Active Seal Assembly Control for Tool Joint Wear Reduction
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Solution Overview
Problem
Existing annular sealing systems in drilling operations, particularly in deepwater applications, face challenges with passive and actively controlled sealing elements that wear out quickly due to factors like high rotary seal velocities, abrasive tool joints, and pressure differentials, leading to frequent replacements and significant downtime.
Innovation Solution
A method of operating actively controlled sealing elements by determining the position of tool joints relative to the sealing elements and adjusting operational parameters based on these positions, sequencing the activation of multiple sealing elements, and using a redundant seal system to extend their runtime and reduce wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If passive or actively controlled sealing elements are used in deepwater drilling operations, then wellbore pressure control is achieved, but the sealing elements wear out quickly due to high rotary seal velocities, abrasive tool joints, and pressure differentials
Solution Approach 1:
The system dynamically adjusts the activation state of multiple sealing elements based on real-time detection of tool joint positions. When a tool joint is detected approaching a sealing element, the system transitions that sealing element from an active sealing state to a passive or deactivated state, and activates a backup sealing element. This dynamic reconfiguration reduces wear on active sealing elements by avoiding contact with abrasive tool joints while maintaining wellbore pressure control.
Solution Approach 2:
The system performs preliminary detection of tool joint positions using sensors (such as magnetic or capacitive sensors) before the tool joint reaches the sealing element. Based on this advance detection, the system pre-activates backup sealing elements and deactivates upcoming sealing elements before contact occurs, preventing wear damage before it happens.
2Reliability
If sealing elements are replaced frequently to maintain performance, then reliability is improved, but operational downtime increases
Solution Approach 1:
The sealing system is divided into multiple independent sealing elements arranged in sequence along the drill string path. Each sealing element can be independently activated or deactivated based on the position of tool joints. This segmentation allows the system to rotate through multiple sealing elements, using each one for a portion of the operational cycle, thereby extending the effective lifespan of the sealing system before any single element requires replacement.
Solution Approach 2:
The system recovers the service life of sealing elements by sequentially activating and deactivating multiple elements. Instead of using one sealing element until failure and then replacing it, the system rotates through multiple elements, allowing each to be used for a fraction of the total operational time. This extends the overall system lifespan and reduces the frequency of replacements needed.
3Reliability
If multiple sealing elements are activated simultaneously to ensure redundancy, then reliability is improved, but system complexity and wear increase
Solution Approach 1:
The system employs sensors to detect the position of tool joints on the drill string and provides feedback to the control system. Based on this feedback, the control system determines which sealing elements should be activated or deactivated at any given time. This feedback mechanism enables intelligent coordination of multiple sealing elements, activating only those needed for current operational conditions while keeping others in standby, thereby reducing unnecessary wear and simplifying system management.
4Duration of action of stationary object
If sealing elements are deactivated to reduce wear, then sealing element lifespan is extended, but wellbore pressure control may be compromised
Solution Approach 1:
The system maintains a bank of standby sealing elements that are pre-positioned and ready for activation. When active sealing elements are deactivated to reduce wear, the standby elements provide immediate backup capability to maintain wellbore pressure control. This cushioning approach ensures that pressure control is never compromised while allowing active elements to be cycled off for wear reduction.
Data Source
AI summary
Methods of operating actively controlled sealing elements are disclosed that extend runtime of one or more actively controlled sealing elements and reduce the wear induced by a transiting tool joint. In certain embodiments, the activation of two or more independent actively controlled sealing elements are coordinated as a function of the position of tool joints in relation to the actively controlled sealing elements. In other embodiments, the activation of two or more independent actively controlled sealing elements are sequenced using a first actively controlled sealing element until the end of its design life and then utilizing a second actively controlled sealing element. In still other embodiments, a single actively controlled sealing element may be variably actuated as a function of the position of tool joints in relation to the actively controlled sealing element. Runtime of actively controlled sealing elements may be extended, improving productivity and reducing operating costs.