Patent Application
20250137335
None
The present invention pertains to a fluid containment apparatus, (commonly referred to as a “mud bucket”) for preventing uncontrolled spray and/or spillage of fluids when joined sections of pipe are separated on a drilling rig. More particularly, the present invention pertains to a lightweight and compact hinge-less mud bucket that can be quickly, efficiently and safely positioned around connected pipe sections, and that selectively contains and collects fluids (such as, for example, drilling mud, completion fluids and/or additives) when adjacent pipe sections are separated.
Drilling rigs typically comprise a supportive rig floor, a derrick that extends in a substantially vertical direction above said rig floor, and a lifting device that can be raised and lowered within said derrick. Generally, such drilling rigs are positioned over a wellbore that extends into subterranean strata. During drilling operations, said drilling rig and associated equipment can be used to manipulate and move tubular goods (including, without limitation, drill pipe, casing and/or other tubular goods) into and out of a wellbore. For example, drill bits and/or other down hole equipment are typically conveyed into a wellbore and maneuvered within said wellbore using a tubular work string comprising a plurality of individual joints of drill pipe. Such individual joints are threadedly connected to one another in end-to-end relationship until a string having a desired length is formed.
Various fluids, commonly referred to as drilling mud and/or drilling fluids, are often pumped into a through-bore of said tubular goods during well drilling and/or completion operations and are then circulated back to the earth's surface. Additives and chemicals are frequently added to drilling mud in order to provide or adjust the various characteristics and/or performance of such drilling mud. Exposure to said drilling mud (with or without additives) can be harmful to rig personnel; drilling mud and/or additives can frequently cause allergic skin reactions and other health problems. Additionally, said drilling mud and additives can be environmentally hazardous and, in many cases, can be extremely expensive. As a result, it is generally desirable to contain said drilling fluids and to prevent said drilling fluids from spraying, splashing, spilling and/or otherwise contacting personnel and drilling rig equipment that is not part of the mud system.
When removing a string of pipe from a wellbore (such as, for example, in order to remove and change a drill bit or other equipment located at the bottom or distal end of the drill string)—a process commonly referred to as “tripping out of the well”—a threaded pipe string is removed from the well one or more sections at a time. During such operations, the upper end of the drill string is lifted within a drilling rig derrick until a threaded connection between two joints of drill pipe is positioned a desired distance above a rig floor-typically a distance wherein said threaded connection can be conveniently accessed by personnel working on a drill floor. Thereafter, the entire pipe string is suspended or hung in place at the rig floor using a device commonly known as “slips.”
After the slips have been set, the threaded connection positioned above the rig floor can then be “broken-out” or loosened by tongs or other similar means. Thereafter, the uppermost section(s) of pipe can be completely unscrewed (typically via rotation of said uppermost pipe section(s)), removed from the drill string and stored within the derrick or on a pipe rack. The process can be repeated numerous times until a desired length of pipe is removed from said wellbore and disconnected from said pipe string.
In many cases, some amount of drilling mud can remain in the central bore of at least some of the pipe that is lifted out of a well and suspended within the derrick. As a result, a significant volume of drilling mud contained within such pipe bore can leak out during separation of two adjacent pipe sections at a threaded pipe connection; depending on the height of the fluid column remaining in the upper pipe section, said fluid in said pipe bore can exert significant hydrostatic pressure at said threaded connection at or near the rig floor. The drilling mud can spray radially outward from the separated pipe sections (typically due to the hydrostatic fluid head from fluid contained in an upper pipe section), splash on personnel, getting into their eyes and/or coming into contact with their skin. Further, the drilling mud can also spill into the surrounding environment, causing pollution or contamination of said environment. Drilling mud can also spill or splash on a rig floor or other nearby rig surfaces thereby creating a slipping hazard to rig personnel.
Attempts have been made to control the spillage of drilling fluids during separation of a threaded connection using a device commonly referred to as “mud bucket.” Generally, such mud buckets comprise a substantially cylindrical-shaped container fabricated by splitting or cutting a length of a relatively large diameter pipe along a mid-plane extending through its longitudinal axis, thereby creating two opposing and substantially semi-cylindrical halves of roughly equal size. Said two halves are movably connected along one long side using at least one hinge assembly, and can include a latching or locking mechanism, typically opposite said hinge assembly.
During use, a conventional mud bucket is typically suspended (usually from a cable or other arrangement) a desired distance above a drilling rig floor, spread apart about said hinge(s) into an open position, and moved laterally into position toward the suspended pipe. Thereafter, the mud bucket is closed about said hinge(s), causing the leading edges of the mud bucket to converge around a portion of the pipe in order to enclose a threaded connection (as well as a portion of adjacent pipe sections above and below said threaded connection). In this position, the mud bucket can then be latched or locked in a closed configuration around said pipe. In most cases, a mud bucket is positioned and secured in this manner after mating threads of a threaded connection have been “broken-out”, but before said mating threads are completely disconnected and the adjoining pipe sections are separated, in order to ensure that any mud within the bore of the pipe remains contained until the mud bucket is secured around the pipe.
After the mud bucket has been positioned around the threaded connection and latched, the upper pipe section can be rotated to fully unscrew the male and female threaded connection members from each other. Thereafter, said upper pipe section can be axially lifted some relatively small distance in order to fully detach and separate it from the lower pipe section. With the mud bucket secured in place surrounding said threaded connection, any drilling fluid flowing out of the disconnected upper pipe section can be contained within an interior chamber formed by the mud bucket. The mud is generally permitted to evacuate said chamber through a drainage hose connected to one or both semi-cylindrical half members of the mud bucket and, eventually, into a mud tank or other storage reservoir. After said mud has fully drained from said mud bucket, the two opposing halves of the mud bucket can be spread apart, thereby allowing the uppermost pipe section to be removed from said mud bucket for further handling.
Conventional mud buckets can be simple mechanical devices that are operated by hand. Such conventional mud buckets can be large, bulky and heavy. Further, such conventional mud buckets can be difficult for personnel to maneuver and position, which can result in operational delays and injury risk. Such conventional mud buckets can also take up a great deal of space which can be problematic on many drilling rigs because available space can be at premium, especially on or around a drilling rig floor.
Perhaps most significantly, said conventional hinged mud buckets present a substantial risk to operating personnel when being closed around pipe. Hands, fingers and other body parts of such personnel can inadvertently be positioned between said opposing semi-cylindrical members. In such cases, any hands, fingers and other body parts that are caught between said opposing members (such as, for example, when closing a mud bucket) can be smashed, severed or otherwise severely damaged.
Thus, there is a need for a fluid containment apparatus that is lighter and more compact than conventional mud buckets, thereby making it easier to maneuver and operate, and also more convenient to store during periods of non-use. Said fluid containment apparatus should also be safer than conventional mud buckets, effectively eliminating the risk of hands, fingers and other body parts being inadvertently caught or pinched between opposing members as said members are closed together.
The fluid containment apparatus of the present invention generally comprises a housing member defining an upper end, a lower end and an inner chamber having a desired internal volume. A longitudinal keyway slot or opening is formed along the front of the housing member from said upper end to said lower end, and extends from the external surface of said housing member into said inner chamber. A removable cap can be installed on the upper end of said housing member using mechanical fasteners or other temporary but secure attachment means. A base member (which, in a preferred embodiment comprises a sump tray) is disposed at said lower end.
A fluid containment door is moveably mounted relative to said housing member. In a preferred embodiment, said fluid containment door is hingedly mounted to said housing member and can alternate between a first open position and a second closed position. When said fluid containment door is in an open position, said longitudinal keyway slot or opening is fully open and is not obstructed, and a pathway is established from outside said housing member through said keyway opening into said inner chamber. However, when said fluid containment door is in a closed position, said at least one fluid containment door blocks said opening, thereby effectively sealing said keyway opening of said housing member.
A latching assembly can be used to selectively secure or lock said fluid containment door in a closed position. Said latching assembly can be manually operated. Alternatively, said latching assembly can be actuated using a fluid-powered actuator or other device. Elastomeric seal members selectively provide a fluid pressure seal between interfacing surfaces of said fluid containment door and said housing when said fluid containment door is in a closed position.
Further, first and second opposing elastomeric seal members provide a fluid pressure seal against the outer surface of a tubular member partially disposed within said inner chamber of said fluid containment apparatus. In a preferred embodiment, said first and second opposing elastomeric seal members comprise a stationary seal member and a movable seal member that cooperate to form a fluid pressure seal against the external surface of a pipe section (around substantially the entire circumference thereof) disposed within the inner chamber of said fluid containment apparatus, and can automatically adjust to seal against pipes having different outer diameters.
At least one optional baffle member is disposed along the inner surface(s) of said housing. Said at least one baffle member(s) acts to block upward flow and dissipate released fluid pressure when opposing pipe sections are separated. Further, any fluids released within the inner chamber of said fluid containment apparatus that splash on said baffle member(s) can be directed or run off toward at least one drain, but will not be released outside of said fluid containment apparatus when said fluid containment door is in the open position.
In operation, said fluid containment apparatus of the present invention is typically suspended or hung within a drilling rig derrick in relatively close proximity to a threaded pipe connection with said fluid containment door in a first open position. With said fluid containment door open, said keyway opening is unobstructed and provides access to said inner chamber of said fluid containment apparatus.
In this configuration, said fluid containment apparatus can be quickly and efficiently positioned about a threaded pipe connection existing between adjacent joined pipe sections, typically positioned a desired distance above a rig floor. More specifically, said pipe sections pass through said unobstructed keyway opening until said pipe sections are received within the inner chamber of the fluid containment apparatus. Further, with said door in an open position, the supply of operating power fluid (air or hydraulic oil) to an actuation device can be selectively blocked, thereby preventing functioning of device.
After the fluid containment apparatus has been positioned about a threaded connection existing between adjacent pipe sections (typically positioned a desired distance above a rig floor), the door can be closed and latched or otherwise secured in a closed position, thereby triggering a switch and permitting supply of operating power fluid (air or hydraulic oil) to an actuation device. With said door closed, personnel cannot inadvertently place hands, fingers or other body parts in said keyway opening of said housing member and have them pinched, crushed or otherwise damaged.
In this configuration, said housing member, cap, fluid containment door and any seal members cooperate to form axially aligned apertures that surround and seal against the outer surface of pipe sections contained therein. The fluid containment apparatus effectively surrounds the threaded pipe connection, which is disposed within the inner chamber thereof. Said adjoining sections of pipe can be separated (typically by lifting of an upper pipe section away from a lower pipe section); during such separation, the fluid containment apparatus contains, diverts and collects drilling fluid in the inner chamber thereof, thereby preventing drilling fluid from uncontrolled spraying, splashing or spilling on a nearby rig floor, personnel and/or surrounding environment.
Thereafter, with said door still in a closed position and the pipe sections separated, fluid can be permitted to evacuate into the inner chamber of the housing. Importantly, the volume of said inner chamber can be selectively adjusted by varying the dimensions of the housing; said volume can beneficially predetermined to exceed the fluid volume of the upper pipe section that is draining into said housing. As a result, said inner chamber can never fill or overflow with drilling fluid. Further, after said upper pipe section has fully evacuated, it can be removed from said fluid containment apparatus by pulling it through the top of the apparatus, even though some amount of fluid may still be contained in said inner chamber. After all of the fluid has been drained from said inner chamber, said pipe seals can be released and said door can be opened. With said door open, said fluid containment apparatus can be quickly and efficiently moved away from the separated pipe section to a stand-by position. Thereafter, the process can be repeated.
The foregoing summary, as well as any detailed description of the preferred embodiments, is better understood when read in conjunction with the drawings and figures contained herein. For the purpose of illustrating the invention, the drawings and figures show certain preferred embodiments. It is understood, however, that the invention is not limited to the specific methods and devices disclosed in such drawings or figures.
Door 20 can further comprise door handle 28 and at least one latch bracket 22. Although the placement and configuration of said door handle 28 may vary, it is to be observed that door handle 28 provides a convenient and accessible handle for gripping said door 20 by personnel. Similarly, handle members 18 are disposed on said first side wall member 14 and second side wall member 15 of said housing member 10 and also provide convenient and accessible handles for gripping said fluid containment apparatus 100 by personnel. Shackles 43 can be provided for attachment to slings or other lifting means used to suspend said fluid containment apparatus 100.
In the embodiment depicted in
In a preferred embodiment, housing 10 of fluid containment apparatus 100 is depicted with four interconnected wall members defining a substantially rectangular cross-section and cooperating to form an enclosure having an inner chamber. However, it is to be observed that said housing can have any number of other shapes, configurations and/or side walls without departing from the scope of the present invention. For example, said housing 10 could have more or less than four side walls, and could embody a hexagonal, octagonal or other cross-sectional shape.
Front wall member 13, first side wall member 14, second side wall member 15, rear wall member 16, upper lid member 40 and base 50 cooperate to form an enclosure defining an inner chamber 9. Elongated vertical keyway opening 2 is formed along the length of front wall member 13 from top 11 to bottom 12, and extends from the external surface of said housing 10 into said inner chamber 9. Lower keyway slot 51 is formed in base member 50, while an aligned upper keyway slot 41 is also formed in upper lid member 40. Lower keyway slot 51 is also depicted in
Still referring to
A linear actuator (such as a pneumatic cylinder) having an extendable lower pipe seal cylinder rod 62 is contained within lower pipe seal cylinder housing 61. Said lower pipe seal cylinder rod 62 is attached to bracket 65a which, in turn, is attached to said movable lower pipe seal carrier 65. Lower pipe seal carrier 65 is also attached to lower pipe seal motion guide 63 that is slidably received on axially aligned lower pipe seal motion guide rod 64.
Stationary upper pipe seal member 90 is disposed on upper lid member 40. Said stationary upper seal member 90 is constructed of rubber or elastomeric material; in a preferred embodiment, said stationary upper seal member 90 comprises compressible oil resistant closed-cell foam material. Movable upper pipe seal member 80 is disposed on movable upper pipe seal carrier 85. Movable upper pipe seal member 60 is also beneficially constructed of rubber or elastomeric material, such as compressible oil resistant closed-cell foam material.
A linear actuator (such as a pneumatic cylinder) having an extendable upper pipe seal cylinder rod 82 is contained within upper pipe seal cylinder housing 81. Said upper pipe seal cylinder rod 82 is attached to bracket 85a which, in turn, is attached to said movable upper pipe seal carrier 85. Upper pipe seal carrier 85 is also attached to upper pipe seal motion guide 83 that is slidably received on axially aligned upper pipe seal motion guide rod 84.
Stationary lower pipe seal member 70 is disposed on said base member 50. Said stationary lower pipe seal member 70 generally comprises a concave surface 70a that is configured to receive said pipe section 301, and can be removably secured in place on said base member 50 using lower stationary pipe seal member mounting bolts 76. Said stationary lower seal member 70 can beneficially comprise compressible oil resistant closed-cell foam material.
A movable lower pipe seal member 60 is disposed on movable lower pipe seal carrier 65. Said movable lower pipe seal member 60 generally comprises a concave surface 60a that is oriented in opposing relationship to surface 70a of stationary lower pipe seal member 70, and is configured to receive said pipe section 301. Movable lower pipe seal member 60 can be removably secured in place on said movable lower pipe seal carrier 65 using lower movable pipe seal member mounting bolts 66. Said movable lower pipe seal member 60 is also beneficially constructed of compressible oil resistant closed-cell foam material.
A linear actuator (such as a pneumatic cylinder) having an extendable lower pipe seal cylinder rod 62 is contained within lower pipe seal cylinder housing 61. Said lower pipe seal cylinder rod 62 is attached to bracket 65a which, in turn, is attached to said movable lower pipe seal carrier 65. Lower pipe seal carrier 65 is also attached to lower pipe seal motion guide 63 that is slidably received on axially aligned lower pipe seal motion guide rod 64.
Said extendable lower pipe seal cylinder rod 62 can be selectively extended or retracted, and can be powered using air supplied from a rig or other source via air supply conduit 210 connected to air inlet 53. Extension or retraction of lower pipe seal cylinder rod 62 imparts force upon bracket 65a and attached movable lower pipe seal carrier 65, causing said lower pipe seal carrier 65 (and attached movable lower pipe seal member 60) to move along a path that is oriented substantially parallel to axially aligned lower pipe seal motion guide 63 and lower pipe seal motion guide rod 64, and also generally perpendicular to the orientation of pathway 3.
A movable upper pipe seal member 80 is disposed on movable upper pipe seal carrier 85. Said movable upper pipe seal member 80 generally comprises a concave surface 80a that is oriented in opposing relationship to concave surface 90a of stationary upper pipe seal member 90, and is configured to receive said pipe section 302. Movable upper pipe seal member 80 can be removably secured in place on said movable upper pipe seal carrier 85 using upper movable pipe seal member mounting bolts 86. Said movable upper pipe seal member 80 is constructed of compressible oil resistant closed-cell foam material.
A linear actuator (such as a pneumatic cylinder) having an extendable upper pipe seal cylinder rod 82 is contained within upper pipe seal cylinder housing 81. Said upper pipe seal cylinder rod 82 is attached to bracket 85a which, in turn, is attached to said movable upper pipe seal carrier 85. Upper pipe seal carrier 85 is also attached to upper pipe seal motion guide 83 that is slidably received on axially aligned upper pipe seal motion guide rod 84.
Said extendable upper pipe seal cylinder rod 82 can be selectively extended or retracted. Such extension or retraction imparts force upon bracket 85a and attached movable upper pipe seal carrier 85, causing said upper pipe seal carrier 85 (and attached movable upper pipe seal member 80) to move along a path that is oriented substantially parallel to axially aligned upper pipe seal motion guide 83 and upper pipe seal motion guide rod 84, and also generally perpendicular to the orientation of pathway 3.
Still referring to
In a closed configuration depicted in
In a closed configuration depicted in
Referring back to
As said larger tool joint threaded connection 302a continues to move upward, said tool joint threaded connection 302a applies upward force to said stationary upper pipe seal member 90 and movable upper pipe seal member 80. Said upward force causes said stationary upper pipe seal member 90 to rotate about stationary upper seal hinge 98 and movable upper pipe seal member 80 to rotate about movable upper seal hinge 88. When this occurs, said stationary upper pipe seal member 90 and movable upper pipe seal member 80 move out of contact with said upper lid member 40, thereby permitting upper pipe section 302 to be removed from fluid containment apparatus 100 through upper keyway slot 41. It is to be noted that said upper pipe section 302 can be removed from fluid containment apparatus 100 in this manner even if some amount of drilling mud or other fluids remain within inner chamber 9 of housing 10.
In the embodiment depicted in
In operation, as depicted in
After said fluid containment apparatus 100 is positioned about a threaded connection existing between adjacent pipe sections 301 and 302 (typically positioned a desired distance above a rig floor), said manual fluid containment door 20 can be closed. An operator (such as a roughneck on a drilling rig, for example) can use controller 52 to selectively latch door 20, while also shifting simultaneously shifting movable lower pipe seal carrier 65 and movable upper pipe seal carrier 85. In instances where excessive upward splashing of fluids is not expected, movement of upper pipe seal carrier 85 (and attached movable upper pipe seal member 80) can be selectively locked out or disengaged.
More specifically, referring to
In this configuration, said housing 10, upper lid 40, fluid containment door 20, base member 5, movable lower pipe seal carrier 65, movable upper pipe seal carrier 85, as well as closed upper opposing pipe seal members 80 and 90, and opposed lower pipe seal members 60 and 70, cooperate to surround the pipe sections contained therein. Put another way, fluid containment apparatus 100 effectively surrounds the threaded pipe connection formed between joined pipe sections 301 and 302, which is disposed within the inner chamber 9 thereof.
Said adjoining sections of pipe 301 and 302 can be separated (typically by lifting of an upper pipe section 302 away from a lower pipe section 301); during such separation, housing 10 of fluid containment apparatus 100 contains, diverts and collects drilling fluid in the inner chamber 9 thereof, thereby preventing drilling fluid from uncontrolled spraying, splashing or spilling on a nearby rig floor, personnel and/or surrounding environment. Said contained fluid can drain out of outlets port(s) 56, and said fluid can flow through attached hoses 220 or other conduits to a rig's active mud system or other collection location.
After said fluid drains from inner chamber 9 of fluid containment apparatus 100, an operator can function controller 52 in order to selectively retract fluid cylinder rods 62 and 82, thereby moving movable lower pipe seal carrier 65 (and attached movable lower pipe seal 60) and movable upper pipe seal carrier 85 (and attached movable upper pipe seal 80) away from joined pipe sections 301 and 301. Additionally, rod 35 shifts to a retracted configuration, causing latch finger hook(s) 32 to disengage against latch bracket rollers 23 of latch brackets 22 of door 20, thereby unlocking door 20. Said door 20 can be opened, and said fluid containment apparatus 100 can be moved away from said pipe.
Unlike said conventional hinged mud buckets, fluid containment apparatus 100 cannot be inadvertently or accidentally closed (including, on a body part of nearby personnel). Further, fluid containment apparatus 100 is significantly easier to maneuver and position, and contains more fluids, than conventional hinged mud buckets. When desired, upper pipe seal members 80 and 90, and lower pipe seal members 60 and 70 can be easily removed and selectively replaced with other seal member(s) having different concave surface dimensions for accommodating and sealing against pipe having different outer diameter(s). Further, when said door 20 is in an open position, a proximity switch can be utilized to ensure that operating power fluid supply (air or hydraulic oil) can be selectively blocked, thereby preventing inadvertent or unwanted functioning of fluid containment apparatus 100.
Importantly, the volume of said inner chamber 9 can be selectively adjusted by varying the dimensions of the housing 10 of fluid containment apparatus 100; said volume can beneficially predetermined to exceed the fluid volume of said upper pipe section 302 that will drain into inner chamber 9 of said housing 10. As a result, said inner chamber 9 can never fill or overflow with drilling fluid because its volume exceeds the fluid capacity of upper pipe section 302.
Further, after said upper pipe section 302 has been fully evacuated, it can be removed from said fluid containment apparatus by pulling it through the top of the apparatus as depicted in
After all of the fluid has been drained from said inner chamber 9, said pipe seals can be released and said door 20 can be opened. With said door 20 open, said fluid containment apparatus 100 can be quickly and efficiently moved away from the separated pipe section to a stand-by position.
Fluid containment apparatus 100 is lighter and more compact than conventional mud buckets, thereby making it easier to maneuver and operate, and also more convenient to store on a drilling rig during periods of non-use. Said fluid containment apparatus 100 is also much safer than conventional mud buckets, effectively eliminating the risk of hands, fingers and other body parts being inadvertently caught or pinched between opposing members as said members are closed together.
The above-described invention has a number of particular features that should preferably be employed in combination, although each is useful separately without departure from the scope of the invention. While the preferred embodiment of the present invention is shown and described herein, it will be understood that the invention may be embodied otherwise than herein specifically illustrated or described, and that certain changes in form and arrangement of parts and the specific manner of practicing the invention may be made within the underlying idea or principles of the invention.
This application claims priority of U.S. provisional patent application Ser. No. 63/595,146, filed Nov. 1, 2023, incorporated by reference herein for all purposes
| Number | Date | Country | |
|---|---|---|---|
| 63595146 | Nov 2023 | US |
