RCD seal and bearing condition

Abstract

A system for use with a well can include a rotating control device, a sensor configured to measure a parameter indicative of a condition of a seal of the rotating control device, and an artificial intelligence configured to provide an alert if the parameter is outside of an acceptable range. A method of monitoring a condition of a seal of a rotating control device can include sensing a parameter indicative of a condition of the seal, thereby generating sensor data, and providing an alert when the parameter is outside of an acceptable range. Another system can include sensor configured to measure a parameter indicative of a condition of a seal of a rotating control device, with the sensor being in or on the rotating control device.

Description

[0001] RCD SEAL AND BEARING CONDITION

[0002] TECHNICAL FIELD

[0003] This disclosure relates generally to equipment utilized and operations performed in conjunction with a subterranean well and, in an example described below, more particularly provides for monitoring and maintaining seal condition in a rotating control device (RCD).

[0004] BACKGROUND

[0005] In a typical RCD (also known as a rotating control head, a rotating diverter, or a pressure control device), one or more annular seals are used to seal about a tubular string (such as, a drill string, a testing string, a stimulation string, etc.) positioned in the RCD. The seals are mounted on bearings, so that the seals can rotate with the tubular string.

[0006] It will, therefore, be readily appreciated that improvements are continually needed in the art of designing, constructing and utilizing RCD’s with a subterranean well. The present disclosure provides such improvements to the art..

[0007] BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a representative partially cross-sectional view of an example of a well system and associated method which can embody principles of this disclosure.

[0009] FIG. 2 is a representative cross-sectional view of an example of a rotating control device that may be used in the FIG. 1 system and method. FIG. 3 is a representative flow chart for an example of a method of monitoring and maintaining ROD seal condition.

[0010] FIG. 4 is a representative schematic view of an example of a system for monitoring and maintaining RCD seal condition.

[0011] DETAILED DESCRIPTION

[0012] Representatively illustrated in FIG. 1 is a system 10 for use with a subterranean well, and an associated method, which can embody principles of this disclosure. However, it should be clearly understood that the system 10 and method are merely one example of an application of the principles of this disclosure in practice, and a wide variety of other examples are possible. Therefore, the scope of this disclosure is not limited at all to the details of the system 10 and method as described herein and / or depicted in the drawings.

[0013] In the FIG. 1 example, a tubular string 12 is positioned in a wellbore 14. The tubular string 12 is a drill string having a drill bit 16 connected at a distal end thereof for the purpose of drilling into the earth. In other examples, the tubular string 12 could be a work string, a stimulation string, a completion string, an injection string, a production string, or another type of tubular string. The scope of this disclosure is not limited to use of any particular type of tubular string in a well, or to use of a tubular string at all.

[0014] As depicted in FIG. 1 , a pump 18 is used to maintain a fluid flow 20 through the tubular string 12 in the wellbore 14. In this example, the fluid flow 20 enters the tubular string 12 at the surface via a standpipe 22, which may be connected to the tubular string via a top drive, a kelly, or other equipment (not shown). The fluid flow 20 exits the tubular string 12 in the wellbore 14 via nozzles (not shown) in the drill bit 16.

[0015] The fluid flow 20 returns to the surface via an annulus 24 formed between the tubular string 12 and the wellbore 14. In managed pressure drilling operations, the annulus 24 may be isolated from the atmosphere at the surface by well equipment 26 known to those skilled in the art as a rotating control device, rotating drilling head, rotating blowout preventer, rotating control head, etc. For well control operations, the well equipment 26 may comprise an annular blowout preventer, pipe rams, or other equipment. However, the scope of this disclosure is not limited to use of any particular well equipment to isolate an annulus from the atmosphere at the surface.

[0016] The returned fluid flow 20 may pass through a choke manifold 28 and various types of fluid conditioning equipment 30 (such as, a gas separator, a shale shaker, etc.) prior to flowing into a reservoir 32 (also known as a “mud pit”). The pump 18 draws fluid from the reservoir 32. Note that the FIG. 1 example is simplified for purposes of clarity of illustration and description, and those skilled in the art will appreciate that additional equipment or different equipment may be used, depending in part on the particular well operation being performed.

[0017] In the FIG. 1 example, a flow measurement apparatus 34 is connected between the pump 18 and the tubular string 12. Thus, the fluid flow 20 exiting the pump 18 passes through the flow measurement apparatus 34 and the standpipe 22 prior to entering the tubular string 12. In this manner, characteristics of the fluid flow 20 (such as, volumetric and mass flow rate, density, other rheological parameters, etc.) can be accurately measured as it is being introduced into the well. In some examples, another flow measurement apparatus (or another type of flow measurement apparatus) may also measure characteristics of the fluid flow 20 after it exits the well (such as, a flowmeter connected downstream of the choke manifold 28).

[0018] In the FIG. 1 system 10, the well is depicted as being on land or onshore. In other examples, the well may be offshore or water-based.

[0019] Referring additionally now to FIG. 2, a cross-sectional view of an example of a rotating control device 40 is representatively illustrated. The rotating control device 40 may be used with other systems and methods, but for convenience the rotating control device is described below as it may be used with the FIG. 1 system 10 and method. In the FIG. 1 system 10, the well equipment 26 can include the rotating control device 40, a blowout preventer stack, and / or other equipment. As depicted in FIG. 2, the tubular string 12 extends through a central bore 42 of the rotating control device 40. Annular seals 44, 46 seal against an outer surface of the tubular string 12.

[0020] The conditions of the seals 44, 46 are important to monitor, since the seals are part of a primary barrier between the well and the outside environment at certain points in well operations. This monitoring can enable failures to be identified, prevented or mitigated.

[0021] In the FIG. 2 example, the rotating control device 40 comprises an outer housing 48, a bearing assembly 50 and a latch assembly 52. The outer housing 48 can include upper and / or lower connectors 54, 56 for connecting the rotating control device 40 in a wellhead assembly or a riser string.

[0022] The bearing assembly 50 includes bearings 58 to rotatably mount the annular seals 44, 46 in the outer housing 48. In this manner, the annular seals 44, 46 are able to rotate with the tubular string 12 relative to the outer housing 48.

[0023] The latch assembly 52 releasably secures the seals 44, 46 and bearing assembly 50 in the outer housing 48. When the latch assembly 52 is unlatched, the seals 44, 46 and bearing assembly 50 can be withdrawn from the outer housing 48, for example, for inspection, and repair or replacement if needed.

[0024] Unfortunately, it can be difficult to know when the seals 44, 46 are at the end of their useful lives, or if for some other reason the seals should be replaced to prevent a failure. However, the FIG. 2 rotating control device 40 includes a variety of sensors 60, 62, 64, 66, 68, 70 for measuring parameters that can be indicative of the conditions of the seals 44, 46. An alert or alarm can be generated when one or more of the parameters (including changes in the measured parameters and comparisons between measured parameters) is outside of an acceptable range, at which point a failure may be avoided (e.g., by replacing the seals 44, 46 before one or both seals fail, or by reducing a misalignment between the seals and the tubular string), or may be mitigated if the failure has already occurred.

[0025] In the FIG. 2 example, the sensor 60 comprises a pressure sensor (or a combined pressure and temperature sensor). The sensor 60 is in fluid communication with an annulus 72 formed radially between the tubular string 12 and the bearing assembly 50, and axially between the seals 44, 46.

[0026] The lower annular seal 46 operates to isolate the lower annulus 24 (in communication with pressure in the well below) from the annulus 72. Typically, pressure in the annulus 24 will be greater than pressure in the annulus 72 in managed pressure drilling operations in which pressure in the annulus 24 at the surface is manipulated to balance (or nearly balance) formation and wellbore pressures downhole.

[0027] If an increase in pressure in the annulus 72 is sensed by the pressure sensor 60, this can be an indication that the lower annular seal 46 is failing to isolate the annulus 72 from the annulus 24. In some situations, a decrease in pressure in the annulus 72 can be an indication that the upper or lower annular seal 44, 46 is failing or has failed. An alert or alarm (such as, a visual, audible or textual signal) can be generated to advise an operator of the failure or impending failure of the seal or seals 44, 46. The operator can then replace the failed or failing seal or seals 44, 46.

[0028] In some examples, the sensor 60 may comprise a differential pressure sensor capable of measuring a pressure differential across the seal 44 and / or the seal 46. The pressure differential measurements can be used to monitor the conditions of one or both of the seals 44, 46. Abnormalities in the pressure differential measurements can indicate leaking or failure of the seals 44, 46.

[0029] If the sensor 60 comprises a temperature sensor, it may be positioned to monitor temperature proximate either of the seals 44, 46 and / or the bearings 58. Excessive temperature at the bearings 58 can indicate wear or damage to the bearings, and excessive temperature at the seals 44, 46 can indicate wear or damage to the seals, or indicate that a replacement schedule for the seals should be adjusted.

[0030] In the FIG. 2 example, the sensor 62 comprises a rotational speed sensor. The rotational speed sensor 62 is capable of measuring a rotational speed of the seals 44, 46 and an inner barrel of the bearing assembly 50. The sensor 62 is depicted in FIG. 2 as being mounted in the upper connector 54, but other positions of the sensor may be used in keeping with the scope of this disclosure.

[0031] Ideally, to prolong the useful lives of the seals 44, 46, the seals should rotate at a same speed as the tubular string 12 against which they seal. However, friction (such as, in the bearing assembly 50) or slippage (such as, between the seals 44, 46 and the outer surface of the tubular string 12) can cause the seals to rotate at a slower speed than the tubular string.

[0032] This difference in rotational speed can lead to increased wear of the seals 44, 46. The greater the difference in rotational speed between the tubular string 12 and the seals 44, 46, the greater the rate of seal wear and damage.

[0033] The rotational speed of the seals 44, 46 can be measured by the sensor 62, and the rotational speed of the tubular string 12 can be measured by a sensor 74 incorporated into a lifting apparatus 76 (such as a top drive) used to raise and lower the tubular string (see FIG. 1 ), or incorporated into a rotary table. In other examples, the sensor 74 could be mounted in or on the rotating control device 40 (such as, in the upper connector 54).

[0034] If a difference between the measurements taken by the rotational speed sensors 62, 74 has increased to a first level, this can be an indication that the seals 44, 46 are experiencing increased wear. If the difference in rotational speeds has increased to a second, higher level, this can be an indication that the seals 44, 46 are or have been experiencing excessive wear, and the seals should be replaced. An alert or alarm (such as, a visual, audible or textual signal) can be generated to advise an operator of the increased wear (such as, when the difference in rotational speeds is between the first and second levels) or impending failure of the seal or seals 44, 46 (such as, when the difference in rotational speeds is above the second level).

[0035] The operator can then replace the failed or failing seal or seals 44, 46. Alternatively, the operator can mitigate the wear or damage due to the difference in rotational speeds. For example, if the difference in rotational speeds is due to increased friction in the bearing assembly 50, lubricant flow to the bearing assembly could be increased, or other steps could be taken to reduce the friction in the bearing assembly.

[0036] In the FIG. 2 example, the sensor 64 comprises an alignment sensor. As depicted in FIG. 2, the sensor 64 is positioned to measure a radial distance between the central bore 42 and the tubular string 12. The sensor 64 could be, for example, a proximity sensor, a laser measurement device, an ultrasonic measurement device, a Hall effect device, etc.

[0037] If the tubular string 12 is not in alignment with the central bore 42 and the annular seals 44, 46, the seals will experience increased wear and likelihood of eventual damage. Therefore, it is important to correct such misalignment and repair any damage caused by the misalignment.

[0038] In the FIG. 2 system 10, the distance measurement data received from the sensor 64 is used to determine a level of the misalignment. If the misalignment exceeds a first level, an alert or alarm is provided and an action item to correct the misalignment is logged. Once the misalignment has been corrected (so that the misalignment is less than the first level), the rotating control device 40 can continue to be used in well operations. Minor misalignment can typically be resolved without taking the rotating control device 40 out of service.

[0039] If the misalignment exceeds a second level, then the rotating control device 40 is taken out of service, repaired, inspected, etc., in order to prepare it for further service. When the misalignment exceeds the second level, then likely the rotating control device 40 has sustained some damage (such as, to the bearings 58 or the annular seals 44, 46) and is in need of repair and refurbishment. In some cases (such as, due to limitations of a rig on which the rotating control device 40 is used), the misalignment cannot be satisfactorily reduced or eliminated. In such cases, the measured misalignment may be used to adjust a replacement schedule for the bearings 58 and / or seals 44, 46, in order to prevent or mitigate the damage to the bearings and / or seals due to the misalignment.

[0040] In the FIG. 2 example, the sensor 66 comprises a vibration sensor. The sensor 66 is used to measure the amplitude, frequency and other characteristics of vibration produced in operation of the rotating control device 40. It is not necessary for the vibrations to be produced by the operation of the rotating control device 40, since the vibrations could be produced by other equipment (e.g., a rotary table, a top drive, tongs, draw works, etc.).

[0041] The sensor 66 can comprise any type of sensor capable of producing measurements related to parameters (amplitude, frequency, etc.) of the vibration. For example, the sensor 66 may be a three-axis accelerometer, a piezoelectric or magnetostrictive device, etc. The sensor 66 can in some examples measure acoustic or ultrasonic emissions (e.g., sound, or vibrations transmitted through the material of the rotating control device) in operation of the rotating control device 40 (such as, due to wear or damage to the bearings 58, or due to misalignment).

[0042] If the vibration measurements exceed a first level, an alert or alarm is provided. Once the source of the vibration has been identified and the vibration has been reduced, (so that the vibration level is less than the first level), the rotating control device 40 can continue to be used in well operations. Minor vibration can typically be resolved without taking the rotating control device 40 out of service.

[0043] If the vibration measurements exceed a second level, then the rotating control device 40 is taken out of service, repaired, inspected, etc., in order to prepare it for further service. When the vibration exceeds the second level, then likely the rotating control device 40 has sustained some damage (such as, to the bearings 58 or the annular seals 44, 46) and is in need of repair and refurbishment. The source of the vibration should also be identified and repaired. In the FIG. 2 example, the sensor 68 comprises a liquid level sensor. The sensor 68 outputs measurements indicative of a level or volume of liquid 78 (such as, well fluids) above the upper annular seal 44. The presence of a volume of liquid 78 in the area above the upper seal 44 is an indication of leaking past the seals 44, 46. Since the area above the upper seal 44 has a fixed shape, the level of the liquid 78 corresponds to a particular volume of the liquid.

[0044] Alternatively, or in addition, a level sensor 70 may be positioned in a trip tank or reservoir 80 for the liquid 78. A pump 82 circulates the liquid 78 between the reservoir 80 and the area above the upper seal 44.

[0045] The sensor 70 outputs measurements indicative of a level or volume of the liquid 78 in the reservoir 80. The level of the liquid 78 in the reservoir 80 is directly related to the level of the liquid in the area above the upper seal 44.

[0046] If the level and volume of the liquid 78 in the area above the upper seal 44 increases, or increases to greater than a first level, then the rotating control device 40 is taken out of service, repaired, inspected, etc., in order to prepare it for further service. The seals 44, 46 will likely need to be replaced if they have been leaking.

[0047] The rotating control device 40 may also include a sensor 84 capable of outputting measurements (such as viscosity, particle count, chemical composition, etc.) indicative of a condition of lubricant used in the bearing assembly 50. The sensor 84 may be positioned in the rotating control device 40 (such as, in the bearing assembly 50), or external to the rotating control device (such as, in or in communication with a lubricant reservoir). If the measurements output by the sensor 84 are outside of an acceptable range, this can be an indication that the lubricant should be replaced.

[0048] Referring additionally now to FIG. 3, a flow chart for an example of a method 90 of monitoring and maintaining RCD seal condition is representatively illustrated. For convenience, the method 90 is described below as it may be used with the system 10 and rotating control device 40 of FIGS. 1 & 2, but the method may be used with other systems and RCD’s in keeping with the scope of this disclosure.

[0049] Upon initiation, the system 10 receives various types of data from the sensors 60, 62, 64, 66, 68, 70, 74. In the FIG. 3 example, this data comprises rotational speed data 92, load data 94, pressure data 96, vibration data 98, alignment data 100 and volume data 102. Other types or combinations of sensor data may be used in other examples.

[0050] As depicted in FIG. 3, an evaluation 104 is made as to whether the seal slippage (difference in rotational speed as measured by the sensors 62, 74) has reached a minor or major level. If the slippage has reached only a minor level (exceeding a first slippage level), then an alert or alarm 116 is produced, along with information regarding the reason for the alarm.

[0051] If the slippage has reached a major level (exceeding a second slippage level), then the rotating control device 40 is likely taken out of service for mitigation / remediation 126 (including, for example, repair, refurbishing, inspection, etc.) to correct the cause of the excessive slippage condition and to repair any damage to components of the rotating control device. When the rotating control device 40 is repaired / refurbished, it can be returned to service.

[0052] The load data 94 in this example can be received from a load sensor 128 (see FIG. 1 ) included with the lifting apparatus 76. The load sensor 128 outputs measurements indicative of the upwardly directed force applied from the lifting apparatus 76 to the tubular string 12. This force corresponds to a weight of the tubular string 12, including friction, buoyancy, etc., effects.

[0053] It will be appreciated by those skilled in the art that, as a radially enlarged tool joint in the tubular string 12 is displaced through the seals 44, 46 in the rotating control device 40, an increase and then decrease in the load as measured by the load sensor 128 is experienced. Trends or changes in patterns of load data 94 can be used to identify when there has been a corresponding change in the seals 44, 46. For example, when a seal 44, 46 has been worn, so that its inner diameter is increased, an amplitude of the load increase due to a tool joint passing through the seal will be reduced. When a material of a seal 44, 46 has been degraded, so that it has reduced elasticity, the amplitude of the load increase due to a tool joint passing through the seal will be reduced, and a slope of the load increase and decrease will be reduced.

[0054] An evaluation 106 is made of changes in patterns or trends in the load data 94. If the measured change exceeds a certain level, an alert or alarm 118 is produced, along with information regarding the reason for the alarm. The evaluation 106 can include an evaluation of whether the rotating control device 40 should be taken out of service for mitigation / remediation 126.

[0055] As depicted in FIG. 3, an evaluation 108 is made of any changes in the pressure data 96 received from the pressure sensor 60. An increase in pressure between the seals 44, 46 can be an indication that the lower seal 46 is leaking or has already failed.

[0056] If the pressure change exceeds a certain level, an alert or alarm 120 is produced, along with information regarding the reason for the alarm. The evaluation 108 can include an evaluation of whether the rotating control device 40 should be taken out of service for mitigation / remediation 126.

[0057] As depicted in FIG. 3, an evaluation 110 is made as to whether any increase in the vibration data 98 received from the vibration sensor 66 has reached a minor or major level. If the vibration has reached only a minor level (exceeding a first vibration level), then an alert or alarm 122 is produced, along with information regarding the reason for the alarm.

[0058] If the vibration has reached a major level (exceeding a second vibration level), then the rotating control device 40 is likely taken out of service for mitigation / remediation 126 (including, for example, repair, refurbishing, inspection, etc.) to correct the cause of the excessive vibration condition and to repair any damage to components of the rotating control device. When the rotating control device 40 is repaired / refurbished, it can be returned to service. As depicted in FIG. 3, an evaluation 112 is made as to whether any misalignment indicated by the alignment data 100 received from the alignment sensor 64 has reached a minor or major level. If the misalignment has reached only a minor level (exceeding a first misalignment level), then an alert or alarm 122 is produced, along with information regarding the reason for the alarm.

[0059] If the misalignment has reached a major level (exceeding a second misalignment level), then the rotating control device 40 is taken out of service for mitigation / remediation 130 (including, for example, repair, refurbishing, inspection, etc.) to correct the cause of the excessive misalignment condition and to repair any damage to components of the rotating control device. When the rotating control device 40 is repaired / refurbished, it can be returned to service. If the misalignment cannot be satisfactorily corrected then the misalignment measurements may be used to adjust a replacement schedule for the bearings 58 and / or seals 44, 46 (e.g., so that the bearings and / or seals are replaced more frequently).

[0060] As depicted in FIG. 3, an evaluation 114 is made of any changes in the volume data 102 received from the level sensor 68 or 70. An increase in liquid level / volume above the upper seal 44 can be an indication that the upper and lower seals 44, 46 are leaking or have already failed. If the volume exceeds a certain level, the rotating control device 40 may be taken out of service for mitigation / remediation 126, including replacement of the seals 44, 46.

[0061] Although the existence of minor seal slippage 104, minor load trend change 106, minor pressure change 108 between the seals 44, 46 or minor vibration increase 110 does not necessarily prompt taking the rotating control device 40 out of service for issue mitigation / remediation 126, the existence of multiple divergences (see evaluation 132) of these measurements from acceptable ranges will prompt taking the rotating control device 40 out of service for issue mitigation / remediation 126 in the FIG. 3 example.

[0062] Referring additionally now to FIG. 4, a schematic view of an example of a system 134 for monitoring and maintaining rotating control device seal condition is representatively illustrated. For convenience, the system 134 is described below as it may be used with the rotating control device 40 and method 90 of FIGS. 2 & 3, although the system 134 may be used with other rotating control devices and methods in keeping with the scope of this disclosure.

[0063] In the FIG. 4 example, an artificial intelligence 136 is used to evaluate the data 92, 94, 96, 98, 100, 102 to determine whether an alarm 116, 118, 120, 122, 124 should be produced, or whether the rotating control device 40 is in need of mitigation / remediation 126. Outputs of the sensors 60, 62, 64, 66, 68, 70, 74, 128 are received by the artificial intelligence 136, and the evaluations 104, 106, 108, 110, 112, 114, 132 are performed based on predetermined levels (such as, an acceptable measurement range, a minor divergence from the acceptable range, and a major divergence from the acceptable range).

[0064] The artificial intelligence 136 may comprise any type or combination of artificial intelligence devices and processes, implemented in hardware and / or software. An artificial intelligence can include, for example, neural networks, genetic algorithms, machine learning, etc., to enable the artificial intelligence to model the useful life of a rotating control device seal as influenced by various factors (such as, seal slippage, loading, pressure between seals, vibration, misalignment and leakage volume).

[0065] The artificial intelligence 136 can be trained using historical data 138. The historical data 138 can include the data 92, 94, 96, 98, 100, 102 accumulated during previous operations, as well as information obtained in mitigation / remediation 126 activities and post-job inspections (such as, post-job seal condition evaluations). Once trained, the artificial intelligence 136 can perform the evaluations 104, 106, 108, 110, 112, 114, 132 to determine if the measurements output by the sensors 60, 62, 64, 66, 68, 70, 74, 128 diverge from an acceptable range by a minor amount or a major amount.

[0066] For the sensor data 92, 94, 96, 98, 100, when the measurement divergence reaches a certain “minor” level, a corresponding alert or alarm 116, 118, 120, 122, 124 is generated. Misalignment mitigation 130 may also be performed if the misalignment measurements reach a certain level. For the evaluations 104, 106, 108, 110, if multiple minor divergences from the acceptable ranges are recognized, the more extensive mitigation / remediation 126 is performed. In addition, the mitigation / remediation 126 is performed if a major vibration increase is experienced (vibration reaches at least a major level or divergence from an acceptable range), a major misalignment is experienced (misalignment reaches at least a major level or divergence from an acceptable range), or if a fluid volume increase above the seals 44, 46 is experienced.

[0067] It may now be fully appreciated that the above disclosure provides significant advancements to the art of designing, constructing and utilizing RCD’s with a subterranean well. In an example described above, the conditions of the annular seals 44, 46 and / or bearings 58 can be monitored in real time while the RCD 40 is being used in well operations, adverse factors can be identified and mitigated in real time to prolong the useful lives of the seals, or bearings, and damage to the seals or bearings can be identified or predicted in real time, so that appropriate mitigation / remediation 126 can be performed prior to a failure of one or both of the seals or bearings.

[0068] The above disclosure provides to the art a system 10 for use with a subterranean well. In one example, the system 10 can comprise a rotating control device 40, at least one sensor 60, 62, 64, 66, 68, 70, 74, 84, 128 configured to measure a parameter indicative of a condition of at least one seal 44, 46 or bearing 58 of the rotating control device 40, and an artificial intelligence 136 configured to provide an alert 116, 118, 120, 122, 124 if the parameter is outside of an acceptable range.

[0069] The at least one sensor may comprise a first rotational speed sensor 62. The at least one sensor may comprise a second rotational speed sensor 74. The artificial intelligence 136 may be configured to provide the alert 116 if a difference between measurements of the first and second rotational speed sensors 62, 74 is outside of the acceptable range.

[0070] The sensor 128 may comprise a load sensor. The artificial intelligence 136 may be configured to provide the alert if a change in a pattern of loads measured by the load sensor 128 is outside of the acceptable range. The sensor 60 may comprise a pressure and / or temperature sensor. The at least one seal may include first and second annular seals 44, 46. The pressure sensor 60 may sense pressure between the first and second annular seals 44, 46.

[0071] The sensor may comprise a vibration sensor 66, an alignment sensor 64, a liquid level sensor 68, 70 or a lubricant condition sensor 84.

[0072] Also provided to the art by the above disclosure is a method 90 of monitoring a condition of at least one seal 44, 46 or bearing 58 of a rotating control device 40. In one example, the method 90 can include: sensing a parameter indicative of a condition of the seal 44, 46 or bearing 58, thereby generating sensor data 92, 94, 96, 98, 100, 102; and providing an alert 116, 118, 120, 122, 124 when the parameter is outside of an acceptable range.

[0073] The method 90 may include training an artificial intelligence 136 to determine whether the parameter is outside of the acceptable range. The training step may include training the artificial intelligence 136 to determine a level of divergence between the parameter and the acceptable range.

[0074] The step of providing the alert may include selecting the alert 116, 118, 120, 122, 124 based in part on the level of the divergence.

[0075] The sensing step may include mounting a sensor on the rotating control device 40, the sensor being selected from the group consisting of a rotational speed sensor 62, a pressure sensor 60, a temperature sensor 60, a vibration sensor 66, an alignment sensor 64, a level sensor 68 and a lubricant condition sensor 84.

[0076] A system 10 described above for use with a subterranean well can include a rotating control device 40, at least one sensor 60, 62, 64, 66, 68 configured to measure a parameter indicative of a condition of at least one seal 44, 46 or bearing 58 of the rotating control device 40, the sensor 60, 62, 64, 66, 68 being in or on the rotating control device 40, and an artificial intelligence 136 configured to provide an alert 116, 120, 122, 124 if the parameter is outside of an acceptable range. The at least one sensor may be selected from the group consisting of a first rotational speed sensor 62, a pressure sensor 60, a temperature sensor 60, a vibration sensor 66, an alignment sensor 64, a liquid level sensor 68 and a lubricant condition sensor 84.

[0077] The at least one sensor may comprise a second rotational speed sensor 74. The artificial intelligence 136 is configured to provide the alert if a difference between measurements of the first and second rotational speed sensors 62, 74 is outside of the acceptable range.

[0078] The at least one seal may comprise first and second annular seals 44, 46. The at least one sensor 60 may sense pressure between the first and second annular seals 44, 46.

[0079] The artificial intelligence 136 may be trained with historical data 138 to predict a useful life of the at least one seal 44, 46 or bearing 58.

[0080] Although various examples have been described above, with each example having certain features, it should be understood that it is not necessary for a particular feature of one example to be used exclusively with that example. Instead, any of the features described above and / or depicted in the drawings can be combined with any of the examples, in addition to or in substitution for any of the other features of those examples. One example’s features are not mutually exclusive to another example’s features. Instead, the scope of this disclosure encompasses any combination of any of the features.

[0081] Although each example described above includes a certain combination of features, it should be understood that it is not necessary for all features of an example to be used. Instead, any of the features described above can be used, without any other particular feature or features also being used.

[0082] It should be understood that the various embodiments described herein may be utilized in various orientations, such as inclined, inverted, horizontal, vertical, etc., and in various configurations, without departing from the principles of this disclosure. The embodiments are described merely as examples of useful applications of the principles of the disclosure, which is not limited to any specific details of these embodiments.

[0083] In the above description of the representative examples, directional terms (such as “above,” “below,” “upper,” “lower,” “upward,” “downward,” etc.) are used for convenience in referring to the accompanying drawings. However, it should be clearly understood that the scope of this disclosure is not limited to any particular directions described herein.

[0084] The terms “including,” “includes,” “comprising,” “comprises,” and similar terms are used in a non-limiting sense in this specification. For example, if a system, method, apparatus, device, etc., is described as “including” a certain feature or element, the system, method, apparatus, device, etc., can include that feature or element, and can also include other features or elements. Similarly, the term “comprises” is considered to mean “comprises, but is not limited to.”

[0085] Of course, a person skilled in the art would, upon a careful consideration of the above description of representative embodiments of the disclosure, readily appreciate that many modifications, additions, substitutions, deletions, and other changes may be made to the specific embodiments, and such changes are contemplated by the principles of this disclosure. For example, structures disclosed as being separately formed can, in other examples, be integrally formed and vice versa. Accordingly, the foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the invention being limited solely by the appended claims and their equivalents.

Claims

WHAT IS CLAIMED IS:1 . A system (10) for use with a subterranean well, the system (10) comprising: a rotating control device (40); at least one sensor (60, 62, 64, 66, 68, 70, 74, 84, 128) configured to measure a parameter indicative of a condition of at least one seal (44, 46) or bearing (58) of the rotating control device (40); and an artificial intelligence (136) configured to provide an alert (116, 118, 120, 122, 124) if the parameter is outside of an acceptable range.

2. The system (10) of claim 1 , in which the at least one sensor comprises a first rotational speed sensor (62).

3. The system (10) of claim 2, in which the at least one sensor comprises a second rotational speed sensor (74), and in which the artificial intelligence (136) is configured to provide the alert if a difference between measurements of the first and second rotational speed sensors (62, 74) is outside of the acceptable range.

4. The system (10) of claim 1 , in which the sensor comprises a load sensor (128).

5. The system (10) of claim 4, in which the artificial intelligence (136) is configured to provide the alert if a change in a pattern of loads measured by the load sensor (128) is outside of the acceptable range.

6. The system (10) of claim 1 , in which the sensor comprises a pressure sensor (60).

7. The system (10) of claim 6, in which the at least one seal comprises first and second annular seals (44, 46), and in which the pressure sensor (60) senses pressure between the first and second annular seals (44, 46).

8. The system (10) of claim 1 , in which the sensor comprises a vibration sensor (66).

9. The system (10) of claim 1 , in which the sensor comprises an alignment sensor (64).

10. The system (10) of claim 1 , in which the sensor comprises a liquid level sensor (68, 70).11 . A method of monitoring a condition of at least one seal (44, 46) or bearing (58) of a rotating control device (40), the method comprising: sensing a parameter indicative of a condition of the seal (44, 46) or bearing (58), thereby generating sensor data (92, 94, 96, 98, 100, 102); and providing an alert (116, 118, 120, 122, 124) when the parameter is outside of an acceptable range.

12. The method of claim 11 , further comprising training an artificial intelligence (136) to determine whether the parameter is outside of the acceptable range.

13. The method of claim 12, in which the training comprises training the artificial intelligence (136) to determine a level of divergence between the parameter and the acceptable range.

14. The method of claim 13, in which the providing the alert (116, 118, 120, 122, 124) comprises selecting the alert based in part on the level of the divergence.

15. The method of claim 11 , in which the sensing comprises mounting a sensor on the rotating control device (40), the sensor being selected from the group consisting of a rotational speed sensor (60), a pressure sensor (60), a temperature sensor (60), a vibration sensor (66), an alignment sensor (64), a level sensor (68) and a lubricant condition sensor (84).

Images