Apparatus and method for transporting and deploying downhole completion components

Description

TECHNICAL FIELD OF THE INVENTION

This invention relates, in general, to preventing the production of particulate materials from an extended horizontal wellbore traversing a hydrocarbon bearing subterranean formation and, in particular, to an apparatus and method for transporting and deploying completion components that enhance the efficiency of gravel pack completions in such wellbores.

BACKGROUND OF THE INVENTION

Without limiting the scope of the present invention, its background will be described in relation to gravel pack completions as an example. It is well known in the subterranean well drilling and completion art that particulate materials such as sand may be produced during the production of hydrocarbons from a well traversing an unconsolidated or loosely consolidated subterranean formation. Numerous problems may occur as a result of the production of such particulates. For example, the particulates cause abrasive wear to components within the well, such as tubing, chokes and valves. In addition, the particulates may partially or fully clog the well creating the need for an expensive workover. Also, if the particulate matter is produced to the surface, it must be removed from the hydrocarbon fluids by processing equipment at the surface.

One method for preventing the production of such particulate material to the surface is gravel packing the well adjacent the unconsolidated or loosely consolidated production interval. In one type of gravel pack completion, numerous joints of gravel pack screen are lowered into the wellbore on a workstring to a position proximate the desired production interval. A fluid slurry including a liquid carrier and a particulate material such as sand, gravel, proppants or the like, referred to hereinafter as gravel, is then pumped down the workstring and into the well annulus formed between the gravel pack screens and the perforated well casing or open hole production zone.

The liquid carrier either flows into the formation or returns to the surface by flowing through the gravel pack screens or both. In either case, the gravel is deposited around the gravel pack screens to form a gravel pack, which is highly permeable to the flow of hydrocarbon fluids but blocks the flow of the particulates carried in the hydrocarbon fluids. As such, gravel packs can successfully prevent the problems associated with the production of particulate materials from the formation.

It has been found, however, that in extended horizontal completions wherein the producing interval may be several thousand feet, it may not be feasible to perform a conventional gravel pack operation. In these cases, numerous joints of prepacked gravel pack screen may be lowered into the wellbore to a position proximate the desired production interval. The prepacked screens typically include a baked-resin of sand between two screening elements or between a screening element and an outer shroud. The prepacked layer within these gravel pack screens is highly permeable to the flow of hydrocarbon fluids but blocks the flow of the particulates carried in the hydrocarbon fluids. As such, prepacked gravel pack screens also successfully prevent the problems associated with the production of particulate materials from the formation.

In these extended horizontal gravel pack completions, the process for deploying the gravel pack screens is extremely time intensive as several thousand feet of gravel pack screen may need to be installed. Typically, each forty-foot joint of gravel pack screen is constructed and tested at a manufacturing facility. The gravel pack screens are then packaged by placing wood around the screens and securing the wood in place with steel wraps. This packaging is designed to protect the gravel pack screens until they are unpackaged on site. The packaging is required as the joints of gravel pack screen are typically secured together in stacks with pipes supports positioned therebetween such as those described in U.S. Pat. No. 5,123,547. This type of transportation system protects the individual joints from contacting one another and enables the movement of numerous joint at the same time.

It has been found, however, that this type of stacked transportation system leaves the joints of gravel pack screen susceptible to numerous perils. For example, the system does not protect the joints of gravel pack screen from external impacts, shocks or vibrations. This is critical as movement of the stacks is typically accomplished using a crane. As such, it is common for the stack that is being moved to contact a stationary stack, the surface onto which the stack is being placed or other heavy equipment in the area. Such contact may damage the gravel pack screens or cause a loss of integrity of the prepack layer within the gravel pack screens. Due to the potential for damage during the transportation process, each joint of gravel pack screen must be inspected at least twice. For example, in an offshore application, one inspection typically takes place prior to leaving the dock and another inspection takes place once the screens arrive on the offshore platform.

When it is time to install the gravel pack screens downhole, the joints of gravel pack screen are removed from the stack and placed one by one on the catwalk using a crane. Each joint of gravel pack screen is then unpackaged to remove the wood and steel wrap from around the screen. Each joint of gravel pack screen is then pulled up the vee-door, into the rig substructure such that it can be made up to another joint. This process continues one joint at a time until the desired length of screen is assembled and installed. For example, if a 2000-foot interval in being completed, fifty joints of gravel pack screen must be assembled together. This assembly process may take as much as one hour per joint as each step in handling, unpackaging, inspecting, connecting and running the joints of gravel pack screen downhole must take place very carefully as damage to a single joint of screen may result in a loss of integrity of the gravel pack. In addition, each step in transporting and deploying the gravel pack screens is labor-intensive requiring significant human interaction with the screens and other heavy equipment that creates opportunities for injury.

Therefore, a need has arisen for an apparatus for transporting and deploying completion components that improves the efficiency of gravel pack completions particularly in extended horizontal gravel pack completions taking place offshore. A need has also arisen for such an apparatus that protects the gravel pack screens during transportation thereby eliminating the need for packaging of the gravel pack screens and minimizing the number of required inspections of the gravel pack screens. Further, a need has arisen for such an apparatus that reduces the likelihood of injury during the deployment of the gravel pack screens on the rig site.

SUMMARY OF THE INVENTION

The present invention disclosed herein comprises an apparatus for transporting and deploying completion components such as gravel pack screens that improves the efficiency of gravel pack completions particularly in extended horizontal gravel pack completions taking place offshore. The apparatus of the present invention protects the completion components during transportation such that, for example, the need for packaging of individual gravel pack screens is eliminated and the number of required inspections of gravel pack screens is minimized. Importantly, the apparatus of the present invention reduces the likelihood of bodily injury during the deployment of the completion components on the rig site.

The apparatus for transporting and deploying completion components of the present invention comprises a container having first and second openings that are substantially orthogonally disposed relative to one another. More specifically, the container has a substructure including a rear wall, a pair of oppositely disposed side walls and a bottom wall. The side walls are operably associated with the rear wall and the bottom wall is operably associated with the rear wall and the side walls. Preferably, each wall of the substructure is made from steel and is welded to the adjacent walls.

A front panel is positionable opposite the rear wall. The front panel has open and closed positions relative to the substructure to selectively permit and prevent access to the container through the first opening. In one embodiment, the front panel is pivotally moveable relative to one of the side walls to operate the front panel between the open and closed positions. In another embodiment, the front panel includes a pair of doors each of which is pivotally moveable relative to one of the side walls to operate the front panel between the open and closed positions. In a further embodiment, the front panel may be removably positionable opposite the rear wall to operate the front panel between the open and closed positions.

A top panel is positionable opposite the bottom wall. The top panel has open and closed positions relative to the substructure to selectively permit and prevent access to the container through the second opening. In one embodiment, the top panel is removably positionable opposite the bottom wall to operate the top panel between the open and closed positions. In another embodiment, the top panel is pivotally moveable relative to at least one of the rear wall and the side walls to operate the top panel between the open and closed positions. In yet another embodiment, the top panel includes a pair of doors each of which is pivotally moveable relative to one of the side walls to operate the top panel between the open and closed positions.

A support member is securably coupled within the substructure proximate the second opening. The support member has a plurality of slots that receive and support the completion components. In one embodiment, a plurality of braces extends between the support member and the rear wall. For example, at least one brace may be positioned between each slot of the support member. The slots of the support member are sized such that the collar of a certain size of the completion component cannot pass therethrough. Additionally or alternatively, insert members having slots may be positioned within the slots of the support member. The insert members may have a variety of slot widths and may be slidably received within the slots of the support member such that different insert members may be interchangeably used within the support member allowing the same container to accommodate a variety of sizes of completion components.

In operation, the completion components are loaded within the container in a predetermined sequence. A plurality of sets of spacers is positioned within the container to prevent contact between adjacent completion components during transportation which eliminates the need for packaging certain types of completion components as the spacers, the container and the support member protect the completion components from external shock and vibration as well as environmental factors. In addition, the container of the present invention allows for the completion components to be arranged within the support member in a sequence that enhances completion efficiency. Specifically, not only does the present invention increase completion efficiency by providing a container that may be positioned on or near the rig floor, but also, the present invention provides for an engineered deployment of the completion components wherein the individual completion components are deployed from the container in the order in which the completion string is assembled and installed downhole. Accordingly, as each completion component is removed from the container with the traveling block and the aid of a crane, each joint of the completion components is raised into the derrick then stabbed into the completion component that is at the top of the completion string. Importantly, the completion components may include a variety of different types of downhole components such as gravel pack screens, blank pipe, packers and the like. When the container is loaded in a predetermined sequential manner, the deployment of the completion components at the rig site is engineered such that the various completion components are deployed from the container, assembled at the rig floor and installed into the well in the desired sequence for downhole operations.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:

FIG. 1 is a schematic illustration of an offshore oil and gas platform operating an apparatus for transporting and deploying completion components of the present invention;

FIG. 2 is a front view of an apparatus for transporting and deploying completion components of the present invention with its front panels open and loaded with gravel pack screens;

FIG. 3 is a cross sectional view of the apparatus for transporting and deploying completion components of the present invention taken along line 3-3 of FIG. 2;

FIG. 4 is a top view of an apparatus for transporting and deploying completion components of the present invention with its top panel removed and loaded with gravel pack screens;

FIG. 5 is a top view of an apparatus for transporting and deploying completion components of the present invention with its top panel removed, its front panels open and its gravel pack screens deployed;

FIG. 6 is an isomeric view of a support member for an apparatus for transporting and deploying completion components of the present invention; and

FIG. 7 is a side elevation view of a set of spacers for an apparatus for transporting and deploying completion components of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the present invention.

Referring initially to FIG. 1, an apparatus for transporting and deploying completion components of the present invention is operating from an offshore oil and gas platform that is schematically illustrated and generally designated 10. A semi-submersible platform 12 is centered over a submerged oil and gas formation 14 located below sea floor 16. A subsea conduit 18 extends from deck 20 of platform 12 to wellhead installation 22 including blowout preventers 24. Platform 12 has a hoisting apparatus 26 and a derrick 28 for raising and lowering pipe strings such as a completion string 30 that may include tubulars such as prepacked gravel pack screens, production tubing and the like as well as tools such as packers and safety valves that provide the path for the production of hydrocarbons from formation 14 to the surface.

A wellbore 32 extends through the various earth strata including formation 14. Wellbore 32 has a substantially vertical portion 34 that has a casing 36 secured therein by cement 38. Wellbore 32 also has a substantially horizontal open hole portion 40 that traverses hydrocarbon bearing subterranean formation 14. In the illustrated embodiment, the fluids produced from formation 14 include particulate materials such as sand. Accordingly, to prevent the problems associated with sand production, the completion of wellbore 32 requires sand control.

As the production interval associated with wellbore 32 is an extended, open hole, horizontal production interval, it is not desirable to perform a conventional gravel pack operation. Instead, the illustrated embodiment depicts completion string 30 including of numerous joints of prepacked gravel pack screen 45 as well as other completion components such as packers 43 and blank pipe 41. Preferably, prepacked screens 45 include a baked-resin of sand between two screening elements or between a screening element and an outer shroud such that prepacked screen 45 will allow the flow of hydrocarbon fluids therethrough but block the flow of the particulates carried in the hydrocarbon fluids. In the illustrated embodiment, the completion components are being deployed from an apparatus for transporting and deploying completion components 42 that is positioned on vee-door 44 of the rig.

Importantly, apparatus 42 enables a highly efficient completion process by allowing the sequencing of the completion components upon loading apparatus 42. For example, in the illustrated embodiment, the completion components include a plurality of joints of production tubing or blank pipe 41, a plurality of packers 43 and a plurality of joints of prepacked screen 45. These completion components are sequentially loaded into one or more apparatuses 42 such that the various completion components are deployable from the one or more apparatuses 42 in the sequence required downhole.

Specifically, in the illustrated embodiment, production interval 46 has three prepacked screens 45 positioned therein between two packers 43. Likewise, production interval 48 has four prepacked screens 45 positioned therein between two packers 43. Positioned in non production interval 49 are two joints of blank pipe 41. Accordingly, the completion components for intervals 46, 48, 49 of wellbore 32 would be loaded within one or more apparatuses 42 such that theses completion components are sequentially deployable as follows: packer-screen-screen-screen-screen-packer-blank pipe-blank pipe-packer-screen-screen-screen-packer. As such, considerable rig time is eliminated using the apparatus for transporting and deploying completion components of the present invention.

Even though FIG. 1 depicts apparatus 42 positioned in a particular non horizontal angular orientation, it should be noted by one skilled in the art that the apparatus for transporting and deploying completion components of the present invention is equally well-suited for deploying completion components at other angular orientations, including a vertical orientation, depending upon the available space on the rig floor. Accordingly, it should be apparent to those skilled in the art that the use of directional terms such as above, below, upper, lower, upward, downward, top, bottom, front, rear and the like as used herein are in relation to the apparatus for transporting and deploying completion components of the present invention in its vertical orientation. Also, even though FIG. 1 depicts an offshore operation, it should be noted by one skilled in the art that the apparatus for transporting and deploying completion components of the present invention is equally well-suited for use in onshore operations.

Referring now to FIGS. 2-5, an apparatus for transporting and deploying completion components of the present invention is depicted that is generally designated 50. Apparatus 50 includes a container 52 having a front opening 54, as best seen in FIGS. 2 and 5, and a top opening 56, as best seen in FIGS. 4 and 5. Container 52 has a substructure 58 formed from a rear wall 60, a pair of oppositely disposed side walls 62, 64 and a bottom wall 66. In a preferred configuration of substructure 58, side walls 62, 64 are welded to rear wall 60 and form right angles therebetween. Likewise, bottom wall 66 is welded to rear wall 60 and side walls 62, 64 forming right angles therebetween. Also in a preferred configuration of substructure 58, rear wall 60, side walls 62, 64 and bottom wall 66 are made from a steel, such as carbon steel.

In the illustrated embodiment, container 52 has a front panel 68 that consists of a door 70 and a door 72. Door 70 is pivotally moveable relative to side wall 62. Likewise, door 72 is pivotally moveable relative to side wall 64. As such, front panel 68 may be opened, as best seen in FIGS. 2 and 5, and closed, as best seen in FIGS. 3 and 4, to selectively permit and prevent access to container 52 through front opening 54. In a preferred configuration of container 52, door 70 is hingeably mounted to side wall 62 and door 72 is hingeably mounted to side wall 64. In the closed position, doors 70, 72 are latched together to prevent doors 70, 72 from accidentally or prematurely opening or otherwise moving relative to side walls 62, 64, respectively. Likewise, in the open position, doors 70, 72 may be latched to side walls 62, 64, respectively, to prevent any undesired movement of doors 70, 72.

Even though front panel 68 has been described and depicted as two doors 70, 72, it should be understood by those skilled in the art that front panel 68 could have alternative configurations that selectively permit and prevent access to container 52 through front opening 54. For example, front panel 68 could alternatively be a single door that is pivotally moveable relative to either side wall 62 or side wall 64. As another alternative, front panel 68 could be slidably received within grooves in side wall 62 and side wall 64 such that front panel 68 is detachable from container 52.

In the illustrated embodiment, container 52 has a top panel 74 that is slidably received within grooves 76, 78, 80 of side walls 62, 64 and rear wall 60. Top panel 74 is detachable from container 52, as best seen in FIG. 4, to selectively permit and prevent access to container 52 through top opening 56. When top panel 74 is positioned within grooves 76, 78, 80, one or more pins or other locking devices may be used to secure top panel 74 within container 52 and prevent any undesired movement of top panel 74.

Even though top panel 74 has been described and depicted being slidably received within grooves 76, 78, 80, it should be understood by those skilled in the art that top panel 74 could have alternative configurations that selectively permit and prevent access to container 52 through top opening 54. For example, top panel 74 could alternatively be a single door that is pivotally moveable relative to either rear wall 60, side wall 62 or side wall 64. As another alternative, top panel 74 could consist of a pair of doors that are pivotally moveable relative to side wall 62 and side wall 64, respectively.

A support member 90 is securably coupled by welding or suitable technique within container 52 near top opening 76, as best seen in FIGS. 3 and 5. As best seen in FIG. 6, support member 90 has an upper support portion 91. Upper support portion 91 has a plurality of slots 92 formed therein. Depending upon the size of the completion components being transported and deployed from apparatus 50, the completion components may be received directly within slots 92. In the illustrated embodiment, however, each of the slots 92 has a pair of grooves 94, 96 cut in a side wall portion thereof that are capable of slidably receiving inserts 100 therein. Each insert 100 has a slot 102 formed therein. As illustrated, slots 102 are narrower than slots 92. Importantly, inserts having different sized slots may be interchangeably received within slots 92 such that apparatus 50 may accommodate a variety of sizes of completion components.

As best seen in FIGS. 2 and 4, a plurality of completion components illustrated as gravel pack screens 104 are positioned within support member 90 of apparatus 50. Each of the gravel pack screens 104 has an internally threaded box end 106 and an externally threaded pin end 108 such that gravel pack screens 104 can be connected end to end by conventional means for installation within the wellbore. Box end 106 of gravel pack screens 104 includes a collar 110 that has an outer diameter larger than the outer diameter of the blank pipe portion 111 of gravel pack screens 104. As such, gravel pack screens 104 may be received within slots 102 of inserts 100 when apparatus 50 is, for example, in a horizontal position as the outer diameter of blank pipe portions 111 of gravel pack screens 104 is less than the width of slots 102. In addition, slots 102 of inserts 100 partially or fully support gravel pack screens 104 when apparatus 50 is in a non horizontal position or a vertical position as the outer diameter of collars 110 of gravel pack screens 104 is greater than the width of slots 102.

In such a vertical orientation, support member 90 of apparatus 50 supports the entire weight of the plurality of gravel pack screens 104 that hang in tension therefrom. As such, support member 90 includes a plurality of braces 112, as best seen in FIGS. 3 and 6. Preferably, support member 90 has a brace 112 positioned adjacent to side wall 62 and side wall 64, as best seen in FIGS. 2 and 5, and a brace 112 between each slot 92 extending from each leg 114 of upper support portion 91 to rear wall 60, as best seen in FIGS. 3 and 5. In a preferred configuration of apparatus 50, braces 112 are welded to upper support portion 91 of support member 90 and rear wall 60 of container 52.

As gravel pack screens 104 are loaded within container 52, a plurality of sets of spacers 120 are positioned at predetermined intervals within container 52, as best seen in FIGS. 2 and 3. Spacers 120 are positioned between each row of gravel pack screens 104 to prevent contact between adjacent gravel pack screens 104 during transportation. As best seen in FIG. 7, spacers 120 include semi-cylindrical sections 122 having a diameter that approximates the outer diameter of gravel pack screens 104. In this manner, movement of gravel pack screens 104 within apparatus 50 is highly restricted. Spacers 120 may be substantially independent of one another, as illustrated, or spacers 120 may be releasably securable to one another using clamps, straps, rods or other suitable coupling devices. In either case, spacers 120 protect gravel pack screens 104 from contacting one another during transportation or other movement of apparatus 50.

A typically operation using the apparatus for transporting and deploying completion components of the present invention will now be described. After each joint of the completion components is manufactured and tested, the joints are positioned one by one into apparatus 50 such that the desired order of deployment from apparatus 50 is achievable. Apparatus 50 is prepared to receive the completion components by preferably opening both front panel 68 and top panel 74. Thereafter, a first layer of spacers 120 is placed at predetermined intervals within container 52. The spacers 120 of the first layer are flat on one side and have a plurality of semi-cylindrical sections 122, four in the illustrated embodiment, on the other side. In addition, inserts 100 having the appropriate width to receive and support the completion components are slidably received in slots 92 of support member 90.

The first row of the completion components, four in the illustrated embodiment, is then placed within apparatus 50 using one or more cranes or other suitable lifting equipment. The box ends 106 of the completion components are received in slots 102 such that collars 110 will be above support member 90 if apparatus 50 is placed in a vertical position. The next layer of spacers 120 is then placed within container 52 at the predetermined intervals. These spacers 120 have a plurality of semi-cylindrical sections 122 on both sides. In the illustrated embodiment, this process continues until four rows of the completion components are received within slots 102 of support member 90. The last layer of spacers 120 is then placed within container 52. The spacers 120 in this layer are flat on one side and have a plurality of semi-cylindrical sections 122 on the other side. Once apparatus 50 is filled with the desired number of the completion components, sixteen in the illustrated embodiment, top panel 74 is inserted into grooves 76, 78, 80 and secured in place. In addition, doors 70, 72 of front panel 68 are operated to the closed position and secured in place. Apparatus 50 may now be moved to a staging area with other similar apparatuses 50 for loading onto a truck, boat or other transportation medium.

Importantly, when the completion components are gravel pack screens 104, prior to placing gravel pack screens 104 into apparatus 50, it is not necessary to package gravel pack screens 104 as apparatus 50 protects gravel pack screens 104 from damage during transportation. In addition, use of apparatus 50 reduces the number of inspections of gravel pack screens 104 as gravel pack screens 104 are protected from impacts, shocks and vibrations within apparatus 50.

Once apparatus 50 has been transported to the well site, an offshore platform in the illustrated embodiment, and it is time to install the completion components downhole, apparatus 50 is placed in or near the rig floor, at the vee-door in the illustrated embodiment. Doors 70, 72 of front panel 68 are operated to the open position and secured in place and top panel 74 is removed from grooves 76, 78, 80. In this location and configuration, the box end 106 of each joint of the completion components can be rapidly coupled to the traveling block with the aid of a crane supporting the pin end 108. Each joint of the completion components is raised into the derrick such that its pin end 108 can be stabbed into the box end 106 and coupled with the completion component that is at the top of the completion string. This joint of the completion string is then lowered part way into the well such that the next completion components may be coupled therewith. This process continues until all of the completion components 104 in a given apparatus 50 are deployed. Additional apparatuses 50 may then be positioned for the deployment of additional completion components that were transported therein such that the desired sequence of completion components are deployed, assembled and installed.

Importantly, use of the apparatus for transporting and deploying completion components of the present invention enhances the efficiency of the completion operation by positioning numerous completion components in close proximity to the rig floor and in a desired deployment sequence. Additional efficiency gains are achieved using the apparatus for transporting and deploying completion components of the present invention when the completion components are gravel pack screens. In this case, gravel pack screens 104 that are transported in apparatus 50 do not require unpackaging at the well site as apparatus 50 protects gravel pack screens 104 without the need for such packaging. Accordingly, the time required to install the numerous joints of gravel pack screens 104 in significantly reduced when gravel pack screens 104 are deployed from apparatus 50. In addition, as the labor required to deploy the completion components using apparatus 50 is significantly reduced, the likelihood for injury is also reduced.

While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.