Patent Publication Number: US-2022228454-A1

Title: Washover tools, systems, and methods of use

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims benefit of U.S. Provisional Patent Application Ser. No. 63/140,146, filed Jan. 21, 2021, which is herein incorporated by reference in its entirety. 
    
    
     BACKGROUND 
     Field 
     The disclosure relates to pipe removal systems and methods and associated components thereof that include a washover tool for underground pipe removal. 
     Description of the Related Art 
     Pipelines are designed to transport products, such as sewage, water, or petroleum products, including oil and gas, between two different locations. These pipelines are typically steel or plastic tubes which may be buried underground. Processes and tools currently used in the art require craftsmen to sequentially dig up and cut out sections of the pipe from beneath the ground. Accordingly, these processes and tools used to remove these pipelines are extremely time consuming and often require highly skilled labourers, costly equipment, and dangerous conditions. 
     These pipelines are often installed using the Horizontal Directional Drilling method (or “HDD”). Drilling machines utilize drilling rods or drill pipe that sometimes become stuck in the ground during the HDD process. When the drilling rods or pipe become stuck, in most cases, the rods or pipe are abandoned and a new pilot hole is created, because as stated above the processes and tools required to remove the suck rods or pipe are extremely burdensome. 
     Therefore, there is a need for a new and improved tools for underground pipe removal. 
     SUMMARY 
     Implementations of the present disclosure relate to pipe removal systems, and methods of using pipe removal systems to remove underground pipes. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       So that the manner in which the above-recited features of the disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments. 
         FIGS. 1A, 1B, and 1C  are top views of an outer housing and an inner housing of a washover tool, and a top view of a pipe, according to one or more embodiments. 
         FIG. 2A  is a cross-sectional front view of a portion of a washover tool, according to one or more embodiments. 
         FIG. 2B  is a front view of a portion of a washover tool, according to one or more embodiments. 
         FIGS. 3A and 3B  are top views of washover tools with a rod member and one or more stabilization members, according to one or more embodiments. 
         FIGS. 4A and 4B  are side elevation views of the washover tools with the rod members, stabilization members, and a plurality of fluid jets spraying from the washover tools, according to one or more embodiments. 
         FIG. 5  is a schematic side view of a washover system in operation to remove a pipe from the ground, according to one or more embodiments. 
         FIG. 6  is a flow chart illustrating a method of using a washover tool, according to one or more embodiments. 
     
    
    
     To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements disclosed in one implementation may be beneficially utilized on other implementations without specific recitation. 
     DETAILED DESCRIPTION 
     Aspects of the disclosure relate to pipe removal systems, and methods for using pipe removal systems to remove underground pipes. In one aspect, the disclosure relates to a washover tool system, and methods of using the washover tool system. 
       FIGS. 1A and 1B  are top views of an outer housing  110  and an inner housing  120  of a washover tool  100  (more fully illustrated as washover tools  100   a ,  100   b  in  FIGS. 3A and 3B , respectively). When assembled, the inner housing  120  is positioned within the outer housing  110 .  FIG. 1C  illustrates a pipe  130  that can be washed over by the washover tool  100  and removed from being buried underground. 
     The outer housing  110  is a cylindrical pipe having an outer diameter d 1   a , an inner diameter d 1   b  (illustrated in  FIG. 2A ), and a length L 1 . The outer diameter d 1   a  may be within a range of 1.0 inches to 60 inches. The inner diameter d 1   b  (illustrated in  FIG. 2A ) may be within a range of 0.90 inches to 59.9 inches. The length L 1  may be within a range of 0.2 feet to 50 feet. An upper opening  115  is formed through a top side  117  of the outer housing  110 . The upper opening  115  allows the outer housing  120  to receive a fluid, such as wash water, for washing over the pipe  130  as further described below. 
     The inner housing  120  is a cylindrical pipe having an outer diameter d 2   a , and inner diameter d 2   b  (illustrated in  FIG. 2A ), and a length L 2 . The outer diameter d 2   a  may be within a range of 0.75 inches to 59.75 inches. The inner diameter d 2   b  (illustrated in  FIG. 2A ) may be within a range of 0.65 inches to 59.65 inches. The length L 2  may be within a range of 0.2 feet to 50 feet. In some embodiments, the length L 1  of the outer housing  110  is the same as length L 2  of the inner housing  120 . In some embodiments, the length L 2  of the inner housing  120  is greater than the length L 1  of the outer housing  110 . 
       FIG. 1C  illustrates the pipe  130  having an outer diameter d 3  and a length L 3 , all or portions of which may be buried underground in a vertical orientation, a horizontal orientation, and/or at an angled orientation between vertical and horizontal. The outer diameter d 3  may be within a range of 0.50 inches to 60 inches. The inner diameter may be within a range of 0.40 inches to 59.9 inches. The length L 3  may be within a range of 1.0 feet to 5,280 feet. 
     The outer housing  110  is larger in diameter than the inner housing  120 . The difference in diameters of the outer and inner housings  110 ,  120  creates an annulus  220  (illustrated in  FIG. 2A ) between the two housing for receiving a high-pressure fluid, such as water or a drilling mud slurry, that flows out of the washtool  100 . The actual diameters of the outer and inner housings  110 ,  120  can be varied, as long as there is an adequate annulus  220  between the outer and inner housings  110 ,  120  for fluid flow. The size of the inner housing  120  relative to the pipe  130  to be removed may depend on the ground conditions that the pipe  130  is buried or stuck in, but the inner housing  120  should be large enough to slip over the pipe  130  freely. The lengths L 1 , L 2  of the outer and inner housings  110 ,  120  can vary depending on jobs side conditions and/or customer preferences. In some embodiments, the length L 1  of the outer housing  110  is the same as length L 2  of the inner housing  120 . In some embodiments, the length L 2  of the inner housing  120  is greater than the length L 1  of the outer housing  110 . 
     In operation, the washover tool  100  is positioned circumferentially around the pipe  130  such that the pipe  130  extends through the inner housing  120 . The washover tool  100  is moved along the length L 3  of the pipe  130  while spraying a wash fluid to washover the pipe  130  to remove dirt, debris, and/or the ground surrounding the pipe  130 . The pipe  130  may be any type or size used to transport fluids, solids, and/or mixtures of fluids and solids, including but not limited to oil and gas. The pipe  130  may also be any type or size of drill rod or drill pipe utilized by an HDD or road boring machine. 
       FIG. 2A  is a cross-sectional front view of only a portion of the washover tool  100 , according to one or more embodiments. The inner housing  120  is positioned circumferentially within the outer housing  110 . The inner diameter d 2   b  of the inner housing  120  is greater than the outer diameter d 3  of the pipe  130 , so as to allow the washover tool  100  to be positioned around the pipe  130 . The inner diameter d 2   b  defines the bore  250 , in which the pipe  130  is located when the washover tool  100  is used to washover the pipe  130 . 
     The inner diameter d 1   b  of the outer housing  110  is greater than the outer diameter d 2   a  of the inner housing  120 , as to form an annulus  220  between the outer housing  110  and the inner housing  120 . The difference between the inner diameter d 1   b  of the outer housing  110  and the outer diameter d 2   a  of the inner housing  120  determines the width of the annulus  220 . The width of the annulus  220  may be within a range of 2 inches to 24 inches. The width of the annulus  220  may be large enough to provide sufficient fluid flow to washover the pipe  130 . 
     The outer housing  110  has a thickness  215 . The thickness  215  of the outer housing  110  may be within a range of 0.10 inches to 2.0 inches. Additionally, the inner housing  120  has a thickness  225 . The thickness  225  of the inner housing  120  may be within a range of 0.10 inches to 2.0 inches. In some embodiments, the thickness  215  and the thickness  225  are the same. In some contemplated embodiments, the thickness  215  and the thickness  225  are different. The thickness of the outer housing  110  and the inner housing  120  may be thick enough to allow proper welds to be made to assemble the washover tool  100 . 
     The washover tool  100  further includes a plurality of centering members  210  disposed between the outer housing  110  and the inner housing  120  to center the outer and inner housings  110 ,  120 , and to provide structural support to the washover tool  100  and the annulus  220 . In some embodiments, the centering members  210  are metal blocks welded to the inner housing  120  and the outer housing  110  and disposed within the annulus  220 . The centering members  210  may be radially spaced within the annulus  220  and may only extend along a portion of the length of the inner and/or outer housings  110 ,  120 . 
       FIG. 2B  is a front view of only a portion of the washover tool  100 , according to one or more embodiments. The washover tool  100  includes a front face plate  230  that covers the annulus  220 . The front face plate  230  is welded to an end or front surface of the outer housing  110  and to the outer surface of the inner housing  120  such that an outer edge portion  260  of the inner housing  120  extends from the outer housing  110  (e.g. the length of the inner housing  120  is longer than the length of the outer housing  110 ). In some embodiments, the front face plate  230  may be welded to the outer and inner housings  110 ,  120  such that the front face plate  230  covers the ends or front surfaces of the inner and outer housings  110 ,  120  (e.g. the length of the inner housing  120  is the same as the length of the outer housing  110 ). In some embodiments, the front face plate  230  may be welded to the inner diameter of the outer housing  110  and the end or front surface of the inner housings  120  (e.g. the length of the outer housing  110  is longer than the length of the inner housing  120 ). 
     The washover tool  100  may similarly include a back face plate, which is disposed at an opposite end of washover tool  100  from the front face plate  230 . The back face plate may be welded in a similar manner as the front face plate  230 . Together, the front face place  230  and black face plate enclose the annulus  220  between the outer housing  110  and the inner housing  120 . 
     The front face plate  230  includes a plurality of openings  240  formed through the front face plate  230 , through which several jets or streams of wash fluid may flow through. The openings  240  may be radially positioned about the center axis  205  on the front face plate  230 . The front face plate  230  includes enough openings  240  to allow for adequate fluid flow through the washover tool  100  to properly wash, loosen, and/or remove any material surrounding the pipe  130 . For example, the front face plate  230  may include between four and five hundred openings  240  (although any number, orientation, and/or arrangement of openings  240  may be used) formed through the front face plate  230  radially about the center axis  205 . Each opening  240  may be drilled, or drilled and tapped to allow for threaded opening inserts to be installed into the front face plate  230 . The openings  240  and/or the threaded opening inserts may be sized to achieve a certain pressure of washover spray. For example, the openings  240  and/or the threaded opening inserts could be between 0.0001 inches and 1 inches. Each opening  240  and/or threaded opening insert could provide for an angle of spray between 0 degrees and 360 degrees. Each opening  240  allows fluid supplied to the washover tool  100  to spray from the washover tool  100  over the buried pipe  130 . The wash fluid flowing out of the plurality of openings  240  washes over the pipe  130 , thereby allowing the pipe  130  to be easily removed from the ground. 
       FIGS. 3A and 3B  are top views of washover tools  100   a ,  100   b  with a rod member  320  and one or more stabilization members  300   a ,  300   b  coupled to the outer housing  110 , according to one or more embodiments. The rod member  320  is a cylindrical pipe having a fixed end  325 , an elongated body  327  and a receiving end  329  opposite the fixed end  325 . The rod member  320  has a bore extending therethrough which receives a fluid and supplies the fluid to the annulus  220  formed between the outer housing  110  and the inner housing  120 . The rod member further includes an opening  315  formed at the fixed end  325 . The rod member is coupled to the top side  117  of the outer housing  110  and aligned in such a way that the opening  315  of the rod member  320  is axially aligned with the opening  115  formed in outer housing  110 . By aligning the opening  115  and the opening  315 , the bore of the rod member  320  and the annulus  220  are in fluid communication with one another. A fluid, such as a wash water, may be supplied from a control source  510  (illustrated in  FIG. 5 ) through the rod member  320 , into the annulus  220 , and out of the openings  240  formed in the front face plate  230 . In some embodiments, a tracking tool may be disposed within the rod member  320  to track the location of the washover tools  100   a ,  100   b  during operation. 
     The washover tools  100   a ,  100   b  may further include a cap  330   a ,  330   b  coupled to the fixed end  325  of the rod member  320  and the outer housing  110 . As illustrated in  FIG. 3A , the cap  330   a  is an ellipsis shape and has a width which is equal to the diameter of the rod member  320 . As illustrated in  FIG. 3B , the cap  330   b  is rectangular in shape, having a width which is equal to the diameter of the rod member  320 . The caps  330   a ,  330   b  seal and close off the end of the rod member  320  to direct wash fluid into the annulus  220  formed between the inner and outer housings  120 ,  110 . 
       FIGS. 3A and 3B  further illustrate the washover tools  100   a ,  100   b  with a plurality of stabilization members  300   a ,  300   b . The primary difference between the washover tools  100   a ,  100   b  are the shape of the stabilization members  300   a ,  300   b , and the connection of the rod member  320  to the outer housing  120  as further described below with respect to  FIGS. 4A and 4B . The stabilization members  300   a ,  300   b  prevent the washover tool  100  from rotating about the center axis  205  during operation. The stabilization members  300   a ,  300   b  include angled or rounded edges  310   a ,  310   b  that can be forced into the ground surrounding the buried pipe  130  to prevent rotation of the washover tools  100   a ,  100   b.    
       FIG. 3A  depicts the washover tool  100   a  with triangular stabilization members  300   a  coupled to the outer housing  110 .  FIG. 3B  depicts the washover tool  100   b  with semi-circular stabilization members  300   b . Each stabilization member  300   a ,  300   b  is coupled to the outer housing  110  of the washover tool  100 . In some embodiments, the washover tools  100   a ,  100   b  include two stabilization members  300   a ,  300   b  coupled to the outer housing  110 . The stabilization members  300   a ,  300   b  are coupled to the outer housing  110  at a position perpendicular to the positon that the rod member  320  is coupled to the outer housing  110 . The washover tool  100  may include between two and eight stabilization members  300   a ,  330   b  (although any number, orientation, and/or arrangement of stabilization members  300   a ,  300   b  may be used) coupled to the outer housing  110  and spaced radially around the axis  205 . In some embodiments, the washover tools  100   a ,  100   b  do not include any stabilization members  300   a ,  300   b . In some embodiments, the stabilization members  300   a ,  300   b  have one or more openings to allow for the wash fluid supplied to the annulus  220  to be ejected from the stabilization members  300   a ,  300   b  to provide additional lubrication as the washover tools  100   a ,  100   b  move through the ground. 
       FIGS. 4A and 4B  are side elevation views of the washover tools  100   a ,  100   b  with the rod member  320  and a plurality of fluid jets W spraying from the washover tools  100   a ,  100   b , according to one or more embodiments. The washover tools  100   a ,  100   b , may include one or more rod member supports  410  coupled between the elongated body  327  of the rod member  320  and the outer housing  110 . The rod member supports  410  provide additional support to the rod member  320  to prevent lateral rotation of the rod member  320  during operations. In some embodiments, the rod member supports  410  are the same length as the length L 1  of the outer housing  110 . In another embodiment, the rod member supports  410  are have a length less than the length L 1  of the outer housing  110 . The rod member supports  410  may be welded to both the rod member  320  and the outer housing  110 . 
     In some embodiments, the elongated body  327  of the rod member  320  is disposed on and coupled directly to the outer housing  110  as illustrated in the washover tool  100   a  of  FIG. 4A . The rod member  320  of the washover tool  100   a  has a tapered end  420  so that the rod member  320  is in contact with the outer housing  110  along the entire length L 1  of the outer housing. The cap  330   a  is coupled to the tapered end  420 .  FIG. 4A  further illustrates the alignment of the opening  115  of the outer housing  110  and the opening  315  of the rod member  320 . The alignment of the openings  115 ,  315  provides for the fluid communication between the rod member  320  and the annulus  220 . The openings  115 ,  315  are axially aligned and are sealed together to form a single fluid chamber between the annulus  220  and the bore of the rod member  320 . 
     In some embodiments, the elongated body  327  of the rod member  320  is coupled to the outer housing  110  via a connection member  450  as illustrated in the washover tool  110   b  of  FIG. 4B . The connection member  450  is a cylindrical pipe with a bore formed therethrough. The connection member  450  may be axially aligned and formed within the opening  115  of the outer housing  110 . The opening  315  of the rod member  320  may be aligned with and coupled to the connection member  450 , so as to provide fluid communication between the rod member  320  and the annulus  220  through the connection member  450 . The rod member  320  has one or more rod member supports  410  formed between the elongated body  327  and the outer housing  110  to provide support to the rod member  320  during operation of the washover tool  100   b.    
       FIGS. 4A and 4B  illustrate the plurality of fluid jets W being sprayed from the washover tools  100   a ,  100   b . Pressurized fluid, such as a water, is supplied to the washover tools  100   a ,  100   b  and carried to the annulus  220  by the rod member  320 . The pressurized fluid is then sprayed from the annulus  220  through the plurality of openings  240  in the form of fluid jets W along and/or about the center axis  205 . The number of fluid jets W from the washover tools  100   a ,  100   b  is equal to the number of openings  240  formed in the front face plate  230 . The fluid jets W washover the pipe  130 . 
       FIGS. 4A and 4B  further illustrate the washover tools  100   a ,  100   b  having the outer edge  260  of the inner housing  120  extending past the front face plate  230 . In such embodiments, the inner housing  120  has a length L 2  greater than the length L 1  of the outer housing  110 , such that the outer edge  260  and front surface  265  of the inner housing  120  extend past the front face plate  230 . The front surface  265  and the outer edge  260  provide for additional ground removal during washover operations of the washover tools  100   a ,  100   b . Similarly, the inner housing  120  may extend past the back face plate such that the outer edge  260  extends past the back face plate. In some embodiments, the back face plate completely covers the rear or back ends of the inner housing  120  and the outer housing  110 . 
       FIG. 5  is a schematic side view of a washover system  500  in operation to remove the pipe  130  from the ground  520 , according to one or more embodiments. The washover system  500  includes the washover tool  100   a  (but may similarly include the washover tool  100   b  or any other embodiments of the washover tools described herein) and a control source  510 . The control source  510  supplies the fluid, such as washover water to the washover tool  100 . Furthermore, the control source  510  provides power to move the washover tool  100   a  along the length of the pipe  130  and into the ground  520  by pushing on the rod member  320 . In some embodiments, the control source  510  is configured to disconnect from the washover tool  100   a  and reconnect to the pipe  130  to remove the pipe  130  from the ground  520  after the pipe  130  has been washed over with the washover tool  100   a , and while the washover tool  100   a  remains on the pipe  130  The ability to disconnect and reconnect from the washover tool  100   a  and the pipe  130  without having to completely remove the washover tool  100   a  increases the efficiency and decreases the cost of the pipe removal operations by limiting the operation time normally associated with removing one or more tools from the control source and/or the pipe  130  before attempting to remove the pipe  130  from the ground. 
     The rod member  320  of the washover tool  100  connects to the control source  510  to receive a fluid, such as washover water, from the control source  510 . As discussed, the rod member  320  is coupled to the top side  117  of the outer housing  110  so that the opening  115  of the outer housing  110  and the opening  315  of the rod member  320  are aligned. The bore of the rod member  320  and the annulus  220  are in fluid communication, allowing pressurized fluid to be supplied to the washover tools  100   a ,  100   b  from the control source  510 . The fluid flows through the rod member  320 , into the annulus  220 , and out of the plurality of openings  240  to washover the pipe  130 . 
     The washover system  500  removes the pipe  130  embedded in the ground  520 . The ground  520  may be any earth-like material, such as a sand or soft clay. The pipe  130  may extend some distance into the ground  520 , thus requiring the washover tool  100   a  to be moved along the pipe  130  and into the ground  520  to remove any earth material surrounding the pipe  130 . As the washover tool  100  extends farther into the ground  520 , additional pipe members may be fastened the rod member  320  by the control source  510  to provide continuous fluid communication between the control source  510  and the washover tool  100   a . As each additional pipe member is added to the washover system  500 , the control source  510  supplies power to move the washover tool  100  along the length of the pipe  130  by pushing the pipe members connected to the rod member  320 , while simultaneously providing pressurized fluid to washover the pipe  130 . 
     The pressurized fluid is carried by the pipe members and the rod member  320  into the annulus  220  and ejected from the annulus  220  through the plurality of openings  240  formed in the front face plate  230 . The plurality of openings  240  form a plurality of water jets W, which remove any ground  520  surrounding the pipe  130 . The water jets W loosen the ground  520  around the pipe  130  and allow the source  510  to remove the pipe  130 . 
     In some embodiments, the outer edge  260  and front surface  265  of the inner housing  120  remove additional ground  520  surrounding the pipe  130  as they contact the ground  520 . As the washover tool  100  is moved along the pipe  130 , the front surface  265  extending past the front face plate  230  loosens the ground  520  immediately surrounding the pipe  130 . Simultaneously or after, pressurized fluid is supplied to the washover tool  100   a  to washover the pipe  130  and remove additional ground  520  around the pipe  130 . This process repeats along the length of the pipe  130  until the pipe  130 , or a section thereof, can be removed from the ground  520 . 
       FIG. 6  is a flow chart illustrating a method  600  of using the washover system  500 , according to one or more embodiments. Operation  602  of the method  600  comprises placing the washover tool (such as washover tools  100   a ,  100   b ) around the pipe  130  extending into the ground  520 . In operation  602 , the washover tool is placed around the pipe  130  at a location where a starting end  530  of the pipe  130  is exposed from the ground  520 . 
     At operation  604 , pressurized water is injected into the washover tool. The pressurized water is supplied from the control source  510  through the rod member  320 , or through a series of additional pipe members coupled between the rod member  320  and the control source  510 . At operation  606 , the pressurized water is ejected from the washover tool through a plurality of openings  240  formed in the washover tool to washover the pipe  130 . During operation  606 , the pressurized water may be continuously ejected from the washover tool until a requisite amount of the ground  520  is removed from the area surrounding the pipe  130  while the washover tool remains in a stationary position. 
     At operation  608 , the washover tool is then moved along the length of the pipe  130  to washover the pipe  130  with the pressurized water to remove the ground  520  surrounding the pipe  130 . In some embodiments, the front surface  265  of the inner housing  120  also removes the ground  520  surrounding the pipe  130  as the washover tool is moved along the length of the pipe  130 . 
     Finally, at operation  610 , the pipe  130  is removed from the ground  520 . Operation  610  includes disconnecting the washover tool system from the control source  510  by decoupling the rod member  320 , or the series of pipe members coupled to the rod member  320 , from the control source  510 . The control source  510  is then coupled (such as by a threaded coupling) to the starting end  530  of the pipe  130 . The control source  510  then applies a pulling force on the pipe  130  to remove the pipe  130  from the ground  520 . If the pipe  130  is not sufficiently loosened from the ground  520 , the control source  510  is recoupled to the washover tool system, and operations  602  through  610  are repeated until the pipe  130  may be removed from the ground  520 . 
     The embodiments of the washover tools  100 ,  100   a ,  100   b , the washover system  500 , and the method  600  of using the washover tools and system can be equally used to remove pipes, such as drill pipe, that gets stuck in a wellbore when drilling oil and gas wells from a drilling rig. The washover tools  100 ,  100   a ,  100   b  can be placed over the stuck pipe, which may be oriented vertically, and moved along the pipe down into the wellbore while spraying high pressure fluid to remove any dirt, debris, or the materials from around the pipe. The pipe can then be removed and the drilling operation resumed. The embodiments of the washover tools  100 ,  100   a ,  100   b , the washover system  500 , and the method  600  of using the washover tools and system are not limited to use in pipeline and oil and gas drilling operations, but can equally be used in any other type of applications and industries where pipe removal may be needed. 
     It is contemplated that one or more of the embodiments disclosed herein may be combined. Moreover, it is contemplated that one or more of these embodiments may include some or all of the aforementioned benefits. 
     It will be appreciated by those skilled in the art that the preceding embodiments are exemplary and not limiting. It is intended that all modifications, permutations, enhancements, equivalents, and improvements thereto that are apparent to those skilled in the art upon a reading of the specification and a study of the drawings are included within the scope of the disclosure. It is therefore intended that the following appended claims may include all such modifications, permutations, enhancements, equivalents, and improvements. The disclosure also contemplates that one or more aspects of the embodiments described herein may be substituted in for one or more of the other aspects described. The scope of the disclosure is determined by the claims that follow.