Wellhead Mud Containment Stack for Zero-Discharge Returns
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Solution Overview
Problem
Existing drilling fluid systems struggle to effectively contain and manage the return of mud from subsea wells, leading to potential environmental contamination and inefficient fluid management.
Innovation Solution
A containment system comprising a mechanical barrier, tertiary wiper, and water jet assembly is integrated into the wellhead assembly, which includes a variable opening and axially stacked components to capture and clean returning mud, directing it to a volume control system for reuse or storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a containment system is added to capture and clean returning mud, then environmental protection and fluid management are improved, but device complexity increases
Solution Approach 1:
The containment system integrates multiple functional components (mechanical barrier, tertiary wiper, water jet assembly) in a nested configuration within the wellhead assembly. The mechanical barrier body with variable opening contains the drill string, while the tertiary wiper and water jet assembly are positioned within or around the barrier structure, creating a compact nested arrangement that provides comprehensive functionality without excessive spatial complexity
Solution Approach 2:
The mechanical barrier body serves multiple functions: it provides a variable opening to control fluid flow, acts as a structural housing for the tertiary wiper, and works in conjunction with the water jet assembly to contain and direct returning mud. This multi-functionality reduces the need for separate dedicated components, thereby managing system complexity while achieving environmental protection goals
2Reliability
If a mechanical barrier with variable opening is used to contain mud, then fluid containment is improved, but device complexity increases
Solution Approach 1:
The mechanical barrier incorporates a variable opening that can dynamically adjust its size and configuration. This dynamic feature allows the barrier to adapt to different operational conditions (drilling, tripping, cementing) while maintaining reliable fluid containment. The variable opening mechanism provides flexibility without requiring multiple separate barrier structures
Solution Approach 2:
The containment system divides fluid management into distinct functional zones: the mechanical barrier provides the primary containment boundary, the tertiary wiper handles surface cleaning, and the water jet assembly manages additional fluid control. This segmentation allows each component to specialize in a specific containment function, improving overall reliability while keeping individual component structures relatively simple
3Productivity
If multiple stacked components are integrated in the wellhead assembly, then mud return control is improved, but ease of operation decreases
Solution Approach 1:
The mechanical barrier, tertiary wiper, and water jet assembly are merged into a single integrated containment system that operates as a cohesive unit. This integration allows the components to work together automatically based on the flow conditions of returning mud, reducing the need for separate manual operations while maintaining high mud return control efficiency
Solution Approach 2:
The containment system is designed to automatically respond to returning mud conditions. The variable opening in the mechanical barrier and the positioning of the tertiary wiper and water jet assembly allow the system to self-regulate fluid containment and cleaning operations based on operational conditions, reducing manual intervention requirements
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 system ensures zero discharge of well fluids into the ocean environment, effectively cleans the drill string, and manages fluid volume, facilitating efficient reuse and storage of mud.
Implementation Method 1
An inlet may be fluidly connected to the array of nozzles to spray water or other fluid through the nozzles
Implementation Method 2
The main functions of drilling fluids include providing hydrostatic pressure to prevent formation fluids from entering into the borehole
Implementation Method 3
A tertiary wiper may have an elastomeric body and a hole extending centrally through the elastomeric body
Data Source
AI summary
A wellhead assembly includes a containment system having a mechanical barrier, a tertiary wiper, and a fluid jet assembly. A mechanical barrier includes a body disposed in a housing, the body having an opening extending through an axial thickness of the body. A tertiary wiper has an elastomeric body with a hole extending centrally therethrough. A fluid jet assembly includes a jet assembly body having a wall defining a cavity extending axially through the jet assembly body and an array of nozzles positioned circumferentially around the wall, wherein each nozzle has an outlet directed in a radially inward direction from the wall toward a central region in the cavity. The components of the containment system are arranged an axially stacked arrangement relative to each other.