Rotating Control Seal and Bearing Assembly for Low-Downtime Drilling
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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 complex designs and mechanical clamping mechanisms, leading to frequent downtime and increased costs of ownership.
Innovation Solution
A simplified rotating control device design featuring a clamp-less, hydraulically-actuated latching assembly with indirectly mounted tapered-thrust bearings and a unique seal carrier design for easy installation, removal, and replacement, along with a fail-last-position latching mechanism to ensure stability without hydraulic power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mechanical clamping mechanisms and complex bearing assemblies are used, then the rotating control device can maintain structural stability, but mechanical wear increases and maintenance costs rise
Solution Approach 1:
The patent removes the complex mechanical clamping mechanisms entirely, replacing them with a simplified bearing assembly design. The bearing assembly is extracted as a separate, self-contained unit that can be easily installed and removed without requiring complex clamping structures, thereby reducing mechanical wear and maintenance needs while maintaining structural stability.
Solution Approach 2:
The rotating control device is segmented into modular components, with the bearing assembly as a distinct unit. This segmentation allows the bearing assembly to be independently serviced and replaced without affecting the entire device, reducing maintenance complexity and downtime while preserving overall structural integrity.
2Reliability
If complex designs with mechanical clamping mechanisms are used, then structural stability is maintained, but non-productive downtime increases due to frequent maintenance
Solution Approach 1:
By extracting the bearing assembly as a separate, standalone unit, the patent enables quick removal and replacement without disassembling complex clamping mechanisms. This significantly reduces maintenance time and non-productive downtime while the bearing assembly itself maintains the necessary structural stability during operation.
Solution Approach 2:
The bearing assembly is pre-configured as a complete, self-contained unit with all necessary components integrated. This preliminary preparation allows for rapid installation and replacement during maintenance, minimizing non-productive downtime while ensuring structural stability is immediately restored upon installation.
3Stability of the object's composition
If indirectly mounted tapered-thrust bearings are used, then radial stability is enhanced, but manufacturing complexity increases
Solution Approach 1:
The indirectly mounted tapered-thrust bearings are extracted as a standardized, off-the-shelf component rather than a custom-manufactured part. This approach maintains the radial stability benefits of indirect mounting while avoiding the complexity of custom manufacturing, as the bearings can be sourced from standard catalogs and installed using established procedures.
4Productivity
If seal and bearing assemblies are designed for easy removal and replacement, then maintenance time is reduced, but structural integrity may be compromised
Solution Approach 1:
The seal and bearing assemblies are segmented into modular units that can be easily removed and replaced. Each module is designed with standardized interfaces that maintain structural integrity during operation while allowing for quick removal during maintenance. The segmentation enables maintenance without compromising the overall structural strength of the rotating control device.
Solution Approach 2:
The seal and bearing assemblies are pre-configured with installation features such as alignment guides and standardized mounting interfaces. These preliminary design actions ensure that when the assemblies are removed and reinstalled, structural integrity is automatically maintained without requiring complex alignment procedures or additional structural reinforcement.
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 lowers maintenance costs by simplifying the design and enhancing radial stability, while ensuring safety and efficient pressure management during drilling operations.
Implementation Method 1
a plurality of tapered-thrust bearings to facilitate rotation of the rotatable mandrel
Implementation Method 2
an upper seal carrier attached to a top side of the seal and bearing housing including a dynamic sealing element that contacts the rotatable mandrel
Implementation Method 3
a preload spacer disposed between the top and bottom tapered-thrust bearings
Data Source
AI summary
A seal and bearing includes a seal and bearing housing, a rotatable mandrel disposed within an inner aperture of the seal and bearing housing, an upper seal carrier attached to a top side of the seal and bearing housing having a dynamic sealing element that contacts the rotatable mandrel, a plurality of tapered-thrust bearings to facilitate rotation of the rotatable mandrel including top tapered-thrust bearings indirectly mounted at a positive offset angle from a perpendicular line to a longitudinal axis of the rotating control device and bottom tapered-thrust bearings indirectly mounted at a negative offset angle from the perpendicular line to the longitudinal axis of the rotating control device, a preload spacer disposed between the top and bottom tapered-thrust bearings, and a lower seal carrier attached to a bottom side of the seal and bearing housing having a plurality of removable seal carrier trays.