U.S. patent application number 16/051527 was filed with the patent office on 2020-02-06 for well cellar assembly with alternate plate well slots and method of using same.
This patent application is currently assigned to National Oilwell Varco, L.P.. The applicant listed for this patent is National Oilwell Varco, L.P.. Invention is credited to James A. Rose.
Application Number | 20200040711 16/051527 |
Document ID | / |
Family ID | 69227399 |
Filed Date | 2020-02-06 |
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United States Patent
Application |
20200040711 |
Kind Code |
A1 |
Rose; James A. |
February 6, 2020 |
WELL CELLAR ASSEMBLY WITH ALTERNATE PLATE WELL SLOTS AND METHOD OF
USING SAME
Abstract
A well cellar assembly, and a method of using same, with the
well cellar including a base plate, the base plate having at least
two well slot openings therein for receiving a conductor pipe, and
at least one vertically extending side wall connected to the base
plate with a fluid tight seal. The at least two well slot openings
provide alternative locations for the conductor pipe and at least
one of the at least two well slot openings is selected for
placement of the conductor pipe.
Inventors: |
Rose; James A.;
(Murrysville, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
National Oilwell Varco, L.P. |
Houston |
TX |
US |
|
|
Assignee: |
National Oilwell Varco,
L.P.
Houston
TX
|
Family ID: |
69227399 |
Appl. No.: |
16/051527 |
Filed: |
August 1, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 33/03 20130101;
E21B 33/13 20130101; E21B 43/0122 20130101; E21B 41/00
20130101 |
International
Class: |
E21B 43/01 20060101
E21B043/01; E21B 33/03 20060101 E21B033/03 |
Claims
1. A well cellar assembly with alternate base plate well slots for
receiving a well conductor pipe, the assembly comprising a base
plate forming a floor of the well cellar assembly, the base plate
having at least two well slot openings therein for receiving the
conductor pipe; at least one vertically extending side wall
connected to the base plate with a fluid tight seal; and a
conductor cement bushing adapted to be mounted in at least one of
the at least two well slot openings, the conductor cement bushing
having an interior opening to receive the well conductor pipe;
wherein the at least two well slot openings provide alternative
locations for the conductor pipe.
2. The well cellar assembly of claim 1, wherein the at least two
well slot openings overlap.
3. The well cellar assembly of claim 2, wherein the at least two
well slot openings overlap to form a "Figure 8."
4. (canceled)
5. The well cellar assembly of claim 2, further comprising a ring
adaptor plate slid over the conductor and connected with a fluid
tight seal to the conductor and the base plate.
6. The well cellar assembly of claim 1, wherein the fluid tight
seal is a weld.
7. The well cellar assembly of claim 5, wherein the fluid tight
seal is a weld and forms a structural connection between the well
cellar and the conductor.
8. The well cellar assembly of claim 1, wherein the conductor
cement bushing comprises one or more holes located inside an outer
circumference of the conductor cement bushing for use in receiving
cement to cement the conductor pipe in place.
9. The well cellar assembly of claim 1, wherein the assembly is
modular and has at least one connectable frame member to allow
connection to an adjacent modular well cellar.
10. A method of using a well cellar assembly with a base plate and
at least one well slot opening in the base plate for receiving a
well conductor pipe after the well cellar assembly is installed in
the ground, the at least one well slot opening having a
predetermined location, and the method comprising the steps of: a)
Drilling a well hole through the at least one well slot opening; b)
Inserting the conductor pipe through the at least one well slot
opening and into the well hole; c) Mounting a conductor cement
bushing on the at least one well slot opening before or after
insertion of the conductor pipe into the at least one well slot
opening, the conductor cement bushing having a central opening to
hold and center the conductor pipe; d) Cementing the conductor pipe
into place; and e) Sliding an adaptor plate over the conductor
pipe, with the conductor pipe passing through an internal opening
in the adaptor plate, and connecting the adaptor plate to the
conductor pipe and the floor plate with a fluid tight seal.
11. The method of claim 10, wherein the base plate has at least two
well slot openings.
12. The method of claim 11, where the at least two well slot
openings overlap.
13. The method of claim 12, wherein the at least two well slot
openings overlap to form a "Figure 8."
14. The method of claim 10, wherein the fluid tight seal is a
weld.
15. The method of claim 14, wherein the weld forms a structural
connection between the well cellar and the conductor pipe.
16. The method of claim 10, wherein the conductor cement bushing
also includes one or more holes located inside the outer
circumference of the conductor cement bushing for use in receiving
the cement to cement the conductor pipe into place.
17. The well cellar assembly of claim 1, wherein the conductor
cement bushing comprises a plurality of radial fins, wherein an
outside edge of at least a portion of the plurality of radial fins
contacts the slot opening.
Description
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0001] Not applicable.
BACKGROUND OF THE APPLICATION
[0002] In the field of oil and gas exploration/production, a well
cellar can be positioned below ground level underneath a drilling
rig. A well is drilled within the well cellar. The present
application is directed to containment well cellars of the types
generally described and claimed in U.S. Pat. Nos. 7,637,692,
7,987,904, 8,127,837, 8,256,505, and 8,485,250, each of which is
hereby incorporated by reference in its entirety. These well
cellars also may contain equipment such as blow out preventers,
valves, and other equipment associated with drilling, completion
and other well operations.
[0003] Outside of the well cellar designs described and claimed in
the above-noted patents, other well cellars often are made only
from a section of steel culvert pipe installed in the ground with a
dirt floor. These other designs provide no protection against fluid
spills that can arise during drilling operations. More
specifically, during drilling, completion and other well
operations, fluids from the drilling rig and production equipment,
such as lubricants, drilling mud, completion fluids, and oil, can
leak or spill into and out of the well cellar. These spills can
create ecological problems, polluting soil samples as well as
surface and subsurface aqueous sources. Such corrupted soil areas
must be remediated before a well is capped, adding expense to
taking an under-producing well off-line.
[0004] In the well cellars associated with the present application,
the well conductor pipe extends through a well slot in the floor or
base plate of the well cellar into the underlying subterranean
formation. Preferably, the conductor pipe is cemented into place
and then sealed to the floor or base plate to protect against fluid
spills during operation. Preferably, the floor or base plate is
also sealed to the wall or walls of the well cellar so that the
walls not only provide structural support to prevent collapse of
the surrounding earth onto the equipment, but also act to protect
against fluid spills as well.
[0005] Many well pads have multiple parallel rows of wells, and
equipment access to the wells is part of the layout planning. Where
well cellars with floor or base plates, as described above, are
used for such well pads, and the floor or base plates have
predetermined or fixed locations for well slots into which a
conductor pipe is placed, a need has arisen for an installation
process that facilitates well pad construction and layout options
for the operator (i.e., the customer).
BRIEF SUMMARY OF THE APPLICATION
[0006] The well cellar of the present application allows for below
grade well head installations and also for installation of the
conductor pipe after underground installation of the well cellar
through what is described as a "Dril-Thru" process. In particular,
in the Dril-Thru process, the well cellar of the present
application has a floor or base plate with a predetermined location
of a slot or slots for installation of a conductor pipe. The well
cellar is first installed at a desired location, and, after
installation, the conductor pipe is installed through the floor or
base plate of the well cellar.
[0007] In this context, it is preferable to have multiple slot
locations within the floor or base plate of the well cellar to
provide options for equipment access, piping, and worker access.
Alternate well slots within a single well cellar allow the customer
to plan wellbore access from any direction. The alternate slot
locations also facilitate an ambidextrous or flexible design of the
internal features and equipment within the cellar--that is, the
alternate slots allows for reversal of the location of the
conductor pipe within the well cellar. As a result, the alternate
locations of the well slots give the operator complete flexibility
in pad development and well maintenance.
[0008] In one embodiment, the alternate well slots of the present
application overlap or intersect in the form of a Venn diagram
(where two well slots overlap or intersect, a "Figure 8" figure is
formed), and the conductor pipe is installed in a desired well
slot, after placement of the well cellar below ground, through
interaction with a conductor cement bushing that mounts within the
desired well slot and has a central opening to hold and center the
conductor pipe while the conductor pipe is cemented into place. In
addition, the assembly of the present application can have an
adaptor plate that slides over the conductor pipe after the
conductor pipe is cemented into place. The adaptor plate has a
shape and surface area that covers all open holes or spaces in the
base plate, including the well slot not selected and spacing
between the selected well slot and the conductor pipe, and the
plate is welded or otherwise sealed to the conductor pipe and the
base plate of the well cellar to create leak-proof seal while also
making a structural connection between the well cellar and the
conductor pipe, whereby the base plate of the well cellar provides
load-bearing support and stabilization to the conductor pipe.
[0009] While the alternate slot location concept of the present
application is particularly useful with the Dril-Thru process, the
alternate slot locations also can be used with other well cellar
installation processes.
[0010] Various other features, advantages, and characteristics of
the present application will become apparent after a reading of the
following detailed description.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] FIG. 1 is a side perspective view of one embodiment of the
present application.
[0012] FIG. 2 is a top view of one embodiment of the present
application.
[0013] FIG. 3 is a top perspective view of a conductor cement
bushing for use with the present application.
[0014] FIG. 3A is a side cut-away view of the conductor cement
bushing in FIG. 3.
[0015] FIG. 3B is one-half of the side cut-away view of the
conductor cement bushing in FIG. 3A.
[0016] FIG. 4 is a top perspective view of an adaptor plate for use
with the present application.
[0017] FIG. 5 is a top perspective view of one embodiment of the
present application showing the interaction between the floor
plate, conductor pipe, conductor cement bushing, and adaptor
plate.
[0018] FIG. 6 is a top view of two side by side well cellars of the
present application.
DETAILED DESCRIPTION OF THE APPLICATION
[0019] Referring to FIGS. 1 and 2, the alternate well slots within
a well cellar of the present application are shown. In particular,
FIGS. 1 and 2 depict a well cellar 10 with a floor or base plate
11. In one embodiment, floor or base plate 11 is welded or
otherwise sealed in a fluid-tight manner to the one or more
vertical side walls of well cellar 10. The shape, size and
dimension of well cellar 10 can vary to facilitate the specific
operational plans of a user or customer. In particular, while a
box-shaped well cellar 10 is shown in FIGS. 1 and 2, the well
cellar of the present application can be round or circular and have
one continuous side wall. The well cellar of the present
application also can have more than four side walls with, for
example, the shape of a pentagon, hexagon or octagon, among others.
The forward wall of well cellar 10 in FIG. 1 has been removed in
order to show the inner area of well cellar 10. As shown further in
FIG. 6, well cellar 10, as depicted in FIG. 1, can operate, in one
embodiment, as a modular trench cellar or unit that can be extended
to connect to two or more well cellars together through connectable
frame members 18. In one embodiment, connectable frame members 18
are U-shaped, are located opposite each other, and are bolted or
otherwise connected to the corresponding U-shaped frame member 18
of the adjoining well cellar 10, without a central wall between
them, as shown in FIG. 6. The end well cellar 10 in a series of
well cellars 10 can have a wall or door 41 mounted on the external
U-shaped frame 18. Connectable frame members 18 also can be
located, in other embodiments, in adjoining wall sections of well
cellar 10 in order to form angled modular connections or well rows
of varying lengths and configurations as may be desired. In the
modular well cellars 10 shown in FIGS. 1 and 6, well cellars 10
also can have apertures 40a and 40b of varying predetermined sizes
and locations for use with well accessories 17.
[0020] Alternate slots 13 and 14 are located in well cellar floor
or base plate 11 and one of alternate slots 13 and 14 operate to
receive conductor pipe 15. Alternate slots 13 and 14 have a
predetermined diameter D that can vary depending upon the size of
the conductor pipe 15 and the bit size necessary to install the
alternate slots 13 and 14. In this respect, alternative slots 13
and 14 provide options for equipment access, piping, and worker
access. Further, alternate well slots within a single well cellar
allow the customer to plan wellbore access from any direction. The
alternate slot locations also facilitate an ambidextrous or
reversible design of the internal features of the cellar--that is,
the alternate slots allows for reversal of the location of the
conductor pipe within the well cellar. As such, the alternate
locations of the well slots give the operator complete flexibility
in pad development and well maintenance. For example, and as shown
in FIG. 6, well cellars 10 can be installed side by side in a well
pad. In each well cellar 10, conductor pipe 15 has been installed
in an alternate well slot in the floor plate that is positioned
similar to well slot 14 in FIG. 2. This placement allows for
orientation of well accessories 17 around conductor pipe 15 and the
associated well hole. Depending upon the layout of the well pad,
conductor pipe 15 could also be located in the well slot
corresponding to the location of well slot 13 shown in FIG. 2.
[0021] In one embodiment involving two alternate slots, alternate
slots 13 and 14 overlap or intersect to form a Venn diagram or
"Figure 8" shape--as opposed to a uniform oval-shaped slot--as
shown in FIG. 2. This overlapping configuration of slots 13 and 14
allows for a relatively close, but flexible, positioning of the
conductor pipe 15. The exact amount of overlap or intersection
between alternate slots 13 and 14 is predetermined as part of the
design process of the well cellar and based on input from and
knowledge of the lay-out plans of the customer or use of the well
cellar. For example, but without limitation, the center 19 of
alternate well slots can be located at about 10 to 12 inches from
the center line or waistline 16, as shown in FIG. 2. The distance
between center 19 and center line or waistline 16 can vary in other
embodiments. In another embodiment, alternate well slots 13 and 14
can be separate and not overlapping.
[0022] The overlapping configuration of alternate slots 13 and 14,
or "Figure 8" design provides a "waist line" 16 between indented
points 16A and 16B that aids in centering and aligning conductor
pipe 15 so that piping and other components will line up correctly.
Specifically, the "Figure 8" shape of the alternate slots 13 and 14
allow, in a further embodiment of the assembly of the present
application, a "fit for purpose" conductor cement bushing 20 (as
shown in FIGS. 3, 3A and 3B) to be installed in one of the desired
slots 13 or 14. The central opening 22 of bushing 20 has a central
opening 22 that is configured to receive conductor pipe 15, whereby
conductor pipe 15 is centered for cementing. More specifically,
bushing 20 has an inner ledge 25 that serves as a fulcrum point for
adjusting the location of the bottom of conductor pipe 15 to
achieve a predetermined angle measured from vertical or "plumbness"
with respect to the well hole. Once the plumbness of conductor pipe
15 is adjusted, cement is poured or pumped into one or more
openings 23 that are located inside the outer circumference of the
bushing 20. In one embodiment, where a plurality of openings 23
exists in bushing 20, openings 23 are arranged in a symmetrical
pattern inside the outer circumference of the bushing 20. The
openings 23 can also have an asymmetrical pattern. Bushing 20 is
made of a hard material, such as steel.
[0023] In operation, cement is pumped through a grout tube
extending through one of the openings 23 and to the bottom of the
conductor hole (typically around one hundred feet). The grout then
fills up the annulus between the wall of the well or conductor hole
and the outside diameter of the conductor pipe 15. This process of
pumping the grout from the bottom up assures that water is
displaced entirely with cement in the annulus between the wall of
the conductor hole and the outside diameter of the conductor pipe
15. In cases where ground water is not present, the grout may be
poured or pumped directly through openings 23 and without a grout
tube extending to the bottom of the well hole.
[0024] The underside of bushing 20 has a plurality of fins 21
arranged in a circular symmetric pattern inside the outer
circumference of the bushing 20 in one embodiment. Again, an
asymmetrical pattern also can be used. Fins 21 act to fit bushing
20 down into the desired well slot 13 or 14 and, in turn, center
the bushing 20 and conductor pipe 15 within bushing 20. The outside
edges 24 of fins 21 on bushing 20 are located to contact as much of
a slot opening 13 or 14 as possible; preferably, seven of the eight
fins 20 shown in FIGS. 3, 3A and 3B are contacting a portion of its
respective slot opening. The "waist line" 16 of the "Figure 8"
orientation of slots 13 and 14 allows for this interaction between
a selected slot 13 or 14 and fins 20 of the bushing 15. Without
"waist line" 16, such as in the case of an extended slot or oval,
bushing 20 would be free to move in one dimension and not stay
centered. The dimensions of bushing 20 can vary, as can the number
of fins 21.
[0025] In alternative embodiments, three or more overlapping slots
can be used, with multiple waistlines 16 formed between each pair
of slots. For example, three overlapping slots can form a
triangular design and present three location options for conductor
pipe 15. The location of the slots within the floor or base plate
of the well cellar can also vary. In FIGS. 1 and 2, for example,
slots 13 and 14 are proximate to side A. Depending upon the size
and shape of the well cellar 10, slots 13 and 14 can be centrally
located or positioned elsewhere in floor or base plate 11. Also, in
a large well cellar 10, two or more sets of alternative well slots
can be used, with one slot selected from all of the available
alternative well slots.
[0026] The well slot assembly of the present application also can
include an adaptor plate 30. After conductor pipe 15 is cemented
into place, bushing 20 is removed by sliding bushing 20 over
conductor pipe 15, and opening 31 of adapter plate 30 (as shown in
FIG. 5) is slid over conductor pipe 15. Preferably, adapter plate
30 has a shape and surface area that includes closed portion 32. As
shown in FIG. 4, adapter plate 30 can have an oval shape, but other
shapes can be used as well. The closed portion 32 of adapter plate
30 is positioned over the slot 13 or 14 that did not receive
conductor pipe 15. The adapter plate 30 is then welded or otherwise
sealed in a fluid tight manner to the floor or base plate 11 of
well cellar 10 and also to conductor pipe 15, and this welding or
sealing creates a leak-proof seal while also forming a structural
and load-bearing connection between the well cellar 10 and the
conductor pipe 15. In one embodiment, adaptor plate 30 has a raised
upper ring or tube section 33 above opening 31, with a wavy or
scalloped upper edge 34. The bottom edge 35 of ring 33 is attached
to adaptor plate 30 in a fluid-tight manner, such as by welding.
The wavy edge 34 of ring 33 helps assure that one cross section of
the sealed or welded connection between adaptor plate assembly 30
and conductor pipe 15 is fully complete, e.g., it has a 100% weld.
More specifically, ring 33 increases the connection or weld area
between adaptor plate 30 and conductor pipe 15, by allowing a
welder to bend in the upper tabs 36 and thereby reduce the gap
between the conductor pipe 15 and ring 33 and, in turn, inhibiting
a crack from growing all the way around the conductor pipe 15.
[0027] In operation, and referring to FIG. 5, the alternative well
slot assembly of the present application is used in the manner
described above. In particular, after a hole is dug for placement
of well cellar 10, well cellar 10 is installed and oriented in a
manner to present a desired location for alternate slots 13 and 14.
A well hole is then dug within the selected alternate slot 13 or 14
for placement of conductor pipe 15. In one embodiment, conductor
cement bushing 20 is then placed on either of alternate slots 13 or
14 (depending upon which will received conductor pipe 15).
Conductor pipe 15 is then lowered and inserted through the central
hole 22 of bushing 20, the internal ledge 20 of bushing 20 is used
to align the conductor pipe, and the conductor pipe 15 is cemented
into place. In particular, internal ledge 20 projects inward within
central hole 22 and acts as a fulcrum against which conductor pipe
15 is moved so that the bottom of conductor pipe 15 aligns
correctly at the bottom of the well hole. In an alternative
embodiment, conductor pipe 15 is lowered into either of alternate
slots 13 or 14, and conductor cement bushing 20 then is slid over
conductor pipe 14 and fitted into the corresponding slot. The
internal ledge 28 of bushing 20 is again used as a fulcrum to align
conductor pipe before cementing. After cementing, bushing 20 is
removed. Adapter plate 30 next is slid over conductor pipe 15 and
the adapter plate 30 is then welded or otherwise sealed to the
floor or base plate 11 of well cellar 10 and conductor pipe 15.
[0028] Various changes, alternatives, and modifications will become
apparent to a person of ordinary skill in the art after a reading
of the foregoing specification. It is intended that all such
changes, alternatives, and modifications as fall within the scope
of the appended claims be considered part of the present
application.
* * * * *