Patent Publication Number: US-2023151702-A1

Title: Weldless drilling diverter adapter

Description:
BACKGROUND 
     The present invention relates generally to adapters for conductor pipe, more particularly, to an improved weldless adapter for mechanical hook-up to conductor pipe. 
     Adapters for conductor pipe are used in the oilfield and may be welded or weldless to facilitate pressurized connections to conductor pipe. The design and size of adapters limits the maximum wellbore working pressure as well as the time and energy necessary to install and utilize adapters at a plurality of well sites. An adapter may be used for pressure testing seals on conductor casing at the wellhead. Welded adapter casings require increased resources and downtime to mount or remove compared to weldless adapters. 
     SUMMARY OF THE INVENTION 
     An objective of the present invention is to provide an improved weldless adapter assembly for conductor pipe 20 inch diameter or less. 
     Another objective of the present invention is to provide a weldless adapter operable to latch on to conductor casing to allow for pressure testing and drilling. 
     Yet another object of the present invention is to provide a weldless adapter that can easily be installed, removed, and moved to another conductor casing well site. 
     Another object of the present invention is to provide a weldless adapter with pressurized seals to allow for testing on the conductor. 
     Still another object of the present invention is to provide a weldless adapter that may be slipped onto a conductor and attached by slips contracting onto the conductor casing. 
     Yet another object of the present invention is to provide a method to test seals that operate in all ranges of temperature, pressure, and types of fluid that are encountered in oilfield applications. 
     These and other objects and advantages may or may not be used depending on the various possible embodiment of the invention. 
     One general aspect includes a weldless adapter operable for attachment to a conductor casing. The weldless adapter also includes an adapter body. The adapter body defines a bore therethrough. The adapter also includes an adapter body which may include a body cavity. The body cavity defines a slip cavity. A plurality of slip segments is mounted within the slip cavity and positioned for engagement with the conductor casing. The adapter also includes the body cavity which may include two seal recesses. The adapter includes two seals mounted in the two seal recesses where the two seals are positioned to seal around the conductor casing. The adapter has a body cavity defining two injection ports in fluid communication with the two seal recesses. Two injection fittings are mounted in the two injection ports. The two injection ports receive pressurized fluid to energize the two seals for sealing around the conductor casing. A test port is positioned between the two seals. The test port is in communication with an annulus formed between the two seals and the conductor casing. The adapter also includes a test fitting mounted to the test port. 
     The weldless adapter may include a plurality of slip actuator bolts mounted along a periphery of the adapter body within receptacles through the adapter body where the plurality of slip actuator bolts engages the slip segments. A plurality of jack bolts is arranged along a circumference of the bottom of the adapter body when the adapter body is mounted for operation. The plurality of jack bolts fit within receptacles along the bottom of the adapter body, the plurality of jack bolts engages the slip segments. The slip actuator bolts and the jack screws bolts urge the slip segments into the conductor casing during latching the weldless adapter to the conductor casing and to retract the slip segments when releasing the weldless adapter from the conductor casing. The weldless adapter may include a test port for receiving pressurized fluid between the two seals to provide a pressurized test of the two seals. The slip segments may be constructed with teeth along an inner wall of the slip segments relative the adapter body. The teeth bite into the conductor casing when latching the weldless adapter to the conductor casing and retracting when releasing the weldless adapter from the conductor casing. 
     One general aspect includes a method of providing a weldless adapter operable for attachment to a conductor casing. The method includes mounting an adaptor body onto the conductor casing. Grease is injected to activate two seal rings around the conductor casing. Grease is also injected into an annulus between the two seal rings and the conductor casing to test the two seal rings. 
     The method may include supporting the adaptor body on the conductor casing on a shoulder formed within the adaptor body. Bolts above and below a plurality of slip segments may be utilized for tightening and releasing the plurality of slip segments against the conductor casing. At least one of the bolts above and below the slip segments may be utilized for centralizing the adaptor body on the conductor casing. To activate the two seal rings, grease may be injected through two injector ports. The plurality of slip actuator bolts engages the plurality of slip segments. A plurality of jack screws bolts is arranged along the circumference of the bottom of the adapter body. The plurality of jack bolts fits within receptacles along the bottom of the adapter body. The plurality of jack bolts engages the plurality of slip segments. The body cavity may define two bleeder ports in fluid communication with the two seal recesses. Two bleeder fittings may be mounted to the two bleeder ports. 
     One general aspect includes a weldless adapter operable for attachment to a conductor casing. The weldless adapter also includes an adapter body. The adapter also includes a plurality of slip segments mounted in the adapter body. A first plurality of bolts is along a periphery of the adapter body to engage an upper portion of the plurality of slip segments. A second plurality of bolts is mounted to engage a lower portion of the plurality of slip segments. 
     The weldless adapter may include a third plurality of bolts mounted to engage the plurality of slip segments. The third plurality of bolts may be positioned between the first plurality of bolts and the second plurality of bolts. The weldless adapter may include the adapter body defining a bore therethrough. The bore may define a first axis. The plurality of slip segments may have an angled surface relative the first axis. The angled surface is adjacent the adapter body and may define a second axis. The third plurality of bolts may move axially along the second axis. The second plurality of bolts may move axially along the first axis. 
     The plurality of slip segments may be constructed with teeth on an inner side of the plurality of slip segments relative the adapter body for engagement with the conductor casing. The adapter body may define a body cavity. The body cavity may include two seal recesses. Two seals may be mounted in the two seal recesses where the two seals are positioned to seal around the conductor casing. The body cavity has two injection ports in fluid communication with the two seal recesses. Two injection fittings are mounted in the two injection ports. The two injection ports receive pressurized fluid to energize the two seals for sealing around the conductor casing. The body cavity has two bleeder ports in fluid communication with the two seal recesses. Two bleeder fittings are mounted to the two bleeder ports. A test port is positioned between the two seals. The test port is in communication with an annulus formed between the two seals and the conductor casing. A test fitting is mounted to the test port. 
     The weldless adapter may include the adapter body defining a bore therethrough. The bore may define a first axis. The plurality of slip segments may have an angled surface relative to the first axis. The angled surface is adjacent the adapter body which may define a second axis. The first plurality of bolts may move axially along the second axis. The second plurality of bolts operable may move axially along the first axis. 
     These and other objectives, features, and advantages of the present invention will become apparent from the drawings, the descriptions given herein, and the appended claims. However, it will be understood that above-listed objectives and/or advantages of the invention are intended only as an aid in understanding aspects of the invention, are not intended to limit the invention in any way, and therefore do not form a comprehensive or restrictive list of objectives, and/or features, and/or advantages. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following detailed description and claims are merely illustrative of the generic invention. Additional modes, advantages, and particulars of this invention will be readily suggested to those skilled in the art without departing from the spirit and scope of the invention. A more complete understanding of the invention and many of the attendant advantages thereto will be readily appreciated by reference to the following detailed description when considered in conjunction with the accompanying drawings, wherein like reference numerals refer to like parts and wherein: 
         FIG.  1 A  is a perspective view in partial section of a weldless adapter in accord with one embodiment of the present invention. 
         FIG.  1 B  is an exploded view of a weldless adapter in accord with one embodiment of the present invention. 
         FIG.  2    is a sectional side view of a weldless adapter comprising seals with injections port and bleeder ports. 
         FIG.  3    is a sectional side view of a weldless adapter comprising seals with a test port. 
         FIG.  4    is a sectional side view of a weldless adapter with slip retainers shown in accord with one embodiment of the present invention. 
         FIG.  5    is a sectional side view of a weldless adapter with slip retainers shown in accord with one embodiment of the present invention. 
         FIG.  6    is a sectional side view of an assembled weldless adapter. 
         FIG.  7    is a sectional side view of a weldless adapter mounted on a conductor casing. 
     
    
    
     DETAILED DESCRIPTION 
     Detailed descriptions of the invention are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner. 
     The weldless adapters described below comply with the latest edition of API 6A and API 16A and has fully implemented API Q1 quality system. 
     The API 16A license applies to drill-through equipment. 
     Products are designed to NACE MR-01-75 materials standards for resistance to sulfide stress cracking. 
     The weldless adapter permits mechanical hook-up to the conductor eliminating welding while providing a fully pressurized integral connection on top of the conductor pipe. 
     This adapter is designed to be used with 20″ or s a ler O.D. pipe. However, the invention is not intended to be limited to a particular size. However, the maximum rated wellbore working pressure of this adapter is limited by the working pressure of the top connection (usually a flange) or the working pressure of the conductor pipe. 
     The actual maximum working pressure of the weldless adapter when installed on the conductor pipe should not exceed two-thirds (0.666) of the internal yield pressure of the pipe or the working pressure of the top connection, whichever is less, in other words, use the smallest number as the maximum working pressure of the adapter. 
     Internal metal-to-metal engagement slips  6  are mechanically activated for frictional engagement with the conductor  42 . Seal pressurization is accomplished by hydraulic activation of rubber seals  4 . 
     The use of the weldless adapter results in a significant time savinas. As the conductor is being installed, the diverter can be nippled up to the weldless adapter and the complete unit can be lowered onto the conductor at the appropriate time. 
     Now referring to  FIG.  1 A- 1 B , wherein various views are shown of weldless adapter  100 . Weldless adapter  100  comprises a body  2  with a body cavity  38 . Body  2  may be constructed of metal suitable to withstand pressures necessary for operation in well operations. Within the body cavity is at least one seal  4 . In the preferred embodiment, two seals  4  are used, one upper  5  and one lower seal  7 . The seals  4  encircle the entire body cavity. Below the seals  4  within the body cavity  38 , are slips  6  arranged around the perimeter. Slips  6 , comprise teeth or grooves  9 , which engage slip actuator bolts  10  located around the perimeter of the body  2  and are operable to engage the body Wall to contact the teeth or grooves in slips  6 . Slip retainer bolts  8  are located below slip actuator bolts  10  and above jack screw  12 . In one possible embodiment, slip retainer bolts  8  may be moveable by engagement from hex head cap screws  12  which may also be referred to as cap screws or jack up screws or bolts. However, in another possible embodiment the slip retainer bolts  8  may be moveable without engagement of the jack bolts  12  and slip actuator bolts  10  thereby could be moveable independently. Jack up screws  12  are located at the bottom of the body  2  of adapter  100 . 
     Additionally, in one possible embodiment, slip retainer bolts  8  may be angled relative to jack screws  12 . In another possible embodiment, slip actuator bolts  10  may be angled relative jack screws  12 . In yet another possible embodiment, both slip retainer bolts  8 , actuator bolts  10 , and jack screws  12  may all be at different angles relative to each other. In one possible embodiment, the retainer bolts  8  and/or the actuator bolts  10  may move along a different or second axis  46  (See  FIG.  7   ) than the jack bolts  12 . In yet a further possible embodiment, retainer bolts  8 , actuator bolts  10 , and jack bolts  12  may all move axially along different axis or a combination thereof. 
     Additional components may be mounted on adapter  100  such as gate valve  30  which may be secured to flanges  26 ,  27  nuts or fasteners  28 , and stud tap ends  24 . Ring gaskets  22  along with stud bolts  32  may also be used to mount components to gate valve  30 . Other valves or components may be mounted to the adapter  100  as well such as diverters or medium service pressure devices. Plugs  18  may be used to seal and cover valves or other like devices attached to weldless adapter  100 . Within the side of the body  2  along the seals  4  may be plugs (not shown) to retain and protect grease fittings as well as to assist to energize or de-energize the seals. Eye bolts  20  may be mounted to the body  2  to allow for lifting and lowering the adapter  100  into position. 
     After the conductor pipe is landed and cemented, the pipe or casing may be cut at the desired elevation. This can be done with either gas cutting equipment or high-pressure water cutters. The cut should be square With the casing to ensure that when the adapter is installed, the casing rests squarely on the inside shoulder  40  (See  FIG.  7   ) of the adapter  100  as indicated along axis  44 . In a preferred embodiment, the outer edge of the cut casing should be ground with a slight taper to ensure that the seals  4  are not damaged when the adapter  100  is installed on the casing. If the casing has a wall thickness greater than 1″, a taper should be ground on the inside of the casing to ensure that drilling tools do not hang up on the exposed shoulder. If the casing is seam welded, the seam should be ground smooth twenty-four inches (24″) down from the top of the casing. This ensures full contact between the slip segments  6  and the casing O.D. and assures the seal  4  engages a smoother surface for best seal contact. 
     In a preferred embodiment, fittings or ports  14 , 16  (See  FIGS.  2 - 3   ) are mounted on each side of body  2  for grease to be directed to seals  4 . Grease fittings  14  may also be referred to as injection ports that allow grease to be injected into or around the seals  4 . Bleeder fittings  16 , also referred to as bleeder ports, allow grease to exit as pressure builds to show a positive seal as well as to allow grease to be removed to depressurize the seals  4 . 
     Turning to  FIGS.  2 - 3   , a side sectional view of a weldless adapter  100  comprising seals  4  and injection  14 , bleeder  16 , and test  36  ports is shown in accord with one embodiment of the present invention. 
     Prior to the installation of the adapter  100  on the casing, inspection of the underside of the adapter  100  may be performed to ensure that all seals  4  are installed. The teeth  9  of the slip segments  6  may also be inspected to ensure that they are clean and free of any foreign metal particles that may have been deposited there from previous well operations. 
     If the seals  4  are not installed in the body of the adapter  100 , inspection of the seal grooves or recesses  17  ( FIGS.  1 A and  6   ) may be completed to ensure they are clean of any foreign material. The seals  4  may be lubricated with a light application of oil or grease. Installation of the rubber seals  4  may be completed with a rubber mallet, rubber hammer, or other suitable device. Use of a metal hammer could damage the rubber seals  4 . In a preferred method, installation should start with the lowest seal ring  7  and move upward, concluding with the top seal ring  5 . 
     Grease injection fittings may be installed in N.P.T. openings within body  2  for injection ports  14 . Plugs (not shown) are installed on the test ports  36 . Ball check fittings, with vent port holes, may be installed in the bleeder ports  16 . Additional plugs (not shown) may be fitted onto injection ports  14  and bleeder ports  16 . 
     The seals  4  may be energized with a grease gun or other suitable grease injection pump by pumping or injecting grease into the injector port  14  for the top seal. The relief or bleed fitting  16  for that seal should be in the “open” position. 
     When returns are observed through the appropriate relief port  16  the relief port  16  may be dosed while continuing to pump grease into the seal  4  until a continuous pressure of approximately 1500 PSI is reached. The appropriate pressure may vary more or less depending on the desired application. The grease gun or other like device may be removed from upper seal  5  and the procedure repeated on the lower seal  7  to energize both seals  4 . 
     After both seals  4  have been energized, a test pressure can then be applied into test port  36  between the two seals  4 . The pressure from the seals assists in clamping the adapter  100  onto the conductor casing  42 . For this purpose, grease can be injected into the test port  36 . The test pressure may be approximately 1000 PSI between the seals  4 . If the test pressure cannot be maintained, check the grease pressure on the seals  4  to ensure that the previously applied pressure is still holding on the seals  4 . Repressurize the seals  4  with grease if necessary and retest. 
     If the test pressure cannot be maintained, recheck the grease pressure in all seals  4 . If the grease pressure is low, repressurize the seals  4  with grease. Reapplication of the test pressure can then verify whether the proper pressure can be maintained between the seals  4 . If the seals  4  will not hold test pressure, the weldless adapter  100  should be removed from the pipe and all damaged seals  4  should be replaced. 
     Now turning to  FIGS.  4 - 5   , a side sectional view of weldless adapter with slip retainers  6  is shown in accord with one embodiment of the present invention. In a preferred embodiment, prior to install of weldless adapter  100  all slip segments  6  should be placed in the fully retracted (UP) position. In some embodiments, a diverter may be installed with the adapter over the casing prior to installing the weldless adapter  100  on the conductor casing  42 . The adapter  100  should be completely down over the casing  42  with the top of the casing resting on the mating shoulder  40  of the adapter body  2 . 
     In a preferred embodiment, the slip actuator bolts  10  may then be tightened at 12 o&#39;clock, 6 o&#39;clock, 3 o&#39;clock and 9 o&#39;clock positions (as viewed from the top). The distance from the casing O.D. to the adapter bottom I.D. may then be measured to ensure that the adapter is centered over the casing (± 1/16″). The distance may vary depending on the application and can be larger or smaller than 1/16″. This dimension should be taken or measured in line with the slip actuator bolts  10 . If the dimension at all four points is not equal, tighten the slip actuator bolt  10  on the side with the smaller dimension until the adapter  100  is centered with the casing  42  and all dimensions are equal along axis  44 . 
     The four actuator bolts  10  may be tightened to approximately “1000 foot-pounds” of torque. The actual torque requirement may vary depending on a plurality of factors such as pressure, metal type, or the like. The dimensions on the actuator bolts  10  should be inspected to make sure that the weldless adapter  100  is still centered over the casing  42 . After the torque and dimensions have been verified, the remaining actuator bolts  10  may be evenly tightened to approximately to “800-1000 foot-pounds” of torque. The slips should be secured in place as shown in  FIG.  4   . After the slip actuator bolts have been uniformly tightened, the seals  4  are ready to be energized as described above. 
     In  FIG.  5   , the jack up screws  12  may be utilized to engage the slips  6  upwards thereby pushing or engaging slips  6  to bite or latch to the conductor casing  42 . The slip teeth  9  are driven into the conductor casing  42  as the slips  6  are pushed further upward by the jack up screws  12  to firmly latch into place and ensure the adapter  100  remains in proper position. 
     Annulus  37  is formed between adapter  100  and conductor casing  42  and allows for fluid movement during operations. After both seals  4  have been energized, a test pressure can then be applied into test port  36  between the two seals  4 . The pressure from the seals assists in clamping the adapter  100  onto the conductor casing  42 . The seals  4  prevent fluid from flowing through the annulus. A test pressure is injected between the upper seal  5  and lower seal  7 , collectively seals  4 , to ensure the required seal pressure is maintained and each seal is operating satisfactorily. If the seals  4  will not hold test pressure, the weldless adapter  100  should be removed from the pipe and all damaged seals  4  should be replaced. 
     Turning to  FIGS.  6 - 7   , weldless adapter  100  can be seen fully assembled but unmounted on conductor casing  42  and then also fully mounted. In  FIG.  6   , adaptor  100  is ready to be lowered onto a conductor casing using the procedures supra to align the adapter and slips relative to the casing and then latch or bite into the conductor casing. In  FIG.  7   , the conductor casing can be seen with the adapter mounted onto casing  42 . The adapter  100  comprises a shoulder  40  internally formed to engage the conductor casing  42 . Once the slips are tightened, the seals  4  may be energized to further buttress the adapter securely on the conductor casing and create a positive seal between the adapter and the casing. 
     One of the advantages of utilizing a weldless adapter is the decreased amount of time to deploy the adapter. Another advantage is decreased time for engaging or disengaging the adapter for moving it from one conductor casing location to another. Accordingly, after the adapter  100  is mounted and finishing any pressure testing or initial drilling operations, the weldless adapter may be moved to another location. 
     The weldless adapter may be removed from the conductor pipe by first releasing the grease pressure from the upper and lower seals  5 , 7  by opening the two relief ports  16  (as can be seen in  FIG.  4   ′ The jacking bolts  12  may then be installed in the threaded holes beneath the slip segments  6 . The slip actuator bolts  10  may be rotated counterclockwise. The actuator bolts  10  will loosen and then tighten back up. This will allow room between the head of the slip actuator bolt  10  and the slip  6 . The jacking bolts  12  may be further tightened to move the slips  6  up slightly. The slip segments  6  will stop against the head of the slip actuator bolts  10 . This initial movement may be enough to release the slip segments  6  from the conductor pipe  42 . 
     To further loosen the adapter  100 , the slip actuator bolts  10  may be rotated counterclockwise to move the slip segments  6  to the fully retracted position. Check all actuator bolts  10  to make sure that all slip segments  6  are in the fully retracted position. This check can be done by measuring the length of the actuator bolt  10  protruding above the adaptor body  2 . 
     Pressure may then be applied to the test port  36  which will loosen the seals  4  contact with the conductor pipe  42 . The eye bolts  20  may be attached to and used to pull on the bolts  20  perpendicular to the connector. This will also loosen the seals against the conductor pipe. After all slip segments  6  are fully retracted and seals  4  released, the adapter  100  may be lifted and removed from the casing  42  for inspection, service, redeployment, or the like. 
     The foregoing disclosure and description of the invention is illustrative and explanatory thereof, and it will be appreciated by those skilled in the art, that various changes in the size, shape and materials as well as in the details of the illustrated construction or combinations of features of the various coring elements may be made without departing from the spirit of the invention. Moreover, the scope of this patent is not limited to its literal terms but instead embraces all equivalents to the claims described.