The present disclosure relates to systems and methods for removing components of a subsea well, particularly methods included in the abandonment of a subsea well including a wellhead, a surface conductor and multiple downhole casing strings.
Conventional practices used in the abandonment of a subsea hydrocarbon producing, injection or disposal wells include cutting and removing individual portions or components of the subsea well in separate pieces. This is illustrated in
Conventional practices involving the multiple drill string trips required to remove each of the individual well casings 18 and components separately are time-consuming and costly. The multiple lowering and raising of the drill pipe 7 and cutter 3, and multiple trips with the spear assembly 22 also create greater potential for safety incidents, equipment downtime and weather delays.
An improved process for subsea well abandonment, subsea wellhead recovery and/or subsea well plugging that avoids the aforementioned problems would be desirable.
In one aspect, a method is provided for removing components of a subsea well having a wellhead located at or on a seabed and multiple well casings connected to the wellhead and penetrating the seabed. The method includes lowering a utility line through the water column from a floating vessel. The utility line has an upper end connected to an actuator on the floating vessel and a lower end connected to a cutting tool. The utility line is lowered until the cutting tool is positioned inside the subsea well at a predetermined cut location. The cutting tool is used to sever the multiple well casings at the predetermined cut location such that the multiple well casings are completely severed concurrently. The utility line and the cutting tool are retrieved to the floating vessel. The wellhead and the severed multiple well casings are raised together from the seabed to the floating vessel as a single assembly.
In another aspect, the wellhead and the severed multiple well casings are raised out of the seabed to a predetermined height above the seabed at the well location as a single assembly, and meanwhile a cement dispensing line connected to a cement source on the floating vessel is lowered until the lower end of the cement dispensing line is positioned at the subsea well location above the abandoned subsea well casing strings. Cement is dispensed through the cement dispensing line sufficiently to form a cement plug in the abandoned subsea well casing strings and above the seabed, proximate the subsea well location. The cement dispensing line is then retrieved to the floating vessel, and the wellhead and the severed multiple well casings are raised together from the predetermined height above the subsea well location to the floating vessel as a single assembly.
In yet another aspect, a system is provided for removing components of a subsea well having a wellhead located at or on a seabed and multiple well casings connected to the wellhead and penetrating the seabed. The system includes a floating vessel and a cutting mechanism deployable from the floating vessel. The cutting mechanism includes an actuator located on the floating vessel, a utility line having an upper end connected to the actuator and a lower end, and a cutting tool capable of cutting the multiple well casings. The cutting tool is connected to the lower end of the utility line. The utility line and cutting tool are capable of being lowered from the floating vessel until the cutting tool is positioned at a predetermined cut location in the subsea well.
These and other objects, features and advantages of the present invention will become better understood with reference to the following description, appended claims and accompanying drawings. The drawings are not considered limiting of the scope of the appended claims. The elements shown in the drawings are not necessarily to scale. Reference numerals designate like or corresponding, but not necessarily identical, elements.
Once a subsea well 4 is decommissioned and plugged, typically with cement or resin (referred to interchangeably as “cement”), it may be required to abandon the well by removal of the wells components on and below the seabed surface 1. This involves removing the casing strings 18, the surface conductor 18o and the wellhead 8, as well as optional additional equipment connected to the top of the wellhead. Throughout the present disclosure, the terms “casing,” “well casing,” and “casing string” may be used interchangeably to refer to pipe inserted into the seabed to drill and construct a well. Casings 18 are typically cemented in place and serve a variety of well-known purposes during the life cycle of a subsea well. Multiple casings 18 are typically inserted into the wellbore during well construction, beginning with the largest diameter or outermost diameter casing 18o, also known as the structural casing, or conductor. Casings having incrementally smaller diameters are subsequently inserted into the largest diameter casing, also referred to herein as the “conductor” 18o In one illustrative example, a 30 inch diameter conductor 18o can be first inserted into the seabed 1 by drilling or pile driving, followed by a 20 inch diameter casing 18o-1, a 13⅜ inch diameter casing 18i+1 and a 9⅝ inch diameter casing 18i (the innermost diameter casing), so that the four concentric casings 18 are cemented in place forming the wellbore, each successively going deeper below the seabed surface 1.
A wellhead 8 is connected to the top of the multiple casings 18, typically above the seabed surface 1 (i.e. the “mudline”), but sometimes at the seabed surface or even below the surface in an excavation known as a “glory hole.” In one illustrative example, the wellhead 8 has a low-pressure wellhead housing 8A attached to the 30 inch diameter casing 18o and a high-pressure wellhead housing 8B attached to the 20 inch diameter casing 18o-1. Additional equipment can be connected to the top of the wellhead. For instance, such additional equipment can include, but is not limited to, a blowout preventer 9 and associated equipment, a subsea tree and/or a shut off system that may include shut off valves. Other equipment can be present as would be appreciated by those of ordinary skill in the art.
A system 100 and methods for removing components of the subsea well will now be described in more detail. As shown in
The multiple casings 18 and the wellhead 8 can be severed and raised together on to the floating vessel 2 in one operation using methods described herein. The system 100 utilizes a cutting mechanism for cutting through the multiple casings 18 in a single operation. The cutting mechanism includes an actuator 12 located on the floating vessel 2. A utility line 14 is connected to the actuator 12 at an upper end and to a cutting tool 16 at a lower end.
In one embodiment, a method for removing components of the subsea well 4 includes lowering the utility line 14 and cutting tool 16 from the floating vessel 2 while the utility line is connected to the actuator 12 until the cutting tool 16 is positioned at a predetermined cut location in the subsea well 4 at a depth below the seabed 1. The cutting tool 16 severs the multiple well casings 18 completely and concurrently in one operation below the seabed surface, utilizing an energy source either in the tool 16 or on the floating vessel 2. Once the multiple well casings 18 are severed, two separate bodies are formed, one including the well casings to be abandoned below the cut 17, and one including the severed well casings and wellhead to be retrieved above the cut 17. The utility line 14 and the cutting tool 16 are retrieved to the floating vessel 2. The wellhead 8 and the severed multiple well casings 18 can then be raised together from the seabed to the floating vessel 2 as a single severed assembly.
The cutting tool 16 of the cutting mechanism can take any of a variety of forms. In one embodiment, as shown in
In one embodiment, as shown in
In one embodiment, not shown, the cutting tool 16 can be one or more directionally controlled explosives or shaped charges, e.g. fast-burning pyrotechnic shaped charges. The cutting tool 16 is capable of generating a plasma that can sever the multiple well casings 18.
In one embodiment, not shown, the cutting tool is a chemical cutter 16. The chemical cutter 16 directs chemicals capable of dissolving steel from a reservoir inside the tool 16, through openings in the tool and into contact with the multiple casings 18 to be cut where the chemicals can dissolve the multiple casings 18 and effect a cut there through. Once the cutting tool 16 is positioned in the predetermined cut location within the multiple well casings 18, the cutting equipment or mechanism 16 can be directed outwards towards the innermost well casing to cut the multiple casings 18. In one embodiment, the multiple well casings 18 are severed, i.e., completely disconnected at the cut location, forming the cut 17.
In one embodiment, the multiple well casings 18 are severed in a single round trip. By “single round trip” is meant one occurrence of running the cutting tool 16 into and out of the well 4 from the floating vessel 2.
In one embodiment, as shown in
In one embodiment, the elongated tensile element 20 includes a spear grapple 22 capable of engaging an internal surface of the multiple well casings 18. The spear grapple 22 expands to hold the interior of the well casings 18 as would be appreciated by one of ordinary skill in the art. In this case, the elongated tensile element 20 with the spear grapple 22 has a tensile strength sufficient to carry the utility line 14, the cutting tool 16, the wellhead 8 and the multiple well casings 18 in tension so that the utility line 14, cutting tool 16, wellhead 8 and severed multiple casings 18 can be raised together from the well location to the floating vessel 2 using the elongated tensile element 20 with spear grapple 22.
In one embodiment, as shown in
In one embodiment, as shown in
According to one method, the lifting mechanism 24 is used to lower the conduit 28 from the floating vessel 2 such that the conduit 28 is positioned generally vertically over the subsea well 4. The lower end of the conduit 28 is then connected to the wellhead 8 using any suitable means. At this point, the utility line 14 and cutting tool 16 can be lowered to the predetermined cut location as described above through the conduit 28. The severing cut can be made through the multiple casings 18. The utility line 14 and cutting tool 16 are then retrieved back up to the floating vessel 2 through the conduit 28. At this point, the lifting mechanism 24 is used to raise the conduit 28 while still connected to the wellhead 8 and the severed multiple casings 18. In this way, all of the wellhead 8 and severed casings 18 can be raised concurrently to the floating vessel 2. In some embodiments, the utility line 14 and cutting tool 16 can be lowered and retrieved through the conduit 28 using the lifting mechanism 24.
In some embodiments, additional equipment connected to the wellhead 8 may be present. Such additional equipment can include, but is not limited to, a blowout preventer 9 and associated equipment, a subsea tree and/or a shut off system that may include shut off valves. In this case, the lower end of the conduit 28 is connected to the wellhead by way of the additional equipment connected to the wellhead 8. In other words, the lower end of the conduit 28 is connected to whatever additional equipment is present. In such case, the additional equipment is raised together with the conduit 28, the wellhead 8 and the severed multiple well casings 18 to the floating vessel 2.
In some embodiments, it may be advantageous for the conduit 28 to be made up of a number of conduit segments 28a connected by conduit joints 28b. For example, this can be a known type of segmented joined pipe, e.g., having 50 foot segments. In this case, when the conduit 28, wellhead 8 and severed multiple well casings 18 are raised together to the floating vessel 2 as a single assembly, the assembly can then be disassembled by individually disconnecting and placing each uppermost conduit segment from the raised assembly on the floating vessel 2 until all of the conduit segments 28a have been disconnected and placed on the floating vessel 2. The conduit segments 28a can be stowed or secured. Prior to disconnecting each uppermost conduit segment from the raised assembly, the uppermost conduit segment is supported and the tension is released. What remains is a smaller assembly including the wellhead 8 connected to the severed multiple well casings 18. This smaller assembly can then be placed on the floating vessel 2.
In one embodiment, a cement source 30 is provided on the floating vessel 2, connected to a cement dispensing line 32 capable of being lowered to deliver cement to the subsea well 4, i.e. in the abandoned subsea well casing strings remaining below the seabed. By “cement” herein is meant any cement, resin or other material capable of plugging or isolating a wellbore. The cement dispensing line 32 can be a coiled tubing line or a jointed pipe, or any other suitable means for dispensing cement known to those of ordinary skill in the art. In one embodiment, as described above, a method includes lowering the utility line 14 and cutting tool 16 from the floating vessel 2 while the utility line is connected to the actuator 12 until the cutting tool 16 is positioned at a predetermined cut location in the subsea well 4 at a depth below the seabed 1. The cutting tool 16 severs the multiple well casings 18 completely and concurrently in one operation below the seabed surface. The utility line 14 and the cutting tool 16 are then retrieved to the floating vessel 2. The wellhead 8 and the severed multiple well casings 18 can then be raised together from the seabed to a predetermined height above the seabed 1 and the subsea well 4 as a single severed assembly. At this point, the cement dispensing line 32 is lowered until the lower end of the cement dispensing line 32 is positioned in the subsea well 4 at a desired location in the abandoned subsea well casing strings for dispensing cement. Cement is dispensed through the cement dispensing line 32 proximate the subsea well 4 sufficiently to form a cement plug 34 at or below the seabed 1. The cement dispensing line 32 can then be retrieved to the floating vessel 2. Finally, the wellhead 8 and the severed multiple well casings 18 can then be raised together from the predetermined height above the subsea well 4 to the floating vessel 2 as a single assembly. In this way, the well 4 can be efficiently plugged at the seabed 1 as the well components are removed.
In one embodiment, as shown in
In one embodiment, as shown in
In some embodiments, it may be advantageous for multiple wells to be arranged with the use of structural templates on the seabed. In such cases, multiple wellheads 8 and sets of multiple well casings 18 can be connected to each other via the frame of the template. The multiple wellheads 8 and sets of multiple well casings 18 (and optional additional equipment) can in some cases be removed using the systems and methods disclosed herein such that the multiple wellheads 8 and sets of multiple well casings 18 are raised as one assembly with the structural template.
According to embodiments disclosed herein, components of a subsea well can be removed using a method that is significantly simpler, safer, faster, less costly and more efficient than known methods.
It should be noted that only the components relevant to the disclosure are shown in the figures, and that many other components normally part of a system for retrieving components of a subsea well, for abandoning and or plugging a subsea well or of the subsea well itself are not shown for simplicity.
For the purposes of this specification and appended claims, unless otherwise indicated, all numbers expressing quantities, percentages or proportions, and other numerical values used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by the present invention. It is noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the,” include plural references unless expressly and unequivocally limited to one referent.
Unless otherwise specified, the recitation of a genus of elements, materials or other components, from which an individual component or mixture of components can be selected, is intended to include all possible sub-generic combinations of the listed components and mixtures thereof. Also, “comprise,” “include” and its variants, are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that may also be useful in the materials, compositions, methods and systems of this invention.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope is defined by the claims, and can include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. All citations referred herein are expressly incorporated herein by reference.
From the above description, those skilled in the art will perceive improvements, changes and modifications, which are intended to be covered by the appended claims.
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