U.S. patent application number 11/796168 was filed with the patent office on 2008-10-30 for modular well servicing combination unit.
Invention is credited to James D. Crawford.
Application Number | 20080264649 11/796168 |
Document ID | / |
Family ID | 39885628 |
Filed Date | 2008-10-30 |
United States Patent
Application |
20080264649 |
Kind Code |
A1 |
Crawford; James D. |
October 30, 2008 |
Modular well servicing combination unit
Abstract
A single well servicing combination unit comprising: a hydraulic
manifold removably connectable to the power-take-off of a power
source to drive a plurality of hydraulic pumps and motors that
control a plurality of well servicing modules that are removably
mounted on said combination unit, said well servicing modules being
interconnectable by plumbing.
Inventors: |
Crawford; James D.;
(Laffayette, LA) |
Correspondence
Address: |
ARTHUR M. DULA
3106 BEAUCHAMP STREET
HOUSTON
TX
77009
US
|
Family ID: |
39885628 |
Appl. No.: |
11/796168 |
Filed: |
April 29, 2007 |
Current U.S.
Class: |
166/381 |
Current CPC
Class: |
E21B 19/22 20130101;
E21B 21/00 20130101; E21B 43/168 20130101 |
Class at
Publication: |
166/381 |
International
Class: |
E21B 23/00 20060101
E21B023/00 |
Claims
1. A single well servicing combination unit comprising: a hydraulic
manifold removably connectable to the power-take-off of a power
source to drive a plurality of hydraulic pumps and motors that
control a plurality of well servicing modules that are removably
mounted on said combination unit, said well servicing modules being
interconnectable by plumbing.
2. The combination unit according to claim 1, wherein said power
source comprises a power pack module.
3. The combination unit according to claim 2, wherein said power
pack module is removably connected to said well servicing
combination unit.
4. The combination unit according to claim 2, wherein said power
pack module comprises a truck power pack.
5. The combination unit according to claim 2, wherein said power
pack module comprises a marine mobile power pack.
6. The combination unit according to claim 2, wherein each module
comprises a skid.
7. The combination unit according to claim 1, wherein said well
servicing modules comprise: i. an operator control module; ii. a
combination module; iii. a nitrogen module; said modules being
interconnectable by plumbing.
8. The combination unit according to claim 7, wherein said
combination module comprises a coil tubing module and an acid
module.
9. The combination unit according to claim 8, wherein said coil
tubing module comprises a coiled tubing reel and a coil tubing
string.
10. The combination unit according to claim 9, wherein said coiled
tubing reel ranges in diameter from about 102 inches to over 122
inches and said coil tubing string ranges in diameter from about
1.25 inches to about 2 inches.
11. The combination unit according to claim 7, wherein said
combination module comprises a coil tubing module and a cement
module.
12. The combination unit according to claim 11, wherein said coil
tubing module comprises a coiled tubing reel and a coil tubing
string.
13. The combination unit according to claim 12, wherein said coiled
tubing reel ranges in diameter from about 102 inches to over 122
inches and said coil tubing string ranges in diameter from about
1.25 inches to about 2 inches.
14. The combination unit according to claim 7, wherein said
combination module comprises a cement module and an acid
module.
15. The combination unit according to claim 7, wherein said
nitrogen module comprises a tank of cryogenic nitrogen.
16. The combination unit according to claim 7, wherein said
nitrogen module comprises a nitrogen generator that gathers
nitrogen from the earth's atmosphere and wherein said combination
unit further comprises a compressor connectable by plumbing to said
nitrogen generator.
17. The combination unit according to claim 7, wherein said
nitrogen module comprises a tank of compressed nitrogen gas.
18. The combination unit according to claim 7, wherein said
combination module comprises a sand fracturing tool.
19. The combination unit according to claim 1, wherein said well
servicing modules comprise: an electric wireline apparatus
comprising a tubing encapsulated wire conveyance medium suitable
for electric wireline operations.
20. The combination unit according to claim 2, wherein said well
servicing modules comprise: a combination module and an electric
wireline apparatus comprising a tubing encapsulated wire conveyance
medium suitable for electric wireline operations.
21. The combination unit according to claim 1, wherein said well
servicing modules comprise: a wireline inspection unit and a coiled
tubing unit.
22. The combination unit according to claim 4, wherein said
combination unit comprises a crane trailer and said Truck Power
Pack comprises a truck capable of towing said crane trailer.
23. The combination unit according to claim 4, wherein said well
servicing modules are removably mounted on said crane trailer and
comprise an Operator Control Module, a Coiled Tubing Deployment
Module, an Injector Head Module, Well Control Stack Blow Out
Preventer Module, and a Nitrogen Module.
24. The combination unit according to claim 23, wherein said
Nitrogen Module comprises a Self Generating Nitrogen Module.
25. The combination unit according to claim 1, wherein each of said
modules and components is designed to function in conjunction with
a plurality of combinations of said well servicing modules.
26. The combination unit according to claim 1, wherein said modules
may be custom arranged to allow the combination unit to fit in
available space for a particular well servicing job.
27. The combination unit according to claim 1, further comprising a
transportation module.
28. The combination unit according to claim 27, wherein said
transportation module comprises a marine vessel.
29. The combination unit according to claim 28, further comprising
a marine mobile power pack.
30. The combination unit according to claim 27, wherein said
transportation module comprises an amphibious vessel.
31. The combination unit according to claim 30, further comprising
a marine mobile power pack.
32. The combination unit according to claim 27, wherein said
transportation module comprises a trailer.
33. The combination unit according to claim 30, further comprising
a truck power pack.
34. The combination unit according to claim 27, wherein said
transportation module comprises a skid.
35. The combination unit according to claim 1, wherein said well
servicing units comprise: a high pressure pump and a blending tank;
said high pressure pump and blending tank being interconnectable by
plumbing.
36. The combination unit according to claim 35, further comprising
a crane, said blending tank, high pressure pump and crane being
interconnectable by plumbing.
37. The combination unit according to claim 1, wherein said well
servicing modules comprise: i. a wireline inspection module; ii. a
coiled tubing module; iii. a nitrogen module; iv. a unit pump
module; and v. a blending tank module.
38. The combination unit according to claim 37 further comprising
an acid pump module and an acid tank module that is connectable by
plumbing to said blending tank module and said coil tubing module,
wherein said hydraulic manifold is removably connectable to said
power-take-off of said power source to also drive hydraulic pumps
and motors that control said acid pump module. The combination unit
according to claim 1, wherein said well servicing modules comprise:
a coil tubing module and at least one other well servicing
module.
39. The combination unit according to claim 1, wherein said well
servicing modules comprise: a wireline inspection module; and at
least one other well servicing module.
40. The combination unit according to claim 37, further comprising
a combination nitrogen and high pressure pump module that is
connectable by plumbing to said blending tank module and said coil
tubing module, wherein said hydraulic manifold is removably
connectable to the power-take-off of said power source to also
drive hydraulic pumps and motors that control said combination
nitrogen and high pressure pump module.
41. The combination unit according to claim 1, wherein said well
servicing modules comprise: coiled tubing reel module for
introducing well treatment fluid into a well; and an injector
module that can advance said coiled tubing into a wellbore.
42. The combination unit according to claim 1, wherein said well
servicing modules comprise a coiled tubing injector module and a
crane module for picking up and lowering the coiled tubing injector
of said coil tubing injector module.
43. The combination unit according to claim 1, further comprising
an operator's console module whereby said motors and pumps may be
controlled by an operator.
44. The combination unit according to claim 1, wherein at least one
of said modules is skid mounted.
45. The combination unit according to claim 1, wherein at least one
of said modules is skid mounted.
46. A method of well servicing unit maintenance comprising keeping
functional modules in inventory and replacing broken or
unsatisfactory modules of a modular well servicing combination unit
as desired.
47. A method of producing a well servicing unit comprising
assembling standardized well servicing modules having standardized
interfaces and connectors.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a CONTINUATION IN PART of PCT Patent
Application PCT/U.S.07/06891 entitled "WELL SERVICING COMBINATION
UNIT", filed 20 Mar. 2007 at the USPTO, which is herein
incorporated by reference. This application claims the benefit of
US Provisional Patent Application entitled "WELL SERVICING MODULAR
COMBINATION UNIT", filed 19 Apr. 2007 at the USPTO, which is herein
incorporated by reference.
FIELD
[0002] This invention relates, generally, to the treatment of oil
and gas wells using fluids to increase the production capability of
the wells, and more specifically, to providing for treatment of oil
and gas wells with a means and apparatus that combines multiple
modules--which may include: coiled tubing, nitrogen generation,
fluid pumping, blending tanks, wireline inspection, and other
modules--into a single unit.
BACKGROUND
[0003] It is known in the art to use self-powered units to provide
wireline inspection and workover operations using gaseous nitrogen
to remove sand and/or water or other impediments to production of
oil and gas wells. The prior art has not recognized that a single,
relatively small, engineless unit requiring minimal
set-up/take-down time can be provided with all of the equipment and
accessories for tapping into an onsite power source to run a
combined and integrated system that may include one or more of the
following: coiled tubing unit, nitrogen generator, fluid pumps,
blending tanks, and wireline inspection unit, or other units.
[0004] The prior art equivalent typically brings as many as five
transportation units (tractor-trailers, barges, or boats) to the
well to be treated, one having a coil tubing unit; one having
either a liquid nitrogen tank or a large footprint nitrogen
generation unit; one having the nitrogen pumping unit; one high
pressure pumping unit for acids and other chemicals; and a separate
wireline unit. Alternatively, the prior art may have a very large
boat or barge with multiple units, each with its own power source.
Separate, dedicated power sources for each unit drastically
increases the mass and volume that must be transported. Current
power packs are horsepower limited, which limits the equipment that
each can drive. Conventionally, each of the five units above has
its own engine. Even with a hydraulic power manifold to drive
multiple units from a single engine, the horsepower limits how many
can be integrated. The requirement for multiple (or much larger)
transportation units increases the transportation costs, time, and
personnel required to bring the units to the well and run these
services.
[0005] U.S. Provisional Patent application 60/699,759 teaches a
single, relatively small, self-powered unit with all of the
equipment and accessories for running a nitrogen generation system
and pressure pumping chemicals to treat wells.
[0006] U.S. Pat. No. 6,230,805 (Vercaemer) teaches a method of
hydraulic fracturing in which at least two separate fracturing
fluid components are pumped downhole--one of said components being
pumped downhole within coiled tubing--but does not teach how to
accomplish this with a single compact unit in which all equipment
is powered by an onsite engine and that also provides for the coil
tubing operation and wireline inspection.
[0007] U.S. Pat. No. 6,273,188 (McCafferty) teaches a trailer
mounted coiled tubing rig.
[0008] U.S. Pat. No. 6,702,011, also by the present inventors,
teaches a combined nitrogen treatment system and coiled tubing
system in one tractor/trailer apparatus. A single tractor-trailer
unit is provided, in which the tractor itself drives a plurality of
hydraulic motors that control the pumps and motors associated with
a nitrogen system that is used for injecting nitrogen into a well.
A crane unit and a coiled tubing injection unit are also provided.
Unlike the present invention, no disclosure is made for the
provision of wireline inspection, well servicing fluid tanks,
mixers, and pumps. Unlike the present invention, the preferred type
of nitrogen system is tanks of liquid nitrogen, although an
alternative mode is disclosed in which the liquid nitrogen system
is replaced with one or more nitrogen generators that gather
nitrogen from the earth's atmosphere. However, it was not
disclosed, as in the present invention, that the nitrogen could be
mixed with well servicing fluids provided by the same unit.
[0009] PCT Application US2004/034521 teaches a three in-one
nitrogen treatment system, fluid system, and coiled tubing system
in one unit. A single tractor-trailer or marine unit is provided,
but unlike the engineless present invention, an onboard engine
drives a plurality of hydraulic motors that control the pumps and
motors associated with a nitrogen system and a fluid system that is
used for injecting nitrogen and fluid into a well. Like the present
invention, a coil tubing system is also provided. The only means
disclosed for pumping fluid to the well is through the coil tubing
system and no disclosure is made for the injection of well
servicing fluids directly into the well, and no fluid blending tank
is disclosed. Also, no means for wireline inspection is
provided.
[0010] The off-shore prior art that has the same functionality as
the present invention is larger, more expensive, and requires
either multiple barges or ships--necessitating additional time and
expense for set up and take down of ship to ship plumbing- or a
larger, more expensive barge or ship that has a deeper draft and
can therefore depart from and reach fewer locations.
[0011] The primary object of this present invention is to provide a
small engineless unit that can be placed on a single small barge or
ship or a single tractor-trailer or marsh buggy and use an onsite
power supply to provide wireline inspection, coil tubing
operations, and nitrogen generation and pump a combination of high
pressure nitrogen and acids or other chemicals into wells. The
configuration of the present invention on a marsh buggy could be
nearly identical to the configuration on a boat or barge.
Combination of multiple units such as a wireline, coil tubing unit,
nitrogen generator with fluid pumping and mixing on a single
transportation unit and all powered by an external power source
through a single onboard custom hydraulic manifold is not known in
the prior art to the best of the inventor's knowledge.
[0012] The primary object of the present invention is to provide a
modular well servicing unit that can be placed on a single
tractor-trailer, amphibious vehicle, or a small barge or ship.
[0013] The approaches described in this section are approaches that
could be pursued, but not necessarily approaches that have been
previously conceived or pursued. Therefore, unless otherwise
indicated, it should not be assumed that any of the approaches
described in this section qualify as prior art merely by virtue of
their inclusion in this section.
SUMMARY
[0014] A single well servicing combination unit comprising: a
hydraulic manifold removably connectable to the power-take-off of a
power source to drive a plurality of hydraulic pumps and motors
that control a plurality of well servicing modules that are
removably mounted on said combination unit, said well servicing
modules being interconnectable by plumbing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] These and other features, aspects, and advantages of the
present invention will become better understood when the following
detailed description is read with reference to the accompanying
drawings in which like characters represent like parts throughout
the drawings, wherein:
[0016] FIG. 1 is a top view diagram of the lay out of a 105 class
jack-up boat with a custom hydraulic manifold, wireline inspection
module, coil tubing module, crane, mixing tank module, storage tank
module, fluid pump with power pack, operator console module, and
nitrogen generation module, in accordance with an embodiment of the
present invention.
[0017] FIG. 2 is an elevated, block diagram side view of the deck
of the boat from FIG. 1, that shows a nitrogen generation module
that is connected to the discharge line at a tee, and storage,
mixing, and pumping modules for well servicing fluid connected to
said discharge line at said tee, in accordance with an embodiment
of the present invention.
[0018] FIG. 3 illustrates, in block diagram, the various systems
that are used in accordance with the present invention to treat a
well with nitrogen and well servicing fluid, in accordance with an
embodiment of the present invention.
[0019] FIG. 4 is a pictorial view of three nitrogen generator
modules, in accordance with an embodiment of the present
invention.
[0020] FIG. 5 is a pictorial view of a module using membrane
technology to pull gaseous nitrogen out of the atmosphere, in
accordance with an embodiment of the present invention.
[0021] FIG. 6 shows the external interfaces of the entire WISE.TM.
unit including customer-furnished modules, in accordance with an
embodiment of the present invention.
[0022] FIG. 7 shows the external interfaces of a subset of the
entire WISE.TM. unit, in accordance with an embodiment of the
present invention.
[0023] FIG. 8 shows injector head performance, in accordance with
an embodiment of the present invention.
[0024] FIG. 9 shows injector head performance, in accordance with
an embodiment of the present invention.
[0025] FIG. 10 is a block diagram of a WISE.TM. Unit including a
coil tubing deployment module, injector head module, and well
control stack module, in accordance with an embodiment of the
present invention.
[0026] FIG. 11 is a block diagram of a WISE.TM. CTN2 Unit including
a coil tubing deployment module, injector head module, and well
control stack BOP Module, in accordance with an embodiment of the
present invention.
DESCRIPTION
[0027] The preferred embodiment of the present invention is the
"WISE.TM. Unit", comprising a plurality of modules and
components.
[0028] The "WISE.TM. Unit" is the entire package of equipment
delivered. [0029] Example configurations: [0030] a WISE.TM. 2 Unit,
or [0031] an OFFSHORE WISE.TM. Unit
[0032] A "Module" can be any of the removably connectable major
parts of the "WISE.TM. Unit." Examples: [0033] the CT Module,
[0034] the Nitrogen Module, [0035] the Operator Control Module
[0036] the power pack module
[0037] A Component is a sub part of a Module. This specification
defines components only to the extent necessary for manufacturing
or operational flexibility. [0038] EXAMPLES [0039] Pumps [0040]
Cranes [0041] Valves [0042] Gauges
[0043] The WISE.TM. CT SGN2 unit's architecture (also called the
"WISE.TM. Architecture") allows the insertion of different
servicing modules (i.e., coiled tubing, self-generating nitrogen,
and servicing fluid pumps) when ordering future WISE.TM. Units
without redesign of other Modules (i.e., operator control module,
transportation modules, and power packs).
[0044] The WISE.TM. Unit's architecture and design documentation
allow substitution of major Modules and Components supplied by one
manufacturer with Modules and Components meeting the same
specifications supplied by another manufacturer to take advantage
of shorter lead times. A system integrator approach is enabled by
completely modularity. Every piece of well intervention equipment
becomes a Module to be "integrated" into a working unit. This gives
WISE flexibility of design without sacrificing producibility of
design (manufacturability--standards) and has direct impact on
depot maintenance program and reduces the number of different spare
parts in inventory (Standardization).
[0045] This specification uses the terms "vendor" and
"manufacturer" interchangeably.
[0046] Referring now to FIG. 1, a top view of jack-up boat 10
having either a gasoline engine or a diesel engine is illustrated.
Mounted on the boat deck 30 is nitrogen generator module 31 (also
shown in FIG. 4) that extracts nitrogen from the atmosphere to
eliminate the need for (and the associated cost of) transporting
and filling nitrogen tanks. Mounted to boat deck 30 are chemical
storage tank modules 42 that supply chemicals to blending tank
modules 50 where the chemicals are mixed. The mixed chemicals flow
to the well servicing fluid pump module 48. The mixed chemicals may
flow through the coil tubing 82, 50 to the well head. Wireline
inspection module 52 is mounted to deck 30. Also mounted on the
deck 30 is control cabin module 34 in which the electrical and
hydraulic modules 36 are controlled by a human operator. Components
are described in greater detail in the description of FIG. 2
below.
[0047] Referring now to FIG. 2, a diagram of a jack-up boat 10 is
illustrated. Mounted on the boat deck 30 is a custom hydraulic
manifold 70 that distributes power from an external power source
200 to all engineless modules on deck 30--nitrogen air feed module
32, injector module 44, crane module 46, well servicing pump module
48, blending tank module 50, and Wireline module 52. Mounted on
deck 30 is a feed air system 32 that is connected to nitrogen
membranes 33. Together, the feed air system 32 and nitrogen
membranes 33 function as a nitrogen generator module 31 (also shown
in FIG. 4) that extracts nitrogen from the atmosphere to eliminate
the need for (and the associated cost of) transporting and filling
nitrogen tanks. In the preferred embodiment, nitrogen generator
module 31 utilizes a membrane 33 (also shown in detail in FIG. 5)
that allows nitrogen-rich air from the earth's atmosphere to be
continuously fed into the bundle housing. The air reaches the
center of the bundle of membrane fibers which, at that point,
consists mostly of gaseous nitrogen. The nitrogen collects in the
mandrel at the center of the bundle. As the air passes through the
bundle of membrane fibers, the oxygen and other fast gases pass
through the wall of the membrane fibers as the fast gases go
through to be collected at the end. Oxygen, water vapor, and the
other fast gases are continuously collected and are moved from the
bundle, thus leaving the nitrogen available to be used for
injection into the well being treated. This occurs at near ambient
pressure and temperature. It is an advantage of this embodiment
that large volumes of nitrogen can be provided at the well site to
be pumped into the well, without the need to transport that entire
volume in either liquid or gaseous form to the well site. The
nitrogen generator modules 31 of the preferred embodiment
accomplish this nitrogen generation with a smaller footprint than
any prior art the inventor knows. The nitrogen then flows to the
nitrogen booster compressor 38 that then compresses the dry
nitrogen to the desired pressure. The nitrogen will then be pumped
to the tee 39 where it mixes with a fluid or a fluid mix, such as
an acid, and then the resulting mixture enters the discharge line
41. The nitrogen in the discharge line may be either liquid or gas.
Mounted to boat deck 30 are chemical storage tank modules 42 that
supply chemicals to blending tanks 50 where the chemicals are
mixed. The mixed chemicals flow first to the centrifugal pump 47
and then to the well servicing fluid pump module 48. The mixed
chemicals flow to the tee 39 where the mixed chemicals mix with
nitrogen and the resulting mixture flows into the discharge line
41. From the discharge line 41 the resulting mixture can flow
directly to the well head or through the coil tubing 55 to the well
head. An injector module 44, also described in more detail
hereinafter, is situated on the boat deck. A hydraulically driven
crane module 46 is also situated on the boat deck for situating the
coiled tubing injector module 44 immediately above the well being
treated. A hose reel module 45 and a coiled tubing reel module 55
are situated on the deck 30. A goose neck module 53 is also
situated on the deck 30 adjacent the coiled tubing injector module
44 for feeding the coiled tubing from the reel into the injector. A
stripper 54 is located on the lower end of the coiled tubing
injector system 44 for enabling the coiled tubing 55 to be placed
into the well being treated. A blow out preventer module 56 is also
located on the boat deck to be used in shutting in the well to be
treated, if needed. Wireline inspection module 52 is mounted to
deck 30. Also mounted on the deck 30 is a control cabin 34 in which
the electrical 36 (not shown) and hydraulic modules 70 are
controlled by a human operator. Referring now to FIG. 3, there is
illustrated in block diagram some of the components that are
illustrated in FIGS. 1 and 2.
[0048] The nitrogen air feed module 32 has its output connected
into the input of a hydraulic pump 90. The custom hydraulic
manifold 70, which may be connected to either a gasoline powered or
diesel powered external power source or marine mobile power pack
200, has a return line 74. A hydraulic pump 90 is connected into a
hydraulic motor 92 that is used to drive the return line 74.
[0049] A hydraulic pump 96 is connected into a hydraulic motor 98
that is used to drive the chains of the injector module 44 that can
either move the coiled tubing into the well being treated or pull
the coiled tubing out of the well being treated, as desired,
depending on the direction of the chain rotation.
[0050] Another hydraulic pump 100 drives a motor 102 to drive the
crane 46 illustrated in FIG. 2.
[0051] Another hydraulic pump 110 drives a motor 112 to power the
well servicing pump 48, which is illustrated in FIG. 2.
[0052] Another hydraulic pump 116 drives a motor 118 to power the
blending tank modules 50, which are illustrated in FIG. 2.
[0053] Another hydraulic pump 122 drives a motor 124 to power the
wireline inspection module 52, which is illustrated in FIG. 2.
[0054] It should be appreciated that from the power-take-off of a
power source 200, a custom hydraulic manifold distributes power to
each of the five modules. Said power source with a power-take-off
200 routed through custom hydraulic manifold 70 drives each of the
hydraulic pumps 90, 96, 100, 116 and 122 as shown by the line 106.
Coming off of the custom hydraulic manifold 70, the hydraulic pumps
90, 96, 100, 116 and 122 are preferably driven by one or more belts
that can be used with clutch pulleys as desired. The compressor
module 108 is also driven by the custom hydraulic manifold 70 via
the drive line 106 to bring the nitrogen down to its desired
temperature. By using a power-take-off on the vessel (rig,
platform, work boat, tug boat, or jack up barge) that is already on
site, that power source 200, with over 1000 horsepower available,
can drive more machines than a less powerful onboard source
could.
[0055] The preferred embodiment of the present invention can
operate with a separate land or marine external power source. As
long as the preferred embodiment of the present invention can avail
itself of an adequate power source it can do all of the following
well servicing, including but not limited to: [0056] Completions
[0057] Workovers [0058] Underbalanced drilling Well servicing
[0059] Enhanced oil recovery [0060] Industrial plant degassing and
purging [0061] Mining [0062] Purging pipelines with nitrogen [0063]
Deepwater marine applications [0064] LNG & LPG tanks and
facilities [0065] Nitrogen lifting, the flooding wells that won't
flow with nitrogen [0066] Nitrified Acid [0067] Nitrogen
Displacement Pipeline testing Tubing testing
Acidizing
Cleanouts
[0068] Fix sanding up--Paraffins--Foam wash Jet with nitrogen
Nitrify acid Nitrogen inhibitor
Wireline Inspection
[0069] One advantage of the present invention is that it makes it
possible to do with one unit and an single power source what
previously required five separate powered units--a wireline
inspection unit, a coiled tubing unit, a liquid nitrogen tank
transport means, a powered unit with a high pressure pumping system
for other chemicals and acids, and a unit with a nitrogen pumping
means. Because this embodiment allows one unit to do what once
required several powered units connected together with the
requisite hoses and plumbing, the time and expense of plumbing
rig-up is avoided. Disconnecting and stowing all of the plumbing
after completion is also avoided, saving additional time and labor.
Where the prior art would have taken several units and several days
(for set-up, inspection, well treatment, and disassembly), the
preferred embodiment of the present invention can do the same job
with one unit in one day. The present invention saves the trouble
and expense of transporting five separate power sources to the
site, each of which takes up over sixty square feet of deck space,
allowing this combined unit to be smaller and cheaper than any
prior art equivalent. The smallest existing vessel with a coil
tubing unit is a 175 class boat, yet an embodiment of the present
invention with an integrated coil tubing module along with four
other integrated modules can be placed on a single 105 class boat.
The deck load of the prior art equivalent would be about 150,000
pounds, yet an embodiment of the present invention has a deck load
of only about 50,000 pounds, allowing operations in shallower
water. The danger of transporting liquid nitrogen, which is an
explosion hazard, is also avoided. Hazards associated with running
plumbing and hoses from boat to boat are also avoided, and fewer
personnel are required. As far as the inventor knows, the preferred
embodiment of the present invention has a smaller footprint and
lighter weight than any functional equivalent.
[0070] The preferred embodiment of the present invention is even
more advantageous in remote locations where liquid nitrogen is rare
and expensive, or extremely difficult to transport to the well
head.
[0071] The invention is well suited for off shore use. Because of
its small footprint, this invention allows replacement of large,
expensive vessels with much smaller and cheaper barges or ships
that have shallower drafts.
[0072] It should be noted that while the embodiment described so
far is powered by a prime mover such as a marine mobile power pack,
the invention can also be mounted on and use the engine of a truck
power pack and is equally suited for on shore use. An embodiment of
the present invention may be trailered on land, to replace as many
as five separate units and realize similar time and cost
savings.
[0073] Another embodiment of the present invention comprises an
onshore-offshore convertible WISE.TM. Combination Coiled Tubing
(CT) and Nitrogen (N2) Unit with a Self-Generating Nitrogen (SGN2)
Module. This WISE.TM. Unit is called the "WISE.TM. CT SGN2
ONSHORE-OFFSHORE CONVERTIBLE UNIT" abbreviated as "CT SGN2".
[0074] In the onshore configuration, a Truck Power Pack will tow a
crane trailer module loaded with modules such as: an Operator
Control Module, Coiled Tubing Deployment Module, Injector Head
Module, Well Control Stack BOP Module, and SGN2 Nitrogen Module to
and from well servicing sites. At well servicing sites, the Truck
Power Pack will power the servicing equipment.
[0075] An advantage of the present invention is that
customer-furnished equipment (CFE) can be provided to be integrated
into the WISE.TM. Unit, allowing a high degree of customization and
cost savings. Changes to the unit configuration can be made much
later in the manufacturing/assembly process, or even after the unit
is in use in the field.
Reconfiguration between On-Shore and Off-Shore Jobs
[0076] This WISE.TM. Unit can be deployed for both on-shore and
off-shore jobs: [0077] The onshore subset of this WISE.TM. Unit is
a truck power pack that tows all servicing modules mounted on a
crane trailer to the job site and then powers the servicing
equipment on the job site. [0078] The offshore subset of this
WISE.TM. Unit is the operator control module and servicing modules
removed from the onshore crane trailer plus marine mobile power
pack. These modules are transported on a customer-furnished truck
to port and on a customer-furnished boat to an offshore oil
platform. On the offshore oil platform, the marine mobile power
pack supplies all power required for the WISE.TM. Unit. [0079] By
itself, the marine mobile power pack can be used as a backup or
substitute for the WISE.TM. III marine power pack.
Reconfiguration for Different Well-Servicing Functions
[0080] In the onshore configuration, the WISE.TM. CTN2 Unit can be
augmented by an independently-powered fluid pump
(customer-furnished) to deliver servicing fluid or nitrified
servicing fluid into the well.
[0081] In the offshore configuration, the WISE.TM. CTN2 Unit
provides fluid pumping from its Marine Mobile Power Pack to deliver
servicing fluid or nitrified servicing fluid into the well.
[0082] The WISE.TM. Unit can be reconfigured for different
well-servicing functions at the maintenance depot level. The
cryogenic liquid nitrogen module can be replaced by or augmented by
a fluid servicing pump without modifying the operator control
module.
[0083] In the preferred embodiment, to facilitate modularity the
following interface standards are universal throughout all of the
WISE.TM. units. These standards govern connections between the
Operator Control Module and other modules within the WISE.TM.
Unit.
TABLE-US-00001 Equipment Interface Table Air Pneumatics 3/4'' and
Smaller "Parker" 30 Series QD couplers & Industrial Interchange
Nipples 1'' Industry Standard "crow's foot" couplers Hydraulic
Fluid 1'' and Smaller "Parker 6600 Series" QD Couplers and Nipples
11/4'' and Larger "Snap-Tite" 75 Series Wing Type QD Couplers and
Nipples Water Glycol All "Snap-Tite" VH Series QD Vaporization
Loops Couplers and Nipples Water Glycol All "Snap-Tite" VH Series
QD Vaporization Loops Couplers and Nipples Liquid Nitrogen All 150N
Acme Thread Couplers and Nipples Gaseous Nitrogen All Figure 1502
Hammer Unions Well Treatment Fluids All Figure 1502 Hammer Unions
120/220 VAC Electrical All NEMA Twist Lock Power Connectors DC
Instrumentation All Meltric SS PN 12 Series Connectors 12 VDC Power
All 4-Pin SAE Truck/Trailer couplings
Functional and Performance Requirements
Nitrogen Delivery
[0084] The WISE.TM. Unit will preferably provide nitrogen at a
discharge pressure ranging from 0-7500 psig and at an
operator-controllable flow rate ranging from 0-850 scfm, while
maintaining the discharge temperature at 10.degree. F. above
ambient.
Onshore Configuration
[0085] In the onshore configuration, the WISE.TM. Unit will
preferably transfer servicing fluid from an independently-powered,
customer-furnished source to the well via 2-inch pipe with 1502
Hammer unions compatible with well-servicing fluids.
TABLE-US-00002 TABLE CTN2-4 Well-Servicing Fluid Supply Circuit
Flow acid 1500 gal cement 10 bbl sand slurry 1500 lbs
Offshore Configuration
[0086] In the offshore configuration, the WISE.TM. Unit will
preferably pressurize and transfer servicing fluid from a
customer-furnished source to the well via the CT at an
operator-controllable flow rate ranging from 0-50 gpm and a
pressure ranging from 0-5000 psig.
Transportability Requirements
[0087] In between well interventions, the Truck Power Pack will tow
the WISE.TM. Unit trailer (comprising for example: a crane trailer
loaded with an Operator Control Module, Coiled Tubing Deployment
Module, and Nitrogen Module) to and from well servicing sites.
[0088] The Unit travels over a wide range of roads, paved and
unpaved, between well-servicing jobs. The Unit should configure for
transportation to minimize need for special permits in onshore and
offshore configurations.
[0089] At well servicing sites, the Unit can operate beyond its
transportation envelope with an operator-extended crane and other
extensions such as coolers or open ventilation doors.
[0090] The Unit may be Shipped Overseas.
[0091] Well servicing modules can be installed onto the Onshore
Transport Trailer Module with cranes or forklifts.
Onshore
[0092] The WISE.TM. Unit can provide self-contained onshore
transportation for the onshore configuration. An embodiment of the
onshore configuration comprises all modules except the offshore
marine mobile power pack, transportation skid kit, and hose basket
with offshore hose bundle.
[0093] In the preferred embodiment of an onshore transportation
configuration, the WISE.TM. Unit should preferably have a total
height less than 13 feet, 6 inches.
[0094] In the preferred embodiment of an onshore transportation
configuration, the WISE.TM. Unit should preferably have a total
width of less than 8 feet, 6 inches.
[0095] In the preferred embodiment of an onshore transportation
configuration, the WISE.TM. Unit should preferably have a total
length of less than 64 feet.
Offshore
[0096] The preferred embodiment of a marine mobile power pack
should preferably be transportable onshore on trucks.
[0097] In the preferred embodiment, it is preferable that no single
skid in the offshore transportation configuration weigh more than
18,500 pounds, except for the coil tubing drum loaded with coil
tubing in its transportation skid.
[0098] In the offshore configuration, the WISE.TM. Unit should
preferably weigh less than 85,000 pounds including one full
cryogenic nitrogen storage vessel and 10,000 feet of 11/4'' coil
tubing.
Onshore To Offshore Conversion
[0099] The WISE.TM. Unit should preferably be designed so that the
following modules and components can be removed from its onshore
transportation trailer for separate transport to an offshore site:
[0100] operator control module [0101] coil tubing deployment module
[0102] cryogenic liquid nitrogen module except cryogenic liquid
nitrogen storage vessel
[0103] The goal for this onshore to offshore conversion is
completion in 8 hours using a three-person operations crew and the
following equipment: [0104] customer-furnished forklift [0105]
customer-furnished crane [0106] Transportation Skid Kit included
with the WISE.TM. Unit [0107] Hose Reel Skid included with the
WISE.TM. Unit
Offshore to Onshore Conversion
[0108] The goal for this onshore to offshore conversion is
completion in 24 hours using a three-person operations crew and the
following equipment: [0109] customer-furnished forklift [0110]
customer-furnished crane [0111] Transportation Skid Kit included
with the WISE.TM. Unit [0112] Hose Reel Skid included with the
WISE.TM. Unit
Availability and Reliability
[0113] Overall WISE.TM. Unit availability is a function of the
WISE.TM. Unit reliability and maintenance and logistics systems.
"Availability" is defined as the WISE.TM. Unit being ready for
transit between well-servicing sites and for performing
well-servicing activities. Increasing availability of units
minimizes maintenance down time and increases utilization rate. By
keeping modules at the depot in inventory, a "broken" module is
simply replaced by a certified working. This keeps a unit in
service more days per month but with no additional fixed costs
(such as crew, etc.). Taking this maintenance approach improves
unit availability (utilization).
WISE.TM. Unit Maintainability Requirements
[0114] The WISE.TM. Unit should preferably provide well services
for 12 hours without refueling.
[0115] The WISE.TM. Unit should preferably require no preventive
maintenance beyond that described in Appendix C, Customer
Maintenance Program.
Growth Requirements
[0116] The WISE.TM. Unit should preferably incorporate the
following provisions (hardware "scars") for the post-deployment
addition of a well servicing fluid pump integrated into the onshore
configuration: [0117] operator control module fluid pump
control
WISE.TM. Architecture and Design Constraints
Module Definition
[0118] The complete WISE.TM. Unit has the following modules
integrated: [0119] One (1) Operator Control Module [0120] One (1)
Truck Power Pack [0121] One (1) Trailer with Crane for Onshore
Operations [0122] One (1) Coiled Tubing Deployment Module (Reel
assembly) with major components: [0123] One (1) Coiled Tubing Reel
Skid (cfe) [0124] One (1) Coiled Tubing Reel Drum (cfe) [0125]
Tubing (cfe) [0126] One (1) Injector Head Module (cfe) [0127] One
(1) Well Control Stack (Blow Out Preventor (BOP) Module (cfe)
[0128] One (1) Cryogenic Liquid Nitrogen Pumping Module [0129] One
(1) Marine Mobile Power Pack [0130] One (1) Crew Cab Truck (cfe)
[0131] One (1) Tools (cfe) [0132] One (1) Electrical Generator
[0133] One (1) Transportation Skid Kit [0134] One (1) Hose Reel
Skid
3.2 Internal Interfaces
[0135] Interface P-1 and P-2 should preferably be identical for
hydraulics and electrical.
[0136] Interface P-2 should preferably be identical to the
interface between the WISE.TM. III power pack and the remainder of
the WISE.TM. III Unit.
Module-Level Requirements
[0137] The following sections contain the requirements for the
modules and their major components.
Operator Control Module
[0138] The Operator Control Module (WISE.TM. Power Management
Module) represents the core of the WISE.TM. technology principal of
central control and operation of multiple well-serving functions
from a single power source and control point. Mated with the
appropriate power sources and ancillary equipment packages, this
module monitors and controls: Coiled Tubing Deployment, Cryogenic
Nitrogen, and Fluid Pumping Operations (if installed).
[0139] The Operator Control Module should preferably provide:
1. Operator Control and Monitoring interface for entire WISE.TM.
Unit except crane 2. Electrical power transformation (120 VAC to 12
VDC) and distribution to all systems needing electrical power 3.
Hydraulic power distribution control to all well-servicing modules
and crane 4. Heat transfer water and glycol distribution to N2 (if
installed). 5. Well servicing fluid distribution and control in
offshore configuration. 6. Well servicing fluid control if
integrated in onshore configuration (see 2.11, Growth
Requirements).
[0140] Note that external customer-furnished fluid pumping is not
controlled by the operator control module,
[0141] The Operator Control Module should preferably be a
skid-mounted module with a crash frame; forklift guide tubes and a
four point sling lift attachment points. Lifting slings are
CFE.
[0142] In the transportation configuration, the Operator Control
Module should preferably e 96'' long.times.96'' wide with height to
allow 13'6'' height clearance when loaded on a 48'' tall truck
trailer. The Operator Control Module should preferably weigh 15,500
lbs or less.
[0143] The Operator Control Module should preferably operate in the
offshore well servicing environment.
[0144] The Operator Control Module should preferably operate in the
onshore well servicing environment.
Operator Control and Monitoring
Telescoping Operator Control Cabin
[0145] The control cabin shall: [0146] Telescope upward to an
operator-controllable height (up to 5' maximum extension) from the
volume of the transportation skid. (to provide operator with
visibility of well-servicing operations) [0147] Be 84''
wide.times.84'' long (interior) [0148] Have two (2) side access
doors for operator entry with stainless steel door hardware, fixed
windows in doors, and rain gutter above doors. [0149] Have operator
access by ladder on one side and steps on the other [0150] Have
front window protected with hinged metal guard that can be fully
removed by operator. [0151] Have fixed side wall windows. [0152]
Have Sliding rear windows. [0153] Have tempered safety glass in all
windows. [0154] Have all windows tinted. [0155] Light its interior
with one (1) 110 volt interior fluorescent lamp [0156] Contain an
unmounted, portable office-style chair with armrest for operator
comfort. [0157] Contain a 48'' wide bench seat along rear of cabin
with removable to access storage below bench seat. [0158] Contain
one (1) chart recorder of a two (2) pen type Well Head Pressure and
Circulating Pressure. [0159] Be cooled by one (1) through the wall
Air Conditioner of 12,000 btuh cooling capacity. [0160] Interface
with electrical distribution via one (1) electrical junction box
for 110/220 volt power connection for Lighting and Air Conditioner.
[0161] Contain a Control Console of an open "L" shape having a
lower section sloped and an upper near vertical section running
along the front of the cabin so that operators in both sitting and
standing positions can read all instruments and move all controls
through their full ranges.
Operator Interface
Controls and Indicators
[0162] The preferred embodiment of the control console module
provides the following controls and indicators for the
operator:
1) 6-Bank BOP control valve with a single function handles. BOP
control valves should preferably be labeled from left to right
"Blinds", "Cutters", "Slips", "Pipe", "Aux Pipe" and "Blind
Shears". BOP's to have an emergency back-up circuit from an air or
hand operated in cabin pump.
2) BOP Circuit Master Push/pull Actuation Valve and Pressure
Gauge
[0163] 3) 5-Bank valve panel with integral locking Walvoil type SD6
valves in corner of console for remote plug valve operations.
Valves to be labeled "BOP Kill", "Aux Kill", "Return", "Spare 1"
and "Spare 2" 4) Air Regulator Valve and Air Supply Gauge for
Stripper Pack-off Air over Hydraulic Pump. 5) Stripper Circuit Air
Drive pump with emergency manual operator. 6) Snap-Tite Stripper
control valve and Stripper circuit hydraulic pressure gauge. 7)
Injector Weight Indicator mounted in center of Panel Upper section.
Indicator should preferably read 60,000 lb pipe heavy and 15,000 lb
pipe light. 8) Single Pressure Regulator Valve and isolation valves
with circuit pressure gauges for three (3) injector traction
circuits. 9) Emergency Accumulator systems for: a) injector
traction circuits with full pressure activation valve b) injector
head skate system chain tension circuits with TBD valve 10) Single
Pressure Regulator Valve and isolation valve with circuit pressure
gauge for a single injector chain tension circuit. 11) Gresen
(Munson-Tyson Type) Control Valve for Injection speed and
direction, with Cartridge valve for fine control of injector speed.
(Auto-driller arrangement) 12) Selector Valves for Injector speed
range and injector brake circuit with status indicator gauges. 13)
Pressure Control Valve for Setting Injector Power Circuit pressure
with gauge. 14) Needle Valve for injector chain oiler control. 15)
Three (3) single bank directional control valves for Tubing Reel
Pay-Out and Take-Up; Levelwind Raise and Lower; and Levelwind
Override. 16) Pressure Control Valve for Reel tension Control with
tension pressure gauge. 17) Control Valve for reel brake circuit
with pressure gauge. 18) Two (2) 6'' face 4:1 ratio 15,000 psig
reading pressure gauges, One (1) for circulating pressure to the
left of weight indicator and one (1) for well head pressure to the
right of the weight indicator. 19) Air operated controls for power
pack engine throttle, shutdown and emergency kill. 20) Power Pack
Engine remote instrumentation Package to include, Tachometer,
Coolant Temperature. 21) Cryogenic Nitrogen Centrifugal Boost Pump
Speed control Valve. 22) N2 Boost Pump hydraulic pressure gauge.
23) N2 Boost Pump LN2 discharge pressure gauge (150 psi) with
debooster or remote sender to protect operators from cryogenic N2
exposure in case of gauge or gauge plumbing failure. 24) N2 tank
discharge (vaporizer inlet) pressure gauge (10,000 psi) with
debooster or remote sender to protect operators from cryogenic N2
exposure in case of gauge or gauge plumbing failure. 25) Cryogenic
Nitrogen Triplex Injection Pump Speed control valve (warm end). 26)
N2 Triplex pump hydraulic pressure gauge. 27) N2 Triplex pump LN2
discharge pressure gauge.
28) Auxiliary Heat Load Hydraulic Pressure Control Valve.
29) Auxiliary Heat Load Hydraulic Pressure Gauge.
[0164] 30) Remote Air Operated Low Pressure LN2 Prime to Atmosphere
control valve. 31) Remote Air Operated Low Pressure LN2 bypass to
tank control valve. 32) Remote Air Operated High Pressure LN2
bypass to tank control valve.
[0165] 33) Remote Air Operated High Pressure GN2 tempering control
valve.
[0166] The hydraulic controls should preferably be rated for
operation at 3000 psi working pressure.
Hydraulic Distribution
[0167] The hydraulic distribution component of the operator control
module should preferably include:
[0168] Permanently installed hoses from the control cabin bulkhead
for connection to the following: [0169] Injector main drive
hoses--power pack to rear of trailer plus extensions to the hose
reel. [0170] Reel pivot hose [0171] BOP control hoses installed
with extensions to the hose rack [0172] Injector control hoses
installed with extensions to the hose rack [0173] Reel control
jumper hoses [0174] Two (2) 15 gallon accumulators for BOP circuits
mounted inside trailer frame rails.
[0175] The hoses should preferably be labeled at each end with
bands imprinted with customer-specified text and by numbered
stainless steel washers.
Electrical Transformation and Distribution
[0176] The electrical distribution component of the operator
control module should preferably distribute 120 VAC from the
electric generator to the listed components at no more than listed
current: [0177] the control cabin air conditioning component (10.0
amps) [0178] the control cabin lighting (2.0 amps)
[0179] The electrical distribution component of the operator
control module should preferably distribute 120 VAC from an
offshore platform supply to the listed components at no more than
listed current: [0180] the control cabin air conditioning component
(10.0 amps) [0181] the control cabin lighting (2.0 amps)
[0182] The electrical distribution component should preferably
transform 120 VAC to 12 VDC and distribute 12 VDC to: [0183]
monitoring instrumentation
Heat Transfer Water-Glycol Distribution
[0184] The Water-Glycol Distribution component should preferably
distribute a water and glycol mix from the power pack to the
cryogenic liquid nitrogen modules via the hydraulics heat
exchanger.
Well-Servicing Fluid Distribution and Control
[0185] In the off-shore configuration, the operator control module
shall: [0186] Control the well-servicing fluid pump in the marine
mobile power pack [0187] Distribute well-servicing fluid from the
power pack to the CT
Truck Power Pack
[0188] An over-the-road truck tractor provides onshore
transportation and onshore power to the hydraulic systems for all
Coiled Tubing and Nitrogen Modules.
[0189] The truck power pack should preferably tow the trailer
containing the crane and well-servicing modules to onshore well
servicing sites and maintenance locations.
[0190] At the well-servicing site, the truck power pack should
preferably provide hydraulic power to concurrently operate the coil
tubing and nitrogen modules at their maximum capabilities described
in section 2.2 (functional and performance requirements).
[0191] The truck power pack should preferably operate in the
onshore well servicing environment.
[0192] The truck power pack consists of a Freightliner 515-hp
Detroit Diesel series 60, 14.0 L tractor with 10-speed transmission
plus "wet kit" consisting of: an auxiliary transmission, a pair of
PTO's, a hydraulic reservoir, a glycol reservoir, fluid coolers,
hydraulic pumps, and various hoses, fittings, and control valves.
Its features include: [0193] 515 peak Horsepower Tractor Engine
[0194] Full power capacity driveshaft driven auxiliary transmission
with forward and rear facing hydraulic pump mounts. [0195] Two (2)
truck transmission mounted PTO's. [0196] Two (2) axial piston
pressure compensated hydraulic pumps, one for Nitrogen Modules, and
one to drive the Coiled Tubing Injector Head. [0197] One (1) single
vane hydraulic pump to serve dual purposes, powering either the
pedestal crane, or an auxiliary heat load circuit. [0198] One (1)
double-vane hydraulic pump, with one (1) circuit dedicated to the
coiled tubing reel hydraulics distribution, and one (1) circuit
dedicated to BOP and safety control modules hydraulic distribution.
[0199] One (1) double-gear glycol and water pump for circulation of
water glycol mixture for LN2 vaporization. [0200] Multiple baffled
hydraulic reservoir with integral return filters, strainers and
connection points for truck power pack to trailer. [0201] Two (2)
hydraulic fan powered fluid coolers. [0202] One (1) glycol
reservoir and expansion chamber. OnShore Transport Trailer with
Crane
[0203] Major components of this module are the Transport Trailer
and Crane.
[0204] The OnShore Transport Trailer with Crane should preferably
operate in the onshore well servicing environment.
Transport Trailer
[0205] Preferably, a 48 ft long single drop-deck triple-axle
trailer provides the transportation and work platform for all the
well servicing equipment and a hydraulic pedestal crane.
Trailer
[0206] Trailer specifications are: [0207] Three air ride axles with
third (rearmost) axle set up with a dump valve to shorten effective
trailer turn radius. [0208] 48 ft long single drop deck trailer
with 11 ft long upper deck, 37 ft lower section. [0209] Upper deck
should preferably be plate, lower section should preferably be bare
frame rails. [0210] 8' width [0211] 12'' minimum ground clearance
[0212] Standard king pin setting [0213] Landing legs 160,000 lb.
[0214] Three (3) each 25,000 lbs. Axles (minimum) [0215] Brakes
161/2.times.7 air type [0216] Michelin tires or equivalent 11R24.5
[0217] Parking brake air chambers mounted above axles [0218] 31/2''
SAE King pin with 3/8 rub plate [0219] Lights, stop/turn armored
clearance [0220] Mud flaps [0221] Rear bumper [0222] Running lights
for highway use
Equipment Mounts
[0223] Complete equipment mounts installed on the trailer should
preferably allow quick pin-on and rig-up of equipment: [0224] Well
control stack [0225] Injector head [0226] All skidded equipment
[0227] Tool boxes
[0228] Injector head and well control stack equipment mount should
preferably be within the crane's operating envelope. As shown in
FIGS. 8 and 9, the injector may be operated continuously at the
intersection of any speed and pull combination as long as the
intersection remains on or to the left and below of the 100 hp
continuous output curve.
[0229] Injector head mount should preferably position the HydraRig
635 injector head so that the COIL TUBING can remain stabbed during
transport between well servicing sites.
[0230] Mounting brackets and setups should preferably secure one
1800-gallon cryogenic liquid nitrogen tank (tank itself is
described in nitrogen module specification).
Crane Assembly
[0231] A hydraulically-operated pedestal crane (such as: National
Crane Model 638, 18 ton Pedestal Crane) should preferably be
installed on the crane trailer.
Specifications of the Crane are:
Crane Capacities:
TABLE-US-00003 [0232] 36,000 lbs. maximum 23,000 lbs. @ 8 ft. boom
Radius 16,550 lbs. @ 12 ft. boom Radius 10,500 lbs. @ 20 ft. boom
Radius 5,050 lbs. @ 35 ft. boom Radius Note: Crane capacities may
vary with boom length and attachments.
Frame:
[0233] Box construction pedestal with turret mounted on shear type
ball bearing and bulkhead fittings for crane operation.
Rotation:
[0234] 270.quadrature. non-continuous by means of planetary gear,
hydraulic drive unit, and swing stops.
Boom:
[0235] Three (3) section hydraulic telescoping boom, 16 ft.
retracted to 38 ft. extended (maximum horizontal reach).
Winch:
[0236] High performance planetary winch rated at 10,000 lbs. bare
drum single line pull
Controls:
[0237] "RVC" (or equivalent) remote valve control group
Anti-Two Block:
[0238] Explosion-proof system that helps prevent cable damage by
sensing position of winch cable and attachments with respect to
sheave case.
Stabilizers:
[0239] Rear hydraulic stabilizers, "A" type.
Physical Dimensions for Transportability:
[0240] The crane must fold up and fit in the space provided on the
crane trailer during transport.
Reel Pivot:
[0241] A reel pivot cylinder that will pivot to either side of the
unit will be installed on the unit.
3.3.4 Coiled Tubing Deployment Module
[0242] The WISE.TM. Unit should preferably deploy coiled tubing
using the following combinations of coil tubing deployment modules
and injector heads:
TABLE-US-00004 Configuration Coil Tubing Deployment Module Injector
Head 122''-A Modified HPT 122'' CT Reel Assembly HydraRig 635
122''-B Modified HPT 122'' CT Reel Assembly LSI 102''-A LSI 102''
CT Reel Assembly HydraRig 635 102''-B LSI 102'' CT Reel Assembly
LSI
[0243] In the 122'' A and B configurations the WISE.TM. Unit can:
[0244] spool 13/4'' diameter CT @ 2500 psig operating pressure.
[0245] provide coiled tubing storage capacity for 11/4''-13/4''
Coiled Tubing (CT). [0246] provide CT capacity by volume of: [0247]
21,500 feet of 11/4'' tubing [0248] 15,500 feet of 11/2'' tubing
and [0249] 11,500 feet of 13/4'' tubing.
[0250] In the 102'' A and B configuration embodiments the WISE.TM.
Unit can: [0251] spool 11/2'' diameter.times.0.125'' wall thickness
CT @ 2500 psig operating pressure. [0252] provide coiled tubing
storage capacity for 1''-11/2'' Coiled Tubing (CT). [0253] provide
CT capacity by volume of: [0254] 16,000 feet of 11/4'' tubing and
[0255] 111,000 feet of 11/2'' tubing. [0256] provide coil tubing
capacity by weight for carrying and deploying a total of 20,000
pounds of continuous coiled tubing.
[0257] Note that this embodiment of the WISE.TM. Unit's CT length
is limited by weight carrying capacity, not volume. Depending upon
the wall thickness string length capacities will vary.
[0258] This embodiment of the WISE.TM. Unit supplies hydraulic
fluid to an injector at an operator-controllable rate ranging from
0-85 gpm (inclusive) and at an operator-controllable pressure
ranging from 0-3000 psig (inclusive).
Cryogenic Liquid Nitrogen Module
[0259] The Cryogenic Liquid Nitrogen Module should preferably
output up to 1,500 scfm gaseous nitrogen at 10,000 psig. However,
note that overall integrated unit nitrogen capacities are below
this peak due to horsepower limitations.
[0260] The Cryogenic Liquid Nitrogen Module should preferably meet
these output requirements in the onshore well servicing
environment.
[0261] The cryogenic liquid nitrogen module has two major
components: [0262] the cryogenic liquid nitrogen storage vessel
[0263] the nitrogen pump and vaporization component
Cryogenic Liquid Nitrogen Storage Vessel
[0264] In the preferred embodiment the Cryogenic Liquid Nitrogen
Storage Vessel module should preferably comprise a double layer
vacuum insulated pressure vessel. This tank should preferably be
provided with fill, suction vent, and pressure building manifolds
and valves. The vessel capacity should preferably be approximately
1800 liquid gallons. This vessel will be removably attached to the
upper deck on the land transport trailer: [0265] Inner vessel
design pressure of 45 psi [0266] 21/2'' Fill and Drain piping
[0267] 11/2'' Vent, Recirculation, Rear Fill, and Top Fill piping
[0268] 1'' pressure-build pipes
Cryogenic Liquid Nitrogen Pump and Vaporization Component
[0269] The Cryogenic Liquid Nitrogen Pump and Vaporization
Component should preferably draw cryogenic liquid nitrogen from the
Cryogenic Liquid Nitrogen Storage vessel and force it through the
vaporizer to produce gaseous nitrogen.
[0270] The Cryogenic Liquid Nitrogen Pump and Vaporization
Component should preferably meet its output requirements in the
offshore well servicing environment.
[0271] The preferred embodiment of the Cryogenic Liquid Nitrogen
Pump and Vaporization Component comprises: [0272]
2''.times.1''.times.41/2'' cryogenic centrifugal boost pump with
mated high speed hydraulic motor to draw cryogenic liquid nitrogen
from the storage vessel and pump it at low pressure (less than 100
psig) to a triplex injection pump. [0273] Triplex ICMP 100 type
Cryogenic Nitrogen Positive displacement Pump, with mated bent axis
hydraulic motor, to develop pressure necessary to overcome the
resistance to the fluid through the vaporizer. [0274] Pressure oil
lubrication system for triplex pump crankcase. [0275] Liquid
circulation type Liquid Nitrogen Vaporizer.
[0276] This component should preferably be packaged separate from
other systems and the cryogenic liquid nitrogen storage vessel.
[0277] The Cryogenic Liquid Nitrogen Pump and Vaporization
Component should interface with customer-furnished offshore
cryogenic liquid nitrogen storage vessels without modification.
Marine Mobile Power Pack
[0278] The Marine Mobile Power Pack provides hydraulic power to
concurrently operate the coil tubing and nitrogen modules at their
maximum capabilities.
[0279] The Marine Mobile Power Pack should meet its power output
requirement in the offshore well servicing environment.
[0280] The preferred embodiment of the Marine Mobile Power Pack
should preferably be skid-mounted and comprise a crash frame,
forklift guide tubes and a 4-point lift attachment for lifting
slings, and one fall protection harness tie off point incorporated
into its crash frame.
[0281] The Marine Mobile Power Pack should preferably be no larger
than 126''long.times.96'' wide.times.102'' high including the
structural skid to allow 13'6'' height clearance when loaded on a
48'' tall truck trailer.
[0282] The Marine Mobile Power Pack should preferably weigh no more
than 18,500 lbs maximum wet.
[0283] The preferred embodiment of the Marine Mobile Power Pack
will preferably have the following features: [0284] Caterpillar
3406C Diesel Engine with a double pump drive attached directly to
the flywheel housing. [0285] Caterpillar matched heavy duty solder
dripped radiator. [0286] Engine has onboard systems for shutdown in
over-temperature and low oil pressure situations. Engine also has
overspeed auto-shutdown protection and spark arrester exhaust.
[0287] Engine has mechanical lever for remote throttle position to
control engine speed at power pack. [0288] Air Operated fuel
shutdown system, and air operated emergency shutdown (air
shut-off). Emergency Kill system is failsafe (air signal to run,
absent signal shutdown) type. [0289] Engine mounted Tachometer, oil
pressure gauge, coolant temperature gauge and reservoir mounted air
pressure gauge. [0290] 12 cfm air compressor system with 15 gallon
reservoir [0291] Air Starter System [0292] Axial Piston high
pressure open-loop pump for CT injector drive. [0293] Axial Piston
high pressure open-loop pump for Nitrogen System drive. [0294]
Double Vane pump for tubing reel and BOP functions. [0295] Single
Gear pump for water/glycol circulation. [0296] Pump for
well-servicing fluid with manifold designed to pump small volumes
of acid (1500 gal), cement (10 bbl), and sand slurry (1500 lbs)
[0297] Single fan powered air to oil heat exchanger mounted above
fluid pump for hydraulic fluid cooling. [0298] Hydraulic Oil
Reservoir capacity 250 gallons. Reservoir supplied with protected
sight glass, returning fluid filters, and sampling port. [0299]
Hydraulic Pump relief valves are piloted to a series of dump valves
at a system start panel. [0300] Crash Frame provides an integrated
access ladder to skid top
Electric Generator
[0301] An Electric Generator provides electric power for
distribution by the operator control module in onshore
applications.
[0302] The preferred embodiment of the electric generator will:
[0303] Use Diesel Fuel [0304] Meet a 6500 Watt Surge capacity
[0305] Produce 5500 Watts continuous [0306] Start using a
self-contained Electric Start system [0307] Output 120 VAC at 51
amps [0308] Output 120 VAC at TBD amps Duplicate Specification
[0309] Run at least 12 hours on one tank of fuel [0310] fit within
36'' length.times.24'' width.times.24'' height space on the onshore
crane trailer [0311] weigh no more than 400 lbs
[0312] The Electric Generator should preferably meet these
requirements in the onshore well servicing environment.
Coil Tubing Reel Carry Skid
[0313] A Coil Tubing Reel Carry Skid is used for transport of a
Coil Tubing Reel Drum when the drum is removed from unit.
[0314] The Coil Tubing Reel Carry Skid should preferably hold the
Coil Tubing Reel Drum in axle-horizontal position during: [0315]
onshore transport [0316] offshore boat transport
[0317] The preferred embodiment of the Coil Tubing Reel Carry Skid
should comprise forklift and crane sling provisions for moving
between ground, truck, and boat in loaded and unloaded
configurations, and one fall protection harness tie off point
incorporated into its crash frame.
Coil Tubing Component Carry Skid
[0318] A Coil Tubing Component Carry Skid is used for transport of
injector head, well control stack, and CT-specific tools when
removed from a WISE.TM. Unit onshore transportation trailer.
[0319] The Coil Tubing Component Carry Skid should preferably hold
the injector head, well control stack, and CT-specific tools
during: [0320] onshore transport from onshore-to-offshore
conversion location to dock [0321] offshore boat transport
[0322] The Coil Tubing Component Carry Skid should preferably have
provisions for moving between ground, truck, and boat in loaded and
unloaded configurations.
Hose Reel Skid
[0323] In the preferred embodiment, when the WISE.TM. Unit is
converted to offshore use, a hose reel skid will provide the
hydraulic fluid distribution between the modules. The onshore
hydraulic fluid distribution will remain on the crane trailer.
[0324] The Hose Reel Skid should preferably carry all the WISE.TM.
Unit's interconnecting hoses needed for offshore use.
[0325] The Hose Reel Skid should preferably protect the WISE.TM.
Unit's interconnecting hoses from damage during transport from
onshore to offshore.
[0326] The Hose Reel Skid should preferably have provisions for
moving between ground, truck, and boat in loaded and unloaded
configurations.
[0327] The Hose Reel Skid should preferably comprise: [0328] All
hoses necessary to connect the Operator Control Module to the
injector head and well control stack in 150-foot lengths. [0329]
All hoses necessary to connect the Marine Mobile Power Pack to the
Operator Control Module in 35-foot lengths. [0330] All hoses
necessary to connect the Operator Control Module to the CT Reel in
35-foot lengths.
[0331] The hoses should preferably be labeled at each end with
bands imprinted with text and by numbered stainless steel
washers.
[0332] The Hose Reel Skid should preferably include 3 hose reels:
[0333] One reel for OCM to injector head power hoses [0334] One
reel for injector head control hoses [0335] One reel for BOP
control hoses
[0336] The Hose Reel Skid should preferably include a hose rack for
the marine mobile power pack-to-operator control module hoses.
[0337] An advantage of the present invention is that modularity
enables change scenarios that can be quickly and cost effectively
implemented: [0338] 1) Customer desires a change to WISE.TM.
Unit-level requirements (addition, deletion, or change of
capability) due to changing business environment [0339] 2) Vendor
discovers that requirements cannot be met on schedule (i.e.,
component supplier lead times too great) and proposes alternatives
that meet schedule.
Abbreviations
Abbreviation Definition
BOP Blowout Preventer
[0340] btuh British Thermal Units-Hour CT Coiled tubing gpm gallons
per minute
LSI Lamb Services, Inc
NEMA National Electrical Manufacturers Association
N2 Diatomic Nitrogen
[0341] PN Part number psig Pounds per square inch gauge scfm
Standard cubic feet per minute SS Stainless steel
MTBF Mean Time Between Failures
VDC Volts DC
[0342] VAC Volts AC
Definitions
[0343] Availability--The days on which the WISE.TM. Unit is ready
for transit between well-servicing sites and for well-servicing
activities Scar--A hardware provision for a module or component
coming later: must be consistent with the interface requirement
Hook--A software provision for programming coming later, such as
the ability to expand functionality etc. Depot
Maintenance--maintenance done at a shop Field
Maintenance--maintenance done at a job site (other than inside the
shop) Line-replaceable subsystem-- Glycol--antifreeze used with
water in heat transfer loops
[0344] Although the present invention has been described by
reference to its preferred embodiment as is disclosed in the
specification and drawings above, many more embodiments of the
present invention are possible without departing from the
invention. Thus, the scope of the invention should be limited only
by the appended claims.
* * * * *