U.S. patent application number 14/958098 was filed with the patent office on 2017-06-08 for inflatable variable bore ram.
The applicant listed for this patent is General Electric Company. Invention is credited to Bodhayan Dev, Deepak Trivedi, Jifeng Wang.
Application Number | 20170159392 14/958098 |
Document ID | / |
Family ID | 57472050 |
Filed Date | 2017-06-08 |
United States Patent
Application |
20170159392 |
Kind Code |
A1 |
Trivedi; Deepak ; et
al. |
June 8, 2017 |
INFLATABLE VARIABLE BORE RAM
Abstract
A variable ram packer includes a body with a bore contact
region, at least one fluidic flexible matrix component (FFMC) tube,
an inflation mechanism, and a fluid port. The FFMC tube is
positioned inside the body next to the bore contact region. The
fluid port is fluidly coupled with a connecting line, which is
fluidly coupled with the inflation mechanism. The FFMC tube
inflates in response to an increase in pressure from the inflation
mechanism, which translates the bore contact region inward.
Inventors: |
Trivedi; Deepak; (Halfmoon,
NY) ; Wang; Jifeng; (Niskayuna, NY) ; Dev;
Bodhayan; (Niskayuna, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
General Electric Company |
Schenectady |
NY |
US |
|
|
Family ID: |
57472050 |
Appl. No.: |
14/958098 |
Filed: |
December 3, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 33/062 20130101;
E21B 33/1208 20130101; E21B 33/06 20130101; E21B 33/127 20130101;
F16J 15/46 20130101 |
International
Class: |
E21B 33/06 20060101
E21B033/06 |
Claims
1. A variable ram packer comprising a body comprising: a bore
contact region thereon; at least one fluidic flexible matrix
component (FFMC) tube disposed within said body and positioned
radially adjacent said bore contact region; an inflation mechanism;
and a fluid port disposed within said body, said fluid port fluidly
coupled with said FFMC tube and with at least one connecting line
fluidly coupled with said inflation mechanism, wherein said FFMC
tube inflates in response to a pressure increase from said
inflation mechanism, thereby translating said bore contact region
radially inward.
2. The variable ram packer in accordance with claim 1, wherein said
inflation mechanism is a hydraulic inflation mechanism.
3. The variable ram packer in accordance with claim 1, wherein said
inflation mechanism is a pneumatic inflation mechanism.
4. The variable ram packer in accordance with claim 1, wherein said
variable ram packer is coupled to a ram block.
5. The variable ram packer in accordance with claim 1 further
comprising a plurality of packer inserts axially juxtaposed above
and below said bore contact region.
6. The variable ram packer in accordance with claim 5, wherein said
plurality of packer inserts are configured to rotate radially
inward.
7. The variable ram packer in accordance with claim 1, wherein said
at least one FFMC tube comprises an outer tube and an inner liner
disposed within said outer tube.
8. The variable ram packer in accordance with claim 7, wherein said
outer tube comprises a plurality of interwoven fibers.
9. The variable ram packer in accordance with claim 8, wherein said
plurality of interwoven fibers comprises a weave angle within a
range from and including about 40 degrees to and including about 60
degrees.
10. The variable ram packer in accordance with claim 8, wherein
said plurality of interwoven fibers comprises a weave angle within
a range from and including about 45 degrees to and including about
54 degrees.
11. The variable ram packer in accordance with claim 1, wherein
said FFMC tube is semi-circular and defines a channel positioned
radially adjacent said bore contact region.
12. The variable ram packer in accordance with claim 1, wherein
said fluid port extends radially outward from at least a portion of
said FFMC tube.
13. The variable ram packer in accordance with claim 1, wherein
said fluid port extends axially away from at least a portion of
said FFMC tube.
14. A variable bore ram assembly comprising: at least one ram
block; and at least one variable ram packer disposed in said at
least one ram block, said at least one variable ram packer
comprising a body comprising: a bore contact region thereon; at
least one fluidic flexible matrix component (FFMC) tube disposed
within said body and positioned radially adjacent said bore contact
region; an inflation mechanism; and a fluid port disposed within
said body, said fluid port fluidly coupled with said FFMC tube and
with at least one connecting line fluidly coupled with an inflation
mechanism, wherein said FFMC tube inflates in response to a
pressure increase from said inflation mechanism, thereby
translating said bore contact region radially inward.
15. The variable bore ram assembly in accordance with claim 14,
wherein said inflation mechanism is a hydraulic inflation
mechanism.
16. The variable bore ram assembly in accordance with claim 14,
wherein said inflation mechanism is a pneumatic inflation
mechanism.
17. The variable bore ram assembly in accordance with claim 14
further comprising a plurality of packer inserts axially juxtaposed
above and below said bore contact region.
18. The variable bore ram assembly in accordance with claim 17,
wherein said plurality of packer inserts are configured to rotate
radially inward.
19. The variable bore ram assembly in accordance with claim 14,
wherein said at least one FFMC tube comprises an outer tube and an
inner liner disposed within said outer tube.
20. A method of using a variable ram packer for use with a blowout
preventer, the variable ram packer including a body including at
least one bore contact region thereon, a plurality of packer
inserts, configured to rotate radially inward, at least one fluidic
flexible matrix component (FFMC) tube disposed within the body and
positioned radially adjacent to the bore contact region, and a
fluid port disposed within the body, the fluid port fluidly coupled
with the FFMC tube and a connecting line, the connecting line
fluidly coupled with an inflation mechanism, said method
comprising: translating the variable ram packer into a first closed
position around a drill pipe; rotating the plurality of packer
inserts radially inward into a second closed position around the
drill pipe; translating the at least one bore contact region into a
sealing arrangement with the drill pipe by inflating the at least
one FFMC tube through activating the inflation mechanism to
increase the pressure of a fluid disposed within the at least one
FFMC tube.
Description
BACKGROUND
[0001] The field of the disclosure relates generally to a blowout
preventer (BOP) for oil and gas wells, and more particularly, to a
variable ram for a BOP.
[0002] Most known BOPs mount on top of a wellhead and provide a
means to regulate the pressure of a wellbore. Variable bore rams
typically include a pair of rams on opposing sides of a BOP stack
that actuate to form a sealed arrangement with a drill pipe. When
the variable bore rams are actuated radially inward, the inner most
bore face contacts the outer surface of a drill pipe and forms a
sealing arrangement. Some known variable rams include metallic
inserts and elastomer packers that cooperate as a coherent unit to
create a seal across drill pipes of different sizes.
[0003] Many known variable rams can only seal-off a range of pipe
sizes ranging from L to L/2 (where L is the circumferential length
of all inserts placed side by side). BOPs therefore require at
least two variable bore rams in the BOP stack to cover the entire
range of pipe sizes, which adds extra cost and complexity to the
BOP design. Furthermore, the contact pressure between a typical
variable ram and the pipe is limited to the force transmitted by
the operator to the rubber on the sealing surface. The force
transmitted may not be adequate for sealing high wellbore pressure
or could cause excessive strain on the variable ram.
BRIEF DESCRIPTION
[0004] In one aspect, a variable ram packer for a blowout preventer
(BOP) is provided. The variable ram packer includes a body with a
bore contact region, at least one fluidic flexible matrix component
(FFMC) tube, an inflation mechanism, and a fluid port. The FFMC
tube is positioned inside the body next to the bore contact region.
The fluid port is fluidly coupled with a connecting line, which is
fluidly coupled with the inflation mechanism. The FFMC tube
inflates in response to an increase in pressure from the inflation
mechanism, which translates the bore contact region inward.
[0005] In another aspect, a variable bore ram assembly for a BOP is
provided. The variable bore ram assembly includes at least one ram
block and at least one variable ram packer inside at least one ram
block. The variable ram packer includes a body with a bore contact
region, at least one FFMC tube, an inflation mechanism, and a fluid
port. The FFMC tube is positioned inside the body next to the bore
contact region. The fluid port is fluidly coupled with a connecting
line, which is fluidly coupled with the inflation mechanism. The
FFMC tube inflates in response to an increase in pressure from the
inflation mechanism, which translates the bore contact region
inward.
[0006] In yet another aspect, a method of using a variable ram
packer for use within a blowout preventer is provided. The variable
ram packer includes a body with a bore contact surface, a plurality
of packer inserts designed to rotate radially inward, at least one
FFMC tube inside the body adjacent to the bore contact region, and
a fluid port inside the body. The fluid port is fluidly coupled
with a connecting line, which is fluidly coupled with the inflation
mechanism. The method includes translating a variable ram packer
into a first closed position around a drill pipe. The method
further includes rotating the plurality of packer inserts radially
inward to a second closed position around the drill pipe. The
method further includes translating the bore contact region to seal
with the drill pipe by inflating the FFMC tube. The FFMC tube is
inflated by activating the inflation mechanism to increase the
pressure of a fluid inside the FFMC tube.
DRAWINGS
[0007] These and other features, aspects, and advantages of the
present disclosure 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:
[0008] FIG. 1 is a schematic view of an exemplary blowout preventer
(BOP) stack;
[0009] FIG. 2 is an isometric view of an exemplary variable bore
ram in an open position that is used with the BOP shown in FIG.
1;
[0010] FIG. 3 is a top plan view of exemplary variable bore ram
packers in a first closed position used with the variable bore ram
shown in FIG. 2;
[0011] FIG. 4 is a perspective view of an exemplary fluidic
flexible matrix composite (FFMC) tube used with the variable bore
ram packer shown in FIG. 3;
[0012] FIG. 5 is a top plan view of the variable bore ram packers
shown in FIG. 3 in a second closed position; and
[0013] FIG. 6 is a top plan view of the variable bore ram packers
shown in FIG. 3 in a third closed position.
[0014] Unless otherwise indicated, the drawings provided herein are
meant to illustrate features of embodiments of this disclosure.
These features are believed to be applicable in a wide variety of
systems comprising one or more embodiments of this disclosure. As
such, the drawings are not meant to include all conventional
features known by those of ordinary skill in the art to be required
for the practice of the embodiments disclosed herein.
DETAILED DESCRIPTION
[0015] In the following specification and the claims, reference
will be made to a number of terms, which shall be defined to have
the following meanings.
[0016] The singular forms "a", "an", and "the" include plural
references unless the context clearly dictates otherwise.
[0017] "Optional" or "optionally" means that the subsequently
described event or circumstance may or may not occur, and that the
description includes instances where the event occurs and instances
where it does not.
[0018] "Variable bore ram" and "variable ram" are used
interchangeably, unless the context clearly dictates otherwise.
[0019] Pipe sizes "L" and "L/2" are used herein to denote the
diameter of the pipe that the variable bore ram can seal against.
Many known variable bore rams specify an upper limit, L, of the
largest diameter pipe they can seal against. These known variable
bore rams have a lower limit of about one-half the diameter of L,
i.e., L/2, which indicates the smallest diameter pipe they can seal
against.
[0020] Approximating language, as used herein throughout the
specification and claims, may be applied to modify any quantitative
representation that could permissibly vary without resulting in a
change in the basic function to which it is related. Accordingly, a
value modified by a term or terms, such as "about",
"approximately", and "substantially", are not to be limited to the
precise value specified. In at least some instances, the
approximating language may correspond to the precision of an
instrument for measuring the value. Here and throughout the
specification and claims, range limitations may be combined and/or
interchanged; such ranges are identified and include all the
sub-ranges contained therein unless context or language indicates
otherwise.
[0021] The variable bore ram for a blowout preventer (BOP)
described herein facilitates increasing the variety of drill pipe
sizes that the variable bore ram can engage. Many known variable
bore rams can seal a pipe of size L/2 in diameter. Specifically,
adding a fluidic flexible matrix composite (FFMC) tube behind the
bore contact region facilitates translating the bore contact region
into a sealed arrangement with the drill pipe once the FFMC tube is
inflated by pressurized fluid. The FFMC tube pressurizes to seal
pipes of smaller diameters than L/2. The increased sealing effect
of the pressurized FFMC tube potentially eliminates the need of one
or more additional variable bore rams in the BOP stack. By
eliminating additional variable bore rams in the BOP stack, the
infrastructure surrounding the BOP is simplified, reducing the
plumbing and controls necessary to run an additional variable bore
ram.
[0022] FIG. 1 is a schematic view of an exemplary blowout preventer
(BOP) stack 100. BOP stack 100 surrounds a drill pipe 101 and
mounts on top of a wellhead connector 102 that includes both a
wellhead and a tree (not shown). Known BOP stacks, such as BOP
stack 100, typically include a test ram 103, a plurality of
variable bore rams 104, a plurality of shear rams 105, a plurality
of annular rams 106, and a plurality of control pods 107.
[0023] FIG. 2 is an isometric view of an exemplary variable bore
ram 104 in an open position that is used with BOP 100 (shown in
FIG. 1). Variable bore ram 104 includes two opposed variable ram
packers 110, 112, each housed with a respective ram block 114, 116.
Variable ram packers 110, 112 are replaced when sufficiently worn
and are therefore removed and replaced by inserting a new set of
variable ram packers 110, 112 into ram block 114, 116. When
variable bore ram 104 is in use, ram blocks 114, 116 are actuated
or translated toward each other, typically through piston or
hydraulic means, such that ram blocks 114, 116 couple together and
packers 110, 112 couple together to define a substantially circular
bore 118. Bore 118 is configured to receive drill pipe 101, around
which variable ram packers 110, 112 form a sealing arrangement as
described herein.
[0024] Although variable bore ram 104 is shown in an open position
in this view, the embodiments disclosed below show' variable bore
ram 104 in a variety of closed positions. Ram blocks 114, 116 are
piston-actuated or translated into a first closed position (shown
in FIG. 3), where a bore 118 is configured to receive pipe 101 of
diameter L. Alternatively, ram blocks 114, 116 are hydraulically
actuated or translated into a first closed position, or actuated or
translated by any other suitable means to couple packers 110, 112
to define bore 118. If variable bore ram 104 needs to seal a
smaller pipe 101 with a diameter as small as L/2, variable ram
packers 110, 112 are piston actuated or translated or hydraulically
actuated or translated to a second closed position (shown in FIG.
5). If variable bore ram 104 needs to seal a pipe 101 with a
diameter smaller than L/2, variable ram packers 110, 112 are
inflated, as described herein, to a third closed position (shown in
FIG. 6).
[0025] FIG. 3 is a top plan view of exemplary variable bore ram
packers 110, 112 in a first closed position used with variable bore
ram 104 (shown in FIG. 2). Packer 110 is substantially symmetrical
to packer 112, such that packer 110 receives packer 112 when in a
sealed arrangement. Ram blocks 114, 116 (shown in FIG. 2) and the
corresponding variable ram packers 110, 112 are piston-actuated or
translated into a first closed position, where a bore 118 is
configured to receive pipe 101 of diameter L. Alternatively,
packers 110, 112 are hydraulically actuated or translated into a
first closed position, or actuated or translated by any other
suitable means to couple packers 110, 112 to define bore 118. The
parts of packer 110 disclosed herein describe the same or similar
parts on packer 112.
[0026] Packer 110 includes body 120, including a contact region 130
and a non-contact region 131. The remaining portion of body 120 of
packer 110 that is not contact region 130 is non-contact region 131
of packer 110. Contact region 130 includes both a bore contact
region 132 and a packer contact region 134. Bore contact region 132
is adjacent to packer contact region 134 laterally on both sides of
bore contact region 132. Bore contact region 132 is at least
partially arcuate, i.e. semi-circular or arcual, to receive drill
pipe 101 when in a sealed position. Bore contact region 132, as
described herein, is also known as a tubular contact region or a
bore-face region, and includes the extent of contact region 130
that seals with drill pipe 101.
[0027] Packer 110 includes one or more packer pins 142 coupled to
body 120 that enable packer 110 to couple to ram block 114. Packer
pins 142 provide a means to couple packer 110 to ram block 114.
Body 120 further includes packer inserts 144, which are
triangular-shaped members arranged around bore 118 and are
positioned axially juxtaposed above and below bore contact region
132. Packer inserts 144 are configured to rotate radially inward
towards bore 118 to provide-support for bore contact region 132.
Packer inserts 144 extend radially outward from bore 118 to
non-contact region 131. Body 120 also includes a fluidic flexible
matrix composite (FFMC) tube 150 disposed within body 120 and
extending semi-circularly inside body 120, recessed from bore
contact region 132, but circumferentially extending around bore
contact region 132 to define a channel 152. In the embodiment,
shown in the first closed position, FFMC tube 150 is in a deflated
position, as described herein. FFMC tube 150 is fluidly coupled to
fluid port 156, which is fluidly coupled to connecting line 157,
which fluidly couples to inflation mechanism 158.
[0028] FIG. 4 is a perspective view of an exemplary fluidic
flexible matrix composite (FFMC) tube 150 used with the variable
bore ram packer shown in FIG. 3. In one embodiment, FFMC tube 150
includes an inner liner 162 and an outer tube 164. Inner liner 162
is disposed substantially entirely inside outer tube 164. Outer
tube 164 includes a plurality of interwoven fibers 166. At rest,
interwoven fibers 166 are positioned at substantially equal and
opposite angles 167, 168 above and below longitudinal axis 169.
Inner liner 162 defines an inner volume 172 of FFMC tube 150. As
fluid is applied to inner liner 162, and the pressure within inner
volume 172 increases, radially outward pressure is applied to outer
tube 164, causing outer tube 164 to expand radially, i.e.,
inflating FFMC tube 150. As the pressure increases, interwoven
fibers 166 displace from their resting angles 167, 168 and
interlock at a predetermined weave angle 174, preventing FFMC tube
150 from further inflation. In one embodiment weave angle 174 is
between about 40 degrees and about 60 degrees, and more
specifically between about 45 degrees and about 54 degrees.
Interwoven fibers 166 can be made of a polymer based material
including, but not limited to, nylon, rayon, or metal such as steel
or Inconel. Inner liner 162 can be made of materials including, but
not limited to, fluorocarbon elastomer material (FKM),
perfluoro-elastomers (FFKM), tetrafluoro ethylene propylene rubber
(FEPM), hydrogenated nitrile butadiene rubber (HNBR), carboxylated
nitrile butadiene rubber (XNBR), or any suitable material that
enables an operator to inflate FFMC tube 150.
[0029] FIG. 5 is a top plan view of variable bore ram packers 110,
112 (shown in FIG. 3) in a second closed position. Ram blocks 114,
116 are actuated or translated into a first closed position (shown
in FIG. 3), where bore 118 is configured to receive pipe 101 of
diameter L. If variable bore ram 104 needs to seal a smaller pipe
101 with a diameter as small as L/2, variable ram packers 110, 112
are actuated or translated to a second closed position (shown in
FIG. 5) by rotating packer inserts 144 radially inward towards bore
118. Many known variable bore rams are limited by the ability to
seal around a pipe size of only L/2.
[0030] FIG. 6 is a top plan view of variable bore ram packers 110,
112 (shown in FIG. 3) in a third closed position. After packers
110, 112 are actuated or translated to a second closed position, if
variable bore ram 104 needs to seal a pipe 101 with a diameter
smaller than L/2, variable ram packers 110, 112 are inflated to a
third closed position. As such, FFMC tube 150 is not solely a seal
or a packer element, but inflates to tighten bore contact region
132 around smaller pipe sizes than L/2. Inflation mechanism 158
pumps fluid into FFMC tube 150 causing FFMC tube 150 to expand
radially, thereby translating bore contact region 132 radially
inward to seal against pipe 101 smaller than L/2. Inflation
mechanism 158 fluidly coupled with connecting line 157 fluidly
coupled with fluid port 156 fluidly coupled with FFMC tube 150.
Inflation mechanism 158 is any mechanism suitable for inflating
FFMC tube 150. In one embodiment, inflation mechanism 150 is a
hydraulic mechanism. In another embodiment, inflation mechanism 158
is a pneumatic mechanism. In one embodiment, fluid port 156 is
fluidly coupled with FFMC tube 150 and extends radially outward
from FFMC tube 150 such that connecting line 157 extends out of the
back of packer 110. In another embodiment, fluid port 156 is
coupled with FFMC tube 150 and extends axially upward, such that
connecting line 157 extends through the top of packer 110. Any
suitable fluid is used to apply pressure to the inner walls of
inner liner 162 and therefore inflate FFMC tube 150. In one
embodiment, a fluid with a bulk modulus of greater than 2.0
gigapascals (GPa) is used, such as, and without limitation,
water.
[0031] The above-described variable bore ram described herein
overcomes several deficiencies associated with known blowout
preventers (BOP). Many known variable bore rams can seal a pipe of
size L/2 in diameter. Specifically, adding a fluidic flexible
matrix composite (FFMC) tube behind the bore contact region
facilitates translating the bore contact region into a sealed
arrangement with the drill pipe once the FFMC tube is inflated by
pressurized fluid. The FFMC tube pressurizes to seal pipes of
smaller diameters than L/2. The increased sealing effect of the
pressurized FFMC tube potentially eliminates the need of one or
more additional variable bore rams in the BOP stack. By potentially
eliminating additional variable bore rams in the BOP stack, the
infrastructure surrounding the BOP is simplified, reducing the
plumbing and controls necessary to run an additional variable bore
ram.
[0032] An exemplary technical effect of the methods, systems, and
apparatus described herein includes at least one of: (a)
potentially eliminating the need of one or more additional variable
bore rams on the BOP stack by increasing the contact pressure
between the variable bore ram and the drill pipe by inflating the
FFMC tube; (b) eliminating the need for surrounding infrastructure,
such as plumbing and controls, for the one or more additional
variable bore rams on the BOP stack; (c) sealing against a large
wellbore pressure without excessive strain along the bore contact
region; and (d) increasing the variety of drill pipe sizes that the
variable bore ram can engage over many known variable bore rams
that can only seal against a drill pipe between L and L/2 in
diameter.
[0033] Exemplary embodiments of a variable bore ram are described
above in detail. The variable bore ram and methods of manufacturing
or operating such a system and device are not limited to the
specific embodiments described herein, but rather, components of
systems and/or steps of the methods may be utilized independently
and separately from other components and/or steps described herein.
For example, the systems, apparatus, and methods may also be used
in combination with other types of rams for BOPs, such as fixed
bore rams or annular rams, and are not limited to practice with
only the devices, systems and methods as described herein. Rather,
the exemplary embodiment can be implemented and utilized in
connection with many other applications, equipment, and systems
that may benefit from using an FFMC tube for inflating around a
pipe or regulating pressure of a pipe.
[0034] Although specific features of various embodiments of the
disclosure may be shown in some drawings and not in others, this is
for convenience only. In accordance with the principles of the
disclosure, any feature of a drawing may be referenced and/or
claimed in combination with any feature of any other drawing.
[0035] This written description uses examples to disclose the
embodiments, including the best mode, and also to enable any person
skilled in the art to practice the embodiments, including making
and using any devices or systems and performing any incorporated
methods. The patentable scope of the disclosure is defined by the
claims, and may include other examples that occur to those skilled
in the art. Such other examples are intended to be within the scope
of the claims if they have structural elements that do not differ
from the literal language of the claims, or if they include
equivalent structural elements with insubstantial differences from
the literal language of the claims.
* * * * *