BOP Stack Alignment Using Laser Guidance and Compact Mast
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Solution Overview
Problem
Conventional completion systems for wells, particularly those with long lateral boreholes, face challenges such as slow and unsafe insertion of production tubing, limited maximum horizontal insertion distance, and increased operational costs due to the need for larger and more complex rigs, which hinder efficient hydrocarbon production and fracturing in low permeability reservoirs.
Innovation Solution
A long lateral completion system featuring a compact mast assembly, catwalk-pipe arm, and automated pipe handling mechanisms that allow for precise alignment and insertion of tubing with reduced rig footprint, enabling faster and safer operation, and the ability to work in close proximity to other wells, thereby enhancing productivity and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional completion systems are used for long lateral boreholes, then the insertion of production tubing can be performed, but the insertion process is slow and unsafe
Solution Approach 1:
The patent replaces manual mechanical alignment and insertion operations with an automated system that uses laser alignment technology and automated pipe handling mechanisms. The laser alignment system provides precise visual guidance for positioning the pipe end at the wellhead, eliminating the need for manual alignment by workers, thereby improving both speed and safety of the insertion process
Solution Approach 2:
The automated pipe handling system enables the insertion process to proceed with minimal human intervention. The system self-regulates the positioning and insertion of production tubing through automated mechanisms, reducing the need for workers to be in hazardous positions and improving overall operational safety while maintaining continuous productivity
2Ease of operation
If conventional rigs with larger footprint are used, then the insertion equipment can be supported, but the operational costs increase and proximity to other wells is limited
Solution Approach 1:
The rig system is divided into separate functional modules: a compact mast assembly for vertical support, a separate automated pipe handling system, and an independent laser alignment system. This segmentation allows each component to be optimized independently and reduces the overall footprint while maintaining full functionality, enabling operation in confined spaces near other wells
Solution Approach 2:
The patent transitions from a traditional horizontal spread of rig equipment to a vertical configuration with the mast assembly standing upright. This dimensional change consolidates the equipment footprint horizontally while utilizing vertical space, allowing the rig to operate in areas with limited horizontal clearance from other wells
3Manufacturing precision
If precise alignment of mast and BOP stack is achieved, then the insertion accuracy is improved, but the alignment process becomes more complex
Solution Approach 1:
The patent replaces complex mechanical alignment procedures with an optical laser alignment system. The laser provides a visual reference that guides the positioning of the pipe end relative to the wellhead and BOP stack, achieving precise alignment through optical guidance rather than mechanical measurement and adjustment, thereby simplifying the alignment process while improving accuracy
Data Source
AI summary
A method and apparatus for aligning a wellhead or BOP stack with a mast assembly comprising a sensor which provides an initial alignment between a mast and a wellhead or BOP stack. A mast assembly is transported to a well site by a rig carrier and positions the mast assembly adjacent a wellhead, or BOP stack. The mast assembly is raised to an upright position whereby a rear portion of the mast extends over the wellhead. In one embodiment, at least one sensor is mounted to a top drive and/or crown located within the mast assembly. The top drive has a predetermined path of movement and the sensor aligns itself with the wellhead. In another embodiment, at least one sensor is mounted to the wellhead and aligns itself with a laser alignment target fastened to a crown and/or top drive of the mast. In yet another embodiment, at least one sensor is located on a lower portion of the mast assembly to align the mast with the wellhead. The apparatus is designed to achieve an accuracy of alignment which in different embodiments could be less than 5 degrees, less than 3 degrees, or less than 1 degree.