Continuous Circulation Coupler for Drilling Fluid Flow
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Solution Overview
Problem
Conventional drilling operations experience interruptions in fluid circulation during phases of drillpipe assembly and disassembly, leading to issues like cutting settlement, temperature excursions, and formation damage due to decoupling of the pipe drive system from the drill string.
Innovation Solution
A continuous circulation management system with a quick coupler that facilitates sealed engagement with the drill string stump, allowing for continuous fluid circulation by redirecting fluid flow through the system during decoupling phases, using a coupling device with gripping features or rigid attachment to maintain fluid flow without leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the pipe drive system is decoupled from the drill string during drillpipe assembly and disassembly, then the drillpipe can be assembled and disassembled, but fluid circulation is interrupted causing cutting settlement, temperature excursions, and formation damage
Solution Approach 1:
A coupling device is introduced as an intermediary component that maintains fluid circulation pathways during drillpipe assembly and disassembly operations. The coupling device includes a coupling body with a fluid passage that connects to the drill string stump, allowing drilling fluid to continue flowing through the wellbore even when the pipe drive system is decoupled for operational purposes.
Solution Approach 2:
The system is divided into separate functional components: the drill string stump, the coupling device with its own fluid passage, and the pipe drive system. This segmentation allows the coupling device to independently maintain circulation while the pipe drive system is decoupled for assembly/disassembly operations, resolving the contradiction between operational ease and circulation continuity.
2Reliability
If a coupling device is used to maintain fluid circulation during decoupling phases, then continuous circulation is achieved, but the device complexity increases
Solution Approach 1:
The coupling device is designed with multi-functionality to reduce overall system complexity. It serves both as a support structure for the drill string stump and as a fluid circulation pathway. The coupling body simultaneously provides mechanical support and maintains fluid flow, eliminating the need for separate circulation maintenance equipment.
Solution Approach 2:
The coupling device merges the support function and fluid circulation function into a single integrated component. The coupling body combines structural support elements with internal fluid passages, reducing the number of separate components needed and simplifying the overall system architecture while maintaining continuous circulation.
3Strength
If the coupling device uses gripping features to engage the drill string stump, then secure engagement is achieved, but the manufacturing precision requirements increase
Solution Approach 1:
The coupling device incorporates movable gripping features that can adapt to variations in the drill string stump geometry. The gripping members are designed to move and adjust their position to achieve secure engagement, reducing the need for extremely precise manufacturing tolerances while maintaining strong mechanical connection.
Solution Approach 2:
The coupling device design allows for adjustment of engagement parameters such as gripping force and contact point position. By making these parameters variable rather than fixed, the system can accommodate manufacturing variations in the drill string stump while maintaining secure engagement, thereby reducing the stringency of manufacturing precision requirements.
Data Source
AI summary
Present embodiments are directed to a circulation system including a circulation management system. A housing of a coupling feature of the circulation management system is configured to extend over a box end of a pipe element. A seal disposed within the housing is configured to engage with a face of the box end. A force-application feature is configured to force the seal against the face of the box end to establish a sealed engagement between the circulation management system and the pipe element. A flow path of the circulation management system extends through the housing and the seal, wherein the flow path facilitates fluid flow into the pipe element from the circulation management system when the sealed engagement is established. A port to the flow path is configured to couple with a fluid flow supply feature.