MODULAR WELL INTERVENTION ASSEMBLY
A modular well intervention assembly includes a jack assembly having increased stroke length that can be installed directly over a well or above a BOP assembly. Modular work platforms and a telescoping mast assembly can be installed and secured in place around the jack assembly. Tongs can be suspended from a hydraulically operated “track system”, eliminating the need for a conventional tong pole and spring. Pipe can be manipulated relative to the well intervention assembly using a hydraulically powered pipe handling device.
Priority of U.S. Provisional Patent Application Ser. No. 61/764,075, filed Feb. 13, 2013, incorporated herein by reference, is hereby claimed.
STATEMENTS AS TO THE RIGHTS TO THE INVENTION MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENTNone
BACKGROUND OF THE INVENTION1. Field of the Invention
The present invention pertains to a modular assembly for conducting intervention operations on oil and/or gas wells. More particularly, the present invention pertains to a modular assembly for conducting operations on wells including, without limitation, work over operations and snubbing operations.
2. Brief Description of the Prior Art
Intervention operations have been performed on oil and/or gas wells for many years. When a conventional drilling or workover rig is used to perform such operations, a well is frequently “killed” using drilling mud or other drilling fluids. In such instances, the hydrostatic pressure exerted by such drilling mud or fluids in a wellbore equals or exceeds the reservoir pressure of the well, thereby leaving the wellbore in a pressure-balanced state at the earth's surface.
In certain circumstances, it may be impractical or undesirable to kill a well (that is, to offset reservoir pressure with hydrostatic pressure in order to put the well in a pressure-balanced state) prior to performing well intervention operations. In such cases, operations are sometimes performed even though positive fluid pressure exists at the upper opening of the well. However, in order to perform such operations in a pressurized well system, specialized well intervention equipment is required.
One common type of conventional system used to conduct well intervention operations in pressurized wells is the so-called “snubbing unit”, also sometimes referred to as a hydraulic workover unit (“HWU”). Such conventional snubbing units generally comprise well servicing systems capable of running and retrieving pipe and other jointed tubular goods, including under “live” well conditions such as high pressure. Specifically, conventional snubbing units comprise hydraulic power systems and associated equipment to install such pipe and tubular goods in a well, and remove such pipe and/or tubular goods, with or without the presence of surface pressure.
Conventional snubbing units typically comprise multiple sets of pipe gripping devices, commonly referred to as “slips,” that can be operated in sequence in order to grip the external surface of pipe as it is “snubbed” into or out of a well. Although specific slip configurations can vary, conventional snubbing units typically comprise at least four separate sets of slips that can be used during well intervention operations. Certain of said slips remain stationary, while other slips are capable of moving or traveling, typically in axial alignment with the surface portion of a well being serviced.
Conventional snubbing units also typically comprise a snubbing “basket” that forms a support or work platform for personnel. In many cases, such basket also contains hydraulic controls for operating various features of a snubbing unit, as well as blow out preventer (“BOP”) and hydraulic valve controls.
Snubbing units and HWU's have sometimes suffered from negative connotations, likely resulting from the nature of the intervention operations that such units are typically called upon to perform. For example, snubbing units and HWU's are frequently used to conduct operations on wells suffering from well control problems, blowouts, stuck pipe and/or other negative or dangerous conditions. As a result, snubbing units or HWU's are often viewed as a means of last resort, thereby negatively impacting the perception of such systems. Further, such conventional snubbing units and HWU's suffer from a number of practical and operational limitations.
Thus, there is a need for a well intervention system that can be used to perform well intervention operations in a safe, efficient and effective manner. Such well intervention system should be more versatile than conventional snubbing units and HWU's, while overcoming the practical and operational limitations associated with such conventional systems.
SUMMARY OF THE INVENTIONIn a preferred embodiment, the well intervention assembly of the present invention comprises a jack assembly that can be installed over a well or, in most cases, on a BOP assembly installed over the upper opening of a well. Such jack assembly has an increased stroke length relative to conventional hydraulic jack systems; whereas conventional hydraulic jack systems typically have a standard stroke length of approximately ten (10) feet, the jack assembly of the present invention beneficially has a stroke length of at least fifteen (15) feet. Said jack assembly is oriented so that the stroke orientation of said jack assembly is substantially axially aligned with the upper portion of said well.
The well intervention assembly of the present invention further comprises an expanded “work window.” A work window of a conventional snubbing unit, which is generally equivalent to the stroke or travel length of a hydraulic jack assembly, ends at or near the top of said stroke length. By contrast, the well intervention assembly of the present invention comprises a hydraulic jack assembly that permits easy access to said work window. As a result, hydraulic cylinders of the jack assembly of the present invention can optimize space occupied by such work window which is typically dormant or unused on conventional snubbing units.
The well intervention assembly of the present invention further comprises a plurality of modular work platforms that can be installed and secured in place around said jack assembly. In a preferred embodiment, nuts, bolts or other similar fasteners are not required to secure such work platforms in place around said jack assembly; instead, said modular platforms are secured in place using guided hooks and pins.
The modular work platforms of the present invention are beneficially designed for ease of transportation. For example, said work platforms can be conveniently and efficiently transported to and from offshore or other remote locations using vessels, trucks or other means. When installed, said platforms provide a stable, secure and safe work environment for personnel, while stairs and ladders provide means for personnel to move or traverse between such work platforms. Importantly, such platforms eliminate the need for personnel to be suspended in the air using harnesses or other similar mechanisms.
Hydraulic tongs are secured on a hydraulically operated “track system”, eliminating the need for a conventional tong pole and spring. The design of the present invention allows a tong operator ease of use in positioning tongs within the intervention assembly of the present invention, including over the center of a well. Further, the movement of pipe (including over the center of said well) is also automated by means of a hydraulically powered pipe handling arm, thereby eliminating most, if not all, hand-to-iron contact and greatly improving personnel safety.
The foregoing summary, as well as any detailed description of the preferred embodiments, is better understood when read in conjunction with the drawings and figures contained herein. For the purpose of illustrating the invention, the drawings and figures show certain preferred embodiments. It is understood, however, that the invention is not limited to the specific methods and devices disclosed in such drawings or figures.
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In a preferred embodiment, lower base plate 1 has lower flange member 4. Said lower flange member 4 can be used to connect jack assembly 10 to the upper end of BOP assembly 100. Although other connection means can be utilized without departing from the scope of the invention, said lower flange member 4 can be bolted to an upper connection flange of said BOP assembly 100 in a manner that is well known.
Jack assembly 10 further comprises a plurality of hydraulic cylinders 11. In a preferred embodiment, said jack assembly 10 comprises four (4) hydraulic cylinders 11 oriented in a substantially square pattern. Said hydraulic cylinders 11 further comprise hydraulic cylinder piston rods 12 that can be extended from barrels of said hydraulic cylinders 11. Upper plate member 3 is connected to said cylinder piston rods 12, such that extension of said cylinder piston rods 12 from hydraulic cylinders 11 will cause said upper plate 3 to travel upward relative to BOP assembly 100.
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Lower modular deck assembly 20 comprises a plurality of individual structural support members 21 that are joined to form a support frame, typically oriented in a substantially square or rectangular external shape and defining an inner space. Individual support members 21 can be of tubular steel construction or other material in order to provide desired strength characteristics while also being relatively lightweight. Lower modular deck assembly 20 further comprises floor surface 22 and stair case 23 leading from said floor surface 22 to the upper extent of said lower modular deck assembly 20. Optional door 24 is hingedly attached to lower modular deck assembly 20 and can be closed to block external access to a portion of jack assembly 10.
Similarly, lower modular deck assembly 30 also comprises a plurality of individual structural support members 31 that are joined to form a support frame defining an inner space. Like modular deck assembly 20, individual structural support members 31 are typically oriented in a substantially square or rectangular external shape and have the same basic construction as structural support members 21. Lower modular deck assembly 30 further comprises floor surface 32 and stair case 33 leading from said floor surface 32 to the upper portion of said lower modular deck assembly 30. Floor surface 32 can include opening 32A which is aligned with the upper end of stair case 23 of lower modular deck assembly 20. Optional door 34 is hingedly attached to lower modular deck assembly 30 and can be closed to block external access to a portion of jack assembly 10.
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Specifically, lower modular deck assembly 40 comprises a plurality of individual structural support members 41 that are joined to form a support frame, typically oriented in a substantially square or rectangular external shape and defining an inner space. Individual support members 41 can be of tubular steel construction or other material in order to provide desired strength characteristics while also being relatively lightweight. Lower modular deck assembly 40 further comprises floor surface 42 and ladder 43 (as opposed to a stair case) leading from said floor surface 42 to the upper extent of said lower modular deck assembly 40. Optional door 44 is hingedly attached to lower modular deck assembly 40 and can be closed to block external access to a portion of jack assembly 10.
Lower modular deck assembly 50 also comprises a plurality of individual structural support members 51 that are joined to form a support frame defining an interior space. Like modular deck assemblies 20, 30 and 40, individual structural support members 51 are typically oriented in a substantially square or rectangular external shape. Lower modular deck assembly 50 further comprises floor surface 52 and ladder 53 leading from said floor 52 to the upper portion of said lower modular deck assembly 50. Floor surface 52 can include opening 52A which is aligned with the upper end of ladder 43 of lower modular deck assembly 40. Optional door 54 is hingedly attached to lower modular deck assembly 50 and can be closed to block external access to a portion of jack assembly 10.
Lower modular deck assemblies 20, 30, 40 and 50 each comprise work platforms for personnel and/or equipment that can be installed and secured in place around jack assembly 10; said work platforms can be used by personnel to perform operations around jack assembly 10. In a preferred embodiment, no nuts, bolts or other similar fasteners are required to secure such deck assemblies in place around said jack assembly; instead, said modular platforms are secured in place using guided hooks and pins. Although not visible in
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Upper deck assembly 70 also comprises support floor 72 that includes at least one opening to permit passage to and from mid-deck assembly 60. Said floor also includes an opening, generally aligned with jack assembly 10; when extended, the traveling portion of said jack assembly 10 (including, without limitation, upper plate member 3) can pass though said opening in upper deck assembly 70. Additionally, said upper work deck assembly 70 also includes v-door 73. Although it can have different embodiments or configurations, in a preferred embodiment said v-door 73 comprises an opening or pathway from the exterior of upper work deck assembly 70 into the interior work space defined by said upper work deck assembly 70. More specifically, said v-door 73 should permit a relatively unobstructed path from the exterior of said upper work deck assembly 70 to jack assembly 10 (as well as the area axially above BOP assembly 100 and a well situated therebelow).
In a preferred embodiment, modular work decks 20, 30, 40, 50, 60 and 70 of the present invention are beneficially designed for ease of transportation. Said work decks can be conveniently and efficiently transported to and from offshore installations and/or other remote locations using vessels, trucks or other means. When installed, said decks provide a stable, secure and safe work environment for personnel, as well as a support structure for storage or staging of materials. Steps and ladders provide means for personnel to move or traverse between such interconnected or adjoining work platforms. Importantly, such platforms eliminate the need for personnel to be suspended in the air using harnesses or other similar means while the modular well intervention assembly is being installed and removed, and while operations are being performed.
Mast assembly 120 (also sometimes referred to as a “gin pole”) comprises a plurality of hydraulically powered telescoping members that can be selectively extended or retracted in order to adjust the length of said mast assembly 120. Further, said mast assembly 120 is equipped with a plurality of winch assemblies; in a preferred embodiment, said mast assembly 120 has a main winch 123 (typically positioned at or near the upper end of said mast assembly 120) that can be used to lift large or heavy tools and assemblies, as well as at least one smaller winch 124 that can be used to lift pipe sections or relatively lightweight tools or assemblies. As depicted in
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Power tong unit 83, which is suspended from tong positioning assembly 80, can be used to apply torque to pipe section 200 in order to rotate said pipe, particularly when said pipe section 200 is disposed over rotary table assembly 15. In a preferred embodiment, tong positioning assembly 80 generally comprises support beam 81 and hydraulically-powered telescoping member 82. Said support beam 81 and telescoping member 82 are mounted at or near the top of upper work deck 70, and are oriented in substantially perpendicular alignment to elongate track 94 of pipe handling assembly 90. Power tong unit 83 is suspended from telescoping member 82 using tong mounting line 84.
When not in use, power tong unit 83 can be moved away from the area above rotary table assembly 15 by retracting telescoping member 82 of tong positioning assembly 80. In such retracted position, power tong unit 83 is located away from v-door 73 and the area above rotary table assembly 15, so as to avoid interference with any ongoing operations in such vicinity. Power tong unit 83 can be selectively moved into position above rotary table assembly 15 using telescoping member 82 of tong positioning assembly 80. Additionally, body section 91 of pipe handling assembly 90 can be pivotally raised to provide clearance in the area above jack assembly 10.
Unlike conventional snubbing units and/or HWU's, it is to be observed that the well intervention assembly of the present invention can be easily and efficiently installed and removed including, without limitation, on platforms or other installations lacking crane boom length and/or lifting capacity. The well intervention assembly of the present invention is exceptionally versatile, allowing for the various components other than jack assembly 10 to be installed in virtually any sequence or order.
In operation, jack assembly 10 can be installed over a well or, in most cases, on a BOP assembly (such as BOP assembly 100) which is itself installed over the upper opening of a well. In a preferred embodiment, jack assembly 10 of the present invention has an increased stroke length relative to conventional hydraulic jack systems; whereas conventional hydraulic jack systems have a standard stroke length of approximately ten (10) feet, jack assembly 10 of the present invention beneficially has a stroke length of at least fifteen (15) feet or more.
Unlike conventional snubbing units, the well intervention assembly of the present invention comprises an expanded work window. As a result, hydraulic cylinders 11 of jack assembly 10 of the present invention extend through space occupied by such work window (which is typically dormant or unused on conventional snubbing units). Further, the work deck assemblies of the present invention, individually and collectively, provide a stable, secure and safe work environment for personnel, while also providing access to such work window. Steps and ladders provide means for personnel to move or traverse between such work deck assemblies; personnel are not required to be suspended in the air using harnesses or other similar mechanisms.
During well intervention operations, pipe can be retrieved from a well using the well intervention assembly of the present invention. In one common illustrative example, the upper portion of a pipe string can be externally gripped using a set of slips attached to rotary table assembly 15 disposed on upper plate 3 of jack assembly 10. As said jack assembly 10 is hydraulically extended, said gripped pipe can be pulled upward and out of said well (and any BOP assembly installed above said well). As said jack assembly is hydraulically extended, telescoping member 82 of tong positioning assembly 80 can be retracted to move power tong unit 83 away from the area above extended jack assembly 10 and rotary table assembly 15. Additionally, body section 91 of pipe handling assembly 90 can be pivotally raised to provide clearance in the area above jack assembly 10.
Once said pipe section has been pulled a desired distance out of said well, lower pipe gripping slips can be set against the external surface of said pipe string at lower plate 1 of jack assembly 10 in order to suspend such pipe. Thereafter, telescoping member 82 of tong positioning assembly 80 can be extended to move power tong unit 83 into proximity with such pipe. Said power tong unit 83 can be used to apply torque to such pipe and unscrew a threaded pipe connection. Thereafter, a disconnected or unscrewed length of pipe can be attached to a line connected to winch 124 of mast assembly 120. Pipe handling assembly 90 can be used to move said pipe section toward v-door 73 of upper work deck 70, and said pipe section can be lowered for further handling to a pipe rack or other staging area below using winch 124. Thereafter, the process can be repeated to remove additional lengths of pipe from said well. The well intervention assembly of the present invention can also be beneficially used to install pipe sections into a well bore.
The above-described invention has a number of particular features that should preferably be employed in combination, although each is useful separately without departure from the scope of the invention. While the preferred embodiment of the present invention is shown and described herein, it will be understood that the invention may be embodied otherwise than herein specifically illustrated or described, and that certain changes in form and arrangement of parts and the specific manner of practicing the invention may be made within the underlying idea or principles of the invention.
Claims
1. A well intervention assembly comprising:
- a) a jack assembly mounted above a well;
- b) at least one modular deck assembly attached to said jack assembly;
- c) a mast assembly attached to said jack assembly; and
- d) at least one winch mounted to said mast assembly.
2. The well intervention assembly of claim 1, wherein said jack assembly further comprises:
- a) a plurality of plate members oriented substantially parallel to each other; and
- b) at least one hydraulic cylinder disposed between said plurality of plate members.
3. The well intervention assembly of claim 2, wherein each of said plurality of plate members has a bore extending through said plate members and said bores are at least partially aligned with each other.
4. The well intervention assembly of claim 1, wherein said mast assembly further comprises:
- a) a first elongate member;
- b) a second elongate member telescopically disposed within said first elongate member; and
- c) at least one hydraulic cylinder adapted to selectively extend and retract said second elongate member relative to said first elongate member.
5. The well intervention assembly of claim 1, wherein said at least one modular deck assembly comprises:
- a) a structural support frame defining an interior space; and
- b) a floor.
6. A well intervention assembly comprising:
- a) a jack assembly mounted above a well, wherein said jack assembly further comprises: i) a plurality of plate members oriented substantially parallel to each other, wherein each of said plate members has a bore extending through said plate member and said bores are at least partially aligned with each other; and ii) at least one hydraulic cylinder disposed between said plurality of plate members;
- b) at least one modular deck assembly attached to said jack assembly;
- c) a telescoping mast assembly attached to said jack assembly;
- d) at least one winch mounted to said mast assembly; and
- e) a rotary table disposed on said jack assembly.
7. The well intervention assembly of claim 6, wherein said mast assembly further comprises:
- a) a first elongate member;
- b) a second elongate member telescopically disposed within said first elongate member; and
- c) at least one hydraulic cylinder adapted to selectively extend and retract said second elongate member relative to said first elongate member.
8. The well intervention assembly of claim 6, wherein said at least one modular deck assembly comprises:
- a) a structural support frame; and
- b) a floor.
9. The well intervention assembly of claim 6, wherein said at least one modular deck assembly comprises:
- a) a plurality of lower deck assemblies;
- b) a mid-deck assembly disposed over said lower deck assemblies; and
- c) an upper deck assembly disposed over said mid-deck assembly.
10. The well intervention assembly of claim 9, wherein said upper deck further comprises a v-door.
11. The well intervention assembly of claim 10, further comprising a pipe handling assembly adapted to guide a section pipe suspended from said mast assembly between said v-door and said jack assembly.
12. The well intervention assembly of claim 10, further comprising a tong support assembly adapted to selectively position a tong unit over said rotary table.
13. The well intervention assembly of claim 12, wherein said tong support assembly further comprises:
- a) a telescoping beam member; and
- b) a line extending between said telescoping beam member and said tong unit.
14. A well intervention assembly comprising:
- a) a jack assembly mounted above a well, wherein said jack assembly further comprises: i) a lower plate member having a bore extending through said lower plate member; ii) a middle plate member having a bore extending through said middle plate member, wherein said middle plate member is oriented substantially parallel to said lower plate member and the bores or said lower and middle plate members are at least partially aligned; iii) at least one hydraulic cylinder disposed between said lower and middle plate members; iv) an upper plate member having a bore extending through said upper plate member, wherein said upper plate member is oriented substantially parallel to said lower and middle plate members and the bores or said upper, lower and middle plate members are at least partially aligned; v) at least one hydraulic cylinder disposed between said upper and middle plate members;
- b) at least one modular deck assembly attached to said jack assembly;
- c) a telescoping mast assembly attached to said jack assembly comprising: i) a first elongate member; ii) a second elongate member telescopically disposed within said first elongate member; and iii) at least one hydraulic cylinder adapted to selectively extend and retract said second elongate member relative to said first elongate member;
- d) at least one winch mounted to said mast assembly; and
- e) a rotary table disposed on said jack assembly.
15. The well intervention assembly of claim 14, wherein said at least one modular deck assembly comprises:
- a) a plurality of lower deck assemblies;
- b) a mid-deck assembly disposed over said lower deck assemblies; and
- c) an upper deck assembly disposed over said mid-deck assembly.
16. The well intervention assembly of claim 15, wherein said upper deck further comprises a v-door.
17. The well intervention assembly of claim 16, further comprising a pipe handling assembly adapted to guide a section pipe suspended from said mast assembly between said v-door and said jack assembly.
18. The well intervention assembly of claim 16, further comprising a tong support assembly adapted to selectively position a tong unit over said rotary table.
19. The well intervention assembly of claim 18, wherein said tong support assembly further comprises:
- a) a telescoping beam member; and
- b) a line extending between said telescoping beam member and said tong unit.
Type: Application
Filed: Feb 12, 2014
Publication Date: Aug 14, 2014
Inventors: TONY SANDERS (LAFAYETTE, LA), JOHN STANSBURY (LAFAYETTE, LA), CLINT MUSEMECHE (LAFAYETTE, LA)
Application Number: 14/178,961
International Classification: E21B 33/072 (20060101);