Modular Rotating Flow Head Bearing Pack Design
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Solution Overview
Problem
Current rotating control devices in the oil and gas industry face premature bearing failure due to inadequate lubrication and seal issues, leading to non-productive time (NPT) and reduced longevity.
Innovation Solution
A modular rotating flow head with a lubricated seal system and a unique assembly that includes elastomeric sealing elements, sacrificial wear sleeves, and a low-profile design to enhance sealing and reduce rotational drag, while maintaining effective lubrication and easy maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional lubrication means are used requiring injection or pumping into an annulus, then bearing lubrication can be maintained, but the device complexity increases with elaborate hydraulic mechanisms and seal arrangements
Solution Approach 1:
The patent extracts the lubrication function from a complex hydraulic pumping system and implements it through a simple gravity-fed annular reservoir and wick wiper mechanism. The lubricant is contained in an annular space between the quill and bearing pack housing, eliminating the need for external injection systems while maintaining continuous bearing lubrication through capillary action and rotational wiping.
2Reliability
If bearing assemblies are secured within the rotating flow head by means of clamps, then the bearing assembly is held in place, but the structural height of the rotating flow head increases
Solution Approach 1:
The patent merges the bearing pack housing with the rotating flow head body, integrating the bearing mounting structure directly into the flow head housing rather than using separate clamp assemblies. This integration eliminates the need for external clamps and reduces the overall structural height while maintaining secure bearing retention through the housing's internal geometry.
3Reliability
If seal or seal stack isolates the wellbore environment from entering the bearing assembly housing, then bearing protection is achieved, but premature seal failure remains a common source of bearing failure
Solution Approach 1:
The patent implements a multi-layer sealing system with stripper elements and sealing rings positioned at the bearing pack inlet to prevent wellbore fluids from reaching the bearings before they can cause damage. The seal stack is pre-configured with multiple sealing elements that create redundant barriers, ensuring bearing protection even if one sealing element fails.
4Productivity
If the rotating control device is designed with traditional sealing and lubrication systems, then basic functionality is achieved, but non-productive time increases due to premature bearing failure
Solution Approach 1:
The patent implements a self-lubricating bearing system where the rotating quill acts as a wiper that automatically distributes lubricant from the annular reservoir to the bearing surfaces through rotational motion. The system serves itself by using the operational rotation of the drill string to distribute lubrication without requiring external intervention, monitoring, or adjustment, thereby eliminating a common failure mode that causes non-productive time.
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 significantly increases the mean time between failures, reduces operational NPT, and prolongs the lifespan of bearings and seals, ensuring continuous well operations with minimal downtime.
Implementation Method 1
each of the two or more sealing elements has an elastomeric body operable between a first non-activated state and a second activated state. When activated, the elastomeric body of each sealing ring engages the quill for sealing thereto.
Implementation Method 2
A rotating flow head of the present invention comprises a lubricated seal system to improve the longevity of the rotating flow head bearings and sealing elements
Data Source
AI summary
A rotating flow head has a lubricated bearing pack for isolating bearing elements from wellbore fluids under pressure. The bearing pack, having a rotating cylindrical sleeve, bearing elements and two seal assemblies, is secured within an assembly bore of a stationary housing by a retainer plate accepting a plurality of lag bolts circumferentially spaced around a top portion of the stationary housing. Each of the seal assemblies have at least one sealing element having a body, an annular cavity, an inner sealing surface, and a flange that distends radially outwardly when axially compressed. A loading ring fit to the annular cavity urges the inner sealing surface radially inwardly to sealingly engage the rotating cylindrical sleeve. The inner sealing surface further comprises a first and second sealing surface and a debris channel therebetween.