This application claims priority to previously filed U.S. provisional application, Ser. No. 61/305,823 to Bolen et al., filed in the United States Patent Office on Feb. 18, 2010.
The invention is directed to the field of subsea drilling.
Hydrocarbons may be produced from wells drilled below the surface of the sea. In conventional subsea drilling, a riser contains a drilling string, also known as a drilling pipe. A drilling mud column travels through the drilling string from an offshore drilling rig and downward to the bottom of a wellbore being drilled. Drilling mud then returns with cuttings upward along the outside of the drilling string in the annulus region of the riser to the drilling rig.
To drill subsea wells in a deep ocean environment, it may be useful to employ a drilling technique known as dual gradient drilling. Dual gradient drilling is a drilling technique employing drilling mud in the drill string down to the wellbore. It employs a drilling mud return path that does not follow the annulus but instead travels by a different route. In dual gradient drilling it is possible to employ a subsea rotating device above the lower marine riser package. A subsea rotating device functions to seal the annulus between the riser and the drill string. This separates drilling mud in the annular region below the subsea rotating device from seawater or seawater equivalent fluid employed in the annular region above the subsea rotating device.
When drilling in subsea environments, it is sometimes necessary to conduct an emergency disconnect of the lower marine riser package from the blowout preventer stack located adjacent to the sea floor. Emergency disconnects may occur, for example, during severe weather, when sea conditions result in high waves, winds and or currents. Emergency disconnect during dual gradient drilling operations may trap seawater or seawater equivalent fluid within the riser. A drilling vessel with a suspended freely hanging riser during severe weather conditions presents challenges due to the substantial weight of the riser suspended from the vessel. Vessels heave up and down in heavy storms, and such a suspended riser may move vertically up and down, inducing stress upon the riser, with the potential to cause failure and loss of the riser. In such conditions, it would be desirable to minimize the weight or mass of the riser. Trapped seawater or seawater equivalent fluids in the riser adds additional weight and mass to the riser, which is undesirable.
An apparatus, system and method for reliably discharging seawater or seawater equivalent fluids in the event of riser disconnect would be highly desirable. The invention is directed to such operational challenges.
An apparatus, system and method is disclosed for releasing fluid from a marine riser assembly. In one embodiment, it is useful to release the fluid as close the lower end of the riser as possible. The apparatus, sometimes referred to as a dump joint apparatus, or “RDJ”, may comprise a housing defining an interior space and an exterior region. The housing may include first and second ends adapted for respective sealed connection in a marine riser assembly. The housing may be defined on its interior space by a central cavity, the central cavity being adapted for passage of a drilling string and associated tools; casing or seals. Further, the housing may include at least one port adapted for fluid exit. A first gate is provided in mating configuration with the housing, the first gate being moveable from (i) a sealed position that restricts fluid flow through the port to (ii) an open position that facilitates fluid flow through the port from the interior space to the exterior region of the housing. A first actuator assembly may be connected to the first gate and configured for moving the first gate from the sealed position to the open position in response to a signal or hydraulic pressure. The first actuator assembly may be hydraulically or mechanically operated.
In one embodiment of the invention, the first actuator assembly may be provided in fluid communication with stored hydraulic fluid. The actuator assembly may have at least one valve or other operable flow restrictive device. The valve may be configured for opening in response to a signal or pressure pulse to facilitate pressurized flow of the hydraulic fluid to move the first gate to the open position.
The apparatus may include a second gate in mating configuration with the housing. The second gate may be controlled independently of the first gate and may be selectively moveable from (i) a sealed position that restricts fluid flow through the ports to (ii) an open position that facilitates fluid flow through the ports from the interior space to the exterior region of the housing. The apparatus further may comprise a second actuator assembly connected to the second gate and configured for moving the second gate from the sealed position to the open position in response to a signal or hydraulic pressure. In yet another embodiment, a third gate may be employed, in which the third gate is connected to a third actuator assembly. A fourth gate may be connected to a fourth actuator assembly. Additional gates may be employed as well.
In one embodiment of the invention, the first and third gates are positioned on approximately opposite sides of the housing so as to release water in an effective and efficient manner from the housing of the apparatus. The second and fourth gates may be positioned on approximately opposite sides of the housing as well, such that if either actuator assembly should not be deployed and activated for any reason, drilling fluid (or seawater equivalent fluid) still may be released from the housing. In this way, redundancy may be built into the apparatus and system of the invention to ensure that fluid is released from the housing even if a portion of the system fails to operate as planned.
A first set of actuator assemblies may be employed with any number of gates in the event of an emergency disconnect from the well. One or more control systems may activate sets of actuator assemblies in the event of an emergency disconnect from the well, thereby facilitating redundant operation. The failure of one control system to function will still result in drilling fluid being released from the housing in adequate volume, if a second control system is employed in independent fashion.
The housing may be cylindrical or hexagonal in shape, but shall not be limited in arrangement options. In another aspect of the invention, a first set of gates may be distributed in a spaced arrangement along the periphery of the housing, with each being connected to a first set of actuator assemblies. Furthermore, the second, fourth, and sixth gates may be distributed in a spaced arrangement upon the housing and connected to a second set of actuator assemblies, in other embodiments.
In another embodiment of the invention, a first end of the housing may be adapted for connection to a riser joint. The second end of the housing may be adapted for connection to a subsea rotating device, or to another riser section, or another device.
An apparatus is disclosed for releasing fluid from a riser assembly. The riser assembly may be adapted for connection to a drilling structure positioned above the surface of the sea. The riser assembly may be configured for extending below the sea to a lower marine riser package (“LMRP”) or similar structure. The LMRP typically is mounted upon a blowout preventer (“BOP”) adjacent the top of the subsea wellhead. In one embodiment of the invention, the BOP and/or LMRP may be configured for sending pressurized hydraulic fluid to the actuating system upon activation of the BOP. This may occur when the BOP is actuated to shut in a well during an emergency. In that instance, the riser becomes disconnected, and at that point the need for releasing fluid from the riser may be satisfied by actuation of one or more gates, as further disclosed herein.
In some embodiments of the invention, the first set of gates further include apertures as part of their structure. The apertures may be provided for alignment with ports of the housing when the first set of gates are in the open position. A second set of gates may be provided, the second set of gates being in mating configuration with the housing. The second set of gates may be selectively moveable from a sealed position that restricts fluid flow through ports to an open position that facilitates fluid flow through ports from the interior space to the exterior region of the housing. The second set of gates also could employ apertures for alignment with respective ports.
The invention may comprise a system for receiving a drill string. The system may be suspended from a drilling structure, such as a drillship, a floating platform, jack-up platform, or other structure. The system may comprise a riser, the riser being configured for the transport of drilling fluid. Further, the system may be sealed in connection to the riser.
A method also is provided for releasing fluids from a drilling riser in the event of an emergency disconnect of the riser from a well. The method may comprise the steps of providing a fluid release apparatus in sealed connection to a riser, the fluid release apparatus comprising a housing defining an interior space and an exterior region. The apparatus employed in the method may further comprise at least one port and a gate in mating configuration to the port. The gate may be moveable from a sealed position which blocks fluid flow through the port to an open position that facilitates fluid flow through the port. Furthermore, a first actuator assembly moves the gate from the sealed position to the open position. Further, the first actuator assembly may be activated to move the gate to the open position. Fluid then may move from the interior space of the riser through the port to the exterior region of the riser.
In some instances, the first actuator assembly may be hydraulically operated. If hydraulics are employed, hydraulic fluid may be in communication with the actuator assembly. The actuator also may comprise at least one valve. During the activation step, such a valve may be opened by pressure or other means to facilitate pressurized flow of the hydraulic fluid to move the first gate to the open position. A plurality of ports can be employed. A second gate may be provided as well. The second gate may be moveable from a sealed position which covers at least one port to an open position that facilitates fluid flow through at least one port. Any number of gates may be used in the practice of the invention. One or more control systems may be configured for receiving a signal and activating the actuator assembly upon emergency disconnect of the riser from the well.
The invention may be observed by reference to one or more Figures as follows:
While the invention is shown in one or more detailed embodiments, it is recognized that other embodiments of the invention could be conceived and deployed in accordance with the scope of the written description herein, and the invention is not limited to only those embodiments illustrated in the Figures.
In
In the event of an emergency disconnect, lower marine riser package 30 may disconnect from the blow out preventer 32, which allows the riser 24 with associated hardware to freely hang beneath the vessel. Following emergency disconnect, it is possible to release fluid from the interior of the riser through the dump joint apparatus 25.
Gate 50a is shown near the top portion of
A first actuator assembly 54 is configured to move the gate 50a, as further discussed herein. A second actuator assembly 55 is also shown in
A redundant flow port section 57 is configured in a similar manner, and provides additional capacity for release of fluid from assembly 25. In one embodiment of the invention, the redundant section may include an array of sliding gates that are actuated by a hydraulic cylinder that is operated by a control circuit, as further discussed herein. Upon receiving a pilot signal from the BOP control, the dump circuit may fire two position valves (not shown) that allow stored hydraulic fluid to actuate the gates to the open position to uncover ports. This manner of operation is further discussed herein, and also in connection with
Remotely operated vehicles may interact with the apparatus 25 by mechanically engaging ROV intervention connection section 59, which includes multiple points for interconnection and actuation by an ROV vehicle. This may be used, for example, to reset the apparatus 25 back to the open position following a reconnection of the riser 24 to the blow out preventer 32. In other applications of the invention, the ROV vehicle could be used to actuate the apparatus 25 to release fluid in the event of an equipment malfunction which causes the apparatus 25 to fail in the automatic mode to deploy gates for release of riser fluid. In such instances, manual intervention may be used to open gates and release fluid.
Mud return line 58 and choke line 61 may be seen running the length of the apparatus 25. Further, seawater fluid power line 64 and rigid conduit line 65 also run the length of the apparatus 25. Housing 40 has an exterior region 41 and an interior space 42. Controls 60 are provided and shown in
Furthermore, a first control system 56 (shown in
The simplified version of the controls circuit as depicted in
Options to override the RDJ controls via a remote operated vehicle (“ROV”) may be included whereby the ROV can inject a pilot signal to trip a 2 position EDS valve and thereby open the gates 50a-f of the RDJ, allowing fluid to vent through port(s) to the sea. In addition, the ROV may also be capable of adding hydraulic fluid to the RDJ mounted accumulators 74, 75 in the event of an issue with the BOP controls supplying hydraulic fluid power to the RDJ system. The controls may be be capable of opening all redundant RDJ gates (such as those in redundant flow port section 57) as well as closing them. Override ROV options may be employed as part of the controls design.
With reference to
In
An alternate embodiment of the invention is illustrated in
Control system 109 receives a hydraulic pressure pulse or other signal along control line 110. This pressure signal activates the control system 109 which in turn activates first actuator assembly 106. Likewise, control system 109 activates second actuator assembly 107. Each of these actuator assemblies 106, 107 acts upon its respective gates. There is built-in redundancy so that upon failure of either actuator assembly to operate, the other actuator assembly likely may not be affected, as it operates independently, and the other actuator may accomplish the task of opening its respective gate(s) enough to provide adequate fluid flow capacity to drain fluid from the riser 24. This embodiment shows only one control system 109, but multiple control systems could be employed, depending upon engineering requirements.
The invention may be further described by reference to the appended claims.
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