Patent Grant
11105171
The invention relates generally to riser assemblies suitable for offshore drilling and, more particularly, but not by way of limitation, to riser assemblies that can be passed through a rotary of a drilling rig and have auxiliary lines assembled below the rotary.
Offshore drilling operations have been undertaken for many years. Traditionally, pressure within a drill string and riser pipe have been governed by the density of drilling mud alone. More recently, attempts have been made to control the pressure within a drill string and riser pipe using methods and characteristics in addition to the density of drilling mud. Such attempts may be referred to in the art as managed pressure drilling (MPD). See, e.g., Frink, Managed pressure drilling—what's in a name?, Drilling Contractor, March/April 2006, pp. 36-39.
MPD techniques generally require additional or different riser components relative to risers used in conventional drilling techniques. These new or different components may be larger than those used in conventional techniques. For example, riser segments used for MPD techniques may utilize large components that force auxiliary lines to be routed around those components, which can increase the overall diameter or transverse dimensions of riser segments relative to riser segments used in conventional drilling techniques. However, numerous drilling rigs are already in existence, and it is generally not economical to retrofit those existing drilling rigs to fit larger-diameter riser segments.
Currently, MPD riser segment assemblies and/or components with an overall diameter or other transverse dimension that is too large to fit through a rotary or rotary table of a drilling rig must be loaded onto the rig below the deck (e.g., on the mezzanine level) and moved laterally into position to be coupled to the riser stack below the rotary. This movement of oversize components is often more difficult than vertically lowering equipment through the rotary from above (e.g., with a crane). At least some of the present embodiments can address this issue for various MPD components by allowing a riser segment to be lowered through a rotary and having auxiliary lines attached to the riser segment below the rotary. Such auxiliary lines are much smaller and easier to transport on the mezzanine level than an overall riser segment and permit a riser segment to be coupled to other riser segments above the rotary to permit multiple coupled riser segments to be simultaneously lowered through a rotary. Other embodiments include auxiliary lines that remain coupled to the riser segment, but that run through a portion of a housing of a large-diameter and/or large-transverse-dimension component of the riser segment such that the auxiliary lines will fit through a rotary of a drilling rig.
Some embodiments of the present riser segment assemblies comprise: a main tube; two flanges each coupled to a different end of the main tube (each flange comprising: a mating face configured to mate with a flange of an adjacent riser segment; a central lumen configured to be in fluid communication with the main tube; and at least one auxiliary hole configured to receive an auxiliary line); and an auxiliary line configured to extend between the two flanges, the auxiliary line comprising: a first connector coupled to the first flange; a second connector coupled to the second flange; and a variable-length removable body having a first end configured to be connected to the first connector, and a second end configured to be connected to the second connector. In some embodiments, the first and second ends of the removable body are configured to be connected to the first and second connectors without welding. In some embodiments, the removable body includes a third connector configured to be connected to the first connector, and a fourth connector configured to be connected to the second connector. In some embodiments, the removable body includes a telescoping joint. In some embodiments, the telescoping joint includes a male portion and a female portion configured to slidably receive the male portion. In some embodiments, the removable body includes a medial portion that is laterally offset from the first and second ends of the removable body. In some embodiments, the main tube includes an isolation unit configured to substantially seal an annulus in the main tube if a drill string is disposed in the main tube, the medial portion of the removable body configured to extend around the isolation unit.
Some embodiments of the present riser segment assemblies further comprise: a plurality of auxiliary lines configured to extend between the two flanges, each of the plurality of auxiliary lines comprising: a first connector coupled to the first flange; a second connector coupled to the second flange; and a variable-length removable body having a first end configured to be connected to the first connector, and a second end configured to be connected to the second connector. In some embodiments, the first and second connectors fit within a circle having a diameter no larger than 150% of a maximum transverse dimension of either flange. In some embodiments, the first and second connectors fit within a circle having a diameter no larger than 120% of the maximum transverse dimension of either flange. In some embodiments, the first and second connectors fit within a circle having a diameter no larger than the maximum transverse dimension of either flange. In some embodiments, the plurality of auxiliary lines includes at least one booster line and at least one choke/kill line.
Some embodiments of the present riser segment assemblies comprise: a main tube having an isolation unit configured to seal an annulus in the main tube if a drill string is disposed in the main tube, the isolation unit having a housing with a maximum transverse dimension and a passage configured to receive an auxiliary line within the maximum transverse dimension; two flanges each coupled to a different end of the main tube (each flange comprising: a mating face configured to mate with a flange of an adjacent riser segment; a central lumen configured to be in fluid communication with the main tube; and at least one auxiliary hole configured to receive an auxiliary line); and an auxiliary line having a first end coupled to the first flange, a second end coupled to the second flange, and a medial portion laterally offset from the first and second ends and disposed in the passage of the isolation unit. In some embodiments, the body of the isolation unit has a circular cross section and the maximum transverse dimension is the diameter of the circular cross-section. In some embodiments, the auxiliary line comprises: a first connector coupled to the first flange; a second connector coupled to the second flange; and a body having a first end configured to be slidably received in the first connector, and a second end configured to be slidably receive the second connector.
In some embodiments of the present riser segment assemblies, the housing of the isolation unit includes a plurality of passages each configured to receive an auxiliary line within the maximum transverse dimension, and the riser segment assembly further comprises: a plurality of auxiliary lines each having a first end coupled to the first flange, a second end coupled to the second flange, and a medial portion laterally offset from the first and second ends and disposed in one of the plurality of passages of the isolation unit.
Some embodiments of the present methods comprise: lowering an embodiment of the present riser segment assemblies through a rotary of a drilling rig.
Some embodiments of the present methods comprise: lowering a riser segment assembly through a rotary of a drilling rig, the riser segment assembly comprising: a main tube; two flanges each coupled to a different end of the main tube (each flange comprising: a mating face configured to mate with a flange of an adjacent riser segment; a central lumen configured to be in fluid communication with the main tube; and at least one auxiliary hole configured to receive an auxiliary line); a first connector coupled to the first flange; and a second connector coupled to the second flange. Some embodiments further comprise: connecting, below the rotary, an auxiliary line to the first and second connectors without welding. In some embodiments, the auxiliary line includes a variable-length body having a first end configured to be connected to the first connector, and a second end configured to be connected to the second connector. In some embodiments, the auxiliary line includes a telescoping joint. In some embodiments, the telescoping joint includes a male portion and a female portion configured to slidably receive the male portion. In some embodiments, the auxiliary line includes a medial portion that is laterally offset from the first and second ends of the removable body. In some embodiments, the riser segment assembly is coupled to other riser segments before it is lowered through the rotary.
The term “coupled” is defined as connected, although not necessarily directly, and not necessarily mechanically; two items that are “coupled” may be unitary with each other. The terms “a” and “an” are defined as one or more unless this disclosure explicitly requires otherwise. The term “substantially” is defined as largely but not necessarily wholly what is specified (and includes what is specified; e.g., substantially 90 degrees includes 90 degrees and substantially parallel includes parallel), as understood by a person of ordinary skill in the art. In any disclosed embodiment, the terms “substantially,” “approximately,” and “about” may be substituted with “within [a percentage] of” what is specified, where the percentage includes 0.1, 1, 5, and 10 percent.
Further, a device or system that is configured in a certain way is configured in at least that way, but it can also be configured in other ways than those specifically described.
The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”) and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs. As a result, an apparatus that “comprises,” “has,” “includes” or “contains” one or more elements possesses those one or more elements, but is not limited to possessing only those elements. Likewise, a method that “comprises,” “has,” “includes” or “contains” one or more steps possesses those one or more steps, but is not limited to possessing only those one or more steps.
Any embodiment of any of the apparatuses, systems, and methods can consist of or consist essentially of—rather than comprise/include/contain/have—any of the described steps, elements, and/or features. Thus, in any of the claims, the term “consisting of” or “consisting essentially of” can be substituted for any of the open-ended linking verbs recited above, in order to change the scope of a given claim from what it would otherwise be using the open-ended linking verb.
The feature or features of one embodiment may be applied to other embodiments, even though not described or illustrated, unless expressly prohibited by this disclosure or the nature of the embodiments.
Details associated with the embodiments described above and others are described below.
The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers. The figures are drawn to scale for at least the embodiments shown.
Referring now to the drawings, and more particularly to
In the embodiment shown, removable body 140 includes a third connector 152 configured to be connected to first connector 132 (e.g., without welding), and a fourth connector 156 configured to be connected to second connector 136 (e.g., without welding). In this embodiment, and as shown in more detail in
In the embodiment shown, removable body 140 includes a telescoping joint 192. In this embodiment, and as shown in more detail in
In the embodiment shown, body 140 includes a medial portion 224 that is laterally offset from first and second ends 144 and 148, as shown. A lateral offset can accommodate a protruding or otherwise larger section of main tube 100. For example, in the embodiment shown, main tube 100 includes an isolation unit 228 configured to substantially seal an annulus in main tube 100 if a drill string is disposed in main tube 100. As a result, the outer diameter of main tube 100 in the region of isolation unit 228 is greater than the outer diameter of flanges 112a and 112b. To accommodate this larger dimension, medial portion 224 is configured to extend around isolation unit 228; for example, medial portion 224 of body 140 is laterally offset relative to its ends to permit body 140 (and thereby auxiliary line 128) to extend around isolation unit 228.
Isolation unit 228 may, for example, be similar in structure to a spherical or annular (or other type of) blowout preventer (BOP). In this embodiment, isolation unit 228 has an outer diameter of 59 inches and will, by itself, fit through a 60.5-inch rotary (sometimes referred to in the art as a 60-inch rotary) of a drilling rig. Other embodiments of isolation unit 228 can have a different outer diameter (e.g., between 50 and 59 inches, less than 50 inches, greater than 59 inches). For example, some rotaries have diameters greater than 60.5 inches (e.g., 75 inches). Isolation unit 228 is included as an example of a component that may be included in the present riser segment assemblies; other embodiment may not include an isolation unit and/or may include other types of devices (e.g., a rotating control device), other types of BOPs, and/or the like). Medial portion 224 of body 140 can be configured to accommodate the dimension of other types of devices as well. In other embodiment, body 140 may be axially aligned along its length (may not include a laterally offset portion).
While only one auxiliary line 128 is described in detail, it should be understood that, at least in the depicted embodiment, all of the plurality of auxiliary lines 128 are similar in construction, and differ only in the respective diameters of their tubing (e.g., removable bodies 140). For example, the plurality of auxiliary lines can include at least one booster line (e.g., having a relatively smaller diameter) and at least one choke/kill line (e.g., having a relatively larger diameter). In this embodiment, and as shown in detail in
In the embodiment shown, body 140c includes a third connector 152a configured to be connected to first connector 132a (e.g., without welding), and a fourth connector 156a configured to be connected to second connector 136a (e.g., without welding). Rather than forming a threaded union, each pair of connectors (132a and 152a, 136a and 156a) forms a joint that is similar to a telescoping joint (e.g., joint 192 described above). More particularly, in the embodiment shown, connectors 132a and 136a are female connectors that include an enlarged end with a recess configured to slidably receive male connectors 152a and 156a, respectively. In this embodiment, connectors 132a and 136a are coupled to flanges 112a and 112b in similar fashion to connectors 132 and 136 of assembly 18. In particular, conduit 134a extends from connector 132a to (e.g., and is welded to) a female fitting 256 sized to fit within the corresponding one of auxiliary holes 124 of flange 112a, and conduit 138a extends from connector 136a (e.g., and is welded to) a male fitting 264 sized to fit within the corresponding one of auxiliary holes 124 in and extend beyond flange 112b, as shown in
In the embodiment shown, body 140c includes a medial portion 224a that is laterally offset from first and second ends 144a and 148a, as shown. For example, in the embodiment shown, main tube 100a includes an isolation unit 228a configured to substantially seal an annulus in main tube if a drill string is disposed in the main tube, such that medial portion 224a is configured to extend around isolation unit 228a. Isolation unit 228a may, for example, be similar in structure to a spherical or annular (or other type of) blowout preventer (BOP). In this embodiment, isolation unit 228a has an outer diameter of 59 inches and will, by itself, fit through a 60.5-inch rotary of a drilling rig. As mentioned above for isolation unit 228, isolation unit 228a can have various other outer diameters. Isolation unit 228a is included as an example of a component that may be included in the present riser segment assemblies; other embodiment may not include an isolation unit and/or may include other types of devices (e.g., a rotating control device), other types of BOPs, and/or the like). In this embodiment, the outer diameter of isolation unit 228a is greater than the outer diameter of flanges 112a and 112b, such that the lateral offset of medial portion 224a of body 140c relative to its ends permits body 140c (and thereby auxiliary line 128a) to extend around isolation unit 228. In other embodiment, body 140 may be axially aligned along its length (may not include a laterally offset portion).
However, in some embodiments (such as the one shown), rather than auxiliary lines 128a extending entirely around isolation unit 228a, the housing (232a and 240a) of the isolation unit includes a passage 300 configured to receive an auxiliary line 128a within a maximum transverse dimension 304 (e.g., diameter in the depicted embodiment) of the isolation unit. More particularly, in the embodiment shown, the housing (232a and 240a) of the isolation unit includes a plurality of passages 300, each configured to receive an auxiliary line (128a) within the maximum outer transverse dimension of the isolation unit, and a plurality of auxiliary lines 128a each disposed within and extending through one of the plurality of passages 300. In the embodiment shown, passages 300 include insets on the housing (232a and 240a) that extend inwardly from an outer perimeter 308 of isolation unit 228a to define open channels (that are laterally open to the exterior of the isolation unit. In other embodiments, passages 300 may include channels with closed cross-sections (bores) that extend through the housing of the isolation unit but are not laterally open to the exterior of the isolation unit.
Some embodiments of the present methods include lowering assembly 18a through a rotary 272 of a drilling rig (e.g., with assembly 18a connected to other riser segments).
The above specification and examples provide a complete description of the structure and use of illustrative embodiments. Although certain embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. As such, the various illustrative embodiments of the devices are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and embodiments other than the one shown may include some or all of the features of the depicted embodiment. For example, components may be omitted or combined as a unitary structure, and/or connections may be substituted. Further, where appropriate, aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples having comparable or different properties and addressing the same or different problems. Similarly, it will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments.
The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) “means for” or “step for,” respectively.
This application is a continuation of U.S. Ser. No. 15/910,770, filed Mar. 2, 2018, which is a continuation of U.S. Ser. No. 15/596,781, filed May 16, 2017, which is a continuation of U.S. Ser. No. 14/888,894, filed Nov. 3, 2015, which is a national phase application under 35. U.S.C. § 371 of International Application No. PCT/US2014/0036317, filed May 1, 2014, which claims benefit of U.S. Provisional Patent Application No. 61/819,210, filed May 3, 2013; all of which applications are incorporated by reference in their entireties.
| Number | Name | Date | Kind |
|---|---|---|---|
| 3955621 | Webb | May 1976 | A |
| 4183562 | Watkins | Jan 1980 | A |
| 4210208 | Shanks | Jul 1980 | A |
| 4444401 | Roche et al. | Apr 1984 | A |
| 4987956 | Hansen | Jan 1991 | A |
| 7210531 | van Belkom | May 2007 | B2 |
| 7237623 | Hannegan | Jul 2007 | B2 |
| 7347455 | Taquino | Mar 2008 | B1 |
| 8127854 | Haheim | Mar 2012 | B2 |
| 8317234 | McKay | Nov 2012 | B2 |
| 8413724 | Carbaugh | Apr 2013 | B2 |
| 8528647 | Guesnon | Sep 2013 | B2 |
| 8746348 | Reed | Jun 2014 | B2 |
| 8783359 | Reed | Jul 2014 | B2 |
| 8960302 | Shilling et al. | Feb 2015 | B2 |
| 9074425 | Feasey | Jul 2015 | B2 |
| 9109420 | Tindle | Aug 2015 | B2 |
| 9121227 | Thommesen | Sep 2015 | B2 |
| 9428975 | Fraczek et al. | Aug 2016 | B2 |
| 9725966 | Tavner | Aug 2017 | B2 |
| 9765587 | Boulanger et al. | Sep 2017 | B2 |
| 9803443 | Tindle et al. | Oct 2017 | B2 |
| 9909379 | Fraczek | Mar 2018 | B2 |
| 9970247 | Fraczek et al. | May 2018 | B2 |
| 10012031 | Fraczek et al. | Jul 2018 | B2 |
| 10012044 | Leba et al. | Jul 2018 | B2 |
| 10294746 | Gilmore | May 2019 | B2 |
| 10392890 | Fraczek | Aug 2019 | B2 |
| 20020014340 | Johnson | Feb 2002 | A1 |
| 20080264644 | Sawtell | Oct 2008 | A1 |
| 20090260831 | Moksvold | Oct 2009 | A1 |
| 20100300699 | Papon | Dec 2010 | A1 |
| 20110017466 | Averbuch | Jan 2011 | A1 |
| 20110073315 | Guesnon et al. | Mar 2011 | A1 |
| 20110209876 | Reed et al. | Sep 2011 | A1 |
| 20110225789 | Darnell | Sep 2011 | A1 |
| 20110253445 | Hannegan et al. | Oct 2011 | A1 |
| 20120037377 | Walker | Feb 2012 | A1 |
| 20120055677 | Boyd | Mar 2012 | A1 |
| 20120132432 | Carbaugh et al. | May 2012 | A1 |
| 20120312544 | Tavner | Dec 2012 | A1 |
| 20130043036 | Kotrla et al. | Feb 2013 | A1 |
| 20130161021 | Makosey et al. | Jun 2013 | A1 |
| 20140193282 | Stave et al. | Jul 2014 | A1 |
| 20140209316 | Tindle et al. | Jul 2014 | A1 |
| 20140262313 | Gilmore et al. | Sep 2014 | A1 |
| 20150096759 | Gilmore | Apr 2015 | A1 |
| 20160032662 | Walker et al. | Feb 2016 | A1 |
| 20160076312 | Fraczek | Mar 2016 | A1 |
| 20160138352 | Leba et al. | May 2016 | A1 |
| 20170067295 | Gilmore et al. | Mar 2017 | A1 |
| 20180245416 | Fraczek et al. | Aug 2018 | A1 |
| Number | Date | Country |
|---|---|---|
| 2992166 | Mar 1916 | EP |
| WO 8602696 | May 1986 | WO |
| WO 2013024354 | Feb 2013 | WO |
| WO 2014151724 | Sep 2014 | WO |
| WO 2014179532 | Nov 2014 | WO |
| WO2014179538 | Nov 2014 | WO |
| Entry |
|---|
| International Search Report and Written Opinion issued in International Patent Application No. PCT/US2018/026513, dated Jun. 28, 2018. |
| International Search Report and Written Opinion issued in International Patent Application No. PCT/US2018/026518, dated Jul. 2, 2018. |
| Extended European Search Report issued in Application No. 14791006, dated Apr. 11, 2017. |
| Frink, “Managed pressure drilling—what's in a name?” Drilling Contractor, Mar./Apr. 2006, pp. 36-39. |
| International Search Report and Written Opinion issued in PCT/US2014/036317, dated Sep. 4, 2014. |
| Partial European Search Report issued in Application No. 14791006, dated Dec. 23, 2016. |
| Office Action Issued in Corresponding Canadian Patent Application No. 2,911,287, dated Jul. 8, 2019. |
| Number | Date | Country | |
|---|---|---|---|
| 20200182002 A1 | Jun 2020 | US |
| Number | Date | Country | |
|---|---|---|---|
| 61819210 | May 2013 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15910770 | Mar 2018 | US |
| Child | 16512761 | US | |
| Parent | 15596781 | May 2017 | US |
| Child | 15910770 | US | |
| Parent | 14888894 | US | |
| Child | 15596781 | US |
