Rotating control device with cooling mandrel

Abstract

A removable cooling mandrel assembly for a rotating control device for use in a drilling system. The present disclosure provides an outer swivel housing enclosing an elongate passage and connected to the uppermost end of an upper housing of the rotating control device. An inner swivel mandrel is mounted in the elongate passage of the outer swivel housing for rotation relative to the outer swivel housing and may be connected to an RCD mandrel of the rotating control device to which the outer swivel housing is connected. A tubular cooling mandrel extends from the inner swivel mandrel out of the outer swivel housing to reduce operating temperatures thereby increasing bearing performance and life and seal life.

Claims

1. A removable cooling mandrel assembly for a rotating control device for use in a drilling system comprising: an outer swivel housing enclosing an elongate passage and having a first connector at a first end thereof by means of which the outer housing may be secured to the uppermost end of an upper housing of a rotating control device; an inner swivel mandrel mounted in the elongate passage of the outer swivel housing for rotation relative to the outer swivel housing, the inner mandrel having a second connector at a first end thereof by means of which the inner mandrel may be connected to an RCD mandrel of the rotating control device to which the outer swivel housing is connected; and a tubular cooling mandrel which extends from the inner swivel mandrel out of the outer swivel housing at the first end thereof.

2. The assembly according to claim 1, wherein the inner swivel mandrel has an outer surface and a seal assembly to provide a substantially fluid tight seal between the outer surface of the inner swivel mandrel and the outer swivel housing and encloses a passage along which a tubular extending through the elongate passage of the outer swivel housing may pass.

3. The assembly according to claim 1, wherein the inner swivel mandrel has an outer surface and a bearing which engages with the outer swivel housing to support the inner swivel mandrel for rotation relative to the outer swivel housing.

4. The assembly according to claim 1, further comprising: a sealing element which is secured to the inner swivel mandrel for rotation with the inner swivel mandrel and which is configured to seal against a radially outwardly facing surface of a tubular extending along the elongate passage of the outer swivel housing.

5. The assembly according to claim 1, wherein the outer swivel housing is provided with an outlet port which fluidly connects the exterior of the outer swivel housing to a cavity partly enclosed by the sealing element and the inner swivel mandrel via an outlet port provided in the inner swivel mandrel, and an outlet hose connector is mounted on an exterior surface of the outer swivel housing and fluidly connected to the outlet port, the hose connector being configured to facilitate the connection of the outlet port to a hose.

6. The assembly according to claim 1, wherein the cooling mandrel is either integral with the inner swivel mandrel or separate to the inner swivel mandrel and connected to the inner mandrel so that the cooling mandrel rotates with the inner swivel mandrel.

7. The assembly according to claim 1, wherein the outer swivel housing is provided with an inlet port which is fluidly connected to an annular space around the cooling mandrel, and the inlet port is fluidly connected to an annular space between a radially inward facing surface of the first end of the inner swivel mandrel and a radially outward facing surface of the cooling mandrel via an inlet port provided in the inner swivel mandrel.

8. A rotating control device for use in a drilling system, the rotating control device comprising: a non-rotating RCD housing enclosing an elongate passage which extends from a first end of the RCD housing to a second end of the RCD housing; a tubular RCD mandrel which encloses an elongate space whose diameter is equal to an internal diameter of the RCD mandrel and which extends along the elongate passage of the RCD housing, the RCD mandrel having an axis and being configured in use to rotate relative to the RCD housing about said axis, and having a first end and a second end which is closer to the second end of the RCD housing than the first end; and a tubular cooling mandrel which is connected to the RCD mandrel to rotate with the RCD mandrel, the cooling mandrel having an outer diameter which is smaller than an inner diameter of the RCD mandrel and being arranged to extend within the RCD mandrel, so that the cooling mandrel is surrounded by and spaced from the RCD mandrel to form a cooling annulus between an outer surface of the cooling mandrel and an inner surface of the RCD mandrel.

9. A rotating control device according to claim 8, further comprising: a bearing assembly supporting the RCD mandrel for rotation in the RCD housing; an elastomeric stripper element which is mounted to the RCD mandrel and which is configured to seal against and rotate with a tubular extending along the elongate passage of the RCD housing; and a seal assembly arranged to isolate the bearing assembly from pressurized fluid in the RCD housing, and which engages with the RCD mandrel between the stripper element and the bearing assembly.

10. The rotating control device of claim 8, further comprising: an inlet port which provides a path for flow of fluid from the exterior of the rotating control device into the cooling annulus to facilitate pumping of fluid from an external fluid source into the cooling annulus, the inlet port being located to provide a path for flow of fluid from the exterior of the rotating control device into a first end of the cooling annulus closest to the first end of the RCD mandrel.

11. The rotating control device of claim 8, further comprising: an outlet port which provides a path for return flow of fluid from the cooling annulus back to the exterior of the rotating control device, the outlet port being located to provide a path for flow of fluid from a second end of the cooling annulus closest to the second end of the RCD mandrel.

12. The rotating control device according to claim, 8 further comprising: an outer swivel housing enclosing an elongate passage and having a first connector at a first end thereof by means of which the outer swivel housing is secured to the first end of the RCD housing so that the elongate passage of the outer swivel housing forms a continuation of the elongate passage of the RCD housing; and an inner swivel mandrel which is mounted in the elongate passage of the outer swivel housing for rotation relative to the outer swivel housing, the inner swivel mandrel having a second connector at a first end thereof by means of which the inner mandrel is connected to the first end of the RCD mandrel, and the cooling mandrel supported by the inner swivel mandrel.

13. The rotating control device of claim 12, wherein the inner swivel mandrel has an outer surface and a seal assembly to provide a substantially fluid tight seal between the outer surface of the inner swivel mandrel and the outer swivel housing and encloses a passage along which a tubular extends along the elongate passage of the RCD housing.

14. The rotating control device of claim 12, wherein the inner swivel mandrel has an outer surface and a bearing which engages with the outer swivel housing to support the inner swivel mandrel for rotation relative to the outer swivel housing.

15. The rotating control device of claim 12, further comprising: a sealing element which is secured to the inner swivel mandrel for rotation with the inner swivel mandrel and which is configured to seal around a radially outwardly facing surface of a tubular extending along the elongate passage of the RCD housing, wherein the sealing element is secured to the inner swivel mandrel.

16. The rotating control device of claim 15, wherein the outer swivel housing is provided with an outlet port which fluidly connects the exterior of the outer swivel housing to a cavity partly enclosed by the sealing element and the inner swivel mandrel via an outlet port provided in the inner swivel mandrel.

17. The rotating control device of claim 12, wherein the outer swivel housing is provided with an inlet port which is fluidly connected to a first end of the cooling annulus adjacent the first end of the RCD mandrel, and the inlet port is fluidly connected to the cooling annulus via an annular space between a radially inward facing surface of the first end of the inner swivel mandrel and a radially outward facing surface of the cooling mandrel via an inlet port provided in the inner swivel mandrel.

18. The rotating control device of claim 8, wherein the cooling mandrel is either integral with the inner swivel mandrel or separate from the inner swivel mandrel and connected to the inner swivel mandrel so that the cooling mandrel rotates with the inner swivel mandrel.

19. The rotating control device of claim 8, wherein the outer surface of the cooling mandrel is provided with at least one guide which extends radially from the outer surface of the cooling mandrel into the cooling annulus to change the direction of fluid flowing in the cooling annulus generally parallel to the axis of the RCD mandrel.

20. A drilling system comprising a rotating control device, the rotating control device comprising: a non-rotating RCD housing enclosing an elongate passage which extends from a first end of the RCD housing to a second end of the RCD housing; a tubular RCD mandrel which encloses an elongate space whose diameter is equal to an internal diameter of the RCD mandrel and which extends along the elongate passage of the RCD housing, the RCD mandrel having an axis and being configured in use to rotate relative to the RCD housing about said axis, and having a first end and a second end which is closer to the second end of the RCD housing than the first end; and a tubular cooling mandrel which is connected to the RCD mandrel to rotate with the RCD mandrel, the cooling mandrel having an outer diameter which is smaller than the inner diameter of the RCD mandrel and being arranged to extend within the RCD mandrel, so that the cooling mandrel is surrounded by and spaced from the RCD mandrel to form a cooling annulus between an outer surface of the cooling mandrel and an inner surface of the RCD mandrel, wherein the drilling system further comprises a drill string extending along the elongate passage of the RCD housing, a cooling fluid reservoir and a pump operable to pump cooling fluid from the cooling fluid reservoir into the cooling annulus.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) For a more complete understanding of the present disclosure, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

(2) FIG. 1 is a cross-sectional view of a prior art rotating control device;

(3) FIG. 2 is cross-sectional view of a rotating control device showing the location of a seal of the present disclosure;

(4) FIG. 3 is an isometric view of the proposed cooling embodiment of the present disclosure;

(5) FIG. 4 is a schematic cross section of the proposed cooling embodiment of the present disclosure; and

(6) FIG. 5 is an isometric view of the inner cooling mandrel of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTIONS

(7) The present disclosure is best understood by referring to FIGS. 1-5 of the drawings, in which like numbers designate like parts.

(8) FIG. 1 is a schematic cross section of a typical prior art rotating control device (RCD) which will serve to illustrate the common current methods of achieving sealing. The RCD has a housing which encloses an elongate passage which extends along a longitudinal axis from a first end of the RCD housing to a second end of the RCD housing. In this example, the RCD housing comprises an upper housing 12 and a lower housing 10, wherein the upper housing 12 has an adapter 30 with threads 31 to enable a clamp 22 to connect the upper housing 12 to the lower housing 10. This is a common arrangement for land RCDs. The assembly may be in one piece and latched into a drilling riser (not shown) below a slip joint (not shown) for a floating drilling rig (not shown) or latched into a diverter (not shown) just above a blowout preventer (BOP) on a jack-up drilling rig (not shown). A tubular, which in this embodiment may be a drill pipe 20, extends through the RCD assembly substantially co-axial with the longitudinal axis and is sealed with a stripper element or stripper rubber 14 attached to a RCD mandrel 38 which is also substantially co-axial to the longitudinal axis. The RCD mandrel 38 is located in the elongate passage in the RCD housing, and has a first end, and a second end which is closer to the second end of the RCD housing (in this example the lowermost end of the lower RCD housing 10) than the first end of the RCD mandrel 38 is. There is a side outlet 27 with a seal groove 25 and stud holes 29 for bolting on a side outlet adapter (not shown). The pressure load from the stripper element 14, due to pressure in a wellbore cavity 15 when drilling with pressure, is transmitted via a load shoulder 17 on the RCD mandrel 38 via a spacer ring 28. The load is transferred to a bearing assembly, which supports the RCD mandrel 38 for rotation in the upper RCD housing 12. In this embodiment, the bearing assembly comprises two sets of conical roller bearings, a lower roller bearing 16 and an upper roller bearing 18, separated by a spacer sleeve 36. The RCD mandrel 38 is free to rotate, as the drill pipe 20 rotates and frictionally transmits the torque through the stripper element 14 and transmits this rotation to the RCE mandrel 38. The upper part of the upper housing 12 has a retention plate 24 with an upper seal carrier 26 below the retention plate 24 which is sealed with a static seal 23 to the upper housing 12. A dynamic seal 21 seals a bearing cavity 13 from the outside environment. The dynamic seal 21 may be a sealing system consisting of multiple seals, like an excluder seal and a dynamic seal. A similar lower seal carrier 32 seals the bearing cavity 13 against the wellbore pressure in the wellbore cavity 15. Similar to the upper seal carrier 26, the lower seal carrier 32 has a similar static seal 35 and a dynamic seal assembly 33 which can have one or more seals. The exact embodiment depends on the design of the RCD, and whether there is a pressurized oil supply to the bearing cavity 13, as this is a common method for cooling and lubricating bearings.

(9) FIG. 2 shows a seal assembly 34 implemented within the RCD and schematically positioned just below the lower seal carrier 32. This seal assembly 34 can be a mechanical seal as described in U.S. formal patent application Ser. No. 16/709,997 or a multiple lip seal assembly as described in U.S. formal patent application Ser. No. 16/744,258, wherein such disclosures are fully incorporated by reference. It is the intent of this disclosure that the seal assembly 34 takes the full pressure differential from the wellbore cavity 15 to the external environment with no pressure staging in the bearing cavity 13. As such, dynamic seals 21a and 21b on the upper seal carrier 26 and the lower seal carrier 32 will be the same, as the dynamic seals 21a and 21b are not sealing any pressure differential. Outer static seals 23a and 23b will also be the same. This allows for a much simpler design of the RCD, as the need for complex PV reduction strategies is removed.

(10) The mechanical seal or the multiple lip seal of the seal assembly 34 will generate significant heat when operated under a high load i.e. high wellbore pressure conditions and high RPM of the drillstring. This will also generate significant heat from the bearings 16 and 18. The disclosure is a removable cooling mandrel and cooling system that can be retrofitted to any common RCD assembly.

(11) FIG. 3 shows an external view of the RCD assembly having an outer swivel housing 220 and a first end of which is connected to the first end of the original upper housing 12 by means of a first connector. The outer swivel housing 220 encloses an elongate passage along which the drill pipe 20 extends and has various externally visible components that are described in detail in FIG. 4.

(12) FIG. 4 shows a schematic cross-section that has like parts with FIG. 2 labelled the same. The seal assembly 34 as shown in FIG. 2 is shown in FIG. 4 as a multiple seal cartridge 70 (details not shown). The rotating part of the seal cartridge 70 is secured to the RCD mandrel 38 with a key 64, and the outer part of the seal cartridge 70 is locked to the upper housing 12 by anti-rotation bolts 63. A cooling mandrel 224, having an outer diameter which is smaller than the inner diameter of the RCD mandrel 38, is inserted inside the RCD mandrel 38 and is substantially co-axial with the longitudinal axis thereby creating an annular fluid path 235 between the outer surface of the cooling mandrel 224 and the inner surface of the RCD mandrel 38. An inlet port, which in this embodiment is provided with a hose connector 231b, allows a cooling fluid (not shown) to enter into a circumferential fluid annulus 233 from where the cooling fluid flows through multiple ports 234 into the annular fluid path 235. In this embodiment, the inlet port is located so as to provide a path for flow of fluid from the exterior of the RCD into a first end of the fluid path 235 closest to the first end of the RCD mandrel 38. The cooling fluid is supplied under pressure from a simple low-pressure diaphragm pump or centrifugal pump (not shown) taking clean drilling fluid or water from the drilling rig mud system (not shown). The cooling fluid flows down the fluid path 235 from the first end of the fluid path 235, cooling the bearings 16 and 18, then cooling the seal cartridge 70, finally to a second end of the fluid path 235 closest to the second end of the RCD mandrel 38, exiting at a cavity 236 below the cooling mandrel 224 and then flowing up along an annular cavity 237 defined between the drill pipe 20 and the RCD mandrel 38 as the bottom of the cavity 236 is sealed by the stripper element 14 between the RCD mandrel 38 and the drill pipe 20.

(13) The cooling fluid now having warmed up with heat from the bearings 16 and 18 and the seal cartridge 70 is now in contact with the drill pipe 20 which will have cool drilling fluid circulating downwards when drilling will induce cooling of the cooling fluid through heat exchange.

(14) An inner swivel mandrel 222 is located in the elongate passage of the outer swivel housing 220 and encloses a cavity 238 above the cooling mandrel 224. The cavity 238 is closed by a low-pressure stripper rubber 227 which extends from the inner swivel mandrel 222 and seals around the drill pipe 20.

(15) The cooling fluid travels up and exits into the cavity 238. The cooling fluid then exits through exit ports 246 provided in the inner swivel mandrel 222 into a fluid annulus 239 between a radially outwardly facing surface of the inner swivel mandrel 222 and the internal surface of the outer swivel housing 220, and then through an outlet port in the outer swivel housing 220. The outlet port in the outer swivel housing 220 is provided with a hose connector 231a and may be fitted with a hose (not shown) to direct the returning cooling fluid back to the drilling rig. The cooling fluid, having been cooled somewhat by the heat exchange with the drill pipe 20, can be routed back to a tank (not shown) used to supply the cooling fluid. Such tanks are typically large on a drilling rig thereby holding several thousands of gallons of cooling fluid which means that this volume of cooling fluid will heat up slowly. Alternatively, the cooling fluid could be routed to a dedicated water tank (not shown) which could be smaller and have additional coolers like a radiator (not shown).

(16) Obviously, the supply of cooling fluid to and from the RCD mandrel 38 requires a swivel mechanism and a seal which are now explained. The top of the original RCD upper housing 12 has a seal retention plate 24 with a lip seal 67 towards the upper seal carrier 26 which is threaded and rotates with the rotating RCD mandrel 38. The upper housing 12 is slightly modified with a threaded extension 244 enabling the outer swivel housing 220 to be mounted on top of the upper housing 12 (the first end of the RCD housing) and connected thereto by means of the first connector, which in this embodiment is a correspondingly threaded portion at the first (lowermost) end of the outer swivel housing 220.

(17) Whilst the cooling mandrel 224 may be integral with the inner swivel mandrel 222, in this embodiment, the cooling mandrel 224 and the inner swivel mandrel 222 are separate, an end of the cooling mandrel 224 being connected to the inner swivel mandrel 222 so that the cooling mandrel 224 rotates with the inner swivel mandrel 222. In this embodiment, the cooling mandrel 224 is held in place by a threaded retainer ring 226 and sealed with a seal 225, which fixes the cooling mandrel 224 to the inner swivel mandrel 222, a first end of which is turn is connected to the first end of the RCD mandrel 38 by a second connector which in this example is an inner swivel mandrel thread 245, and sealed with a seal 223. As such, it will be appreciated that the cooling mandrel 224 rotates with the RCD mandrel 38 and the drill pipe 20.

(18) The sealing between the inner swivel mandrel 222 and the outer swivel housing 220 is achieved by multiple lip seals 221a-221f which are paired between required pressure isolation points with weep ports 241a-241c to enable detection of any leaks. An annular groove 240 between the lip seals 221a and 221b allows communication to the weep ports 241a-241c. Similar annular grooves are present for the other pairs of lip seals 221c-221f. The inner swivel mandrel 222, being rigidly affixed to the RCD mandrel 38, is centered by the RCD bearings 16 and 18. In this embodiment, an additional bearing 232 is placed between the inner swivel mandrel 222 and the outer swivel housing 220 to keep the required gap for optimal performance of the lip seals 221.

(19) The low-pressure stripper rubber 227 is much softer than the main stripper element 14, as the main purpose of the low-pressure stripper rubber 227 is to provide low pressure isolation for the cooling fluid. The low-pressure stripper rubber 227 is retained by bolts 228 onto the inner swivel mandrel 222 and as such, rotates at the same RPM with the drill pipe 20 and the RCD mandrel 38. An annular protective plate 229 is attached to the uppermost end of the outer swivel housing 220 with bolts 230 and serves to protect the low-pressure stripper rubber 227 whilst providing a central aperture through which the drill pipe 20 passes. Any accumulation of mud or drilling fluids can escape through a port 242.

(20) FIG. 5 shows the cooling mandrel 224 with multiple guides 247 which serve to maintain a constant annular gap with the RCD mandrel 38 and also to guide the cooling fluid flow by evenly distributing the cooling fluid as illustrated by the fluting and spiral formation of the guides 247. This can be optimized based on the flow required and the identification of main hot spots, like bearing contact points with the RCD mandrel 38. As such there can be multiple sets of flutes and spacers to improve the efficiency of the cooling path.

(21) Although the present disclosure has been described with reference to specific embodiments, these descriptions are not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the present disclosure, will become apparent to persons skilled in the art upon reference to the description of the present disclosure. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed might be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the present disclosure as set forth in the appended claims.

(22) It is therefore contemplated that the present disclosure will cover any such modifications or embodiments that fall within the scope of the claims.