Multifunctional Rotating Control Device with Integrated Flow Detection
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Solution Overview
Problem
Current pressure control systems in drilling and completion operations face challenges such as downhole gas invasion, overflow, and leakage due to low integration levels, complex site layouts, long installation periods, high costs, and difficult maintenance, primarily because key devices are functionally independent and connected through long high-pressure lines.
Innovation Solution
A multifunctional rotating control device (RCD) is integrated with a flow detection module and a compression mechanism, featuring a rotating sealing assembly, double-output actuator, and transmission mechanism, which reduces occupied space, improves control efficiency, and allows for remote and automatic operation with a manual backup, ensuring reliable compression and fluid detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If key devices are functionally independent and connected through long high-pressure lines, then each device can be designed and manufactured separately, but the system has low integration level, complex site layout, long installation and debugging period, high cost, and hard maintenance
Solution Approach 1:
The patent combines multiple functionally independent devices (RCD assembly and flow detection module) into a single integrated multifunctional RCD. The flow detection module is directly connected to the RCD assembly through a common cavity, eliminating the need for long high-pressure lines and external connections. This merging approach maintains the functional independence of each module while achieving high-level system integration, thereby reducing site layout complexity, installation time, and maintenance difficulty.
2Area of stationary object
If the flow detection module is integrated onto the RCD assembly and extends upward in the direction of the bore through hole, then the occupied space in horizontal direction is reduced, but the main occupied space extends upward requiring vertical clearance
Solution Approach 1:
The flow detection module is oriented to extend upward in the vertical direction (along the bore through hole axis) rather than spreading horizontally. This dimensional reorientation concentrates the module's volume along the vertical axis, minimizing its horizontal footprint while requiring adequate vertical clearance. The module's components (flowmeter, cut-off valves) are arranged vertically within the common cavity, effectively trading horizontal space for vertical space.
3Device complexity
If a double-output actuator is used to drive both first and second flow cut-off valves, then the number of actuators is reduced and control efficiency is improved, but the actuator structure becomes more complex
Solution Approach 1:
A single double-output actuator is designed to perform multiple functions by controlling both the first flow cut-off valve and the second flow cut-off valve. The actuator contains two independent output mechanisms that can independently drive each valve, enabling one actuator to replace what would traditionally require two separate actuators. This multi-functional design reduces the total number of actuators and simplifies the overall system while accepting increased complexity within the actuator itself, which is manufactured as a single integrated component.
4Volume of stationary object
If the flowmeter, first flow cut-off valve, and second flow cut-off valve are integrated into a compact module, then the overall RCD size is reduced, but the internal arrangement and connection complexity increases
Solution Approach 1:
The flow detection module employs a nested arrangement where components are housed within a common cavity. The first and second flow cut-off valves are positioned at opposite ends of the flowmeter, with all three components (flowmeter, first valve, second valve) nested within the same cavity space. This nesting strategy maximizes space utilization, reduces the overall module volume, and organizes complex internal connections in a compact, systematic manner that facilitates both integration and maintenance.
Data Source
AI summary
A multifunctional rotating control device (RCD) is provided. The multifunctional RCD includes an RCD assembly and a flow detection module. Further, the RCD assembly includes a body and a rotating sealing assembly. A bore through hole and a bypass outlet are formed in the body, and the rotating sealing assembly is provided in the bore through hole. Additionally, the bypass outlet is connected to a straight-through cut-off valve, and the flow detection module includes a flowmeter, a first flow cut-off valve, and a second flow cut-off valve. Further, the flowmeter extends upward in a direction of the bore through hole, and the first flow cut-off valve and the second flow cut-off valve are respectively provided at two ends of the flowmeter, and communicate with the flowmeter. Additionally, an inlet of the flowmeter is a flow detection input outlet, and the flow detection input outlet communicates with the straight-through cut-off valve.