Abstract
This disclosure includes riser-component assemblies and methods of assembling the same that are suitable for managed pressure drilling (MPD) systems. For example, this disclosure includes integrated flow spool and isolation tool riser components that can be permanently coupled together and that can be configured to pass through a rotary table or other rig equipment.
Claims
1. A riser-component assembly having a primary lumen, the assembly comprising: a housing having a first opening, a second opening, and defining a central chamber in fluid communication with the primary lumen and configured to receive an annular seal in the central chamber such that the annular seal can selectively seal an annulus in the central chamber around a tubing extending through the first and second openings of the housing; and a flow diverter permanently coupled to the housing, the flow diverter having: a collar defining a lateral opening in fluid communication with the primary lumen, the collar having a collar lumen in fluid communication with the primary lumen, a main tube coupled to the collar and having a main tube lumen in fluid communication with the primary lumen, and a valve in fluid communication with the lateral opening; wherein the housing comprises a maximum transverse dimension and a first passage within the maximum transverse dimension of the housing, the first passage configured to be circumferentially aligned with a first flow line.
2. The assembly of claim 1, comprising the first flow line, wherein the first flow line includes a first flow line lumen and at least a portion of the first flow line lumen is configured to be aligned with the first passage.
3. The assembly of claim 2, wherein the first passage is configured to at least partially receive the first flow line.
4. The assembly of claim 2, wherein the first flow line is an auxiliary line.
5. The assembly of claim 1, wherein the housing comprises a second passage within the maximum transverse dimension of the housing and wherein the second passage is configured to be circumferentially aligned with a second flow line.
6. The assembly of claim 5, comprising the second flow line having a second flow line lumen in fluid communication with the valve.
7. The assembly of claim 5, wherein the second passage is configured to at least partially receive the second flow line.
8. The assembly of claim 6, wherein the second flow line lumen has an inlet through which fluid can enter in a first direction substantially parallel to a longitudinal flow axis of the valve, and an outlet through which fluid may exit in a second direction, the second direction substantially different than the first direction.
9. The assembly of claim 1, wherein each of the maximum transverse dimension of the housing and a maximum transverse dimension of the flow diverter is sized such that each of the housing and the flow diverter can fit through a rotary of a drilling rig.
10. The assembly of claim 1, wherein the valve has a longitudinal flow axis that is more parallel than perpendicular to a longitudinal axis extending through the primary lumen.
11. The assembly of claim 1, wherein a maximum transverse dimension of the flow diverter is less than or equal to the maximum transverse dimension of the housing.
12. The assembly of claim 11, wherein the maximum transverse dimension of the housing is less than 60.5 inches.
13. A method comprising: lowering a riser-component assembly of claim 1 through a rotary of a drilling rig.
14. A method of assembling a riser-component having a primary lumen, the method comprising: permanently coupling a main tube of a flow diverter to a housing; wherein the housing includes: a first opening, a second opening, and the housing defines a central chamber in fluid communication with the primary lumen; a maximum transverse dimension; and a first passage within the maximum transverse dimension of the housing, the first passage configured to be circumferentially aligned with a first flow line; and wherein the flow diverter includes: a collar defining a lateral opening in fluid communication with the primary lumen, the collar having a collar lumen in fluid communication with the primary lumen, the main tube coupled to the collar and having a main tube lumen in fluid communication with the primary lumen; and a valve in fluid communication with the lateral opening.
15. The method of claim 14, wherein the first flow line includes a first flow line lumen and the method comprises aligning the first passage with at least a portion of the first flow line lumen.
16. The method of claim 15, comprising at least partially inserting the first flow line into the first passage.
17. The method of claim 14, wherein the first flow line is an auxiliary line.
18. The method of claim 14, wherein the housing comprises a second passage within the maximum transverse dimension of the housing, the second passage configured to be circumferentially aligned with a second flow line.
19. The method of claim 18, wherein the second flow line includes a second flow line lumen and the method comprises: aligning the second passage with at least a portion of the second flow line lumen; and coupling a first end of the second flow line to the valve such that the second flow line lumen is in fluid communication with the valve.
20. The method of claim 18, comprising at least partially inserting the second flow line into the second passage.
21. The method of claim 14, comprising permanently coupling a first flange to the housing, the first flange having a first central flange lumen in fluid communication with the primary lumen and a first mating face configured to mate with a flange of a first adjacent riser segment.
22. The method of claim 14, comprising permanently coupling a second flange to the flow diverter, the second flange having a second central flange lumen in fluid communication with the primary lumen and a second mating face configured to mate with a flange of a second adjacent riser segment.
23. The method of claim 14, moving the housing and the flow diverter through a rotary of a drilling rig after coupling the main tube of the flow diverter to the housing.
24. A riser-component assembly having a primary lumen, the assembly comprising: a housing having a first opening, a second opening, and defining a central chamber in fluid communication with the primary lumen and configured to receive an annular seal in the central chamber such that the annular seal can selectively seal an annulus in the central chamber around a tubing extending through the first and second openings of the housing; and a flow diverter coupled to the housing, the flow diverter having: a collar defining a lateral opening in fluid communication with the primary lumen; a main tube coupled to the collar and having a main tube lumen in fluid communication with the primary lumen; and a valve in fluid communication with the lateral opening, the valve positioned such that the lateral opening is disposed between the housing and the valve in a direction along a primary axis of the primary lumen.
25. The assembly of claim 24, wherein the collar of the flow diverter is permanently coupled to the housing.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers. The figures are drawn to scale for at least the embodiments shown.
(2) FIG. 1 depicts a perspective view of a prior art riser stack including an isolation tool and flow spool.
(3) FIG. 2A depicts a perspective view of an embodiment of the present riser-component assemblies that includes an integral isolation tool and flow spool component.
(4) FIG. 2B depicts a partially-exploded side view of the riser-component assembly of FIG. 2A.
(5) FIG. 2C depicts a top view of the riser-component assembly of FIG. 2A.
(6) FIG. 2D depicts a side view of the riser-component assembly of FIG. 2A being lowered through a rotary according to some embodiments of the present disclosure.
(7) FIG. 2E depicts a cross-sectional view of the riser-component assembly of FIG. 2A.
(8) FIG. 2F depicts an enlarged cross-sectional view of a portion of the riser-component assembly of FIG. 2A, as indicated by region 2F in FIG. 2E.
(9) FIG. 3A depicts a perspective view of another embodiment of the present riser-component assemblies that includes an integral isolation tool and flow spool component.
(10) FIG. 3B depicts a partially-exploded side view of the riser-component assembly of FIG. 3A.
(11) FIG. 3C depicts a top view of the riser-component assembly of FIG. 3A.
(12) FIG. 3D depicts a side view of the riser-component assembly of FIG. 3A being lowered through a rotary according to some embodiments of the present disclosure.
(13) FIG. 3E depicts a cross-sectional view of the riser-component assembly of FIG. 3A.
(14) FIGS. 3F and 3G depict enlarged cross-sectional views of portions of the riser-component assembly of FIG. 3A, as indicated by regions 3F and 3G in FIG. 3E.
(15) FIGS. 4A and 4B depict a side and top view, respectively, of another embodiment of the present riser-component assemblies that includes an integral isolation tool and flow spool component.
DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
(16) Referring now to the drawings, and more particularly to FIG. 1, shown there and designated by the reference numeral 10 is a prior art riser assembly or stack that includes multiple riser components. As shown, assembly 10 includes a rotating control device (RCD) body component 14, an isolation unit component 18, a flow spool component 22, and two crossover components 26 (one at either end of assembly 10). Isolation unit component 18 and flow spool component 22 are coupled together by joining flanges 42. FIGS. 2A-3G described below illustrate embodiments of an integral isolation tool and flow spool riser-component that does not require flanges 42 when used in a riser-component assembly or stack.
(17) FIG. 2A shows integral riser-component assembly 38a, which comprises a first flange 108, a housing 116, a flow spool 120, and a second flange 112. Flanges 108, 112 can include mating faces 108b, 112b, respectively, that can be configured to mate with adjacent riser segments. Flange 108 can be permanently coupled (e.g., by welding) to housing 116, housing 116 can be permanently coupled to flow spool 120, and flow spool 120 can be permanently coupled to flange 112. As used herein, the term “permanently coupled” means not easily removable and includes coupling by welding, but does not include coupling by only removable fasteners (e.g., screws, bolts) or coupling by only removable threading (e.g., threading on the interior and/or exterior of adjacent tubulars). Integral riser-component assembly 38a can include primary axis 104 and primary lumen 104a, which can be in fluid communication with a lumen of adjacent riser-components. Flow spool 120 can include collar 128, main tube 132, valve assemblies 134, first flow lines 152 and retainer 168, as described more fully with reference to FIGS. 2B and 2E-F below.
(18) FIG. 2B shows components of integral riser-component assembly 38a as they might appear prior to assembly at a wellsite. In the orientation and configuration shown, flange 108 has been welded to the top of housing 116, the bottom of housing 116 has been welded to the top of collar 128, the top of main tube 132 has been welded to the bottom of collar 128, and the top of flange 112 has been welded to the bottom of main tube 132. An annular seal 124 can be received within a central chamber 116c of housing 116, as shown in FIG. 2E, prior to coupling the top and bottom portions 116e, 116f, respectively, of housing 116 together (e.g., via bolts 116g). Valve assemblies 134 can include valves 136 having ports 160, fittings 140, first connectors 144, and second connectors 148. The components of valve assemblies 134 can be permanently or removably coupled together in the configuration shown in FIG. 2B, as more fully described with reference to FIG. 2E below. Fittings 140 of valve assemblies 134 can be coupled to collar 128 over lateral openings 120a (see FIG. 2E) via, e.g., bolts. Retainer 168 can be coupled to main tube 132 permanently (e.g., via welding) or removably (e.g., via bolts through cut-outs 168c). In this configuration, retainer 168 should be coupled to main tube 132 such that it is entirely below the lower-most portion of valve assemblies 134. First flow lines 152 can be coupled to valve assemblies 134 by inserting pin ends 152d through passages 168a (see FIG. 2F) of retainer 168 and into recesses 148b (see FIG. 2F) of second connectors 148. Valves 136 can be connected to other types of flow lines such as a choke line or kill line through ports 160. Valves 136 can control the flow of fluid from primary lumen 104a through first flow lines 152.
(19) As shown in FIGS. 2C and 2D, integral riser-component assembly 38a can have a maximum transverse diameter 116d (e.g., defined in housing 116 for the embodiment shown) that is less than the transverse diameter of an opening, such as opening 300 of rotary 304, such that integral riser-component assembly 38a can fit through a rotary such as rotary 304. In particular, maximum transverse diameter 116d can be less than 60.5 inches, which is a common diameter for a rotary on various drilling rigs (often referred to as a 60-inch rotary). Other embodiments of integral riser-component assembly 38a can have a different maximum transverse diameter (e.g., greater than 60.5 inches).
(20) As shown in the cross-sectional view of FIG. 2E, flanges 108, 112 can include central flange lumens 108a, 112a, respectively, that can be in fluid communication with primary lumen 104a. Housing 116 can include first opening 116a, second opening 116b, and central chamber 116c, that can each be in fluid communication with primary lumen 104a. Central chamber 116c can receive annular seal 124 around primary axis 104. Annular seal 124 can be configured to seal around tubing, such as a drill string, that is axially run through central chamber 116c around primary axis 104.
(21) Flow spool 120 can include lateral openings 120a in collar 128 that can be in fluid communication with primary lumen 104a. Fittings 140 can each include a fitting lumen 140a and be disposed at one end over lateral openings 120a such that fitting lumens 140a are in fluid communication with lateral openings 120a and primary lumen 104a. Fittings 140 can define a shoulder such that a portion of fitting lumens 140a have a longitudinal flow axis that runs substantially parallel to primary axis 104. Valves 136, which can a known type of valve such as a double ball valve, can be coupled to fittings 140 directly or via a connector, such as first connector 144, such that fitting lumens 140a are in fluid communication with valves 136. For example, first connectors 144 can include first connector lumens 144a that are in fluid communication with both fitting lumens 140a and valves 136. First connectors 144 can be permanently connected (e.g., via welding) or removably connected (e.g., via bolts or threading) to fittings 140 on one end and permanently (e.g., via welding) or removably coupled (e.g., via bolts or threading) to valves 136 on another end. Valves 136 can each include a longitudinal flow axis 136a that can be substantially parallel to primary axis 104. This configuration can advantageously reduce the transverse diameter of flow spool 120 so that flow spool 120 can fit through a rotary or other mechanism as shown in FIG. 2D (e.g., so that the maximum transverse diameter of flow spool 120 is less than or equal to maximum transverse diameter 116d).
(22) Valves 136 can also be coupled (e.g., on the end opposite first connectors 144 and/or fittings 140) to first flow lines 152 directly or via a connector such as second connector 148 such that first flow line lumens 152a are in fluid communication with valves 136. For example, second connectors 148 can include second connector lumens 148a that are in fluid communication with both valves 136 and first flow line lumens 152a. Second connectors 148 can be permanently connected (e.g., via welding) or removably connected (e.g., via bolts or threading) to valves 136 on one end. While another end of second connectors 148 can be permanently connected (e.g., via welding) or removably coupled via bolts and/or threads to first flow lines 152, second connectors 148 can also be coupled to first flow lines 152 by receiving a portion of pin ends 152d of first flow lines 152 in recesses 148b of second connectors 148, as shown more clearly in FIG. 2F. In this configuration, second connectors 148 can further include grooves 148c sized to receive sealing and/or lubricating components (e.g., O-rings, rigid washers, grease) to facilitate insertion of a portion of pin ends 152d in recesses 148b of second connectors 148.
(23) When connected, fluid can enter first flow line lumens 152a from valves 136 in a first direction, such as direction 152b, and exit first flow line lumens 152a in a second direction that is different than the first direction, such as directions 152c. First flow lines 152 can include flange portions 152e near or at their exit. Flange portions 152e can facilitate coupling of first flow lines 152 to second flow lines (not shown), such as auxiliary lines. The second flow lines can be attached to first flow lines 152 after integral riser-component assembly 38a passes through a rotary (e.g., as shown in FIG. 2D). The second flow lines can have a lumen with an inlet that can receive fluid from first flow line lumens 152a in direction 152c. This configuration (i.e., having fluid exit first flow line lumens 152a and enter the second flow line lumens in direction 152c) allows the second flow lines to be coupled to first flow lines 152 without interfering with other riser segments, such as a riser segment coupled to mating face 112b of flange 112. Such an advantageous configuration can be accomplished without increasing the transverse diameter of flow spool 120 (e.g., so that flow spool 120 can have a maximum transverse diameter less than maximum transverse diameter 116d) by including curvilinear portions such as curvilinear portions 152f, 152g, in first flow lines 152. For example, curvilinear portion 152f can curve toward main tube 132 and curvilinear portion 152g can curve away from main tube 132 such that fluid is directed in directions 152c without increasing the transverse diameter of flow spool 120.
(24) As shown more clearly in FIG. 2F, first flow lines 152 can be secured to main tube 132 via retainer 168. Retainer 168 can include passages 168a that can receive a portion of pin ends 152d of first flow lines 152. Pin ends 152d of first flow lines 152 can include protrusions 152h that can mate with indents 168b of retainer 168 to ensure that first flow lines 152 are properly aligned within passages 168a. Retainer 168 can prevent valve assemblies 134 from moving laterally (e.g., bending) during riser operations or otherwise.
(25) FIGS. 3A-3G depict another embodiment of the riser-component assemblies that allows auxiliary or other lines to be connected to the flow spool portion of the assembly above the isolation tool portion of the assembly, which may be advantageous in certain operations. FIG. 3A shows integral riser-component assembly 38b, which comprises a first flange 208, a housing 216, a flow spool 220, a second flange 212, a spacer collar 296, a diversion collar assembly 292, and a third flange 280. Flanges 208, 212, and 280 can include mating faces 208b, 212b, 280b, respectively, that can be configured to mate with adjacent riser segments or with each other. A fourth flange (not shown) may be coupled to diversion collar assembly 292 on the opposite side of flange 280 and may include a mating face configured to mate with an adjacent riser segment. Diversion collar assembly 292 can be permanently coupled (e.g., via welding) to flange 280; mating face 280b of flange 280 can be removably coupled (e.g., via bolts) to mating face 208b of flange 208; flange 208 can be permanently coupled to spacer collar 296, spacer collar 296 can be permanently coupled to housing 216; housing 216 can be permanently coupled to flow spool 220; and flow spool 220 can be permanently coupled to flange 212. As used herein, the term “permanently coupled” means not easily removable and includes coupling by welding, but does not include coupling by only removable fasteners (e.g., screws, bolts) or coupling by only removable threading (e.g., threading on the interior and/or exterior of adjacent tubulars). Integral riser-component assembly 38b can include primary axis 204 and primary lumen 204a, which can be in fluid communication with a lumen of adjacent riser-components. Flow spool 220 can include collar 228, main tube 232, valve assemblies 234, first flow lines 252 and retainer 268. Diversion collar assembly 292 can include diversion collar 292b and second flow lines 276. The components of flow spool 220 and diversion collar assembly 292 are described more fully with reference to FIGS. 3B-3G below.
(26) FIG. 3B shows components of integral riser-component assembly 38b as they might appear prior to assembly at a wellsite. In the orientation and configuration shown, the bottom of diversion collar 292b has been welded to the top (i.e., not mating face 280b) of flange 280, the bottom of flange 208 (i.e., not mating face 208b) has been welded to the top of spacer collar 296, the bottom of spacer collar 296 has been welded to the top of housing 216, the bottom of housing 216 has been welded to the top of collar 228, the bottom of collar 228 has been welded to the top of main tube 232, and the bottom of main tube 232 has been welded to the top (i.e., not mating face 212b) of flange 212. An annular seal 224 can be received within central chamber 216c of housing 216, as shown in FIG. 3E, prior to coupling the top and bottom portions 216e, 216f, respectively, of housing 216 together (e.g., via bolts). A portion of first flow lines 252 can be laterally offset from primary axis 204 and can be received within passages 216g of housing 216 (which can be different than holes for bolts) such that the maximum transverse diameter of riser-component assembly 38b is maximum transverse diameter 216d, as described more fully with reference to FIGS. 2C and 2D below. Spacer collar 296 can have an axial length sufficient to permit alignment of first flow lines 252 and second flow lines 276 above housing 216.
(27) Valve assemblies 234 can include valves 236 having ports 260, fittings 240, first connectors 244, and second connectors 248. The components of valve assemblies 234 can be permanently coupled (e.g., via welding) or removably coupled (e.g., via bolts) together in the configuration shown in FIG. 3B and are more fully described with reference to FIG. 3E below. Fittings 240 of valve assemblies 234 can be coupled to collar 228 over lateral openings 220a (see FIG. 3E) via, e.g., bolts. Retainer 268 can be coupled to main tube 232 permanently (e.g., via welding) or removably (e.g., via bolts through cut-outs 268c). In this configuration, retainer 268 should be coupled to main tube 232 such that retainer 268 is entirely above the highest portion of valve assemblies 234. First flow lines 252 can be coupled to valve assemblies 234 by inserting pin ends 252d of first flow lines 252 through passages 268a of retainer 268 and into recesses 248b (see FIG. 2F) of second connectors 248. Valves 236 can be connected to other types of flow lines such as a choke line or kill line through ports 260. Valves 236 can control the flow of fluid from primary lumen 204a through first flow lines 252.
(28) Second flow lines 276 of diversion collar assembly 292 can have ends permanently coupled (e.g., via welding) or removably coupled (e.g., via bolts and/or threads) to diversion collar 292b. Second flow lines can also include pin ends 276b, a portion of which can be received in peripheral flange lumen 280c of flange 280, as shown in FIG. 3B. While second flow lines 276 can be coupled to first flow lines 252 permanently (e.g., via welding) or removably via bolts and/or threads, second flow lines 276 can also be coupled to first flow lines 252 removably by inserting a portion of pin ends 276b of second flow lines 276 through peripheral flange lumens 208c of flange 208 (e.g., after first being inserted through peripheral flange lumens 280c of flange 280) and into recesses 252b (see FIG. 3G) of box ends 252c of first flow lines 252, as described more fully by reference to FIGS. 3E and 3G below.
(29) As shown in FIGS. 3C and 3D, integral riser-component assembly 38b can have a maximum transverse diameter 216d (e.g., defined in housing 216 for the embodiment shown) that is less than the transverse diameter of an opening, such as opening 300 of rotary 304, such that integral riser-component assembly 38b can fit through a rotary such as rotary 304. In particular, maximum transverse diameter 216d can be less than 60.5 inches, which is a common diameter for a rotary on various drilling rigs (often referred to as a 60-inch rotary). Other embodiments of integral riser-component assembly 38b can have a different maximum transverse diameter (e.g., greater than 60.5 inches).
(30) As shown in the cross-sectional view of FIG. 3E, flanges 208, 212, 280 can include central flange lumens 208a, 212a, 280a, respectively, that can be in fluid communication with primary lumen 204a. Housing 216 can include first opening 216a, second opening 216b, and central chamber 216c, that can each be in fluid communication with primary lumen 204a. Central chamber 216c can receive annular seal 224 around primary axis 204. Annular seal 224 can be configured to seal around tubing, such as a drill string, that is axially run through central chamber 216c around primary axis 204.
(31) Flow spool 220 can include lateral openings 220a in collar 228 that can be in fluid communication with primary lumen 204a. Fittings 240 can each include a fitting lumen 240a and be disposed at one end over lateral openings 220a such that fitting lumens 240a are in fluid communication with lateral openings 220a and primary lumen 204a. Fittings 240 can define a shoulder such that a portion of fitting lumens 240a have a longitudinal flow axis that runs substantially parallel to primary axis 204. Valves 236, which can be a known type of valve such as a double ball valve, can be coupled to fittings 240 directly or via a connector, such as first connector 244, such that fitting lumens 240a are in fluid communication with valves 236. For example, first connectors 244 can include first connector lumens 244a that are in fluid communication with both fitting lumens 240a and valves 236. First connectors 244 can be permanently connected (e.g., via welding) or removably connected (e.g., via bolts or threading) to fittings 240 on one end and permanently (e.g., via welding) or removably coupled (e.g., via bolts or threading) to valves 236 on another end. Valves 236 can each include a longitudinal flow axis 236a that can be substantially parallel to primary axis 204. This configuration can advantageously reduce the transverse diameter of flow spool 220 so that flow spool 220 can fit through a rotary or other mechanism as shown in FIG. 3D (e.g., so that the maximum transverse diameter of flow spool 220 is less than or equal to maximum transverse diameter 216d).
(32) Valves 236 can also be coupled (e.g., on the end opposite first connectors 244 and/or fittings 240) to first flow lines 252 directly or via a connector such as second connector 248 such that first flow line lumens 252a are in fluid communication with valves 236. For example, second connectors 248 can include second connector lumens 248a that are in fluid communication with both valves 236 and first flow line lumens 252a. Second connectors 248 can be permanently connected (e.g., via welding) or removably connected (e.g., via bolts or threading) to valves 236 on one end. While another end of second connectors 248 can be permanently connected (e.g., via welding) or removably coupled via bolts and/or threads to first flow lines 252, second connectors 248 can also be coupled to first flow lines 252 by receiving a portion of pin ends 252d of first flow lines 252 in recesses 248b of second connectors 248, as shown more clearly in FIG. 3F. In this configuration, second connectors 248 can further include grooves 248c sized to receive sealing and/or lubricating components (e.g., O-rings, rigid washers, grease) to facilitate insertion of a portion of pin ends 252d in recesses 248b of second connectors 248.
(33) When connected, fluid can enter first flow lines 252 through pin ends 252d from valves 236 and exit first flow lines 252 through box ends 252c. As shown more clearly in FIG. 3G, recesses 252b of box ends 252c can receive a portion of pin ends 276b of second flow lines 276 such that first flow line lumens 252a and second flow line lumens 276a are in fluid communication. In this configuration, box ends 252c can further include grooves 252f sized to receive sealing and/or lubricating components (e.g., O-rings, rigid washers, grease) to facilitate insertion of a portion of pin ends 276b of second flow lines 276 in recesses 252b of first flow lines 252. Another end of second flow lines 276 (e.g., the end spaced apart from pin end 276b can be permanently coupled (e.g., via welding) or removably coupled (e.g., via bolts or threading) to diversion collar 292b of diversion collar assembly 292 such that second flow line lumens 276a are in fluid communication with diversion collar lumens 292a.
(34) When connected, fluid can enter diversion collar lumens 292a from second flow line lumens 276a in a first direction, such as direction 292c, and exit diversion collar lumens 292a in a second direction that is different than the first direction, such as directions 292d. Diversion collar 292b can be coupled to third flow lines (not shown), such as an auxiliary line, via, e.g., bolts at joining surfaces 292e (see FIG. 3A). The third flow lines can be attached to diversion collar 292b after integral riser-component assembly 38b passes through a rotary (e.g., as shown in FIG. 3D). The third flow lines can have a lumen with an inlet that can receive fluid from diversion collar lumens 292a in direction 292d. This configuration (i.e., having fluid exit first diversion collar lumens 292a and enter the third flow line lumens in direction 292d) allows the third flow lines to be coupled to diversion collar 292b without interfering with other riser segments, such as a riser segment coupled above diversion collar assembly 292 in the orientation shown in FIG. 3E.
(35) As shown in FIGS. 3E and 3F, first flow lines 252 can be secured to main tube 232 via retainer 268. Retainer 268 can include passages 268a that can receive a portion of pin ends 252d of first flow lines 252. Pin ends 252d of first flow lines 252 can include protrusions 252e that can mate with indents 268b of retainer 268 to ensure that first flow lines 252 are properly aligned within passages 268a. Retainer 268 can prevent valve assemblies 234 from moving laterally (e.g., bending) during riser operations or otherwise.
(36) FIGS. 4A and 4B depict another embodiment of an integral riser-component assembly 38c that allows lines, such as auxiliary lines, to be connected to the assembly around the flow spool without increasing the maximum diameter of the assembly. As shown, assembly 38c includes many of the same components as previous embodiments, including a first flange 408, a housing 416, a flow spool 420, a retainer 468, and a second flange 412. These components generally operate and have the same characteristics and assembly as previously described embodiments. Housing 416 includes a plurality of passages 416g similar to passages 216g that can receive a portion (including all) of the transverse diameter of lines, such as auxiliary lines 480, such that the lines fit within the maximum transverse diameter 416d of housing 416. Maximum transverse diameter 416d is greater than or equal to the maximum transverse diameter of flow spool 420 such that assembly 38c can fit through a rotary or other mechanism, similar to that shown in FIGS. 2D and 3D, when gooseneck-like flow lines 452 are not connected. Flow lines 452 are similar to curvilinear flow lines 152 in that they can receive fluid from valves 436 in one direction but direct the flow out in another direction 452c that is different than the first direction. As shown in FIG. 4A, direction 452c is substantially opposite of the inlet direction (though other outlet directions are also possible). As shown in FIGS. 4A and 4B, flow lines 452 extend beyond the maximum transverse diameter 416d of housing 416. Accordingly, flow lines 452 may be removeably coupled to flow spools 420, for example, through threaded and/or bolted connection 484, so that they may be connected to the rest of assembly 38c after it passes through a rotary. Handles 476 may be coupled to flow lines 452 (e.g., via welding or integrally) to facilitate this connection. Additionally, because flow lines 452 extend beyond the maximum transverse diameter 416d of housing 416, they are more at risk of inadvertent contact and damage from other riser components. Accordingly, handles 476 provide some protection from such contact.
(37) The above specification and examples provide a complete description of the structure and use of illustrative embodiments. Although certain embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. As such, the various illustrative embodiments of the methods and systems are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and embodiments other than the one shown may include some or all of the features of the depicted embodiment. For example, elements may be omitted or combined as a unitary structure, and/or connections may be substituted. Further, where appropriate, aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples having comparable or different properties and/or functions, and addressing the same or different problems. Similarly, it will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments.
(38) While the above specification refers to the embodiments of integral riser-component assemblies 38a and 38b, the invention is not to be so limited. Permanent connection of other riser-components such as rotating control device (RCD) body components (e.g., RCD body component 14) is also contemplated.
(39) The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) “means for” or “step for,” respectively.
