Circulation Coupler for Continuous Drilling Mud Control
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Solution Overview
Problem
Current drilling systems lack effective control over drilling mud flow and pressure during drill pipe loading/tripping operations, leading to potential kick phenomena and hydraulic fracturing, as well as inefficient mud circulation that can cause debris to move upwards and potentially stick the drill string.
Innovation Solution
The implementation of a circulation coupler with Radial Control Device (RCD) assemblies that maintain continuous mud circulation and rotation of the drill string by redirecting mud flow through a circulation sub with radial and axial valves, ensuring constant fluid pressure and flow during pipe connections and disconnections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard drilling systems are used during drill pipe loading/tripping, then the system structure is simple and easy to operate, but continuous mud circulation and pressure control are lost leading to kick phenomena and hydraulic fracturing
Solution Approach 1:
A circulation sub is introduced as an intermediary device installed in the drill string during tripping operations. This circulation sub includes radial control devices with valves that act as mediators to redirect mud flow from the annulus back into the drill string, enabling continuous circulation without requiring complex surface equipment modifications.
Solution Approach 2:
The circulation control function is segmented into multiple radial control devices distributed along the circulation sub. Each radial control device contains valves that can independently regulate flow in different radial directions, allowing localized flow management and enabling continuous circulation during tripping operations without affecting the entire drilling system.
2Productivity
If mud circulation is stopped during tripping operations, then the equipment complexity is reduced, but kick phenomena occur due to pressure loss and debris accumulates causing drill string sticking
Solution Approach 1:
The circulation sub enables continuous mud circulation during tripping operations by providing alternative flow paths. Mud that would normally flow only up the annulus is redirected through the drill string via radial valves, maintaining continuous fluid movement that prevents pressure loss, kick phenomena, and debris accumulation throughout the entire drilling process.
Solution Approach 2:
The radial control devices incorporate valves that can dynamically adjust flow distribution between the annulus and drill string based on operational needs. This dynamic flow control allows the system to adapt circulation patterns during different phases of tripping operations, maintaining optimal flow conditions to prevent harmful effects while maximizing operational efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables continuous mud circulation and drill string rotation during tripping operations, preventing kick phenomena and hydraulic fracturing, while maintaining constant pressure and flow, thus enhancing drilling efficiency and preventing drill string sticking.
Implementation Method 1
redirecting mud flow through a circulation sub with radial and axial valves, ensuring constant fluid pressure and flow during pipe connections and disconnections
Data Source
AI summary
A circulation coupler for continuous or constant circulation of drilling mud during operation of a drill string, the circulation coupler comprising: a housing having an upper open end and a lower open end, wherein the housing has a port through the housing between the upper and lower ends; an upper rotating control device positioned in the upper open end of the housing, wherein the upper rotating control device comprises a bearing package and a sealing component for sealing engagement with a drill string; and a lower rotating control device position in the lower open end of the housing, wherein the upper rotating control device comprises a bearing package and a sealing component for sealing engagement with a drill string, wherein when a drill sting is positioned within the circulation coupler and engaged by the sealing components of the upper and lower rotating control devices a chamber is defined within the housing between the upper and lower rotating control devices around the drill string.