and second pistons. The first and second pistons are responsive to hydraulic fluid to move the first and second cutters from an open position to a closed position. In the closed position, the first and second cutters shear pipe when a pipe is within the subsea pipe cutter. First and second position shafts are rigidly connected to the first and second pistons. The first and second position shafts extend outside the subsea pipe cutter housing past the outer wall of the piston chamber and are connected to first and second visual indicators that show whether the first and second cutters are in the open position or the closed position. The first and second position shafts define first and second openings. First and second piston rods connect to the first and second pistons and the first and second cutters. The first and second position shafts are connected to the first and second pistons on an opposite side of the first and second pistons from the first and second piston rods. First and second locking members for the first and second position shafts. The first and second locking members being positioned along the first and second position shafts at a fixed distance with respect to the subsea pipe cutter housing. The first and second locking members are moveable between a locked position and an unlocked position. In the unlocked position, the first and second locking members are outside the first and second openings on the first and second position shafts. When the first and second cutters are in the closed position, then the first and second locking members are moveable to the locked position in the first and second openings in the first and second position shafts to fix the first and second cutters in the closed position. The first and second locking members are moveable to the unlocked position outside the first and second openings to permit movement of the first and second cutters to the open position.
Implementations may comprise the locking mechanism further comprises each of the first and second locking members is sized with a diameter smaller than a diameter of the first and second position shafts to fit within the first and second openings formed in the first and second position shafts. The first and second lock sliders are movable between an unlocked position and a locked position. In the unlocked position, the first and second lock sliders are shaped to permit the first and second locking members to remain in the unlocked position outside the first and second openings on the first and second position shafts. In the locked position, the first and second lock sliders are shaped to urge the first and second locking members into the first and second openings. The first and second lock sliders are slidable in response to hydraulic pressure. The first and second lock sliders each comprise a recess and a lock surface. In the unlocked position, the first and second lock sliders are slidably positioned so that the recess in the first and second lock sliders receives the first and second locking members. In the locked position, the first and second lock sliders are slidably positioned so that the lock surface of the first and second lock sliders engages the first and second locking members to urge the first and second locking members into the first and second openings. The first and second visual indicators comprise first and second position indicators movable with the first and second position shafts. In the closed position, the first and second position indicators are configured to engage first and second valve switches. Each of the first and second valve switches is operable to direct a first and second valve to allow fluid flow to move the first and second lock sliders to the locked position or the unlocked position. In the open position, the first and second position indicators are positioned away from the first and second valve switches, the first and second valves switches being closed. In the unlocked position, the first and second lock sliders, the first and second valves are configured to stop fluid flow to the first and second lock sliders. The first and second valves may be four-way two-way valves.
The locking mechanism further comprising the first and second lock sliders are each linked respectively to first and second valve switches. The first and second valve switches being responsive to movement of the first and second lock sliders. The first and second valve switches are operable to direct first and second valves to allow fluid flow to move the first and the second pistons to the open or closed position. The locking mechanism may also include in the closed position, the first and second lock sliders are configured to maintain the first and second valve switches to operate the first and second valves to direct fluid to the first and second pistons. The locking mechanism may also comprise in the open position, the first and second lock sliders are operable to move the first and second valve switches to prevent fluid from flowing to the first and second pistons
Another general aspect comprises an override tool for a subsea pipe cutter. The subsea pipe cutter comprises a pipe cutter housing and a bore through the pipe cutter housing. A cutter is connected to a position rod. A piston moves with the position rod and the cutter between an open and a closed position with respect to the bore. A lock is mounted adjacent to the position rod to lock or unlock movement of the position rod and the cutter when the cutter is in the closed position. The position rod is connected to visual indicators that visually show whether the cutter is in an open position or a closed position from a location external to the subsea pipe cutter.
The override tool comprises an override tool cylinder. The override tool also comprises a piston mounted in the override tool cylinder. An override tool piston rod is connected to the piston. An override tool housing has a housing connector connectable to the pipe cutter housing to secure the override tool cylinder from movement with respect to the pipe cutter housing. A coupler is on the override tool piston rod, the coupler being connectable to the position rod. The override tool is attachable and detachable to the subsea pipe cutter. The housing connector being connectable the pipe cutter housing and the coupler being connectable to the position rod so that the piston is moveable to move the cutter between the open position and the closed position. The override tool also comprises a lock adaptor, the lock adaptor being connectable to the lock on the subsea pipe cutter to lock and unlock the position rod when the pipe cutter is in the closed position.
The override tool is selectively mountable to a remotely operable vehicle. The coupler includes an enlarged portion that interconnects to the position rod.
The override tool includes a profile that permits the visual indicators to be visible when the override tool is secured to the subsea pipe cutter.
The lock adaptor is hydraulically activated.
The override tool has an open side wherein the housing connector, the coupler, and the lock adaptor are configured to be mountable to a lock mechanism from above the lock mechanism whereby the override tool is lowered onto the lock mechanism for mounting when the subsea pipe cutter is in position for operation.
One general aspect includes a sequence of operation for a locking mechanism for a subsea pipe cutter. The subsea pipe cutter defines a bore through the subsea pipe cutter. The subsea pipe cutter has first and second cutters that are moveable between an open position and a closed position utilizing first and second pistons. In the open position, the first and second cutters permit fluid flow through the bore. In the closed position, at least one of the first and second cutters prevents fluid flow through the bore. First and second position rods are mechanically secured to the first and second cutters on opposite sides of the first and second pistons from the first and second cutters. The first and second position rods are connected to visual indicators that visually show whether the first and second cutters are in an open position or a closed position from a position external to the subsea pipe cutter. The locking mechanism comprises first and second locks that engage the first and second position rods to lock and unlock the first and second cutters in the closed position.
The sequence of operation comprises the steps of: for closing the subsea pipe cutter from the open position, the first and second locks being unlocked in the open position. The sequence of operation also includes applying hydraulic fluid to the first and second pistons to move the first and second cutters to the closed position. After the first and second cutters move to the closed position, then first and second valves direct hydraulic fluid to the first and second locks that engage the first and second position rods to lock the first and second cutters in the closed position. For opening the subsea pipe cutter when the first and second cutters are locked in the closed position, the sequence of operation also includes directing hydraulic fluid to the first and second locks to disengage from the first and second position rods so that the first and second locks are unlocked. After the first and second locks are unlocked, hydraulic fluid is applied to the first and second pistons to move the first and second cutters to the open position.
Implementations may include the sequence of operation further including the first and second position rods being mechanically linked to the first and second valves so that after the first and second cutters are in the closed position, then the first and second valves direct hydraulic fluid to the first and second locks that engage the first and second position rods to lock the first and second cutters in the closed position.
Another general aspect includes a locking mechanism for a subsea pipe cutter, comprising: a subsea pipe cutter housing; a cutter connected to a piston, the piston being responsive to hydraulic fluid to move the piston from an open position to a closed position, in the closed position the cutter shearing a pipe when a pipe is within the subsea pipe cutter; a position shaft rigidly connected to the piston, the position shaft extending outside a piston chamber outer wall of the subsea pipe cutter housing and being connected to a visual indicator that shows whether the cutter is in the open position or the closed position, the position shaft defining an opening; a piston rod connects to the piston and the cutter, the position shaft being connected to the piston on an opposite side of the piston from the piston rod; and a locking member for the position shaft, the locking member being positioned along the position shaft at a fixed distance with respect to the piston chamber outer wall, the locking member being moveable between a locked position and an unlocked position, in the unlocked position the locking member being outside the opening on the position shaft, when the cutter is in the closed position then the locking member is moveable to the locked position within the opening in the position shaft to fix the cutter in the closed position, the locking member being moveable to the unlocked position to permit movement of the cutter to the open position.
The general description listed above and following detailed description is merely illustrative of the generic invention. Additional modes, advantages, and particulars of this invention will be readily suggested to those skilled in the art without departing from the spirit and scope of the invention. A more complete understanding of the invention and many of the attendant advantages thereto will be readily appreciated by reference to the following detailed description when considered in conjunction with the accompanying drawings, wherein like reference numerals refer to like parts and wherein:
Detailed descriptions of the preferred embodiment are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner.
Abbreviations include the following:
API—American Petroleum Institute
DNV—Det Norske Veritas (The Norwegian Veritas)
ISO—International Standardization Organization
ROV—remotely operated vehicle
NACE—National Association of Corrosion Engineers
QTC—Qualification Test Coupon
The use of CCD complies with codes and standards including:
API 6A, Specification for wellhead and Christmas tree equipment, 20th Edition, October 2010;
API 16A, Specification for Drill-through equipment, 3rd Edition, June 2004;
API 16D Control Systems for Drilling Well control Equipment, 2nd Edition, July 2004;
NORSOK D-002, Well intervention equipment, Revision 2, June 2013;
DNV-OS-E101, Drilling Plant, October 2013;
ISO 13533, Drilling and production equipment-Drill-through equipment, 1st Edition, December 2001;
API 17G, Recommended practice for completion/workover risers, 2nd Edition, July 2006
NACE MR0175/ISO 15156, Petroleum and natural gas industries—materials for use in H2S— containing environments in oil and gas production, 2nd Edition, October 2009.
Further details regarding a preferred embodiment of a compact cutting device used in the Dual compact cutting intervention system can be found in U.S. Pat. No. 9,732,576, which is incorporated by reference herein in its entirety.
Looking at
It will be appreciated that the wedge dog 16 and machined groove 28 form a lock that prevents movement of the cutter in the closed position. This lock then locks the cutters in the closed position so that they no longer can be pushed open.
Collar 12 may also be referred to as a lock slider. Collar or lock slider 12 may be in surrounding relationship to position shaft 22. Collar or lock slider 12 is axially moveable within a specific range of movement with respect to the CCD 501 housing after CCD 501 is placed in the shut or closed position. The range of axial movement of the position shaft 22 is different than the range of movement of the collar or lock slider 12 but is along the same axis of movement. The collar or lock slider 12 has an internal profile or shape as shown with a recess 13 and a lock surface 15.
A position shaft is preferably used on both sides of CCD 500 so that the position of each cutter can be ascertained using an ROV. However, the position shaft 22 may be of a different length than position shaft 22a when a different stroke length is utilized. Also, the position shaft on each side is used as part of the locking mechanism for each cutter. However, the locking mechanism 100 is essentially the same. The two sides of the CCD 501 housing are shown in
The present invention is described for use in
In
Once closed, the CCD 500 is then locked. To open, the CCD must be unlocked first and then opened. The CCD 500 remains unlocked in the open position.
The position shaft 22 shown on the right hand side of CCD 500 is secured to and moves with the piston 502 of the CCD 500 where an external view of the position of the piston may be provided by a position indicator, whether it is locked, unlocked, or malfunctioning when in between the locked or unlocked positions. In other words, a portion of the position shaft 22 necessarily extends outside of the CCD housing 501 outermost piston chamber wall 20. Piston 502 operates the piston shaft, which may also be referred to as piston rod 503 that connects to upper gate 508. The CCD 500 is always unlocked in the open position. The CCD 500 preferably always locks after reaching the closed position as described hereinafter. The CCD must be unlocked before moving to the open position.
Corresponding piston 512 connects to piston rod 514 to operate gate 510. Because the stroke length of piston 512 is different from that of piston 502, the length of piston indicating shaft 22, also referred to as the position shaft or rod, is shorter than that of piston indicating shaft 22a on the opposite side of the CCD 500. The locking mechanism is the same on each side so that only locking of piston indicating shaft 22 is described. Gate 510 is used to seal off bore 504. Gate 508 is used to centralize pipe in bore 504 but does not seal the bore 504.
Referring back to
Referring to
Referring to
The reverse order is utilized to hydraulically unlock wedge dog 16. Wedge dog 16 is biased upward or away from position shaft 22 by springs 14. As fluid pressure is increased in unlocking chamber 26, locking piston collar or lock slider 12 is urged or slid towards bore side 20 thereby decreasing downward engagement between locking piston collar 12 and wedge dog 16. When locking piston collar 12 has substantially cleared wedge dog 16, wedge dogs 16 is disengaged from machined groove 28 by the upward bias of springs 14. This in turn unlocks position shaft 22 and allows it to be moved outward or away from bore side 20 and into the open position.
Referring now to a quite different feature,
The CCD Override Tool may be used to override the current position of CCD 500. The CCD Override Tool may be carried into position by a remotely operated vehicle (ROV), which is used to interact with the CCD, typically after control is no longer otherwise available.
Referring to
It will be appreciated that the override tool 200 may simply be lowered onto the three interfaces 47, 49 (to secure override tool housing 30 to CCD housing 500) and 48, 51 (secure override tool piston rod 42 to position shaft 22) and 32, 12 (see also slot 33 in
Override tool Piston rod 42 may move in an axis through override tool cylinder 40. As fluid pressure is increased on the outer portion of piston head 38, then piston head 38, piston rod 42, and OT interface coupler 52 are urged closer to bore side 20 which is the closed position. Fluid and pressure are retained within OT cylinder 40 by cylinder cap 36 which may be secured through bolts 44 or like means.
Turning to
Referring to
In one possible embodiment, therefore override tool 200 may be secured in just three locations allowing for a quick yet secure attachment to override tool interface assembly 300. These interfaces may be summarized as: (1) lip 49 (of OT housing 30 also referred to as a housing connector) into slot 47 (of OT reaction pipe 46); (2) locking adapter 32 onto locking collar 50 (with slot 33); and (3) OT coupler interface 52 (with opening 51) onto OT interface 48. This embodiment provides quickly deployable and retrievable mounting points for an ROV to secure/retrieve override tool 200. Other possible embodiments may utilize greater or less than three mounting points and may be secured in other ways.
Referring to
Position indicator 56 is adjacent OT interface 48 and moves laterally with movement of position shaft 22. In the open position, position indicator 56 is at the outermost position and may be positioned on the position scale at the O position. As the position shaft 22 is urged towards the closed position, position indicator 56 likewise is urged to indicate the current position. In the closed position, position indicator 56 may be at the innermost position at the S position indicating that the gate or ram is shut. This may be helpful to assist a user to visually inspect the current position status of the Override tool 200 and the gates. Other markings may be used to indicate the position, as well as non-mechanical means such as electronically or the like. Interface 48 may be a flat circular protrusion or knob at the terminal end of position shaft 22. Other shapes may also be used as desired such that OT interface 48 is operable to engage OT interface coupler 52. OT reaction pipe 46 may be secured to the CCD by bolts or other like means. OT reaction pipe 46 protrudes outwardly from the CCD with a slot 47 operable to engage a corresponding flange or lip 49 on OT housing 30. Locking collar 50 surrounds position shaft 22 and may comprise a slot operable to engage locking adapter 32. In the unlocked and open position as shown, wedge dog 16 is recessed within inner locking housing 18. When position shaft 22 is moved to the closed position, wedge dog 16 may then be extended downward into machined groove 28 within position shaft 22 thereby locking position shaft 22 in place.
The current position of the gate is indicated by position indicator 56 marking the corresponding position on position scale 54. As shown, the gate is in the open position. In the open position, wedge dog 16 is in the retracted position and not engaging machined groove 28. In one embodiment, locking override cylinder 34 is mounted to inner side of OT housing 30. Locking adapter 32 is in the extended position whereby locking override cylinder 34 is fully extended. Locking adapter 32 engages a slot 33 within locking collar 50 (See
Referring to
Referring to
The reverse operation may be used to unlock and open the gate. Override tool 200 may be lowered or mounted onto CCD locking mechanism 100. In this embodiment, OT piston rod 42 is fully extended and locking override cylinder 34 is fully retracted. This will ensure the correct position for each component to properly engage the corresponding part on the respective override tool 200 and locking mechanism 100. After override tool 200 is mounted, pressure may be supplied to locking cylinder 34 to extend the rod inward. This will, in turn, push locking adapter 32 and the collar piston 12 inward thereby disengaging the wedge dogs 16 and unlocking position shaft 22. In this embodiment, the locking mechanism 100 is first placed in the unlocked position prior to opening or extending the position shaft 22. With the piston collar 12 retracted, the springs 14 will push the wedge dog 16 upwards or outwards relative to position shaft 22 releasing position shaft 22 from being locked. With the dogs 16 in the unlocked position, pressure may now be applied to the OT cylinder 40 on the inner face of piston head 38. This will pull position shaft 22 along with the stem/gate to the open position. Once the override tool 200 has fully retracted position shaft 22 along with the stem/gate, the CCD is now unlocked and in the open position. Override tool 200 can then be recovered as discussed above.
One of the main ideas of the present invention is that mechanically operated valves will be engaged by the moving parts of the system as shown in
When referencing the diagrams, if the lever 59 is up on the 4-way/2-position valve, the circuit is parallel through the bores. If the lever 59 is down on the 4-way/2-position valve, the circuit is switched through the bores. If the Ball valve lever 75 is to the right with a clear circle, then the ball valve 74 is open. If the Ball valve lever 75 is to the left with a crossed through circle, then the ball valve 74 is closed.
Referring to
One non-limiting example of a ball valve 74 used in the presently preferred embodiment is shown in
Referring to
Turning now to
In
Looking to
In summary, in this embodiment there is a preferred method for the order of operation to open or close the gates. In the fully open position, the wedge dogs are not in engagement with the machined groove and therefore the system is in the unlocked position. Additionally, the position rod and gate are fully extended outward in the open position. The system remains unlocked in the open position. Therefore, pressure may be applied to move the position rod inward to the closed position.
Once the position rod has moved to the closed position or in some embodiments the partially closed position, the locking collar may then be urged to engage the wedge dogs which in turn move them towards the position rod and the machined groove. The wedge dogs then fit within the machined groove securing the position rod in the closed and locked position.
To move the position rod back to the open position, the locking collar must be moved to disengage the wedge dogs. The wedge dogs will then retract or move away from the position rod and machined groove, therefore unlocking the system. The position rod may then be moved outward or to the open position.
A quick summary of the Sequence of Operation:
When the Actuator is to be Closed from Open Position:
Actuator “Open” position—Locking mechanism “Unlock” position
Actuator is move to “Close” position while Locking mechanism is still “Unlocked”.
After actuator closed completely, the position indicator rod activates ball valves which will open hydraulic supply to locking mechanism to “Lock.”
Actuator to be Opened from Close Position:
Hydraulic supply will go to locking mechanism to “unlock” first.
Once Locking mechanism “Unlocked” completely, it will open a needle valve to send hydraulic supply to actuator to start “Open”
Locking mechanism “Locks” only when gates are in closed position.
Referring to
Referring to
Referring to
Referring to
While the present invention is described in terms of a specific compact cutting device, the invention could be utilized for other cutting/sealing devices such as shear rams in BOPs and the like.
The foregoing description of the preferred embodiments of the invention has been presented for purposes of illustration and description only. It is not intended to be exhaustive or to limit the invention to the precise form disclosed; and obviously many modifications and variations are possible in light of the above teaching. Such modifications and variations that may be apparent to a person skilled in the art are intended to be included within the scope of this invention as defined by the accompanying claims.
Number | Date | Country | |
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62669536 | May 2018 | US | |
62650710 | Mar 2018 | US | |
62650688 | Mar 2018 | US |
Number | Date | Country | |
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Parent | 14518404 | Oct 2014 | US |
Child | 15647490 | US |
Number | Date | Country | |
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Parent | 15806919 | Nov 2017 | US |
Child | 16259081 | US | |
Parent | 15647490 | Jul 2017 | US |
Child | 15806919 | US |