Patent Application
20240301761
Aspects of the present disclosure relate to washpipe assemblies for use in drilling rig systems.
A washpipe assembly is a critical component of drilling rig systems, serving as a conduit for circulating drilling fluid and removing cuttings from a wellbore. The washpipe assembly provides a fluid seal between a stationary, nonrotating component (such as a gooseneck) and a non-stationary, rotating component (such as a drill string). The washpipe assembly must maintain a fluid-tight seal to prevent the escape of drilling fluid and ensure the safe and effective operation of the drilling rig system. Current washpipe assembly designs have seals that degrade over time and require frequent replacement, which can be a time consuming process.
Therefore, there is a need for new and/or improved washpipe assembly designs that are long lasting and easy to repair and install.
In one embodiment, a washpipe assembly comprises a washpipe, a static seal assembly coupled to one end of the washpipe, and a dynamic seal assembly coupled to an opposite end of the washpipe. The dynamic seal assembly comprises a seal disposed within an outer housing, wherein the seal is contained within a seal cavity formed by the outer housing and an outer diameter of the washpipe. The dynamic seal assembly is rotatable relative to the washpipe while maintaining sealing contact with the outer diameter of the washpipe.
In one embodiment, a washpipe assembly comprises an upper housing, a spring housing coupled to the upper housing, and a lower housing having a lower seal member. The spring housing comprises a biasing member that biases an upper seal member out of the spring housing and into contact with the lower seal member.
So that the manner in which the above-recited features of the disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments.
To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements disclosed in one embodiment may be beneficially utilized on other embodiments without specific recitation.
The disclosure contemplates that terms such as “couples,” “coupling,” “couple,” and “coupled” may include but are not limited to welding, interference fitting, and/or fastening such as by using bolts, threaded connections, pins, and/or screws. The disclosure contemplates that terms such as “couples,” “coupling,” “couple,” and “coupled” may include but are not limited to integrally forming. The disclosure contemplates that terms such as “couples,” “coupling,” “couple,” and “coupled” may include but are not limited to direct coupling and/or indirect coupling, such as indirect coupling through components such as subs, mandrels, links, etc.
The dynamic seal assembly 70 may comprise an outer housing 71, a removable end cap 72 coupled to the outer housing 71, and a plurality of dynamic seals 73 disposed in the outer housing 71. The plurality of dynamic seals 73 seal against the outer diameter of the washpipe 110. The outer housing 71 may be coupled to the upper end 101 of the drill string 25 illustrated in
A bearing 350 is positioned below the seals 330 and the seal support members 340. Specifically, the bearing 350 is positioned below the last seal support member 340. The bearing 350 provides rotational support of the seals 330, the seal support members 340, and the outer housing 320 relative to the washpipe 110. The arrangement of the seals 330, the seal support members 340, and the bearing 350 can be reversed such that the bearing 350 is positioned on top, adjacent to the end cap 315, followed by one seal support member 340, one seal 330, one seal support member 340, and so forth. Alternatively, the end cap member 310 can be coupled to a lower end of the outer housing 320, or a pair of end cap members 310 can be used and coupled to both the upper and lower ends of the outer housing 320.
The end cap member 310, the outer housing 320, and the washpipe 110 form a seal cavity 317 in which the seals 330, the seal support members 340, and the bearing 350 are contained. Specifically, the seals 330, the seal support members 340, and the bearing 350 are secured in position from above by the end cap member 310. The seals 330, the seal support members 340, and the bearing 350 are secured in position from below by an inner shoulder of the outer housing 320, and on one side by the sidewall of the outer housing 320. The seals 330, the seal support members 340, and the bearing 350 are secured in position on an opposite side by the outer diameter of the washpipe 110.
The seals 330 seal against the outer diameter of the washpipe 110 and the inner diameter of the outer housing 320. The dynamic seal assembly 300 is configured to rotate relative to the washpipe 110, while the seals 330 maintain a seal against the outer diameter of the washpipe 110 and the inner diameter of the outer housing 320. An end seal 360, such as an O-ring, may be used to seal against a lower rotating component, such as the upper end 101 of the drill string 25 as illustrated in
A seal fluid (injectable packing) 440 is contained within an area between the upper seal 430 and the lower seal 450 from above and below. The seal fluid (injectable packing) 440 is further contained on the sides between the outer housing 420 and the outer diameter of the washpipe 110. The seal fluid (injectable packing) 440 is injected through a port 421 formed in the sidewall of the outer housing 420. The seal fluid (injectable packing) 440 energizes the seals 430, 450 to form a seal against the outer diameter of the washpipe 110 and the inner diameter of the outer housing 420. The arrangement of the seals 430, 450 can be reversed. Alternatively, the end cap member 410 can be coupled to a lower end of the outer housing 420, or a pair of end cap members 410 can be used and coupled to both the upper and lower ends of the outer housing 420.
The end cap member 410, the outer housing 420, and the washpipe 110 form a seal cavity 417 in which the seals 430, 450 and the seal fluid (injectable packing) 440 are contained. Specifically, the seals 430, 450 and the seal fluid (injectable packing) 440 are secured in position from above by the end cap member 410. The seals 430, 450 and the seal fluid (injectable packing) 440 are secured in position from below by an inner shoulder of the outer housing 420, and on one side by the sidewall of the outer housing 420. The seals 430, 450 and the seal fluid (injectable packing) 440 are secured in position on an opposite side by the outer diameter of the washpipe 110.
The seals 430, 450 seal against the outer diameter of the washpipe 110 and the inner diameter of the outer housing 420. The dynamic seal assembly 400 is configured to rotate relative to the washpipe 110, while the seals 430, 450 maintain a seal against the outer diameter of the washpipe 110 and the inner diameter of the outer housing 420. An end seal 460, such as an O-ring, may be used to seal against a lower rotating component, such as the upper end 101 of the drill string 25 as illustrated in
Each seal 530 is located within one seal cavity 517, 518, 519 formed by the outer housing 510. Each seal cavity 517, 518, 519 is formed by inner shoulders of the outer housing 510 located above and below each seal 530, and on one side by inner sidewalls of the outer housing 510. The seals 530 are secured in position on an opposite side by the outer diameter of the washpipe 110.
A fluid, such as grease, is injected through one or more ports 521 formed in the sidewall (and top) of the outer housing 510. The fluid flows through one or more fluid paths 520 formed in the body of the outer housing 510, which direct the fluid to each seal cavity 517, 518, 519. The fluid is pumped into each seal cavity 517, 518, 519 on a side of each seal 530 that is opposite from the outer diameter of the washpipe 110. The fluid energizes the seals 530 to form a seal against the outer diameter of the washpipe 110 and the inner shoulders of the outer housing 510. The ports 521 may be plugged by one or more plug members 515 (shown in the port 521 at the top of the outer housing 510) after injection of the fluid.
The dynamic seal assembly 500 is configured to rotate relative to the washpipe 110, while the seals 530 maintain a seal against the outer diameter of the washpipe 110 and the inner surfaces of the outer housing 510. An end seal 560, such as an O-ring, may be used to seal against a lower rotating component, such as the upper end 101 of the drill string 25 as illustrated in
The primary difference between the dynamic seal assembly 600 and the dynamic seal assembly 500 is the location of the port 621. In the dynamic seal assembly 500, the port 521 is located on the outer diameter (and top) of the outer housing 510, whereas in the dynamic seal assembly 600, the port 621 is located on the inner diameter (and top) of the outer housing 610. Specifically, the port 621 is located below all of the seals 630 so that a fluid 650 (such as a drilling fluid) that flows through the inner bore 111 of the washpipe 110, can be the fluid that energizes the seals 630. The dynamic seal assembly 600 is configured to be self-energizing and does not require a separate or an additional fluid to be injected externally through the outer housing 610.
In one embodiment, the dynamic seal assembly 600 may have the port 621 individually going through the shoulders that are separating the seals 619, 618, 617. This would result in pressurizing the lower most seal first and only upon its failure would it energize the next seal above it.
The seal 730 is located within a seal cavity 717 formed by the outer housing 710. The seal cavity 717 is formed by inner shoulders of the outer housing 710 located above and below the seal 730, and on one side by the inner sidewall of the outer housing 710. The seal 730 is secured in position on an opposite side by the outer diameter of the washpipe 110.
A pair of bearings or bushings 720 are disposed in recesses 718, 719, respectively, formed in the inner diameter of the inner shoulders of the outer housing 710. The bearings or bushings 720 are positioned above and below the seal 730 and the seal cavity 717, and engage the outer diameter of the washpipe 110. The bearings or bushings 720 provides rotational support of the seal 730 and the outer housing 710 relative to the washpipe 110.
The seal 730 seals against the outer diameter of the washpipe 110 and the inner diameter of the outer housing 710. The dynamic seal assembly 700 is configured to rotate relative to the washpipe 110, while the seal 730 maintains a seal against the outer diameter of the washpipe 110 and the inner diameter of the outer housing 710. An end seal 760, such as an O-ring, may be used to seal against a lower rotating component, such as the upper end 101 of the drill string 25 as illustrated in
The end cap member 810, the outer housing 820, and the washpipe 110 form a seal cavity 817 in which the seal 830 is contained. Specifically, the seal 830 is secured in position from above by the end cap member 810. The seal 830 is secured in position from below by an inner shoulder of the outer housing 820, and on one side by the inner sidewall of the outer housing 820. The seal 830 is secured in position on an opposite side by the outer diameter of the washpipe 110.
In one embodiment, the dynamic seal assembly 800 may incorporate the bearings or bushings 720 as described in the dynamic seal assembly 700.
The seal 830 seals against the outer diameter of the washpipe 110 and the inner diameter of the outer housing 820. The dynamic seal assembly 800 is configured to rotate relative to the washpipe 110, while the seal 830 maintains a seal against the outer diameter of the washpipe 110 and the inner diameter of the outer housing 810. An end seal 860, such as an O-ring, may be used to seal against a lower rotating component, such as the upper end 101 of the drill string 25 as illustrated in
The washpipe assembly 900 comprises an upper housing 910 coupled to a spring housing 920. The spring housing 920 comprises an upper end having an outer shoulder 913 that engages an inner shoulder 912 of the upper housing 910 (and/or a lower end cap 909 coupled to the upper housing 910). A seal 911, such as an O-ring, may be disposed in a top surface of the outer shoulder 913 of the spring housing 920. The seal 911 forms a seal between the spring housing 920 and an upper component, such as the gooseneck 45 illustrated in
A lower end section 923 of the spring housing 920 may be coupled to the spring housing 920 by one or more fasteners 915, such as screws or bolts. A biasing member 930, such as a spring, is disposed within a cavity 922 of the spring housing 920. An upper seal member 940 is also disposed within the cavity 922 of the spring housing 920 adjacent to the biasing member 930. A lower end of the upper seal member 940 extends out of the cavity 922 of the spring housing 920 (such as out of an opening 908 formed in or adjacent a bottom of the lower end section 923 of the spring housing 920). Seals 941, 942, such as O-rings, are disposed between outer diameter portions of the upper seal member 940 and inner diameter portions of the spring housing 920. A chamber 921 is formed within the cavity 922 of the spring housing 920, specifically between the outer walls of the upper seal member 940 and the inner walls of the spring housing 920. The chamber 921 is sealed by the seals 941, 942.
The biasing member 930 biases the lower end of the upper seal member 940 out of the spring housing 920 and into contact with a lower seal member 945, which is coupled to a lower housing 950. The lower housing 950 may be coupled to a lower component, such as the upper end 101 of the drill string 25 so that the lower housing 950 rotates with the drill string 25. A seal 951, such as an O-ring, may be disposed in a bottom surface of an inner shoulder of the lower housing 950. The seal 951 forms a seal between the lower housing 950 and the upper end 101 of the drill string 25 illustrated in
The lower housing 950 rotates (with the drill string 25) relative to the spring housing 920. A dynamic seal is formed by the contact between the lower end of the upper seal member 940, which remains stationary, and the lower seal member 945, which rotates. The biasing member 930 forces the lower end of the upper seal member 940 out of the spring housing 920 and into contact with the lower seal member 945 to maintain the dynamic seal. The upper seal member 940 itself may be formed out of a material configured to seal with the lower seal member 945, or an additional seal material 943 may be coupled to the upper seal member 940 which contacts the lower seal member 945 to form the dynamic seal. The dynamic seals prevents leakage of fluid when flowing from the gooseneck 45 to the drill string 25 through the inner bore 111 of the washpipe assembly 900.
With reference to the left side of
A seal 1030, such as a fluid/spring energized seal, is disposed within the outer housing 1020. The seal 1030 may comprise a seal support member 1033 positioned above a seal member 1034, and a pair of spring members 1031, 1032 disposed within the seal member 1034. The seal support member 1033 may be formed out of a material (e.g. polyetheretherketone) that is harder than the material which the seal member 1034 is formed out of (e.g. plastic). The spring members 1031, 1032 may be formed out of metal. The spring members 1031, 1032 may be U-cup shaped springs. Although two spring members 1031, 1032 are shown, the seal 1030 may comprise only one spring member, or three, four, five, six, seven, eight, nine, ten, or more spring members 1031, 1032. Although only one seal 1030 is shown, two, three, four, five, six, seven, eight, nine, ten, or more seals 1030 may be disposed within the outer housing 1020 and stacked on top of each other.
The end cap member 1010, the outer housing 1020, and the washpipe 110 form a seal cavity 1017 in which the seal 1030 is contained. Specifically, the seal 1030 is secured in position from above by the end cap member 1010. The seal 1030 is secured in position from below by an inner shoulder of the outer housing 1020, and on one side by the inner sidewall of the outer housing 1020. The seal 1030 is secured in position on an opposite side by the outer diameter of the washpipe 110.
A fluid 1050, such a drilling fluid, flows through the inner bore 111 of the washpipe 110 and up into one or more ports 1021 formed in a sidewall of the outer housing 1020. The fluid 1050 flows through one or more fluid paths 1025 formed in the body of the outer housing 1020, which direct the fluid 1050 into the seal cavity 1017. The fluid 1050 then flows through one or more ports 1035 formed in the seal member 1034, and into and/or against an inner surface of the spring member 1031. The fluid 1050 energizes the seal 1030 by forcing one or both of the spring members 1031, 1032 radially outward, which forces the seal member 1034 radially outward to form a seal against the outer diameter of the washpipe 110 and the inner diameter or sidewall of the outer housing 1020. The seal support member 1033 helps retain the seal member 1034 within the outer housing 1020.
The dynamic seal assembly 1000 is configured to be self-energizing and does not require a separate or an additional fluid to be injected externally through the outer housing 1020. The dynamic seal assembly 1000 is configured to rotate relative to the washpipe 110, while the seal 1030 maintains a seal against the outer diameter of the washpipe 110 and the inner diameter of the outer housing 1010. An end seal 1060, such as an O-ring, may be used to seal against a lower rotating component, such as the upper end 101 of the drill string 25 as illustrated in
It will be appreciated by those skilled in the art that the preceding embodiments are exemplary and not limiting. It is intended that all modifications, permutations, enhancements, equivalents, and improvements thereto that are apparent to those skilled in the art upon a reading of the specification and a study of the drawings are included within the scope of the disclosure. It is therefore intended that the following appended claims may include all such modifications, permutations, enhancements, equivalents, and improvements. The disclosure also contemplates that one or more aspects of the embodiments described herein may be substituted in for one or more of the other aspects described. The scope of the disclosure is determined by the claims that follow.
This application claims benefit of United States provisional patent application Ser. No. 63/451,175, filed Mar. 9, 2023, which is herein incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63451175 | Mar 2023 | US |
