Modular Wellhead System With Hydraulic Jacking Mechanism
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Solution Overview
Problem
Conventional wellhead systems are cumbersome and expensive to retrofit and install in subsea environments, especially after damage from storms like Hurricane Katrina, due to damaged casing structures and tubing issues, limiting the ability to repair or properly plug and abandon wells without specialized vessels.
Innovation Solution
A modular, stackable wellhead system with a unique capping system, hydraulic jacking mechanism, and interchangeable components that allows for single or dual annulus operations, enabling divers to assemble and disassemble quickly, lift tubing, and apply tension without a jack-up barge, using a reverse wedge locking system and interchangeable bushings for various casing sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional wellhead systems are used in subsea environments, then wellhead functionality is maintained, but installation becomes cumbersome and expensive requiring specialized vessels
Solution Approach 1:
The wellhead system is divided into multiple modular components including a wellhead body, interchangeable heads, capping systems, and jacking mechanisms that can be assembled and disassembled independently. This segmentation allows for easier installation and removal without requiring complex specialized vessels, as each component can be handled and positioned separately by divers or ROVs.
Solution Approach 2:
The system incorporates dynamic elements such as movable jacking mechanisms, interchangeable heads, and adjustable capping systems that can be operated and reconfigured in the field. The hydraulic jacking system allows for dynamic lifting and positioning of tubing, while the interchangeable heads enable adaptation to different well configurations without requiring complete system replacement.
2Productivity
If specialized vessels are used for tubing recovery operations, then tubing can be lifted from the well, but the cost and availability of such vessels becomes a limiting factor
Solution Approach 1:
The wellhead system incorporates an integrated hydraulic jacking mechanism that enables the wellhead itself to perform tubing lifting operations without requiring external specialized vessels. The jacking system uses hydraulic pressure to generate the necessary lifting force, allowing the wellhead to service itself or be serviced by minimal equipment, thereby eliminating the need for expensive and scarce specialized vessels.
Solution Approach 2:
The system employs a hydraulic jacking mechanism that uses fluid pressure to generate lifting force for tubing recovery operations. The hydraulic system converts hydraulic energy into mechanical lifting force, enabling the wellhead to perform tasks that would otherwise require specialized vessels. This hydraulic approach provides a cost-effective and available solution compared to relying on specialized vessel equipment.
3Adaptability or versatility
If the well is at an angle due to collapse or catastrophic failure, then the well structure is damaged, but this further limits the availability of vessels which could handle the operation
Solution Approach 1:
The wellhead system is designed with universal adaptability to handle various well configurations including vertical, directional, and angled wells. The interchangeable heads and adjustable components allow the same wellhead system to accommodate different well geometries and damage conditions. This universality enables the system to operate in challenging environments where conventional wellheads would be unsuitable, maintaining ease of operation across diverse well scenarios.
4Ease of operation
If the tubing is bent, compressed, or otherwise damaged in the well, then the tubing cannot be easily lifted from the well, but conventional systems cannot address this issue
Solution Approach 1:
The system incorporates a dynamic hydraulic jacking mechanism that can apply controlled lifting forces to damaged tubing. The hydraulic system can gradually apply pressure to straighten and lift bent or compressed tubing sections, making the tubing suitable for removal. This dynamic approach allows the system to handle tubing that would be too damaged for conventional static lifting methods, improving both lifting ease and preserving tubing integrity where possible.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides a portable, efficient, and cost-effective solution for well repair and plug and abandonment operations in subsea environments, reducing the need for specialized vessels and enabling quick installation and removal of wellheads, while accommodating various casing sizes and configurations.
Implementation Method 1
a reverse wedge locking system
Implementation Method 2
a hydraulic jack for lifting the tubing from the well to reintroduce tension
Data Source
AI summary
A modular wellhead system having the capability for single or dual annulus via interchangeable heads, a unique capping system, and other features. A unique wellhead manual positive lock system incorporating an energizable inner bite ring for engaging the casing tubing, a compressible slip hanger for the tubing, as well as a hydraulic jack for lifting the tubing from the well to reintroduce tension are provided, the system being particularly suitable for use in conjunction with repair or low pressure plug and abandon (P&A) operations. Components of the system are designed for assembly via locking pins for diver friendly operation, While the present system is designed principally for use in subsea environments, the system can likewise be utilized on land or platforms.