APPARATUS AND METHOD FOR ISOLATING A SECTION OF A PIPE RISER BORE IN THE COURSE OF RISER RENEWAL
The isolation tool works at depth in the bore of a pipe whose upper end is to be severed and replaced. The tool isolates the lower pipe bore from the upper bore so that flammable downhole fluid is prevented from reaching a welding site along the pipe wall. The tool incorporates: means for establishing a pair of axially spaced apart annular seals engaging the pipe inner surface; means for venting downhole fluid to ground surface; and means for monitoring for seal leakage. The tool is primarily mechanical in nature. It finds use in connection with off-shore platform riser renewal operations.
This application is a continuation of U.S. patent application Ser. No. 14/244,017, filed Apr. 3, 2014, entitled “APPARATUS AND METHOD FOR ISOLATING A SECTION OF A PIPE RISER BORE IN THE COURSE OF RISER RENEWAL”, which claims priority to U.S. Provisional Patent Application No. 61/809,284, filed Apr. 5, 2013, entitled “TESTING AND ISOLATING APPARATUS AND METHOD FOR RISERS,” the entireties of which are incorporated herein by reference as if set forth in full.
FIELD OF THE INVENTIONThe invention relates to a mechanical assembly or “isolation tool” for use in controlling fluid movement through a pipe bore during the course of replacing a section of the pipe. For example, the tool may be used in connection with the process of replacing the worn or damaged upper section of a vertical “riser” associated with an off-shore oil or gas production platform. The invention further relates to a method associated with the pipe section replacement procedure.
BACKGROUND OF THE INVENTIONThe invention was developed in connection with providing an isolation tool which could be used ‘downhole’ in connection with the process of replacing the upper section of an upwardly oriented riser associated with an off-shore oil or gas production platform. Such platforms are prevalent in the Gulf coast region of the U.S. It will be described herein in that connection. However, it is contemplated that the tool and method may find application in other fields of use as well and is not limited to downhole applications in upwardly oriented pipes.
The word “riser” is commonly used to identify a steel pipe extending up from the sea floor to a production platform. Oil or natural gas is produced through the bore of the riser from one or more wells connected to it.
Many of these risers have been in use for decades in the Gulf coast region. As a consequence, in many cases their upper sections have become weakened and worn by wave action, corrosion and other damaging actions. The well operators pay close attention to this deterioration and will initiate replacement of the upper section of the riser when appropriate.
Typically the prior art replacement operation has involved:
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- closing the valves of the sea floor wellhead(s) to terminate production into the base of the riser;
- setting a packer at depth in the riser bore (for example, this might take place at a depth of up to 40′ below the platform), so as to provide a barrier sealing off or isolating the upper section of the riser bore from its lower section;
- severing the riser wall at a point above the packer with a mechanical cutting tool;
- removing the severed upper section of the riser and lowering a replacement pipe section into its place; and
- welding the new riser section end to end to the old section.
It follows that one needs to isolate the pipe wall area, where welding is to occur, from the flammable gas which may still be present in the bore of the riser.
Heretofore there have been various downhole tools employed to so control the riser bore. In one case, a pig-type device or packer is displaced to the appropriate depth in the bore and then actuated from ground surface by means of an electronic signal. Upon actuation, the packer mechanically expands its seal element radially into sealing engagement with the pipe wall and anchors itself to the wall, thereby providing a barrier to gas movement along the inner surface of the upper pipe segment.
These prior art tools are closely held and are not publically disclosed in detail in the literature, to our knowledge. However, we understand that they are characterized by several shortcomings, including that:
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- the tools are complex and their use entails lengthy set-up times;
- the tools are not adapted to monitor and provide a real time indication of the on-going competence or possible leakage of the packer seal element; and
- rental of the known tools is expensive.
It is therefore one object of the present invention to provide an isolation tool for use downhole that can be comparatively quickly installed and deployed at the desired depth in a riser bore.
It is another object to provide a tool adapted to provide a real time indication of seal competency or leakage.
And it is another object to provide a tool which, due to the simplicity of its structure and operation, can be supplied at less cost than has been common in the past.
If the tool is to be used at an off-shore platform, it is desirable that it be adapted to be insertable into the riser inlet within the space available. While these platforms are huge structures, the space available to feed an isolation tool into the open upper end of the riser bore is commonly very limited. Typically there might be only about 2½-6′ of “head room” available at the riser inlet. It therefore is a preferred object of the invention to provide a tool which is adapted to be fed into the pipe bore in spite of the usual space limitations at the inlet.
If the tool is to be used in the context of an off-shore platform riser, it is desirable that it remain cohesive in use. Dropping a steel part down the riser bore is unacceptable to the well operator. It therefore is a preferred object to provide a tool whose components are well tied together to maintain its cohesiveness while still allowing tool components to move to a limited extent in the course of ‘setting’ the tool.
If the tool is to be used in close proximity to a welding operation, it is desirable to avoid heat damage of the elastomer seals. It therefore is another preferred object to provide a tool adapted to protect the seals against deterioration from heat.
SUMMARY OF THE INVENTIONIn one aspect, the present invention provides a primarily mechanical isolation tool adapted for use downhole. The tool is designed to work at depth within the bore of a pipe, such as an upwardly oriented riser associated with an off-shore production platform.
The tool provides a sealed pressurized barrier internally dividing the pipe bore into upper and lower sections. The barrier functions to block fluid movement along the inner surface of the pipe. But the tool also provides a conduit extending upwardly to the pipe's open end, for venting rising bore fluid at ground surface. The barrier is actuated or ‘set’ from ground surface by mechanical means extending down through the upper section of the bore.
In addition, the tool incorporates a system for monitoring, at ground surface, whether the downhole seal elements are leaking and it further preferably incorporates means for tieing tool components together so as to ensure cohesiveness.
One embodiment of the downhole isolation tool, when used in the pipe, comprises, in combination:
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- a support frame, at ground surface, for engaging the upper end of the pipe and supporting and anchoring downwardly extending segments of the tool;
- an isolation assembly for positioning lengthwise in the pipe bore at depth, said assembly comprising a linear assemblage of components including a front plate, a front seal element, a central body, a back seal element and a back plate, said seal elements being axially spaced apart, resilient, deformable and annular, each said seal element being positioned between one end of the body and a plate, whereby, when the plates and body are compressed together, the seal elements are squeezed and deformed outwardly into sealing engagement with the pipe and thereby combine with the outer surface of the body and the inner surface of the pipe to form a sealed annular space;
- a tubular housing assembly, preferably comprising a string of tubular joints connectable end to end, suspending the isolation assembly in the pipe bore and positioning it at the desired operational depth, said housing assembly being operative to be anchored at its upper end to the support frame, said housing assembly being connected at its lower end with the front plate, whereby the front plate is held stationary and fixed in place by said housing assembly;
- a tubular vent rod assembly, preferably comprising a string of tubular rods connectable end to end, connected with the back plate and slidably extending through the isolation assembly, housing assembly and bore inlet, said vent rod assembly forming a passageway communicating with the pipe bore beneath the tool for venting fluid therefrom to ground surface;
- a tensioner connected with the vent rod assembly at ground surface and operative to draw said assembly upwardly to thereby compress the plates and body together and deform the seal elements so that they sealably engage the pipe, said tensioner being lockable to fix said assembly in a tensioned state;
- a seal leakage monitoring assembly connected with the isolation assembly and comprising a conduit extending from ground surface for circulating pressurized liquid through the sealed annular space and back to ground surface;
- whereby the isolation assembly provides a sealing barrier having a pair of annular seal elements sealing against the pipe's inner surface at axially spaced apart positions, the vent rod assembly provides a passageway for segregated venting of pipe bore fluid from the pipe bore's lower section through the barrier to ground surface and said vent rod assembly additionally functions when pulled and tensioned to actuate the isolation assembly, the housing assembly is operative to lower, hold and recover the isolation assembly and fixes the front plate in position to enable compression of the isolation assembly and the monitoring assembly functions to provide an indication as to whether the seal elements are leaking.
In a preferred optional feature, the back plate is connected by floating locking pins with the back end of the body, said pins being positioned internally of the body in bores which permit limited axial movement of the pins and back plate but the body has shoulders which prevent separation of the back plate and body. In addition, the front plate is connected with the body by locking pins which permit limited axial movement of the body toward the front plate. As a consequence of this arrangement the vent rod assembly can pull the back plate and body toward the front plate and thereby squeeze the seal elements to actuate the isolation assembly, while the locking pins still ensure cohesiveness of the isolation assembly.
These and other features of the invention will become more apparent in the following detailed description in which reference is made to the appended drawings wherein:
Throughout the description the following terms will be assumed to have the following meanings.
“Axial”—this term is used to indicate a direction along the longitudinal axis of the pipe and tool. Thus, the term “axially extending” will be understood to mean extending in a direction parallel to the longitudinal axis of the pipe.
“Front” and “back” and “upper” and “lower”—these terms are used interchangeably to describe the positions of various components of the tool. The terms “front” and “upper” indicate a position closer to the open end of the pipe. The terms “back” and “lower” indicate a position away from the open end of the pipe.
“Ground surface” is intended to mean the off-shore platform (not shown) or an alternative surface structure adjacent the upper end of the pipe.
The isolation tool 1 is shown assembled and ready to operate in
The isolation tool 1 comprises a combination of assemblies which can be deployed into and can work together in the bore 3 of the pipe 2 at depth (usually the depth is less than 40 feet).
The purpose of the tool 1 is to provide a sealed barrier which prevents flammable downhole fluid from migrating up along the inner surface 4 of the pipe 2 to the point where cutting and welding operations are to take place. Instead the fluid is to be vented through the tool to ground surface in a segregated way.
It is intended to provide an isolation tool 1 that is primarily mechanical in nature. The tool can be actuated from ground surface and the competence of its seals can be monitored in real time.
Having reference to
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- an isolation assembly 100a incorporating a linear assemblage of components including: a front plate 112, a front seal element 31, a central body 61, a back seal element 35 and a back plate 11. When the components are compressed together, the axially spaced apart annular seal elements 31, 35 are deformed radially outward and seal against the inner surface 4 of the pipe 2, thereby combining with the outer surface 62 of the body 61 and the pipe inner surface 4 to define an annular sealed space 63;
- a housing assembly 7 incorporating a string 8 of tubular pipe joints 9 for lowering the isolation assembly 100a into position, holding it stationary during operation and recovering it upon completion of the work;
- a vent rod assembly 10, comprising a string 17 of tubular vent rods, which is connected with the back plate 11, communicates with the pipe lower bore 12, slidably extends through the balance of the isolation assembly 100a and up through the housing assembly 7 to ground surface. The vent rod string 17 can be pulled upwardly and tensioned from ground surface to actuate the isolation assembly 100a by compressing its components together. It also functions to vent downhole fluid through the isolation assembly 100a to ground surface;
- an actuating means, such as a long nut 651 or a hydraulic tensioner, is provided at ground surface for pulling and maintaining the vent rod string 17 in a tensioned state so that the seal elements 31, 35 engage and continue to seal against the pipe 2;
- a support means, such as a frame 21, is positioned at ground surface for engaging the pipe 2 and cooperating therewith to support and anchor the downwardly extending components; and
- a monitoring means 24, comprising conduits 161, 163 extending down through the bore of the pipe 2 from ground surface and connecting with the isolation assembly's annular sealed space 63. The monitoring means 24 circulates pressurized water down through the annular sealed space 63 and back up to ground surface. The water pressure is monitored and provides an indication in real time of seal leakage.
Now in greater detail and having reference to
The back plate 11 serves as a barrier extending transversely of the pipe bore 3. It also plays a role in the action of compressing the body 61 and plates 11, 112 together to deform the seal elements 31, 35 outwardly into sealing engagement with the pipe's inner surface 4.
Referring to
The front face 14 of the back plate 11 is beveled along its perimeter to form an annular bevel 22. The bevel 22 is rearwardly angled, preferably at about 15°.
As previously indicated, the tubular vent rod string 17 is connected with the back plate 11 and extends through it. Having regard to
The vent rod string 17 can be formed by adding one or more modular extension to the isolation assembly's vent rod 311. In the case where the available head room between the deck of the off-shore platform and the riser inlet is only about 3′, extension rods may be only 2′ in length.
The body 61 is generally cylindrical in configuration and is shown in
The body 61 forms a plurality of through holes 65, a plurality of threaded recesses 67, a first port 69 for coupling a first monitoring conduit 161 to the body and a second port 71 for coupling a second monitoring conduit 163 to the body. It further forms a central bore 73 extending therethrough.
The central bore 73 is provided through the body 61 to allow the vent rod 311 to extend therethrough. The diameter of the body bore 73 is slightly greater than the outer diameter of the vent rod 17. As a result the body 61 is slidable on the vent rod 311.
As shown in
As shown in
As shown in
The front plate 112 is a circular disk having a front face 113 and a back face 114. The front plate forms a central aperture 125, a plurality of through holes 121, a first opening 115 for the first monitoring conduit 161 to extend through and a second opening 117 for the second monitoring conduit 163 to extend through. The front plate 112 further has an outwardly flared surface or bevel 123 formed at the perimeter of its back face 114 and a circumferential groove 119 formed by its side surface. The bevel 123 is adapted to squeeze the front seal element 31 to radially deform it into sealing engagement with the inner surface of the pipe 2.
The sleeve 131 is a tubular member having a back end, a front end and a central bore 133 extending axially therethrough.
The flange plate 143 forms a threaded central aperture 153 for engaging the sleeve 131, a plurality of bolt holes 151 and openings 145, 147 for enabling the monitoring conduits 161, 163 to extend therethrough.
As shown in
The annular back seal element 35 is positioned between the back face 78 of the body 61 and the front face 14 of the back plate 11.
Having reference to
The front end of the larger diameter portion 96 of the through hole 65 may be plugged by a cap 190 as shown in
Having reference to
In summary, the two sets of locking pins 181, 191 limit the maximum separation distance between the front plate 112 and the body 61, and between the body 61 and the back plate 11, while enabling the back plate 111 and body 61 to move a short distance toward or away from the stationary front plate 112.
As previously indicated, the seal elements 31, 35 are annular and formed of deformable, resilient material, such as buna rubber. Preferably they have a D-ring configuration with a rounded inner surface profile and a flat outer surface.
To complete the isolation assembly 100a, a lock nut 251 may be screwed onto the front end of the vent rod string 17 to abut the flange plate 143. The monitoring conduits 161, 163 are connected to the body ports 69, 71.
The isolation assembly 100a may be operated and its seal elements monitored from ground surface.
Operation of the isolation assembly 100a involves: pulling the vent rod string 17 upwardly at ground surface with a tensioner such as a hydraulic tensioner (not shown) or a long nut 5, thereby drawing the back plate 11 and body 61 upwardly so that they press against the stationary fixed front plate 112 and squeeze the annular seal elements 31, 35 between the beveled surfaces 22, 87, 85, 123, whereby the seal elements 31, 35 deform and extend outwardly to seal effectively against the circular inner surface 4 of the pipe 2, thereby combining with the body 61 and pipe 2 to define the sealed annular space 63; then locking the vent rod string 17 in a tensioned condition so as to maintain the seal; circulating water or the like under pressure from ground surface and through the conduits 161, 163 and sealed space 63, to provide an indication as to whether seal leakage is occurring; and eventually releasing the vent rod string 17 so as relax it and the seal elements whereby the tool may be withdrawn.
Having regard to
In summary, the isolation assembly 100a is progressively lowered into the riser bore 3 by adding short modular extensions to the isolation assembly vent rod 311, front plate assembly 111 and conduits 161, 163, thereby forming the vent rod string 17, housing string 8 and conduit assembly 24, 26, 27. Spacer plates 451 may be supplied to centralize the strings 17, 8 and minimize twisting of the strings.
As shown in
A long nut 651 is threaded onto the upper end of the vent rod string 17, which protrudes out of the upper end of the housing string 8. The nut 651 can be turned to pull and tension the vent rod string 17 to actuate and then lock the isolation assembly 100a in place. Alternatively a hydraulic tensioner can be used for the same purpose.
As shown in
As shown in
The isolation tool described is characterized by several advantages, including:
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- it can be relatively quickly deployed—commonly this can be accomplished within a day;
- the provision of two axially separated seal elements provides a safety factor—if the primary lower seal begins to leak, there may still be an opportunity to terminate welding;
- the spaced double seals and conduit system provide a way to monitor for seal leakage;
- the modular design allows the tool to be inserted into the riser bore despite limited head room; and
- tieing together of components with the floating locking pins is beneficial in reducing the possibility of losing parts down the riser bore.
Claims
1. A method for isolating an open end section of the bore of a pipe from the remainder of the bore, said pipe extending upwardly to ground surface, comprising:
- positioning a pair of axially spaced apart annular seal elements, mounted on a body, at depth in the bore of the pipe, using a string of joints joined to end;
- deforming the seal elements from ground surface, using a string of tubular rods, so that they seal against the pipe and combine with the body and the pipe to define a sealed space; and
- circulating pressurized liquid through the sealed space from ground surface and back through conduit means to provide an indication of seal competence.
Type: Application
Filed: Oct 20, 2015
Publication Date: Feb 11, 2016
Inventors: Guy Berube (Sarnia), Graham T. Brown (Sarnia), Tom Blair (Port Lambton)
Application Number: 14/918,138