Multi-pipeline riser macropore connector

Abstract

A system for connecting more than one flow line includes a connector housing and a connector. The connector housing includes a first connection channel formed through a wall of the connector housing. The connector is disposed within the connector housing. A first annular flow path connection is formed between the connector housing and the connector. The first housing annular flow path connection is formed by the first housing annular flow path connection groove. A first housing annular flow path connection groove is formed in an outer side surface of the connector. Alternatively, the first annular flow path connection is formed by a combination of first housing annular flow path connection slots axially aligned with the first connector annular flow path connection slots. A first connection channel through the connector housing intersects the first annular flow path connection. A related method includes inserting a connector into a connector housing.

Description

BACKGROUND OF THE INVENTION

[0001] In offshore drilling operations, a floating structure (such as a platform or a ship) can be positioned at the water level above a well location on the seafloor. A blowout preventer (BOP) stack can be installed at the wellhead, which can be used to control the flow of fluids from the well. A drill string extends from the floating structure to the well location to drill a well into a formation below the seafloor. During drilling, a drilling fluid (also referred to as "drilling mud" or simply "mud") is used to facilitate the drilling of the hole into the ground and can be circulated through the drill string, through the well being drilled, and back to the surface. Offshore drilling systems can be configured differently depending on the drilling location and other operating parameters to circulate the drilling fluid through the drilling system using different components and component arrangements.

[0002] In many offshore drilling systems, the drill string runs through a riser (in a coaxial configuration) from the floating structure to the well. In such a system, the drilling fluid can be pumped through the drill string into the well and return around the drill string through the riser. In some drilling systems, referred to as open water drilling, the drill string and the riser can extend from the floating structure to the well in a spaced non-coaxial configuration. In such a configuration, the drilling fluid return annulus through the well can be fluidly connected to the riser through one or more pipes and / or hoses. The drilling fluid can then be pumped through the drill string into the well and return through the riser. SUMMARY OF THE INVENTION

[0003] This Summary of the Invention is provided to introduce a selection of concepts that are further described below in the Detailed Description. This Summary of the Invention 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.

[0004] In one aspect, embodiments disclosed herein generally relate to systems and methods for connecting a riser to a BOP stack using a connector, as described herein.

[0005] In another aspect, embodiments disclosed herein generally relate to systems and methods using a connector having a plurality of holes machined into a cylindrical forging to form fluid connections to mating female sockets on different components without any existing structural connections.

[0006] In another aspect, embodiments disclosed herein generally relate to systems and methods for connecting one or more flow lines using a system. In some embodiments, the system includes a connector housing and a connector. The connector housing may include a first connection passage formed through a wall of the connector housing. The connector may be disposed within 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 through a first housing annular flow path connection groove. The first housing annular flow path connection groove may be formed in an outer surface of the connector. Alternatively, the first annular flow path connection may be formed through a combination of the first housing annular flow path connection groove that is axially aligned with a first connector annular flow path connection groove. The first connection passage through the connector housing may intersect the first annular flow path connection.

[0007] In another aspect, embodiments disclosed herein generally relate to a method for connecting a riser to a BOP stack. The method includes providing a connector housing connected to the BOP stack, the connector housing including a first connection passage formed through a wall of the connector housing. The method further includes connecting the riser to the connector via a riser connection. The connector includes a first hole formed through a body of the connector. The method further includes inserting the connector into the connector housing. When the connector is inserted into the connector housing, a first annular flow path connection is formed between the connector housing and the connector through 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. The first connector annular flow path connection groove may be formed in an outer surface of the connector, or in a combination with the first housing annular flow path connection groove that is axially aligned with the first connector annular flow path connection groove. The first connection passage through the connector housing may intersect the first annular flow path connection. The first hole may be in fluid communication with the first annular flow path connection.

[0008] Other aspects and advantages of the claimed subject matter will be apparent from the following description and the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Specific embodiments of the presently disclosed technology will now be described in detail with reference to the drawings. For consistency, like elements in the various figures are denoted by like reference numerals. The dimensions and relative positions of the elements in the figures are not necessarily drawn to scale. For example, angles and the shapes of the various elements are not necessarily drawn to scale, and some of these elements may be arbitrarily enlarged and positioned to improve the readability of the figures. Further, the particular shapes of the elements drawn are not necessarily intended to convey any information regarding the actual shape of the particular elements, and are merely selected for convenience of identification in the figures.

[0010] Figure 1 A connector according to an embodiment of the present disclosure is shown.

[0011] Figure 2 Shows a connector housing according to an embodiment of the present disclosure.

[0012] Figure 3 Shows a cross-sectional view of a connector connected to the connector housing according to an embodiment of the present disclosure.

[0013] Figure 4 Shows an open water drilling system according to an embodiment of the present disclosure.

[0014] Figure 5 Shows a BOP stack having a connector assembly assembled thereto according to an embodiment of the present disclosure.

[0015] Figure 6 and Figure 7 Shows a connection / disconnection sequence according to an embodiment of the present disclosure. Detailed Description

[0016] Embodiments of the present disclosure are described in detail below with reference to the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the claimed subject matter. However, it will be apparent to one of ordinary skill in the art that the described embodiments 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.

[0017] Embodiments of the present disclosure generally relate to methods and apparatus for connecting one or more flow lines using a single connector. For example, a connector disclosed herein may include a body having a plurality of holes machined therethrough that may be fluidly connected to an annular flow path connection formed between the connector and a connector housing when the connector is inserted into the connector housing.

[0018] The connector housing may have a female shape that matches the male shape of the connector body such that the connector housing may act as a receiver to receive the connector. According to an embodiment of the present disclosure, the connector housing may be assembled to various types and configurations of structures, thereby allowing connection on different types of components. For example, a connector housing according to an embodiment of the present disclosure may be mounted to different types and configurations of BOP stacks without the need for pre-formed structural connections. In this way, the connector housing may be attached to various structures (e.g., using bolts, welding, or other post-manufacture attachment techniques) as disclosed herein, allowing the connector to be fluidly connected to different components. In some embodiments, the connector housing may be integrally formed in the structure or connected to the structure during the manufacture of the structure.

[0019] Figures 1 to 3Generally shown is a connector (100), a connector housing (136), and a connection between the connector (100) and the connector housing (136) in accordance with an embodiment of the present disclosure. The connector (100) may have a generally cylindrical body (112) and one or more holes machined or otherwise formed through the body (112), and the cylindrical body (112) may be forged from metal or a metal composite. In the illustrated embodiment, a plurality of holes having different hole diameters are formed through the body (112), the plurality of holes including a first hole (146) having a first diameter, a second hole (144) having a second diameter, and a third hole having a third diameter. However, other combinations and sizes of holes may be formed through the connector (100).

[0020] The holes may open at one end of the top (108) of the connector (100) and may open at an opposite end around the body (112) of the connector (100). For example, as Figure 1 shown, the third hole may open at a third hole inlet (114) around the body (112) of the connector (100) and at a third hole outlet (106) at the top (108) of the connector (100). Similarly, the second hole (144) may open around the body (112) of the connector (100) at a second hole inlet and at a second hole outlet (104) at the top (108) of the connector (100), and the first hole (146) may open around the body (112) of the connector (100) at a first hole inlet (118) and at a first hole outlet (102) at the top (108) of the connector (100). The openings for the holes passing through the connector (100) are referred to herein as "inlets" and "outlets" solely for the purpose of differentiating between different openings. Depending on the direction of fluid flow through the connector holes, an opening may serve as an inlet or an outlet. Additionally, a hole 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 Figure 3 ), or a hole 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).

[0021] The connector housing can be configured to receive and mate with a connector (100) to form a fluid connection with a bore formed through the connector (100). According to an embodiment of the present disclosure, the connector housing can have a generally tubular shape. The connector housing can 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) can be attached to the top end of the connector housing, and the guide funnel (122) can be used to guide the connector (100) into the connector housing.

[0022] According to an embodiment of the present disclosure, the connector housing can have one or more annular flow path connectors that can be fluidly connected to one or more hole openings formed around the side of the connector body (112). The annular flow path connectors can be formed as grooves around the inner surface of the connector housing (where the inner diameter of the annular flow path connectors is greater than the inner diameter of the inner surface of the connector housing).

[0023] For example, as Figure 2 shown, the connector housing can have a first housing annular flow path connection groove (140) formed around the inner surface of the connector housing at a first axial position, a second annular flow path connection groove (132) formed around the inner surface of the connector housing at a different axial position, and a third annular flow path connection groove (128) formed around the inner surface of the connector housing at a different axial position. A seal (or alternatively, a sealing surface) (134) extending around the entire inner surface diameter of the connector housing can be axially disposed between the annular flow path connection grooves to separate and seal the annular flow path connectors. For example, the inner diameter of the seal or sealing surface (134) can be less than the inner diameter of the adjacent annular flow path connection grooves, and when the connector (100) is inserted into the connector housing (136), the inner diameter of the seal or sealing surface (134) can seal against the side surface of the connector body.

[0024] In some embodiments, in addition to or instead of the annular flow path connectors formed by grooves around the inner surface of the connector housing (136), the annular flow path connectors can be formed by grooves around the side surface of the connector body (112). For example, as Figure 1As shown, the slot can extend circumferentially around the entire periphery of the side surface of the connector body (112), wherein the diameter of the body (112) at the annular flow path connection slot (116) is less than the diameter of the outer surface of the body (112). In embodiments where the annular flow path connection slot (116) is formed in both the inner surface of the connector housing and the side surface of the connector body (112), the connector (100) and the connector housing (136) can be designed such that the corresponding annular flow path connection slots (such as 116, 132, 128, 140) are axially aligned to provide an annular flow path connection between the connector (100) and the connector housing (136) when the connector (100) and the connector housing (136) are assembled together.

[0025] A passage (or alternatively, a fluid connection passage) through the connector housing wall (139) can be formed to provide fluid access to each annular flow path connection. For example, as shown, a first connection passage (142) can be formed through the connector housing wall (139) and intersect the first annular flow path connection (152); a second connection passage (138) can be formed through the connector housing wall (139) and intersect each second annular flow path connection (150); and a third connection passage (130) can be formed through the connector housing wall (139) and intersect each third annular flow path connection (148). A flange or other pipe connection for the connection passage can be provided around the outer surface of the connector housing (136) to fluidly connect the annular flow path connection to the pipes, hoses, or other flow paths of different devices.

[0026] As Figure 3 shown, when the connector (100) is inserted into the connector housing (136), the hole openings around the side surface of the connector body (112) can be axially aligned with the annular flow path connections formed in the connector housing (136). In this way, fluid can flow through the connection passage (formed through the connector housing wall (139)), through the annular flow path connection formed between the connector housing (136) and the connector (100), and through the fluidly connected holes (formed through the connector body (112)).

[0027] According to an embodiment of the present disclosure, a hole can turn right (or a turn of nearly 90 degrees) to extend from the top (108) of the connector (100) to the side of the body (112) of the connector (100). This configuration can reduce the pressure end load typically associated with large-hole (e.g., holes having a diameter of about 5-1 / 8 inches or greater) connectors, thereby reducing the fixation required. For example, according to an embodiment of the present disclosure, a first hole (146) can be formed through the connector (100) to provide a drilling fluid return path and can have a large-hole diameter of sufficient size to carry the returned drilling fluid, such as a diameter of 7 inches or greater. Additionally, the connector (100) and hole geometries disclosed herein and shown in the figures can allow for scalable and configurable designs based on the needs and applications of the end user.

[0028] According to an embodiment of the present disclosure, the connector (100) and connector housing (136) disclosed herein can be used for connections in mechanical control, risers, and BOP stacks, as well as any fluid connections. In some embodiments, the connector (100) and connector housing (136) according to an embodiment of the present disclosure can be used to connect a riser to a BOP stack.

[0029] For example, generally referring to Figures 4 to 7 , a system and method according to an embodiment of the present disclosure can include using a connector and connector housing assembly (e.g., as Figures 1 - 3 shown) to connect a riser (156) to a BOP stack (162).

[0030] The BOP stack (162) can be disposed at the wellhead on the seabed surface. A floating structure (154) (e.g., a floating platform, a ship, or a semi-submersible structure) can be positioned at the sea surface generally above the well. A drill string (158) can extend from the floating structure (154), through the BOP stack (162), and into the well to drill the well. A return line (164) can be connected between a fluid outlet (174) to the well and a connector assembly (101) (e.g., as Figure 3 shown, the connector assembly (101) includes a connected connector (100) and connector housing (136)). A riser connection (160) (e.g., a flexible hose) can connect the connector assembly to the riser (156), and the riser (156) can extend to the floating structure (154).

[0031] During a drilling operation, drilling fluid can be pumped through the drill string (158) to the bottom of the well to assist with 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 can flow back up the well annulus formed between the drill string (158) and the wellbore wall to the top of the well. The returned drilling fluid can then exit through the fluid outlet (174), pass through the return line (164) connection, pass through the connector (100) assembly, pass through the riser connection (160), and return through the riser (156). In some embodiments, a pump (166) can be disposed along the riser (156) to assist in pumping the returned drilling fluid to the floating structure (154).

[0032] The connector assembly (101) can be provided on the BOP stack (162), e.g., by first providing a connector housing (136) on the BOP stack (162). For example, the connector housing (136) can be attached to the BOP stack frame (168). In some embodiments, the connector housing (136) can be attached to the upper end of the BOP stack (162), which can provide more space for a remotely operated vehicle (ROV) to assist with assembly, and / or more space for connections to the riser connection (160) and other equipment. With the connector housing (136) provided on the BOP stack (162), the connector (100) can be inserted (bottom end first) into the top end of the connector housing (136) and axially moved into the connector housing (136) until the connector (100) and the connector housing (136) are engaged and mated with each other.

[0033] In some embodiments, a winch system can be used to pull the connector into the connector housing (136). For example, in some embodiments, a winch assembly (170) can be provided with the BOP stack (162). The group-mounted winch system can allow the ROV to reel in any component that may present a large resistance greater than the ROV thruster capabilities.

[0034] According to embodiments of the present disclosure, a group-mounted subsea winch system can be provided with a BOP near the lower end of the connector housing (136). The connector (100) can be moved closer to the connector housing (136), e.g., using an ROV. As Figure 6 best shown, the upper end of the winch assembly (170) can be connected to the bottom end of the connector, e.g., using one or more pins (120), as Figure 1 and Figure 7Shown in. Using a connected hydraulic piston (172), the winch (176) can be connected to the winch housing (178), and the connector (100) can be pulled into the connector housing (136) until the hole opening in the side of the connector (100) is axially aligned with the annular flow path connection between the connector (100) and the connector housing (136).

[0035] To disconnect the connector (100) from the connector housing (136), the winch assembly (170) can be released from the connector (100), for example, by releasing the winch pin (120). In some embodiments, a buoyancy-assisted disconnection feature can be provided, which in most configurations requires a minimal amount of force to break the connection. To implement the buoyancy-assisted disconnection feature, one or more buoyancy modules (169) can be attached to the top of the connector (100). The buoyancy module (169) can be formed of foam (such as polystyrene foam), where the foam composition can be designed to provide a selected density. Other configurations may require additional intervention to break the connection (e.g., using an ROV, a disconnecting machine, rig control, etc.).

[0036] In some embodiments, a plurality of holes formed through the connector (100) can be used to provide multiple flow paths for different types of fluids. For example, referring to Figures 1 to 3 , the first hole (146) (having a large diameter) can be used to form part of the drilling fluid return, where the drilling fluid returning from the well can pass through the first hole (146) and be directed from the well to the riser (156). The second hole (144) can be used to form part of a different choke line (through which choke fluid flows), and the third hole can be used to form part of a different hydraulic line (through which hydraulic fluid flows). As mentioned above, the holes through the connector (100) can have different diameters, and the holes can be used to accommodate different fluids and for different applications (e.g., for forming hydraulic lines or choke lines). Accordingly, in some embodiments, the annular flow path connection formed between the connector (100) and the connector housing (136) can also have different sizes to accommodate different fluids.

[0037] In some embodiments, the riser connection (160) can include a bundle of hoses, where each hose can be connected at the top (108) of the connector (100) to be fluidly connected to the holes formed through the connector (100). For example, in Figure 1In the illustrated embodiment, five hoses can be connected at the top (108) of the connector (100) (e.g., using an API connection) to fluidly connect each hose to the hole opening. In one or more embodiments, the hole opening can be a flange opening or an opening of another fluid connection type to provide a connection to the hose in the riser connection. The riser connection (160) can be connected to the top (108) of the connector (100) between a plurality of strap mounts (110), and the strap mounts (110) can be connected to a traction system for assisting in raising and lowering the connector (100) in the connector housing (136). For example, in some embodiments, the riser connection (160) can be connected to the top (108) of the connector (100). Then, the strap mounts (110) of the connector (100) can be connected to the traction system via a traction line, and the traction line can be used to release the tension on the line when the connector (100) is inserted into the connector housing (136). In some embodiments, the strap mounts (110) can enable an electrical connector to be incorporated into the disconnect sequence of the connector (100).

[0038] Compared with previously used or conventional riser connections, the connector assembly according to embodiments of the present disclosure can provide at least one of the following advantages. Conventional connections typically require an external structure to assist in the alignment process and / or the mating components must be part of the same external structure. Conventional connections are typically only usable for small hole applications (less than 5-1 / 8 inches). Conventional connections do not utilize buoyancy-assisted disconnect or winch-assisted connection. Additionally, conventional connections do not incorporate electrical connector disconnect features or other techniques for reducing tension during connection.

[0039] Although only a few example embodiments have been described in detail above, it will be readily apparent to those skilled in the art that many modifications are possible in the example embodiments without materially departing from the invention. Accordingly, all such modifications are intended to be included within the scope of the present disclosure as defined by the following claims.

Claims

1. A system for connecting one or more flow lines, the system comprising: A connector housing including a first connection passage formed through a wall of the connector housing; A connector disposed within the connector housing; And A first annular flow path connector formed between the connector housing and the connector, wherein the first annular flow path connector is formed by a first housing annular flow path connection groove formed in an inner surface of the connector housing, by a first connector annular flow path connection groove formed in an outer surface of the connector, or by a combination of a first housing annular flow path connection groove axially aligned with the first connector annular flow path connection groove, Wherein the first connection passage through the connector housing intersects the first annular flow path connector.

2. The system according to claim 1, wherein the connector housing is configured to be attached to a structure for fluidly connecting a BOP stack to the connector.

3. The system according to claim 2, wherein the connector housing is integrally formed with the structure.

4. The system according to claim 2, wherein the connector housing is attached to the structure by a plurality of bolts or by welding.

5. The system according to claim 1, wherein the connector housing includes a circumferentially extending seal around the inner surface of the connector housing to seal the first annular flow path connector.

6. The system according to claim 1, wherein the connector housing is attached to an end of a frame of a BOP stack.

7. The system according to claim 1, wherein: The connector has a body including a first hole; The first hole is formed through the body of the connector.

8. The system according to claim 7, wherein: The body of the connector includes a second hole; The second hole is formed through the body of the connector, and The system includes a second annular flow path connector formed between the connector housing and the connector, wherein the second annular flow path connector is formed by a second housing annular flow path connection groove formed in the inner surface of the connector housing, by a second connector annular flow path connection groove formed in the outer surface of the connector, or by a combination of a second housing annular flow path connection groove axially aligned with the second connector annular flow path connection groove.

9. The system according to claim 8, wherein: The body of the connector includes a third hole; The third hole is formed through the body of the connector, and The system includes a third annular flow path connector formed between the connector housing and the connector, where the third annular flow path connector is formed by a third housing annular flow path connection groove formed in the inner surface of the connector housing, by a third connector annular flow path connection groove formed in the outer side surface of the connector, or by a combination of the third housing annular flow path connection groove axially aligned with the third connector annular flow path connection groove.

10. The system according to claim 1, wherein the connector includes one or more winch strap mounts configured to be connected to a winch system for disconnecting the connector from the connector housing.

11. The system according to claim 10, wherein the winch strap mounts enable the electrical connector to be incorporated into the disconnect sequence of the connector.

12. The system according to claim 9, wherein the connector has a body that includes one or more holes, each hole including a 90-degree bend and extending from the top of the connector through the body of the connector.

13. The system according to claim 1, further comprising one or more buoyancy modules attached to the top of the connector.

14. A method for connecting a riser to a BOP stack, the method comprising: providing a connector housing connected to the BOP stack, the connector housing including a first connection passage formed through the wall of the connector housing; connecting the riser to the connector via a riser connector, where the connector includes a first hole formed through the body of the connector; inserting the connector into the connector housing, wherein when the connector is inserted into the connector housing, a first annular flow path connector is formed between the connector housing and the connector by a first housing annular flow path connection groove formed in the inner surface of the connector housing, by a first connector annular flow path connection groove formed in the outer side surface of the connector, or 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 intersects the first annular flow path connector, and the first hole is in fluid communication with the first annular flow path connector.

15. The method according to claim 14, wherein: the BOP stack is supported on a frame; and the method includes pulling the connector into the connector housing by a winch mounted on the frame.

16. The method according to claim 15, further comprising: connecting a pump to the riser, where the pump is configured to pump fluid.

17. The method according to claim 14, wherein inserting the connector includes sealing the first annular flow path connector with a seal.

18. The method according to claim 14, wherein: the body of the connector includes a third hole; the third hole is formed through the body of the connector, and The system includes a second annular flow path connector formed between the connector housing and the connector, wherein the second annular flow path connector is formed by a second housing annular flow path connection groove formed in the inner surface of the connector housing, by a second connector annular flow path connection groove formed in the outer side surface of the connector, or by a combination of the second housing annular flow path connection groove axially aligned with the second connector annular flow path connection groove.

19. The method according to claim 18, wherein: The body of the connector includes a third hole; The third hole is formed through the body of the connector, and The system includes a third annular flow path connector formed between the connector housing and the connector, wherein the third annular flow path connector is formed by a third housing annular flow path connection groove formed in the inner surface of the connector housing, by a third connector annular flow path connection groove formed in the outer side surface of the connector, or by a combination of the third housing annular flow path connection groove axially aligned with the third connector annular flow path connection groove.

20. The method according to claim 14, wherein the riser connector includes one or more hoses connecting the riser to one or more holes of the connector.

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