Abstract
The invention relates to a well bore control apparatus, system and method for sealing a well bore. The invention relates to a well bore control apparatus comprising a housing having a guide element defining a path, the housing defining a throughbore for receiving a tubular, a first tapered gate and a tapered second gate located within the housing, the first and second gates being adapted to engage with the guide element. In use the first and second gates are moveable along the path defined by the guide element in a direction substantially transverse to the throughbore between an open position of the throughbore and a closed position of the throughbore. The well bore control apparatus comprises a first seal seat for forming a first seal with the first gate in the closed position to seal the throughbore. The well bore control apparatus may include a second seal seat. The second seal seat may be adapted for forming a second seal with the second gate in the closed position to seal the throughbore.
Claims
1. A well bore control apparatus comprising: a housing having a guide element defining a path, the housing defining a throughbore for receiving a tubular; a first tapered gate and a second tapered gate located within the housing, the first and second tapered gates being adapted to engage with the guide element, wherein in use the first and second tapered gates are moveable by an actuation force along the path defined by the guide element in a direction substantially transverse to the throughbore between an open position of the throughbore and a closed position of the throughbore, wherein a taper of the first tapered gate engages a taper of the second tapered gate, when the first and second tapered gates are closing or are in the closed position; and a first seal seat for forming a first seal with the first gate in the closed position to seal the throughbore; and wherein the guide element is arranged, in use, to actuate the first tapered gate into sealing engagement with the first seal seat in the closed position.
2. A well bore control apparatus according to any claim 1, wherein the first tapered gate and the second tapered gate are tapered along a direction of travel.
3. A well bore control apparatus according to claim 1, wherein, as the first tapered gate and the second tapered gate move, the tapers pass over each other to create a displacement component of motion which is perpendicular to the direction of actuation.
4. A well bore control apparatus according to claim 1, wherein the well bore control apparatus includes a second seal seat adapted for forming a second seal with the second tapered gate in the closed position to seal the throughbore.
5. A well bore control apparatus according to claim 4, wherein the guide element is arranged, in use, to actuate the first and/or second tapered gate into sealing engagement with the second seal seat in the closed position.
6. A well bore control apparatus according to claim 5, wherein the throughbore is sealed when either the first or the second tapered gate is in the closed position.
7. A well bore control apparatus according to claim 5, wherein the throughbore is sealed when both the first and second tapered gates are in the closed position.
8. A well bore control apparatus according to claim 1, wherein the first and/or second seal minimises or prevents flow of fluids, such as well bore fluids, through the throughbore.
9. A well bore control apparatus according to claim 1, wherein in the closed position the first and/or second tapered gate abuts the respective first and/or second seal seats to form the first and/or second seals.
10. A well bore control apparatus according to claim 1, wherein the guide element is arranged in the housing in a substantially transverse direction to the throughbore.
11. A well bore control apparatus according to claim 1, wherein the guide element is inclined or declined with respect to a longitudinal axis of the housing.
12. A well bore control apparatus according to claim 1, wherein the guide element is arranged within the housing to define an acute angle to a longitudinal axis of the housing.
13. A well bore control apparatus according to claim 1, wherein the guide element has a plurality of protrusions, recesses and/or grooves, such as elongated protrusions, recesses and/or grooves, arranged in the housing in a substantially transverse direction to the throughbore.
14. A well bore control apparatus according to claim 1, wherein the housing comprises a first and a second guide element, provided in the housing so as to oppose one another.
15. A well bore control apparatus according to claim 14, wherein the first and/or second tapered gate has a first and a second engagement element provided on opposing sides or surfaces of the first and/or second tapered gate for mating, interoperating and/or co-acting with the respective first and second guide elements of the housing.
16. A well bore control apparatus according to claim 1, wherein the first and/or second tapered gate is adapted to engage with the guide element.
17. A well bore control apparatus according to claim 1, wherein the first and/or second tapered gate includes an engagement element, arranged for mating, interoperating and/or co-acting with the guide element of the housing.
18. A well bore control apparatus according to claim 17, wherein the engagement element has a plurality of further protrusions, recesses and/or grooves for mating, interoperating and/or co-acting with the respective plurality of protrusions, recesses and/or grooves of the guide element.
19. A well bore control apparatus according to claim 17, wherein the engagement element is in line with the taper of the first and/or second tapered gate.
20. A well bore control apparatus according to claim 17, wherein the engagement element is inclined or declined with respect to a longitudinal axis of the first and/or second tapered gate.
21. A well bore control apparatus according to claim 1, wherein the first and/or second tapered gate includes a first and/or second metal tapered gate.
22. A well bore control apparatus according to claim 1, wherein the first and/or second seal seat include a first and/or second metal seal seat.
23. A well bore control apparatus according to claim 1, wherein in the closed position, the first and/or second tapered gate engages or abuts the respective first and/or second seal seat to form a respective first and/or second metal to metal seal.
24. A well bore control apparatus according to claim 1, wherein in the closed position, the first and/or second tapered gate engages or abuts the guide element and/or the housing to form a further first and/or second seal between the first and/or second tapered gate and the guide element and/or the housing.
25. A method of servicing the interior of a well bore control apparatus as claimed in claim 1, said method comprising the steps of removing an end cover of a well bore control apparatus, said end cover being coupled to a shear ram assembly, removing said end cover and said shear ram assembly to permit replacement of a cutting blade, a tapered sealing gate or a valve seal.
26. A method for sealing a well bore, the method comprising: providing a well bore control apparatus including a housing having a guide element defining a path, the housing defining a throughbore for receiving a tubular, a first tapered gate and a second tapered gate located within the housing, the first and second tapered gates being adapted to engage with the guide element, and a first seal seat; actuating or moving the first and/or second tapered gate in a direction transverse to the throughbore from an open position of the throughbore to a closed position of the throughbore, wherein the taper of the first tapered gate engages a taper of the second tapered gate when the first and second tapered gates are closing or are in the closed position; engaging the first tapered gate with the first seal seat; forming a first seal between the first tapered gate and the first seal seat to seal or close the throughbore; and wherein the first tapered gate is actuated by the guide element into sealing engagement with the first seal seat in the closed position.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) It should be understood that the features defined above in accordance with any aspect of the present invention or below in relation to any specific embodiment of the invention may be utilised, either alone or in combination with any other defined feature, in any other aspect or embodiment of the invention.
(2) These and other aspects of the invention will become apparent from the following description when taken in combination with the accompanying drawings in which:
(3) FIG. 1 is a perspective view of a well control system with a well bore control apparatus located above a set of pipe rams;
(4) FIG. 2 is an enlarged view of the well bore control apparatus shown in FIG. 1 with the device in the open position;
(5) FIG. 3a is a vertical section view taken through the apparatus of FIG. 2 on lines 3-3 of FIG. 2 with shear rams and sealing gates removed;
(6) FIG. 3b is an enlarged view of part of FIG. 3a;
(7) FIG. 3c is a vertical section view taken through the apparatus of FIG. 2 on the lines 4-4;
(8) FIG. 4 is a cross sectional view taken through the apparatus shown in FIG. 2 on the lines 4-4;
(9) FIG. 5 is a cross sectional view through the device of FIG. 2 taken on the lines 3-3;
(10) FIG. 6 is a vertical section view taken through the device of FIG. 2 on the lines 5-5;
(11) FIG. 7a is a vertical section view similar to FIG. 3a, illustrating a the lower shear ram and gate, having a cutting blade, of the apparatus of FIG. 1 in the open position;
(12) FIG. 7b is enlarged isometric view of the lower gate of FIG. 7a;
(13) FIGS. 8a and 8b are vertical section views similar to FIG. 7a, showing the lower gate being actuated by a guide element to seal a well bore in the closed position of the apparatus of FIG. 1;
(14) FIG. 9a is a vertical section view similar to FIG. 8a, showing the upper and lower gates being actuated by the guide element to seal the well bore in the closed position of the apparatus of FIG. 1;
(15) FIG. 9b is a cross sectional view similar to FIG. 5 in the closed position of the apparatus of FIG. 1;
(16) FIG. 10 depicts the well bore control apparatus of FIG. 2 but with the actuators moved so that the device is in the closed position to seal the well bore;
(17) FIG. 11 is a cross sectional view similar to FIG. 9b but with no guide element present according to an embodiment of the present invention;
(18) FIG. 12 is a similar vertical sectional view of FIG. 9a but with no guide element present according to an embodiment of the present invention;
(19) FIG. 13 is a view similar to FIG. 6 but with no guide element present and with an end butt plate and attached gate rod and sealing gate shown removed;
(20) FIGS. 14a and 14b are vertical sectional views through the well bore control apparatus with the gates actuated in the open position as shown in FIG. 14a and in the closed position as shown in FIG. 14b;
(21) FIG. 15a is a vertical sectional and diagrammatic view similar to FIGS. 14a and 14b and showing diagrammatically tapered gates;
(22) FIG. 15b is an enlarged detail of part of FIG. 15a shown in broken outline.
(23) FIG. 16 shows a graph of the relationship of pressure applied to the actuators during movement of the gates for a well bore apparatus having parallel and tapered gates according to embodiments of the invention and for a wellbore apparatus with rams that are pushed together;
(24) FIGS. 17a and 17b are views similar to FIG. 2, depicting coupling arrangement of the well bore apparatus, with the well bore apparatus being in the open position as shown in FIG. 17a and in the closed position as shown in FIG. 17b.
(25) FIGS. 18a and 18b depict similar views to FIGS. 15a and 15b but with gate rod and sealing gate removed to illustrate accessibility to the interior;
(26) FIGS. 19a, 19b, 19c, 19d and 19e depict a mechanism for locking the position of a reciprocating piston within a hydraulic cylinder to illustrate a method which is used in locking the position of the actuators and thus the sealing gates in the apparatus of FIGS. 1 to 18;
(27) FIG. 20a is an enlarged detail of part of the apparatus shown in FIG. 6 in broken outline with, in a perspective view taken in the direction of arrow 13 and depicting the engagement of the end plate with the actuator housing;
(28) FIG. 20b depicts an illustrative view of how inserts can be used to remove an end butt plate; and
(29) FIGS. 21a, 21b, 21c and 21d depict the end plate with C-rings in place and illustrating in sequence how wedges can be inserted into slots for engagement with C-rings and removal of the end plate to provide access to the interior.
DETAILED DESCRIPTION OF THE INVENTION
(30) Reference is first made to FIG. 1 of the drawings which depicts a blow out preventer (BOP) stack generally indicated by reference numeral 20, which consists of a well bore control system provided by a well bore control apparatus 22 in accordance with an embodiment of the present invention, which has a pair of shear rams, as will later be described in detail, for closing a well bore 23 in the event of an emergency, and two sets of pipe rams 24, 26 disposed orthogonally to each other and disposed on the BOP stack 20 beneath the well bore control apparatus 22.
(31) Reference is now made to FIG. 2 of the drawings which depict an enlarged view of the apparatus 22 shown in FIG. 1. The well bore control apparatus consists of a housing 27, including a main steel body 28 and two cylindrical actuator housings generally indicated by reference numerals 30 and 32 which are fastened together by a coupling arrangement 34, which will be described in more detail below.
(32) As will be later explained in detail, the ends 30 and 32 contain actuators for actuating shear rams carrying cutting blades and sealing gates to move between an open position and a closed position. The actuators and rams are arranged so that for the position shown in FIG. 2 the gates are in the open position and the bore 23 is open, as shown in broken outline 23a.
(33) Referring to FIGS. 3a and 3b, which are vertical sections taken on lines 3-3 of FIG. 2 with shear rams and sealing gates removed. In this embodiment, the housing 27 includes a guide element 36, which consist of a plurality of parallel and elongated ribs 37. The guide element 36 is adapted to interact with the lower and/or upper gate 64a,64b and defines a path for the upper and/or lower gate to be moved on. It will be appreciated that in further embodiments, only one rib 37 may be provided in the housing 27. It will be further appreciated that the in further embodiment, the guide element 36 may include one or more recesses and/or grooves.
(34) As can be seen in FIGS. 3a and 3b, the ribs 37 are arranged in the housing 27 in a substantially transverse direction to the throughbore 23. Here, the ribs 37 are inclined with respect to a longitudinal axis A of the housing 27. The ribs 37 are arranged within the housing 27 to define an acute angle α to the longitudinal axis A of the housing 27. The angle α of the ribs 37 shown in FIG. 3a is not to scale and exaggerated for illustrative purposes. Here, the ribs 37 are part of the main body 28, extending substantially transverse to the through bore. For friction lock coefficient of friction (μ)>sin(α). For no friction lock μ<sin(α).
(35) Referring to FIG. 3c, this figure shows a vertical section taken on the line 4-4 of FIG. 2. The housing 27 has first and second guide elements 36a and 36b. Both the first and second guide elements 36a and 36b have a plurality of ribs 37. It will be appreciated that in further embodiments, the housing may include more or less than two guide elements 37. Here, the first and second guide elements 36a and 36a are provided in the housing 27 so as to oppose one another, e.g. the first and second guide elements 36a and 36b are provided on two opposing surfaces of the bore 23 within the main body 28.
(36) Reference is now made to FIG. 4 of the drawings which is a vertical section taken on the lines 4-4 of FIG. 2. It will be seen that the main body 28 defines the bore 23 and the main body has an internal bore profile 40 into which are disposed upper metal valve seal 42 and lower metal valve seal 44. Between the seals 42, 44 are shown parts of shear rams, the parts being upper and lower travelling block portions 46a and 46b respectively, which are coupled to ram drive rods and sealing gates, as will be later described in detail. The upper travelling block is shown coupled to cutting blade 54a. When the apparatus is actuated the shear rams move horizontally and traverse the well bore 23 and in combination with a similar blade (not shown) coupled to lower travelling block 46b shear any tubular passing through the well bore, as will be later described in detail.
(37) Reference is now made to FIG. 5 of the drawings, which is a horizontal sectional view through the apparatus shown in FIG. 2. It will be seen that the main body 28 has, at each respective cylindrical end 30 and 32, respective end caps 30a, 32a butt plates 30b, 32b. The end caps 30a, 32a are fastened to cylindrical ends 30, 32. The flanges 34a, 34b are fastened to the main body 28 by super nuts and studs 36 and the butt plates 30b, 32b are fastened to inner hollow pistons 66a, 68a as will be later described. The main body structure and end plate structure define approximately the external length of the apparatus shown in the closed position.
(38) The flanges 34a, 34b and main body 28 define an interior chamber generally indicated by reference numeral 52 into which are disposed the shear rams generally indicated by reference numerals 60a and 60b. The combination of butt plates and flanges are end covers.
(39) Each shear ram 60a, 60b has a rod portion 62a, 62b, a travelling block portions 46a, 46b and gates 64a and 64b for sealing the well bore 23 when the apparatus is actuated, as will be later described in detail. Also shown in FIG. 5 is top cutting blade 54a which is generally V shaped in plan view and which has a hardened cutting edge made of Inconel or similar very hard material suitable for cutting through steel tubulars, cables, wires and the like.
(40) Each cylindrical end 30, 32 also houses a hollow moveable inner pistons generally indicated by reference numeral 66a, 68a which are coupled to the respective movable outer pistons 66b and 68b. It will also be seen from FIG. 5 that butt plates 30b and 32b are coupled to respective inner pistons 66a, 68a and butt plates and are also coupled to shear ram rods 62a and 62b so that, as will later be described in detail, when the inner and outer pistons are actuated to move between an open and closed position, the piston rods and travelling blocks and cutting gates are moved between the open and the closed position.
(41) FIG. 6 depicts a vertical sectional view through the apparatus of FIG. 2 and in this diagram upper and lower cutting blades 54a and 54b are shown coupled to the respective rams 60a and 60b.
(42) Referring to FIGS. 7a and 7b, there is shown a further vertical view through the apparatus 22 of FIG. 2 and in these figures the lower shear ram 60b and lower gate 64b with lower cutting blade 54b are in the open position.
(43) As can be seen in FIG. 7b, the lower gate 64b has first and second engagement elements 65a and 65b, which are arranged on outer opposing surfaces 67a and 67b of the lower gates 64b for mating, interoperating and/or co-acting with the ribs 37 of the first and second guide elements 36a and 36b of the housing 27. In FIG. 7b, the lower gate 64b has two recesses 69 provided on outer surfaces 67a and 67b, which can engage with ribs 37 of the housing 27. It will be appreciated that in further embodiments the lower gate 64b may comprise a single ribs, recess and/or groove or a plurality of ribs, recesses and/or grooves for engagement with a respective single rib, recess and/or groove or a respective plurality of ribs, recesses and/or grooves of the guide element 37.
(44) Referring to FIG. 7b, the recesses 69a, 69b are arranged on the lower gate 64b along a length or in a longitudinal direction of the lower gate 64b. The recesses 69a,69b are inclined with respect to a longitudinal axis B of the lower gate 64b and arranged on the lower gate 64b to define an acute angle β to the longitudinal axis B of the lower gate 64b, as illustrated in FIG. 7b. The angle β shown in FIG. 7b is not to scale and exaggerated for illustrative purposes. In some embodiments, the acute angle β defined by the recesses 69a,69b is the same as the acute angle α defined by the ribs 37.
(45) It will be appreciated that further embodiments, the acute angle β may differ from the acute angle α but it will be understood that the recesses 69a, 69b define a groove 69c which has a sufficient spacing to accept a rib 37.
(46) As can be seen in FIG. 7b, the lower gate 64b has a taper along a length of the lower gate 64b. As will be further described below, the taper allows for the upper and lower gates 64a, 64b to co-act with each other when the upper and lower gates 64a,64b gates are open, closing or in the closed position. It will be appreciated that the features of the lower gate 64b, described above with reference to FIG. 7b, are equally applicable to the upper gate 64a.
(47) FIGS. 8a and 8b show the lower gate 64b of FIG. 7b in the closed position of the bore 23. FIGS. 8a and 8b show the apparatus 22 actuated such that the hollow inner pistons 66a, 68a are moved outwardly and pull butt plates 30b and 32b and shear rams 60a (not shown) and 60b coupled thereto so that the cutting blades 54a (not shown), 54b cut the tubular (not shown). At the extent of travel shown in FIGS. 8a and 8b the lower gate 64b is shown sealing the bore 23. It will be seen that the lower surface 80 of gate 64b is shown abutting the upper surface 82 of valve seal 44 thus providing metal to metal sealing between the lower gate 64b and the valve seal 44 to provide an effective metal to metal seal.
(48) As illustrated in FIG. 8b the ribs 37 of the guide element 36 are arranged to guide the lower gate 64b into sealing engagement with the lower valve seal 44. When the lower gate 64b moves from the open position to the closed position the ribs 37 vertically displace the lower gate 64b. The ribs 37 create or provide a displacement component of the movement of the gate lower 64b, which is perpendicular to the direction of actuation and parallel to the bore 23, as indicated by the arrows in FIG. 8b. The vertical displacement of the lower gate 64b, creates a deflection of material within the adjacent valve seal 44, thereby energising the metal to metal valve seal against surface 80 of the lower gate 64b. By vertically displacing the lower gate 64b into sealing engagement with the lower valve seal 44, a substantially fluid tight seal is formed between the lower gate 64b and the valve seal 44, which is substantially independent of any wellbore fluids and/or pressure. This arrangement provides a fluid tight metal to metal seal, which results in a more robust and enhanced seal integrity in well bores. If the angle α is sufficiently acute, friction between the seat and gate and gate and rib will be limiting and the gate will experience zero backlash. The gate can/will be effectively locked by friction alone.
(49) In the closed position, the engagement elements 65a, 65b of the lower gate 64b engage or abut the ribs 37 of guide element 36 and the main body 28 to form a further seal, which is a metal to metal seal, between the lower gate 64b and the guide element 36 and the main body 28.
(50) As can be seen in FIGS. 8a and 8b, by arranging the guide element 36 to actuate the lower and/or upper gate 64a, 64b into sealing engagement with the respective upper and/or lower valve seal 42,44, the bore 23 is sealed when either the upper or the lower gate 64a,64b is in the closed position. The guide element 36 can actuate the lower and upper gates 64a,64b so that the upper and lower gates 64a, 64b provide the upper and lower seals independently from each other in the closed position. This arrangement provides a failsafe well bore control apparatus 22. It will be appreciated that the features of the lower gate 64b, described above with reference to FIGS. 8a and 8b, equally applicable to the upper gate 64a.
(51) Referring to FIG. 9a, there is shown the upper and lower gates 64a, 64b in the closed position, thereby sealing the bore 23. FIG. 9b of the drawings, which is a horizontal sectional view through the apparatus shown in FIG. 2 with the lower gate 64b in the closed position. Although the above formation of the lower seal and further seal has been described with respect to the lower gate 64b in FIGS. 8a and 8b, it will be appreciated that the upper gate 64a may form an upper seal with the upper valve seal 42 in the same manner as described above in relation to the lower gate 64b. Similarly, it will appreciated that both the lower and upper gate 64a, 64b can sealingly engage the upper and lower seal seats 42,44 as shown in FIG. 9a. At the extent of travel shown in FIG. 9a the gates 64a, 64b are shown sealing the bore 23. It will be seen that an upper surface 76 of gate 64a abuts a lower surface 78 of valve seal 42 and similarly the lower surface 80 of gate 64b is shown abutting an upper surface 82 of valve seal 44 thus providing metal to metal sealing between the gate and the seals to provide an effective metal to metal seal in two positions within the apparatus.
(52) Reference is now made to FIGS. 9a and 9b, 10, 11 and 12 of the drawings which depict the well bore control apparatus in the closed position. Referring first to FIG. 10 it will be seen that the pistons have been hydraulically actuated to move the gates 64a, 64b to a closed position such that the inner pistons 66a, 68a are shown displaced to a position where they extend from the bore 23 beyond their respective housing cylinders 30 and 32. Internally this is best illustrated by reference to FIGS. 9, 11 and 12 which are respective horizontal and vertical sectional views similar to FIGS. 5 and 6 respectively. Referring first to FIG. 11, it will be seen that the outer pistons have been actuated and moved within the respective cylindrical housings to the positions shown and, as such, as they are coupled to inner pistons 66a, 68a, these pistons are moved away from the well bore. However, the butt plates 30b, 32b are coupled to the shear ram actuation rods 62a, 62b and these are pulled in the same direction as the pistons 66a, 68a such that the shear rams 60a, 60b are displaced or pulled outwardly in the opposite direction to the position shown in FIG. 11. In this case, the gates 64a, 64b are displaced over the well bore 23. It will be understood that, should a tubular have been present within the well bore, the tubular would have been first sheared by the blades 54a, 54b to allow the gates 64a, 64b to cover and seal the well bore as shown in FIGS. 11 and 12. Within each cylindrical housing 30 and 32 respective stop rings 70a, 70b are located which limit the extent of travel of the outer and inner pistons thereby adjusting the exact positioning of the gates to seal the well bore.
(53) As will be later described in detail, when the piston is either in the closed or the open position, it can be retained therein by using a plurality of locking dogs 72 which are shown disposed around the periphery of the cylinder. The locking dogs are spring loaded to be retained in recesses 74 in the outer surface of pistons 66b, 68b.
(54) Reference is now made to FIG. 13 which depicts a vertical sectional view through the well bore control apparatus in a view similar to FIG. 6, but with the lower shear ram assemblies 60b shown removed. The lower shear ram assembly shown here consists of the butt plate 32b, the flange 34a and the shear ram consisting of the rod 62b, the travelling block 46b, the blade 54b and the gate 64b. Thus, it will be appreciated that by removing a shear ram in this way the internal structure of the apparatus can be serviced, maintained and for example the blades 54a, 54b can be replaced and the gates 64a, 64b can also be replaced and/or machined. Similarly, this allows access into the metal to metal seals 42, 44 which can also be removed and replaced by similar types of seals or seals of a different material thus facilitating servicing of the apparatus. FIGS. 11 to 13 shows an alternative embodiment of the well bore apparatus of FIGS. 1 to 10, with no guide element 36 present in the main body 28. It will be appreciated that in further embodiments, the well bore apparatus of FIGS. 11 to 13 may be provided with one or more guide elements, as described above.
(55) Reference is now made to FIGS. 14a, 14b and 15a and 15b of the drawings which better illustrate the operation of the apparatus in accordance with the invention. The apparatus in FIG. 14a is shown closed with the rams in a position such that the well bore 23 is open with a tubular 75 passing therethrough and shown in broken outline. FIG. 14b shows the apparatus actuated such that the hollow inner pistons 66a, 68a are moved outwardly and pull butt plates 30b and 32b and shear rams 60a and 60b coupled thereto so that the cutting blades 54a, 54b cut the tubular which is shown separated in broken outline 75. At the extent of travel shown in FIG. 14b the gates 64a, 64b are shown sealing the bore 23. It will be seen that the upper surface 76 of gate 64a abuts the lower surface 78 of seal 42 and similarly the lower surface 80 of gate 64b is shown abutting the upper surface 82 of seal 44 thus providing metal to metal sealing between the gate and the seals to provide an effective metal to metal seal in two positions within the apparatus similar to the arrangement disclosed in the aforementioned UK patent GB2454850B. It will also be understood that metal seals 42, 44 energises against housing 28 providing further metal to metal seals and avoiding the requirement for elastomeric seals.
(56) Reference is made to FIGS. 9, 15a and 15b where it will be seen that the gate blocks 64a, 64b are tapered along the direction of travel shown as exaggerated taper surfaces 67a, 67b such that as the gate blocks move the tapers pass over each other to create a displacement component of motion which is perpendicular to the direction of actuation and parallel to the housing throughbore. This perpendicular component, shown in blue arrows in FIGS. 15a and 15b is axial and is sufficient to create a deflection of material within the adjacent valve seats 42, 44 thus energising the metal to metal valve seat seal against the surfaces 76, 80 of the respective gates 64a and 64b and it also energises the seals 42, 44 against housing 28 providing further metal to metal seals. The angle of taper illustrated in FIGS. 15a and 15b is shown not to scale. It is preferable that a shallow angle is used in order to generate the required preload to energise the metal to metal seals and to minimise the depth of the galley.
(57) The minimum angle of the taper that can be utilised is limited by the preload capacity of the seal arrangement and/or the stroke length of the actuator.
(58) The maximum angle of the taper that can be utilised is limited by the preload requirements of the seal and/or the capacity of the actuator and/or the capacity of the actuator locks.
(59) A shallow angle is preferred in order maximise the transfer of work done by the actuator to seal preload, but the angle must sufficient to be compliant with the system in terms of its manufacturing and assembly tolerances.
(60) The angle of taper may be so shallow such that it is difficult to perceive by eye, but the gates will have sufficient tapers to generate an intended component of displacement perpendicular to the direction of travel of the gates sufficient to energies a seal.
(61) This has a significant advantage that once the valve is closed, the seal is already fully energised independent of any well bore pressure or fluid excitement, providing an extremely robust seal for both low pressure fluids and low density fluids. This arrangement places all seal locations of the bore in a state of high compressive pre load irrespective of the state of bore conditions or conditions of any fluid within the bore. This provides a true self energising bi-directional metal to metal seal and the seal state of high compressive pre load allows for the use of full metal to metal seal thus providing a more robust and enduring seal integrity.
(62) FIG. 16 shows a graph of the relationship of pressure or hydraulic pressure applied to the actuators, for example the inner and outer pistons 66a,66b,68a 68b, during the movement of the upper and lower gates 64a, 64b from the open to the closed position of the bore 23 for different configurations of the upper and lower gates in a wellbore control apparatus. The solid line in FIG. 16 relates to a well bore control apparatus 22 with parallel gates, i.e. gates without a taper. The dashed line in FIG. 16 illustrates a well bore control apparatus 22 with tapered gates. The dotted line refers to a wellbore control apparatus with rams, which are pushed to one another to close the throughbore.
(63) Referring to FIG. 16, it can be seen that at about 10 percent (A) of the movement, pressure is increased to the actuators to move the gates into the bore from the closed position. For ram preventors, this initial pressure is higher as a pressure of the bore pressure has to be overcome to push the gates into the bore.
(64) Between 20 and 30 percent of the movement (B) the actuator pressure increases while the tubular contained in the bore 23 is cut by cutting blades 64a, 64b. For the well bore control apparatus with rams, the movement terminates at about 50 percent (C) as the rams only travel to a midpoint of the bore 23. For the embodiment of a well bore control apparatus with tapered gates and parallel gates (solid and dashed lines, respectively), the gate movement continues. At above 90 percent (D), the actuating pressure increases for the embodiment of a well bore apparatus with tapered gates. This increase is due to the interaction of the upper and lower gates, e.g. when the upper and lower gates 64a,64b slide over each other. Alternatively or additionally, this increase in actuating pressure can be due to the interaction of the guide element 37 with the engagement elements 65a,65b of the upper and/or lower gate 64a,64b.
(65) In the embodiment of a well bore control apparatus with parallel gates, the seal provided by the upper and lower gates of the bore depends on wellbore pressure or fluid excitement. By providing a wellbore control apparatus with tapered gates, the seal of the bore is energised by the interaction and friction between the upper and lower seals 64a, 64b, as described above. The use of tapered gates may minimise the occurrence of leaks of wellbore fluids in the wellbore control apparatus and thus, lead to enhanced safety. Alternatively or additionally, by providing a well bore apparatus with a guide element, the seal of the bore is energised actuating the gates, e.g. tapered or parallel gates, into sealing engagement with the upper and/or lower valve seat 42,44, as described above.
(66) Referring to FIGS. 17a and 17b, there is shown enlarged views of the apparatus of FIG. 1 in the open position (FIG. 17a) and in the closed position of the bore 23 (FIG. 17b). As described with reference to FIG. 2, first and second actuator housings 30 and 32 are fastened together by the coupling arrangement 34. Each cylindrical actuator housing 30,32 includes the first and second actuators, which in this example include the inner pistons 66a,68a and outer pistons 66b,68b as described above. As can be seen in FIGS. 17a and 17b, the actuator housings 30,32 are coaxially arranged external of the bore 23.
(67) The coupling arrangement 34 is arranged to pull the first and second actuator 30,32 housings to one another in a longitudinal direction of the housing 27. Here, the coupling arrangement 34 biases or pulls the first and second actuator housings 30,32 inwards and towards the bore 23 by applying an inwardly directed force and/or load, e.g. a force and/or load towards the bore 23, on the first and second actuator housings 30,32.
(68) In FIG. 17b, the inner and outer pistons 66a,68a,66b,68b have been hydraulically actuated to move the gates 64a,64b into the closed positions, as described above. As can be seen in FIG. 17b in the closed position the inner pistons 66a,68a have been actuated outwards, so as to extend from their respective actuator housings 30,32. The inner pistons 66a,68a can exert an outwards directed force and/or load, e.g. a force and/or load directed away from the bore 23, on the first and second actuator housings 30,32 in use. In use, a force and/or load exerted by the coupling arrangement 34 on the first and second actuator housing 30,32 is in an opposite or reversed direction to a force and/or load exerted on the first and second actuator housings 30,32 by the actuation of the inner pistons 66a,68a. when the gates are moved to the closed position.
(69) Here, the coupling arrangement 34 minimises and/or prevents movement, such as outwards movement, of the first and second actuator housings 30,32 when the gates 64,64b are moved and/or actuated from the open position to the closed position of the bore 23 by the respective inner and outer pistons 66a,68a,66b,68b. As can be seen in FIGS. 17a and 17b, the coupling arrangement 34 is provided external of the bore 23, extending along a longitudinal direction of the housing 27. The coupling arrangement provides an efficient load path between the first and second actuator housings 30,32. The coupling arrangement avoids the use of flanges or the like for coupling the actuator housings 30,32 to the bore 23, which leads to a reduction in weight of the wellbore control apparatus.
(70) In this embodiment, the coupling arrangement includes six elongate members or tie arrangements, three of which are shown in FIGS. 17a and 17b, indicated by reference numeral 35. It will be appreciated that in further embodiments, such as those shown in FIGS. 2 and 10, there may be provided more or less than six elongate members 35. The elongate members 35 are arranged parallel to one another in this example. Each of the tie arrangement 35 includes a first tie portion or rod 36a and a second tie portion or rod 36b. As can be seen in FIGS. 17a and 17b the first and second tie portions 36a,36b extend from the respective first and second actuator housings 30,32.
(71) The coupling arrangement 34 includes six connection members or turn buckles 38, three of which are shown in FIGS. 17a and 17b, for connecting together the respective first and second tie portions 36a,36b of elongate members 35. It will be appreciated that in further examples, such as those shown in FIGS. 2 and 10, there may be provided more or less than six connection member 38. Each turn buckle 38 and each of the first and second tie portions 36a,36b have screw threads, such as left hand and right hand screw threads as in this example, so that rotation of the turn buckles 38 can pull the first and second actuator housings 30, 32 together.
(72) Rotating the turn buckles permits tension between first and second actuator housings 30,32 to be adjusted or varied. For example, tension between the first and second actuator housings 30,32 may be varied by rotating the turn buckles 38 to pull the first and second actuator housings 30,32 together or rotating the turn buckles 38 to release tension between the first and second actuator housings 30,32.
(73) Reference is now made to FIGS. 18a and 18b of the drawings where, in a manner similar to that shown and described with reference to FIG. 13, an end plate and associated shear ram assembly is shown removed to allow access to the interior of the apparatus. This is enabled by providing the actuators 66a, 68a as hollow pistons around the closing body, which are the gates, so that the pistons and gates are effectively in parallel rather than in series. This structure has the advantage of shortening the overall length of the arrangement compared to an arrangement where the piston and gate are in series and furthermore, because the ram is mounted on the butt plate, removal of the butt plate and ram is not hindered or disrupted by the location of the actuator, which means that, as shown in FIGS. 15a and 15b, the assembly and gates can be removed with the actuator remaining in situ. Similarly, it will also be appreciated that it is possible to disconnect the piston actuator from the gate and rod thereby allowing the actuator to be function tested in isolation without operating the gate. Furthermore, the shear ram rod which provides transmission for the stroke of the valve gate can remain in situ while the actuator is removed providing the significant advantage of eliminating any requirement to disturb the pressure integrity of the valve when servicing or removing the actuator.
(74) Operation of the outer piston arrangement show in FIGS. 1 to 18 will now be described in detail with reference to FIGS. 19a to 19e. It will be appreciated that as pistons are controlled by hydraulic fluid it is important to provide a control system that ensures that the inner and outer pistons afore described are maintained in position and do not reciprocate in the event of a hydraulic failure. This is provided using a control mechanism locking the position of the reciprocating piston within a hydraulic cylinder.
(75) With reference to FIGS. 19a to 19e which show the outer piston 66b at various stages of actuation, it will be seen that the hydraulic cylinder has two actuating volumes 82, 84 which are isolated by the outer piston 66b, 68b, one volume 82 for extending the piston and the other volume 84 for retracting the piston. The piston has a sealing arrangement provided by the seals 86, 88 which separate the actuating volumes 82, 84 and also isolates and defines a third volume 90 which exists between the piston seals 86, 88. This third volume 90 travels with the piston as it moves within the housing on main volume defined between the outer cylinders 30, 32 and the main body of the apparatus 28 as can be best seen in FIGS. 14a and 14b.
(76) The volume 90 is controlled independently as the two actuating volumes 84, 86 and is pressurised hydraulic fluid via a port 92. Pressuring this volume controls a series of circumferentially disposed locking dogs 72. As shown in all of the diagrams aforementioned, it will be understood that each locking dog is sprung loaded with a spring washer (not shown in the interests of clarity) which means that each locking dog is biased into engagement with one of the piston bearing grooves 94, thus locking the piston in one of two positions i.e. either in the closed position or in the open position. Applying hydraulic pressure to the volume 90 will force the locking dogs against the spring washers moving them out of engagement with the bearing groove 94 and allowing actuation of the outer inner piston and the rams to move between the open and closed positions as afore described.
(77) In FIG. 19a it will be seen that the piston is locked in a retracted position such that the dogs are biased into groove 94. Hydraulic pressure is applied via line 92 to force the locking dogs to retract as shown in FIG. 19b. This allows hydraulic pressure to be applied to volume 86 to extend the piston as shown in FIG. 19c. When hydraulic pressure is released from volume 1 and volume 3 the locking dogs are spring biased in position such that the dogs engage with groove 94. This prevents the piston from recoiling in the event of hydraulic failure.
(78) Reference is now made to FIGS. 20a, 20b and FIGS. 21a, 21b which explain how the butt plates are retained within the inner piston actuator and how the butt plates are then removed so that the ram assembly can provide access to the interior of the apparatus as described with reference to FIGS. 12a, 12b.
(79) Referring first to FIG. 20a, it will be seen that the end plate and the actuator has three spaced square section grooves 100a, b, c, 102a, b, c and there is a C-ring 104a, b, c disposed in each pair of grooves shown. It will be appreciated that the grooves are large enough to accommodate the C-rings shown but are also large enough to allow displacement of the C-rings either to the butt plate 32b or to the actuator as will be described. This is achieved by providing slots 104 in the butt plate which are disposed around the periphery of the butt plate. The slots extend through the butt plate and allow wedges to be inserted so that once the wedges 106 (FIG. 20b) are inserted the C-rings are displaced into the grooves in the inner actuator piston and this allows the stud and nuts to be turned and release the butt plate 32b which carries the shear ram assembly 60a. The wedges 104 when inserted allow removal of the butt plate 32b in the direction of the arrow shown in FIG. 20b.
(80) It will be appreciated that various modifications may be made to the embodiment of the apparatus and parts thereof herein before described without departing from the scope of the invention.
(81) For example, it will be appreciated that the gate blocks 64a, 64b need not be tapered, although the provision of tapered gate blocks provides the aforementioned advantage of energising the seals, so that once the valve is closed an extremely robust seal is provided for low pressure fluids and low density fluids, thus providing better seal integrity.
(82) The material of the blades may be Inconel or any equivalent hard material sufficient to cut through tubulars and the like. The axial slots 104 which intersect the circumferential groves as shown in FIGS. 20 to 21 could also be placed in the actuator as well as or instead of the end plate 32b. It will also be understood that the C-rings 102 may be displaced by other methods such as providing a cam shaft with surfaces which abut each of the C-rings and location of the cam shaft could displace the C-rings into the groves either on the actuator or on the end plate to allow the end plate to be removed.
(83) It will thus be appreciated that the aforementioned apparatus provides significant advantages over the art in terms of providing energised seal integrity and ease of access to allow maintenance of the interior of the apparatus. The arrangement is such that either the actuator can be removed to leave the gate in place, thus ensuring seal integrity or the shear ram can be removed allowing replacement of blades and seals facilitating rapid maintenance and significantly reduced time and therefore expense than with existing arrangement. The structure herein before described is applicable to various sizes of apparatus from the 5″ to 7″ inch product all the way to an 18¾ inch product, all of which operate on a similar principle as the aforementioned embodiment. For example, ribs 37 may be declined with respect to a longitudinal axis A of the housing 27.
(84) For example, the recesses 69a,69b may be decline with respect to a longitudinal axis B of the upper and/or lower gate 64a,64b.
