The present invention relates to techniques for replacing equipment at a wellsite. More specifically, the invention relates to techniques for replacing equipment, such as blowout preventers (BOPs), strippers, and/or components thereof used, for example, in subsea applications.
Oilfield operations are typically performed to locate and gather valuable downhole fluids. Oil rigs are positioned at wellsites, and downhole tools, such as drilling tools, are deployed into the ground to reach subsurface reservoirs. Many oilfield operations occur in the sea, or ocean. Subsea oilfield operations typically require the wellhead and other wellsite equipment to be located on the seabed, while an oil platform or vessel may be located at the water's surface. The wellsite equipment located at the seabed may comprise equipment, such as blow out preventers (BOPs), strippers, control devices, supporting tubing injectors, tubing reels, wireline units, or other subsea equipment.
In sub-sea oil and gas operations, there is often a need for a pressure barrier for moving conveyances, such as a slickline or coiled tubing. The stripper may act as a seal, or pressure barrier, that the conveyance is run through. As the coiled tubing is fed through the stripper, the stripper may seal the outer surface of the coiled tubing, thereby preventing sea water from entering the well, and/or wellbore fluids from leaving the wellbore inadvertently. The BOP may act as a safety device designed to ‘seal in’ large pressure surges in the wellbore. The BOP may have rams that automatically shut thereby closing and sealing in the wellbore.
The subsea equipment may become damaged over the life of the drilling operations. In some cases, the subsea equipment may be repaired and/or replaced by subsea divers, and/or brought to the surface by the diver. Techniques for performing repairs and/or replacement of certain wellsite equipment are disclosed, for example, in U.S. Pat. Nos. 3,741,296; 6,484,808; 5,961,094; 6,012,528; and 6,113,061 and U.S. Publication Nos. 2008/0185153; 2008/0185152; and 2009/0152817, the entire contents of which are incorporated by reference.
Despite the development of techniques for replacing BOP and/or stripper components, there remains a need to provide advanced techniques for performing replacement operations.
In at least one aspect, the present invention relates to a replaceable seal assembly. The replaceable seal assembly is for sealing equipment at a wellsite. The wellsite has a subsea stripper installed proximate a subsea borehole and a conveyance for delivering a BHA into the subsea borehole. The replaceable seal assembly has at least one packer extendable within the subsea stripper to form a seal thereabout. The replaceable seal assembly has at least one locator sleeve for positioning the seal assembly in an install position within the subsea stripper. The replaceable seal assembly has a frangible member for connecting the seal assembly to the conveyance prior to deployment in the subsea stripper.
The packer(s) of the replaceable seal assembly may have two packers with the at least one locator sleeve located therebetween, and an actuation sleeve(s) for actuating the at least one packer. The actuation sleeve(s) of the replaceable seal assembly may have a tapered end for engaging an actuator of the subsea stripper. The tapered end axially aligns the seal assembly within the subsea stripper. The locator sleeve(s) of the replaceable seal assembly may have a guide for aligning the seal assembly in the install position when the guide is engaged by a locator sleeve actuator of the subsea stripper. The guide may have a reduced necked-down dual chamfer. The replaceable seal assembly may have a sleeve connection member for linearly coupling the at least one packer to the at least one locator sleeve, and a neck portion of the locator sleeve and having a shoulder extending therefrom, and a connector segment having a groove and at least one upset proximate to the groove, wherein the groove is for receiving the shoulder. The connector segment may have a plurality of connector segment joints for radially expanding and contracting the connector segment. The frangible member of the replaceable seal assembly may be a shear pin and/or a neck-down shear area.
In at least one aspect, the present invention relates to a system for replacing equipment at a wellsite. The wellsite has subsea equipment installed proximate a subsea borehole and a conveyance for delivering a BHA into the subsea borehole. The system has a subsea stripper having a central bore for passing the conveyance and the BHA therethrough. The system has at least one replaceable seal assembly for installation within the stripper. The replaceable seal assembly has at least one packer extendable within the subsea stripper to form a seal thereabout. The replaceable seal assembly has at least one locator sleeve for positioning the seal assembly in an install position within the subsea stripper. The replaceable seal assembly has a frangible member for connecting the seal assembly to the conveyance prior to deployment in the subsea stripper. The system has at least one actuator for actuating the packer whereby the wellbore is sealed.
The actuator(s) of the system has a packer actuator and a locator actuator. The locator actuator of the system is for engaging a locator sleeve of the seal assembly and thereby moving the seal assembly to an install position. The locator actuator of the system has an engager for mating with a guide on the locator sleeve. The packer actuator of the system has a motivator for motivating the packer within the subsea stripper and the motivator moves in a longitudinal direction relative to the seal assembly during actuation of the packer and moves in a radial direction in order to allow the seal assembly to be installed and removed from the stripper. The motivator of the system has a slip surface for engaging a bowl of the packer actuator and the slip surface and the bowl are for facilitating the movement of the motivator in the radial direction. The motivator of the system may engage an actuator sleeve of the seal assembly.
In at least one aspect, the present invention relates to a method for replacing equipment at a wellsite. The wellsite has a subsea stripper located proximate a subsea wellbore. The method comprises connecting a seal assembly to a conveyance for delivering a BHA. The seal assembly has at least one packer extendable within the subsea stripper to form a seal thereabout. The seal assembly has at least one locator sleeve for positioning the seal assembly in an install position within the subsea stripper. The seal assembly has a frangible member for connecting the seal assembly to the conveyance prior to deployment in the subsea stripper. The method comprises deploying the conveyance into the subsea stripper and passing the seal assembly past at least one actuator within the subsea stripper. The method comprises locating the seal assembly in the install position with a locator actuator. The method comprises actuating at least one of the packers of the seal assembly into sealing engagement with the conveyance.
The locating of the seal assembly comprises actuating a motivator of at least one packer actuator into a position for engaging the seal assembly. Further, the locating of the seal assembly comprises engaging the motivator with seal assembly. The method comprises breaking the frangible member and thereby disengaging the conveyance from the seal assembly and opening a stop located below the subsea stripper after the seal assembly is in sealing engagement with the conveyance. The method comprises running the conveyance and the BHA past the stop and performing downhole operations. The method comprises removing the seal assembly, the conveyance and the BHA from the subsea stripper and installing a new conveyance with a new seal assembly, wherein the conveyance has an outer diameter and the new conveyance has second outer diameter.
So that the above recited features and advantages of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof that are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are, therefore, not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments. The Figures are not necessarily to scale and certain features and certain views of the Figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
The description that follows includes exemplary apparatus, methods, techniques, and instruction sequences that embody techniques of the present inventive subject matter. However, it is understood that the described embodiments may be practiced without these specific details.
It may be desirable to provide techniques that are capable of performing at even high depths. It may be further desirable that such techniques be performed remotely and/or automatically. Preferably, such techniques involve one or more of the following, among others: efficient replacement, reduced downtime, simpler structure, reduced manning, etc. The present invention is directed to fulfilling this need in the art.
This application relates to a pressure barrier, such as that provided by a packer, or seal assembly disclosed herein, that contains two sealing elements, or packers, into the same body or housing so that tools can be delivered and retrieved therethrough without the limitation of having to disconnect the guide, for example. This may result in a sealing mechanism, or seal assembly, that may either be retrievable or have the functionality to seal on small diameters (e.g., slickline) while being capable of opening to a diameter large enough for tools to pass through. A tool catcher may also be included.
Such a dynamic seal, or seal assembly, may include a body with a single packer element, although two complete units may be used to comply with certain operational requirements. However, a dual-packer system within a single body or housing is shown and described below.
The structure disclosed herein may be applied to a unit, or stripper, to accommodate both coiled tubing and slickline; or may be adapted to one or the other of these applications, such as, for example, slickline-specific. The system also preferably provides a dual acting piston, packer actuators, and system that allows full control over de-energizing the packing element, or packers, when returning to surface.
The dual-packer structure shown and described below may provide a number of advantages over using two complete single-packer arrangements. For example, the dual-packer assembly reduces the overall weight of the system. This design provides the same functionality as its dual-packer predecessor and weighs an estimated 42% less than its predecessor. The dual-packer structure is also modular in design. The unit is comprised of modular subassemblies, or seal assembly. Downtime may be reduced due to the ability to replace upper or lower subassemblies. The dual-packer structure also preferably has fewer components. The design may rely on two actuators, or packer actuators, versus six. This arrangement also may have fewer hydraulic circuits. Two tandem single-packer assemblies may use five hydraulic circuits; whereas, the dual-packer system may require only three.
The subsea system 106 may comprise the stripper 102, a blow out preventer (BOP) 114, a wellhead 116, a conduit 118, and a conveyance delivery system 120. The conveyance delivery system 120 may be configured to convey one or more downhole tools 122 into the wellbore 112 on the conveyance 110. Although the equipment replacement system 104 is described as being used in subsea operations, it will be appreciated that the wellsite may be land or water based and the equipment replacement system 104 may be used in any drilling environment. A surface system 124 may be used to facilitate the oilfield operations at the offshore wellsite 100. The surface system 124 may comprise a rig 126, a platform 128 (or vessel) and a controller 130. Further, there may be one or more subsea controllers 132. As shown the controller 130 is at a surface location and the subsea controller 132 is in a subsea location, it will be appreciated that the one or more controllers 130/132 may be located at various locations to control the surface and/or subsea systems.
The conveyance delivery system 120, as shown, is located proximate the subsea equipment 108, for example the stripper 102 and the BOP 114. The conveyance 110 in an example may be a coiled tubing. The conveyance delivery system 120 may be, for example, a coiled tubing injector. The coiled tubing injector may inject and/or motivate the coiled tubing and/or downhole tool 122 into the wellbore 112 through the subsea equipment 108. As shown, the conveyance delivery system 120 is located within the conduit 118, although it should be appreciated that it may be located at any suitable location, such as at the sea surface, proximate the subsea equipment 108, without the conduit 118, and the like. Although the conveyance delivery system 120 is described as being a coiled tubing injector, it should be appreciated that the conveyance delivery system 120 may be any suitable device for conveying the conveyance 110 through the subsea equipment 108 and into the wellbore 112. Further, the conveyance 110 may be any suitable conveyance 110 such as a wireline, a slickline, a production tubing, and the like. The downhole tools 122 may be any suitable downhole tools for drilling, completing, evaluating and/or producing the wellbore 112, such as drill bits, packers, testing equipment, perforating guns, and the like.
The stripper 102 is preferably configured to allow the conveyance 110 to pass through the stripper 102 and into other subsea equipment, such as the BOP 114, without allowing seawater into the wellbore 112 and/or allowing wellbore fluids out of the wellbore 112. Portions of the equipment replacement system 104 may be located in and/or proximate to the stripper 102. Portions of the equipment replacement system 104 may further be locatable within the stripper 102 and may be run into the stripper 102 on the conveyance 110.
As shown in
The seal assembly 200 coupled to the conveyance 110 may then be run into the subsea equipment 108 until the downhole tool 122, the end of the conveyance 110 and/or a portion of the seal assembly 200 engages a stop 206 as shown in
The uppermost actuator 202 may engage the seal assembly 200 as the conveyance 110 is pulled up in order to locate the seal assembly 200 proximate an actuation position as shown in
With the seal assembly 200 in the install position, the actuators 202 may all be actuated in order to secure the seal assembly in the stripper 102 and/or engage the one or more packer assemblies 204 into a sealing engagement with the conveyance 110, as shown in
The upper actuator and lower actuator 202 may be configured to actuate the one or more packer assemblies 204 into sealing engagement with the conveyance 110 while the middle actuator 202 may be configured to locate the seal assembly 200 in the install position. With the seal assembly 200 in sealing engagement with the conveyance 110, the conveyance 110 may be detached from the seal assembly 200, for example by breaking a frangible member as will be discussed below. The stop 206 may then be opened and the conveyance 110 and the downhole tools 122 may be run into the wellbore 112 (as shown in
The seal assembly 200 may remain in this actuated position as the conveyance 110 and downhole tools 122 run into the well to perform downhole operations in the wellbore 112. When the downhole operations are complete and/or the seal assembly 200 needs to be replaced, the conveyance 110 may run the downhole tools 122 up into the subsea equipment 108 until the downhole tools 122 pass the stop 206. The stop 206 may then be closed and the actuators 202 may be disengaged in order to allow the conveyance 110 and downhole tool 122 to pass through the stripper 102. As the downhole tool 122 passes through the stripper 102, the seal assembly 200 is taken out of the stripper 102 with the downhole tools 122 as shown in
A new seal assembly 200 may then be used on the next conveyance 110 to enter the wellbore 112. The new seal assembly 200 may be placed on the same type of conveyance 110 used previously, for example the coiled tubing, or may be used on a different type of conveyance 110, for example a slick line, a wire line, a different sized coiled tubing, and the like. Although shown as having two packer assemblies 204 and three actuators 202, it should be appreciated that the equipment replacement system 104 may have any number of packer assemblies 204 for example one, and any suitable number of actuators 202 for example one. Further, the location of the actuators 202 and the one or more packer assemblies 204 may be moved to any suitable location so long as the seal assembly 200 may sealingly engage the conveyance 110.
A frangible member 310, as shown in
The locator sleeve 302 may be a locator sleeve 314 having a guide 312 (or an upset) on an outer surface of the locator sleeve 314. The guide 312 may be configured to be engaged by at least one of the one or more actuators 202 (as shown in
The locator sleeve 314 may be a substantially cylindrical sleeve with a similar inner diameter as the inner diameter 306 of the seal assembly 200. The locator sleeve 314 may have a sleeve connection member 316 at one or more of the ends of the locator sleeve 314. As shown in
The locator sleeve 314, as shown in
The locator sleeve 314 may be coupled to and/or proximate the packer assemblies 204. As shown in
The packer 334 as shown in
The one or more actuation sleeves 304, as shown in
The one or more actuation sleeves 304 may have an actuation end 336. The actuation end 336 may be configured to engage the actuator 202 (as shown on
The connector segment 322 may be configured to secure the linearly aligned portions of the seal assembly 200 to one another. As shown in
The tool connection portion 404 may be configured to secure the stripper 102 to another tool, and/or pipe, downstream of the stripper 102, for example the BOP 114 (as shown in
The seal assembly portion 402 of the stripper 102 may comprise a body with the actuators 202 therein and a stripper central bore 406 therethrough. The stripper central bore 406 may be configured to allow the conveyance 110 with the attached seal assembly 200 to enter and pass through the stripper central bore 406 when the stripper 102 is in an open position (as shown in
The seal assembly portion 402 of the stripper 102, as shown in
As shown in
The packer actuators 408 may be configured to sealingly engage the packer 334 against the conveyance 110.
The slip portions may move radially inward until the slip portions 426 reach a seal assembly engagement position wherein the slip central bore ends 432 are positioned for engaging seal assembly 200 and/or actuating the packer 334 (as shown in
A motivator connector 440 may couple the motivator 426 to the piston 422. The motivator connector 440 may be any suitable device that allows the motivator 426 to move axially with the piston while allowing the motivator 426 to move radially relative to the piston 422. As shown, the motivator connector 440 is a pin connector coupled to the piston 422 and the motivator 426.
The slip portions 430 of the motivator 426 may have a seal assembly engagement edge 444. The seal assembly engagement edge 444 as shown in FIGS. 5A and 5C-5E is a sloped surface configured to engage the tapered end 338 of the actuation sleeve 304 of the seal assembly 200. As the tapered end 338 of the seal assembly 200 is engaged by the seal assembly engagement edge 444, the seal assembly 200 may be further aligned and secured along the central bore 406 of the stripper 102. Although the seal assembly engagement edge 444 is shown as a sloped edge configured to engage the tapered edge 338 of the seal assembly, it should be appreciated that any arrangement for securing the seal assembly 200 to the actuators 202 within the stripper 102 may be used. The continued movement of the motivator 426 against the actuation sleeve 304 may actuate the one or more packers 334 into sealing engagement with the conveyance 110.
The system may also include the hydraulic system, or a plurality of hydraulic operators which drive or move the one or more actuators 202, the BOP 114 and/or the stop 206 (as shown in FIGS. 1 and 3A-3D). One or more hydraulic lines 450 (as shown in
The conveyance 110 may then be pulled toward the closed motivator 426 (or upwards) until the seal assembly 200 engages a portion of the uppermost packer actuator 408, as shown in
The seal assembly 200 engaging the closed motivator 426 may be detected as a force increase in the conveyance 110 by the operator, and/or the controllers 132 and/or 134. Upon detection of the seal assembly 200 engaging the uppermost actuator 408, movement of the conveyance 110 may be temporarily stopped until the seal assembly 200 is in the install position.
With the seal assembly 200 engaged with the uppermost actuator 408, the locator actuator 406 may be actuated to align the seal assembly in the install position, as shown in
The lowermost of the two packer actuators 408 may then be actuated until its corresponding motivator 426 engages the actuation sleeve 304 of the seal assembly 200, as shown in
Note the tapers (the seal assembly engagement edge 444, and/or the tapered end 338 as shown in
The seal assembly 200 (or the consumables) are first located and secured in the stripper 102 assembly. At this time force is put on the conveyance 110 (and/or the tool string) by the injector 120 (as shown in
The conveyance 110 may then be moved in order to break the frangible member 310, and/or 1100 in
Regarding design of the packing element and brass bushings, a split-packer or a solid, non-split packer may be used for this application. The solid packer allows for ease of manufacturing (and potentially less cost), but may result in the BHA connector having to be disconnected from the tool string each time the consumables are removed. This split design may be used throughout the seal assembly 200 (or the consumable package) to allow for ease of installation around the coil tubing and/or the conveyance 110. Once the split halves are situated around the coil tubing, they may be fastened together prior to deploying. The split design may also allow for ease in the retrieval process.
Once downhole operations are complete, the conveyance 110 and the seal assembly 200 may be removed from the stripper 102. In removing the seal assembly 200 (or the consumables), the conveyance 110 with the downhole tools 122 (or tool string) may be brought up to the lower of the actuators 202 (or the actuators/subassembly). Actuators 202 and/or the pistons 414/422 may then be opened and the seal assembly 200 (or the components) may rest on a BHA connector 1104 as shown in
Once the job is complete the seal assembly 200 (or the consumable package) may be returned to surface. The conveyance 110 with the downhole tools 122 (or the tool string) ascends through the BOP 114 and tags off on the bottom of the retrievable stripper 102. The packer actuators 408 (or the upper and lower pistons) may be actuated to the open position as are the locator actuators 410; there is no protocol necessary regarding the sequence for opening these. Once the upper, lower pistons and actuators are in the open position, the seal assembly 200 (or the consumable assembly) comes to rest on the BHA. At this time, it may continue its ascent through the stripper 102 with the consumables on the tool string.
To automate the replacement of the one or more seal assemblies 200, the equipment replacement system 104 may be in communication with the controller(s) 130/132. The equipment replacement system 104 may communicate with the controllers 130 and/or 132 via one or more communication links 133, as shown in
It will be appreciated by those skilled in the art that the techniques disclosed herein can be implemented for automated/autonomous applications via software configured with algorithms to perform the desired functions. These aspects can be implemented by programming one or more suitable general-purpose computers having appropriate hardware. The programming may be accomplished through the use of one or more program storage devices readable by the processor(s) and encoding one or more programs of instructions executable by the computer for performing the operations described herein. The program storage device may take the form of, e.g., one or more floppy disks; a CD ROM or other optical disk; a read-only memory chip (ROM); and other forms of the kind well known in the art or subsequently developed. The program of instructions may be “object code,” i.e., in binary form that is executable more-or-less directly by the computer; in “source code” that requires compilation or interpretation before execution; or in some intermediate form such as partially compiled code. The precise forms of the program storage device and of the encoding of instructions are immaterial here. Aspects of the invention may also be configured to perform the described functions (via appropriate hardware/software) solely on site and/or remotely controlled via an extended communication (e.g., wireless, internet, satellite, etc.) network.
While the embodiments are described with reference to various implementations and exploitations, it will be understood that these embodiments are illustrative and that the scope of the inventive subject matter is not limited to them. Many variations, modifications, additions and improvements are possible.
Plural instances may be provided for components, operations or structures described herein as a single instance. In general, structures and functionality presented as separate components in the exemplary configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements may fall within the scope of the inventive subject matter.
This application claims the benefit of U.S. Provisional Application No. 61/222,251 filed Jul. 1, 2009, the entire content of which is hereby incorporated by reference.
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