Rotating control device with damper assembly

Abstract

A rotating control device (RCD) for a drilling system includes an outer housing, a seal element positioned within the outer housing and configured to form an annular seal about a tubular, and a damper assembly positioned with the outer housing and configured to dampen forces exerted on the seal element as the tubular rotates, moves axially, or both.

Description

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to Indian Patent Application No. 202311019454, filed on Mar. 21, 2023, the entirety of which is incorporated by reference herein.BACKGROUND

[0002] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and / or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

[0003] Natural resources have a profound effect on modern economies and societies. In order to meet the demand for such natural resources, numerous companies invest significant amounts of time and money in searching for, accessing, and extracting oil, natural gas, and other natural resources. Particularly, once a desired natural resource is discovered below the surface of the earth, drilling systems are often employed to access the desired natural resource. These drilling systems can be located onshore or offshore depending on the location of the desired natural resource. Such drilling systems may include a drilling fluid system configured to circulate drilling fluid into and out of a wellbore to facilitate drilling the wellbore.BRIEF DESCRIPTION

[0004] A summary of certain embodiments disclosed herein is set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below.

[0005] In certain embodiments, a rotating control device (RCD) for a drilling system includes an outer housing, a seal element positioned within the outer housing and configured to form an annular seal about a tubular, and a damper assembly positioned with the outer housing and configured to dampen forces exerted on the seal element as the tubular rotates, moves axially, or both.

[0006] In certain embodiments, a rotating control device (RCD) for a drilling system includes a seal element positioned configured to form an annular seal about a tubular and a damper assembly configured to dampen forces exerted on the seal element as the tubular rotates, moves axially, or both. The RCD also includes a piston actuation system configured to provide active control to adjust a sealing force of the annular seal.

[0007] In certain embodiments, a method of operating a drilling system includes placing a tubular through a rotating control device (RCD) and actuating a piston actuation system to compress a seal element to cause the seal element to form an annular seal about the tubular. The method also includes dampening, via a damper assembly, forces exerted by rotating the tubular, moving the tubular axially, or both while the seal element forms the annular seal about the tubular.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Various features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying figures in which like characters represent like parts throughout the figures, wherein:

[0009] FIG. 1 is a schematic diagram of a drilling system, in accordance with an embodiment of the present disclosure;

[0010] FIG. 2 is a cross-sectional view of a rotating control device (RCD) that may be used in the drilling system, wherein a seal assembly of the RCD is in a first configuration, in accordance with an embodiment of the present disclosure;

[0011] FIG. 3 is a cross-sectional view of the RCD that may be used in the drilling system, wherein the seal assembly of the RCD is in a second configuration, in accordance with an embodiment of the present disclosure;

[0012] FIG. 4 is a schematic cross-sectional side view of a portion of a seal element that may be used in the seal assembly, wherein the seal element is in a relaxed configuration, in accordance with an embodiment of the present disclosure;

[0013] FIG. 5 is a schematic cross-sectional side view of the portion of the seal element, wherein the seal element is in a compressed configuration, in accordance with an embodiment of the present disclosure;

[0014] FIG. 6 is a schematic cross-sectional side view of the portion of the seal element, wherein the seal element is in the compressed configuration and in contact with a radially expanded portion of a tubular, in accordance with an embodiment of the present disclosure;

[0015] FIG. 7 is a schematic cross-sectional side view of the portion of the seal element, wherein the seal element is in the compressed configuration and in contact with the radially expanded portion of the tubular along an entirety of an axial length of the seal element, in accordance with an embodiment of the present disclosure; and

[0016] FIG. 8 is a schematic cross-sectional side view of the seal assembly positioned within a spool housing to facilitate insertion and removal of the seal assembly, in accordance with an embodiment of the present disclosure.DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

[0017] One or more specific embodiments of the present disclosure will be described below. These described embodiments are only exemplary of the present disclosure. Additionally, in an effort to provide a concise description of these exemplary embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers'specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0018] When introducing elements of various embodiments, the articles “a,”“an,”“the,”“said,” and the like, are intended to mean that there are one or more of the elements. The terms “comprising,”“including,”“having,” and the like are intended to be inclusive and mean that there may be additional elements other than the listed elements. The use of “top,”“bottom,”“above,”“below,” and variations of these terms is made for convenience, but does not require any particular orientation of the components relative to some fixed reference, such as a direction of gravity.

[0019] A drilling system may include a drilling fluid system that is configured to circulate drilling fluid into and out of a wellbore to facilitate drilling the wellbore. For example, the drilling fluid system may provide a flow of the drilling fluid through a tubular (e.g., drill string) as the tubular rotates a drill bit that is positioned at a distal end portion of the tubular. The drilling fluid may exit through one or more openings at the distal end portion of the tubular and may return toward a platform of the drilling system via an annular space between the tubular and a casing that lines the wellbore.

[0020] In some cases, the drilling system may use managed pressure drilling (“MPD”). MPD regulates a pressure and a flow of the drilling fluid within the tubular so that the flow of the drilling fluid does not over pressurize a well (e.g., expand the well) and / or blocks the well from collapsing under its own weight. The ability to manage the pressure and the flow of the drilling fluid enables use of the drilling system to drill in various locations, such as locations with relatively softer sea beds.

[0021] Embodiments of the present disclosure relate generally to a rotating control device (RCD) with a seal assembly that is configured to seal against a tubular (e.g., drill string) that extends through the RCD. More particularly, the seal assembly includes a seal element (e.g., annular seal element) that is configured to contact the tubular to form an annular seal that extends circumferentially about the tubular. The seal element may form the annular seal about the tubular as the tubular rotates and / or moves axially within the wellbore.

[0022] It should be appreciated that the annular seal formed between the seal assembly and the tubular may block fluid flow through an annular space that surrounds the tubular. For example, the annular seal may block drilling fluid, cuttings, and / or natural resources (e.g., carbon dioxide, hydrogen sulfide) from passing across the RCD from the wellbore toward a platform. In some embodiments, the fluid flow may be diverted toward another suitable location (e.g., a collection tank) other than the platform.

[0023] The seal assembly may include one or more bearings to facilitate rotation of at least the seal element with the tubular as the tubular rotates and / or moves axially within the wellbore (e.g., the seal element may be driven to rotate by the tubular). The seal assembly may include a damper assembly (e.g., springs or other biasing members) to absorb forces, such as forces exerted by the tubular on the seal element as the tubular rotates and / or moves axially within the wellbore. The seal assembly may include a piston that is configured to drive the seal element from a relaxed configuration to a compressed configuration to enable the seal element to form the annular seal about the tubular.

[0024] As the tubular moves axially through the RCD, the seal element may be compressed and may deform (e.g., increase and decrease its inner diameter; compress axially and / or radially), which induces stress in the seal element. Advantageously, the damper assembly may absorb the forces exerted by the tubular on the seal element and may thereby reduce the stress in the seal element (e.g., as compared to another seal assembly without the damper assembly). Further, the piston may provide active control to adjust the seal element, which may facilitate a desirable level of sealing force against the tubular. The piston may provide the active control to adjust the seal element as the seal element deforms and experiences wear over time to thereby provide the desirable level of sealing force against the tubular for longer durations of time (e.g., more working hours; as compared to a passive seal element that relies on material properties and geometry of the passive seal element, without the piston). In this way, the RCD may have fewer maintenance operations, lower maintenance costs, more reliable sealing, and so forth.

[0025] FIG. 1 is a schematic diagram that illustrates an embodiment of a drilling system 10 that is configured to carry out drilling operations. The drilling system 10 may be a subsea system, although the disclosed embodiments may be used in a land-based (e.g., surface) system. The drilling system 10 may use MPD techniques. As illustrated, the drilling system 10 includes a wellhead assembly 12 coupled to a mineral deposit 14 via a well 16 having a wellbore 18.

[0026] The wellhead assembly 12 may include or be coupled to multiple components that control and regulate activities and conditions associated with the well 16. For example, the wellhead assembly 12 generally includes or is coupled to pipes, bodies, valves, and seals that enable drilling of the well 16, route produced minerals from the mineral deposit 14, provide for regulating pressure in the well 16, and provide for the injection of drilling fluids into the wellbore 18. A conductor 22 may provide structure for the wellbore 18 and may block collapse of the sides of the well 16 into the wellbore 18. A casing 24 may be disposed within the conductor 22. The casing 24 may provide structure for the wellbore 18 and may facilitate control of fluid and pressure during drilling of the well 16. The wellhead assembly 12 may include a tubing spool, a casing spool, and a hanger (e.g., a tubing hanger or a casing hanger) to enable installation of the casing 24. As shown, the wellhead assembly 12 may include or be coupled to a blowout preventer (BOP) assembly 26, which may include one or more BOPs (e.g., one or more ram BOPs, one or more annular BOPs, or a combination thereof). For example, the BOP assembly 26 shown in FIG. 1 includes a ram BOP having moveable rams 28 configured to seal the wellbore 18.

[0027] A drilling riser 30 may extend between the BOP assembly 26 and a platform 32. The platform 32 may include various components that facilitate operation of the drilling system 10, such as pumps, tanks, and power equipment. The platform 32 may also include a derrick 34 that supports a tubular 36 (e.g., drill string), which may extend through the drilling riser 30. A drilling fluid system 38 may direct the drilling fluid into the tubular 36, and the drilling fluid may exit through one or more openings at a distal end portion 40 of the tubular 36 and may return (along with cuttings and / or other substances from the well 16) toward the platform 32 via an annular space (e.g., between the tubular 36 and the casing 24 that lines the wellbore 18; between the tubular 36 and the drilling riser 30). A drill bit 42 may be positioned at the distal end portion 40 of the tubular 36. The tubular 36 may rotate within the drilling riser 30 to rotate the drill bit 42, thereby enabling the drill bit 42 to drill and form the well 16.

[0028] As shown, the drilling system 10 may include a rotating control device (RCD) 44 that is configured to block fluid flow through the annular space that surrounds the tubular 36. For example, the RCD 44 may be configured to block the drilling fluid, cuttings, and / or other substances from passing across the RCD 44 from the well 16 toward the platform 32. The RCD 44 may be positioned at any suitable location within the drilling system 10, such as any suitable location between the wellbore 18 and the platform 32. For example, as shown, the RCD 44 may be positioned along the drilling riser 30 (e.g., in-line with the drilling riser 30) and between the BOP assembly 26 and the platform 32. In some embodiments, the RCD 44 may be positioned at or near a sea floor, mounted or fastened to the BOP assembly 26 or other portion of the wellhead assembly 12, or other suitable location.

[0029] The RCD 44 and its components may be described with reference to the axial axis 2 (or axial direction), a radial axis 4 (or radial direction), and a circumferential axis 6 (or direction) to facilitate discussion. In operation, the tubular 36 may be rotated in the circumferential direction 6 and / or may be moved along the axial axis 2 to enable the drill bit 42 to drill the well 16. The RCD 44 and its components may provide the annular seal while the tubular 36 is stationary within the RCD 44, and also while the tubular 36 is rotated in the circumferential direction 6 and / or moved along the axial axis 2.

[0030] FIG. 2 is a cross-sectional side view of an embodiment of the RCD 44. As shown, the RCD 44 includes a seal assembly 50 (e.g., annular seal assembly) within an outer housing 54 (e.g., annular outer housing). The seal assembly 50 may include an inner housing 56 (e.g., annular inner housing), a seal element 58 (e.g., annular seal element), one or more bearings 60 (e.g., annular bearing assemblies), one or more support plates 62 (e.g., annular support plates), a piston 64 (e.g., annular piston), a damper assembly 66 (e.g., annular damper assembly), and one or more retainer rings 68 (e.g., annular retainer rings). As shown, a portion of the piston 64 is positioned in a chamber 70 (e.g., annular chamber), which may be formed in the outer housing 54 or other suitable structure.

[0031] It should be appreciated that one or more additional internal seal elements (e.g., annular internal seal elements; o-rings) may be provided between certain components of the RCD 44. The one or more additional internal seal elements may be formed from an elastomer material and / or a metal material (e.g., metal or metal alloy material). Further, the seal element 58 may be formed from an elastomer material, and the one or more support plates 62 may be formed from a metal material (e.g., metal or metal alloy material). In some embodiments, at least one of the one or more support plates 62 includes protrusions (e.g., annular protrusions) that extend into the seal element 58 to facilitate engagement with the seal element 58. In some embodiments, the protrusions may be molded into the seal element 58.

[0032] Additionally, the seal element 58 includes a radially outer surface 78 (e.g., annular surface) that is configured to face away from the tubular 36 when the tubular 36 extends through the RCD 44 and a radially inner surface 80 (e.g., annular surface) that is configured to face toward the tubular 36 when the tubular 36 extends through the RCD 44. At least portions of the radially inner surface 80 are configured to contact and seal against the tubular 36 when the tubular 36 extends through the RCD 44.

[0033] The inner housing 56 defines a center bore 82 and a recess 84 (e.g., cavity). More particularly, the inner housing 56 defines a first orifice 86 (e.g., upper orifice; first orifice) at a first end 88 (e.g., upper end) of the center bore 82, and a radially inner wall 90 (e.g., annular wall) of the inner housing 56 defines the recess 84 with a curved dome shape. The seal element 58 is positioned within the recess 84 of the inner housing 56. More particularly, the radially outer surface 78 of the seal element 58 may face and contact the radially inner wall 90 of the inner housing 56.

[0034] The outer housing 54 may be configured to couple to an adjacent structure or component (e.g., axially above and / or below the outer housing 54; via one or more fasteners, such as bolts; to part of the drilling riser 30 or the BOP assembly 26 of FIG. 1). The outer housing 54 defines an outer housing recess 120 (e.g., outer housing cavity) that is configured to receive the seal assembly 50. In particular, a radially outer wall 126 (e.g., annular wall) of the inner housing 56 of the seal assembly 50 may face toward a radially inner wall 128 (e.g., annular wall) of the outer housing 54. At least one of the one or more bearings 60 may be positioned between the inner housing 56 and the outer housing 54. For example, as shown, at least one of the one or more bearings 60 may be positioned radially between the radially outer wall 126 of the inner housing 56 and the radially inner wall 128 of the outer housing 54.

[0035] In some embodiments, the one or more retainer rings 68 engage the inner housing 56 and the outer housing 54. For example, the one or more retainer rings 68 may insert into corresponding grooves or recesses of the inner housing 56 and the outer housing 54 to block the inner housing 56 from moving axially relative to the outer housing 54, while also enabling the inner housing 56 to rotate circumferentially relative to the outer housing 54.

[0036] In some embodiments, the damper assembly 66 is positioned axially between the seal element 58 and the piston 64. In particular, in some embodiments, a lower surface 92 (e.g., axially-facing surface; annular surface) of the seal element 58 may contact an upper surface 94 (e.g., axially-facing surface; annular surface) of a first support plate 96 of the one or more support plates 62. As shown, the upper surface 94 of the first support plate 96 may include at least one portion with a flat surface (e.g., in a plane that contains the radial axis 4) that contacts the seal element 58, although other configurations (e.g., protrusions, tapered, stepped) are envisioned.

[0037] Further, one or more dampers 98 may be positioned axially between the first support plate 96 and a second support plate 100 of the one or more support plates 62. Further, a lower surface 102 (e.g., axially-facing surface; annular surface) of the second support plate 100 may contact a thrust bearing 104 (e.g., one of the one or more bearings 60; annular bearing). Further, an upper surface 106 (e.g., axially-facing surface; annular surface) of the piston 64 may also contact the thrust bearing 104. Thus, as shown, the thrust bearing 104 may be positioned axially between the second support plate 100 and the piston 64. Indeed, as shown, these components may be arranged in a stack (e.g., axially stacked).

[0038] As discussed herein, the damper assembly 66 may include one or more dampers 98 that are configured to absorb forces, such as forces exerted by the tubular on the seal element 58 as the tubular rotates and / or moves axially within the wellbore. For example, the one or more dampers 98 may include one or more biasing members, such as coil springs, that are positioned axially between the first support plate 96 and the second support plate 100. It should be appreciated that and the one or more dampers 98 may be positioned axially between additional support plates and / or may be utilized in conjunction with additional components. Further, it should be appreciated that the one or more dampers 98 may have any suitable configuration or form to facilitate the techniques disclosed herein. Indeed, the damper assembly 66 may have any suitable configuration or form to facilitate the techniques disclosed herein.

[0039] In operation, the one or more dampers 98 may adjust (e.g., compress) and enable the seal element 58 and the first support plate 96 to move axially toward the second support plate 100 and the piston 64 as the tubular moves axially through the RCD 44. For example, as the tubular moves axially through the RCD, a joint (e.g., radially expanded portion; joins two adjacent pipe portions to one another) of the tubular may move through the RCD 44. The joint may exert a force on the seal element 58, and the force is at least partially absorbed (or dampened) by the damper assembly 66. After the joint passes through the RCD 44, the damper assembly 66 may adjust (e.g., extend) to enable the seal element 58 to maintain the annular seal about the tubular and / or to enable the damper assembly 66 to absorb or dampen forces that will be exerted on the seal element 58 by another joint along the tubular.

[0040] The piston 64 may be part of a piston actuation system 140 system that operates to adjust the seal element 58 between a relaxed configuration (e.g., initial or first seal element configuration; original state) and a compressed configuration (e.g., second seal element configuration; deformed state). In the relaxed configuration, the seal element 58 may be withdrawn from the center bore 82 and / or may have a first inner diameter. In the compressed configuration, the seal element 58 may extend into the center bore 82 and / or may have a second inner diameter that is less than the first inner diameter. It should be appreciated that the piston actuation system 140 may adjust the seal element 58 to the compressed configuration with various levels of compression. Thus, in the compressed configuration, the seal element 58 may have any of a variety of second inner diameters that are less than the first inner diameter. Further, the seal assembly 50 may be considered to be in a first configuration (e.g., first actuation configuration; the piston 64 is retracted into the chamber 70) while the seal element 58 is in the relaxed configuration, and the seal assembly 50 may be considered to be in a second configuration (e.g., second actuation configuration; the piston 64 is extended out of the chamber 70) while the seal element 58 is in the compressed configuration.

[0041] In FIG. 2, the seal element 58 is in the relaxed configuration, and the seal assembly 50 is in the first configuration. To transition the seal element 58 to the compressed configuration, a fluid circuit 142 may provide a fluid to the chamber 70. In particular, the fluid circuit 142 may include a fluid source 144. A controller 150 (e.g., electronic controller) may control a first valve 152 to enable flow from the fluid source 144 to the chamber 70 and / or to drain the flow from the chamber 70 to the fluid source 144 (or to another fluid drain). It should be appreciated that the fluid circuit 142 may have any suitable components or configuration that enable techniques disclosed herein (e.g., to drive movement of the piston 64). As described in more detail herein, such circulation of the fluid through the chamber 70 may adjust the seal element 58 relative to the inner housing 56 (and the tubular, when the tubular is within the RCD 44).

[0042] The controller 150 may control the delivery of the fluid from the fluid source 144 to the chamber 70 based on any of a variety of inputs, such as in response to an input received from a user interface device at the platform (e.g., from an operator) and / or in response to an input received from one or more sensors, such as one or more sensors that monitor one or more parameters indicative of the annular seal formed between the seal element 58 and the tubular, wellbore conditions, rotation of the tubular, or the like. For example, the controller 150 may receive an input that indicates an undesirable pressure below the RCD 44 (e.g., between the wellhead and the RCD 44) and / or above the RCD 44 (e.g., between the platform and the RCD 44) and may then adjust (e.g., increase) the fluid pressure in the chamber 70 to form and / or adjust (e.g., increase) the annular seal (e.g., sealing force; radial force) between the seal element 58 and the tubular. As another example, the controller 150 may receive an input that indicates that the tubular will begin to move or is moving within the RCD 44 (e.g., rotating in the circumferential direction 6 and / or moving in the axial direction 2), and the controller 150 may then adjust (e.g., increase or decrease) the fluid pressure in the chamber 70 to thereby form and / or adjust (e.g., increase or decrease) the annular seal between the seal element 58 and the tubular. In this way, the RCD 44 may provide an adjustable and dynamic seal about the tubular (e.g., as the tubular rotates in the circumferential direction 6 and / or moves in the axial direction 2 through the RCD 44).

[0043] As shown in FIG. 2, the controller 150 includes a processor 156 and a memory device 158. It should be appreciated that the controller 150 may be a dedicated controller for the RCD 44 and / or the controller 150 may be part of or include a distributed controller with one or more electronic controllers in communication with one another to carry out the various techniques disclosed herein. The processor 156 may also include one or more processors configured to execute software, such as software for processing signals and / or controlling the components of the RCD 44. The memory device 158 disclosed herein may include one or more memory devices (e.g., a volatile memory, such as random access memory [RAM], and / or a nonvolatile memory, such as read-only memory [ROM]) that may store a variety of information and may be used for various purposes. For example, the memory device 158 may store processor-executable instructions (e.g., firmware or software) for the processor 156 to execute, such as instructions for processing signals and / or controlling the components of the RCD 44. It should be appreciated that the controller 150 may include various other components, such as a communication device that is capable of communicating data or other information (e.g., a current configuration of the RCD 44) to various other devices (e.g., a remote computing system or display system at the platform).

[0044] In operation, the fluid delivered from the fluid source 144 to the chamber 70 may exert a force on a lower surface 170 (e.g., axially facing surface) of the piston 64 to drive the piston 64 axially through the outer housing 54 toward the seal element 58. In turn, the piston 64 drives the seal element 58, the one or more support plates 62, the damper assembly 66, and the thrust bearing 104 axially through the inner housing 56 and / or the outer housing 54. As shown and described herein, the thrust bearing 104 is positioned axially between the second support plate 100 and the piston 64. Thus, the thrust bearing 104 is configured to transfer force (e.g., axial force) from the piston 64 to the second support plate 100, while also enabling relative rotation (e.g., in the circumferential direction 6) between the piston 64 and the second support plate 100.

[0045] The curved dome shape of the radially inner wall 90 of the inner housing 56 blocks the seal element 58 from moving axially within the inner housing 56 and guides the seal element 58 into the center bore 82. Thus, as the piston 64 drives the seal element 58 axially within the inner housing 56, the seal element 58 is compressed between the first support plate 96 and the curved dome shape of the radially inner wall 90 of the inner housing 56, and the seal element 58 is also guided into the center bore 82.

[0046] In operation, the tubular may extend through the RCD 44. Because the seal element 58 protrudes into the center bore 82 in the compressed configuration and / or because the inner diameter of the seal element 58 in the compressed configuration is less than an outer diameter of the tubular, the seal element 58 contacts and engages with the tubular. Further, the contact between the seal element 58 and the tubular may cause the seal element 58 to form the annular seal about the tubular.

[0047] To facilitate discussion, FIG. 3 is a cross-sectional view of the RCD 44 with the seal element 58 in the compressed configuration and the seal assembly 50 in the second configuration. Further, the seal element 58 is sealed against the tubular 36. During drilling operations, the tubular 36 may rotate in the circumferential direction 6 and / or move along the axial axis 2. In some embodiments, certain portions of the seal assembly 50 are supported on the one or more bearings 60, such as the thrust bearing 104 and one or more additional bearings 182 (e.g., bearing ring; annular bearing; cylindrical bearing), to rotate with the tubular 36 (e.g., the rotation of the tubular 36 drives the rotation of the seal assembly 50). For example, as shown, the rotation of the tubular 36 may drive the rotation of the seal element 58, the one or more support plates 62, the damper assembly 66, and the inner housing 56 relative to the outer housing 54 (e.g., facilitated by the one or more bearings 60). It should be appreciated that the rotation of the tubular 36 may drive the rotation of the seal element 58, the one or more support plates 62, the damper assembly 66, and the inner housing 56 relative to other components as well, such as relative to the piston 64. Thus, certain components (e.g., the piston 64) move only axially (e.g., without rotation) relative to the outer housing 54, while other components (e.g., the sealing element 58, the one or more support plates 62, and the damper assembly 66) move both axially and with rotation relative to the outer housing 54. Further, certain components (e.g., the inner housing 56) rotate relative to the outer housing 54, but do not move axially relative to the outer housing 54.

[0048] In this way, the tubular 36 may not slip or rotate relative to the seal element 58, which may reduce wear on the seal element 58. In FIGS. 2 and 3, the thrust bearing 104 is positioned between the second support plate 100 and the piston 64 along the axial axis 2, and the one or more additional bearings 182 are positioned between the inner housing 56 and the outer housing 54 along the radial axis 4. However, the one or more bearings 60 may be positioned at any suitable location to enable the rotation of the tubular 36 to drive the rotation of at least the seal element 58.

[0049] FIGS. 4-7 illustrate the seal element 58 in various configurations and during various operations. For example, FIG. 4 is a schematic cross-sectional side view of a portion of the seal element 58 in the relaxed configuration within the inner housing 56. As shown, in the relaxed configuration, the seal element 58 is withdrawn from the center bore 82 defined by the first orifice 86 of the inner housing 56 and / or the seal element 58 does not contact the tubular 36 in the center bore 82.

[0050] FIG. 5 is a schematic cross-sectional side view of the portion of the seal element 58 in the compressed configuration within the inner housing 56. As shown, in the compressed configuration, the seal element 58 extends into the center bore 82 defined by the first orifice 86 of the inner housing 56 and / or the seal element 58 contacts the tubular in the center bore 82. Further, the seal element 58 may have the first inner diameter in the relaxed configuration and the second inner diameter in the compressed configuration, wherein the first inner diameter is greater than the second inner diameter.

[0051] As described herein, the seal element 58 may be driven from the relaxed configuration of FIG. 4 to the compressed configuration of FIG. 5 via the piston actuation system 140 of FIG. 3. In particular, the piston actuation system 140 may drive the piston 64 shown in FIGS. 2 and 3 axially to compress the seal element 58 against the curved dome shape of the radially inner wall 90, which drives the seal element 58 into the center bore 82 and / or toward the tubular 36.

[0052] In FIG. 5, the seal element 58 is axially aligned with and sealed against a first portion 190 of the tubular 36. The first portion 190 of the tubular 36 may be a pipe section of a drill string, for example. FIG. 6 is a schematic cross-sectional side view of the portion of the seal element 58 in the compressed configuration within the inner housing 56, wherein a portion of the seal element 58 is axially aligned with and sealed against a second portion 192 of the tubular 36. The second portion 192 of the tubular 36 may be a joint of the drill string (e.g., the joint that joins two pipe sections together), for example. The first portion 190 of the tubular 36 may have a first outer diameter, and the second portion 192 of the tubular 36 may be a radially expanded portion that has a second outer diameter greater than the first outer diameter. Accordingly, as the second portion 192 of the tubular 36 is inserted into the sealing element 58, the sealing element 58 compresses radially outwardly against the inner housing 56 and / or axially against the first support plate 96 to accommodate the second portion 192 of the tubular 36. The sealing element 58 experiences forces as the joint enters and moves through the sealing element 58, and the damper assembly 66 dampens or absorbs the forces. As described herein, this may reduce stress and wear on the sealing element 58. In this way, the RCD 44 may have lower maintenance costs, more reliable sealing, and so forth.

[0053] FIG. 7 is a schematic cross-sectional side view of the portion of the seal element 58 in the compressed configuration within the inner housing 56, wherein the seal element 58 is axially aligned with and sealed against the second portion 192 of the tubular 36 (e.g., along an entirety of an axial length of the seal element 58). It should be appreciated that as the tubular 36 moves axially through the RCD (e.g., into or out of the wellbore), the seal element 58 will continuously cycle between the configurations shown in FIGS. 5-7 to accommodate various portions of the tubular 36, and the damper assembly 66 will absorb and dampen the forces exerted by the tubular 36 on the seal element 58.

[0054] It should be appreciated that FIGS. 4-7 are intended to generally represent that at least some changes (e.g., deformation) occur between the relaxed configuration (FIG. 4) and the compressed configuration (FIGS. 5-7) of the seal element 58. Indeed, the seal element 58 may not have the cross-sectional shapes shown in FIGS. 4-7, and these figures are merely intended to generally represent that the seal element 58 will deform in some way due to actuation of the piston actuation system 140 and / or contact with the tubular 36, and thus, that the damper assembly 66 may provide advantages by dampening or absorbing forces exerted by the tubular 36 on the seal element 58.

[0055] Further, it should be appreciated that variations in form are envisioned. For example, FIG. 8 is a cross-sectional side view of an embodiment of a seal assembly 200 (e.g., annular seal assembly) and a spool 202 (e.g., annular spool) that may be used in the RCD 44. The seal assembly 200 and the spool 202 may each be considered sub-assemblies that are configured to be coupled together to form the RCD 44. In particular, the seal assembly 200 is configured to be inserted into the spool 202 to form the RCD 44.

[0056] As shown, the seal assembly 200 may include or be positioned within an outer housing 204 (e.g., annular outer housing), an inner housing 206 (e.g., annular inner housing), a seal element 208 (e.g., annular seal element), one or more bearings 210 (e.g., annular bearings), one or more support plates 212 (e.g., annular support plate), a piston 214 (e.g., annular piston; first piston; seal assembly piston), a damper assembly 216, and one or more retainer rings 218. One or more internal seal elements (e.g., annular internal seal elements; o-rings; packer seals) may be provided between certain components of the seal assembly 200 and / or between the seal assembly 200 and the spool 202.

[0057] The inner housing 206 defines a center bore 232 and a recess 234 (e.g., cavity). More particularly, the inner housing 206 defines a first orifice 236 (e.g., upper orifice; first orifice) at a first end 238 (e.g., upper end) of the center bore 232, and a radially inner wall 240 (e.g., annular wall) of the inner housing 206 defines the recess 234 with a curved dome shape. The seal element 208 is positioned within the recess 234 of the inner housing 206.

[0058] As shown, the spool 202 may include a spool housing 300 (e.g., annular spool housing) with a flange 302 (e.g., annular flange) that is configured to couple to an adjacent structure or component (e.g., axially below the spool 202; via one or more fasteners, such as bolts; to part of the drilling riser 30 or the BOP assembly 26 of FIG. 1). The spool 202 may also include a spool piston 304 (e.g., annular piston; second piston) that is configured to move axially within a chamber 306 (e.g., annular chamber). The spool 202 may also include spool retaining rings 308 (e.g., annular spool retaining rings), and one or more latches 310 (e.g., piston latches) that are configured to be placed within one or more openings 312 (e.g., radially extending through holes) formed in the spool housing 300. One or more spool internal seal elements (e.g., annular spool internal seal elements; o-rings) may be provided between certain components of the spool 202.

[0059] The spool 202 defines a spool recess 320 (e.g., spool cavity) that is configured to receive the seal assembly 200 (that includes the outer housing 204, or with the outer housing 204). For example, the one or more latches 310 may be retracted from the one or more openings 312 (e.g., withdrawn from the spool recess 320) to enable insertion or placement of the seal assembly 200 in the spool recess 320. Then, the one or more latches 310 may be inserted into the one or more openings 312 (e.g., extended into the spool recess 320) to hold the seal assembly 200 in the spool recess 320. In some embodiments, the one or more latches 310 may be electrically and / or mechanically actuated (e.g., via a hydraulic system).

[0060] The piston 214 and the spool piston 304 may be part of a split piston actuation system 340 that operates to adjust the seal element 208 between a relaxed configuration and a compressed configuration. In FIG. 8, the seal element 208 is in the relaxed configuration. To transition the seal element 208 to the compressed configuration, a fluid circuit may provide a fluid to the chamber 306. As described in more detail herein, such circulation of the fluid through the chamber 306 may adjust the seal element 208 relative to the outer housing 204 (and the tubular 36, when the tubular 36 is within the RCD 44). For example, the fluid delivered to the chamber 306 may exert a force on the spool piston 304 to drive the spool piston 304 axially toward the piston 214. The spool piston 304 contacts the piston 214, and the spool piston 304 and the piston 214 move axially together to thereby drive the seal element 208 axially within the inner housing 206. Then, during drilling operations, components supported between the tubular 36 and the one or more bearings 60 rotate with the tubular (e.g., the rotation of the tubular drives the rotation of the certain portions of the seal assembly 200).

[0061] It should be appreciated that the seal assembly 200 may be removed from the spool 202 via retracting the one or more latches 310 and then moving the seal assembly 200 axially relative to the spool 202 (e.g., lifting the seal assembly 200 out of the spool 202). Then, another seal assembly (e.g., having the same features as the seal assembly 200) may be inserted into the spool 202 and locked within the spool via inserting the one or more latches 310. In this way, the disclosed embodiments facilitate replacement of the seal assembly 200 (e.g., from axially above the spool 202) without removal of the spool 202 from the adjacent structure or component (e.g., axially below the spool 202; from its position in line with the drilling riser 30 of FIG. 1 and / or the BOP assembly 26 of FIG. 1).

[0062] Additionally, the seal assembly 200 may include any of the features of the seal assembly 50 (or vice versa). Thus, any of the features disclosed herein may be combined in any suitable manner. Further, the present embodiments may include a seal assembly with any of a variety of shapes and features. For example, the seal element may include inserts (e.g., metal pieces molded into elastomer of the seal element). Alternatively, the seal element may be devoid of inserts (e.g., only elastomer material).

[0063] While the disclosure may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the disclosure is intended to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the following appended claims.

Examples

Embodiment Construction

[0017]One or more specific embodiments of the present disclosure will be described below. These described embodiments are only exemplary of the present disclosure. Additionally, in an effort to provide a concise description of these exemplary embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers'specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0018]When introducing elements of various embodiment...

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to Indian Patent Application No. 202311019454, filed on Mar. 21, 2023, the entirety of which is incorporated by reference herein.BACKGROUND

[0002] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and / or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

[0003] Natural resources have a profound effect on modern economies and societies. In order to meet the demand for such natural resources, numerous companies invest significant amounts of time and money in searching for, accessing, and extracting oil, natural gas, and other natural resources. Particularly, once a desired natural resource is discovered below the surface of the earth, drilling systems are often employed to access the desired natural resource. These drilling systems can be located onshore or offshore depending on the location of the desired natural resource. Such drilling systems may include a drilling fluid system configured to circulate drilling fluid into and out of a wellbore to facilitate drilling the wellbore.BRIEF DESCRIPTION

[0004] A summary of certain embodiments disclosed herein is set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below.

[0005] In certain embodiments, a rotating control device (RCD) for a drilling system includes an outer housing, a seal element positioned within the outer housing and configured to form an annular seal about a tubular, and a damper assembly positioned with the outer housing and configured to dampen forces exerted on the seal element as the tubular rotates, moves axially, or both.

[0006] In certain embodiments, a rotating control device (RCD) for a drilling system includes a seal element positioned configured to form an annular seal about a tubular and a damper assembly configured to dampen forces exerted on the seal element as the tubular rotates, moves axially, or both. The RCD also includes a piston actuation system configured to provide active control to adjust a sealing force of the annular seal.

[0007] In certain embodiments, a method of operating a drilling system includes placing a tubular through a rotating control device (RCD) and actuating a piston actuation system to compress a seal element to cause the seal element to form an annular seal about the tubular. The method also includes dampening, via a damper assembly, forces exerted by rotating the tubular, moving the tubular axially, or both while the seal element forms the annular seal about the tubular.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Various features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying figures in which like characters represent like parts throughout the figures, wherein:

[0009] FIG. 1 is a schematic diagram of a drilling system, in accordance with an embodiment of the present disclosure;

[0010] FIG. 2 is a cross-sectional view of a rotating control device (RCD) that may be used in the drilling system, wherein a seal assembly of the RCD is in a first configuration, in accordance with an embodiment of the present disclosure;

[0011] FIG. 3 is a cross-sectional view of the RCD that may be used in the drilling system, wherein the seal assembly of the RCD is in a second configuration, in accordance with an embodiment of the present disclosure;

[0012] FIG. 4 is a schematic cross-sectional side view of a portion of a seal element that may be used in the seal assembly, wherein the seal element is in a relaxed configuration, in accordance with an embodiment of the present disclosure;

[0013] FIG. 5 is a schematic cross-sectional side view of the portion of the seal element, wherein the seal element is in a compressed configuration, in accordance with an embodiment of the present disclosure;

[0014] FIG. 6 is a schematic cross-sectional side view of the portion of the seal element, wherein the seal element is in the compressed configuration and in contact with a radially expanded portion of a tubular, in accordance with an embodiment of the present disclosure;

[0015] FIG. 7 is a schematic cross-sectional side view of the portion of the seal element, wherein the seal element is in the compressed configuration and in contact with the radially expanded portion of the tubular along an entirety of an axial length of the seal element, in accordance with an embodiment of the present disclosure; and

[0016] FIG. 8 is a schematic cross-sectional side view of the seal assembly positioned within a spool housing to facilitate insertion and removal of the seal assembly, in accordance with an embodiment of the present disclosure.DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

[0017] One or more specific embodiments of the present disclosure will be described below. These described embodiments are only exemplary of the present disclosure. Additionally, in an effort to provide a concise description of these exemplary embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers'specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0018] When introducing elements of various embodiments, the articles “a,”“an,”“the,”“said,” and the like, are intended to mean that there are one or more of the elements. The terms “comprising,”“including,”“having,” and the like are intended to be inclusive and mean that there may be additional elements other than the listed elements. The use of “top,”“bottom,”“above,”“below,” and variations of these terms is made for convenience, but does not require any particular orientation of the components relative to some fixed reference, such as a direction of gravity.

[0019] A drilling system may include a drilling fluid system that is configured to circulate drilling fluid into and out of a wellbore to facilitate drilling the wellbore. For example, the drilling fluid system may provide a flow of the drilling fluid through a tubular (e.g., drill string) as the tubular rotates a drill bit that is positioned at a distal end portion of the tubular. The drilling fluid may exit through one or more openings at the distal end portion of the tubular and may return toward a platform of the drilling system via an annular space between the tubular and a casing that lines the wellbore.

[0020] In some cases, the drilling system may use managed pressure drilling (“MPD”). MPD regulates a pressure and a flow of the drilling fluid within the tubular so that the flow of the drilling fluid does not over pressurize a well (e.g., expand the well) and / or blocks the well from collapsing under its own weight. The ability to manage the pressure and the flow of the drilling fluid enables use of the drilling system to drill in various locations, such as locations with relatively softer sea beds.

[0021] Embodiments of the present disclosure relate generally to a rotating control device (RCD) with a seal assembly that is configured to seal against a tubular (e.g., drill string) that extends through the RCD. More particularly, the seal assembly includes a seal element (e.g., annular seal element) that is configured to contact the tubular to form an annular seal that extends circumferentially about the tubular. The seal element may form the annular seal about the tubular as the tubular rotates and / or moves axially within the wellbore.

[0022] It should be appreciated that the annular seal formed between the seal assembly and the tubular may block fluid flow through an annular space that surrounds the tubular. For example, the annular seal may block drilling fluid, cuttings, and / or natural resources (e.g., carbon dioxide, hydrogen sulfide) from passing across the RCD from the wellbore toward a platform. In some embodiments, the fluid flow may be diverted toward another suitable location (e.g., a collection tank) other than the platform.

[0023] The seal assembly may include one or more bearings to facilitate rotation of at least the seal element with the tubular as the tubular rotates and / or moves axially within the wellbore (e.g., the seal element may be driven to rotate by the tubular). The seal assembly may include a damper assembly (e.g., springs or other biasing members) to absorb forces, such as forces exerted by the tubular on the seal element as the tubular rotates and / or moves axially within the wellbore. The seal assembly may include a piston that is configured to drive the seal element from a relaxed configuration to a compressed configuration to enable the seal element to form the annular seal about the tubular.

[0024] As the tubular moves axially through the RCD, the seal element may be compressed and may deform (e.g., increase and decrease its inner diameter; compress axially and / or radially), which induces stress in the seal element. Advantageously, the damper assembly may absorb the forces exerted by the tubular on the seal element and may thereby reduce the stress in the seal element (e.g., as compared to another seal assembly without the damper assembly). Further, the piston may provide active control to adjust the seal element, which may facilitate a desirable level of sealing force against the tubular. The piston may provide the active control to adjust the seal element as the seal element deforms and experiences wear over time to thereby provide the desirable level of sealing force against the tubular for longer durations of time (e.g., more working hours; as compared to a passive seal element that relies on material properties and geometry of the passive seal element, without the piston). In this way, the RCD may have fewer maintenance operations, lower maintenance costs, more reliable sealing, and so forth.

[0025] FIG. 1 is a schematic diagram that illustrates an embodiment of a drilling system 10 that is configured to carry out drilling operations. The drilling system 10 may be a subsea system, although the disclosed embodiments may be used in a land-based (e.g., surface) system. The drilling system 10 may use MPD techniques. As illustrated, the drilling system 10 includes a wellhead assembly 12 coupled to a mineral deposit 14 via a well 16 having a wellbore 18.

[0026] The wellhead assembly 12 may include or be coupled to multiple components that control and regulate activities and conditions associated with the well 16. For example, the wellhead assembly 12 generally includes or is coupled to pipes, bodies, valves, and seals that enable drilling of the well 16, route produced minerals from the mineral deposit 14, provide for regulating pressure in the well 16, and provide for the injection of drilling fluids into the wellbore 18. A conductor 22 may provide structure for the wellbore 18 and may block collapse of the sides of the well 16 into the wellbore 18. A casing 24 may be disposed within the conductor 22. The casing 24 may provide structure for the wellbore 18 and may facilitate control of fluid and pressure during drilling of the well 16. The wellhead assembly 12 may include a tubing spool, a casing spool, and a hanger (e.g., a tubing hanger or a casing hanger) to enable installation of the casing 24. As shown, the wellhead assembly 12 may include or be coupled to a blowout preventer (BOP) assembly 26, which may include one or more BOPs (e.g., one or more ram BOPs, one or more annular BOPs, or a combination thereof). For example, the BOP assembly 26 shown in FIG. 1 includes a ram BOP having moveable rams 28 configured to seal the wellbore 18.

[0027] A drilling riser 30 may extend between the BOP assembly 26 and a platform 32. The platform 32 may include various components that facilitate operation of the drilling system 10, such as pumps, tanks, and power equipment. The platform 32 may also include a derrick 34 that supports a tubular 36 (e.g., drill string), which may extend through the drilling riser 30. A drilling fluid system 38 may direct the drilling fluid into the tubular 36, and the drilling fluid may exit through one or more openings at a distal end portion 40 of the tubular 36 and may return (along with cuttings and / or other substances from the well 16) toward the platform 32 via an annular space (e.g., between the tubular 36 and the casing 24 that lines the wellbore 18; between the tubular 36 and the drilling riser 30). A drill bit 42 may be positioned at the distal end portion 40 of the tubular 36. The tubular 36 may rotate within the drilling riser 30 to rotate the drill bit 42, thereby enabling the drill bit 42 to drill and form the well 16.

[0028] As shown, the drilling system 10 may include a rotating control device (RCD) 44 that is configured to block fluid flow through the annular space that surrounds the tubular 36. For example, the RCD 44 may be configured to block the drilling fluid, cuttings, and / or other substances from passing across the RCD 44 from the well 16 toward the platform 32. The RCD 44 may be positioned at any suitable location within the drilling system 10, such as any suitable location between the wellbore 18 and the platform 32. For example, as shown, the RCD 44 may be positioned along the drilling riser 30 (e.g., in-line with the drilling riser 30) and between the BOP assembly 26 and the platform 32. In some embodiments, the RCD 44 may be positioned at or near a sea floor, mounted or fastened to the BOP assembly 26 or other portion of the wellhead assembly 12, or other suitable location.

[0029] The RCD 44 and its components may be described with reference to the axial axis 2 (or axial direction), a radial axis 4 (or radial direction), and a circumferential axis 6 (or direction) to facilitate discussion. In operation, the tubular 36 may be rotated in the circumferential direction 6 and / or may be moved along the axial axis 2 to enable the drill bit 42 to drill the well 16. The RCD 44 and its components may provide the annular seal while the tubular 36 is stationary within the RCD 44, and also while the tubular 36 is rotated in the circumferential direction 6 and / or moved along the axial axis 2.

[0030] FIG. 2 is a cross-sectional side view of an embodiment of the RCD 44. As shown, the RCD 44 includes a seal assembly 50 (e.g., annular seal assembly) within an outer housing 54 (e.g., annular outer housing). The seal assembly 50 may include an inner housing 56 (e.g., annular inner housing), a seal element 58 (e.g., annular seal element), one or more bearings 60 (e.g., annular bearing assemblies), one or more support plates 62 (e.g., annular support plates), a piston 64 (e.g., annular piston), a damper assembly 66 (e.g., annular damper assembly), and one or more retainer rings 68 (e.g., annular retainer rings). As shown, a portion of the piston 64 is positioned in a chamber 70 (e.g., annular chamber), which may be formed in the outer housing 54 or other suitable structure.

[0031] It should be appreciated that one or more additional internal seal elements (e.g., annular internal seal elements; o-rings) may be provided between certain components of the RCD 44. The one or more additional internal seal elements may be formed from an elastomer material and / or a metal material (e.g., metal or metal alloy material). Further, the seal element 58 may be formed from an elastomer material, and the one or more support plates 62 may be formed from a metal material (e.g., metal or metal alloy material). In some embodiments, at least one of the one or more support plates 62 includes protrusions (e.g., annular protrusions) that extend into the seal element 58 to facilitate engagement with the seal element 58. In some embodiments, the protrusions may be molded into the seal element 58.

[0032] Additionally, the seal element 58 includes a radially outer surface 78 (e.g., annular surface) that is configured to face away from the tubular 36 when the tubular 36 extends through the RCD 44 and a radially inner surface 80 (e.g., annular surface) that is configured to face toward the tubular 36 when the tubular 36 extends through the RCD 44. At least portions of the radially inner surface 80 are configured to contact and seal against the tubular 36 when the tubular 36 extends through the RCD 44.

[0033] The inner housing 56 defines a center bore 82 and a recess 84 (e.g., cavity). More particularly, the inner housing 56 defines a first orifice 86 (e.g., upper orifice; first orifice) at a first end 88 (e.g., upper end) of the center bore 82, and a radially inner wall 90 (e.g., annular wall) of the inner housing 56 defines the recess 84 with a curved dome shape. The seal element 58 is positioned within the recess 84 of the inner housing 56. More particularly, the radially outer surface 78 of the seal element 58 may face and contact the radially inner wall 90 of the inner housing 56.

[0034] The outer housing 54 may be configured to couple to an adjacent structure or component (e.g., axially above and / or below the outer housing 54; via one or more fasteners, such as bolts; to part of the drilling riser 30 or the BOP assembly 26 of FIG. 1). The outer housing 54 defines an outer housing recess 120 (e.g., outer housing cavity) that is configured to receive the seal assembly 50. In particular, a radially outer wall 126 (e.g., annular wall) of the inner housing 56 of the seal assembly 50 may face toward a radially inner wall 128 (e.g., annular wall) of the outer housing 54. At least one of the one or more bearings 60 may be positioned between the inner housing 56 and the outer housing 54. For example, as shown, at least one of the one or more bearings 60 may be positioned radially between the radially outer wall 126 of the inner housing 56 and the radially inner wall 128 of the outer housing 54.

[0035] In some embodiments, the one or more retainer rings 68 engage the inner housing 56 and the outer housing 54. For example, the one or more retainer rings 68 may insert into corresponding grooves or recesses of the inner housing 56 and the outer housing 54 to block the inner housing 56 from moving axially relative to the outer housing 54, while also enabling the inner housing 56 to rotate circumferentially relative to the outer housing 54.

[0036] In some embodiments, the damper assembly 66 is positioned axially between the seal element 58 and the piston 64. In particular, in some embodiments, a lower surface 92 (e.g., axially-facing surface; annular surface) of the seal element 58 may contact an upper surface 94 (e.g., axially-facing surface; annular surface) of a first support plate 96 of the one or more support plates 62. As shown, the upper surface 94 of the first support plate 96 may include at least one portion with a flat surface (e.g., in a plane that contains the radial axis 4) that contacts the seal element 58, although other configurations (e.g., protrusions, tapered, stepped) are envisioned.

[0037] Further, one or more dampers 98 may be positioned axially between the first support plate 96 and a second support plate 100 of the one or more support plates 62. Further, a lower surface 102 (e.g., axially-facing surface; annular surface) of the second support plate 100 may contact a thrust bearing 104 (e.g., one of the one or more bearings 60; annular bearing). Further, an upper surface 106 (e.g., axially-facing surface; annular surface) of the piston 64 may also contact the thrust bearing 104. Thus, as shown, the thrust bearing 104 may be positioned axially between the second support plate 100 and the piston 64. Indeed, as shown, these components may be arranged in a stack (e.g., axially stacked).

[0038] As discussed herein, the damper assembly 66 may include one or more dampers 98 that are configured to absorb forces, such as forces exerted by the tubular on the seal element 58 as the tubular rotates and / or moves axially within the wellbore. For example, the one or more dampers 98 may include one or more biasing members, such as coil springs, that are positioned axially between the first support plate 96 and the second support plate 100. It should be appreciated that and the one or more dampers 98 may be positioned axially between additional support plates and / or may be utilized in conjunction with additional components. Further, it should be appreciated that the one or more dampers 98 may have any suitable configuration or form to facilitate the techniques disclosed herein. Indeed, the damper assembly 66 may have any suitable configuration or form to facilitate the techniques disclosed herein.

[0039] In operation, the one or more dampers 98 may adjust (e.g., compress) and enable the seal element 58 and the first support plate 96 to move axially toward the second support plate 100 and the piston 64 as the tubular moves axially through the RCD 44. For example, as the tubular moves axially through the RCD, a joint (e.g., radially expanded portion; joins two adjacent pipe portions to one another) of the tubular may move through the RCD 44. The joint may exert a force on the seal element 58, and the force is at least partially absorbed (or dampened) by the damper assembly 66. After the joint passes through the RCD 44, the damper assembly 66 may adjust (e.g., extend) to enable the seal element 58 to maintain the annular seal about the tubular and / or to enable the damper assembly 66 to absorb or dampen forces that will be exerted on the seal element 58 by another joint along the tubular.

[0040] The piston 64 may be part of a piston actuation system 140 system that operates to adjust the seal element 58 between a relaxed configuration (e.g., initial or first seal element configuration; original state) and a compressed configuration (e.g., second seal element configuration; deformed state). In the relaxed configuration, the seal element 58 may be withdrawn from the center bore 82 and / or may have a first inner diameter. In the compressed configuration, the seal element 58 may extend into the center bore 82 and / or may have a second inner diameter that is less than the first inner diameter. It should be appreciated that the piston actuation system 140 may adjust the seal element 58 to the compressed configuration with various levels of compression. Thus, in the compressed configuration, the seal element 58 may have any of a variety of second inner diameters that are less than the first inner diameter. Further, the seal assembly 50 may be considered to be in a first configuration (e.g., first actuation configuration; the piston 64 is retracted into the chamber 70) while the seal element 58 is in the relaxed configuration, and the seal assembly 50 may be considered to be in a second configuration (e.g., second actuation configuration; the piston 64 is extended out of the chamber 70) while the seal element 58 is in the compressed configuration.

[0041] In FIG. 2, the seal element 58 is in the relaxed configuration, and the seal assembly 50 is in the first configuration. To transition the seal element 58 to the compressed configuration, a fluid circuit 142 may provide a fluid to the chamber 70. In particular, the fluid circuit 142 may include a fluid source 144. A controller 150 (e.g., electronic controller) may control a first valve 152 to enable flow from the fluid source 144 to the chamber 70 and / or to drain the flow from the chamber 70 to the fluid source 144 (or to another fluid drain). It should be appreciated that the fluid circuit 142 may have any suitable components or configuration that enable techniques disclosed herein (e.g., to drive movement of the piston 64). As described in more detail herein, such circulation of the fluid through the chamber 70 may adjust the seal element 58 relative to the inner housing 56 (and the tubular, when the tubular is within the RCD 44).

[0042] The controller 150 may control the delivery of the fluid from the fluid source 144 to the chamber 70 based on any of a variety of inputs, such as in response to an input received from a user interface device at the platform (e.g., from an operator) and / or in response to an input received from one or more sensors, such as one or more sensors that monitor one or more parameters indicative of the annular seal formed between the seal element 58 and the tubular, wellbore conditions, rotation of the tubular, or the like. For example, the controller 150 may receive an input that indicates an undesirable pressure below the RCD 44 (e.g., between the wellhead and the RCD 44) and / or above the RCD 44 (e.g., between the platform and the RCD 44) and may then adjust (e.g., increase) the fluid pressure in the chamber 70 to form and / or adjust (e.g., increase) the annular seal (e.g., sealing force; radial force) between the seal element 58 and the tubular. As another example, the controller 150 may receive an input that indicates that the tubular will begin to move or is moving within the RCD 44 (e.g., rotating in the circumferential direction 6 and / or moving in the axial direction 2), and the controller 150 may then adjust (e.g., increase or decrease) the fluid pressure in the chamber 70 to thereby form and / or adjust (e.g., increase or decrease) the annular seal between the seal element 58 and the tubular. In this way, the RCD 44 may provide an adjustable and dynamic seal about the tubular (e.g., as the tubular rotates in the circumferential direction 6 and / or moves in the axial direction 2 through the RCD 44).

[0043] As shown in FIG. 2, the controller 150 includes a processor 156 and a memory device 158. It should be appreciated that the controller 150 may be a dedicated controller for the RCD 44 and / or the controller 150 may be part of or include a distributed controller with one or more electronic controllers in communication with one another to carry out the various techniques disclosed herein. The processor 156 may also include one or more processors configured to execute software, such as software for processing signals and / or controlling the components of the RCD 44. The memory device 158 disclosed herein may include one or more memory devices (e.g., a volatile memory, such as random access memory [RAM], and / or a nonvolatile memory, such as read-only memory [ROM]) that may store a variety of information and may be used for various purposes. For example, the memory device 158 may store processor-executable instructions (e.g., firmware or software) for the processor 156 to execute, such as instructions for processing signals and / or controlling the components of the RCD 44. It should be appreciated that the controller 150 may include various other components, such as a communication device that is capable of communicating data or other information (e.g., a current configuration of the RCD 44) to various other devices (e.g., a remote computing system or display system at the platform).

[0044] In operation, the fluid delivered from the fluid source 144 to the chamber 70 may exert a force on a lower surface 170 (e.g., axially facing surface) of the piston 64 to drive the piston 64 axially through the outer housing 54 toward the seal element 58. In turn, the piston 64 drives the seal element 58, the one or more support plates 62, the damper assembly 66, and the thrust bearing 104 axially through the inner housing 56 and / or the outer housing 54. As shown and described herein, the thrust bearing 104 is positioned axially between the second support plate 100 and the piston 64. Thus, the thrust bearing 104 is configured to transfer force (e.g., axial force) from the piston 64 to the second support plate 100, while also enabling relative rotation (e.g., in the circumferential direction 6) between the piston 64 and the second support plate 100.

[0045] The curved dome shape of the radially inner wall 90 of the inner housing 56 blocks the seal element 58 from moving axially within the inner housing 56 and guides the seal element 58 into the center bore 82. Thus, as the piston 64 drives the seal element 58 axially within the inner housing 56, the seal element 58 is compressed between the first support plate 96 and the curved dome shape of the radially inner wall 90 of the inner housing 56, and the seal element 58 is also guided into the center bore 82.

[0046] In operation, the tubular may extend through the RCD 44. Because the seal element 58 protrudes into the center bore 82 in the compressed configuration and / or because the inner diameter of the seal element 58 in the compressed configuration is less than an outer diameter of the tubular, the seal element 58 contacts and engages with the tubular. Further, the contact between the seal element 58 and the tubular may cause the seal element 58 to form the annular seal about the tubular.

[0047] To facilitate discussion, FIG. 3 is a cross-sectional view of the RCD 44 with the seal element 58 in the compressed configuration and the seal assembly 50 in the second configuration. Further, the seal element 58 is sealed against the tubular 36. During drilling operations, the tubular 36 may rotate in the circumferential direction 6 and / or move along the axial axis 2. In some embodiments, certain portions of the seal assembly 50 are supported on the one or more bearings 60, such as the thrust bearing 104 and one or more additional bearings 182 (e.g., bearing ring; annular bearing; cylindrical bearing), to rotate with the tubular 36 (e.g., the rotation of the tubular 36 drives the rotation of the seal assembly 50). For example, as shown, the rotation of the tubular 36 may drive the rotation of the seal element 58, the one or more support plates 62, the damper assembly 66, and the inner housing 56 relative to the outer housing 54 (e.g., facilitated by the one or more bearings 60). It should be appreciated that the rotation of the tubular 36 may drive the rotation of the seal element 58, the one or more support plates 62, the damper assembly 66, and the inner housing 56 relative to other components as well, such as relative to the piston 64. Thus, certain components (e.g., the piston 64) move only axially (e.g., without rotation) relative to the outer housing 54, while other components (e.g., the sealing element 58, the one or more support plates 62, and the damper assembly 66) move both axially and with rotation relative to the outer housing 54. Further, certain components (e.g., the inner housing 56) rotate relative to the outer housing 54, but do not move axially relative to the outer housing 54.

[0048] In this way, the tubular 36 may not slip or rotate relative to the seal element 58, which may reduce wear on the seal element 58. In FIGS. 2 and 3, the thrust bearing 104 is positioned between the second support plate 100 and the piston 64 along the axial axis 2, and the one or more additional bearings 182 are positioned between the inner housing 56 and the outer housing 54 along the radial axis 4. However, the one or more bearings 60 may be positioned at any suitable location to enable the rotation of the tubular 36 to drive the rotation of at least the seal element 58.

[0049] FIGS. 4-7 illustrate the seal element 58 in various configurations and during various operations. For example, FIG. 4 is a schematic cross-sectional side view of a portion of the seal element 58 in the relaxed configuration within the inner housing 56. As shown, in the relaxed configuration, the seal element 58 is withdrawn from the center bore 82 defined by the first orifice 86 of the inner housing 56 and / or the seal element 58 does not contact the tubular 36 in the center bore 82.

[0050] FIG. 5 is a schematic cross-sectional side view of the portion of the seal element 58 in the compressed configuration within the inner housing 56. As shown, in the compressed configuration, the seal element 58 extends into the center bore 82 defined by the first orifice 86 of the inner housing 56 and / or the seal element 58 contacts the tubular in the center bore 82. Further, the seal element 58 may have the first inner diameter in the relaxed configuration and the second inner diameter in the compressed configuration, wherein the first inner diameter is greater than the second inner diameter.

[0051] As described herein, the seal element 58 may be driven from the relaxed configuration of FIG. 4 to the compressed configuration of FIG. 5 via the piston actuation system 140 of FIG. 3. In particular, the piston actuation system 140 may drive the piston 64 shown in FIGS. 2 and 3 axially to compress the seal element 58 against the curved dome shape of the radially inner wall 90, which drives the seal element 58 into the center bore 82 and / or toward the tubular 36.

[0052] In FIG. 5, the seal element 58 is axially aligned with and sealed against a first portion 190 of the tubular 36. The first portion 190 of the tubular 36 may be a pipe section of a drill string, for example. FIG. 6 is a schematic cross-sectional side view of the portion of the seal element 58 in the compressed configuration within the inner housing 56, wherein a portion of the seal element 58 is axially aligned with and sealed against a second portion 192 of the tubular 36. The second portion 192 of the tubular 36 may be a joint of the drill string (e.g., the joint that joins two pipe sections together), for example. The first portion 190 of the tubular 36 may have a first outer diameter, and the second portion 192 of the tubular 36 may be a radially expanded portion that has a second outer diameter greater than the first outer diameter. Accordingly, as the second portion 192 of the tubular 36 is inserted into the sealing element 58, the sealing element 58 compresses radially outwardly against the inner housing 56 and / or axially against the first support plate 96 to accommodate the second portion 192 of the tubular 36. The sealing element 58 experiences forces as the joint enters and moves through the sealing element 58, and the damper assembly 66 dampens or absorbs the forces. As described herein, this may reduce stress and wear on the sealing element 58. In this way, the RCD 44 may have lower maintenance costs, more reliable sealing, and so forth.

[0053] FIG. 7 is a schematic cross-sectional side view of the portion of the seal element 58 in the compressed configuration within the inner housing 56, wherein the seal element 58 is axially aligned with and sealed against the second portion 192 of the tubular 36 (e.g., along an entirety of an axial length of the seal element 58). It should be appreciated that as the tubular 36 moves axially through the RCD (e.g., into or out of the wellbore), the seal element 58 will continuously cycle between the configurations shown in FIGS. 5-7 to accommodate various portions of the tubular 36, and the damper assembly 66 will absorb and dampen the forces exerted by the tubular 36 on the seal element 58.

[0054] It should be appreciated that FIGS. 4-7 are intended to generally represent that at least some changes (e.g., deformation) occur between the relaxed configuration (FIG. 4) and the compressed configuration (FIGS. 5-7) of the seal element 58. Indeed, the seal element 58 may not have the cross-sectional shapes shown in FIGS. 4-7, and these figures are merely intended to generally represent that the seal element 58 will deform in some way due to actuation of the piston actuation system 140 and / or contact with the tubular 36, and thus, that the damper assembly 66 may provide advantages by dampening or absorbing forces exerted by the tubular 36 on the seal element 58.

[0055] Further, it should be appreciated that variations in form are envisioned. For example, FIG. 8 is a cross-sectional side view of an embodiment of a seal assembly 200 (e.g., annular seal assembly) and a spool 202 (e.g., annular spool) that may be used in the RCD 44. The seal assembly 200 and the spool 202 may each be considered sub-assemblies that are configured to be coupled together to form the RCD 44. In particular, the seal assembly 200 is configured to be inserted into the spool 202 to form the RCD 44.

[0056] As shown, the seal assembly 200 may include or be positioned within an outer housing 204 (e.g., annular outer housing), an inner housing 206 (e.g., annular inner housing), a seal element 208 (e.g., annular seal element), one or more bearings 210 (e.g., annular bearings), one or more support plates 212 (e.g., annular support plate), a piston 214 (e.g., annular piston; first piston; seal assembly piston), a damper assembly 216, and one or more retainer rings 218. One or more internal seal elements (e.g., annular internal seal elements; o-rings; packer seals) may be provided between certain components of the seal assembly 200 and / or between the seal assembly 200 and the spool 202.

[0057] The inner housing 206 defines a center bore 232 and a recess 234 (e.g., cavity). More particularly, the inner housing 206 defines a first orifice 236 (e.g., upper orifice; first orifice) at a first end 238 (e.g., upper end) of the center bore 232, and a radially inner wall 240 (e.g., annular wall) of the inner housing 206 defines the recess 234 with a curved dome shape. The seal element 208 is positioned within the recess 234 of the inner housing 206.

[0058] As shown, the spool 202 may include a spool housing 300 (e.g., annular spool housing) with a flange 302 (e.g., annular flange) that is configured to couple to an adjacent structure or component (e.g., axially below the spool 202; via one or more fasteners, such as bolts; to part of the drilling riser 30 or the BOP assembly 26 of FIG. 1). The spool 202 may also include a spool piston 304 (e.g., annular piston; second piston) that is configured to move axially within a chamber 306 (e.g., annular chamber). The spool 202 may also include spool retaining rings 308 (e.g., annular spool retaining rings), and one or more latches 310 (e.g., piston latches) that are configured to be placed within one or more openings 312 (e.g., radially extending through holes) formed in the spool housing 300. One or more spool internal seal elements (e.g., annular spool internal seal elements; o-rings) may be provided between certain components of the spool 202.

[0059] The spool 202 defines a spool recess 320 (e.g., spool cavity) that is configured to receive the seal assembly 200 (that includes the outer housing 204, or with the outer housing 204). For example, the one or more latches 310 may be retracted from the one or more openings 312 (e.g., withdrawn from the spool recess 320) to enable insertion or placement of the seal assembly 200 in the spool recess 320. Then, the one or more latches 310 may be inserted into the one or more openings 312 (e.g., extended into the spool recess 320) to hold the seal assembly 200 in the spool recess 320. In some embodiments, the one or more latches 310 may be electrically and / or mechanically actuated (e.g., via a hydraulic system).

[0060] The piston 214 and the spool piston 304 may be part of a split piston actuation system 340 that operates to adjust the seal element 208 between a relaxed configuration and a compressed configuration. In FIG. 8, the seal element 208 is in the relaxed configuration. To transition the seal element 208 to the compressed configuration, a fluid circuit may provide a fluid to the chamber 306. As described in more detail herein, such circulation of the fluid through the chamber 306 may adjust the seal element 208 relative to the outer housing 204 (and the tubular 36, when the tubular 36 is within the RCD 44). For example, the fluid delivered to the chamber 306 may exert a force on the spool piston 304 to drive the spool piston 304 axially toward the piston 214. The spool piston 304 contacts the piston 214, and the spool piston 304 and the piston 214 move axially together to thereby drive the seal element 208 axially within the inner housing 206. Then, during drilling operations, components supported between the tubular 36 and the one or more bearings 60 rotate with the tubular (e.g., the rotation of the tubular drives the rotation of the certain portions of the seal assembly 200).

[0061] It should be appreciated that the seal assembly 200 may be removed from the spool 202 via retracting the one or more latches 310 and then moving the seal assembly 200 axially relative to the spool 202 (e.g., lifting the seal assembly 200 out of the spool 202). Then, another seal assembly (e.g., having the same features as the seal assembly 200) may be inserted into the spool 202 and locked within the spool via inserting the one or more latches 310. In this way, the disclosed embodiments facilitate replacement of the seal assembly 200 (e.g., from axially above the spool 202) without removal of the spool 202 from the adjacent structure or component (e.g., axially below the spool 202; from its position in line with the drilling riser 30 of FIG. 1 and / or the BOP assembly 26 of FIG. 1).

[0062] Additionally, the seal assembly 200 may include any of the features of the seal assembly 50 (or vice versa). Thus, any of the features disclosed herein may be combined in any suitable manner. Further, the present embodiments may include a seal assembly with any of a variety of shapes and features. For example, the seal element may include inserts (e.g., metal pieces molded into elastomer of the seal element). Alternatively, the seal element may be devoid of inserts (e.g., only elastomer material).

[0063] While the disclosure may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the disclosure is intended to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the following appended claims.

Examples

Embodiment Construction

[0017]One or more specific embodiments of the present disclosure will be described below. These described embodiments are only exemplary of the present disclosure. Additionally, in an effort to provide a concise description of these exemplary embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers'specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0018]When introducing elements of various embodiment...

Claims

1. A rotating control device (RCD) for a drilling system, the rotating control device comprising:an outer housing;a seal element positioned within the outer housing and configured to form an annular seal about a tubular; anda damper assembly positioned with the outer housing and configured to dampen forces exerted on the seal element as the tubular rotates, moves axially, or both.

2. The RCD of claim 1, wherein the damper assembly comprises one or more biasing members.

3. The RCD of claim 2, wherein the one or more biasing members comprise one or more springs.

4. The RCD of claim 2, further comprising a first support plate and a second support plate, wherein the one or more biasing members are positioned axially between the first support plate and the second support plate.

5. The RCD of claim 1, wherein the damper assembly is annular and extends circumferentially about a center bore of the RCD.

6. The RCD of claim 1, further comprising a piston positioned within the outer housing, wherein the piston is configured to drive the seal element axially relative to the outer housing to enable the seal element to form the annular seal about the tubular.

7. The RCD of claim 6, wherein the piston is supported in a chamber formed in the outer housing, and the outer housing comprises or is coupled to a fluid circuit that is configured to provide a fluid into the chamber to move the piston axially within the outer housing.

8. The RCD of claim 6, further comprising a bearing configured to enable the seal element to rotate relative to the piston.

9. The RCD of claim 1, further comprising a bearing configured to enable the seal element and the damper assembly to rotate relative to the outer housing.

10. The RCD of claim 1, further comprising a spool configured to couple in line with a drilling riser, a blowout preventer assembly, or both, and the spool is configured to removably receive the outer housing.

11. A rotating control device (RCD) for a drilling system, the RCD comprising:a seal element configured to form an annular seal about a tubular;a damper assembly configured to dampen forces exerted on the seal element as the tubular rotates, moves axially, or both; anda piston actuation system configured to provide active control to adjust a sealing force of the annular seal.

12. The RCD of claim 11, wherein the damper assembly comprises one or more biasing members.

13. The RCD of claim 12, further comprising a first support plate and a second support plate, wherein the one or more biasing members are positioned axially between the first support plate and the second support plate.

14. The RCD of claim 11, wherein the piston actuation system comprises a piston configured to drive the seal element to enable the seal element to form the annular seal about the tubular and to provide the active control to adjust the sealing force of the annular seal.

15. The RCD of claim 14, wherein the piston is supported in a chamber, and the piston actuation system comprises a fluid circuit that is configured to provide a fluid into the chamber to move the piston in the chamber.

16. £ The RCD of claim 14, further comprising a bearing configured to enable the seal element to rotate relative to the piston.

17. The RCD of claim 11, further comprising a bearing configured to enable the seal element and the damper assembly to rotate with the tubular.

18. The RCD of claim 11, further comprising a housing, wherein the seal element, the damper assembly, and a piston of the piston actuation system are positioned within the housing.

19. The RCD of claim 18, further comprising a bearing configured to enable the seal element and the damper assembly to rotate relative to the housing and the piston.

20. A method of operating a drilling system, the method comprising:placing a tubular through a rotating control device (RCD);actuating a piston actuation system to compress a seal element to cause the seal element to form an annular seal about the tubular; anddampening, via a damper assembly, forces exerted by rotating the tubular, moving the tubular axially, or both while the seal element forms the annular seal about the tubular.

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