Intelligent Rotating Control Device Tubular Detection
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Solution Overview
Problem
Conventional well pressure control equipment, such as BOP stacks, face challenges in efficiently sealing and managing pressure variations during drilling operations, particularly when dealing with varying tubular sizes and non-cylindrical components, which can lead to undesirable pressure fluctuations and increased wear on sealing elements.
Innovation Solution
A smart automated managed pressure drilling/underbalanced drilling rotating control device (RCD) with integrated sensors and a programmable logic controller (PLC) that uses coils to detect tubular characteristics and adjust sealing pressure automatically, allowing for intelligent and automated sealing and fluid diversion, and includes a lubrication system to minimize wear on seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional BOP stacks with fixed sealing elements are used, then the device structure is simple, but the sealing performance deteriorates when dealing with varying tubular sizes and non-cylindrical components
Solution Approach 1:
The sealing element is designed to be dynamically adjustable rather than fixed. The system varies sealing pressure in real-time based on detected tubular characteristics, allowing the seal to adapt to different tubular sizes and shapes while maintaining reliable sealing performance
Solution Approach 2:
A feedback control system is implemented where sensors detect tubular characteristics and this information is fed back to the pressure control system. The system automatically adjusts sealing pressure based on the feedback, resolving the contradiction between simple structure and reliable sealing for varying tubulars
2Productivity
If manual pressure control methods are used, then the device complexity is low, but the productivity and response time to pressure variations are reduced
Solution Approach 1:
The pressure control system is designed to be self-regulating through automated detection and control. The system detects tubular characteristics and automatically adjusts sealing pressure without manual intervention, improving productivity and response time while accepting increased device complexity
Solution Approach 2:
Manual mechanical pressure control is replaced with an automated electromechanical system. Sensors and controllers substitute for manual operation, enabling faster response to pressure variations and improving overall productivity
3Reliability
If high sealing pressure is applied to ensure sealing on all tubular sizes, then sealing reliability is improved, but the wear on sealing elements increases
Solution Approach 1:
The system dynamically changes the sealing pressure parameter based on detected tubular characteristics. Instead of applying consistently high pressure, the system adjusts pressure to the minimum required for effective sealing on each specific tubular, maintaining sealing reliability while reducing unnecessary wear and extending seal longevity
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 provides precise and adaptive pressure control, reducing wear on sealing elements and maintaining consistent sealing performance across different tubular sizes and formations, thereby enhancing the efficiency and longevity of drilling operations.
Implementation Method 1
an intelligent RCD/rotating head may include several sensors to increase the quality and duration efficiency of the sealing onto the tubular. These measurements are fed to the PLC which controls the RCD or I-RAP operation. For example, the optimum sealing pressure to seal against the tubular may be determined (and used) based on the diameter and/or location of the portion of the drill string (tubular body, joint, etc.) or bottom hole assembly (BHA) passing therethrough against which the seal will engage.
Data Source
AI summary
A pressure control device may include a body having a central axis extending therefrom; at least one rotatable seal within the body, the rotatable seal configured to seal against a tubular extending through the pressure control device along the central axis and rotate within the body with the tubular; at least one coil within the body wrapped at least once around the central axis, wherein the at least one coil is configured to send characteristics of the tubular to a controller; an outlet to divert fluid from an annulus, wherein the outlet being located axially below the at least one rotatable seal, wherein the controller is configured to control the at least one rotatable seal and its engagement against the tubular based on the characteristics of the tubular received by the controller.