The present invention relates generally to wear bushings for use in oil and gas wells, and, more particularly, to a wear bushing that can be installed and selectively retrieved from the bore of a surface or subsea wellhead.
Wear bushings are used while drilling to protect the bore of a surface or subsea wellhead from damage or wear. The bore of the wellhead must be protected so that metal-to-metal seal assemblies can later be installed when a casing hanger is landed and the annulus between the wellhead bore and the casing run is “packed-off’ with the metal seal assembly. Scratches in the wellhead bore would prevent the metal seal from passing pressure tests.
After a casing string is run in the wellhead, a special trip is typically made to install a shorter wear bushing with a smaller bore (via drill pipe) above the casing hanger to again protect the wellhead. Drilling can then commence again.
When subsea wellheads were initially introduced, they were used in shallow water depths, e.g., 300 feet (ft.)-500 feet (ft.). The time required to install (trip in) and retrieve (trip out) a wear bushing for such shallow depths was short. One trip was performed via drill pipe just to install the wear bushing and a separate trip was performed via drill pipe just to retrieve the wear bushing.
Later, designs of wear bushings were introduced to install and retrieve wear bushings while the drill bit and bottom hole assembly were being run and retrieved. These were called “bit runable wear bushings” and later shortened to “wear sleeves.” A drawback of these designs is that every time the bit is retrieved, the wear sleeve is also retrieved. There is still risk involved with this process, however, because the drill bit passes through the exposed wellhead before the wear sleeve is installed and, on the trip out, the wear sleeve is retrieved first, and later the drill bit will pass through the exposed wellhead. In the case of the smaller, deeper drilling intervals, the drilled hole may require multiple trips because worn drill bits would have to be replaced before the desired depth of penetration is reached.
United States Patent Application Publication No. U.S. 2002/0092656 proposes another solution, which employs a selectively retrievable wear sleeve. The invention is a running tool having an enlarged diameter section fitted with a gripping mechanism designed to engage selectively the wear sleeve. The gripping mechanism is activated with hydrostatic pressure created using a plug, which engages a shoulder formed on the inner diameter of the running tool just below the gripping mechanism. A drawback of this design is that the plug blocks the ability to circulate the drilling fluid (mud) down hole. Thus, when the plug is dropped down the drill string, the plug then lands on a shoulder and the retrieval process begins. If, at this time, a well kick occurs and the blowout preventer (BOP) rams are closed, the operator is not permitted to circulate out the kick by pumping down the drill pipe and taking returns up through the Choke and Kill lines located below the blowout preventer (BOP) rams. Such a case of not being able to circulate out the kick can lead to a dangerous situation. A further drawback of this design is that the enlarged diameter section of the tool, which is designed to travel down hole with the rest of the drill string during the drilling operation, is large enough to interfere with the inner diameter of the casing string and thereby potentially damage the casing string.
The present invention is directed to a selectively retrievable wear bushing assembly that overcomes or at least minimizes some of the drawbacks of prior art wear sleeves.
The selectively retrievable wear bushing assembly according to the present invention comprises a bit sub adapted for coupling to the drill string, a drill string adapter removably coupled to the bit sub, and a wear bushing removably coupled to the drill string adapter and adapted for recoupling to the drill string adapter. The wear bushing according to the present invention is designed to stay in the wellhead when a drill bit and/or a bottom hole assembly is retrieved. The wear bushing or sleeve according to the present invention can be retrieved on the last trip out of the hole with the drill bit. With this design, the time savings of the “bit runable” feature can be enhanced with the improved risk factor of keeping the subsea or surface wellhead bore protected as much as possible while drill bits pass through the subsea or surface wellhead.
A complete understanding of the present disclosure and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which the leftmost significant digit(s) in the reference numerals denote(s) the first figure in which the respective reference numerals appear, wherein:
While the present invention is susceptible to various modifications and alternative forms, specific exemplary embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, alternatives, that fall within the spirit and scope of the invention as defined by the appended claims.
Illustrative embodiments of the invention are described in detail below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
The details of various illustrative embodiments of the present invention will now be described with reference to the figures. Turning to
The bit sub 112 is part of the drill string 114 and has a female thread 140 on an upper end of the bit sub 112 and a male thread 142 on a lower end of the bit sub 112. The bit sub 112 is formed with four J-lugs 120 equally spaced around an outer circumferential surface of the bit sub 112 at about a mid-section of the bit sub 112. The bit sub 112 also has a continuous stop shoulder 122 formed below the J-lugs 120.
The drill string adapter 116 is formed with four J-slots 124 equally spaced around an inner circumferential surface of the drill string adapter 116 proximate one end, as shown in
The wear bushing 118 is preferably formed of metal and generally cylindrical in shape. Indeed, the wear bushing 118 is similar in construction to conventional wear bushings used to protect the bores of surface and subsea wellheads. The wear bushing 118 has eight threaded pockets spaced around an outer circumferential surface of the wear bushing 118 that are designed to accommodate eight corresponding spring-loaded shear pin assemblies 136, two of which can be seen in
The operation of the selectively retrievable wear bushing assembly 110 will be now be described. First, the selectively retrievable wear bushing assembly 110 in accordance with various illustrative embodiments of the present invention is set up for initial installation of the wear bushing 118 within the bore of the wellhead 440. Setup of the selectively retrievable wear bushing assembly 110 includes the following steps: (1) installing four spring-loaded shear pin assemblies 132 in the pockets of the lower shoulder 328 only; (2) installing the eight spring-loaded shear pin assemblies 136 in the pockets of the wear bushing 118; and (3) assembling the bit sub 112, the drill string adapter 116, and the wear bushing 118, which this includes fitting the J-lugs 120 on the bit sub 112 into the corresponding J-slots 124 in the drill string adapter 116, rotationally and axially fixing the drill string adapter 116 to the bit sub 112 with the eight shear pins 126, and locking the shear pins of the four spring-loaded shear pin assemblies 132 in the pockets of the lower shoulder 328 into the corresponding recesses 346 formed in the wear bushing 118.
Next, the drill string 114 is lowered into the subsea or surface wellhead 440 and the wear bushing 118 lands on the casing hanger or landing shoulder 438 in the wellhead 440, as shown in
If the drill bit 100 becomes worn or damaged before the final depth is reached, the drill bit 100 must be tripped out of the hole. As the bit sub 112 makes contact with the drill string adapter 116, the bit sub 112 contacts a solid shoulder and/or the J-lugs 120 make contact with a solid shoulder. Continued pull on the drill string 114 will shear the four spring-loaded shear pins 132, leaving the wear bushing 118 in place and retrieving the drill string adapter 116 back to the surface, as shown in
If it is decided that on the next drill bit 100 run the wear bushing 118 must be retrieved, then eight heavier duty spring-loaded shear pins 334 are added to the second level of shear pin pockets, in the upper shoulder 330 on the drill string adapter 116 along with the original four spring-loaded shear pins 132 on the first level, in the lower shoulder 328, as shown in
If there are any intermediate drill bit 100 trips where it is intended to leave the wear bushing 118 in the wellhead 440, the drill string adapter 116 is simply not installed on the drill string 114.
In various illustrative embodiments, as shown in
The method 1200 may also comprise lowering the drill string into a wellhead, as indicated at 1220, and coupling the wear bushing removably to at least one of a casing hanger in the wellhead and the wellhead using at least a portion of the second plurality of spring-loaded shear pin assemblies in the wear bushing, as indicated at 1230. For example, as described above, the drill string 114 may be lowered into the wellhead 440, and the wear bushing 118 may be removably coupled to at least one of the casing hanger 438 in the wellhead 440 and the wellhead 440, using at least a portion of the second plurality of spring-loaded shear pin assemblies 136 in the wear bushing 118.
The method 1200 may also comprise removing the coupling of the drill string adapter removably coupled to the bit sub, allowing the bit sub to trip down hole with at least one of a drill bit and a bottom hole assembly, as indicated at 1240. For example, as described above, the coupling of the drill string adapter 116 removably coupled to the bit sub 112 may be removed, allowing the bit sub 112 to trip down hole with at least one of the drill bit 100 and/or the bottom hole assembly 100.
Therefore, the various illustrative embodiments of the present invention enabled and described herein are well adapted to carry out the objects and attain the ends and advantages mentioned, as well as those that are inherent therein. While the present invention has been depicted, described, and defined by reference to exemplary embodiments of the present invention, such a reference does not imply any limitation of the present invention, and no such limitation is to be inferred. The present invention is capable of considerable modification, alteration, and equivalency in form and function as will occur to those of ordinary skill in the pertinent arts having the benefit of this disclosure. The depicted and described illustrative embodiments of the present invention are exemplary only and are not exhaustive of the scope of the present invention. Consequently, the present invention is intended to be limited only by the spirit and scope of the appended claims, giving full cognizance to equivalents in all respects.
The particular embodiments disclosed above are illustrative only, as the present invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present invention. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood as referring to the power set (the set of all subsets) of the respective range of values, in the sense of Georg Cantor. Accordingly, the protection sought herein is as set forth in the claims below.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/505,012, filed Sep. 22, 2003, which is herein incorporated by reference in its entirely as if set forth below.
Number | Date | Country | |
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60505012 | Sep 2003 | US |