Funnel system and method

A system in some embodiments includes a two-part funnel that guides a first component to engage or connect with a second component of a mineral extraction system. The two-part funnel having a first funnel portion, and a second funnel portion, wherein the second funnel portion is configured to be disposed in at least two positions relative to the position of the first funnel portion.

BACKGROUND

Wells are often used to access mineral resources below the surface of the earth. For instance, oil, natural gas, and water are often extracted via wells. Wells generally include various mechanisms for drilling and recovery of the mineral resources. For instance, a well is generally drilled from the earth's surface into a deposit of mineral resources. Once the mineral resources are reached, a sub-surface well-bore provides a path between the mineral deposit and the surface. Generally, the sub-surface well-bore terminates into a wellhead that is capped off with what is referred to as a “christmas tree” at or near the surface. The tree generally includes various paths for the minerals to be extracted through, as well as numerous valves and controls to regulate the flow of the minerals. Wells may be located on land (e.g., surface systems) and under the surface of the water (e.g., offshore and subsea systems). With the advance of technology, subsea systems are being drilled and completed in oceans, seas, the Gulf of Mexico, and the like. In certain subsea systems, wells may be located on the ocean floor at depths exceeding 10000 feet.

A well located on the ocean floor may create additional difficulties and costs, such as those relating to installation and maintenance. For instance, if a well is drilled on the ocean floor, a christmas tree and other subsea system components (e.g., a manifold) are generally attached to the wellhead at or near the ocean floor. Accordingly, tools and various equipment are often lowered from the surface (e.g., an offshore vessel) to the ocean floor for installation, operation, and maintenance of the tree and the other system components. However, at increased depths, the fluid pressures may be so great that direct human interaction (e.g., a diver) at the depth of the system in not feasible. Thus, devices and components are lowered, operated and/or retrieved via cables, drill pipe, or a remote operated vehicle (ROV), for instance. Unfortunately, aligning and operating tools from the platform or other remote locations may introduce increased difficulties relating to alignment of various components. As a result, performing installation, operation and maintenance of the system may involve an increased amount of time and effort.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

When introducing elements of various embodiments of the present invention, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Moreover, the use of “top,” “bottom,” “above,” “below,” and variations of these terms is made for convenience, but does not require any particular orientation of the components.

Certain exemplary embodiments of the present invention include a funnel system that addresses one or more of the above-mentioned inadequacies of conventional subsea extraction systems. As explained in greater detail below certain embodiments include a two-part funnel, which has a portion of the funnel that can be rotated and/or repositioned such that the funnel system does not interfere with other components of the extraction system. In some embodiments, a first portion of the funnel system may be coupled to a second portion of the funnel system via a hinge, such that the first portion of the funnel can be rotated to reduce potential interference with other components. Further, certain embodiments may include a two-part funnel that has a telescopic configuration, such that a portion of the funnel slides relative to another portion of the funnel in a coaxial manner. Additionally, certain embodiments may include a latching mechanism to prevent the funnel system from inadvertently rotating and/or sliding.

FIG. 1illustrates a mineral extraction system10. The illustrated resource extraction system10can be configured to extract various minerals, including hydrocarbons (e.g., oil and/or natural gas). In some embodiments, the resource extraction system10may be land-based (e.g., a surface system) or subsea (e.g., a subsea system). Further, the system10may be configured to extract minerals and/or inject other substances. As illustrated, the system10includes what is colloquially referred to as a christmas tree12(hereinafter, a tree) and a wellhead hub14. Generally, the wellhead hub14includes a large diameter hub that provides a connection to a sub-surface well bore extending from the surface16(e.g., ground or ocean floor) to a reservoir of minerals, such as oil and natural gas, located below the surface16. For instance, in one embodiment, the wellhead hub14includes a DWHC (Deep Water High Capacity) hub manufactured by Cameron, headquartered in Houston, Tex.

The tree12may attach to the wellhead hub14via a tubing head spool18that includes a collet connector internal to the tubing head spool18. For instance, the collet connector may include a DWHC connector, also manufactured by Cameron. Generally, the tree12is coupled to the wellhead hub14via the tuning head spool18and various connectors.

When assembled, the tree12may include a variety of flow paths (e.g., bores), valves, fittings, and controls for operating the well. For instance, the depicted tree12includes a frame20that is disposed about a tree body22, a flow-loop24, actuators26, hydraulic/electric actuators28, and valves30. Generally, the tree body22includes a well bore32that provide access to the well head hub14and the sub-surface well bore. Access to the sub-surface well bore may provide for various operations, such as the insertion of tubing into the well, the injection of various chemicals into the well (down-hole), as well as other completion and workover procedures. Further, the flow-loop24may include an additional bore in fluid communication with the well bore32, the wellhead hub14, and/or the subsurface well bore. When minerals, such as oil and natural gas, are extracted from the well, they may be routed via the flow-loop24. For instance, the output of the flow-loop24is generally coupled to a jumper or a flowline that is tied back to other components, such as a manifold. Accordingly, produced minerals may flow from the well to the manifold before being routed to shipping or storage facilities. In operation, a single manifold may gather and route mineral production from multiple mineral extraction systems10.

The flow of minerals, gases, and fluids within the mineral extraction system10and the tree12is generally regulated by the actuators26and valves30. In certain embodiments, the valves30are configured such that they may open or close, and, thus, enable or cut-off flow in a bore or channel regulated by the valve30. Certain valves30may include actuators26that are manually operated while others may include hydraulic/electric actuators28. Manually operated actuators26generally interact with an ROV or other external source of mechanical power to operate (e.g., open or close) the valve30. For instance, an ROV may extend an arm into an ROV bucket34that surrounds a stem36extending from the actuator26. The ROV may, then, rotate the stem36to operate a mechanism (e.g., a screw) within the actuator26, and, in turn, close or open the valve30. In the case of a hydraulic actuator28, the system10or ROV may provide the actuator28with pressurized hydraulic fluid to operate the valve30. However, in certain circumstances (e.g., a manual override), the hydraulic actuator28may be operated in a similar manner as the actuator26. An electric actuator28may be operated via electrical power. For example, power may be supplied from a remote location, or via a battery.

The system10includes a choke valve40(herein after referred to as the choke40) located in line with the flow loop24. The choke40provides for regulation of the flow of mineral production through the flow loop24to the jumper or other external connections. Similar to the valves30described above, the depicted choke40includes a hydraulic choke actuator42that may be operated to open or close the choke40to regulate flow through the flow loop24. Generally operating the choke40includes providing a pressurized hydraulic fluid to open or close the choke40. In one embodiment, the choke actuator42includes a hydraulic stepping Aqua Torq actuator provided by Cameron. For example, the Aqua Torq actuator may use 180 hydraulic pulses to operate the choke40from full open to full close. In such a configuration, operating the Aqua Torq actuator may take approximately 30 minutes to transition between fully open position and the fully closed position.

To ensure a particular rate of closure of the choke40, a Subsea Choke Fast Acting Module (FAM)44, manufactured by Cameron, may be added to the system10. As depicted, the FAM44is disposed on top of the choke40such that it may engage a stem or other coupling device extending from the top of the choke40. The FAM44may be operated such that the choke40opens or closes within 30 seconds via a single hydraulic pulse. The ability to quickly shut-off the flow of production may minimize the wear on valves30in the tree12as well as other down-hole valves.

As with various components of the system10, the FAM44and the choke40may be installed, or removed from, the system10after the tree12has been installed subsea (e.g., on or near the ocean floor). Therefore, each component may be lowered from the surface (e.g., an offshore vessel) to the ocean floor for installation, operation, and maintenance. However, at increased depths, such as those of deep-water systems10, the fluid pressures may be so great that direct human interaction (e.g., a diver) at the depth of the installed system10is not feasible. This concern is also prevalent for other components of the system10. Thus, devices and components, such as the choke40and FAM44are lowered, operated and/or retrieved from the ocean floor via cables, drill pipe, and/or a remote operated vehicle (ROV), for instance. Unfortunately, aligning and operating tools from the platform, or other remote locations, may introduce difficulties relating to aligning and engaging various components. As a result, performing installation, operation and maintenance of components may take an increased amount of time and effort.

To improve the efficiency and ability to properly align and engage components in certain environments, such as the subsea environment, the system10may include a funnel at or near the point of engagement between components. The funnel may aid in guiding components into alignment and/or connection, and, thus, reduce the level of difficulty. Further, the addition of a funnel may provide additional protection of installed components. As depicted, the system10includes a multi-part funnel assembly46disposed about the choke40and FAM44. For example, the funnel assembly includes a funnel extension90and a funnel bucket92. The funnel assembly46aids in the alignment of the choke actuator42to a choke flange48and a choke body50, and, further, aids in alignment of the FAM44to the choke40.

FIG. 2includes a diagram illustrating the general operation of a two-part funnel assembly60. As depicted, a first component62(e.g., choke actuator42or FAM44), may be aligned for engagement with a second component64(e.g., choke actuator42or FAM44). Generally, the first component62is lowered to the funnel60from the surface (e.g., platform). The first component62may be lowered via a running tool66for instance. The running tool66may provide an interface between the first component62and a drill pipe68, or other device, such as a cable or ROV, used to lower the first component62to the funnel60. As the first component62is lowered in the direction of arrows70, a surface of the first component62or the running tool66may contact and engage a chamfer72of an extension73of the funnel assembly60. As the first component62continues to be lowered in the direction of the arrows70, the chamfer72may catch the first component62and/or the running tool66, and guide them into a body74of the funnel60. Lowering the running tool66and the first component62into the body74may continue to align the components with a centerline76, such that the first component62and the second component64are generally aligned (e.g., coaxial) for engagement. The first component62may continue to be lowered until it engages the second component64. After the first component62and the second component64are engaged, the running tool66may provide various operations to complete the engagement (such as activating hydraulic and mechanical locking mechanisms), and then be released from the first component62and retrieved to the surface via the drill pipe68.

Generally, a height78of the funnel assembly60is selected based on the length of the component62to be aligned. For example, as the length of the first component62increases, the height78of the funnel assembly60may be increased to enable the funnel assembly60to catch and align the component62prior to its engagement with the second component64. As depicted inFIG. 2, the height78of the funnel60may be increased such that the running tool66engages the funnel chamfer72and the body74prior to engagement of the first component62to the second component64. For instance, if the FAM44is attached to the choke40, a taller funnel60may be desirable to accommodate the increased length of the FAM44.

Although increasing the height78of the funnel assembly60may aid in aligning and protecting the components62and64, the height78of the funnel60may be limited by other factors. For instance, increasing the height78may increase the potential for interference with other components of the system10. For example, returning now toFIG. 1, various devices and tools are coupled to the tree12during installation, operation, and workover procedures. Specifically, certain workover procedures include coupling a blow-out preventer (BOP) stack to the tree body22. Generally, a BOP stack includes a plurality of valves, actuators and other components coupled to a central body of the BOP. The actuators, valves, and components typically extend outward from the BOP stack. Thus, when the BOP stack is lowered onto the tree body22, clearance may be desired near the top portion of the tree12. Specifically, when the BOP is coupled to the tree12, the actuators, valves and other components may be lowered such that they are near the top of the frame20and extend in a radial direction. Accordingly, a portion of the funnel assembly46that extends above the top of the tree frame20may interfere with or block installation of the BOP stack, and the like. Thus, it is desirable that the funnel assembly46provides for alignment of components of the system10, and has minimal interference with other components of the system10. As discussed below, the funnel assembly46may include a multi-part and/or movable funnel structure, where at least a portion of the funnel46may be relocated such that it reduces the potential for interference with other components of the system10.

FIG. 3illustrates a perspective view of the funnel assembly46ofFIG. 1that includes two-parts in accordance with certain embodiments of the present technique. For example, the funnel assembly46includes the funnel extension90(e.g., a first hollow funnel portion) and the funnel bucket92(e.g., a second hollow funnel portion). In certain embodiments the extension90includes various features that are beneficial to subsea extraction systems10. For example, the extension90includes a cylindrical extension body94, a plurality of ribs96to increase mechanical strength of the extension90, a ROV handles98for ease of access, various cutouts100to reduce the overall weight of the extension90, a chamfer102(e.g., conical portion) to increase the area for engaging a component to be aligned, and a handle104for manipulating the position of the extension90. Similarly, the bucket92includes a cylindrical bucket body106, a plurality of ribs108, handles110, and a bucket chamfer112(e.g., conical portion). Further, the bucket92includes an access cutout114that provides clearance for the assembly of additional tools or components to the system10.

As illustrated inFIGS. 1 and 3, the bucket92includes a portion of the funnel46that connects proximate to the component to be engaged. For example, the bucket106is coupled to choke flange48and the choke body50via a base116. Accordingly, the bucket92may be fixed relative to choke40, and, therefore, provides for consistent and accurate alignment of a component (e.g., the choke actuator42and/or the FAM44) to the choke40. In other embodiments, the bucket92may be fixed relative to components in other configurations. For example, the bucket92may be coupled directly to the component to be aligned (e.g., the choke40), or may be fixed via a remote connection. The bucket92may be mounted to the tree frame20in a position in relative alignment with the component to be aligned with the bucket92, for instance.

Further,FIGS. 1 and 3illustrate the funnel46including the funnel extension90disposed atop the bucket92in a first position. In other words, the funnel extension90and the bucket92are coaxial with one another and are axially stacked one over another in the first position. For example, feet118of the extension90rests in the bucket chamfer112such that the extension90is supported by the bucket92and extends above the bucket92. Generally, the extension90increases the overall height of the funnel46. In one embodiment, the feet118include a tapered metal surface generally contoured to match the angle and curvature of the bucket chamfer112, and, thus, to provide for alignment of the extension90relative to the bucket92. The feet118may also include other features, such as spacers or rubber pads to aid in alignment and positioning. For example, the depicted embodiment includes hooks120(seeFIG. 4) that capture an edge of the bucket chamfer112. Other embodiments may include various configurations to support, align, and mount the extension90. For example, one embodiment may include a lip that runs along the circumference of the bucket92and a complementary lip on the extension90, such that the extension90rest on the bucket92via the lip.

FIG. 4illustrates the funnel46ofFIGS. 1 and 3, wherein the extension90is rotated along arrow121to a second position. In other words, the extension90is rotated such that the overall height of the funnel46is reduced, and, thus, the potential for interference with other components is also reduced. For example, as illustrated inFIG. 5, the funnel46includes an extension90rotated to a second position such that additional components (e.g., BOP stack) may be landed on the top portion of the tree12without interference of the funnel46.

In one embodiment, the funnel assembly46includes a hinge122that enables the funnel90to be rotated. For example, as illustrated inFIGS. 3 and 4, the funnel90is rotated vertically about the horizontally disposed hinge122(e.g., horizontal axis of rotation). In the depicted embodiment, the hinge122includes a hinge pin124disposed through a hinge receptacle126. The hinge receptacle126includes a longitudinal set of holes that pass through an extension gusset128of the extension90, and through a bucket gusset130of the bucket92. Accordingly, the funnel assembly46may be rotated about the hinge122to a full-height configuration, as depicted inFIGS. 1 and 3, as well as rotated to a reduced-height configuration as illustrated inFIGS. 4 and 5. Embodiments may include other variations of the hinge mechanism122. For example, multiple hinges122may be employed. In another embodiment, the hinge mechanism122may not be coupled to the bucket92. For example, the extension90may be coupled to the frame20via the hinge122, and include at least one rotated position that is aligned with the bucket92.

The funnel assembly46also includes a locking mechanism132that may prevent the funnel extension90from inadvertently shifting between full-height and reduced-height positions. For example, as depicted inFIGS. 3 and 4, the locking mechanism132includes a latch pin134that is passed through a latch pin receptacle136. The latch pin134includes a latch handle138, and a latch stem140. The latch handle138provides for insertion or removal of the latch pin134, such as removal by an ROV. The latch stem140includes a shaft that is passed through the latch pin receptacle136and blocks rotation of the extension90. For example, when the extension90is in a full-height configuration (seeFIG. 3) and the latch pin134is inserted into the receptacle136, the hooks141(seeFIG. 4) block the extension90from rotating. Further, when the extension90is rotated to a half-height configuration and the latch pin134is inserted into the receptacle136, the stem140passes through locking receptacles142, such that the extension90can not be rotated. Other embodiments may include any number of locking mechanisms132that are configured to resist movement of the extension90and/or the bucket92relative to one another.

FIG. 6illustrates an embodiment of the funnel46that includes rotating the extension90about an axis running parallel to the longitudinal axis of the bucket92. For example, the funnel46includes a vertically oriented hinge122that is disposed generally tangent to external surfaces of the bucket92and the extension90. Accordingly, the extension90may be rotated in a horizontal plane about a vertical axis143. Thus, similar to the previously discussed embodiments, the extension90may be manipulated from a first position where the extension90is aligned (e.g., coaxial and/or vertically stacked) with the bucket92, to a second position (e.g., off-axis and/or side-by-side) to reduce potential interferences with other components of the system10(e.g., a BOP stack). The rotational path of the extension90is generally represented by arrow144. Similar embodiments may include the addition of a locking mechanism, feet, gussets, and the like to provide flexibility and functionality of the funnel46.

FIG. 7illustrates an embodiment of the funnel46that includes a telescopic extension90. For example, the extension90includes an inside diameter that is slightly greater than the outside diameter of the bucket92. Accordingly, the clearance between the extension90and the bucket92enables the extension90to be disposed around the bucket92and manipulated between a first position, where the extension90is atop the bucket92, and a second position where the extension90is retracted to generally surround the bucket92. For example, the extension90may be moved in the direction of arrows146to a first position, and may be moved in the direction of arrows148to a second position. Accordingly, the first position may provide the funnel46with an increased height, and the second position may provide the funnel46with a reduced height. In other embodiments, the arrangement of the extension90and the bucket92may be varied. For example, the extension90may include an outer diameter that is less than the inner diameter of the bucket92, and thus, the extension90may be disposed internal to the bucket92.

To provide for alignment of the extension90and the bucket92, the funnel46includes alignment features. For example, the depicted extension90includes internal ribs150that are configured to accept a complementary rib152that is external to the bucket92. Accordingly, the ribs150and152guide the relative movement of the extension90and the bucket92. Other embodiments may include multiple alignment features, such as multiple ribs150and152.

Further, an embodiment of the funnel46ofFIG. 7may include a locking mechanism154that is similar to the locking mechanism132discussed with regard toFIG. 3. For example, the locking mechanism154includes a latch pin156having a handle158and a stem160. In operation, the stem160of the latch pin156is inserted into a receptacle162. As depicted, the receptacle162includes a hole that passes through a wall of the extension90. The bucket92includes a first receptacle164and a second receptacle166that are configured to accept the latch pin156. Accordingly, when the extension90is manipulated in the direction of arrows146into the first (e.g. extended) position, the stem160may be inserted into the first receptacle164. Similarly, when the extension90is manipulated in the direction of arrows148into the second (e.g. retracted) position, the stem160may be inserted into the second receptacle166. Other embodiments may include a plurality of locking mechanisms154and/or other forms of locking mechanisms. For example, multiple receptacles may be provided in the bucket92such that the extension may be locked into a plurality of positions to provide any number of funnel heights.

As discussed above, the disclosed embodiments of the funnel46may be described as multi-part, at least partially movable to provide clearance, at least partially rotatable, variable height or height adjustable, telescopic, or a combination thereof. For example, the funnel46may include a plurality of hollow structures, guide channels, or funnel portions, such as funnel extension90and bucket92. In some embodiments, the funnel extension90may be an after market add-on hinge assembly, telescopic assembly, locking mechanism, or a combination thereof. In other embodiments, the funnel extension90and bucket92may be an assembly originally installed with a mineral extraction system and/or component, or it may be sold as a replacement or retrofit assembly for an existing system. Other embodiments may provide the bucket92(without the extension90) alone or in combination with a mineral extraction system and/or component, wherein the bucket92is designed to receive the funnel extension90at a later time. For example, the bucket92may include at least a portion of the hinge122. In addition, the bucket92may be configured to couple with a variety of different funnel extensions90(e.g., different heights, diameters, chamfer sizes, etc.).

The funnel46may couple to various features of the mineral extraction system, including a well, a well head, a subsea christmas tree, a mineral deposit (e.g., oil and/or gas), a tool, a tool connector, a valve, a controller, a conduit/pipe, an offshore vessel at the surface, lines extending from the platform to the christmas tree, or a combination thereof.

The funnel extension90, or the bucket92, or both, may couple to a first component, a second component, or another portion of a mineral extraction system (e.g., subsea). For example, the first component may include a tool, a pipe, a cable, a control line (e.g., electrical, hydraulic, etc.), an ROV, a valve, a FAM or a combination thereof. By further example, the second component may include a choke, a valve, a christmas tree, or various other components. The funnel46may be configured to guide the first component to engage and/or connect with the second component of the mineral extraction system. As discussed above, the funnel extension90and/or the bucket92may have a hollow geometry (e.g., cylindrical and/or conical) with a tapered or chamfered portion to guide the first component progressively toward the second component (e.g., axial and radial alignment) if the funnel46is used to guide components, then the funnel extension90may be vertically stacked directly one over another with the bucket92such that the extension90and bucket92are coaxial with one another. If the funnel46is not in use and/or if access is needed in a nearby portion of the Christmas tree, then the extension may be moved out of the vertically stacked arrangement to another position providing clearance. For example, as discussed above, the extension may slide, rotate, or generally move to a side-by-side position and/or lowered position.