WO2024030812A1

WO2024030812A1 - Rotating control device with sealing insert

Info

Publication number: WO2024030812A1
Application number: PCT/US2023/071086
Authority: WO
Inventors: Nathaniel Pettibone
Original assignee: Schlumberger Technology Corporation; Schlumberger Canada Limited; Services Petroliers Schlumberger; Schlumberger Technology B.V.
Priority date: 2022-08-05
Filing date: 2023-07-27
Publication date: 2024-02-08

Abstract

A seal for a rotating control device includes a ring having an inner diameter sized to permit a joint of a tubular to pass therethrough, a sealing element coupled to the ring, and configured to seal with the tubular both at the joint and the body, and an insert coupled to the sealing element and at least partially made of a material that is rigid in comparison to the sealing element. The insert includes a plurality of segments that are configured to slide at least radially in response to the sealing element expanding and contracting by engagement with the tubular.

Description

ROTATING CONTROL DEVICE WITH SEALING INSERT

Cross-Reference to Related Application

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63/370,583, filed on August 5, 2022, the entirety of which is incorporated by reference herein.

Background

[0002] A rotating control device (RCD) is used to contain and isolate pressure in the wellbore annulus while rotary drilling. The RCD contains a sealing element and a bearing assembly. The sealing element creates a seal against the drill string while drilling. The bearing assembly allows the sealing element to rotate with the drill string, eliminating relative rotation between the drill string and the sealing element.

[0003] The drill string includes multiple drill pipes, connected together end-to-end. Each drill pipe generally has a tool joint at each end, where the diameter is increased from the main body of the drill pipe. The sealing element creates an elastomeric seal against the drill pipe outer diameter. The sealing element thus is called upon to change and conform to the diameter of the drill pipe, including sealing both with the tool joint and the main body of the drill pipe, while the drill string is advancing.

[0004] The sealing element generally includes an elastomeric seal bonded to a metal insert, which provides for attachment to the rest of the RCD assembly. The metal insert is a solid ring with an inner diameter large enough for the tool joint to pass. There is generally a clearance gap between the drill pipe, away from the joint, and the metal ring, so that the tool joint can pass through the solid ring. The elastomeric seal extends across this clearance gap but is unsupported by the metal insert in this area. Because the elastomer is soft and deformable, the seal is prone to extrude into this clearance gap under the wellbore pressure, which can cause excessive wear and eventual damage to the elastomeric seal.

Summary

[0005] Embodiments of the disclosure include a seal for a rotating control device includes a ring having an inner diameter sized to permit a joint of a tubular to pass therethrough, the joint of the tubular being larger than a body of the tubular, a sealing element coupled to the ring, and configured to seal with the tubular both at the joint and the body, and an insert coupled to the sealing element and at least partially made of a material that is rigid in comparison to the sealing element. The insert includes a plurality of segments that are configured to slide at least radially in response to the sealing element expanding and contracting by engagement with the tubular.

[0006] Embodiments of the disclosure include a rotating control device including a stationary body, a bearing, and a rotary seal configured to rotate relative to the stationary body. The rotary seal includes a ring coupled to the bearing and having an inner diameter sized to permit a joint of a tubular to pass therethrough, the joint of the tubular being larger than a body of the tubular, and a clearance gap being defined between the ring and the tubular, a sealing element coupled to the ring and configured to seal with the tubular both at the joint and the body, and an insert coupled to the sealing element configured to prevent the sealing element from extruding through the clearance gap.

[0007] Embodiments of the disclosure include a seal for a rotating control device including a ring coupled to a bearing of the rotating control device and having an inner diameter sized to permit a joint of a tubular to pass therethrough, the joint of the tubular being larger than a body of the tubular, and a clearance gap being defined between the ring and the tubular, a sealing element coupled to the ring and configured to seal with the tubular both at the j oint and the body, the sealing element being at least partially constructed of an elastomeric material, and an insert coupled to the sealing element, engaging the ring, and extending radially at least between an outer diameter surface of the tubular and an inner diameter surface of the ring such that the insert is configured to prevent the sealing element from extruding through the clearance gap, the insert being constructed at least partially of metal, and the insert including a plurality of segments that are configured to slide radially in response to the sealing element expanding and contracting by engagement with the tubular.

Brief Description of the Drawings

[0008] The subject disclosure is further described in the following detailed description, and the accompanying drawing and schematic of non-limiting embodiment of the subject disclosure. The features depicted in the figure are not necessarily shown to scale. Certain features of the embodiments may be shown exaggerated in scale or in somewhat schematic form, and some details of elements may not be shown in the interest of clarity and conciseness [0009] Figure 1 illustrates a sectional view of a seal for a rotating control device, according to an embodiment.

[0010] Figure 2 illustrates a perspective view of an insert for the seal, with the insert in a contracted configuration, according to an embodiment.

[0011] Figure 3 illustrates a perspective view of the insert in an expanded configuration, according to an embodiment.

[0012] Figure 4 illustrates a perspective view of a segment of the insert, according to an embodiment.

[0013] Figure 5 illustrates a side, sectional view of the seal receiving a tubular therethrough, according to an embodiment.

[0014] Figure 6 illustrates a side, sectional view of the seal receiving a tool joint therethrough, according to an embodiment.

[0015] Figure 7 illustrates a perspective view of another insert, according to an embodiment.

[0016] Figure 8 illustrates a perspective view of a segment of the insert of Figure 7, according to an embodiment.

Detailed Description

[0017] One or more specific embodiments of the present disclosure will be described below. These described embodiments are only exemplary of the present disclosure. Additionally, in an effort to provide a concise description of these exemplary embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers’ specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0018] Figure 1 illustrates a perspective view of a section of a seal 100 for a rotating control device, according to an embodiment. The seal 100 generally includes a ring 102, a sealing element 104, and an insert 106. The ring 102 may be made of a relatively rigid (e.g., as compared to the sealing element 104) material, such as metal, and may be configured to be coupled to a bearing, for example, to permit the seal 100 to rotate along with a tubular (e.g., drill pipe) during a drilling operation. The ring 102 may be constructed as a single piece, and thus may have an inner diameter that is sufficiently large to permit the largest diameter of the tubular for use therewith to pass through the ring 102. The tubular may include a body and a joint (e.g., at one or both ends of the body), with the joint extending radially outward from the body. Accordingly, the inner diameter of the ring 102 is at least as large as the outer diameter of the joint of the tubular, and thus a gap may be defined radially between the tubular and the ring 102 as the body of the tubular moves through the ring 102.

[0019] The sealing element 104 may be made at least partially of a relatively soft (e g., compared to the ring 102), resilient material, such as an elastomer. The sealing element 104 may be configured to seal with the tubular that passes therethrough, and may thus be configured to radially expand and contract by engagement with the tubular, e.g., as a joint moves through the sealing element 104 and then the body moves through the sealing element 104. The sealing element 104 may be molded to the ring 102. For example, the ring 102 may include an axial or “lower” extension 105 that may be enveloped within the sealing element 104, thereby anchoring the ring 102 in the sealing element 104. The sealing element 104 may generally have a tapered (conical) geometry, such that wellbore pressure from below presses the sealing element 104 against the tubular received therethrough, forming a positive seal.

[0020] The insert 106 may also be at least partially embedded within the sealing element 104, and may be made of a relatively rigid (e.g., as compared to the sealing element 104) material, such as a metal. For example, the sealing element 104 may be molded onto or around the insert 106. The insert 106 may be configured to expand and contract along with the sealing element 104, so as to permit the sealing element 104 to seal with, and permit passage of, both the joint and the body of the tubular, when the tubular is being run through the seal 100. The insert 106 may extend radially inward of an inner diameter surface 110 of the ring 102, and may engage and slide against a lower surface 112 of the ring 102, as will be described in greater detail below.

[0021] The insert 106 may be formed from a plurality of segments 120, which may be made of a relatively rigid (as compared to the sealing element 104) material, such as metal. The segments 120 may be shaped such that expansion and contraction of the insert 106 in a radial direction is permitted, without opening gaps between adjacent segments 120. For example, as will be described in greater detail below, the segments 120 may generally have a triangular profile, which viewed in an axial direction, and may be arranged to slide, one relative to the other, so as to permit the aforementioned radial expansion and contraction of the insert 106, e.g., similar to changing an aperture of a camera lens. Further, at least a portion of the sealing element 104 may be formed radially inward of the insert 106, for making a sealing engagement with the tubular during drill operations.

[0022] Figures 2 and 3 illustrate perspective views of the insert 106 in a contracted configuration and an expanded configuration, respectively, according to an embodiment. For example, the insert 106 may be in the contracted configuration when the sealing element 104 (Figure 1) is engaging the main body of a tubular, while the insert 106 may be in the expanded configuration when an enlarged tool joint is passing through the sealing element 104. As is visible by comparison of Figures 2 and 3, the segments 120 are permitted to slide relative to one another and pivot, such that the insert 106 is configured to expand/ contract in a radial direction by the segments 120 sliding radially and circumferential with respect to one another. More particularly, the segments 120 each have a generally triangular shape, with at least one side pointed at an acute angle to the radial direction. The sides of adjacent segments 120 thus slide circumferentially and radially relative to one another, while potentially pivoting about a vertical axis, thereby modulating the inside diameter of the insert 106, while avoiding creating gaps between the segments 120.

[0023] Figure 4 illustrates a perspective view of an individual segment 120 of the insert 106, according to an embodiment. As shown, the segment 120 includes a first or “upper” portion 400, a second or “lower” portion 402, and a middle portion 404 that extends between and connects together the upper and lower portions 400, 402. In at least some embodiments, the segment 120 may be integral and formed as a single piece, although two or more pieces connected together may also be employed. The middle portion 404 may be generally smaller in radial dimension than the upper and lower portions 400, 402. Further, the upper portion 400 may include a beveled inner corner 406, e.g., extending from its radially-inward edge 410. Accordingly, when assembled, the segments 120 having beveled corners 406 may present a tapered annular surface that faces upward for engagement with the tubular. As the enlarged joint of the tubular engages the tapered, annular surface presented by the beveled corners 406, the axial force of the tubular advancing wedges the insert 106 radially outwards, thereby causing the insert 106 to expand when engaged by the larger- diameter joint.

[0024] In at least one embodiment, the upper portion 400 may be larger in volume and radial dimension than the lower portion 402. For example, the lower portion 402 may serve as an anchor to secure the segment 120 in the molded, elastomeric material of the sealing element 104, while the upper portion 400 serves as a bearing surface and/or to span a clearance gap between the inner diameter surface 110 of the ring 102 and the tubular, as will be discussed in greater detail below. Specifically, the upper portion 400 may include an upper surface 408 that faces in an axial (“upwards”) direction, and which is configured to engage the lower surface 112 of the ring 102, as shown in Figure 1. Additionally, the inner edge 410 of the upper portion 400 may be configured to engage and slide along the tubular received through the seal 100. The beveled corner 406 may intersect the inner edge 410.

[0025] As can be seen with additional reference to Figure 1, gaps are present between the middle portions 404 of adjacent segments 120. These gaps may permit the elastomeric material of the sealing element 104 to “flow” radially through the insert 106, permitting the insert 106 to move radially. However, gaps are generally not present between the upper portions 400 of adjacent segments 120 or between the lower portions 402 of adjacent segments 120, thereby preventing extrusion of the sealing element 104 axially through the insert 104.

[0026] Figure 5 illustrates a side, cross-sectional view of the seal 100, according to an embodiment. In particular, the seal 100 is shown receiving a tubular 500, such as a drill pipe, therethrough. The seal 100, as part of a rotating control device (RCD), may rotate with the tubular 500. In Figure 5, two elements of the RCD apart from the seal 100 are also shown schematically. In particular, a bearing 501 and a housing 503 are illustrated. The bearing 501 may be part of a more complex rotating assembly that permits the seal 100 to rotate relative to the housing 503, while being supported from a stationary object, such as the housing 503. Various bearings, housings, and other RCD components and their integration with the seal 100 of the present disclosure will be readily apparent to one of ordinary skill in the art.

[0027] The tubular 500 is received through the ring 102, with a clearance gap 502 defined therebetween. The tubular 500 is also received through the insert 106 and through the sealing element 104 below, which forms a seal therewith.

[0028] In this view, the insert 106 is in the contracted configuration. At least in this contracted configuration, the insert 106 extends radially between the inside diameter surface 110 (see, e.g., Figure 1) of the ring 102 and the tubular 500, thereby spanning the clearance gap 502. Further, the upper surface 408 of the insert 106 may engage and slide in a radial direction, e.g., but not an axial direction, against the lower surface 112 of the ring 102. The insert 106, being made of a relatively rigid material, such as metal, generally resists deformation from interaction with the ring 102. Thus, the insert 106, embedded at least partially within the sealing element 104 and spanning the clearance gap 502, blocks the sealing element 104 from extruding through the clearance gap 502.

[0029] As noted above, a portion 510 of the sealing element 104 is radially inward of the middle portion 404 (e.g., Figure 4) of the insert 106. Thus, the sealing element 104 forms a seal with the tubular 500 within the axial extends of the insert 106. Further, the portion 510 of the sealing element 104 radially inward of the insert 106 facilitates the insert 106 returning to its contracted configuration after a tool joint has passed through, as will be described in greater detail below. Another portion of the sealing element 104 is radially outward of the insert 106, e g., between the axial extension 105 of the ring 102 and the insert 106. This portion may be compressed by radially outward movement of the insert 106.

[0030] Figure 6 illustrates a side, cross-sectional view of the seal 100 with a tool joint 600 received therethrough, according to an embodiment. The tool joint 600 may be integral or attached to the tubular 500 shown in and described above with respect to Figure 5. The tool joint 600 may be larger in radial dimension than (e.g., the main body of) the tubular 500, as can be appreciated, e.g., by comparing of the size of the clearance gap 502 in Figure 5 and in Figure 6. Accordingly, the insert 106 is now in its expanded configuration, permitting passage of the relatively large tool joint 600.

[0031] In the expanded configuration, the insert 106 is pressed radially outwards, e.g., by the wedging interaction discussed above, such that the insert 106 advances outwards, toward the axial extension 105 of the ring 102. In some embodiments, the insert 106 may remain spaced radially apart from the axial extension 105 in the expanded configuration. The resilient sealing element 104 is likewise pressed outwards, so as to permit passage of the tool joint 600 while sealing therewith. When the tool joint 600 passes and the seal 100 engages the next tubular 500, the sealing element 104 may resiliently return to (or nearly to) its original size, which may result in the insert 106 returning to its contracted configuration. Further, the body of the sealing element 104 that is radially outward of the insert 106 may press the insert 106 radially inward, while the portion 51 O of the insert 106 that is radially inward of the insert 106 may pull the insert 106 radially inward.

[0032] Figure 7 illustrates a perspective view of another insert 700, according to an embodiment. Referring additionally to Figures 1 and 5, the insert 700 may be used in the seal 100, in lieu of the insert 106. In other embodiments, the insert 700 may be used in other seals. The insert 700 may perform a similar function as the insert 106, and may be embedded in the sealing element 104, such that the insert 106 engages and is permitted to slide against the ring 102, while spanning the clearance gap 502 to prevent extrusion of the sealing element 104 therethrough.

[0033] The insert 700 may be made of a plurality of segments 702. The segments 702 may be formed generally as triangular prisms, similar to the upper portion 400 of the segments 120 (e.g., Figure 4). That is, the segments 702 may include the smaller middle portion 404 or the lower portion 402 (e.g., Figure 4) of the segments 120. Referring again to Figure 7, without a smaller middle portion, there may not be a gap between adjacent segments 120, and thus the elastomeric sealing element 104 may be prevented from flowing radially through the insert 104. However, the segments 702 may still include a beveled corner 704, for converting at least some of the axial movement of the tubular received therethrough into radially outward force on the insert 700, as shown in Figures 7 and 8.

[0034] While the disclosure may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the following appended claims. Any references to “metal” include metal alloys.

[0035] The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for” or “step for” performing a function, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f).

Claims

CLAIMS What is claimed is:

1. A seal for a rotating control device, the seal comprising: a ring having an inner diameter sized to permit a joint of a tubular to pass therethrough, wherein the joint of the tubular is larger than a body of the tubular; a sealing element coupled to the ring, wherein the sealing element is configured to seal with the tubular both at the joint and the body; and an insert coupled to the sealing element and at least partially made of a material that is rigid in comparison to the sealing element, wherein the insert comprises a plurality of segments that are configured to slide at least radially in response to the sealing element expanding and contracting by engagement with the tubular.

2. The seal of claim 1, wherein the sealing element comprises an elastomeric material, and wherein the insert comprises a metal.

3. The seal of claim 1, wherein the insert extends radially between an outer diameter surface of the tubular and an inner diameter surface of the ring, so as to prevent extrusion of the seal through a clearance gap between the ring and the tubular.

4. The seal of claim 1, wherein an upper surface of the insert engages a lower surface of the ring.

5. The seal of claim 1, wherein each of the plurality of segments of the inserts is formed at least partially from a generally triangular prism shape.

6. The seal of claim 5, wherein each of the plurality of segments of the insert comprises: an upper portion providing the generally triangular prism shape; a lower portion that is offset from the upper portion; and a middle portion that extends between and connects together the upper and lower portions, the middle portion being smaller in radial and circumferential dimension than the upper and lower portions.

7. The seal of claim 6, wherein a gap is formed between the middle portions of two adjacent segments of the plurality of segments, such that at least a portion of the sealing element is permitted to move radially through the inserts, between the two adjacent segments via the gap.

8. The seal of claim 6, wherein at least a portion of the seal is positioned radially inward of the middle portion of each of the plurality of segments, and radially between the middle portion of each of the plurality of segments and a lower extension of the ring.

9. The seal of claim 6, wherein an inner edge of the upper portion of each of the plurality of segments is beveled, such that interaction with the joint of the tubular presses the plurality of segments radially outward.

10. The seal of claim 1, wherein at least one side of each of the plurality of segments is formed at an angle to straight radial, such that the plurality of segments are configured to slide radially inward and outward so as to change an inner diameter of the insert without opening a gap between adjacent segments of the plurality of segments.

11. The seal of claim 1, wherein the seal resiliently forces the insert radially inwards.

12. A rotating control device, comprising: a stationary body; a bearing; and a rotary seal configured to rotate relative to the stationary body, the rotary seal comprising: a ring coupled to the bearing and having an inner diameter sized to permit a joint of a tubular to pass therethrough, wherein the joint of the tubular is larger than a body of the tubular, and wherein a clearance gap is defined between the ring and the tubular; a sealing element coupled to the ring and configured to seal with the tubular both at the joint and the body; and an insert coupled to the sealing element configured to prevent the sealing element from extruding through the clearance gap.

13. The rotating control device of claim 11, wherein the insert is constructed at least partially from a metal, and wherein the sealing element is constructed at least partially from an elastomer.

14. The rotating control device of claim 11, wherein the insert extends radially between an outer diameter surface of the tubular and an inner diameter surface of the ring, so as to prevent extrusion of the seal through a clearance gap between the ring and the tubular.

15. The rotating control device of claim 11 , wherein an upper side of the insert engages and slides against a lower side of the ring.

16. The rotating control device of claim 11, wherein the insert comprises a plurality of segments that are configured to slide radially in response to the sealing element expanding and contracting by engagement with the tubular.

17. The rotating control device of claim 15, wherein each of the plurality of segments of the insert comprises: an upper portion; a lower portion that is offset from the upper portion; and a middle portion that extends between and connects together the upper and lower portions, the middle portion being smaller in radial dimension than the upper and lower portions such that a gap is formed between adjacent segments of the plurality of segments.

18. The rotating control device of claim 16, wherein at least a portion of the seal is positioned radially inward of the middle portion of each of the plurality of segments, and radially between the middle portion of each of the plurality of segments and a lower extension of the ring.

19. The rotating control device of claim 15, wherein at least one side of each of the plurality of segments is formed at an angle to straight radial, such that the plurality of segments are configured to slide radially inward and outward so as to change an inner diameter of the insert without opening a gap between adjacent segments of the plurality of segments.

20. A seal for a rotating control device, the seal comprising: a ring coupled to a bearing of the rotating control device and having an inner diameter sized to permit a joint of a tubular to pass therethrough, wherein the joint of the tubular is larger than a body of the tubular, and wherein a clearance gap is defined between the ring and the tubular; a sealing element coupled to the ring and configured to seal with the tubular both at the joint and the body, wherein the sealing element is at least partially constructed of an elastomeric material; and an insert coupled to the sealing element, engaging the ring, and extending radially at least between an outer diameter surface of the tubular and an inner diameter surface of the ring such that the insert is configured to prevent the sealing element from extruding through the clearance gap, wherein the insert is constructed at least partially of metal, and wherein the insert comprises a plurality of segments that are configured to slide radially in response to the sealing element expanding and contracting by engagement with the tubular.