Abstract
A mobile cutting tool is for cutting a subsea tubular structure and has i) a tool body for receiving the subsea tubular structure in an enclosure thereof; ii) an actuator mounted on the tool body at one side of the enclosure; iii) a non-rotatable cutting element provided on the actuator, the actuator with the cutting element for carrying out a translational cutting movement through the enclosure including the subsea tubular structure, and iv) a reaction member mounted at an opposite side of the enclosure of the tool body opposite to the cutting element for applying a reaction force on the subsea tubular structure during cutting. A method is for cutting a subsea tubular structure, wherein a non-rotating translation cutting movement is used for cutting.
Claims
1. A mobile cutting tool for cutting a subsea tubular structure, the mobile cutting tool comprising: a tool body configured for receiving the subsea tubular structure in an enclosure thereof; an actuator mounted on the tool body at one side of the enclosure; a non-rotatable cutting element provided on the actuator, the actuator with the cutting element being configured for carrying out a translational cutting movement through the enclosure including the subsea tubular structure, and a reaction member mounted at an opposite side of the enclosure of the tool body opposite to the cutting element for applying a reaction force on the subsea tubular structure during cutting, wherein the reaction member forms part of a further actuator, wherein the reaction member is provided on or integrated with a piston rod or thread bar of the further actuator, which further actuator is configured for opening and closing said enclosure for receiving said subsea tubular structure.
2. The mobile cutting tool according to claim 1, wherein the actuator comprises a cylinder, for example a hydraulic cylinder or a thread bar actuator.
3. The mobile cutting tool according to claim 2, wherein the reaction member is provided with a further cutting element directed towards the non-rotatable cutting element for facilitating the cutting.
4. (canceled)
5. The mobile cutting tool according to claim 4, wherein the further actuator comprises a further cylinder, for example a further hydraulic cylinder, or a thread bar actuator.
6. The mobile cutting tool according to claim 1, further comprising at least one buoyancy member for controlling the buoyancy of the mobile cutting tool when the mobile cutting tool is used subsea.
7. The mobile cutting tool according to claim 1, further comprising at least one digging device for digging into the seabed for freeing a greater length of a tubular structure extending through the seabed.
8. The mobile cutting tool according to claim 1, further comprising at least one welding device for welding the subsea tubular structure after that it has been cut.
9. The mobile cutting tool according to claim 7, wherein the welding device is selected from a group comprising: a shielded metal arc-welding device, a flux cored arc-welding device, and a gas tungsten arc-welding device.
10. The mobile cutting tool according to claim 1, wherein the mobile cutting tool is provided with a handle for being coupled to and handled by a subsea vehicle, such as an ROV.
11. A subsea system for cutting a subsea tubular structure, the system comprising: a subsea vehicle, and a mobile cutting tool comprising: a tool body configured for receiving the subsea tubular structure in an enclosure thereof; an actuator mounted on the tool body at one side of the enclosure; a non-rotatable cutting element provided on the actuator, the actuator with the cutting element being configured for carrying out a translational cutting movement through the enclosure including the subsea tubular structure, and a reaction member mounted at an opposite side of the enclosure of the tool body opposite to the cutting element for applying a reaction force on the subsea tubular structure during cutting, wherein the reaction member forms part of a further actuator, wherein the reaction member is provided on or integrated with a piston rod or thread bar of the further actuator, which further actuator is configured for opening and closing said enclosure for receiving said subsea tubular structure, wherein the mobile cutting tool is coupled to the subsea vehicle.
12. A subsea system according to claim 10, wherein the subsea vehicle comprises an ROV.
13. A method for cutting a subsea tubular structure, the method comprising the following steps: providing a mobile cutting tool; positioning the mobile cutting tool in cutting position exterior to the subsea tubular structure; fixing the position of the mobile cutting tool with respect to the subsea tubular structure, and activating the mobile cutting tool for cutting the subsea tubular structure in a translation movement of the at least one cutting element.
14. (canceled)
15. A method for recovering a subsea wellhead from a casing of a well, the method comprising the method according to claim 13.
16. The method according to claim 15, wherein the subsea tubular structure comprises a casing of the wellhead between the seabed and the wellhead, and wherein, in the step of positioning the mobile cutting tool, the mobile cutting tool is positioned exterior to the casing and below the wellhead, and wherein, in the step of activating the mobile cutting tool, the wellhead is separated from the well.
17. The method according to claim 16, further comprising the step of digging into the seabed for freeing a greater length of the casing for allowing cutting of the casing below an original level of the seabed.
18. The method according to claim 17, wherein, in the step of positioning the mobile cutting tool the mobile cutting tool is positioned below the original level of the seabed.
19. The method according to claim 13, further comprising the step of welding the subsea tubular structure after that it has been cut.
20. The method according to claim 13, wherein the positioning of the mobile cutting tool is done with a subsea vehicle, for example an ROV.
21. The method according to claim 13, further comprising, before the step of positioning the mobile cutting tool in cutting position, the step of lowering the mobile cutting tool from the sea surface into the sea by means of a hoisting tool, for example a crane.
Description
[0051] In the following is described an example of a preferred embodiment illustrated in the accompanying drawings, wherein:
[0052] FIG. 1 shows a mobile cutting tool in accordance with an embodiment of the invention;
[0053] FIG. 2 shows the mobile cutting tool of FIG. 1, when being hoisted out of a container;
[0054] FIG. 3 shows a top view of the mobile cutting tool of FIG. 1;
[0055] FIG. 4 shows a bottom view of the mobile cutting tool of FIG. 1;
[0056] FIG. 5 shows a top view of the mobile cutting tool of FIG. 1 with the enclosure being closed;
[0057] FIG. 6 shows a top view of the mobile cutting tool of FIG. 5 with the enclosure being closed and the cutting element on the actuator in its fully extended position;
[0058] FIG. 7 shows a front view of the mobile cutting tool of FIG. 1;
[0059] FIG. 8 shows a side view of the mobile cutting tool of FIG. 1;
[0060] FIG. 9 shows an isometric view of the mobile cutting tool of FIG. 1, when being hoisted;
[0061] FIGS. 10-15 show different stages of a method of recovering a wellhead in accordance with an embodiment of the invention;
[0062] FIG. 16 shows a stage of a method of recovering a wellhead in accordance with another embodiment of the invention;
[0063] FIG. 17 shows a flexible riser, which has been cut with a mobile cutting tool and method in accordance with the invention;
[0064] FIG. 18 shows a drill string, which has been cut with a mobile cutting tool and method in accordance with the invention;
[0065] FIG. 19 illustrates the principle of cold welding in accordance with an embodiment of the invention, and
[0066] FIG. 20 illustrates the principle of hot welding in accordance with an embodiment of the invention.
[0067] The figures and description show a mobile cutting tool, which offers a unique and alternative solution to the existing solutions of cutting subsea. The solution of the invention is free from constraints of owning vessels, complex/high-cost equipment and labour-intensive offshore operations. The invention enables a low-cost system, which may utilize existing client vessels, including on-board crew, dedicated remote underwater systems and labour-efficient new technology to offer life-of-field services. It facilitates an on-demand remotely operated kit, which can be easily taken on-board dedicated vessels ready to be launched without any significant mobilization time.
[0068] An important part of the invention resides in the carrying out of a pure translational cutting movement for severing a subsea tubular structure, such as a casing below a wellhead. Prior art methods disclose time-consuming methods such a diamond wire cutting. A translational cutting movement may be carried out with a huge variety of different tools. In the figures and detailed description only one example is given. It must be stressed that the invention is not limited to this example.
[0069] FIG. 1 shows a mobile cutting tool 100 in accordance with an embodiment of the invention. FIG. 2 shows the mobile cutting tool 100 of FIG. 1, when being hoisted out of a container 200. Such container may be conveniently placed on board a vessel, for example. As illustrated in FIG. 2, the mobile cutting tool 100 may be hoisted out of the container 200 by means of a hoisting cable 999 of a crane (not shown). The container 200 may be a 10-feet container and may store spare parts and other required equipment. In this way the cutting tool 100 takes up very little space on board a vessel and thereby provides flexibility and eliminates mobilization costs. Jobs can be planned ahead on-shore. When a window of opportunity opens up, removal of a well-head can be done within a very short time. It is important to note that the cutting tool 100 in accordance with the invention is a mobile/movable cutting tool, i.e. it is meant to be transportable to its desired location for cutting a respective subsea tubular structure.
[0070] FIG. 3 shows a top view of the mobile cutting tool 100 of FIG. 1. The mobile cutting tool 100 comprises a tool body 110, which forms an enclosure 50 for receiving a tubular structure (not shown). In the enclosure 50 there is present a non-rotatable cutting element 130, which is actuated by a (linear) actuator 120, which is connected to the tool body 110. The actuator 120 in this embodiment is a hydraulic cylinder. An alternative actuator could be a thread bar actuator driven by an electric motor, for example. Also, a gear system may be used in order to increase the torque on the thread bar actuator. The cutting element 130 is connected to a piston rod (not shown) of this hydraulic cylinder 120. The cutting tool 100 further comprises a further actuator 150, which function is explained later. The cutting tool 100 is also provided with a buoyancy member 160, which is not essential, yet advantageous when the cutting tool 100 is used subsea. The cutting tool 100 evidently will have a significant weight and the buoyancy member 160 may be used to compensate for this weight to increase the manoeuvrability of the cutting tool 100. The buoyancy member 160 may also comprise a control system, which may be coupled with an ROV (not shown), which handles the cutting tool 100. On top of the cutting tool 100 there is provided a hoisting grip 170, which will be discussed in more detail later. To facilitate handling by an ROV the cutting tool 100 is provided with a handle 180. The embodiment of the figures only shows one buoyancy member 160, but there may be provided more than one distributed over the cutting tool 100 for further fine-tuning of the buoyancy of the cutting tool 100.
[0071] FIG. 4 shows a bottom view of the mobile cutting tool 100 of FIG. 1. This side of the tool shows some further features.
[0072] First of all, there is provided at least one welding device 190. This welding device 190 is not essential to the cutting operation, but might be used in order to seal off the well in a better way. The cutting tool 100 of the invention may be used to cut an already-plugged well, in which case the sealing is not so important. However, the invention opens up the opportunity to combine plugging and cutting as will be explained in more detail later. In such embodiments the sealing of the tubular structure after cutting is important and in such scenario the presence of a welding device 190 is beneficial. It goes almost without saying that, as an alternative of providing a welding device 190 on the cutting tool 100, a separate welding tool (not shown) may be provided. That is why the welding device 190 is not essential to the invention, but an advantageous embodiment.
[0073] A second feature of the cutting tool 100 in FIG. 4 is the presence of a digging device 195. Also said digging device 195 is not essential, and it might be provided on a separate tool. Still, the presence of the digging device 195 is advantageous, because it facilitates quicker cutting at a location below the original level of the seabed. This will be explained in more detail later.
[0074] FIG. 5 shows a top view of the mobile cutting tool 100 of FIG. 1 with the enclosure 50 being closed. This figure shows an important feature of the cutting tool 100, which is the reaction member 140. The reaction members 140 is formed by the piston rod of the earlier mentioned further actuator 150. When this further actuator 150 is activated, the reaction member 140 will show up and effectively close the enclosure 50. While the cutting element 130 is provided at a first side of the enclosure 50, the reaction member 140 provided at a second, opposite side of the enclosure 50. In this embodiment the position of the piston rod (reaction member) 140 is locked when the further actuator 150 is fully extended, in that a force applied on the reaction member 140 will not result in bending of the piston rod. This may be achieved by configuring the tool body 110 with a recess (not shown) such that an end of the piston rod 140 is received therein at full extension of the piston rod 140. The reaction member 140 may be provided with a further cutting element 145 to facilitate cutting of the tubular structure. In this position of the further actuator 150 the cutting tool 100 is ready for cutting the tubular structure.
[0075] FIG. 6 shows a top view of the mobile cutting tool 100 of FIG. 5 with the enclosure 50 being closed and the cutting element 130 on the actuator 120 in its fully extended position. This is the position after carrying out the cutting movement. The piston rod 125 of the actuator 120 is here visible. The figure clearly illustrates what is meant with a translational cutting movement with a non-rotatable cutting element 130, i.e. that the cutting element 130 only makes a translational movement through the enclosure without rotating during cutting. FIGS. 5 and 6 further illustrate the presence of a guide 135 at one side of the enclosure 50 for guiding the cutting element 130 when it is translated during cutting. This guide 135 is not essential, yet it prevents the cutting element 130 from rotating during cutting.
[0076] FIG. 7 shows a front view of the mobile cutting tool 100 of FIG. 1. FIG. 8 shows a side view of the mobile cutting tool 100 of FIG. 1. In these drawings the hoisting grip 170 and the handle 180 are illustrated in a bit more detail. The hoisting grip 170 comprises two fixed hoisting points 171 in the form of rings, and one adjustable hoisting connection point 172. These three hoisting points 171, 172 facilitate stable hoisting with a 3-point hoisting cable (not shown) of a crane (not shown). FIG. 9 shows an isometric view of the mobile cutting tool 100 of FIG. 1, when being hoisted with a hoisting cable 999.
[0077] FIGS. 10-15 show different stages of a method of recovering a wellhead in accordance with an embodiment of the invention. FIG. 10 shows the mobile cutting tool 100 when being hoisted with a crane (not shown) from the container 200, which resides on a vessel 500 and lowered through a so-called moon pool 510 in the vessel into the sea towards the seabed.
[0078] FIG. 11 shows a further stage of the method, wherein the mobile cutting tool 100 when being coupled to an ROV 600 subsea. The ROV 600 is connected with the surface through the umbilical string 610 in the conventional way. The ROV 600 connects itself to the cutting tool 100 via its robot arms 620 (manipulators), which are configured to grip the handle (not clearly shown) of the cutting tool 100. After this stage of the method, the hoisting cable 999 is loosened from the cutting tool 100. The ROV 600 will control all communication and connections, i.e. the system will operate through the ROV control and so-called dirty pack system.
[0079] FIG. 12 shows a further stage of the method, wherein the ROV 600 moves the mobile cutting tool 100 to the wellhead 800 to be recovered. The target position is the casing 810 of the well 820 below the wellhead 800. The seabed has not been drawn in this figure.
[0080] FIG. 13 shows a further stage of the method, wherein the mobile cutting tool 100 has enclosed the casing 810. In this stage of the method a pit may be jetted in the seabed 900 in order to be able to cut the casing 810 below the level of the seabed 900. This will be explained with reference to FIG. 16. As an alternative to the cutting tool 100 jetting a pit, the ROV 600 may be used to carry out this task.
[0081] FIG. 14 shows a further stage of the method, wherein further actuator 150 has been activated to close the enclosure 50 with the reaction member 140. The mobile cutting tool 100 is now ready for cutting.
[0082] FIG. 15 shows a further stage of the method, wherein the cutting operation has been carried out. The mobile cutting tool 100 facilitates cutting the casing 810 in less than 5 minutes. The figure shows a remaining part 810 of the casing, which sticks above the seabed. In the figure the wellhead has already been hoisted back to the surface.
[0083] In the final stage (not shown in the figures) the mobile cutting tool and the ROV are retrieved and returned to the vessel, where the cutting tool 100 will be power-washed, and placed back into the container for the next run.
[0084] It may be desired to cut the casing such that no remaining part 810 is visible above the seabed 900. FIG. 16 shows a stage of a method of recovering a wellhead in accordance with another embodiment of the invention, wherein this problem is solved. The mobile cutting tool 100 in this embodiment is provided with a digging device (not illustrated) at a bottom side thereof. In this example this concerns a jetting device, which creates a jet stream 195JS as illustrated by the arrows. This jet stream 195JS will dig a pit or hole 910 in the seabed 900 such that a part of the casing 810 which was under the original level 900LV of the seabed is freed. It will be understood that instead of jetting a pit or hole 910, also suction or mechanical digging may be used.
[0085] The cutting tool and method of the invention have been tested. FIG. 17 shows a flexible riser, which has been cut with a mobile cutting tool and method in accordance with the invention. The riser has an internal diameter of 8 inch (=203.2 mm). FIG. 18 shows a drill string, which has been cut with a mobile cutting tool and method in accordance with the invention. The cut was even carried out at the location of the joint where the drill string is much thicker. The drill pipe had a diameter of 6,625 inch (=168,275 mm).
[0086] FIG. 19 illustrates the principle of cold welding in accordance with an embodiment of the invention. It has already been explained that in many situations the cutting tool 100 in accordance with the invention will result in the tubular structure 810, for instance a casing of a well below the wellhead, to be squeezed together as illustrated in FIG. 19a, where the tubular structure 810 is being squeezed and finally cut at a specific location L1. The resulting structure is the remaining part 810 of the casing that is illustrated in FIG. 19b. It may very well be that this remaining part 810 is already closed, i.e. cold-welded. FIG. 19b illustrated that the cold-welding effect can be improved by squeezing the structure at a second location L2 a bit below the cutting location L1. It is important that the remaining part 810 is not completely cut in this second run. The resulting structure, a properly cold-welded remaining part 810 of the casing is shown schematically in FIG. 19c.
[0087] FIG. 20 illustrates the principle of hot welding in accordance with an embodiment of the invention. The structure of FIG. 20a is effectively the same as the structure of FIG. 19b. The difference relies in the way this structure is processed further. Instead of carrying out a further squeezing step a (hot) welding step is carried out, which is schematically illustrated with the lightning symbol 190W. Different techniques have been proven to work subsea, such as: shielded metal arc-welding, flux cored arc-welding, and gas tungsten arc-welding. It is very likely, however, that other techniques will also work, such as magnetic-pulse sealing as disclosed in U.S. Pat. No. 5,188,177. After carrying out these steps, the structure, a hot-welded/sealed remaining part 810 of the casing, as illustrated in FIG. 20b, remains.
[0088] The advantage of cold and hot welding of the casing as illustrated in FIGS. 19 and 20 is that this opens up the possibility of omitting plugging of the well before removal of the wellhead, which saves a lot of additional operational costs and time.
[0089] It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. Use of the verb comprise and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. The article a or an preceding an element does not exclude the presence of a plurality of such elements. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.
