MULTILINE RISER BIG BORE CONNECTOR

BACKGROUND

In offshore drilling operations, a floating structure, such as a platform or vessel, may be stationed at water level above a well location at the sea floor. A blowout preventor (BOP) stack may be installed at the well head, which may be used to control fluid flow from the well. A drill string is extended from the floating structure to the well location to drill a well into a formation below the sea floor. During drilling, drilling fluid, also referred to as “drilling mud” or simply “mud,” is used to facilitate drilling boreholes into the earth, and may be circulated through the drill string, through the well being drilled, and returned to the surface. Offshore drilling systems may be configured differently, depending on the drilling location and other operational parameters, to circulate drilling fluid through the drilling system using different components and component arrangements.

In many offshore drilling systems, a drill string is run through a riser (in a coaxial configuration) to extend from the floating structure to the well. In such systems, drilling fluid may be pumped through the drill string into the well and returned around the drill string through the riser. In some drilling systems, referred to as open water drilling, a drill string and riser may be extended from the floating structure to the well in a spaced apart, non-coaxial configuration. In such configurations, the drilling fluid return annulus through the well may be fluidly connected to the riser via one or more pipe and/or hose connections. Drilling fluid may then be pumped through the drill string into the well and returned through the riser.

SUMMARY

This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

In one aspect, embodiments disclosed herein relate generally to systems and methods that utilize a connector, as described herein, to connect a riser to a BOP stack.

In another aspect, embodiments disclosed herein relate generally to systems and methods that utilize a connector with multiple bores machined into a cylindrical forging to form a fluid connection to a mating female receptacle on a different assembly without any existing structural connection.

In another aspect, embodiments disclosed herein relate generally to systems and methods that utilize a system to connect one or more flow lines. In some embodiments, the system includes a connector housing and a connector. The connector housing may comprise a first connection passage formed through a wall of the connector housing. The connector may be disposed withing the connector housing. A first annular flow path connection may be formed between the connector housing and the connector. The first housing annular flow path connection may be formed by a first housing annular flow path connection groove. The first housing annular flow path connection groove may be formed in an outer side surface of the connector. Alternatively, the first annular flow path connection may be formed by a combination of the first housing annular flow path connection groove axially aligned with the first connector annular flow path connection groove. The first connection passage through the connector housing may intersect with the first annular flow path connection.

In another aspect, embodiments disclosed herein relate generally to methods for connecting a riser to a BOP stack that includes providing a connector housing connected to the BOP stack, the connector housing comprising a first connection passage formed through a wall of the connector housing. The method further includes connecting the riser to a connector via a riser connection. The connector comprises a first bore formed through a body of the connector. The method further includes inserting the connector into the connector housing. Once the connector is inserted into the connector housing, a first annular flow path connection is formed between the connector housing and the connector by a first housing annular flow path connection groove. The first housing annular flow path connection groove may be formed in an inner surface of the connector housing. A first connector annular flow path connection groove may be formed in an outer side surface of the connector, or a combination of the first housing annular flow path connection groove axially aligned with the first connector annular flow path connection groove. The first connection passage through the connector housing may intersect with the first annular flow path connection. The first bore may be in fluid communication with the first annular flow path connection.

In yet another aspect, embodiments disclosed herein relate to a system for connecting one or more flow lines, the system including a connector housing having at least one inner guide ledge formed on a connector housing inner surface, the at least one inner guide ledge including a slot, and a first connection passage formed through a wall of the connector housing. The system also includes a connector having a connector protrusion, where the connector protrusion is fitted within the slot to rotationally fix the connector within the connector housing and a first annular flow path connection formed between the connector housing and the connector, where the first annular flow path connection is formed by a first housing annular flow path connection groove formed in an inner surface of the connector housing, a first connector annular flow path connection groove formed in an outer side surface of the connector, or a combination of the first housing annular flow path connection groove axially aligned with the first connector annular flow path connection groove and where the first connection passage through the connector housing intersects with the first annular flow path connection.

In yet another aspect, embodiments disclosed herein relate to a method including providing a connector housing connected to a BOP stack, the connector housing having at least one inner guide ledge formed on a connector housing inner surface and a first connection passage formed through a wall of the connector housing. The method also includes connecting the riser to a connector via a riser connection, where the connector includes a connector protrusion around an outer side surface of the connector and a first bore formed through a body of the connector. The method further includes inserting the connector into the connector housing, including contacting the connector protrusion to the at least one inner guide ledge and guiding the connector protrusion along the at least one inner guide ledge to rotationally align the connector within the connector housing as the connector is inserted into the connector housing until the connector is in a fixed position within the connector housing, where, when the connector is in the fixed position a first annular flow path connection is formed between the connector housing and the connector by a first housing annular flow path connection groove formed in an inner surface of the connector housing, a first connector annular flow path connection groove formed in an outer side surface of the connector, or a combination of the first housing annular flow path connection groove axially aligned with the first connector annular flow path connection groove, the first connection passage through the connector housing intersects with the first annular flow path connection, and the first bore is in fluid communication with the first annular flow path connection.

Other aspects and advantages of the claimed subject matter will be apparent from the following description and the appended claims.

BRIEF DESCRIPTION OF DRAWINGS

Specific embodiments of the disclosed technology will now be described in detail with reference to the accompanying figures. Like elements in the various figures are denoted by like reference numerals for consistency. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not necessarily drawn to scale, and some of these elements may be arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn are not necessarily intended to convey any information regarding the actual shape of the particular elements and have been solely selected for ease of recognition in the drawing.

FIG. 1 shows a connector according to embodiments of the present disclosure.

FIG. 2 shows a connector housing according to embodiments of the present disclosure.

FIG. 3 shows a cross-sectional view of a connector connected to a connector housing according to embodiments of the present disclosure.

FIG. 4 shows an open water drilling system according to embodiments of the present disclosure.

FIG. 5 shows a BOP stack having a connector assembly assembled thereto according to embodiments of the present disclosure.

FIGS. 6 and 7 show a connect/disconnect sequence according to embodiments of the present disclosure.

FIGS. 8A-B show a connector according to embodiments of the present disclosure.

FIGS. 9A-B show a connector housing according to embodiments of the present disclosure.

FIG. 10 shows a cross-sectional view of a connector connected to a connector housing according to embodiments of the present disclosure.

FIG. 11-12 show different views of a system including a connection between a connector housing and a connector according to embodiments of the present disclosure.

FIGS. 13A-G show a connect sequence according to embodiments of the present disclosure.

DETAILED DESCRIPTION

Embodiments of the present disclosure are described below in detail with reference to the accompanying figures. In the following detailed description, numerous specific details are set forth in order to provide a more thorough understanding of the claimed subject matter. However, it will be apparent to one having ordinary skill in the art that the embodiments described may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.

Embodiments of the present disclosure relate generally to methods and equipment for connecting one or more flow lines using a single connector. For example, connectors disclosed herein may include a body having multiple bores machined therethrough, which may be fluidly connected to annular flow path connections formed between the connector and a connector housing when the connector is inserted into the connector housing.

A connector housing may have a female shape that mates with a male shape of the connector body, such that the connector housing may act as a receptacle to receive the connector. According to embodiments of the present disclosure, a connector housing may be assembled to various types and configurations of structures, thereby allowing connection on different types of assemblies. For example, connector housings according to embodiments of the present disclosure may be mounted to different types and configurations of BOP stacks without pre-formed structural connections. In such manner, connector housings may be attached to various structures (e.g., using bolts, welding, or other post manufacturing attachment techniques) to allow a connector, as disclosed herein, to fluidly connect to different assemblies. In some embodiments, a connector housing may be integrally formed in a structure or connected to a structure during manufacturing of the structure.

FIGS. 1-3 collectively show an example of a connector (100), a connector housing (136), and connection between the connector (100) and connector housing (136) according to embodiments of the present disclosure. The connector (100) may have a generally cylindrical body (112) that may be forged from a metal or metal composite and one or more bores machined or otherwise formed through the body (112). In the embodiment shown, multiple bores having different bore diameters are formed through the body (112), including a first bore (146) having a first diameter, second bores (144) having a second diameter, and third bores having a third diameter. However, other combinations and sizes of bore(s) may be formed through a connector (100).

The bore(s) may open at one end on a top (108) of the connector (100) and may open at an opposite end around the body (112) of the connector (100). For example, as shown in FIG. 1, the third bores may open at third bore inlets (114) around the body (112) of the connector (100) and at third bore outlets (106) at the top (108) of the connector (100). Similarly, the second bores (144) may open at second bore inlets around the body (112) of the connector (100) and at second bore outlets (104) at the top (108) of the connector (100), and the first bore (146) may open at a first bore inlet (118) around the body (112) of the connector (100) and at a first bore outlet (102) at the top (108) of the connector (100). The openings to the bores through the connector (100) are referred to herein as “inlet” and “outlet” merely for distinction between the different openings. Depending on the direction of fluid flow through the connector bores, the openings may act as either an inlet or an outlet. Additionally, a bore may extend from a single opening at the top (108) of the connector (100) to a single opening around the body (112) of the connector (100) (e.g., as best shown in FIG. 3), or a bore may extend from a single opening at the top (108) of the connector (100) and branch to two or more openings around the body (112) of the connector (100) (or vice versa).

A connector housing (136) may be configured to receive and mate with a connector (100) to form fluid connections with the bore(s) formed through the connector (100). According to embodiments of the present disclosure, a connector housing (136) may have a generally tubular shape. Connector housing (136) may be attached to other structures (124), such as subsea drilling equipment, using bolts (126), welding, clamps, or other fastening elements. In some embodiments, a guide funnel (122) may be attached to a top end of the connector housing, which may be used to guide a connector (100) into the connector housing (136).

According to embodiments of the present disclosure, a connector housing (136) may have one or more annular flow path connections that may fluidly connect with one or more bore openings formed around a side of a connector body (112). The annular flow path connections may be formed as grooves around an inner surface of the connector housing (where the inner diameter of the annular flow path connection(s) is greater than the inner diameter of the connector housing inner surface).

For example, as shown in FIG. 2, a connector housing (136) may have a first housing annular flow path connection groove (140) formed around the inner surface of the connector housing at a first axial position, second annular flow path connection grooves (132) formed at different axial positions around the inner surface of the connector housing, and third annular flow path connection grooves (128) formed at different axial positions around the inner surface of the connector housing. Seals (or alternatively, sealing surfaces) (134) extending around the entire inner surface diameter of the connector housing (136) may be provided axially between annular flow path connection grooves to separate and seal the annular flow path connections. For example, seals or sealing surfaces (134) may have an inner diameter less than the inner diameters of adjacent annular flow path connection grooves, where the inner diameter of the seal or sealing surface (134) may seal against a side surface of a connector body when the connector (100) is inserted into the connector housing (136).

In some embodiments, in addition to or alternative to annular flow path connection(s) being formed by grooves around an inner surface of the connector housing (136), annular flow path connection(s) may be formed by grooves formed around the side surface of the connector body (112). For example, as shown in FIG. 1, groove(s) may extend circumferentially around the entire perimeter of the connector body (112) side surface, where the diameter of the body (112) at the annular flow path connection groove(s) (116) are less than the diameter of the body (112) outer side surface. In embodiments where annular flow path connection grooves (116) are formed in both the connector housing inner surface and the connector body (112) side surface, the connector (100) and connector housing (136) may be designed to have corresponding annular flow path connection grooves (e.g., 116, 132, 128, 140) axially align to provide an annular flow path connection between the connector (100) and connector housing (136) when assembled together.

Passages (or alternatively, fluid connection passages) through the connector housing wall (139) may be formed to provide fluid access to each annular flow path connection. For example, as shown, a first connection passage (142) may be formed through the connector housing wall (139) and intersect with the first annular flow path connection (152); second connection passages (138) may be formed through the connector housing wall (139) and intersect with each of the second annular flow path connections (150); and third connection passages (130) may be formed through the connector housing wall (139) and intersect with each of the third annular flow path connections (148). Flanges or other pipe connections to the connection passages may be provided around the outer surface of the connector housing (136) to fluidly connect the annular flow path connections with piping, hosing, or other flow paths of different equipment.

As shown in FIG. 3, when a connector (100) is inserted into the connector housing (136), bore openings around the side of the connector body (112) may be axially aligned with annular flow path connections formed in the connector housing (136). In such manner, fluid may flow through connection passage(s) formed through the connector housing wall (139), through annular flow path connections formed between the connector housing (136) and connector (100), and through fluidly connected bores formed through the connector body (112).

According to embodiments of the present disclosure, bores may have a right turn (or near 90-degree turn) to extend from the top (108) of the connector (100) to a side of the body (112) of the connector (100). Such configuration may reduce pressure end load commonly associated with large bore (e.g., bores having diameters of about 5⅛ inches or more) connections, thereby reducing the required fixturing. For example, according to embodiments of the present disclosure, a first bore (146) may be formed through a connector (100) to provide a drilling fluid return path and may have a large bore diameter of sufficient size to carry the returning drilling fluid, e.g., a diameter of 7 inches or more. Additionally, connector (100) and bore geometry disclosed herein and shown in the figures may allow for scalable and configurable designs based on end-user needs and applications.

According to embodiments of the present disclosure, connectors (100) and connector housings (136) disclosed herein may be used for connections in BOP stacks and mechanical controls, risers, and any fluid connections. In some embodiments, connectors (100) and connector housings (136) according to embodiments of the present disclosure may be used to connect a riser to a BOP stack.

For example, referring collectively to FIGS. 4-7, systems and methods according to embodiments of the present disclosure may include using a connector and connector housing assembly (e.g., as shown in FIGS. 1-3) to connect a riser (156) to a BOP stack (162).

A BOP stack (162) may be provided at a well head on the sea floor. A floating structure (154) (e.g., a floating platform, vessel, or semi-submersible) may be stationed at the sea surface generally above the well. A drill string (158) may be extended from the floating structure (154), through the BOP stack (162), and into the well to drill the well. A return line (164) may be connected between a fluid outlet (174) to the well and a connector assembly (101) (e.g., as shown in FIG. 3 including a connected connector (100) and connector housing (136)). A riser connection (160) (e.g., a flexible hose) may connect the connector assembly to a riser (156), and the riser (156) may extend to the floating structure (154).

During drilling operations, drilling fluid may be pumped through the drill string (158) to the bottom of the well to aid in drilling. When the drilling fluid exits the bottom of the drill string (158) (e.g., through a drill bit or other bottom hole assembly tool), the drilling fluid may return to the top of the well through a well annulus formed between the drill string (158) and well wall. The returning drilling fluid may then be directed out a fluid outlet (174), through the return line (164) connection, through the connector (100) assembly, through the riser connection (160), and back through the riser (156). In some embodiments, a pump (166) may be provided along the riser (156) to aid in pumping returning drilling fluid to the floating structure (154).

The connector assembly (101) may be provided on the BOP stack (162), for example, by first providing the connector housing (136) on the BOP stack (162). For example, the connector housing (136) may be attached to the BOP stack frame (168). In some embodiments, the connector housing (136) may be attached to an upper end of the BOP stack (162), which may provide more room for remote operated vehicles (ROVs) to help with assembly and/or more room for connections to the riser connection (160) and other equipment. With the connector housing (136) provided on the BOP stack (162), a connector (100) may be inserted (bottom end first) into a top end of the connector housing (136) and axially moved into the connector housing (136) until the connector (100) and connector housing (136) are mated and interface each other.

In some embodiments, a winching system may be used to pull the connector into the connector housing (136). For example, in some embodiments, a winch assembly (170) may be provided with a BOP stack (162). The stack mounted winching system may allow for an ROV to reel in any component that may present a large resistance greater than the ROV thruster capacity.

According to embodiments of the present disclosure, a stack mounted subsea winching system may be provided with the BOP proximate a lower end of a connector housing (136). A connector (100) may be moved proximate the connector housing (136), for example, using an ROV. As best shown in FIG. 6, an upper end of a winch assembly (170) may be connected to a bottom end of the connector, e.g., using one or more latches (120) as shown in FIGS. 1 and 7. Using a connected hydraulic piston (172), the winch (176) may be connected to a winch housing (178) and may pull the connector (100) into the connector housing (136) until the bore openings in the side of the connector (100) are axially aligned with the annular flow path connections between the connector (100) and connector housing (136).

To disconnect the connector (100) from the connector housing (136), the winch assembly (170) may be released from the connector (100), e.g., by releasing the winch latches (120). In some embodiments, a buoyancy assisted disconnect feature may be provided, which requires a minimal amount of force to break the connection, in most configurations. To achieve a buoyancy assisted disconnect feature, one or more buoyancy modules (169) may be attached to the top of the connector (100). A buoyancy module (169) may be formed from a foam (e.g., polystyrene foam), where the foam composition may be designed to provide a selected density. Other configurations may require additional intervention to break a connection (e.g., using an ROV, breakaway, rig controlled, etc.).

In some embodiments, multiple bores formed through a connector (100) may be used to provide multiple flow paths for different types of fluids. For example, referring to FIGS. 1-3, a first bore (146) (having a large diameter) may be used to form part of a drilling fluid return, where drilling fluid returning from the well may be directed from the well to a riser (156) through the first bore (146). The second bores (144) may be used to form part of different choke lines (having choke fluid flowing therethrough), and the third bores may be used to form part of different hydraulic lines (having hydraulic fluid flowing therethrough). As mentioned above, the bores through the connector (100) may have different diameters, which may be used to accommodate different fluids and for different applications (e.g., to form hydraulic lines or choke lines). Accordingly, in some embodiments, the annular flow path connections formed between the connector (100) and connector housing (136) may likewise have different sizes to accommodate different fluids.

In some embodiments, a riser connection (160) may include a bundle of hoses, where each hose may be connected at the top (108) of the connector (100) to fluidly connect with the bores formed through the connector (100). For example, in the embodiment shown in FIG. 1, five hoses may be connected at the top (108) of the connector (100) (e.g., using API connections) to fluidly connect each hose to a bore opening. In one or more embodiments, a bore opening may be a flanged opening or other fluid connection-type opening to provide connections to hoses in a riser connection. A riser connection (160) may be connected to the top (108) of the connector (100) between tow strap mounts (110), which may be connected to a towing system for helping to raise and lower the connector (100) in a connector housing (136). For example, in some embodiments, a riser connection (160) may be connected to a top (108) of a connector (100). Tow strap mounts (110) of the connector (100) may then be connected to a towing system via tow lines, which may be used to relieve tension on the line as the connector (100) is inserted into a connector housing (136). In some embodiments, tow strap mounts (110) may enable electrical connectors to be tied into the disconnect sequence of the connector (100).

Connector assemblies according to embodiments of the present disclosure may provide at least one of the following advantages over previously used or conventional riser connections. Conventional connections typically require an external structure to aid the alignment process and/or the mating assemblies have to be a part of the same external structure. Conventional connections typically may only be used for small bore applications (<5⅛″). Conventional connections do not utilize a buoyancy assisted disconnect or winch assisted connection. Additionally, conventional connections do not incorporate electrical connector disconnect features or other technique for reducing tension during connection.

FIGS. 8A-B, 9A-B, and 10 collectively show another example of a connector (800), a connector housing (902), and a connector assembly (101) having the connector (800) connected within the connector housing (902) according to embodiments of the present disclosure. The connector (800) may have a generally cylindrical body (112) that may be forged from a metal or metal composite and one or more bores machined or otherwise formed through the body (112). In the embodiment shown, multiple bores having different bore diameters are formed through the body (112), including a first bore (146) having a first diameter, second bores (144) having a second diameter, and third bores having a third diameter. However, other combinations and sizes of bore(s) may be formed through a connector (800).

The bore(s) may open at one end on a top (802) of the connector (800) and may open at an opposite end around the body (112) of the connector (800). For example, as shown in FIG. 8A, the third bores may open at third bore inlets (114) around the side of the body (112) of the connector (800) and at third bore outlets (106) at the top (108) of the connector (800). Similarly, the second bores (144) may open at second bore inlets around the side of the body (112) of the connector (800) and at second bore outlets (104) at the top (802) of the connector (800), and the first bore (146) may open at a first bore inlet (118) around the side of the body (112) of the connector (800) and at a first bore outlet (102) at the top (802) of the connector (800). The openings to the bores through the connector (800) are referred to herein as “inlet” and “outlet” merely for distinction between the different openings. Depending on the direction of fluid flow through the connector bores, the openings may act as either an inlet or an outlet. Additionally, a bore may extend from a single opening at the top (802) of the connector (800) to a single opening around the side of the body (112) of the connector (800) (e.g., as best shown in FIG. 10), or a bore may extend from a single opening at the top (802) of the connector (800) and branch to two or more openings around the side of the body (112) of the connector (800) (or vice versa).

FIG. 8B shows a top-down view (850) of the top (802) of the connector (800). As shown in FIG. 8B, the top (802) of the connector (800) may include a connector plate (852) mounted to a top surface (854) of a structure, e.g., to a top surface of the connector housing (902) or a top surface of a structure to which the connector housing is mounted. In one or more embodiments, the connector plate (852) includes one or more cut-outs (856) aligned with an umbilical connection (858). A multiplexer connector may be mounted on a semi-rigid, spring loaded plate and placed within cut-out (856). The plate is able to float in a plane which is parallel to the connector plate (852), allowing for passive alignment with the umbilical connection (858) as the connector (800) engages the connector housing (902).

A connector housing (902) may be configured to receive and mate with a connector (800) to form fluid connections with the bore(s) formed through the connector (800). According to embodiments of the present disclosure, a connector housing (902) may have a generally tubular shape. Connector housings (902) may be attached to other structures (124), such as subsea drilling equipment, using bolts (126), welding, clamps, or other fastening elements. In some embodiments, a guide funnel (122) may be attached to a top end (e.g., 912 in FIG. 9B) of the connector housing (902), which may be used to guide a connector (800) into the connector housing (902).

According to embodiments of the present disclosure, one or more annular flow path connections may be formed between the connector housing (902) and connector (800), where each annular flow path connection may fluidly connect with one or more bore openings formed around a side of the connector body (112). The annular flow path connections may be formed as grooves around an inner surface of the connector housing (where the inner diameter of the annular flow path connection(s) is greater than the inner diameter of the connector housing inner surface) and/or as grooves around an outer side surface of the connector (800).

For example, as shown in FIG. 9A, a connector housing (902) may have a first housing annular flow path connection groove (140) formed around the inner surface of the connector housing at a first axial position, second annular flow path connection grooves (132) formed at different axial positions around the inner surface of the connector housing, and third annular flow path connection grooves (128) formed at different axial positions around the inner surface of the connector housing. Seals (or alternatively, sealing surfaces) (134) extending around the entire inner surface diameter of the connector housing (902) may be provided axially between annular flow path connection grooves to separate and seal the annular flow path connections. For example, seals or sealing surfaces (134) may have an inner diameter less than the inner diameters of adjacent annular flow path connection grooves, where the inner diameter of the seal or sealing surface (134) may seal against a side surface of a connector body when the connector (800) is inserted into the connector housing (902).

In some embodiments, in addition to or alternative to annular flow path connection(s) being formed by grooves around an inner surface of the connector housing (902), annular flow path connection(s) may be formed by grooves formed around the side surface of the connector body (112). For example, as shown in FIG. 8A, groove(s) may extend circumferentially around the entire perimeter of the connector body (112) side surface, where the diameter of the body (112) at the annular flow path connection groove(s) (116) are less than the diameter of the body (112) outer side surface. In embodiments where annular flow path connection grooves (116) are formed in both the connector housing inner surface and the connector body (112) side surface, the connector (100) and connector housing (902) may be designed to have corresponding annular flow path connection grooves (e.g., 116, 132, 128, 140) axially align to provide an annular flow path connection between the connector (800) and connector housing (902) when assembled together.

As best shown in FIG. 9B, at least one inner guide ledge (904) may be formed on the connector housing inner surface of the connector housing wall (908), which may be used to guide a connector (800) into a rotationally fixed position within the connector housing (902). For example, according to embodiments of the present disclosure, a connector (800) may have one or more connector protrusions (806) extending radially outward from its outer side surface. When the connector (800) is inserted into the connector housing (902), a connector protrusion (806) (or other locking feature) may contact an inner guide ledge (904) formed in the connector housing (902), where the inner guide ledge(s) may guide and/or rotationally fix the connector protrusion (806) as the connector is inserted axially into the connector housing (902). In one or more embodiments, the at least one inner guide ledge (904) may include a slot (910), which may receive and rotationally fix a connector protrusion (806) (or other locking feature) extending from the connector when the connector (800) is inserted into the connector housing (902). In some embodiments, such as shown in FIG. 9B, the slot (910) may have a generally rectangular shape that is formed within the connector housing inner surface (e.g., as a groove or depression).

In one or more embodiments, the at least one inner guide ledge (904) includes one or more sloped guide ledges, where a sloped guide ledge extends in an axially downward direction from an upper end of the connector housing (902) to terminate at a slot (910). In some embodiments, two or more sloped guide ledges may be formed around the connector housing inner surface, which may helically slope downward from an upper axial position (e.g., the connector housing's top) to a slot (910). Sloped guide ledge(s) may rotationally guide a connector's protrusion (806) into the slot (910) as the connector (800) is inserted axially downward into the connector housing (902), where once the protrusion (806) is guided into the slot (910), the slot (910) may rotationally fix the protrusion (806) (and thereby also the connector (800)) into a rotational position relative to the connector housing.

In some embodiments, inner guide ledge(s) (e.g., a slot or an inner guide ledge extending along a single horizontal plane) may stop the connector protrusion (806) (and thus also the connector (800)) from moving past an axial position relative to the connector housing (902). Such inner guide ledge(s) may be referred to as an axial stop ledge. A protrusion's axial location along the connector (800) and an axial stop ledge's axial location along the connector housing (902) may be selected to hold the connector (800) in a fixed axial position relative to the connector housing (902), e.g., which may be an axial position where openings to bores at the side of the connector are axially aligned with connection passages through the connector housing (902). In some embodiments, axial alignment between the connector (800) and connector housing (902) may be provided (in addition to or alternative to an axial stop ledge) by a connector plate (852) at the top of the connector (800), where the connector plate (852) may have a diameter large enough to be mounted to the top surface (854) of the structure to which the connector is being mounted, thereby preventing the connector plate from being inserted into the connector housing. In such embodiments, bore openings provided along an outer side surface of the connector may be axially located relative to the connector plate (852) such that the bore openings axially align with fluid connection passages in the connector housing (902) when the connector is inserted into the connector housing.

As shown in FIG. 10, when a connector (800) is inserted into the connector housing (902), bore openings around the side of the connector body (112) may be axially aligned with annular flow path connections formed in the connector housing (902). In such manner, fluid may flow through connection passage(s) formed through the connector housing wall (139), through annular flow path connections formed between the connector housing (902) and connector (800), and through fluidly connected bores formed through the connector body (112). Passages (or alternatively, fluid connection passages) through the connector housing wall (908) may be formed to provide fluid access to each annular flow path connection. For example, as best shown in FIG. 10, a first connection passage (906) may be formed through the connector housing wall (908) and intersect with the first annular flow path connection (152); second connection passages (138) may be formed through the connector housing wall (139) and intersect with each of the second annular flow path connections (150); and third connection passages (130) may be formed through the connector housing wall (139) and intersect with each of the third annular flow path connections (148). Flanges or other pipe connections to the connection passages may be provided around the outer surface of the connector housing (902) to fluidly connect the annular flow path connections with piping, hosing, or other flow paths of different equipment.

According to embodiments of the present disclosure, a first bore (146) may be formed through a connector (800) to provide a drilling fluid return path (e.g., via a fluid stab connection such as stab (1104) in FIG. 11) and may have a large bore diameter of sufficient size to carry the returning drilling fluid, e.g., a diameter of 7 inches or more. Additionally, connector (800) and bore geometry disclosed herein and shown in the figures may allow for scalable and configurable designs based on end-user needs and applications.

In some embodiments, multiple bores formed through a connector (800) may be used to provide multiple flow paths for different types of fluids. For example, referring to FIGS. 8A-B, 9A-B, and 10, a first bore (146) (having a large diameter) may be used to form part of a drilling fluid return, where drilling fluid returning from the well may be directed from the well to a riser (156) through the first bore (146). The second bores (144) may be used to form part of different choke lines (having choke fluid flowing therethrough), and the third bores may be used to form part of different hydraulic lines (having hydraulic fluid flowing therethrough). As mentioned above, the bores through the connector (800) may have different diameters, which may be used to accommodate different fluids and for different applications (e.g., to form hydraulic lines or choke lines). Accordingly, in some embodiments, the annular flow path connections formed between the connector (800) and connector housing (902) may likewise have different sizes to accommodate different fluids.

In some embodiments, one or more bores may have a right turn (or near 90-degree turn) to extend from the top (108) of the connector (800) to a side of the body (112) of the connector (800). Such configuration may reduce pressure end load commonly associated with large bore connections, thereby reducing the required fixturing.

In some embodiments, one or more bores may have a bend having an oblique angle. For example, as shown in FIG. 10, the first bore (146) includes a bend having an oblique angle, and the second bore (144) and third bore may each include a 90 degree bend. A bend having an oblique angle as part of the first bore (146) may allow for an opening (e.g., first bore inlet 118) to extend at the oblique angle and connect to other equipment, e.g., as will be described more in FIG. 11, a stab (1104) connected to a bottom end of the connector housing (902).

Referring now to FIGS. 4-5, collectively, systems and methods according to embodiments of the present disclosure may include using a connector (800) and connector housing (902) (e.g., as shown in FIGS. 8A-B, 9A-B, 10) as part of connector assembly (101) to connect a riser (156) to a BOP stack (162).

A BOP stack (162) may be provided at a well head on the sea floor. A floating structure (154) (e.g., a floating platform, vessel, or semi-submersible) may be stationed at the sea surface generally above the well. A drill string (158) may be extended from the floating structure (154), through the BOP stack (162), and into the well to drill the well. A return line (164) may be connected between a fluid outlet (174) to the well and a connector assembly (101) (e.g., as shown in FIG. 10 including a connected connector (800) and connector housing (902)). A riser connection (160) (e.g., a flexible hose) may connect the connector assembly to a riser (156), and the riser (156) may extend to the floating structure (154).

In some embodiments, a riser connection (160) may include a bundle of hoses, where each hose may be connected at the top (108) of the connector (800) to fluidly connect with the bores formed through the connector (800). For example, in the embodiment shown in FIG. 8A, five hoses may be connected at the top (802) of the connector (800) (e.g., using API connections) to fluidly connect each hose to a bore opening. In one or more embodiments, a bore opening may be a flanged opening or other fluid connection-type opening to provide connections to hoses in a riser connection. A riser connection (160) may be connected to the top (802) of the connector (800) between tow strap mounts (110), which may be connected to a towing system for helping to raise and lower the connector (800) in a connector housing (902). For example, in some embodiments, a riser connection (160) may be connected to a top (802) of a connector (800). Tow strap mounts (110) of the connector (800) may then be connected to a towing system via tow lines, which may be used to relieve tension on the line as the connector (800) is inserted into a connector housing (902). In some embodiments, tow strap mounts (110) may enable electrical connectors to be tied into the disconnect sequence of the connector (800).

During drilling operations, drilling fluid may be pumped through the drill string (158) to the bottom of the well to aid in drilling. When the drilling fluid exits the bottom of the drill string (158) (e.g., through a drill bit or other bottom hole assembly tool), the drilling fluid may return to the top of the well through a well annulus formed between the drill string (158) and well wall. The returning drilling fluid may then be directed out a fluid outlet (174), through the return line (164) connection, through the connector (800) assembly, through the riser connection (160), and back through the riser (156). In some embodiments, a pump (166) may be provided along the riser (156) to aid in pumping returning drilling fluid to the floating structure (154).

The connector assembly (101) may be provided on the BOP stack (162), for example, by first providing the connector housing (902) on the BOP stack (162). For example, the connector housing (902) may be attached to the BOP stack frame (168). In some embodiments, the connector housing (902) may be attached to an upper end of the BOP stack (162), where remote operated vehicles (ROVs) may help with assembly. With the connector housing (902) provided on the BOP stack (162), a connector (800) may be inserted (bottom end first) into a top end (912) of the connector housing (902) and axially moved into the connector housing (902) until the connector (800) and connector housing (902) are mated and interface each other.

In one or more embodiments, inner guide ledges (e.g., 904 in FIG. 9B) formed on the connector housing inner surface of the connector housing wall (908) may be used to guide axial rotation of the connector (800) within the connector housing (902). As described above, a slot (910) formed in the inner guide ledge (904) may receive and seat a connector protrusion (806) formed on the connector (800). In one or more embodiments, the connector protrusion (806) may be fitted within the slot (910) on the inner guide ledge (904) to rotationally fix the connector (800) within the connector housing (902).

According to embodiments of the present disclosure, a connector assembly may include a connector (800) rotationally and axially aligned within a connector housing (902) (e.g., using interlocking connector protrusion(s) and connector housing inner guide ledge(s)) such that bore opening(s) around the outer side surface of the connector (800) are aligned with fluid connection passages formed through the connector housing (902) and/or other connected equipment. For example, as shown in FIGS. 11-12, a stab (1104) assembly may be connected to the connector assembly for delivering fluid into/out of the connector (800) in the connector assembly. The connector (800) may be rotationally and axially aligned within the connector housing (902) such that a bore opening around the outer side surface of the connector (800) aligns with a fluid passage through the stab (1104) assembly.

FIG. 11 shows a system including a connector assembly having a connector (800) disposed within an inner cavity of the connector housing (902). In FIG. 11, the connected connector housing (902) and the connector (800) are fluidly connected to a stab (1104). A “stab” as used herein refers to a connection device used in oil and gas operations including a male component designed to mate with and fluidly connect to a corresponding female component. According to embodiments of the present disclosure, stabs may be used as part of a mud circulation system, in which case may be referred to as a “mud return stab” or “mud stab,” to help ensure that drilling fluid (mud) returns efficiently from the wellbore to the surface for cleaning and recirculation. The stab may play a crucial role in maintaining pressure control and preventing blowouts by allowing for the safe management of the mud's return flow, helping to stabilize the well during drilling operations.

In some embodiments, a winch assembly (170) may be provided with a BOP stack (162). The stack mounted winching system may allow for an ROV to reel in any component that may present a large resistance greater than the ROV thruster capacity. In one or more embodiments, an ROV may not be needed to reel in a component. For example, in the system of FIG. 11, a winch assembly (170) may be attached to a bottom portion (1424) of the connector (800) on one end of the winch assembly (170) using latches (as will be described in more detail below). In one or more embodiments, a hydraulic piston (1110) may be attached on an opposite end of the winch assembly (170).

Turning to FIG. 12, in one or more embodiments, a winching system (170) may be used to pull the connector (800) into the connector housing (902) and to fluidly connect a stab (1104) to the connector (800). Upon connecting the stab (1104) to the connector (800), an opening (e.g., a first bore inlet (118)) to the first bore (146) may be aligned with an inner cavity opening of the stab (1104). In one or more embodiments, a piston (1106) may be slidably positioned within an inner cavity of the stab (1104). When the piston (1106) enters the first bore (146) via first bore inlet (118), a fluid path is created between the first bore (146) and the stab's inner cavity (1304).

FIGS. 13A-E illustrate methods that utilize a connector housing (902) and a connector (800) to connect one or more flow lines according to one or more embodiments. In one or more embodiments, the method includes providing a connector housing (902) connected to a BOP stack (e.g., 162 in FIG. 4). The connector housing (902) of one or more embodiments may include any components described in FIGS. 9A-B, and 10-12. The connector (800) of one or more embodiments may include any components described in FIGS. 8A-B, 9A-B, and 10-12.

In one or more embodiments, the BOP stack (e.g., 162 in FIG. 4) is supported on a frame (e.g., “structure” 124) and the method includes pulling the connector (800) into the connector housing (902) via a winch (170). In one or more embodiments, the winch (170) may be positioned in an upper portion of the connector housing (902) during beginning steps of the connector-connector housing connection procedure. Using a hydraulic piston (172) connected to the winch (170), the winch system may pull the connector (800) into the connector housing (902) until the bore openings in the side of the connector (800) are axially aligned with the annular flow path connections between the connector (800) and connector housing (902).

As best shown in FIG. 13A, the bottom portion (1424) of the connector (800) may include a winch receiving cavity (1408) extending from a bottom surface of the connector (800) into the body (110) of the connector (800). The winch receiving cavity (1408) may further include one or more latches (120) disposed around an inner perimeter of the winch receiving cavity (1408). In one or more embodiments, the latches (120) may be locking dogs having interlocking grip features that interlock with corresponding features on a connecting component. A T-bar and cable assembly (1302), including a T-bar (1406) and a cable (1404), may be connected to the connector (800) bottom portion (1424) via the winch receiving cavity (1408). In one or more embodiments, the winch system may further include a winch extension (1409) configured to fit within the winch receiving cavity (1408).

In the method, the connector (800) may be moved proximate the connector housing (902), for example, using an ROV. In one or more embodiments, an ROV may not be required to move the connector (800) proximate the connector housing (902). In some embodiments, the connector (800) may be moved proximate the connector housing (902) by pulling a cable attached to the connector through the connector housing using a winch. For example, in the embodiment in FIG. 13A, the connector (800) may be moved toward the connector housing (902) by a T-bar and cable assembly (1302), where the T-bar may help guide and connect the cable to the winch. The T-bar and cable assembly (1302) may be extended in a generally downward direction (1407) towards the winch assembly. The T-bar (1406) may be received by an opening located at a top surface of the winch extension (1409) and extend downward (1407) into a body of the winch (170).

FIG. 13B shows the T-bar (1406) seated in the top surface of the winch extension (1409) and a cable end (1412) attached to the winch (170). Moving from FIG. 13B to FIG. 13C, the connector (800) may be further pulled downward (1407) toward the connector housing (902) by retracting the cable (1404) into the winch (170) using the hydraulic piston (172).

Once the winch extension (1410) on the winch (170) is seated within the winch receiving cavity (1408) located in the bottom portion (1424) of the connector (800) as shown in FIG. 13C, the method may further include latching a bottom portion (1424) of the connector (800) to winch grooves (1426) formed within the winch via at least one latch (120). In the zoomed-in portion of FIG. 13C, open latches (1422) within the connector (800) bottom portion (1424) align with the winch grooves (1426) located on the winch extension (1409). Moving from FIG. 13C to FIG. 14D, the latches (120) close (e.g., closed latches 1432) to form a connection between the connector (800) and the winch extension (1410), as shown in FIG. 13D. In one or more embodiments, latch(es) may be spring loaded or actuated to extend from the winch receiving cavity to grip onto the winch extension (1410). In other embodiments, one or more latches may be actuated to extend from a winch extension into a connector's receiving cavity to connect the winch to the connector.

To disconnect the connector (800) from the connector housing (902), the winch assembly may be released from the connector (800), e.g., by releasing the latches (120). In some embodiments, a buoyancy assisted disconnect feature may be provided, which requires a minimal amount of force to break the connection, in most configurations. To achieve a buoyancy assisted disconnect feature, one or more buoyancy modules (169) may be attached to the top of the connector (800), e.g., attached to a connector's connector plate. A buoyancy module (169) may be formed from a foam (e.g., polystyrene foam), where the foam composition may be designed to provide a selected density. When latches are actuated to release the connector from the winch assembly, the buoyancy modules may provide a lift to the connector to lift the connector out of the connector housing. Other configurations may require additional intervention to break a connector-connector housing connection (e.g., using an ROV, breakaway, rig controlled, etc.).

Moving from FIG. 13D to FIG. 13E, upon latching the connector (800) to the winch extension (1410), the connector (800) may be further pulled downward (1407) into the connector housing (902) using the hydraulic piston (172).

Although not shown in the Figures, upon pulling the connector (800) into the connector housing (902), the connector (800) may be axially rotated within the connector housing (902) until the housing (800) mates with the connector housing (902). In one or more embodiments, the method further includes inserting the connector (800) into the connector housing (902) by contacting the connector protrusion (806) to the at least one inner guide ledge (904). For example, a connector protrusion may contact a sloped guide ledge, the slope of which may rotationally guide the contacting connector protrusion as the connector is pulled axially downward. The method of one or more embodiments further includes guiding the connector protrusion (806) along the at least one inner guide ledge (904) to rotationally align the connector (800) within the connector housing (902), as the connector (800) is inserted into the connector housing (902), until the connector (800) is in a fixed position within the connector housing (902). For example, the connector protrusion (806) may contact and slide along a sloped guide ledge as the connector (800) is pulled axially downward through the connector housing (902), where the slope of the sloped guide ledge may guide the connector protrusion (806) (and thus also the connector) in a rotational downward direction until the connector protrusion (806) reaches a slot, in which the connector protrusion (806) may be fitted to rotationally fix the connector in a rotational position relative to the connector housing (902).

In one or more embodiments, when the connector (800) is in the fixed position, a first annular flow path connection (152) is formed between the connector housing (902) and the connector (800) by: a first housing annular flow path connection groove (140) formed in an inner surface of the connector housing (902), a first connector annular flow path connection groove (152) formed in an outer side surface (e.g., 909 in FIG. 9A) of the connector (800), or a combination of the first housing annular flow path connection groove (140) axially aligned with the first connector annular flow path connection groove (152). In one or more embodiments, when the connector (800) is in the fixed position, the first bore inlet (118) of the connector (800) may intersect with the first annular flow path connection (152), such that the first bore (146) is in fluid communication with a fluid connection passage (906) through the connector housing (902) via the first annular flow path connection (152). In one or more embodiments, inserting the connector (800) in the connector housing (902) includes sealing the first annular flow path connection (152) via a seal (e.g., 134). Upon sealing the first annular flow path connection (152), in one or more embodiments, the method further includes connecting the riser (e.g., 156 in FIG. 4) to a connector (800) via a riser connection (e.g., 160 in FIG. 4).

In other embodiments, a first bore in a connector may be fluidly connected to another equipment without passage through a connector housing fluid connection passage. For example, once a connector is connected within a connector housing, a stab may directly connect with the connector to provide a fluid connection between a bore through the connector and the stab.

Turning to FIG. 13F, upon mating the connector (800) with the connector housing (902), a stab (1104) may further be fluidly connected to a bottom end of the connector (800). Upon connecting the stab (1104) to the connector (800), a fluid path is created between a first bore inlet (118), located at an opening along the side of the connector (800), and an inner cavity opening to an inner cavity (1304) within the stab (1104). In one or more embodiments, a piston (1106) may be slidably positioned within the inner cavity (1304) of the stab (1104), such that the piston (1106) and inner cavity (1304) are coaxial. The piston (1106) may exit an inner cavity opening of the stab (1104) and partially enter the first bore (146) via the first bore inlet (118) to provide a fluid connection between the stab and the first bore.

As demonstrated in moving from FIGS. 13F to 13G, the piston (1106) may enter the opening of the first bore (146) in an uphole direction (1462), as follows. In one or more embodiments, the stab (1104) is connected to a bottom end of the connector housing (902), such that the inner cavity (1304) of the stab extends at an angle from the connector housing's central axis equal to an angle at which an opening (e.g., first bore opening 118) to a bore through the connector (800) extends. In such embodiments, when the connector (800) is connected within the connector housing (902), the stab's inner cavity (1304) is coaxial with an aligned bore opening. In one or more embodiments, an aligned bore opening may be rotationally aligned with a stab's inner cavity opening using one or more inner guide ledges that rotationally guide a connector protrusion (and connector) to a rotational position where the bore opening is rotationally aligned with the stab's inner cavity opening. Further, an aligned bore opening may be axially aligned relative to the stab connected to the connector housing (e.g., using at least one inner guide ledge and/or connector plate) to receive a piston extended from the stab. The stab (1104) may be connected to and oriented relative to the connector housing (902) such that when the connector (800) is in the fixed rotational position, the method further includes fluidly connecting the first bore (146) to the stab (1104) by extending the piston (1106) from the inner cavity (1304) of the stab (1104) into the opening to the first bore (e.g., 118 in FIG. 8A).

In one or more embodiments, a stab's piston may have a generally tubular shape which when extended into a bore opening, seals against the bore opening. For example, a connecting end of a stab piston may have an outer circumferential surface that interfaces and seals against an inner circumferential surface of the bore opening. In some embodiments, the connecting end of a stab piston may have an end surface that contacts and seals against a seal or ledge around the inner surface of the bore opening.

Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims.

	Number	Date	Country
Parent	18492244	Oct 2023	US
Child	19060159		US

MULTILINE RISER BIG BORE CONNECTOR

Information

Publication Number

Date Filed

Date Published

Inventors

Original Assignees

CPC

International Classifications

Abstract

Description

Claims

Provisional Applications (1)

Continuation in Parts (1)