This section is intended to provide relevant contextual information to facilitate a better understanding of the various aspects of the described embodiments. Accordingly, it should be understood that these statements are to be read in this light and not as admissions of prior art.
In the oil and gas industry, a rotating control device (RCD) or rotating control head (also referred to as a rotating drilling device, rotating drilling head, rotating flow diverter, pressure control device and rotating annular) is used to form a seal against the drill pipe and isolate the region of wellbore below the RCD from the region above the RCD. On an offshore drilling rig, the RCD may be located below the rig floor, above the subsea blowout preventer stack (BOP), or at any suitable position along the riser. The RCD employed offshore can be enclosed in a riser joint to interconnect with the riser string and can also include a packer assembly to engage the riser joint and divide the annulus of the riser string. The RCD uses a passive or active sealing element which is mounted to a bearing assembly to form a seal on the drill pipe. The purpose of the bearing assembly is to allow the sealing element to rotate with the drill pipe as the drill pipe is rotated by the rig.
For a detailed description of the embodiments, reference will now be made to the accompanying drawings in which:
The drilling unit 102 may be any type of drilling system operable to perform drilling operations. Although
The drilling unit 102 may include a rig floor 112 that is supported by several support structures (not expressly shown). A rotary table 114 may be located above the rig floor 112 and may be coupled to the drill string 104 in order to facilitate the drilling of a wellbore using a drill bit (not expressly shown) coupled to the opposite end of the drill string 104. The drill string 104 may include several sections of drill pipe that communicate drilling fluid from the drilling unit 102 and provide torque to the drill bit. The drill string 104 may be coupled to a standpipe 118 via a kelly hose 120, both of which may facilitate the flow of drilling fluid into the drill string 104. The standpipe 118 may be a thick metal tubing that is situated vertically along the derrick of the drilling system 100 and is attached to and supports one end of the kelly hose 120. The standpipe 118 is further coupled to a pump 122 that is used to circulate drilling fluid from a tank 124. The drilling fluid may be circulated back to the drilling unit 102 through the riser assembly 110. For a land drilling unit, the drilling fluid may be circulated through the wellbore or a casing included in the wellbore. Additionally, various cables 116 may couple the RCD 106, slip joint 108, and riser assembly 110 to equipment on the drilling unit 102.
A measurement device 109 may be included with the RCD 106 to monitor a parameter indicative of a condition of the sealing element (not shown) deployed with the latch assembly 103 as further described herein. The surface controller 130 collects measurements from the measurement device 109, and includes a computer system 132 for processing and storing the measurements gathered by the measurement device 109. Among other things, the computer system 132 may include a processor and a non-transitory machine-readable medium (e.g., ROM, EPROM, EEPROM, flash memory, RAM, a hard drive, a solid state disk, an optical disk, or a combination thereof) capable of executing instructions to perform such tasks. The surface controller 130 may further include a user interface (not shown), e.g., a monitor or printer, to display the measurements and the condition of the sealing element, as further described herein. In addition to collecting and processing measurements, the computer system 132 may be capable of controlling the measurement device 109 and the RCD 106.
The measurement device 222 is used to monitor the condition of the sealing element 262 during initial installation as well as continued monitoring while the sealing element 262 maintains a fluid barrier in the riser assembly 110. The measurement device 222 may include at least one of a strain gauge 224A-C, a load cell 226A-C, a displacement sensor 228, pressure sensors 230A and B, a temperature sensor 232, or any other suitable device operable to measure a parameter indicative of the condition of the sealing element 262. The strain gauges 224A-C and/or the load cells 226A-C may be engaged with at least one of the sealing element 262, the latch assembly 220, and the RCD body 212. For example, the strain gauge 224A and/or the load cell 226A may be positioned on the packer assembly 260, such as the sealing element 262, to measure an axial force or strain applied to the sealing element 262 as the sealing element 262 is being set or while the sealing element engages the RCD body 212. The strain gauge 224B and/or the load cell 226B may also be positioned on any suitable component of the RCD 210 that communicates a setting force to the sealing element 262, including but not limited to a shifting sleeve 236, a slip assembly 238, an upper push block cylinder 240, a push block 242, a lower push block cylinder 244, a packer push rod 246, a packer retainer 248, a packer spring plate 250, and/or the bearing sleeve 252. The strain gauge 224C and/or the load cell 226C may also be positioned on the RCD body 212 in close proximity to the region of the RCD body 212 on which the sealing element 262 engages to measure an axial force or strain applied to the RCD body 212 by the sealing element 262. As shown, the strain gauge 224C and/or the load cell 226C is located on the outer surface of the RCD body 212, but the strain gauge 224C and/or the load cell 226C may also be located on the inner surface of the RCD body 212 that engages the sealing element 260. The strain gauge 224A-C may include a foil strain gauge, a piezoelectric strain gauge, a fiber optic sensor, a capacitive strain gauge, or any other suitable strain gauge. The load cell 226A-C may include a strain gauge based load cell, a piezoelectric load cell, a fiber optic sensor, a capacitive load cell, or any other suitable load cell.
The displacement sensor 228 is operable to measure the displacement of the sealing element 262, such as detecting whether the sealing element 262 is displaced to engage the RCD body 212 and/or a component of the RCD 210 is displaced while applying a setting force to the sealing element 262. For example, a magnetic device 274 may be positioned on the latch assembly 220 and a hall effect sensor 276 may be positioned on the RCD body 212 to detect whether the latch assembly 220 is displaced relative to the hall effect sensor 276, such that the effect of the displacement is to communicate a setting force to the sealing element 262. The displacement measured by the displacement sensor 228 may include a detected displacement of at least one of the latch assembly 220 relative to the RCD body 212, the sealing element 262 relative to the RCD body 212, and a mechanism of the latch assembly 220 relative to another mechanism of the latch assembly 220 or packer assembly 260 including, but not limited to, the shifting sleeve 236 relative to a top cap 254, the slip assembly 238 relative to a housing 256 for the latch assembly 220, the packer retainer 248 relative to a mandrel 264 of the packer assembly 260, and the packer spring plate 250 relative to the mandrel 264. The displacement sensor 228 may include at least one of a hall effect sensor and a magnetic device, a magnetometer and the magnetic device, a continuity sensor, an electromagnetic proximity sensor (e.g., an optical or infrared sensor), an acoustic proximity sensor (e.g, an ultrasonic transducer), or any other suitable device operable to measure or detect a displacement.
The pressure sensors 230A and B are operable to measure the pressures in the upper pressure region 282 and the lower pressure region 284. For example, the upper pressure sensor 230A is in fluid communication with the upper pressure region 282, and the lower pressure sensor 230B is in fluid communication with the lower pressure region 284. Once the sealing element 262 is set and engages the RCD body 212, there should be no communication of pressure across the sealing element 262 and between the upper and lower pressure regions 282 and 284. The pressure sensors 230A and B may be used to monitor the pressure in the upper and lower pressure regions 282 and 284. A seal integrity test may be performed that raises or lowers the pressure of one of the upper pressure region 282 or the lower pressure region. If the seal integrity test results in a change in pressure of the tested pressure region (e.g., the upper region 282) and does not result in a change of pressure in the other region (e.g., the lower region 284), the seal integrity of the sealing element 262 can be assumed to have passed the seal integrity test. Otherwise, if the seal integrity test results in a change in pressure in both pressure regions 282 and 284, the seal integrity of the sealing element 262 can be assumed to have failed the seal integrity test.
The temperature sensor 232 is located on the packer assembly 260 and is operable to measure a temperature of the sealing element 262. The temperature of the sealing element 262 may be communicated to the surface controller 130, which is used to monitor the temperature of the sealing element 262. For example, the temperature 232 may be used to monitor whether the sealing element 262 is above or below a threshold operating temperature.
The RCD 210 may include a communication device 290 to communicate with the surface controller 130 of
The surface controller 130 is operable to analyze the measured parameter to identify the condition of the sealing element 262 and/or output the condition to a suitable user interface, such as a monitor, tablet, or printer. The surface controller 130 may be used to monitor the measured parameter during the installation process of the sealing element 262. For example, the surface controller 130 may identify whether the sealing element 262 has been successfully installed to engage the RCD body 212 and create the fluid barrier in the riser assembly 110. The surface controller 130 may also be used to monitor the measured parameter while the sealing element 262 is engaged with the RCD body 212 to identify whether the fluid barrier is maintained in the riser assembly 110. The surface controller 130 may also convert the parameter to the condition of the sealing element 262, including but not limited to a force, pressure, temperature, or an indication of whether the sealing element 262 is installed. The surface controller 130 may identify whether the setting force applied to the sealing element 262 satisfies a threshold force or strain for the sealing element 262 to engage the RCD body 212 and output this to the suitable user interface. The surface controller 130 may also indicate whether the sealing element 262 needs to be physically inspected, repaired, and/or replaced based on the measured parameter(s) and output this to the suitable user interface.
As used herein, the parameter indicative of the condition of the sealing element 262 may include at least one of a force, strain, pressure, displacement, and temperature. The condition of the sealing element 262 may include at least one of an installation status of the sealing element 262, a seal integrity status of the sealing element 262, a force applied to the sealing element 262, a pressure applied to the sealing element 260 (e.g., the pressure of the upper pressure region 282 or lower pressure region 284), a temperature of the sealing element 262, a displacement status of the sealing element 262, and a strain of the sealing element 262. As discussed herein, the installation status of the sealing element 262 may refer to whether the sealing element 262 is set and engaged with the RCD body 212. The seal integrity status of the sealing element 262 may refer to whether the sealing element 262 allows pressure to communicate between the upper and lower pressure regions 282 and 284. As used herein, the displacement status of the sealing element 262 may refer to a displacement of the sealing element 262 relative to the RCD body 212 and/or whether the sealing element 262 is displaced relative to the RCD body 212 to engage the RCD body 212.
In addition to the embodiments described above, many examples of specific combinations are within the scope of the disclosure, some of which are detailed below:
A drilling system, comprising:
The system of example 1, wherein the measurement device comprises at least one of a strain gauge, a load cell, a displacement sensor, a pressure sensor, and a temperature sensor.
The system of example 1, wherein the parameter includes at least one of a force, a strain, a pressure, a displacement, and a temperature.
The system of example 3, wherein:
The system of example 1, wherein the measurement device is in fluid communication with an upper pressure region in the RCD body above the sealing element and a lower pressure region in the RCD body below the sealing element and wherein the parameter includes pressures in the upper and lower pressure regions.
The system of example 1, further comprising a bearing assembly including an inner sealing element engagable to seal between a drill string and the bearing assembly.
The system of example 1, further comprising a communication device in communication with the controller to transmit the parameter to the controller.
The system of example 1, wherein the condition of the sealing element comprises at least one of an installation status of the sealing element, a seal integrity status of the sealing element, a force applied to the sealing element, a pressure applied to the sealing element, a temperature of the sealing element, and a strain of the sealing element.
The system of example 2, wherein the displacement sensor comprises at least one of a hall effect sensor and a magnetic device, a magnetometer and the magnetic device, a continuity sensor, an electromagnetic proximity sensor, and an acoustic proximity sensor.
The system of example 1, wherein the measurement device is engaged with at least one of the sealing element, the latch assembly, and the RCD body.
A method of monitoring a condition of a sealing element engageable with a body of a rotating control device (RCD), comprising:
The method of example 11, further comprising:
The method of example 11, wherein the parameter comprises at least one of a force, a strain, a pressure, a displacement, and a temperature.
The method of example 13, wherein:
The method of example 11, wherein the condition of the sealing element comprises at least one of an installation status of the sealing element, a seal integrity status of the sealing element, a force applied to the sealing element, a pressure applied to the sealing element, a temperature of the sealing element, and a strain of the sealing element.
The method of example 11, further comprising transmitting the parameter to the controller with a communication device.
The method of example 11, further comprising performing, based on the condition of the sealing element, at least one of repairing the sealing element, replacing the sealing element, adjusting a force applied to the sealing element, adjusting a pressure applied to the sealing element, and adjusting a temperature applied to the sealing element.
A rotating control device for use in conjunction with a riser assembly, comprising:
The rotating control device of example 18, wherein the measurement device comprises at least one of a strain gauge, a displacement sensor, a pressure sensor, and a temperature sensor.
The rotating control device of example 18, wherein the parameter includes at least one of a force, a strain, a pressure, a displacement, and a temperature.
This discussion is directed to various embodiments. The drawing figures are not necessarily to scale. Certain features of the embodiments may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness. Although one or more of these embodiments may be preferred, the embodiments disclosed should not be interpreted, or otherwise used, as limiting the scope of the disclosure, including the claims. It is to be fully recognized that the different teachings of the embodiments discussed may be employed separately or in any suitable combination to produce desired results. In addition, one skilled in the art will understand that the description has broad application, and the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment.
Certain terms are used throughout the description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function, unless specifically stated. In the discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . .” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. In addition, the terms “axial” and “axially” generally mean along or parallel to a central axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean perpendicular to the central axis. The use of “top,” “bottom,” “above,” “below,” and variations of these terms is made for convenience, but does not require any particular orientation of the components.
Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment may be included in at least one embodiment of the present disclosure. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
Although the present disclosure has been described with respect to specific details, it is not intended that such details should be regarded as limitations on the scope of the disclosure, except to the extent that they are included in the accompanying claims.
Filing Document | Filing Date | Country | Kind |
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PCT/US2016/057482 | 10/18/2016 | WO | 00 |