Patent Application
20150034302
The present disclosure relates generally to the field of drilling and processing of wells, and, more particularly, to a system and method for filling casing during a casing process, a drilling process, or another type of well processing operation.
In conventional oil and gas operations, a well is typically drilled to a desired depth with a drill string, which includes drill pipe and a drilling bottom hole assembly. Once the desired depth is reached, the drill string is removed from the hole and casing is run into the vacant hole. Casing may be defined as pipe or tubular that is placed in a well to prevent the well from caving in, to contain fluids, and to assist with efficient extraction of product. Tubular may be defined as including drill pipe, casing, or any other type of tubular utilized in drilling or well processing operations.
During drilling and casing running operations, a string of tubular (e.g., drill pipe or casing) is typically held by slips mounted to the rig floor while a new length of tubular is connected. Specifically in casing operations, a new length of tubular is positioned above the floor mounted tubular string by a special elevator while connections are made up at the rig floor level. Occasionally, as the string of tubular is assembled at the surface, the string of tubular may be filled with a filling fluid (e.g., mud or water) to provide balance to the string of tubular, to flush drilling material out of the wellbore, and so forth. Alternatively, the string of tubular may be filled after the string of tubular is “floated” or landed in the hole. Unfortunately, the filling process can be lengthy, thereby increasing the costs associated with the filling process. However, increasing the speed of filling the string of tubular with the filling fluid can undesirably lead to aeration of the filling fluid. Accordingly, it is now recognized that there exists a need for a system for increasing the speed of the filling process, while reducing aeration in the filling fluid during the filling process.
In accordance with one embodiment of the present disclosure, a tubular filling tool includes a conductor pipe configured to receive a filling fluid flow from a top drive and a diffuser block communicatively coupled to the conductor pipe and configured to receive the filling fluid flow from the conductor pipe, wherein the diffuser block comprises a plurality of fluid passages extending to external passages formed in an outer diameter of the diffuser block and configured to facilitate passage of the filling fluid flow to the external passages from within the diffuser block, wherein the external passages are configured to generate a swirl flow pattern in the filling fluid flow during a tubular filling process.
In another embodiment, a method includes receiving a filling fluid into a filling tool of a mineral extraction system, passing the filling fluid through a conductor pipe to a diffuser block, generating a swirl flow pattern in the filling fluid with the filling tool by passing the filling fluid through fluid passages of the diffuser block and into external passages arranged in a helical pattern, and flowing the filling fluid into a tubular of the mineral extraction system.
In a further embodiment, a drilling system includes a tubular filling tool, a conductor pipe of the tubular filling tool configured to receive a filling fluid from a filling fluid pump, and a diffuser block of the tubular filling tool coupled to the conductor pipe, a plurality fluid passages in the diffuser block communicatively extending from the conductor pipe to external passages formed in an outer diameter of the diffuser block, wherein the external passages are configured to generate a swirl flow pattern in the filling fluid during a tubular filling process, and a plurality of blades extending radially outward from the conductor pipe about a circumference of the conductor pipe and spaced along a length of the conductor pipe.
These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
Embodiments of the present disclosure are directed toward a filling tool for filling casing or other tubular with a filling fluid. More specifically, during a filling process associated with running or landed casing, a filling tool may be used to increase the speed of filling the casing or tubular with filling fluid. Additionally, the filling tool may be configured to reduce aeration of the filling fluid during the filling process and/or separate entrained filling fluid from air exiting the casing during the filling process.
As discussed in detail below, in one embodiment, the filling tool includes a conductor pipe that flows filling fluid to a diffuser block of the filling tool. Thereafter, the diffuser block generates a swirl, vortex, or other helical flow pattern in the filling fluid as the filling fluid enters the casing or tubular. In this manner, the filling fluid may more completely travel downward against an inner diameter of the casing or tubular, thereby reducing aeration of the filling fluid within the casing or tubular during the filling process. Additionally, the diffuser may include an air chamber configured to collect or gather air exiting the casing or tubular during the filling process and direct the air across stationary blades positioned about the conductor pipe. In the manner described below, the turbine stator blades may reduce entrained fluid (e.g., filling fluid) within the air exiting the casing or tubular as the casing or tubular is filled with the filling fluid.
Turning now to the drawings,
While a new tubular length 28 is being attached to the tubular 30, the tubular 30 is held stationary with respect to the rig floor 12 by a rotary table 34 and slips 36. The tubular 30 extends below the rig floor 12 and through a blow-out preventer 38 before extending into the wellbore 32 at the ground level. After the tubular 30 is landed in the wellbore 32, a tubular filling process may be completed. More specifically, the tubular filling process includes flowing a filling fluid (e.g., mud or water) into the tubular 30 and the wellbore 32. As will be appreciated, the tubular 30 filling process may help balance the tubular 30 within the wellbore 32 and flush up drilling material (e.g., rock, dirt, debris, etc.) created during the drilling process.
In the present embodiments, a filling tool 50 may be used to improve the tubular 30 filling process. As discussed in detail below, the drilling tool 50 may be configured to reduce aeration in the filling fluid as the filling fluid is pumped into the tubular 30. Additionally, the filling tool 50 may be configured to reduce entrainment of filling fluid in air exiting the tubular 30 during the tubular 30 filling process. It should be noted that
While the filling tool 50 is not in active use in
As shown, the filling fluid 60 flows down the conductor pipe 62 toward the tubular 30 until it reaches a diffuser block 66 of the filling tool 50. The diffuser block 66 includes a plurality of filling fluid passages 68 extending from the conductor pipe 62 to an outer diameter 70 of the diffuser block 66. That is, the filling fluid passages 68 exit the diffuser block 66 at exit ports 72 formed in the outer diameter 70 of the diffuser block 66. As such, the diffuser block 66 routes the filling fluid 60 from the conductor pipe 62 of the filling tool 50 to the outer diameter 70 of the filling tool 50. As discussed in detail below, the outer diameter 70 of the diffuser block 66 may further include external passages (e.g., external passages 100 shown in
In the illustrated embodiment, the filling tool 50 extends partially into the tubular 30. Specifically, the length of casing 52 within which the filling tool 50 is positioned axially abuts the tubular 30 landed in the wellbore 32, and a portion of the diffuser block 66 of the filling tool 50 partially extends into the tubular 30. As such, the outer diameter 70 of the diffuser block 66 is coaxial and overlapping with an inner diameter 74 of the tubular 30. For example, the gap or space between the outer diameter 70 of the diffuser block 66 and the inner diameter 74 of the tubular 50 may be approximately 0.125 to 0.375 inches. As the filling fluid 60 exits the exit ports 72 and flows along the external passages of the diffuser block 66, the filling fluid 60 flow may transfer from the outer diameter 70 of the diffuser block 66 to the inner diameter 74 of the tubular 30. Furthermore, the helical, vortex, or swirl flow pattern of the filling fluid 60 may transfer from the outer diameter 70 of the diffuser block 66 to the inner diameter 74 of the tubular 30. As a result, surface tension created between the filling fluid 60 and the inner diameter 74 of the tubular 30 may cause the filling fluid 60 to flow more completely and laminarly along the inner diameter 74 as the filling fluid 60 flows into the tubular 30. Additionally, the helical, vortex, or swirl flow pattern of the filling fluid 60 may create a Coriolis Effect (e.g., an artificial Coriolis Effect) and/or a centripetal force acting on the filling fluid 60, which may also cause the filling fluid 60 to more completely flow along the inner diameter 74 of the tubular 30. In this manner, aeration of the filling fluid 60 within the tubular 30 may be reduced.
Furthermore, as the filling fluid 60 flows downwardly along the inner diameter 74 of the tubular 30, what may be referred to as a void 76 may be created towards a center of the tubular 30. As will be appreciated, air 78 displaced by the filling fluid 60 within the tubular 30 may collect in the void 76 and travel upward through the tubular 30 and toward the filling tool 50. As shown, the diffuser block 66 includes a chamber 80 formed in a bottom surface 82 of the diffuser block 66 (e.g., at a tubular 30 engagement end 56 of the filling tool 50). As shown, when the filling tool 50 is engaged with the tubular 30, the chamber 80 is exposed to the interior of the tubular 30. As the air 78 is displaced upward by the filling fluid 60 within the tubular 30, the air 78 may collect within the chamber 80 of the diffuser block 66. From the chamber 80 of the diffuser block 66, the air 78 is directed toward an outer diameter 84 of the conductor pipe 62 by a plurality of air passages 86 formed in the diffuser block 66. When the air 78 displaced from the tubular 30 reaches exit ports 57 of the air passages 86 formed in a shelf 58 (e.g., an upper shelf) of the diffuser block 66, the air 78 may continue to flow upward between the filling tool 50 and the length of casing 52 disposed about the filling tool 50 toward an exit air vent 88 formed in the length of casing 52. From the exit air vent 88, the air 78 may enter the atmosphere.
As shown, the filling tool 50 also includes a plurality of fins or blades 90 disposed about the conductor pipe 62. That is, the blades 90 extend radially outward from the outer diameter 84 of the conductor pipe 62. As the air 78 travels across the stationary blades 90, the blades 90 guide the air 78 to create a cyclone or swirl effect with the air 78. In other words, the air 78 may swirl around the conductor pipe 62 of the filling tool 50. Additionally, as the air 78 travels across the blades 90 and around the conductor pipe 62, the blades 90 may cause filling fluid 60 entrained in the air 78 to fall out of the air 78. As indicated by arrows 92, entrained filling fluid 60 that falls out of the air 78 may fall downwardly between the outer diameter 70 of the diffuser block 66 and an inner diameter 94 of the length of casing 52. As the length of casing 52 and the tubular 30 axially abut one another, filling fluid 60 that falls between the outer diameter 70 of the diffuser block 66 and an inner diameter 94 of the length of casing 52 may continue to flow downward between the inner diameter 74 of the tubular and the outer diameter 70 of the diffuser block 66, thereby rejoining the filling fluid 60 exiting the filling fluid passages 68 of the diffuser block 66 and flowing into the tubular 30.
Furthermore, as discussed in detail above, the diffuser block 66 includes the chamber 80 formed in the bottom surface 82 of the diffuser block 66. The chamber 80 collects air 78 displaced from the tubular 30 as the tubular 30 is filled with the filling fluid 60. From the chamber 80, the air 78 is directed to the outer diameter 84 of the conductor pipe 62 by air passages 86 formed in the diffuser block 66. In certain embodiments, the air passages 86 may be configured to direct the air 78 in a helical flow pattern. For example, the air passages 86 may be formed in the diffuser block 66 in helical arrangement. Additionally, each of the air passages 86 may have a helical or curved contour within the diffuser block 66. Moreover, in certain embodiments, the air passages 86 may extend at least partially radially outward relative to the conductor pipe 62, while in other embodiments the air passages 86 may extend at least partially radially inward. Thereafter, the air 78 flows across the blades 90 extending radially outward from the outer diameter 84 of the conductor pipe 62, thereby reducing entrainment of filling fluid 60 within the air 78, as discussed above.
As will be appreciated, the disclosed embodiments may include various designs, configurations, or arrangements, all of which are within the scope and spirit of the present disclosure. For example, the filling tool 50 may be formed from a variety of materials, such as steel, aluminum, polymer, plastic, or other material. Additionally, the filling tool 50 may be formed as a single, integral piece (e.g., by a casting process), or the filling tool 50 may be formed by combining multiple pieces together (e.g., by a welding or brazing process). Furthermore, the diffuser block 66 may have various configurations. For example, the diffuser block 66 may include any suitable number of fluid passages 68, and therefore may have any suitable number of respective exit ports 72 and external passages 100 formed in the outer diameter 70 of the diffuser block 66. Similarly, the diffuser block 66 may have any suitable number of air passages 86 extending from the chamber 80 to the outer diameter 84 of the conductor pipe 62.
Additionally, the external passages 100 may have a variety of configurations or shapes to achieve a helical, vortex, or swirl flow pattern in the filling fluid 60 flow. For example, each of the external passages 100 may have a similar configuration (e.g., angle, contour, etc.) or the configuration of each of the external passages 100 may vary. For example, in some embodiments, the external passages 100 may be recesses formed in the outer diameter 70 of the diffuser block 66, and, in other embodiments, the external passages 100 may be enclosed passages. Moreover, the various features of the diffuser block 66 may be formed with a variety of forming and/or machining processes, such as milling, casting, drilling, honing, and so forth.
Furthermore, the blades 90 extending radially outward from the outer diameter 84 of the conductor pipe 62 may have a variety of configurations. For example, the blades 90 may be spaced equally or varyingly around the circumference of the conductor pipe 62, the blades 90 may be staggered relative to one another, the blades may have similar or varying pitches and/or contours, and so forth. In certain embodiments, the position and/or orientation of the blades 90 may be selected to achieve a desired vortex or cyclone flow pattern of the air 78 passing across the blades 90.
As discussed in detail above, embodiments of the present disclosure are directed toward the filling tool 50 for filling casing or other tubular 30 with the filling fluid 30. More specifically, during a filling process associated with running or landed tubular 30, the filling tool 50 may be used to increase the speed of filling the tubular 30 with the filling fluid 60. Additionally, the filling tool 50 may be configured to reduce aeration of the filling fluid 60 during the filling process and/or separate entrained filling fluid 60 from air 78 exiting the tubular 30 during the filling process. As discussed above, the filling tool 50 includes the conductor pipe 62 that flows filling fluid 60 to the diffuser block 66 of the filling tool 50. Thereafter, the diffuser block 66 generates a swirl, vortex, or other helical flow pattern in the filling fluid 60 with external passages 100 as the filling fluid 60 enters the tubular 30. In this manner, the filling fluid 60 may more completely travel downward against the inner diameter 74 of the tubular 30, thereby reducing aeration of the filling fluid 60 during the filling process. Additionally, the diffuser block 66 may include the chamber 80 configured to collect or gather air 78 exiting the tubular 30 during the filling process and direct the air 78 across blades 90 positioned about the conductor pipe 62. In the manner described above, the blades 90 may reduce entrained fluid (e.g., filling fluid 60) within the air 78 exiting the tubular 30 as the tubular 30 is filled with the filling fluid 60.
While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.
