Reduced mechanical energy well control systems and methods of use

• US 9,845,652 B2
• Filed: 08/30/2013
• Issued: 12/19/2017
• Est. Priority Date: 02/24/2011
• Status: Active Grant

• Current Assignee: Foro Energy, Inc.
• Original Assignee: Foro Energy, Inc.
• Inventors: Wolfe, Daniel L., Bailey, Andyle G., Grubb, Daryl L., Kolachalam, Sharath K., Zediker, Mark S., Deutch, Paul D.
• Primary Examiner(s): Buck, Matthew R
• Assistant Examiner(s): Toledo-Duran, Edwin
• Application Number:
  US14/015,003
• Publication Number:
  US 20140000902A1
• Time in Patent Office: 1,572 Days
• Field of Search: 166361, 166363, 166364, 166297, 166298, 166 55, 166 556, 166 854, 13731502, 251 11, 251 12, 251 13, 21912167, 21912172
• CPC Class Codes: E21B 29/00 Cutting or destroying pipes, packers, plugs or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
• CPC Class Codes: E21B 29/02 by explosives or by thermal or chemical means freeing stuck objects by explosives E21B31/002
• CPC Class Codes: E21B 33/063 for shearing drill pipes cutting of wireline E21B29/04

Abstract

There is provided systems, methods and apparatus for the use of directed energy, including high power laser energy, in conjunction with mechanical shearing, sealing and closing devices to provide reduced mechanical energy well control systems and techniques.

Claims

1. A well control system having a reduced potential mechanical energy requirement, the system comprising:

a. a body defining a pressure containment cavity, wherein the body comprises a blowout preventer;

b. a mechanical device associated with the pressure containment cavity, wherein the mechanical device comprises a ram;

c. a source of directed energy, wherein the source of directed energy is a high power laser, has a power greater than about 1 kW; and

, has the capability to deliver a directed energy to a location within the pressure containment cavity, the directed energy having a first amount of energy having a power great than about 1 kW; and

,

d. a source of potential mechanical energy associated with the mechanical device, and capable of delivering mechanical energy to a location within the pressure containment cavity, the source of potential energy having a potential energy having a second amount of energy;

e. wherein, the first amount of energy is at least as great as about 5% of the second amount of energy.

2. The well control system of claim 1, wherein the mechanical device comprises a shear ram.

3. The well control system of claim 1, wherein the ram is selected from the group consisting of a blind ram, a shear ram, a blind shear ram, a pipe ram and a casing shear ram.

4. The well control system of claim 1, comprising a a riser and a blowout preventer stack.

5. The well control system of claim 4, wherein the mechanical device is selected from the group consisting of a blind ram, a fixed pipe ram, a variable pipe ram, a shear ram, a blind shear ram, a pipe ram and a casing shear ram.

6. The well control system of claim 1, wherein the source of potential mechanical energy comprises a charged accumulator.

7. The well control system of claim 1, wherein the source of potential mechanical energy comprises a plurality of charged accumulators.

8. The well control system of claim 1, wherein the source of potential mechanical energy comprises a charged accumulator bank.

9. The well control system of claim 6, wherein the charged accumulator has a pressure of at least about 1,000 psi.

10. The well control system of claim 6, wherein the charged accumulator has a pressure of at least about 3,000 psi.

11. The well control system of claim 6, wherein the charged accumulator has a pressure of at least about 5,000 psi.

12. The well control system of claim 1, wherein the source of directed energy is a high power laser have a power of at least about 10 kW.

13. The well control system of claim 1, wherein the source of directed energy is a high power laser have a power of at least about 15 kW.

14. The well control system of claim 1, wherein the source of directed energy is a high power laser have a power of at least about 20 kW.

15. The well control system of claim 1, wherein the source of directed energy is a high power laser have a power of at least about 40 kW.

16. The well control system of claim 1, wherein the first amount of energy is at least about 150 kJ.

17. The well control system of claim 1, wherein the first amount of energy is at least about 600 kJ.

18. The well control system of claim 12, wherein the well control systems comprises a high power laser system;

the body comprises a blowout preventer;

the source of potential mechanical energy comprises a charged accumulator, having a pressure of at least about 1,000 psi; and

the mechanical device is selected from the group consisting of a blind ram, a shear ram, a ram, a blind shear ram, a pipe ram and a casing shear ram.

19. The well control system of claim 14, wherein the well control systems comprises a high power laser system;

the body comprises a blowout preventer;

the source of potential mechanical energy comprises a charged accumulator, having a pressure of at least about 1,000 psi; and

the mechanical device is selected from the group consisting of a blind ram, a shear ram, a blind shear ram, a ram, a pipe ram and a casing shear ram.

20. The well control system of claim 15, wherein the well control systems comprises a high power laser system;

the body comprises a blowout preventer;

the source of potential mechanical energy comprises a charged accumulator, having a pressure of at least about 1,000 psi; and

the mechanical device is selected from the group consisting of a blind ram, a shear ram, a blind shear ram, a pipe ram, a ram and a casing shear ram.

21. The well control system of claim 16, wherein the well control systems comprises a high power laser system;

the body comprises a blowout preventer;

the source of potential mechanical energy comprises a charged accumulator, having a pressure of at least about 1,000 psi; and

the mechanical device is selected from the group consisting of a blind ram, a shear ram, a blind shear ram, a ram, a pipe ram and a casing shear ram.

22. The well control system of claim 17, wherein the well control systems comprises a high power laser system;

the body comprises a blowout preventer;

the source of potential mechanical energy comprises a charged accumulator, having a pressure of at least about 1,000 psi; and

the mechanical device is selected from the group consisting of a blind ram, a shear ram, a blind shear ram, a ram, a pipe ram and a casing shear ram.

23. The well control system of claim 1, wherein the first amount of energy is greater than the second amount of energy energy.

24. The well control system of claim 1, wherein the first amount of energy is at least as great as about 25% of the second amount of energy.

25. The well control system of claim 1, wherein the first amount of energy is at least as great as about 50% of the second amount of energy.

26. The well control system of claim 1, wherein the first amount of energy is at least as great as about 100% of the second amount of energy.

27. The well control system of claim 1, wherein the first amount of energy is greater than the second amount of energy.

28. The well control system of claim 1, wherein the first amount of energy is at least as great as about 25% of the second amount of energy.

29. The well control system of claim 1, wherein the first amount of energy is at least as great as about 50% of the second amount of energy.

30. The well control system of claim 1, wherein the first amount of energy is at least as great as about 100% of the second amount of energy.

31. The well control system of claim 5, wherein the first amount of energy is greater than the second amount of energy.

32. The well control system of claim 5, wherein the first amount of energy is at least as great as about 25% of the second amount of energy.

33. The well control system of claim 5, wherein the first amount of energy is at least as great as about 50% of the second amount of energy.

34. The well control system of claim 5, wherein the first amount of energy is at least as great as about 100% of the second amount of energy.

35. The well control system of claim 2, wherein the first amount of energy is greater than the second amount of energy.

36. The well control system of claim 4, wherein the first amount of energy is at least as great as about 25% of the second amount of energy.

37. The well control system of claim 9, wherein the first amount of energy is at least as great as about 50% of the second amount of energy.

38. The well control system of claim 12, wherein the first amount of energy is at least as great as about 100% of the second amount of energy.

97. The well control system of claim 6, wherein the charged accumulator has a pressure of at least about 7,500 psi.

39. A well control system having a reduced potential mechanical energy requirement, the system comprising:

a. a body defining a pressure containment cavity, wherein the body comprises a blowout preventer;

b. a mechanical device associated with the pressure containment cavity, wherein the mechanical device comprises a ram;

c. a source of directed energy, wherein the source of directed energy is a high power laser, has a power of at least about 1 kW; and

, has the capability to deliver a directed energy to a location associated with the pressure containment cavity, the directed energy having a first power of at least about 1 kW; and

,

d. a source of potential mechanical energy associated with the mechanical device, and capable of delivering mechanical energy to a location within the pressure containment cavity, the source of potential energy having a potential energy having a second power;

e. wherein, the first power is at least as great as about 5% of the second power.

40. The well control system of claim 39, wherein the ram is selected from the group consisting of a blind ram, a shear ram, a blind shear ram, a pipe ram and a casing shear ram.

41. The well control system of claim 39, comprising a riser and a blowout preventer stack.

42. The well control system of claim 39, wherein the source of potential mechanical energy comprises a bank of charged accumulators.

43. The well control system of claim 42, wherein the charged accumulators has a pressure of at least about 3,000 psi.

44. The well control system of claim 39, wherein the source of directed energy is a high power laser have a power of at least about 10 kW.

45. The well control system of claim 39, wherein the source of directed energy is a high power laser have a power of at least about 20 kW.

46. The well control system of claim 39, wherein the first amount of energy is at least about 150 kJ.

47. The well control system of claim 39, wherein the first amount of energy is at least about 600 kJ.

48. The well control system of claim 44, wherein the well control systems comprises a high power laser system;

the body comprises a blowout preventer;

the source of potential mechanical energy comprises a charged accumulator, having a pressure of at least about 1,000 psi; and

the mechanical device is selected from the group consisting of a blind ram, a shear ram, a ram, a blind shear ram, a pipe ram and a casing shear ram.

49. The well control system of claim 46, wherein the well control systems comprises a high power laser system;

the body comprises a blowout preventer;

the source of potential mechanical energy comprises a charged accumulator, having a pressure of at least about 1,000 psi; and

the mechanical device is selected from the group consisting of a blind ram, a shear ram, a blind shear ram, a ram, a pipe ram and a casing shear ram.

50. The well control system of claim 39, wherein the first power is greater than the second power.

51. The well control system of claim 39, wherein the first power is at least as great as about 25% of the second power.

52. The well control system of claim 39, wherein the first power is at least as great as about 100% of the second power.

53. The well control system of claim 40, wherein the first power is greater than the second power.

54. The well control system of claim 40, wherein the first power is at least as great as about 25% of the second power.

55. The well control system of claim 44, wherein the first power is at least as great as about 50% of the second power.

56. The well control system of claim 44, wherein the first power is greater than the second power.

57. The well control system of claim 47, wherein the first power is at least as great as about 25% of the second power.

58. The well control system of claim 47, wherein the first power is at least as great as about 100% of the second power.

59. The well control system of claim 47, wherein the first power is greater than the second power.

60. The well control system of claim 48, wherein the first power is at least as great as about 25% of the second power.

61. The well control system of claim 48, wherein the first power is at least as great as about 50% of the second power.

62. A well control system having a reduced potential mechanical energy requirement, the system comprising:

a. a high power laser system;

b. a riser;

c. a blowout preventer stack;

d. the blowout preventer stack defining a cavity;

e. a mechanical device for sealing a well associated with the cavity;

f. a source of directed energy, wherein the source of directed energy is a high power laser, has a power of at least about 1 kW, and has the capability to deliver a directed energy to a location associated with the cavity, the directed energy having a first amount of energy of at least about 1 kW; and

,

g. a source of potential mechanical energy associated with the mechanical device, and capable of delivering mechanical energy to a location associated with the cavity, the source of potential energy having a potential energy having a second amount of energy energy;

h. wherein, the first amount of energy is at least as great as about 5% of the second amount of energy, and

i. wherein, the source of directed energy and the source of potential mechanical energy are within the cavity of the blowout preventer stack.

63. The well control system of claim 62, wherein in the source of directed energy is a high power laser have a power of at least about 15 kW, and the source of potential energy is a charged bank of accumulators having a pressure of at least about 1,000 psi.

64. The well control system of claim 62, wherein in the source of directed energy is a high power laser of at least about 20 kW.

65. The well control system of claim 62, wherein the source of potential energy is a charged bank of accumulators having a pressure of at least about 1,000 psi.

66. A constant energy depth independent well control system, the system comprising:

a. a device for delivering directed energy subsea, the directed energy having a power of at least about 1 kW;

b. a device for delivering mechanical energy associated with a potential energy source having an amount of potential energy; and

,

c. the device for delivering directed energy subsea compensatively associated with the device for delivering mechanical energy, whereby the delivery of the directed energy compensates for losses in potential energy;

d. a high power laser, a riser and a blowout preventer stack,

e. wherein the device for delivering directed energy and the device for delivering mechanical energy are located within a cavity in the blowout preventer stack.

67. The well control system of claim 66, wherein the losses of potential energy arise from the potential energy source being positioned under a surface of a body of water at a depth.

68. The well control system of claim 67, wherein the depth is at least about 5,000 ft.

69. The well control system of claim 66, wherein the source of potential energy comprises a bank of charged accumulators.

70. A laser BOP comprising:

a. a first and a second ram block;

b. the first ram block of the laser BOP having within a first and a second laser device, the first laser device defining a first laser beam path for delivery of a laser beam, the second laser device defining a second beam path for delivery of a laser beam;

c. the second ram block of the laser BOP having within a third and a fourth laser device, the third laser device defining a third laser beam path for delivery of a laser beam, the fourth laser device defining a fourth laser beam path for delivery of a laser beam; and

,

d. the ram blocks associated with an actuator center line;

e. whereby the laser beam paths define beam path angles with respect to the actuator center line; and

wherein the laser beam has a power of at least about 5 kW; and

f. wherein the laser is for damaging or cutting a tubular within the laser BOP.

71. A laser BOP comprising:

a. a first ram block;

b. the first ram block of the laser BOP having within a first and a second laser device, the first laser device defining a first laser beam path for delivery of a laser beam, the second laser device defining a second beam path for delivery of a laser beam; and

,

c. the ram block associated with an actuator center line;

d. whereby the laser beam paths define beam path angles with respect to the actuator center line; and

wherein the laser beam has a power of at least about 5 kW; and

e. wherein the laser is for damaging or cutting a tubular within the laser BOP.

72. The laser BOP of claim 71, wherein the beam path angle for the first laser beam path is 900.

73. The laser BOP of claim 71, wherein the beam path angle for the first laser beam path is greater than 90°

.

74. The laser BOP of claim 71, wherein the beam path angle for the first laser beam path is less than 90°

.

75. The laser BOP of claim 71, wherein the beam path angles for the first and second beam paths are greater than 90°

.

76. The laser BOP of claim 71, wherein the beam path angles for the first and second beam paths are less than 90°

.

77. The laser BOP of claim 71, wherein the beam path angles for the first and second beam paths are about the same angle.

78. The laser BOP of claim 71, wherein the beam path angles for the first and second beam paths are different angles.

79. The laser BOP of claim 71, wherein the first laser beam has a power of at least about 10 kW.

80. The laser BOP of claim 71, wherein the first and second laser beams each have a power of at least about 10 kW.

81. The laser BOP of claim 71, comprising:

a. a second ram block;

b. the second ram block having a third and a fourth laser device, the third laser device defining a third laser beam path for delivery of a laser beam, the fourth laser device defining a fourth beam path for delivery of a laser beam; and

,

c. the second ram block associated with the actuator center line;

d. whereby the third and fourth laser beam paths define beam path angles with respect to the actuator center line.

82. A method of severing a tubular in a BOP cavity, comprising:

a. delivering directed energy, having a power of at least about 5 kW, to a predetermined location on a tubular positioned in a cavity of a BOP;

b. the directed energy damaging the tubular in a predetermined pattern; and

,

c. applying a mechanical force to the tubular in association with the damage pattern, whereby the tubular is severed,

d. wherein the directed energy is a high power laser beam having at least about 5 kW of power, and having a focal length, wherein the damage pattern is a slot having a length and a varying width, whereby the width varies proportionally to the focal length of the laser beam,

e. wherein a source of the directed energy is within the BOP cavity.

83. The method of claim 82, wherein the directed energy is a high power laser beam.

84. The method of claim 82, wherein the directed energy is a high power laser beam having at least 10 kW of power.

85. The method of claim 82, wherein the predetermined damage pattern is a slot.

86. The method of claim 82, wherein the predetermined damage pattern is a slot having a length and a varying width.

87. A method for closing a well comprising:

a. a step for delivering a high power laser beam, having a power greater than about 1 kW, to a tubular in a cavity in a BOP, wherein the high power laser beam is within the cavity of the BOP;

b. a step for removing material from the tubular with the delivered high power laser beam;

c. a step for applying a mechanical force to the tubular, wherein the mechanical force is provided by a ram; and

,

d. the step for mechanically closing the well.

88. A laser ram BOP comprising:

a. a means for providing a high power laser beam to a BOP stack, the BOP stack defining a cavity, wherein the means for providing a high power laser beam is within the cavity of the BOP;

b. a means for directing the high power laser beam, having a power greater than 1 kW, to a tubular within the BOP cavity; and

,

c. a means for applying a mechanical force to the tubular, wherein the mechanical force is provided by a ram.

89. The laser ram BOP of claim 88, wherein the means for providing a high power laser beam comprises a battery powered 10 kW laser located subsea adjacent to the BOP stack.

90. The laser ram BOP of claim 88, wherein the means for directing the high power laser beam comprises a pressure compensated fluid laser jet.

91. The laser ram BOP of claim 90, wherein the pressure compensated fluid laser jet comprises a means for pressure compensation.

92. A BOP package comprising:

a. a lower marine rise package;

b. a lower BOP stack;

c. a connector releasable connecting the lower marine riser package and the lower BOP stack; and

,

d. the connector comprising a high power directed energy delivery device, having a power greater than 1 kW, wherein the high power directed energy delivery device is within the connector,

e. wherein the high power energy deliver device comprises a high power laser beam delivery device capable of delivering a high power laser beam having a power of at least about 5 kW.

93. The BOP of claim 92, wherein the connector is capable of being released at an angle, defined by a position of a rig associated with the BOP stack with respect to a vertical line from the BOP stack, that is greater than about 5°

.

94. The BOP of claim 93, wherein the releasable angle is greater than about 6°

.

95. The BOP of claim 93, wherein the releasable angle is greater than about 7°

.

96. The BOP of claim 93, wherein the releasable angle is greater than about 10°

.