Abstract
A decommissioning and abandonment requirement to shear 9 5/8-inch casing in certain circumstances with a 13 5/8-inch × 10,000 psi rated working pressure, RWP, Shear RAM type blowout preventer, BOP, resulted in a need to develop a novel casing shear device and shear calculation method. Results of shear testing, future engineering planning guidance, the new shear calculation method, and comparison to legacy technology are included in this paper.
Interaction with the end user to understand requirements, a five-step problem solving procedure, a basis of design process, materials justification, verification analysis, validation testing, and describing an improved shear operator force/pressure calculation are all described. Shear larger casing in the required and restrictive RAM BOP and well bore presented a problematic challenge. Equally, tubular fish size was required to support fishing extraction operations following shear. Validation test results exceeded requirements and resulted in the need for a new approach to the shear calculation method.
The novel shear RAM geometry was developed utilizing shear calculation methods which were based on legacy considerations. API 16A shear validation procedures and two legacy shear calculation methods where employed. Shear calculations are used to anticipate the RAM BOP operator pressures required to shear a specific tubular. The larger than historically allowed casing size to be sheared in a 13 5/8-inch × 10,000 psi RAM BOP meant higher operator pressures were anticipated for each operator option. A Novel shear RAM geometry was developed as a design intent to lower shear force/pressure. There was an observation during validation testing that the geometry exceeded expectations to lower shear pressure significantly. This observation led to a conclusion that an improved shear calculation method was required for this application. This novel calculation method description / statistical treatment, test results, RAM design methods, and tabular shear engineering planning information are included in this paper.
One additional requirement of the shear RAM geometry was to provide an upper and lower fish deformed surface which could be easily retrieved thru the 13 5/8-inch BOP bore. An additional observation was that the fish width requirement was achieved.
The novel shear calculation method allows an engineer to precisely plan for bonnet actuation pressures when larger casing is sheared. The precise calculation of shear force/pressure also assists with BOP operator size and type selection. The engineer will gain casing size versus shear pressure for specific operator options in tabular format. Planners will gain insight into tubular fish deformation estimation allowing mitigation of tubular extraction risk during operations planning.
Enhanced application limits for crossed helical gearboxes using new geometries for smaller sliding paths or smaller contact pressures