Patent Grant
7367403
1. Field of the Invention
The present invention relates to a method and apparatus for installing pipe and a control line in a well. More specifically, the present invention relates to a method and apparatus for securing a control line to a string of pipe as the pipe is being made up and run into a well.
2. Background of the Related Art
Wells are generally drilled deep into the earth's crust to establish fluid communication between the surface and sub-surface geologic formations containing naturally occurring hydrocarbon deposits, such as oil or gas. A well provides a fluid conduit allowing sub surface deposits of oil and gas to be produced at the surface. It is common for a drilled borehole to penetrate a plurality of formations. Formations may contain hydrocarbons or other fluids of different compositions and at different pressures than the hydrocarbons and fluids contained in other formations. Formations may also contain water (aquifers), brine, hydrogen sulfide gas and other materials that may be undesirable.
A drilled borehole is completed into a well by circulating cement into the annulus between the wall of the drilled borehole and the outer surface of a pipe string called casing to form a cement liner. The cement hardens to isolate penetrated formations from flowing into the well and to the surface. Once a borehole is drilled and completed, decisions are made as to which of the penetrated formations to selectively produce. A perforating tool is used to cut a hole through the casing and the cement liner to selectively establish fluid communication between the targeted formation and the surface. Once a formation is perforated, the well may be produced to (pressure) depletion, until it “waters out” by increasing water content, or both. Once a formation is depleted or watered-out, it may be desirable to intervene in the well to alter or isolate the formation so that other formations may be perforated and produced without the production being burdened by fluid losses into depleted formations or by water intrusion from watered-out formations. Intervention is generally performed by wire line unit (WLU) work over, coiled tubing unit (CTU) work over or by a conventional work over rig. A WLU or CTU work over is performed by lowering an instrument or tool into the well using a specialized rig having a long spooled wire line or tubing for connecting or controlling the downhole instrument or tool from the surface. The conventional work over rig generally requires that all production tubing be removed from the well so that tools or instruments may be run into the well on a work string.
If the depleted or watered-out formations are lower in the well than the formation, the depleted or watered-out formation may be isolated from the well by using one of the three conventional intervention techniques described above. In a conventional intervention work over, material such as cement or sand may be deposited into the bottom of the well to form a plug to seal off the perforations in the depleted or watered-out formation, and to thereby isolate the depleted or watered-out formation from the new formation located above. Once a sand or cement plug is in place, another work over may be required to later remove it. Packers are tools that can be installed in a well during a work over to isolate depleted or watered-out formations.
Conventional workers to install or remove downhole plugs or packers are unnecessary if formations can be isolated or remotely controlled using downhole devices. Downhole devices, such as valves or chokes, may be installed in a pipe string as it is being made up and run into a well to enable the selective production, isolation or flow-control of fluids residing in the formations penetrated by a well. Surface-controlled downhole valves or chokes require continuous control lines that extend from the surface through the well to the depth at which the downhole devices are installed in the pipe string. Control lines must be installed as the pipe string is being made up and run into the well.
Continuous control lines are generally stored and transported to the rig location on spools. The spools of control line are generally mounted on a horizontal axle on or near the rig floor so that the control line may be easily and smoothly “fed” to and fastened to the pipe string by reeling of the spool.
Oil and gas wells may be equipped with control lines for electrically, hydraulically or optically linking various downhole devices to the surface. Control lines may be used to receive data from downhole instruments and to selectively operate from the surface downhole devices such as valves, switches, sensors, relays or other devices. One use of control lines is to open, close or adjust downhole valves in order to selectively produce or isolate formations at locations deep in the well. A control line may transmit downhole data to the surface and communicate commands to the same or other downhole devices. The control line may comprise conductive wires or cables for electrically controlling downhole devices, fibers for optically controlling downhole devices, or small-diameter tubing for hydraulically controlling downhole devices. Control lines are generally of a small diameter relative to the diameter of the pipe string to which they are secured, and are generally between 0.5 and 6 cm in diameter. A plurality of control lines may be aggregated into a single umbilical that may exceed 10 cm in diameter. Control lines are generally secured along the length of the outer surface of a pipe string, generally parallel to the center axis of the bore of the pipe string. Continuous control lines are secured to the pipe string and installed in the well as joints of metal pipe are made up into a pipe string and run into a well. Control lines secured to pipe string are subject to being damaged and made useless if pinched or crushed by pipe slips used to grip and support the pipe string, such as during the process of making up the pipe string and running it into the well.
A spider is a device used on a drilling or work over rig for gripping and supporting the pipe string as joints of pipe are made up into the pipe string. The spider has an interior bore, generally aligned with the pipe string, through which the pipe string passes. The spider has a circumference arrangement of radially inwardly movable pipe slips disposed around the pipe string and within the internal bore. The pipe slips move radially inwardly to grip the outer surface of the pipe string and support the pipe string in the well when the pipe string is not supported by the elevator. It is important that the pipe slips in the spider uniformly engage and grip the pipe string in order to prevent crushing or damaging the pipe making up the pipe string. Each pipe slip within the internal bore of the spider applies a force radially inwardly against the outer surface of the pipe string. It is important that the pipe slips are concave around the pipe in order to contact the pipe over as large an interval as possible in order to minimize the localized stress imposed on the pipe by the pipe slips.
If a control line becomes pinched or trapped between the pipe slips of the spider and the outer surface of the pipe string, or if a control line is pinched between adjacent segments of the pipe slips as they move around and radially inwardly to contact the pipe string, the control line may be damaged and the capacity to receive data from downhole instruments or surface control of downhole devices may be lost or impaired. It is important that the method used to secure control lines to the pipe string be designed to prevent control line damage.
In many installations, it is desirable to secure multiple control lines along the length of the outer surface of the pipe string in order to allow data to be gathered from or surface control of multiple downhole devices. For example, but not by way of limitation, tools and other control valves or instruments may be made up into the pipe at various depths along the pipe string, and the number of control lines at any given depth depends on the depth and the configuration of the pipe string. Multiple control lines are especially useful in deep offshore wells that penetrate multiple formations. Existing designs may require four or more control lines for each string of pipe that is run into the well. Multiple control lines are most efficiently made, stored, transported and installed in bundles comprising control lines coupled together in a generally parallel, side-by-side configuration. Multiple control lines may require larger clamps to secure the bundle along the length of the outer surface of the pipe string.
A method has been developed for securing control lines to a pipe string as the pipe string is made up and run into a well. U.S. Pat. No. 6,131,664 (“the '664 Patent”) is directed to using an elevated work platform constructed on the rig floor. The work platform is equipped with hydraulic tongs for making up the pipe string, and an opening above the well in the floor of the work platform that is generally aligned with the well and with an opening in the rig floor beneath the work platform. The work platform disclosed in the '664 Patent supports the spider and, when the pipe string is supported by the spider, the work platform must support the weight of entire pipe string. This requires the work platform to be built to support 200 tons or more. The work platform described in the '664 Patent must also provide sufficient work area for rig personnel to use the tongs to make up joints of pipe that are lowered and aligned in position above the pipe string to be threadably made up into the pipe string.
The '664 Patent discloses that control lines are provided to the pipe string from a separate work area maintained on the rig floor and below the level of the work platform. The control lines are stored on and continuously provided from spools that may be located lateral to the pipe string and adjacent to the opening in the rig floor. Clamps are installed by rig personnel working in the work area beneath the work platform to secure the control lines to the pipe string. One problem with the method and apparatus for installing control lines described in the '664 Patent is that the control lines and spools themselves may take up a significant area of the rig floor and present an obstacle to various operations.
What is needed is a method of safely securing control lines to a pipe string as the pipe string is being made up and run into a well. What is needed is a method and an apparatus that enables the safe and inexpensive installation of control lines that are being secured to a pipe string as it is made up and run into a well. What is needed is an apparatus for and a method of securing control lines along the length of a pipe string as it is being made up and run in a well that provides protection of control line while facilitating the addition and removal of control lines.
The present invention utilizes a spider that is supported on a table elevated above a rig floor and one or more control line guides for directing control lines through a passage within the spider. The spider comprises a spider body and a plurality of pipe-gripping members, such as slips, received within a tapered bowl within the spider body. The one or more control line guides may include shaped guides, roller guides, slides, cable funnels and the like, either alone or in combination, to position and direct the pathway of control lines.
In one embodiment, the spider body may receive an elongated control line sleeve adapted for being received within a body for containment and protection of one or more control lines from pinching or crushing between slips, or between the slips and the pipe string secured by the slips. The elongated control line sleeve has an opening at each end with one opening disposed generally upwardly and the other opening disposed generally downwardly. The control line sleeve may also assist in directing and positioning the control lines along the pipe for coupling thereto. Optionally, the sleeve may be secured to any structural member, including but not limited to the slip or slips and the spider body, and suspended or supported within the spider. Alternatively, the sleeve may be secured directly to or within the spider, the spider door or the spider body, such as in the bowl of the spider or in or on the spider door. The sleeve must also be selectively operable, such as with a slot in one side, in order to receive a control line or to allow withdrawal of a control line.
In another embodiment, the spider components form a control line passage that is isolated from the slips and the pipe. Such a passage may be formed by a control line gate securable to the spider body or to the spider door, or both, to form the passage between the control line gate and the spider body or spider door. If the control line gate is hinged to a spider component, then the control line is positioned in, or removed from, the passage by opening the spider door and the control line gate. The spider is also opened in order for the spider to be received around or removed from a pipe string. Still further, while the control line passage itself will prevent contact between the control line and the slips, the control line passage may further include a sleeve, which may comprise two or more parts, to reduce abrasion to the sides of the control line. The control line passage and any sleeve used in cooperation with the passage must be selectively operable in order to receive a control line or to allow withdrawal of a control line. With a pipe string positioned within the spider, the opening of the passage and sleeve will typically require supporting the pipe string from the elevator so that the spider can be released and the spider door can be opened. The elevated table must then also include a causable slot extending from the spider door some distance away from the spider so that opening the slot provides sufficient clearance for the spider door to open. Consequently, with the slot open and the spider door open, a control line can be positioned within, or removed from, the spider body for running control line or removing control line. It is not necessary for the slot to extend to the edge of the elevated table, but a slot extending to the edge will facilitate installation of the table around or removal of the table from an existing pipe string.
In a still further embodiment, the control line gate may be slidable or selectively positionable between the pipe string and at least one of the spider door or the spider body so that the control lines are retained within the control line passage. Therefore, the control line gate is positionable to form the control line passage even with the pipe string extending through the spider and with the spider door closed. This embodiment with selective position ability of the control line gate provides a major operational advantage in that a control line can be run through the spider and control lines may be added to or removed from the passage, at all times protected from the slips and the pipe string without having to open the spider door. Accordingly, the control line gate may be installed, removed and positioned while the pipe string is supported by either the elevator or the spider.
The slidable or selectively positionable control line gate is preferably positioned by inserting it with one side facing the pipe string and another side facing the control lines and at least one of the spider door or the spider body. The control line gate is preferably also inserted from the top. After insertion, the control line gate is secured in position. The control line gate is preferably securable to the spider body, the spider door, or a combination thereof Alternatively, the control line gate may be secured or suspended in position from some other structure, such as an assembly securing the control line guides. In a most preferred embodiment, the control line gate has two edges that are slidably received in a pair of slots formed in or on the inner face of one of the spider door or the spider body, or a combination thereof, so that the control line gate can be lifted out of the slots for receiving an additional control line into the passage and then reinstalled into the slots with all the control lines retained within the passage. As used herein, a “slot” may refer to a slot, track, guide, ridge or any feature that facilitates sliding engagement and coupling.
The control lines are fed to the well from generally above the spider. The control lines are routed from a spool and engage one or more guides adapted for being roll ably secured to the spider body. The roller guides direct the control line into an upwardly disposed opening in the spider, through a passageway that is unobstructed by the slips or the pipe string, and along the length of the pipe string into the borehole. If a control line protective sleeve is being used in association with the spider, then the roller guides direct the control line into an upwardly disposed open end of protective sleeve, through the elongated sleeve and out of the downwardly disposed open end of the sleeve. The exposed portion of the pipe string and control line between the elevated table and the rig floor provides a clamping zone where clamps can be installed to secure the control lines to the exterior surface of the pipe string.
The method and apparatus of the present invention allows one or more control lines to be secured along the length of a pipe string as the pipe string is being made up and run into a well. The method and apparatus of the present invention allows control lines to be secured to a pipe string above the rig floor and below the spider that is supported by an elevated work platform strong enough to support the weight of the pipe string. The method and apparatus of the present invention improves rig safety and operation by top-feeding the control line through the spider and thereby preventing impairment of escape routes on the rig floor.
The elevated table supports the spider at a generally fixed distance above the rig floor to permit rig personnel access to the outer surface of the portion of the pipe string located below the elevated spider and above the rig floor. Access to the outer portion of the pipe string below the spider and above the rig floor permits rig personnel to install fasteners to secure control lines to the pipe string.
According to the presently preferred embodiment, a control line is provided to the pipe string from above the spider. Preferably, the spool may be positioned at a remote location on the rig floor and the control line passed up and over an elevated sheave or pulley so as to come downwardly to the spider. The spool may be rotatably mounted in a fixed location that is a sufficient distance above the spider and in sufficient proximity of the axial center line of the pipe string to provide a favorable approach angle. The control line should not be bent or deflected at an angle exceeding manufacturer recommendations as the control line is fed downwardly to and into the spider. Preferably, the angle formed between the control line and the pipe string will not exceed about 60 degrees, and more preferably, will not exceed about 45 degrees. Rollers, pulleys or sheaves may be used to limit localized bending of the control line. The control line may be routed or threaded over a roller guide secured above the spider to strategically direct the top-fed control line from the spool through the spider and along the length of the pipe string so that the control line can be secured to the pipe string. The control line is secured to the pipe string with fasteners, such as clamps, sleeves, bands, clips or other fasteners at a position beneath the elevated spider, but in the adjacent area of the rig floor. The control line may be secured along the outer surface of the pipe string at any radial or circumference location of the pipe string below the spider, but the control line is preferably secured along the outer surface of the pipe string at a radial or circumference location that is generally aligned with the passage through the spider. Accordingly, the control line passes through the spider without being damaged by the pipe slips within the internal bore of the spider.
It should be recognized that any number of control lines may be supplied to the pipe string in accordance with the present invention. Multiple control lines may be supplied as a bundle or they may be supplied separately.
Advantageously, the fasteners or clamps used to secure control lines to the pipe string may be designed independent of restrictions imposed by the size or configuration of the internal bore of the spider. The fasteners may be secured at any desired spacing along the length of the pipe string in the clamping zone below the table and above the rig floor, such as one fastener per joint of pipe. It is specifically anticipated that multiple fasteners may be used along the length of a single joint of pipe or single stand of pipe, or that entire joints or stands of pipe may be skipped.
In a still further embodiment, the invention provides a method comprising the steps of securing an instrument to a pipe string, wherein the instrument is adapted to include a control line extending therefrom, lowering the pipe string so that the instrument and control line pass through a spider having a plurality of gripping members, and positioning a control line gate to separate the control line from the gripping members. Preferably, the control line gate also separates the control line from the pipe string. Most preferably, the steps can be repeated to receive a plurality of control lines as additional instruments or downhole devices are made up into the pipe string.
The foregoing, as well as other, objects, features, and advantages of the present invention will be more fully appreciated and understood by reference to the following drawings, specification and claims.
The control line may be supplied from a spool located on the rig floor or elsewhere, so long as the control line is directed angularly downward to the spider 10, such as by passing the control line from a spool upwardly over one or more pulleys or sheaves 50 and then directing the control line angularly downward to the spider.
In a preferred embodiment, the passage includes a sleeve 40 that extends along the slips 24 (see
In the embodiment of
It should be noted that a variety of tools or devices may be used in place of or in cooperation with the roller guides 42 to bend and direct the control lines 31 to their intended position for being secured to the pipe string 14 and run into the well. Persons skilled in the art will appreciate that a control line guide may include the use of shaped guides, roller guides, cable funnels and the like, either alone or in combination, to position and configure control lines.
In
In
In one embodiment, the opening between the rig floor 6 and the table elevated spider is approximately 1.5 to 2 meters (shown in
The fastener 34 used to secure the control lines 31 to the pipe string 14 may comprise a clamp, clip, spring, wire, strap, band or any fastener or other device that is suitable for securing a control line 31 to the outer surface of the pipe string 14. Typically, the inside of the fastener 34 is adapted to fit the cylindrical outer surface of the pipe string 14 to which it is secured, and may be configured with one or more “pockets,” or circumferentially upset portions, to accommodate and to secure one or more control lines 31 from circumference and/or axial movement relative to the outer surface of the pipe string 14 to which the control lines 31 are secured. Another mechanical fastener, such as a screw, clip, or a bolt and nut, may be employed to close and tighten the fastener 34 in place on the pipe string 14.
After the fastener 34 is applied and the control line 31 is secured to the pipe string 14, the pipe string 14 and control line 31 are lowered into the well 8 through the opening 18 in the rig floor 6. Additional fasteners 34 may be added with each new joint of pipe that is added to the pipe string 14 or, in the alternative, several joints of pipe may be made up into the pipe string 14 before an additional fastener 34 is installed to secure the control line 31 to the pipe string 14. Furthermore, the fastener may be position around the pipe, around the coupling, or some combination thereof.
Optionally, the control line sheave 50 and/or the control line guides 42 may be adapted for applying a tensioning force to the control lines 31 and to prevent inadvertent over-reeling from the control line spools (not shown).
When the control line 31 comprises a bundle of control lines secured one to the others, the control line bundle may be more stiff and inflexible than a single control line 31. The guides 42 may be adapted to assist in bending and redirecting the control line bundle into a parallel position longitudinally along the outer surface of the pipe string 14 suitable for application of a fastener for securing the bundle to the pipe string 14. It should be recognized that any number of rollers may be used, such as an array of rollers in series forming an arc having an effective diameter that prevents the control line from becoming stressed from sharp bends.
In accordance with the present invention, there are three primary methods for positioning a control line within the control line passage that extends through the spider. In all three methods of operation, a section of pipe having an associated instrument (i.e., a “downhole device”) is secured to the pipe string and lowered so that the point 72 for terminating a control line to the downhole device is below the spider 11. The control line and the terminating point on the downhole device may be connected using any available coupling, such as a threaded coupling. Furthermore, the control line may be of any available type, such as an electrical line or fluid tubing.
In a first method for positioning the control line within the passage, the control line has been connected or terminated to the downhole device prior to lowering the terminating point 72 through the spider. The downhole device and pipe string are supported by a lift elevator (not shown) and lowered so that a control line associated with the downhole device is positioned near the spider. The control line gate 64 is vertically slidably removed upwardly out of the slots 70 to provide more room for the control line to pass through the spider. While the pipe gripping members, such as slips, of the spider are disengaged as the pipe is lowered, it may be desirable to generally radially align the terminating point and the control line with the control line passage so that the control line is not damaged as it initially passes through the spider. Accordingly, as the pipe string is lowered further, the control line is drawn through the spider and lies along the surface of the downhole device or pipe string. After the terminating point has passed completely through the spider, the control line 31 is drawn generally radially outwardly toward the inner surface 66. Next, the control line gate 64 is vertically slidably replaced downwardly into the slots 70 to form the control passage around the control line. Once the control line gate is securely in position, normal pipe running operations may continue. It should be noted that to avoid pinching the control line, it is important to position all control lines within the control line passage at any time that the gripping members of the spider are being set to grip the pipe. Furthermore, it is preferable to position all control lines within the control line passage as soon as the control line extends through the spider.
The second method includes running the terminating point of the downhole device through the spider and into the access area below the spider, then threading the end of the control line through the control line passage so that the control line can be terminated to the downhole device in the access area below the spider. In this manner, the control line gate does not require opening or removal.
The third method for positioning the control line within the passage includes running the terminating point of the downhole device through the spider and into the access area below the spider, then terminating the end of the control line to the downhole device with the control line extending laterally from a spool. In order to position the control line within the control line passage, it is necessary to open the slot 55 adjacent the spider 11, open the spider door 52, and remove the control line gate 64 (or open the control line gate 54). After moving the control line into the control line passage, the control line gate is replaced or closed, the spider door is shut and the slot is closed. The control line is then properly secured so that normal pipe running operation can continue.
Therefore, as discussed above, one exemplary method would include the following steps. First, the control line gate 64 is removed as indicated by the upward arrow 74. Second, the pipe string is advanced downwardly so that the point of connection 72 of the control line is below the spider 11, as shown. Next, the control line is positioned into the control line passage by drawing the control line in the direction of the outward arrow 76. Finally, the control line gate 64 is reinstalled as indicated by the downward arrow 78. The pipe string may then be run further into the well and the spider set in preparation for adding additional pipe sections or stands to the pipe string. The control line may be clamped to the pipe string below the spider at appropriate points according to the previous discussion.
The terms “comprising,” “including,” and “having,” as used in the claims and specification herein, shall indicate an open group that may include other elements not specified. The term “consisting essentially of,” as used in the claims and specification herein, shall indicate a partially open group that may include other elements not specified, so long as those other elements do not materially alter the basic and novel characteristics of the claimed invention. The terms “a,” “an,” and the singular forms of words shall be taken to include the plural form of the same words, such that the terms mean that one or more of something is provided. For example, the phrase “an assembly having a control line guide” should be read to describe an assembly having one or more control line guide. The term “one” or “single” shall be used to indicate that one and only one of something is intended. Similarly, other specific integer values, such as “two,” are used when a specific number of things is intended. The terms “preferably,” “preferred,” “prefer,” “optionally,” “may,” and similar terms are used in the specification to indicate that an item, condition or step being referred to is an optional (not required) feature of the invention.
While a preferred form of the present invention has been described herein, various modifications of the apparatus and method of the invention may be made without departing from the spirit and scope of the invention, which is more fully defined in the following claims.
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