Rotating Control Seal Assembly With Hydraulic Latching and Bearing Preload
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Solution Overview
Problem
Conventional rotating control devices in drilling operations suffer from mechanical wear, lack of lubrication, and high maintenance costs due to mechanical clamping mechanisms and bearing assembly failures, leading to increased downtime and safety risks.
Innovation Solution
A simplified rotating control device design featuring hydraulically-actuated, clamp-less latching assemblies with piston-driven dogs and indirectly mounted tapered-thrust bearings, which reduce wear and allow for quick installation, removal, and replacement, along with a unique seal carrier design for precise bearing preload without springs or shims.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical clamping mechanisms and bearing assemblies are used in conventional rotating control devices, then the device can maintain structural stability and secure the seal assembly, but mechanical wear and bearing failures occur leading to high maintenance costs and increased downtime
Solution Approach 1:
The patent replaces the mechanical clamping mechanism with a hydraulic actuation system that uses hydraulic pressure to secure the seal assembly against the housing. The hydraulic system applies radial force through a piston and clamp assembly, eliminating the need for mechanical screws or clamps that are prone to wear and failure. This substitution reduces mechanical wear and extends operational reliability.
Solution Approach 2:
The patent employs a hydraulic actuator with a piston that converts hydraulic pressure into mechanical force to secure the seal assembly. The hydraulic system provides controlled, adjustable clamping force through fluid pressure, enabling reliable securing without the mechanical wear associated with traditional mechanical fastening systems. This hydraulic mechanism reduces maintenance requirements and downtime.
2Ease of operation
If conventional mechanical latching mechanisms are used, then the seal assembly can be securely retained, but the installation and replacement processes are time-consuming and complex
Solution Approach 1:
The patent replaces manual mechanical latching with an automated hydraulic actuation system. The hydraulic piston automatically engages and secures the seal assembly when hydraulic pressure is applied, eliminating the need for manual manipulation of mechanical latches or clamps. This automation significantly reduces installation time and simplifies the operational process.
Solution Approach 2:
The hydraulic actuation system is designed to automatically secure the seal assembly through hydraulic pressure without requiring manual intervention for latching or clamping. The system self-actuates when hydraulic fluid is supplied, reducing the complexity and time required for installation and replacement operations.
3Strength
If directly mounted bearings are used in the seal assembly, then the bearing assembly can be securely attached, but mechanical wear occurs leading to frequent failures and high maintenance costs
Solution Approach 1:
The patent replaces direct mechanical mounting of bearings with an indirect mounting system that uses hydraulic pressure to apply radial loads to the bearings. The hydraulic piston transmits force through a mechanism that distributes the load, reducing concentrated mechanical stress and wear on the bearing surfaces. This indirect mounting improves bearing reliability and reduces maintenance frequency.
Solution Approach 2:
The patent introduces a hydraulic intermediary system between the mounting structure and the bearings. The hydraulic fluid acts as a mediator that transmits and distributes mechanical forces, reducing direct contact and wear between bearing surfaces and mounting structures. This intermediary mechanism enhances bearing assembly reliability by minimizing mechanical wear.
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
The solution reduces non-productive downtime, extends the life of seal and bearing assemblies, and enhances safety by ensuring stable operation even when hydraulic power is lost, while maintaining precise pressure control and reducing overall costs.
Implementation Method 1
a plurality of hydraulically-actuated, clamp-less latching assemblies secured to a rotating control device. Each latching assembly includes a piston-driven dog that fits within a groove of the seal and bearing assembly
Implementation Method 2
indirectly mounted tapered-thrust bearings that reduce wear and facilitate rotation of the mandrel
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A rotating control device includes a bowl housing with an inner aperture to receive a seal and bearing assembly. A plurality of hydraulically-actuated fail-last-position latching assemblies are disposed about an outer surface of the bowl housing to controllably extend a plurality of piston-driven dogs radially into a groove of the seal and bearing assembly. The seal and bearing assembly includes a housing, a mandrel disposed within an inner aperture of the housing, a first interference-fit sealing element attached to a bottom distal end of the mandrel, a plurality of tapered-thrust bearings indirectly mounted to the housing, a preload spacer disposed between top and bottom tapered-thrust bearings, a plurality of jam nuts to adjust a preload of the tapered-thrust bearings and a lower seal carrier attached to the seal and bearing housing comprising a plurality of dynamic sealing elements that contact the mandrel.