Rotational Continuous Circulation System for Drilling
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Solution Overview
Problem
Current drilling methods require cessation of rotation and mud circulation during pipe connection or disconnection, leading to increased risks of pipe sticking, wellbore collapse, and blowout risks due to prolonged static contact and pressure fluctuations.
Innovation Solution
A rotational continuous circulation system incorporating a diversion manifold, clamp, and circulation subs with side-entry ports allows for continuous mud circulation and rotation by diverting mud flow through side-entry ports, maintaining fluid flow and reducing connection time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pipe connection methods are used, then pipe connections can be made, but rotation and mud circulation must cease, increasing the risk of pipe sticking and wellbore collapse
Solution Approach 1:
The pipe string is segmented into multiple sections with circulation subs inserted at intervals. Each circulation sub has side-entry ports that allow independent mud circulation through specific segments, enabling continuous circulation while connections are made in other segments without stopping the entire drilling operation.
Solution Approach 2:
Circulation subs act as intermediary components between the mud pump and the drill string. These subs with side-entry ports serve as mediators that redirect mud flow through alternative paths, allowing connections to be made while maintaining continuous mud circulation through the drill string.
2Ease of operation
If rotation is stopped for pipe connection, then connections can be made, but static contact between formation and pipe string increases, causing pipe sticking
Solution Approach 1:
The system maintains continuous rotation and continuous mud circulation throughout the connection process. The circulation subs with side-entry ports allow mud to continue flowing through the drill string even when connections are being made, eliminating the need to stop rotation and preventing pipe sticking from static formation contact.
3Ease of operation
If mud circulation is stopped for connection, then connections can be made, but pressure on wellbore decreases, causing wellbore collapse or blowout
Solution Approach 1:
Mud circulation is maintained continuously through the circulation subs with side-entry ports. Mud can be pumped through the drill string and returned through the circulation subs without interruption, keeping wellbore pressure stable during connections and preventing wellbore collapse or blowout events.
4Ease of operation
If circulation is stopped, then connections can be made, but cuttings settle and bind the drill bit, causing operational problems
Solution Approach 1:
Mud circulation continues uninterrupted through the circulation subs with side-entry ports. This continuous flow prevents cuttings from settling and binding the drill bit, maintaining drilling productivity while connections are being made in the background without stopping the circulation system.
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
This system minimizes downtime during pipe connections/disconnections, reduces the risk of pipe sticking and wellbore collapse, and maintains stable pressure, ensuring continuous drilling operations with reduced costs and safety risks.
Implementation Method 1
A least one check valve is located within a sidewall of the uphole body and is operable to selectively allow fluid to flow into the uphole internal bore through the at least one check valve
Implementation Method 2
A central valve is located within the uphole internal bore and is operable to selectively open and close the uphole internal bore
Implementation Method 3
The uphole body and the downhole body are configured to rotate about the central axis free of relative rotation between the uphole body and the downhole body
Implementation Method 4
A side-entry port of the sleeve assembly is operable to provide a fluid flow path from an exterior of the sleeve assembly to the at least one check valve
Data Source
AI summary
A rotational continuous circulation system and methods includes a circulation sub having an internal bore extending along a central axis. The circulation sub has an uphole body having a reduced outer diameter along a downhole length of the uphole body. A central valve selectively opens and closes the uphole internal bore. At least one check valve is located within a sidewall of the uphole body to selectively allow fluid to flow into the uphole internal bore through the at least one check valve. A downhole body has an uphole portion circumscribing a downhole portion of the uphole body. A sleeve assembly circumscribes the reduced outer diameter of the uphole body. The uphole body and the downhole body are configured to rotate about the central axis independently from the sleeve assembly. A side-entry port of the sleeve assembly provides a fluid flow path from an exterior of the sleeve assembly to the at least one check valve.