US20190234173A1 - Rotating Control Devices and Methods to Detect Pressure Within Rotating Members - Google Patents
Rotating Control Devices and Methods to Detect Pressure Within Rotating Members Download PDFInfo
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- US20190234173A1 US20190234173A1 US16/257,183 US201916257183A US2019234173A1 US 20190234173 A1 US20190234173 A1 US 20190234173A1 US 201916257183 A US201916257183 A US 201916257183A US 2019234173 A1 US2019234173 A1 US 2019234173A1
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Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/02—Surface sealing or packing
- E21B33/08—Wipers; Oil savers
- E21B33/085—Rotatable packing means, e.g. rotating blow-out preventers
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/02—Surface sealing or packing
- E21B33/03—Well heads; Setting-up thereof
- E21B33/06—Blow-out preventers, i.e. apparatus closing around a drill pipe, e.g. annular blow-out preventers
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B34/00—Valve arrangements for boreholes or wells
- E21B34/16—Control means therefor being outside the borehole
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B44/00—Automatic control systems specially adapted for drilling operations, i.e. self-operating systems which function to carry out or modify a drilling operation without intervention of a human operator, e.g. computer-controlled drilling systems; Systems specially adapted for monitoring a plurality of drilling variables or conditions
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B47/00—Survey of boreholes or wells
- E21B47/06—Measuring temperature or pressure
Abstract
A rotating control device includes a housing with a sensor port extending to a central housing bore, a sensor in the port, and a rotating sleeve assembly (RSA) extending within the central bore. The RSA includes a sleeve configured to rotate relative to the housing and a second bore coaxially aligned with the central bore of the housing, A piston port in the sleeve extends to the second bore, and a piston disposed in the piston port is configured to reciprocate between a first position and a second position in response to a change in pressure of fluid within the second bore. The piston port and the piston are disposed at a location in the rotating sleeve that passes the sensor periodically when the rotating sleeve rotates; the sensor configured to detect the piston when it rotates past the sensor and is in its second position.
Description
- This application claims benefit of U.S. provisional application Ser. No. 62/622,411 filed Jan. 26, 2018, and entitled “Rotating Control Devices and Methods to Detect Pressure Within Rotating Members,” which is hereby incorporated herein by reference in its entirety for all purposes.
- Not applicable.
- The present disclosure relates generally to drilling systems and to rotating control devices for such systems. More particularly, the disclosure relates to systems and methods for monitoring annular seals between concentric fluid conduits as they rotate relative to each other.
- In applications requiring the transmission of fluid under relatively high pressure, it is sometimes necessary to interconnect a rotatable conduit with a stationary conduit, and to provide annular seals therebetween to prevent leakage of the pressurized fluid. One such application is in drilling operations where a drill pipe or another tubular member passes through a rotating control device (RCD), where the outer housing of the RCD remains stationary while an internal sleeve and annular seals surround and rotate along with the drill pipe. The annular seals allow the drill pipe to move axially into or out from a wellbore without fluid leakage. When it is thought that a seal failure has occurred—whether actual or perceived—drilling operations are halted so that the seals can be inspected and possibly replaced. However, drilling costs are very high, such that downtime must be avoided or minimized as much as possible. Consequently, systems and apparatus that can definitively indicate that a seal failure is imminent or has occurred would be welcomed by the industry.
- These and other needs in the art are addressed in one embodiment by a rotating control device (RCD) for a well comprising: a housing having a through-bore extending along a central axis, a housing wall, and a sensor disposed at a sensor position in the housing and extending into the housing wall. The RCD includes a sleeve comprising a sleeve bore aligned with the central axis and configured to rotate about the central axis, within the through-bore of the housing, as well as a pressure-responsive assembly coupled to the sleeve and configured to generate a response to a pressure of fluid within the sleeve bore. The pressure-responsive assembly is coupled to the sleeve at a location such that it passes the sensor position periodically as the sleeve rotates within the through-bore. The sensor is configured to detect the response of the pressure-responsive assembly.
- In some embodiments, the pressure-responsive assembly includes a pressure-responsive element in fluid communication with the sleeve bore; and the pressure-responsive element is configured to be free of sliding engagement with the sleeve when responding to a change in pressure in the sleeve bore.
- In some embodiments, the pressure-responsive assembly comprises a first piston slidingly disposed inside a piston cartridge and configured to move from a first position to a second position relative to the piston cartridge in response to an activation pressure in the fluid within the sleeve; wherein the sensor is configured to detect the presence of the first piston when the first piston is in the second position and passes the sensor position; and wherein the piston is separated from the sleeve by the piston cartridge.
- The sleeve may further include an outer surface, and a first piston port extending from the sleeve outer surface, with the first piston port being in fluid communication with the sleeve bore. In some embodiments, the pressure-responsive assembly is disposed in the first piston port with the first piston in fluid communication with the sleeve bore; wherein the first piston is configured to slide without contacting the first piston port.
- In some embodiments, the rotating control device further comprises a burst disc coupled to the piston cartridge and disposed to seal the first piston from the fluid within the sleeve until the fluid reaches or exceeds a prescribed pressure.
- In some embodiments, the rotating control device further comprises a plurality of pressure-responsive assemblies, each pressure-responsive assembly coupled to the sleeve at a different location such that it passes the sensor position periodically as the sleeve rotates within the through-bore; wherein each pressure-responsive assembly is configured to generate a response to a particular pressure of the fluid within the sleeve bore; and the sensor is configured to detect the responses of each of the plurality of pressure-responsive assemblies.
- In some embodiments, the pressure-responsive assembly comprises a transducer configured to emit a first wireless signal including pressure data corresponding to the pressure of the fluid within the sleeve; wherein the sensor comprises a receiver and transmitter device configured to receive the pressure data from the transducer when the transducer is within a detection range of the sensor, and wherein the receiver and transmitter device is configured to transmit the pressure data beyond the housing.
- Also disclosed is an RCD including: a housing comprising a first bore extending along a central axis, and a sensor port extending to the first bore, the sensor port disposed at a discrete circumferential location about the central axis; a sensor disposed within the sensor port; a rotating sleeve assembly (RSA) extending at least partially within the first bore. The RSA includes: a rotating sleeve configured to rotate about the central axis relative to the housing and comprising a sleeve outer surface, a second bore coaxially aligned with the first bore, and a first piston port extending from the sleeve outer surface to the second bore; and a first piston disposed within the first piston port and configured to reciprocate between a first position and a second position in response to a change in pressure of fluid within the second bore. The first piston port and the first piston are disposed at a location in the rotating sleeve that passes the sensor periodically when the rotating sleeve rotates relative to the housing; and the sensor is configured to detect the first piston when the first piston rotates past the sensor and is in its second position.
- In some embodiments, the rotating sleeve further comprises a plurality of piston ports, and the RSA comprises a plurality of pistons, each piston being disposed within one of the plurality of piston ports and configured to reciprocate between a first position and a second position in response to a change in pressure of a fluid within the second bore; wherein each piston of the plurality of pistons is biased towards its first position and each piston port and each piston are disposed at a location in the rotating sleeve that passes the sensor during each rotation when the rotating sleeve rotates relative to the housing. The sensor is configured to detect each piston when the piston rotates past the sensor and the piston is in its second position; and wherein each piston includes a sensing portion that is in fluid communication with the second bore, each sensing portion having a wettable face area that differs from the wettable face area of another of the plurality of pistons.
- In some embodiments, the RSA further comprises a rotational speed indicator coupled to the rotating sleeve at a location that passes the sensor during each rotation when the rotating sleeve rotates relative to the housing; and wherein the sensor is configured to detect the rotational speed indicator when the rotational speed indicator rotates past the sensor.
- In some embodiments, the plurality of piston ports, the plurality of pistons, the sensor port, the sensor, and the rotational speed indicator are all aligned parallel to a plane that extends perpendicular to the central axis.
- In some embodiments, the RSA further comprises a burst disc disposed to seal the first piston port at a location between the second bore and the first piston.
- In some embodiments, the RSA further includes a piston assembly comprising: a piston cartridge disposed at a fixed location within the first piston port; and the piston slidingly disposed in the piston cartridge; wherein the piston is separated from the sleeve by the piston cartridge. The first piston may be configured to be free from sliding engagement with the first piston port. The sensor may be one configured to detect the first piston by a phenomenon selected from a group consisting of: proximity, magnetic field, Hall Effect, contact, induction, capacitive interaction, and photoelectric interaction.
- Also disclosed is an RCD comprising: a housing having a through-bore extending along a central axis and a sensor positioned at a first axial position; a sleeve configured to rotate within the through-bore of the housing; and a piston coupled to the sleeve and configured to move from a first position to a second position in response to a pressure change of a fluid within the sleeve, the piston being coupled to the sleeve at a location such that it passes by the first axial position periodically when the sleeve rotates within the through-bore. The first piston is configured to be free from sliding engagement with the sleeve, and the sensor is configured to detect the piston when the piston is in the second position. In some embodiments, the sensor is positioned at a discrete circumferential location about the central axis, and in some embodiments, the RCD includes a piston assembly comprising: a piston cartridge disposed at a fixed location in the sleeve, wherein the piston is slidingly disposed in the piston cartridge and the piston is separated from the sleeve by the piston cartridge.
- In some embodiments, the RCD incudes: a plurality of piston assemblies, each piston assembly comprising: a piston cartridge disposed at a fixed location in the sleeve and including a fluid communication bore, a location that passes by the first axial position periodically when the sleeve rotates; and a piston slidingly disposed in the piston cartridge and separated from the sleeve by the piston cartridge, the piston including a piston neck slidingly and sealingly received within the fluid communication bore, the piston configured to move from a first position to a second position in response to a pressure change of a fluid within the sleeve; wherein each piston neck of the plurality of piston assemblies has a different wettable face area than another of the piston necks.
- In some embodiments, the RCD further comprises a rotational speed indicator coupled to the rotating sleeve at a location that passes the sensor during each rotation of the sleeve relative to the housing; wherein the sensor is configured to detect the rotational speed indicator when the rotational speed indicator rotates past the sensor.
- A method for operating a rotating control device is disclosed and includes: providing a housing having a through-bore, a housing wall, and a sensor disposed at a sensor position in the housing; disposing a sleeve within the through-bore of the housing, the sleeve configured to rotate about the central axis of the housing and comprising a sleeve bore aligned with that axis; coupling a pressure-responsive assembly that includes a pressure-responsive element to the sleeve at a location such that the pressure-responsive assembly passes the sensor position periodically as the sleeve rotates within the through-bore, and such that the pressure-responsive element is in fluid communication with the sleeve bore. The method further incudes: disposing a tubular string sealingly within the sleeve bore; rotating the tubular string and the sleeve with respect to the housing; and, using the sensor, detecting a response of the pressure-responsive assembly when pressure in the sleeve bore reaches an activation pressure; performing a system action when the sensor detects a response of the pressure-responsive assembly. The detecting may include measuring periodically the pressure in the sleeve bore. Further, where the detectable member is coupled for movement with a piston disposed in a cartridge, the detecting may include detecting radial movement of the pressure-responsive element relative to the cartridge and the sleeve.
- Thus, embodiments described herein include a combination of features and characteristics intended to address various shortcomings associated with certain prior devices, systems, and methods. The various features and characteristics described above, as well as others, will be readily apparent to those of ordinary skill in the art upon reading the following detailed description, and by referring to the accompanying drawings.
- For a detailed description of the disclosed exemplary embodiments, reference will now be made to the accompanying drawings:
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FIG. 1 shows cross-sectional side view of an embodiment of a rotating control device having a pressure-responsive assembly mounted in a rotating sleeve in accordance with principles described herein; -
FIG. 2 shows an enlarged, cross-sectional side view of the rotating control device ofFIG. 1 ; -
FIG. 3 shows cross-sectional top view of the rotating sleeve of the rotating control device ofFIG. 2 ; -
FIG. 4 shows a cross-sectional side view of the pressure-responsive assembly ofFIG. 2 ; -
FIGS. 5A and 5B show perspective views of a cap covering the external end of the pressure-responsive assembly inFIG. 2 ; -
FIG. 6 shows an enlarged cross-sectional side view of the rotating control device ofFIG. 1 with the pressure-responsive assembly in a deactivated state; -
FIG. 7 shows an enlarged cross-sectional side view of the rotating control device ofFIG. 1 with the pressure-responsive assembly in an activated state; -
FIG. 8 shows another embodiment of a pressure-responsive assembly in accordance with principles described herein; -
FIG. 9 shows another embodiment of a rotating control device having a pressure-responsive assembly mounted in a rotating sleeve in accordance with principles described herein; and -
FIG. 10 is a flow diagram showing a method for operating a rotating control device configured for use in an oil well system in accordance with principles described herein. - The following description is exemplary of certain embodiments of the disclosure. One of ordinary skill in the art will understand that the following description has broad application, and the discussion of any embodiment is meant to be exemplary of that embodiment, and is not intended to suggest in any way that the scope of the disclosure, including the claims, is limited to that embodiment.
- The figures are not drawn to-scale. Certain features and components disclosed herein may be shown exaggerated in scale or in somewhat schematic form, and some details of conventional elements may not be shown in the interest of clarity and conciseness. In some of the figures, in order to improve clarity and conciseness, one or more components or aspects of a component may be omitted or may not have reference numerals identifying the features or components. In addition, within the specification, including the drawings, like or identical reference numerals may be used to identify common or similar elements.
- As used herein, including in the claims, the terms “including” and “comprising,” as well as derivations of these, are used in an open-ended fashion, and thus are to be interpreted to mean “including, but not limited to . . . ” Also, the term “couple” or “couples” means either an indirect or direct connection. Thus, if a first component couples or is coupled to a second component, the connection between the components may be through a direct engagement of the two components, or through an indirect connection that is accomplished via other intermediate components, devices and/or connections. The recitation “based on” means “based at least in part on.” Therefore, if X is based on Y, then X may be based on Y and on any number of other factors. The word “or” is used in an inclusive manner. For example, “A or B” means any of the following: “A” alone, “B” alone, or both “A” and “B.”
- In addition, the terms “axial” and “axially” generally mean along or parallel to a given axis, while the terms “radial” and “radially” generally mean perpendicular to the axis. For instance, an axial distance refers to a distance measured along or parallel to a given axis, and a radial distance means a distance measured perpendicular to the axis. Furthermore, any reference to a relative direction or relative position is made for purpose of clarity, with examples including “top,” “bottom,” “up,” “upper,” “upward,” “down,” “lower,” “clockwise,” “left,” “leftward,” “right,” and “right-hand.” For example, a relative direction or a relative position of an object or feature may pertain to the orientation as shown in a figure or as described. If the object or feature were viewed from another orientation or were implemented in another orientation, it may then be helpful to describe the direction or position using an alternate term.
- The present disclosure involves monitoring potential fluid leakage between a rotatable conduit and a stationary conduit that are interconnected. Leakage between the rotatable conduit and the stationary conduit is inhibited by seals that may rotate with the rotatable conduit or may remain stationary with the stationary conduit, but eventually, a seal may fail, allowing leakage. Gathering information so as to know when a seal fails or predict failure can be challenging. Commonly, fluid leakage is avoided by preventative maintenance. Various embodiments disclosed herein provide indication of fluid leakage past a seal. These embodiments include a pressure-responsive element or assembly, for example a pressure sensor or a movable piston, coupled to a rotating member and arranged in fluid communication with a zone where leakage may occur.
- Referring to
FIG. 1 , in an exemplary embodiment, awell system 90 includes equipment for variouswell operations 92, including a rotating control device (RCD) 100, governed by acontrol system 94.RCD 100 extends along acentral axis 101 and is configured to receive sealingly a tubular member, which in this example is apipe 102, which may be part of a string of tubular members.Device 100 is suitable as a member of a wellhead over a borehole of a well, such as a hydrocarbon well.Device 100 includes anouter housing 110 holding asensor 120 and includes a rotating sleeve assembly (RSA) 125 received withinhousing 110.RSA 125 holds a pressure-responsive assembly withinhousing 110, generally aligned withsensor 120 alongaxis 101. In this embodiment, the pressure-responsive assembly is apiston assembly 200.Sensor 120 is configured to detect the presence of theassembly 200 as a result of one or more pressure conditions that may exist insleeve assembly 125 assleeve assembly 125 orpipe 102 causes assembly 200 to rotate relative tohousing 110 andsensor 120. -
Housing 110 includes a housing wall ortubular body 111 extending along thecentral axis 101 from alower end 112 to anupper end 113, having an outer surface and a through-bore 114. Through-bore 114 is centered onaxis 101 and defines an inner wall.Housing 110 also includes asensor port 116 extending along acentral axis 117 throughtubular body 111 to the through-bore 114.Housing 110 also includes a plurality offluid ports 118 also extending radially throughtubular body 111 to the through-bore 114, and being axially spaced fromport 116.Sensor 120 is disposed insensor port 116, extending toward the through-bore 114. The axial position ofport 116 andsensor 120 may be measured from any convenient location such as a surface at the housing'supper end 113 or a surface at itslower end 112. The location ofport 116 inhousing 110 defines a sensor position forsensor 120. The sensor position may be further defined by the depth ofsensor 120 withinport 116 or the proximity of the inner end ofsensor 120 to the surface of through-bore 114.Port 116 andsensor 120 are positioned at a discrete axial location alongcentral axis 101 and at a discrete circumferential location aboutaxis 101. - Rotating
sleeve assembly RSA 125 extends at least partially within the through-bore 114 ofhousing 110.RSA 125 includes arotatable sleeve 130 received within a bearingassembly 180 to rotate aboutaxis 101 relative to thehousing 110, aspeed indicator 131 received insleeve 130 at a location alongaxis 101 that is aligned withsensor 120 ofouter housing 110, andpiston assembly 200 received insleeve 130 at the same location alongaxis 101 asspeed indicator 131. Consequently,assembly 200 is also axially aligned withsensor 120 so it can be detected bysensor 120.Sleeve 130 andpipe 102, when installed, are configured as rotatable conduit, andhousing 110 is configured as a stationary conduit. -
Sensor 120 is configured to detect the presence ofspeed indicator 131 and to detect the presence ofpiston assembly 200 by any known technology, capability, or phenomenon, which may be selected from the sensor group consisting of: proximity, magnetic field, Hall Effect, contact, reed, induction, capacitive interaction, and photoelectric interaction, as examples. InFIG. 1 ,speed indicator 131 andpiston assembly 200 each include a magnet, andsensor 120 includes Hall Effect sensor; although, various other embodiments include another type ofspeed indicator 131,piston assembly 200, or another type ofsensor 120. -
Rotating sleeve 130 includes a sleeveouter surface 134 and abore 136 extending from alower end 132 to anupper end 133. InFIG. 1 , rotatingsleeve 130 is formed from anupper sleeve member 140 coupled to alower sleeve member 160 by asleeve coupling 165. Referring to bothFIG. 1 andFIG. 2 , acollar 168 is coupled tosleeve member 140 atupper end 133, and anupper packing element 170A extends downward from the bottom ofcollar 168, intomember 140.Collar 168 is generally tubular, being open at both ends to receivepipe 102 therethrough. Alower packing element 170B extends downward fromsleeve member 160 atlower end 132.Packing elements 170A,B are configured to seal around the circumference ofpipe 102, isolating thebore 136 from an upper portion ofcollar 168 and from upper and lower portions ofbore 114 inhousing 110, to prevent fluid leakage from these regions. The seal of packingelements 170A,B is maintained even assleeve 130 andpipe 102 rotate relative tohousing 110 during operation. In at least some modes of operation, rotation ofpipe 102 causessleeve 130 to rotate due to the gripping action ofelements 170A,B. Collar 168, packingelements 170A,B, and bore 136 provide a sealable through-passage for a tubular member,e.g. pipe 102, to extend or pass throughhousing 110, which in some arrangements leads into a borehole.Bore 136 is configured to be an isolated chamber when a tubular member is installed. -
Upper sleeve member 140 extends from a threadedlower end 142, which attaches tosleeve coupling 165, toupper end 133, which attaches tocollar 168.Sleeve member 140 includes a radially protrudingannular shoulder 146 located between ends 142, 133, aport 148 extending intoshoulder 146 along acentral axis 149 coplanar withcentral axis 117 ofport 116, and apiston port 152 extending intoshoulder 146 along thesame axis 149 butopposite port 148. Some misalignment betweenaxis sensor 120.Port 148 is configured to receivespeed indicator 131 at a fixed position alongport axis 149, disposingspeed indicator 131 at a fixed distance fromaxis 101, being generally flush or adjacent toouter surface 134. Wheneversleeve 130 rotates theindicator 131 to the circumferential position ofsensor 120, the magnet ofindicator 131 is at a fixed distance fromsensor 120 within its detection range (e.g. a prescribed distance). Repeated movement ofspeed indicator 131past sensor 120 provides a measurement of the rotational speed ofsleeve 430 with respect tohousing 110. Thus,sensor 120 is configured as a speed sensor. - A shown in
FIG. 3 , in the current embodiment,shoulder 146 ofsleeve member 140 includes a plurality ofports 152 aligned on a common plane withport 148. Eachport 152 extends fromouter surface 134 to thebore 136 and includes first, second, and third portions each having a different diameter and resulting in afirst shoulder 154A and asecond shoulder 154B, both facing radially outward.Shoulder 154A isproximal bore 136 and distalouter surface 134 ofsleeve 130, whileshoulder 154B is proximalouter surface 134. Eachport 152 is configured to receive apiston assembly 200 at a selected or fixed location. InFIG. 3 ,piston assembly 200 threaded withinport 152 and is disposed againstshoulder 154A. Thus, the current embodiment of rotatingsleeve 130 includes a plurality ofpiston assemblies 200. InFIG. 3 , rotatingsleeve 130 includes threepiston ports 152 and threepiston assemblies 200. As stated above, one of thepiston ports 152 is aligned along the samecentral axis 149 asport 148. The other twoports 152 are aligned and extend along a secondcentral axis 149 coplanar with and perpendicular to thefirst axis 149.Piston assemblies 200 inports 152 andspeed indicator 131 inport 148 are aligned parallel to the cross-sectional plane shown inFIG. 3 , which extends perpendicular to thecentral axis 101 ofdevice 100. Some embodiments have other orientations for aport 152 or themultiple ports 152. - Referring again to
FIG. 1 , bearingassembly 180 includes a bearinghousing 182 that is coupled withinhousing 110 to remain stationary, abearing sleeve 184 coupled tosleeve 130 to grasp and rotate withsleeve 130, and bearing 186 coupled betweenhousing 182 andsleeve 186. In this example, bearing 186 includes two opposing sets of tapered roller bearings to resist axial thrust in either vertical direction from, for example,pipe 102. - In
FIG. 1 ,control system 94 is coupled tosensor 120 ofRCD 100 by a communication conductor orcable 192.Control system 94 of well system 95 governs thewell operations 92 and monitors responses from sensor includesRCD 100. For example, during operation, asspeed indicator 131 periodically passessensor 120,control system 90 determines the rotational speed ofsleeve 130 withpipe 102. If a leak occurs through one of theseals bore 136 rises to an activation pressure (described below) for one of thepiston assemblies 200, thecorresponding piston 250 andmagnet 284 will move radially outward to a second position.Sensor 120 will detect this response, andcontrol system 94 will perform a system action, causing a change to awell operation 92, such as activating anindicator 194, storing process data electronically, reducing the flow of drilling mud, reducing drilling speed, or another action.Indicator 194 may produce an audible or visual warning and may be a stand-alone device or may be incorporated into a graphical user interface, as examples. In some instances, when the pressure inbore 136 rises further, another piston assembly 200 (e.g.FIG. 3 ) experiences an activation pressure, causing thecorresponding piston 250 andmagnet 284 to move radially outward to a second position.Sensor 120 will detect this additional response and may perform another system action, such as modifying the performance ofindicator 194 or performing one of the other system actions describe above. - Referring now to
FIG. 4 ,piston assembly 200 extends along acentral axis 201 from afirst end 202 to asecond end 203 and includes apiston 250 slidingly received withinpiston cartridge 210 and held by apiston nut 230.Piston cartridge 210 includes acylindrical body 212 that includes a threadedregion 214 on its outer surface proximal but spaced apart fromend 203, a fluid communication bore 216, acounter bore 218 extending frombore 216, a threaded counter bore 219 extending frombore 218 to end 203, and anannular face seal 222 atend 202 to engageshoulder 154A of port 152 (FIG. 3 ). InFIG. 3 ,piston cartridge 210 is threaded withinport 152 ofrotatable sleeve 130 and is disposed at a fixed location againstshoulder 154A. Referring again toFIG. 4 , the base ofbore 218 forms ashoulder 220 facingend 203 wherebore 218 intersects withbore 216. The base ofbore 219 forms ashoulder 221 facingend 203 wherebore 219 intersects withbore 218.Bores axis 201.Piston nut 230 is received withincartridge 210 and includes a base 232 configured to couple threadingly to counterbore 219, aneck 234 extending frombase 232 distal oropposite end 203, a through-bore 236 extending axially throughbase 232 andneck 234, and atool socket 238 formed in through-bore 236 proximal atend 203.Base 232 is configured to couple threadingly to counterbore 219 and butt againstshoulder 221. In this configuration, bore 219 includes straight threads, but in some embodiments bore 219 includes another type of thread, such as tapered pipe threads. -
Piston 250 extends alongcentral axis 201 from afirst end 252 to asecond end 253.Piston 250 includes abase portion 254 extending fromsecond end 253, ashoulder portion 256 extending frombase portion 254, apiston neck 258 extending fromshoulder portion 256, and acounter bore 272 extending into the outer end ofbase portion 254 atsecond end 253,opposite neck 258.Base portion 254,shoulder portion 256, andneck 258 are each round and concentric aboutaxis 201.Shoulder portion 256 has a larger diameter thanbase portion 254 andneck 258. Assembled as shown,neck 258 is slidingly received withinbore 216,shoulder portion 256 slidingly received withinbore 218, andbase portion 254 extends frombore 216 to bore 218. A clearance is provided between circumference ofshoulder portion 256 and bore 218 to allow a fluid, such as air, that is trapped incartridge 210 to move axially from side to side ofportion 256 aspiston 250 reciprocates during operation. Anannular seal 274 is disposed about the circumference ofneck 258. A resilient member, which in this embodiment is aspring 280, is received aboutpiston base portion 254 and aboutneck 234 ofnut 230. Spring is held between the nut'sbase 232 andpiston shoulder portion 256. The outer end ofpiston 250 includes a detectable portion or member, which in this example is amagnet 284.Magnet 284 is threadingly received into the piston's counter bore 272 and includes a shoulderedend 288 that is located outside and beyondpiston 250, towardend 203. The combined length ofpiston 250 andmagnet 284 is shorter than the length ofcartridge 210. - Referring again to
FIG. 3 , the threepiston assemblies 200 are threaded intopiston ports 152, and a threadedcartridge cap 290 is installed within the outer end of eachport 152adjacent shoulder 154B. Eachpiston assembly 200 is configured to be assembled and then installed as a single unit into aport 152.Caps 290 prevent or discourage liquids, slurries, or contaminants inbore 114 from contactingpiston assembly 200.Cap 290 providespiston assembly 200 with pressure compensation with respect to a fluid in through-bore 114 ofhousing 110. The fluid may be, for example, located abovedevice 100.Cap 290 is configured to isolate or insulatepiston assembly 200 from the pressure or presence of that fluid.FIG. 5A andFIG. 5B provide an outside and an inside view of acap 290. In some embodiments,cap 290 includes a material that is non-magnetic, a polymer, or a non-metal. -
FIG. 6 andFIG. 4 show a resting or deactivated state for apiston assembly 200.FIG. 6 shows a close-view of theassembly 200 installed insleeve 130 ofdevice 100. Piston assembly is assembled such thatspring 280 is partially compressed betweenpiston nut 230 andpiston shoulder portion 256, which pressesshoulder portion 256 radially inward towardcartridge shoulder 220.Piston neck 258 is in fluid communication withbore 136 and performs as a sensing portion ofpiston 250, making piston 250 a pressure-responsive element.Seal 274 onneck 258 prevents fluid communication betweenbore 136 and theother portions piston 250. As a result, the exposed or wettable face area ofneck 258, which is proximal theend 202, governs the response ofpiston 250 to fluid pressure inbore 136. The exposed or wettable face area is the net surface area atend 252 ofpiston 250 that is configured to be in fluid communication withport 152 or bore 136 and is perpendicular toaxis 149. Thus, in some embodiments, in whichpiston end 252 is no perpendicular toaxis 149, whetherend 252 be flat or curved, the exposed or wettable face area is a calculable area that projected to be perpendicular toaxis 149. Onpiston 250, the arrangement ofneck 258 and seal 274 to engagepiston cartridge 210 and not to engageport 152, configurespiston assembly 200 to respond to pressure independently of any diameter ofport 152. In addition, the inclusion ofneck 258 and seal 274 configurespiston assembly 200 to respond to pressure independently of the dimensions of structural portions of piston 250 (e.g. portions 254, 256), structural portions that, for example, provided the mounting ofpiston 250 within a housing bore (e.g. bore 218 ofcartridge 210 or port 152) or interact withspring 280. - Referring still to
FIG. 6 , any fluid inbore 136 is at a pressure P1 that is too low to exert sufficient force againstpiston neck 258 to overcome the force ofspring 280, and thuspiston 250 remains unmoved. The piston'sshoulder portion 256 is axially spaced apart fromneck 234 onnut 230.Piston neck 258 is adjacent, and in this embodiment, is flush withend 202.Piston magnet 284 is displaced axially inward fromend 203 ofpiston cartridge 210 ornut 230 and is displaced axially inward fromouter surflace 134 ofsleeve 130. In this state,piston 250 and, consequently,magnet 284 are disposed at a resting or deactivated position with respect tohousing 210 orsleeve 130, evaluated along the alignedaxes magnet 284 in a deactivated position, the radial distance 295A betweenmagnet 284 andsensor 120 is greater than the detection range ofsensor 120 whenpiston axis 201 is aligned with or adjacent thesensor port axis 117, as is the case inFIG. 6 . Therefore,sensor 120 ignoresmagnet 284 whensleeve 130 rotates relative tohousing 110. -
FIG. 7 shows another close-view of thesame piston assembly 200 withinsleeve 130, showing an activated state forpiston assembly 200. In response to a prescribed pressure of the fluid inbore 136,spring 280 is compressed. The fluid pressure P2 withinbore 136 inFIG. 7 is greater than pressure P1 ofFIG. 6 . Pressure P2 is equal to or greater than a prescribed threshold pressure value and may be called an “activation pressure” for thepiston assembly 200. In general, the activation pressure or a range of activation pressures to whichassembly 200 responds is be predetermined by the configuration ofassembly 200. InFIG. 7 , the increased pressure has acted against the end face ofpiston neck 258, causingpiston 250 andmagnet 284 to move to radially outward, to an activated position with respect topiston housing 210 orsleeve 130, evaluated along theaxes sleeve 130 rises to the value P2,assembly 200 responds bypiston 250 moving from a deactivated position to an activated position. In the activated position,magnet 284 is closer to end 203 ofpiston cartridge 210 ornut 230 and is closer toouter surface 134 ofsleeve 130.Shoulder portion 256 ofpiston 250contacts neck 234 onnut 230, which acts as a “stop,” limiting the leftward movement ofpiston 250. Whenmagnet 284 is in its activated position, and whenpiston axis 201 is aligned with or is adjacent the sensor port axis 177, as is the case inFIG. 7 , then theradial distance 295B betweenmagnet 284 andsensor 120 is within the detection range ofsensor 120. Therefore, during operation,sensor 120 will produce a signal in response to its proximity tomagnet 284, eachtime magnet 284 rotatespast sensor 120.Piston 250 remains in the activated position as long as the pressure inbore 136 remains above the prescribed pressure of the piston assembly.Spring 280biases piston 250 toward the innermost deactivated position and causes piston to move to this or to an intermediate deactivated position when pressure inbore 136 drops below the prescribed pressure. Thus,piston 250 andmagnet 284 are configured to reciprocate withincartridge 210 between a deactivated position and an activated position in response to fluid pressure withinbore 136 ofsleeve 130. For example, the fluid pressure may rise from rising from a value of P1 to a value of P2 and cause the piston to move.Piston assembly 200 is configured such thatpiston 250, includingseal 274, does not engage slidingly thepiston port 152 when responding to a change in pressure in thesleeve bore 136.Piston 250 is separated fromsleeve 130 bypiston cartridge 210. In the embodiment ofFIG. 6 andFIG. 7 ,piston 250 does not contactpiston port 152 in any position ofpiston 250. - The movement of
piston 250 between a deactivated position and an activated position is based on the wettable face area ofpiston neck 258, the “spring constant” ofspring 280, any preloading onspring 280, the pressure insidebore 136, and, in some embodiments, the pressure in the through-bore 114 ofhousing 110 atpiston port 152. In some embodiments or some instances, an intermediate activation pressure that is greater than pressure P1 but less than pressure P2 movesmagnet 284 an intermediate position that is within the detection range ofsensor 120 withoutpiston 250 moving fully to its radially outermost position, not sufficiently displaced to contactneck 234 onnut 230. This type of intermediate position qualifies as another activated. Similarly, it is possible forpiston 250 to be disposed away from the innermost deactivated position that is shown inFIG. 6 and still havemagnet 284 outside detection range ofsensor 120 whenpiston axis 201 is adjacent or aligned withport axis 117. Any such intermediate position ofpiston 250 relative tosleeve 130 may also be called a deactivated position, whereinmagnet 284 is undetectable bysensor 120. - In at least some embodiments,
sensor 120 is selected to produce an output signal having a strength or a value that varies based on the distance betweensensor 120 andpiston 250,e.g. magnet 284, whenpiston axis 201 is adjacent or aligned withport axis 117 andmagnet 284 is in one of a plurality of activated positions.Sensor 120 may be an inductive-type proximity sensor, for example. Whenpiston 250 is moved alongaxis 201 to an intermediate activated position within the detection range of sensor 120 (as explained above), the strength or value of the signal produced bysensor 120 may be less than a maximum strength or value that occurs whenpiston 250 is in its outermost activated position. In some embodiments, this variation in the output signal ofsensor 120 is correlated to pressure values, configuringcontrol device 100 to provide pressure indication or measurement over a range of pressure values rather than just a binary “yes/no” comparison between pressure insidesleeve 130 and a single prescribed pressure value. - Referring again to
FIG. 3 , the threepiston assemblies 200 are additionally labeled with the reference numerals 200A,B,C to distinguish the different diameters and wettable face areas of thenecks 258 of each corresponding piston 250A,B,C. Each piston 250A,B,C is shown in its innermost, deactivated position unmoved by the pressure of a fluid that may be inbore 136 when device is unused or is operating. Piston 250A has a neck with the largest diameter of the three pistons,piston 250B has a neck with a smaller diameter, and piston 250C has a neck with a still smaller diameter. In this embodiment, eachspring 280 has the same spring constant, a property that correlates the force that will be exerted by a spring to the distance the spring is compressed or stretched, having the units of force per unit length of displacement. The force that a fluid inbore 136 exerts on any of the pistons is proportional to the wettable face area of the piston'sneck 258. Each piston 250A,B,C “sees” or experiences the same fluid pressure frombore 136. However, that fluid pressure exerts a larger force on piston 250A than on either of the other two pistons because theneck 258 of piston 250A has the largest wettable face area exposed to the fluid inbore 136. Similarly, the fluid force exerted onpiston 250B is larger than the fluid force exerted on piston 250C, which has the smallest wettable face area exposed to the fluid. Thus, during operation of device 100 (FIG. 1 ), piston 250A will be moved out of a deactivated position and to an activated position by a lower pressure than is required to movepiston 250B or piston 250C. Likewise,piston 250B will be moved out of a deactivated position by a lower pressure than is required to move piston 250C. - Referring to
FIG. 1 andFIG. 3 , an operating condition will be considered in which piston assemblies 200A,B,C become sequentially activated and detected bysensor 120. Four pressures will be discussed, wherein a pressure P1<a pressure P2<a pressure P3<a pressure P4. With packingelements 170A,B initially sealed aroundpipe 102, each piston 250A,B,C is in a deactivated position and is not activated by pressure P1 that exists inbore 136 ofsleeve 130.Pipe 102 andsleeve 130, along with packingelements 170A,B, are rotating. Initially,sensor 120 senses onlyspeed indicator 131, which it senses once per revolution. In this example, as thepipe 102 rotates, packingelement 170B wears, and fluid, which may be drilling mud for example, begins to leak from the lower portion of through-bore 114 inhousing 110, past packingelements 170B, and intobore 136 ofsleeve 130. As fluid enterssleeve 130, bore 136 reaches an activation pressure P2 that is able to push piston 250A, which is the piston with thelargest neck 258, to an activated position (e.g.FIG. 7 ).Sensor 120 now senses bothspeed indicator 131 and themagnet 284 on piston 250A as each of these elements periodically movepast sensor 120 whilesleeve 130 rotates. In at least one embodiment,sensor 120 cannot distinguish betweenspeed indicator 131 and amagnet 284, rather the operator or control system 94 (FIG. 1 ) detects a distinct increase in the detection rate of sensor 120 (e.g., twice as many pulses per second) and attributes this change to piston assembly 200A being activated by a pressure P2 or greater but less that pressure P3. Thus, based on the characteristics ofsensor 120 and the arrangements ofposition indicator 131 andpiston assemblies 200 relative tosensor 120,sensor 120 is configured to detect data for two separate operational conditions, the first condition being rotational speed and the second condition being elevated pressure withinrotatable sleeve 130. In some embodiments, the rotational speed of the pipe is also measured elsewhere in the well operation system, such as in a top drive or in a kelly table, and the data fromsensor 120 is compared against this other measurement of rotational speed to assess whethersensor 120 is detectingspeed indicator 131 alone or it is also detecting amagnet 284 in apiston assembly 200. Thus, a real change in rotational speed can be differentiated from a pressure rise withinsleeve 130 when evaluating the data ofsensor 120. - As the scenario continues, the pressure of fluid in
bore 136 increases to an activation pressure P3 that that is able to pushpiston 250B to an activated position (e.g.FIG. 7 ). Piston 250A remains in its activated position.Sensor 120 now sensesspeed indicator 131 and twomagnets 284 as these three move pastsensor 120 in sequence whilesleeve 130 rotates. Again, the operator or thecontrol system 94 interprets the additional data fromsensor 120 as resulting from pressure P3 or greater being detected inbore 136, the pressure being less than P4. As fluid continues to pushpast packing element 170B intobore 136, the pressure inbore 136 increases to an activation pressure P4 that that is able to push piston 250C, which is the piston with thesmallest neck 258, to an activated position (e.g.FIG. 7 ). Pistons 250A,B remains in their activated positions.Sensor 120 now sensesspeed indicator 131 and threemagnets 284 whilesleeve 130 rotates. The operator or thecontrol system 94 interprets the additional data fromsensor 120 as resulting from a pressure P4 or greater being detected inbore 136. - Referring to
FIG. 8 , another embodiment of a pressure-responsive assembly consistent with the present disclosure and configured for installation in rotating control device (RCD) 100 is apiston assembly 300. Anassembly 300 may replace apiston assembly 200 in various embodiments ofRCD 100 andsleeve 130.Assembly 300 is shown installed in apiston port 152 of arotating sleeve 130 withport 152 extending along acentral axis 149 from a sleeveouter surface 134 and to bore 136, which extends about acentral axis 101.Sleeve 130 includes the features disclosed above, including the figures.Assembly 300 is configured to be assembled into a single, cohesive unit before being installed intoport 152. -
Assembly 300 is similar topiston assembly 200 in thatassembly 300 includes apiston 350 held within piston cartridge 310 by apiston nut 330. However,piston assembly 300 also includes anend cap 360 that is configured to isolatepiston 350 from a fluid inbore 136 until a prescribed pressure is reached inbore 136.Assembly 300 extends along acentral axis 301 from afirst end 302 to asecond end 303. Piston cartridge 310 includes a cylindrical body 312 includes an internally threadedfirst bore 316 extending fromend 302 and acounter bore 218 extending fromend 303 to bore 316. The base ofbore 218 forms ashoulder 220 facingend 203 wherebore 218 intersects withbore 216. Cartridge 310 is threadingly received inport 152 ofrotatable sleeve 130 and is disposed at a fixed location againstshoulder 154A.Piston nut 330 is externally threaded and includes a through-bore 236 forpiston 350 and atool socket 238 formed concentric or withinbore 236.Nut 330 lacks a neck likeneck 234 on nut 220 (FIG. 4 ). However, even some embodiments ofnut 220 lack aneck 234. -
Piston 350 extends alongcentral axis 201 from a first end 352 to asecond end 353.Piston 350 includes abase portion 354 extending fromsecond end 353, ashoulder portion 356 extending fromportion 354 to the outer surface of first end 352, and acounter bore 272 withinportion 354 atsecond end 353.Shoulder portion 356 has a larger diameter thanbase portion 354 and includes a groove to receive aseal 374. A resilient member, aspring 280, is received aboutpiston base portion 254 and is held betweennut 330 andpiston shoulder portion 356. The outer end ofpiston 350 includes a detectable portion or member, which in this example is amagnet 284 threadingly received into the piston's counter bore 272.Spring 280biases piston 350 and thereforemagnet 284 away fromassembly end 303 and toward a deactivated position ofpiston 350 andmagnet 284 in cartridge 310, which is the position shown inFIG. 8 . Some embodiments include a cartridge cap (FIG. 5B ) installed in the outer end ofpiston port 152,adjacent surface 134. In some embodiments,nut 330 exerts a preloading compression tospring 280 whilepiston 350 is in its resting position. -
End cap 360 includes abore 361 extending alongaxis 201 from afirst end 362 to a second end 363 and includes an outwardly extendingannular flange 364, and a burst orrupture disc 366.Disc 366 sealingly covers bore 361 atfirst end 362.Flange 364 has aface seal 222 that engagesshoulder 154A ofport 152proximal bore 136 and distal theouter surface 134 ofsleeve 130. The cap's second end 363 is threadingly received withinbore 316 of cartridge 310 andflange 364.Rupture disc 366 is in fluid communication withsleeve bore 136 and is configured to break when it experiences a prescribed pressure differential that may be caused by a fluid within sleeve bore 136 reaching or exceeding an activation or threshold pressure, as discussed above.Rupture disc 366 is an example of a pressure-responsive element that is configured not to engage slidingly thepiston port 152 when responding to a change in pressure in thesleeve bore 136. - As assembled,
shoulder portion 356 atpiston end 353 is pressed againstcartridge shoulder 220 orcap 360 whenpiston 350 is disposed at a deactivated position as shown inFIG. 8 .Piston 350, which is a pressure-responsive element, and at least a portion of the outer surface ofshoulder portion 356 will be in fluid communication withport 152 and bore 136 ifrupture disc 366 breaks.Shoulder portion 356 is a sensing portion ofpiston 350. Ifrupture disc 366 breaks due to an activation pressure,piston 350 andmagnet 284 will move outward to a second location, and this second location will be within the sensing range ofsensor 120 whenassembly 300 is rotationally aligned withsensor 120.Piston 350 will return to a deactivated position under the influence ofspring 280 when the pressure subsides.Piston assembly 300 is configured such thatpiston 230, includingseal 374, does not engage slidingly thepiston port 152 when installed insleeve 130 and responding to a change in pressure in thesleeve bore 136.Piston 350 is separated fromsleeve 130 by piston cartridge 310. In the embodiment ofFIG. 8 ,piston 350 does not contactpiston port 152 in any position ofpiston 350. -
Piston assembly 300 is configured to operate likeassembly 200 except for the addition ofrupture disc 366, which governs at least an initial the response ofpiston 350 to a change in pressure withinbore 136. This differs fromassembly 200 in which the wetted area ofneck 258 governs the response ofpiston 250. To configureassembly 300 to respond to a higher or lower pressure withinbore 136, arupture disc 366 having an appropriate pressure rating is selected and installed. The pressure rating ofdisc 366 can be varied while maintaining a constant, selected diameter fordisc 366 and while maintaining a constant, selected diameter forport 152 into whichdisc 366 is installed. Thus, inclusion ofdisc 366 configurespiston assembly 300 to respond to an activation pressure independently of any diameter ofport 152. The inclusion ofdisc 366, which initially isolatespiston 350 from fluid inbore 136, configurespiston assembly 300 to respond to an activation pressure independently ofpiston 350. Thus, this response ofpiston assembly 300 to pressure withinsleeve 130 is independent of the dimensions of structural portions of piston 350 (e.g. the diameter of aportion 354, 356), structural portions that, for example, provide the mounting ofpiston 350 within a housing bore (e.g. bore 218 of cartridge 310) or that interact withspring 280. - To use
multiple piston assemblies 300 in the configuration ofFIG. 3 and to have each assembly respond do a different pressure or pressure change, eachassembly 300 is provided with arupture disc 366 having an appropriate pressure rating that differs from theother assemblies 300. In at least some of these embodiments, allsprings 280 have the same spring constant. Some embodiments include arupture disc 366 having a pressure rating of selected from the group of pressure values consisting of: 200; 500; 1,000; 1,500; and 2,000 pounds per square inch (psi), as examples. Some embodiments include arupture disc 366 having a pressure rating outside this group of pressure values, within suitable engineering limits, while some other embodiments include arupture disc 366 having a pressure rating that lies between two of the values listed above, for example, a value of 1,255 psi. - During operation,
assembly 300 remains unchanged while a normal operating pressure P1 exists withinbore 136. Exposed to pressure P1,disc 366 remains intact, andpiston 350 remains in a deactivated position, as shown inFIG. 8 . If the pressure of a fluid inbore 136 rises to a selected activation pressure P2 ofdisc 366, as may occur due to a fluid leak passing through apacking element 170A,B, thendisc 366 will rupture. Afterdisc 366 ruptures, fluid pressure frombore 136 exerts a force on the wettable face area ofshoulder portion 356, causingpiston 350 andmagnet 284 to respond by moving outward to an activated position in whichmagnet 284 is located within the sensing range ofsensor 120. - In at least some embodiments, by selecting an appropriate combination of pressure rating for
rupture disc 366, spring constant forspring 280, and wettable face area ofshoulder portion 356,piston assembly 300 is configured forpiston 350 to move promptly between two discrete locations (e.g. a deactivated position and a fully activated position) without stopping or without pausing at an intermediate position. This configuration can be achieved, for example, by choosing a spring with a sufficiently low spring constant as compared to the pressure rating of theburst disc 366. For example,piston assembly 300 can be configured such that the pressure that can burst thedisc 366 can easily overcome the resistance of the selectedspring 280. In an example, the two discrete locations are the innermost deactivated position shown inFIG. 8 and an outermost activated position of piston 350 (similar toFIG. 7 ). For at least some embodiments, whenassembly 300 is configured for discrete positioning ofpiston 350 andmagnet 284, the signal fromsensor 120 is cleaner, providing a binary response as pressure rises from P1 to P2, whether slowly or quickly, becausemagnet 284 is either positioned outside the range ofsensor 120 or within the range ofsensor 120. - Without regard to the pressure rating of a
burst disc 366, the wettable face area ofshoulder portion 356 ofpiston 350 is initially equal to the cross-section area ofbore 361 ofend cap 360. The force exerted onpiston 350 is proportional to cross-section area ofbore 361 multiplied by the fluid pressure of a fluid acting onportion 356. If this force is sufficient to overcomespring 280 andcause piston 350 to move, then the entire end face ofportions 356 will become wetted. This increase in wetted area results in the same pressure exerting a larger force onpiston 350, causingpiston 350 to move faster or further in opposition tospring 280. This property ofpiston assembly 300 may also be used to configure forpiston 350 to move promptly between two discrete locations (e.g. the innermost, deactivated position and a fully activated position) without stopping or without pausing at an intermediate position) and may result in a more-defined response fromsensor 120. - Referring to
FIG. 9 , in an exemplary embodiment, a rotating control device (RCD) 400 extends along acentral axis 401 and is configured to receive sealingly a tubular member alongaxis 401.FIG. 9 shows a close view of the upper portion ofRCD 400.Device 400 is suitable as a member of a wellhead over a borehole of a well, such as a hydrocarbon well, and may be used in place ofdevice 100 or in addition todevice 100.Device 400 includes anouter housing 410 holding asensor 420 at a selected position alongaxis 401 and includes a rotating sleeve assembly (RSA) 425 received withinhousing 410.RSA 425 holds a pressure-responsive assembly within the detection range ofsensor 420, at least during a portion of the rotation cycle ofRSA 425. In this embodiment, the pressure-responsive assembly is atransducer 490 that senses pressure and wirelessly transmits an electrical signal that is representative of the sensed pressure.Transducer 490, which includes an internally disposed pressure-responsive element, is configured to measure a property of a fluid withinRSA 425 periodically or steadily and to produce wireless communication response corresponding to the measured values.Transducer 490 is selected from a group consisting of: a pressure sensor, a temperature sensor, a flow meter, a viscometer, and a pH meter, as examples. InFIG. 9 ,transducer 490 includes a pressure sensor configured to measure pressure over a range of possible pressures inbore 136 and to transmit a periodic or steady wireless response including pressure data.Sensor 420 is configured as a transceiver to receive the wireless response including data fromtransducer 490 and to generate a second response based on that response fromtransducer 490.Sensor 420 is configured to transmit the second response by wire or wirelessly to a controller or another device configured to display, store, evaluate, distribute, or otherwise utilize the data fromtransducer 490. In at least some embodiments,sensor 420 is also configured to exchange (send or receive) other information withtransducer 490. This “other information” may include, as examples, any of the following: calibration information, diagnostic information, a power on/off signal, and a sleep/wake signal. -
Housing 410 is similar tohousing 110 ofdevice 100 described in reference toFIG. 1 . For example, continuing to referenceFIG. 9 ,housing 410 includes a housing wall ortubular body 111 extending along thecentral axis 401, having a through-bore 114. Through-bore 114 is centered onaxis 401 and defines an inner wall.Housing 410 includes asensor port 116 extending throughtubular body 111 to the through-bore 114. Asensor 120, as previously described, is disposed insensor port 116, extending toward the through-bore 114. In addition,housing 410 includes aport 416 to receive thesensor 420.Port 416 extends throughtubular body 111 to the through-bore 114.Sensor 420 extends from aninner end 422 adjacent the through-bore 114 to an outer end 423 adjacent the outer surface ofhousing 410. InFIG. 9 ,port 416 extends radially with respect toaxis 401 and is axially spaced apart fromport 116. - Rotating sleeve assembly (RSA) 425 is similar to RSA 145 of
device 100. For example,RSA 425 extends at least partially within the through-bore 114 ofhousing 410 and includes arotatable sleeve 430, configured to rotate aboutcentral axis 401 relative to thehousing 410.Sleeve 430 is received within a bearingassembly 180, as described above, to rotate aboutaxis 401.RSA 425 also includes aspeed indicator 131, which includes a magnet in this example, received insleeve 430 at a location alongaxis 401 that is aligned withsensor 120 inouter housing 410. In addition,sleeve assembly 425 includes atransducer 490 received insleeve 430 at a location alongaxis 401 that allowstransducer 490 to communicate withsensor 420 during at least a portion of a revolution ofsleeve 430. - Like
sleeve 130,rotatable sleeve 430 includes a sleeveouter surface 134 and abore 136 extending alongcentral axis 401 with packing elements coupled adjacent each end ofsleeve 430. InFIG. 9 , rotatingsleeve 430 is formed from multiple members coupled. Anupper packing element 170A is shown extending downward from the bottom of anupper collar 168, intomember 140.Collar 168, the packing elements, and bore 136 provide a sealable through-passage for a tubular member, to extend into or pass through thehousing 410, which in some arrangements leads into a borehole.Bore 136 is configured to be an isolated chamber when a tubular member is installed. - Like
sleeve 130,sleeve 430 includes a radially protrudingannular shoulder 146 and aport 148 extending intoshoulder 146.Port 148 is aligned withsensor port 116 alongaxis 401.Port 148 is configured to receivespeed indicator 131 at a fixed radial distance fromaxis 401 and being generally flush or adjacent toouter surface 134. Wheneversleeve 430 rotates theindicator 131 to the circumferential position ofspeed sensor 120, the magnet ofindicator 131 is at a fixed distance fromspeed sensor 120 within its detection range (e.g. a prescribed distance). -
Sleeve 430 also includes asensor port 452 extending from an outer port-end 453 at the bottom ofshoulder 146 to an inner port-end 454 that intersects bore 136. InFIG. 9 ,port 453 includes a 90° turn. Afirst end 492 oftransducer 490 is located withinport 452. Asecond end 493 oftransducer 490 is located outside and adjacent the outer port-end 453, extending belowshoulder 146.Transducer 490, including its pressure-responsive element, is in fluid communication withbore 136. As shown, a first portion ofport 452 andwireless transducer 490 extend parallel toaxis 401 for greater clearance ofsecond end 493, meaning the exposed length ofend 493 is not limited by the radial distance betweenshoulder 146 and the adjacent portion ofhousing 410. The exposedsecond end 493 oftransducer 490 is disposed at a location that gives transducer 490 a wireless communication path to theinner end 422 ofsensor 420. For example, inFIG. 9 , the exposedsecond end 493 oftransducer 490 is disposed alongaxis 401 adjacent the axial location ofinner end 422 ofsensor 420, placingtransducer 490 in the “line-of-sight” ofsensor 420 during at least a portion of the revolution ofsleeve 430. During at least a portion of the revolution ofsleeve 430,transducer 490 communicates wirelessly withsensor 420 to provide data related to a property of a fluid that is inbore 136, which in this example is pressure. -
FIG. 10 shows amethod 500 for operating a rotating control device configured for use in an oil well system.Method 500 is applicable for operating anRCD block 502,method 500 includes providing a housing having a through-bore extending along a central axis, a housing wall, and a sensor disposed at a sensor position in the housing and extending into the housing wall.Block 504 includes disposing a sleeve within the through-bore of the housing, the sleeve comprising a sleeve bore aligned with the central axis and configured to rotate about the central axis.Block 506 includes providing a pressure-responsive assembly that includes a pressure-responsive element configured to be free of sliding engagement with the sleeve.Block 508 includes coupling a pressure-responsive assembly to the sleeve at a location such that the pressure-responsive assembly passes the sensor position periodically as the sleeve rotates within the through-bore and such that the pressure-responsive element is in fluid communication with the sleeve bore.Block 510 includes disposing a tubular string sealingly within the sleeve bore. -
Block 512 includes rotating the tubular string and the sleeve with respect to the housing, as may be accomplished by a rotary table, for example. Block 514 includes operating the sensor to detect a response of the pressure-responsive assembly when pressure in the sleeve bore reaches an activation pressure.Block 516 includes performing a system action when the sensor detects a response of the pressure-responsive assembly. Various embodiments ofmethod 500 may include fewer operations than described, and other embodiments ofmethod 500 include additional operations. - Although various embodiments disclosed herein included
multiple pistons spring 280 having a same spring constant as theother springs 280, in some embodiments, a spring coupled to a piston has a different spring constant than does another spring that is coupled to a different one of the multiple pistons. In some embodiments, a first piston is coupled to a spring having a first spring constant, and a second piston is coupled to a spring having a different spring constant, and both pistons have the same neck area or end area exposed to fluid insleeve bore 136. The first and second pistons respond to different activation pressures on account of the different springs rather than differences in area exposed to bore 136. - In place of
magnet 284, some embodiments include another type of detectable portion or element on apiston sensor 120, as discussed above. - Referring again to
FIG. 9 , in some embodiments,sensor 420 is also configured to display, store, evaluate, or otherwise utilize the data fromtransducer 490 in addition to distributing a response. In some embodiments,transducer 490 is a pressure switch, configured to respond to a prescribed value of pressure inbore 136 similar to the response of apiston assembly multiple transducers 490 installed in arotating sleeve 430. - While exemplary embodiments have been shown and described, modifications thereof can be made by one of ordinary skill in the art without departing from the scope or teachings herein. The embodiments described herein are exemplary only and are not limiting. Many variations, combinations, and modifications of the systems, apparatuses, and processes described herein are possible and are within the scope of the disclosure. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. The inclusion of any particular method step or operation within the written description or a figure does not necessarily mean that the particular step or operation is necessary to the method. The steps or operations of a method listed in the specification or the claims may be performed in any feasible order, except for those particular steps or operations, if any, for which a sequence is expressly stated. In some implementations two or more of the method steps or operations may be performed in parallel, rather than serially.
Claims (22)
1. A rotating control device for a well, the device comprising:
a housing having a through-bore extending along a central axis, a housing wall, and a sensor disposed at a sensor position in the housing and extending into the housing wall;
a sleeve comprising a sleeve bore aligned with the central axis and configured to rotate about the central axis, within the through-bore of the housing; and
a pressure-responsive assembly coupled to the sleeve and configured to generate a response to a pressure of fluid within the sleeve bore, the pressure-responsive assembly coupled to the sleeve at a location such that it passes the sensor position periodically as the sleeve rotates within the through-bore;
wherein the sensor is configured to detect the response of the pressure-responsive assembly.
wherein pressure-responsive assembly includes a pressure-responsive element in fluid communication with the sleeve bore; and
wherein the pressure-responsive element is configured to be free of sliding engagement with the sleeve.
2. The rotating control device of claim 1 wherein the pressure-responsive assembly comprises a first piston slidingly disposed inside a piston cartridge and configured to move from a first position to a second position relative to the piston cartridge in response to an activation pressure in the fluid within the sleeve;
wherein the sensor is configured to detect the presence of the first piston when the first piston is in the second position and passes the sensor position; and
wherein the piston is separated from the sleeve by the piston cartridge.
3. The rotating control device of claim 2 wherein the sleeve further comprises an outer surface, and a first piston port extending from the sleeve outer surface, the first piston port in fluid communication with the sleeve bore;
wherein the pressure-responsive assembly is disposed in the first piston port with the first piston in fluid communication with the sleeve bore; and
wherein the first piston is configured to slide without contacting the first piston port.
4. The rotating control device of claim 3 further comprising a burst disc coupled to the piston cartridge and disposed to seal the first piston from the fluid within the sleeve until the fluid reaches or exceeds a prescribed pressure.
5. The rotating control device of claim 3 further comprising a plurality of pressure-responsive assemblies, each pressure-responsive assembly coupled to the sleeve at a different location such that it passes the sensor position periodically as the sleeve rotates within the through-bore;
wherein each pressure-responsive assembly of the plurality is configured to generate a response to a particular pressure of the fluid within the sleeve bore; and
wherein the sensor is configured to detect the responses of each of the plurality of pressure-responsive assemblies.
6. The rotating control device of claim 1 wherein the pressure-responsive assembly comprises a transducer configured to emit a first wireless signal including pressure data corresponding to the pressure of the fluid within the sleeve; and
wherein the sensor comprises a receiver and transmitter device configured to receive the pressure data from the transducer when the transducer is within a detection range of the sensor, and wherein the receiver and transmitter device is configured to transmit the pressure data beyond the housing.
7. A rotating control device for a well, the device comprising:
a housing comprising a first bore extending along a central axis, and a sensor port extending to the first bore, the sensor port disposed at a discrete circumferential location about the central axis;
a sensor disposed within the sensor port; and
a rotating sleeve assembly (RSA) extending at least partially within the first bore and, comprising:
a rotating sleeve configured to rotate about the central axis relative to the housing and comprising a sleeve outer surface, a second bore coaxially aligned with the first bore, and a first piston port extending from the sleeve outer surface to the second bore; and
a first piston disposed within the first piston port and configured to reciprocate between a first position and a second position in response to a change in pressure of fluid within the second bore;
wherein the first piston port and the first piston are disposed at a location in the rotating sleeve that passes the sensor periodically when the rotating sleeve rotates relative to the housing; and
wherein the sensor is configured to detect the first piston when the first piston rotates past the sensor, and the first piston is in its second position.
8. The device of claim 7 wherein the rotating sleeve further comprises a plurality of piston ports, including the first piston port, extending from the outer surface to the second bore;
wherein the RSA further comprises a plurality of pistons, including the first piston, each piston disposed within one of the plurality of piston ports and configured to reciprocate between a first position and a second position in response to a change in pressure of a fluid within the second bore;
wherein each piston of the plurality of pistons is biased towards its first position;
wherein each piston port and each piston are disposed at a location in the rotating sleeve that passes the sensor during each rotation when the rotating sleeve rotates relative to the housing;
wherein the sensor is configured to detect each piston when the piston rotates past the sensor and the piston is in its second position; and
wherein each piston includes a sensing portion that is in fluid communication with the second bore, each sensing portion having a wettable face area that differs from the wettable face area of another of the plurality of pistons.
9. The device of claim 7 wherein the RSA further comprises a rotational speed indicator coupled to the rotating sleeve at a location that passes the sensor during each rotation when the rotating sleeve rotates relative to the housing; and
wherein the sensor is configured to detect the rotational speed indicator when the rotational speed indicator rotates past the sensor.
10. The device of claim 9 wherein the plurality of piston ports, the plurality of pistons, the sensor port, the sensor, and the rotational speed indicator are all aligned parallel to a plane that extends perpendicular to the central axis.
11. The device of claim 7 wherein the RSA further comprises a burst disc disposed to seal the first piston port at a location between the second bore and the first piston.
12. The device of claim 7 further comprising a piston assembly comprising:
a piston cartridge disposed at a fixed location within the first piston port; and
the piston slidingly disposed in the piston cartridge;
wherein the piston is separated from the sleeve by the piston cartridge.
13. The device of claim 7 wherein the first piston is configured to be free from sliding engagement with the first piston port.
14. The device of claim 7 wherein the sensor is configured to detect the first piston by a phenomenon selected from a group consisting of: proximity, magnetic field, Hall Effect, contact, induction, capacitive interaction, and photoelectric interaction.
15. A rotating control device for a well, the device comprising:
a housing having a through-bore extending along a central axis and a sensor positioned at a first axial position;
a sleeve configured to rotate within the through-bore of the housing; and
a piston coupled to the sleeve and configured to move from a first position to a second position in response to a pressure change of a fluid within the sleeve, the piston being coupled to the sleeve at a location such that it passes by the first axial position periodically when the sleeve rotates within the through-bore;
wherein the first piston is configured to be free from sliding engagement with the sleeve; and
wherein the sensor is configured to detect the piston when the piston is in the second position.
16. The rotating control device of claim 15 wherein the sensor is positioned at a discrete circumferential location about the central axis.
17. The rotating control device of claim 15 further comprising a piston assembly comprising:
a piston cartridge disposed at a fixed location in the sleeve; and
the piston slidingly disposed in the piston cartridge;
wherein the piston is separated from the sleeve by the piston cartridge.
18. The rotating control device of claim 15 further comprising:
a plurality of piston assemblies, each piston assembly comprising:
a piston cartridge disposed at a fixed location in the sleeve and including a fluid communication bore, a location that passes by the first axial position periodically when the sleeve rotates; and
a piston slidingly disposed in the piston cartridge and separated from the sleeve by the piston cartridge, the piston including a piston neck slidingly and sealingly received within the fluid communication bore, the piston configured to move from a first position to a second position in response to a pressure change of a fluid within the sleeve; and
wherein each piston neck of the plurality of piston assemblies has a different wettable face area than another of the piston necks.
19. The rotating control device of claim 15 further comprising a rotational speed indicator coupled to the rotating sleeve at a location that passes the sensor during each rotation of the sleeve relative to the housing;
wherein the sensor is configured to detect the rotational speed indicator when the rotational speed indicator rotates past the sensor.
20. A method for operating a rotating control device, the method comprising:
providing a housing having a through-bore extending along a central axis, a housing wall, and a sensor disposed at a sensor position in the housing;
disposing a sleeve within the through-bore of the housing, the sleeve configured to rotate about the central axis and comprising a sleeve bore aligned with the central axis ;
coupling a pressure-responsive assembly to the sleeve at a location such that the pressure-responsive element is in fluid communication with the sleeve bore and such that the pressure-responsive assembly passes the sensor position periodically as the sleeve rotates , wherein the pressure-responsive assembly that includes a pressure-responsive element configured to be free of sliding engagement with the sleeve;
disposing a tubular string sealingly within the sleeve bore;
rotating the tubular string and the sleeve with respect to the housing;
using the sensor, detecting a response of the pressure-responsive assembly when pressure in the sleeve bore reaches an activation pressure; and
performing a system action when the sensor detects a response of the pressure-responsive assembly.
21. The method of claim 20 wherein detecting a response of the pressure-responsive assembly includes measuring periodically the pressure in the sleeve bore.
22. The method of claim 20 wherein the pressure-responsive element includes a detectable member coupled for movement with a piston disposed in a cartridge; and
wherein detecting a response of the pressure-responsive assembly includes detecting radial movement of the pressure-responsive element relative to the cartridge and the sleeve.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US16/257,183 US20190234173A1 (en) | 2018-01-26 | 2019-01-25 | Rotating Control Devices and Methods to Detect Pressure Within Rotating Members |
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US201862622411P | 2018-01-26 | 2018-01-26 | |
US16/257,183 US20190234173A1 (en) | 2018-01-26 | 2019-01-25 | Rotating Control Devices and Methods to Detect Pressure Within Rotating Members |
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US20190234173A1 true US20190234173A1 (en) | 2019-08-01 |
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US16/257,183 Abandoned US20190234173A1 (en) | 2018-01-26 | 2019-01-25 | Rotating Control Devices and Methods to Detect Pressure Within Rotating Members |
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US (1) | US20190234173A1 (en) |
WO (1) | WO2019147881A1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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US20210340834A1 (en) * | 2020-04-30 | 2021-11-04 | Premium Oilfield Technologies, LLC | Rotary Control Device with Self-Contained Hydraulic Reservoir |
US20230184095A1 (en) * | 2021-12-15 | 2023-06-15 | Helmerich & Payne Technologies, Llc | Transducer assembly for oil and gas wells |
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US20090152006A1 (en) * | 2007-12-12 | 2009-06-18 | Smith International, Inc. | Dual stripper rubber cartridge with leak detection |
US20180087571A1 (en) * | 2015-04-23 | 2018-03-29 | Schlumberger Technology Corporation | Bearing Pressure Indicator |
Family Cites Families (1)
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CA3016460A1 (en) * | 2016-03-04 | 2017-09-08 | National Oilwell Varco, L.P. | Systems and methods for controlling flow from a wellbore annulus |
-
2019
- 2019-01-25 US US16/257,183 patent/US20190234173A1/en not_active Abandoned
- 2019-01-25 WO PCT/US2019/015066 patent/WO2019147881A1/en active Application Filing
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
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US20090152006A1 (en) * | 2007-12-12 | 2009-06-18 | Smith International, Inc. | Dual stripper rubber cartridge with leak detection |
US20180087571A1 (en) * | 2015-04-23 | 2018-03-29 | Schlumberger Technology Corporation | Bearing Pressure Indicator |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20210340834A1 (en) * | 2020-04-30 | 2021-11-04 | Premium Oilfield Technologies, LLC | Rotary Control Device with Self-Contained Hydraulic Reservoir |
US11686173B2 (en) * | 2020-04-30 | 2023-06-27 | Premium Oilfield Technologies, LLC | Rotary control device with self-contained hydraulic reservoir |
US20230184095A1 (en) * | 2021-12-15 | 2023-06-15 | Helmerich & Payne Technologies, Llc | Transducer assembly for oil and gas wells |
US11970933B2 (en) * | 2021-12-15 | 2024-04-30 | Helmerich & Payne Technologies, Llc | Transducer assembly for oil and gas wells |
Also Published As
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WO2019147881A1 (en) | 2019-08-01 |
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