REMOTE-CONTROLLED SELF-POWERED CLAMPING SYSTEM

Abstract

An energy harvesting rotating control device includes an inner member and a locking member. The inner member is configured to rotate about a longitudinal axis. The locking member is configured to move toward the longitudinal axis of the inner member and engage a shoulder of the inner member. An actuator is configured to move the locking member when actuated by an electrical power source. The locking member engaging the shoulder of the inner member limits the movement of the inner member.

Description

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims priority from U.S. Provisional Patent Application 62/017,561, filed Jun. 26, 2014, which is incorporated herein by reference in its entirety.

BACKGROUND OF THE DISCLOSURE

Wells are drilled on land and in marine environments for a variety of exploratory and extractive purposes. Due to the variety of purposes, the conditions experienced while producing the wells also vary greatly. The particular conditions include changes in temperature, pressure, subterranean fluids, and formations, among other variables. The conditions expected during the drilling process affect the type of drilling process used to produce the wellbore. In particular, when a well is drilled to access a particular formation or particular part of a formation, the wellbore follows a predetermined path through the surrounding formation. In a simple instance, the wellbore follows a straight line to the desired region. In other instances, the wellbore to be drilled will include curved sections or include multiple wellbores stemming from an existing wellbore.

The environment through which the wellbore is drilled will affect the conditions of the drilling process. The conditions of the drilling process will, in turn, dictate the equipment and techniques used to create the wellbore. One such technique is managed pressure drilling (“MPD”) or the related underbalanced drilling (“UBD”). MPD and UBD will frequently require a closed system for circulating drilling fluids in order to control the fluid pressure inside the wellbore being drilled. The drilling system includes a drill string and a bottomhole assembly. The drill string includes a series of drill pipe segments that transmit torque and force to the bottomhole assembly while also providing a fluid conduit for the drilling fluids. The drill bit itself is at the terminal end of the bottomhole assembly. The drilling fluid circulates down through the drill string, through the bottomhole assembly, and out through holes in the drill bit. The drilling fluid cools and lubricates the drilling bit while removing cuttings from the wellbore back to the surface through the annular space around the drill string in the wellbore.

The closed system uses a diverter at the top of the wellbore to direct drilling fluid returning to the surface through the annular space to a settling tank and any other appropriate treatment devices before being pumped back down through the drill string. The diverter is the rotating control device (“RCD”), which is also sometimes called the rotating flow head (“RFH”). The RCD provides a seal over the annular space and around the drill pipe extending through the center of the RCD to maintain a closed system. In order to insert and remove the drill bit or other components that have a larger diameter than the drill pipe, a bearing assembly must be removed from the RCD by mechanically or hydraulically releasing locking dogs in the RCD. This is time consuming and difficult when the RCD is not readily accessible such as when the RCD is located in a substructure below a drilling platform or underwater in a marine drilling application. In some underwater RCDs, a worker dives to the RCD and manually disengages the locking dogs if the hydraulic lines running from the deck are compromised. Additionally, the mechanical and hydraulic systems associated with the RCD locking dogs have a large footprint that restricts the space available for other equipment.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to describe the manner in which the above-recited and other advantages and features of the disclosure can be obtained, a more particular description will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. For better understanding, like elements have been designated by like reference numbers throughout the various accompanying figures. While some of the drawings are schematic representations of concepts, at least some of the drawings may be drawn to scale. Understanding that these drawings depict only example embodiments of the disclosure and are not therefore to be considered to be limiting of its scope, the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 illustrates an embodiment of a drilling system including a rotating control device having electrically actuated locking members according to the present disclosure;

FIG. 2 illustrates a linear electromechanical actuator;

FIG. 3 illustrates a rotary electromechanical actuator;

FIG. 4 illustrates rotating control device including an energy harvesting device configured to harvest energy during operation of a drilling system;

FIG. 5 illustrates an energy harvesting device including a turbine;

FIG. 6 illustrates an energy harvesting device located within the bearing assembly; and

FIG. 7 illustrates an embodiment of a rotating control device having redundant energy harvesting devices and electrical energy storage systems.

DETAILED DESCRIPTION

One or more specific embodiments of the present disclosure will be described below. These described embodiments are examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, not all features of an actual implementation may 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 will 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 having the benefit of this disclosure.

When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

Embodiments of this disclosure generally relate to the remote powering and operation of one or more locking members on a rotating control device (“RCD”). The locking members may selectively restrain one or more inner components of the RCD to secure the components relative to an outer housing or allow the removal of the inner components from the outer housing. By way of example, the RCD may include an outer member that is secured near the top of a drilling system. For example, the outer member may be the housing of the RCD itself. The outer member may contain an inner member including a bearing assembly and rotatable mandrel within which a tubular can be held. The remotely operated locking members may allow the inner member to be removed without associated hydraulic lines or equipment on a deck and/or without a worker manually moving the locking members.

An RCD may include one or more energy harvesting devices and one or more electrical energy storage systems to allow the RCD to generate electrical energy during operation of the drilling system and store that electrical energy to power the electrical components on the RCD, including but not limited to the actuators that move the locking members, data collection modules, communication modules, and any other electrically powered devices incorporated into the RCD.

FIG. 1 illustrates an overview of a drilling system 10 including an embodiment of an RCD 100 having an outer member 102, an inner member 104, and at least one electrically actuated locking member 112. The drilling system 10 may include an above ground power source to power the drilling system 10. For example, the drilling system 10 may include a rotary table 12 above the RCD 100. The rotary table 12 may provide a rotational energy to the drilling system 10 and/or may rotate a tubular 14 that extends through the rotary table 12. The tubular 14 may be used in drilling the wellbore 16. In an embodiment, the tubular 14 may include various components while drilling the wellbore 16 such as a drill string 18 and a bottomhole assembly 20. The bottomhole assembly 20 may include a drill motor, a drill bit, a drill collar, a steerable component, measurement-while-drilling components, logging-while-drilling components, and other analytical components (not shown). The RCD 100 may be located above a pressure control device such as a blowout preventer 22 that may help control and manage variations in pressure in the wellbore 16.

In the depicted embodiment, the outer member 102 includes the RCD housing. The RCD housing may serve to protect the inner components of the RCD 100. In other embodiments, the outer member 102 may be part of another component. The outer member 102 may support the inner member 104 and/or may provide a stationary ground for the locking member 112. The locking member 112 is therefore able to restrict the movement of the inner member 104 relative to the outer member 102.

The inner member 104 is a removable component of the RCD 100 that allows the outer member 102 to remain secured to other elements of the drilling system 10 while the inner member 104 is lifted out of the RCD 100. This may be done, for example to enable maintenance on a part of the inner member 104 and/or to allow large components of the tubular 14 to be delivered into the wellbore 16 through the RCD 100.

The outer member 102 shown in FIG. 1 is depicted as having a cylindrical interior shape. For example, the outer member 102 may have a circular transverse cross-section. The outer member 102 may allow the rotation of the inner member 104 or a portion of the inner member 104 within the outer member 102. The transverse cross-section of the outer member 102 may be of any shape suitable to contain the inner member 104. In the depicted embodiment, the transverse cross-sectional dimensions of the outer member 102 and inner member 104 are such that there is substantially no gap between the interior of the outer member 102 and the exterior of the inner member 104. The gapless mating of the outer member 102 and inner member 104 may provide a fluid-tight seal such that fluid returning up the annular space of the wellbore 16 may be contained and/or redirected. In other embodiments, the transverse cross-sectional dimensions of the outer member 102 and inner member 104 may be such that there is a gap left between the two components.

In some embodiments, the RCD 100 may include a fluid seal 110 between the outer member 102 and the inner member 104. The fluid seal 110 may include various materials, components, or combinations thereof. For example, the fluid seal 110 may include a polymer component, an elastomer component, other components, or combinations thereof. In the embodiment depicted in FIG. 1, a fluid seal 110 is located at each end of the inner member 104. The fluid seal 110 may provide a connection between the inner member 104 and the interior of the outer member 102. In other embodiments, the RCD 100 may include a fluid seal 110 at only the top or the bottom of the inner member 104 and/or at any point between the top and bottom of the inner member 104. Additionally, any number of fluid seals 110 may be used and in any combination. For example, an embodiment may have three fluid seals 110 proximate the bottom of the inner member 104 and one fluid seal 110 proximate the top of the inner member 104.

The locking member 112 may include various types of locking mechanisms including locking dogs, threaded rods, bars, or combinations thereof. The locking member 112 may retain the inner member 104 relative to the outer member 102. For example, the locking member 112 may be configured to move toward a longitudinal axis 140 of the RCD 100 to engage a shoulder 114. In some embodiments, the locking member 112 may be oriented perpendicular to the longitudinal axis 140. A perpendicular orientation may maximize the force applied by the locking member 112 to the inner member 104. In other embodiments, the locking member 112 may be oriented such that it extends at another angle relative to the longitudinal axis 140.

The locking member 112 may release the inner member 104 to freely move longitudinally within the outer member 102. For example, the locking member 112 may move away from the longitudinal axis 140 of the RCD 100. In an embodiment, the locking members may move away from the longitudinal axis 140 far enough to completely vacate the interior of the outer member 102.

Vacating the interior of the outer member 102 may allow the entire interior of the outer member 102 to define an outer passthrough diameter. The outer passthrough diameter may be greater than about 12 inches (30.48 centimeters). In another embodiment, the outer passthrough diameter may be less than about 19¾ inches (50.2 centimeters). A space through the inner member 104 may define an inner passthrough diameter. The inner passthrough diameter may be greater than about 13⅝ inches (34.6 centimeters). In another embodiment, the passthrough diameter may be less than about 13⅝ inches (34.6 centimeters). In yet another embodiment, the passthrough diameter may be between about 10 inches (24.5 centimeters) and about 13⅝ inches (34.6 centimeters).

Various mechanisms may be employed to move the locking member 112. In the embodiment of FIG. 1, the RCD 100 may include at least one actuator 116 that is operatively associated with the locking member 112. The actuator 116 may apply a force to move the locking member 112 using, for example, hydraulic, pneumatic, electromagnetic, mechanical, other forces, or combinations thereof. In one example, a hydraulic actuator may include a piston and cylinder that may apply a force to the locking member 112 when the piston moves into or out of the cylinder. The fluid may be provided from a remote location and/or the fluid may be contained within a local reservoir and pumped to the cylinder by an electric motor. In this way, the actuator may utilize both hydraulic and electromagnetic forces. In another embodiment, the actuator 116 may be an electromagnetic or electromechanical actuator. An electromechanical actuator may utilize an electric current to generate a magnetic field and mechanically move an object.

An RCD 100 according to present disclosure may include an electrical energy storage system 118 to provide electrical energy to power the actuator 116. The electrical energy storage system 118 may include any suitable means for storing electrical energy, such as primary cell batteries; secondary cell batteries such as lead-acid batteries, lithium-ion batteries, nickel-cadmium batteries, nickel metal hydride batteries, flow batteries, polymer-based batteries, sodium-ion batteries, silver-zinc batteries, or fuel cells; capacitors; or combinations thereof. The electrical energy storage system 118 may have a number of performance characteristics including both active performance and passive performance characteristics. Active performance characteristics may include the amperage and voltage of the electrical energy storage system 118. Passive performance characteristics of the electrical energy storage system 118 may include weight, power capacity, charge rate, and self-discharge rate.

Active performance characteristics may influence the ability of the electrical energy storage system 118 to generate the electrical current and, hence magnetic force, to move the locking member 112, as described in relation to FIGS. 2 and 3. The magnetic force generated will be a function of the voltage provided by the electrical energy storage system 118 and the resistance of the actuators 116. However, greater voltage and greater amperage of the electrical energy storage system 118 will generally provide greater magnetic force to move the locking member 112. While the locking member 112 may be moved by a hydraulic force, pneumatic force, electromagnetic force, mechanical force, or combinations thereof, the electrical energy storage system 118 may provide the electrical energy to generate the force to move the locking member 112 alone or may be supplemented by an auxiliary electrical energy source. As used herein, “auxiliary electrical energy source” may refer to a remotely located battery or bank of batteries (i.e. not located on the RCD), a generator at the drilling site, a connection to a municipal or private electrical grid, a local energy source such as solar panels, another source of electrical energy not affiliated with the operation or movement of the drilling system, or combinations thereof.

In an embodiment, the electrical energy storage system 118 may provide enough electrical energy to actuate the locking member 112 into an engaged position (i.e. in some embodiments, toward the longitudinal axis 140) of the RCD 100 as shown in FIG. 1. In another embodiment, the electrical energy storage system 118 may provide enough energy to actuate the locking member 112 into a disengaged position (i.e. in some embodiments, away from the longitudinal axis 140) of the RCD 100.

Passive performance characteristics may influence the ability of the electrical energy storage system 118 to maintain a useable electrical energy amount over time. Passive performance characteristics include the electrical energy capacity and/or self-discharge rate of the electrical energy storage system 118. The electrical energy storage system 118 may provide enough energy to actuate the locking member 112 (i.e. toward the engaged position and/or toward the disengaged position) more than once during the operation of the drilling system. The drilling system 10 may be in operation or be idle for extended periods of time between actuations of the locking member 112. The electrical energy storage system 118 may therefore have a self-discharge rate sufficient to provide the electrical energy to actuate the locking member 112 after a one month period of being idle. For example, the rate at which the electrical energy storage system 118 loses stored electrical energy may be low enough to ensure the remaining electrical energy in the electrical energy storage system 118 may actuate the locking members 112. In another example, the capacity of the electrical energy storage system 118 may be sufficient to ensure the remaining electrical energy in the electrical energy storage system 118 may actuate the locking members 112 after one month.

Various embodiments of electrical energy storage systems may have a self-discharge rate as a result of internal resistances of electrical components. For example, batteries dissipate stored electrical energy due the internal resistance of interconnections, cathode and anode plates, the electrolyte, and other components. In an embodiment of the electrical energy storage system 118 including a battery, the capacity of the battery may be high enough and/or the self-discharge rate may be low enough to provide actuation of the locking members 112 after one month.

Similarly, the charge rate of the electrical energy storage system 118 may relate to its ability to provide the electrical energy to actuate the locking members 112 when desired. The charge rate relates to the rate and efficiency at which an input electrical energy may be converted and stored in the electrical energy storage system 118. The electrical energy storage system 118 may have a charge rate sufficient to maintain an amount of electrical energy to actuate the locking member 112. The charge rate may be sufficient to power the locking member 112 without any additional electrical energy input or electrical energy storage. The electric energy to be stored in the electrical energy storage system 118 may originate from various sources, some of which are described herein.

FIG. 2 illustrates an example of an actuator 216. Specifically, FIG. 2 illustrates an embodiment of a linear electromechanical actuator 216. The linear electromechanical actuator 216 may use an electric current 202 to create and apply a magnetic field 204 to a ferromagnetic bar 208 to thereby apply a magnetic force to and accelerate the ferromagnetic bar 208 toward or away from the outer surface of the inner member of the RCD. It should be understood that the ferromagnetic bar 208 need only have portions of the bar that are ferromagnetic or otherwise responsive to the application of a magnetic field. For example, the entire mass of the bar need not be ferromagnetic. In an embodiment, the ferromagnetic bar 208 may act on the locking member 112 (not shown in FIG. 2) or may be the locking member 112, itself. Such a linear electromechanical actuator 216 may move the locking member 112 directly using a magnetic force.

The magnetic force is generated by the flow of electric current 202 through one or more coils 206 of conductive wire. The magnetic field 204, and hence magnetic force, is generated perpendicularly to the flow of the electric current 202. A tightly wound coil 206 may have wires that are substantially perpendicular to a center longitudinal axis 210 of the coil 206. In the depicted embodiment in FIG. 2, the coil 206 is cylindrical. As electric current 202 flows through the coil 206 forming a cylinder, the substantially transverse movement of the electric current 202 produces a magnetic field 204 that is uniform throughout an interior space of the coil 206. The magnetic field 204, therefore, may apply a force to accelerate the ferromagnetic bar 208. To move to the ferromagnetic bar 208 in the opposite direction, an opposing voltage may be applied to the coil 206, thereby creating an electric current 202 that flows through the coil 206 in the opposite direction, generating a magnetic field 204 and force to accelerate the ferromagnetic bar 208 in the opposite direction.

In another embodiment depicted in FIG. 3, a rotary electromechanical actuator 316 may use an electric current 302 to create and apply a magnetic field 304 using coils 306 to a rotary member 308. The rotation of rotary member 308 may apply an axial force to the threaded rod 312 through the movement of the threads 310 past complementary threads (not visible) within an interior surface of the rotary member 308. In such an embodiment, the threaded rod 312 may act on the locking member (i.e. locking member 112 shown in FIG. 1) or may be the locking member, itself. The rotary electromechanical actuator 316 shown in FIG. 3 may apply a greater force per ampere to the threaded rod 312 when compared to the linear electromechanical actuator 216 shown in FIG. 2 acting on the ferromagnetic bar 208. However, the rotary electromechanical actuator 316 may have a slower response time (i.e. the threaded rod 312 may move slower) than the linear electromechanical actuator 216 (i.e. the ferromagnetic bar 208 may move faster).

Referring now to FIG. 4, in some embodiments, the electrical energy source may be the rotation of at least a portion of the inner member 404 relative to the outer member 402 or other component of the RCD. The RCD 400 may include an energy harvesting device 420 located across the gap between the outer member 402 and the inner member 404. In the particular embodiment depicted in FIG. 4, the inner member 404 includes a bearing assembly housing 406 and a mandrel 408. The bearing assembly housing 406 may be rotationally fixed relative to the outer member 402. The mandrel 408 may be able to rotate freely within the bearing assembly housing 406 upon a bearing assembly 432 contained therein. The bearing assembly 432 may contain at least one bearing 434. As depicted in FIG. 4, the bearing assembly 432 includes two bearings 434, which may be tapered roller-element bearings, but other embodiments may also include more or fewer bearings 434 and/or may include ball bearings, roller bearings, bearing surfaces, other types of bearings, or combinations thereof.

The bearing assembly housing 406 may also include one or more fluid seals 436 at each end of the bearing assembly housing 406 to retain a lubricating fluid therein for lubricating and cooling the bearing assembly 432. The one or more fluid seals 436 may also prevent the introduction of drilling fluids to an interior space of the bearing assembly housing 406.

The mandrel 408 may have a central bore 438 disposed along a longitudinal axis 440 to support and contain the tubular 14, such as a drill pipe, therethrough. The mandrel 408 may be generally cylindrical, itself, having a circular transverse cross-section or may have a polygonal transverse cross-section such a square, a pentagon, a hexagon, and the like or an irregular polygon. The mandrel 408 may have any transverse cross-section such that it may rotate within the bearing assembly housing 406. Likewise, the bearing assembly housing 406 may be generally cylindrical, as well, having a circular transverse cross-section or may have a polygonal transverse cross-section such a square, a pentagon, a hexagon, a similar regular polygon, or an irregular polygon. The bearing assembly housing 406 may have any transverse cross-section such that it may align with the interior dimensions of the outer member 402.

It should be understood that while the depicted embodiment illustrates an outer member 402 having a substantially similar shape on the interior and exterior surfaces, in other embodiments, the outer member 402 may have a different shape between the interior and exterior. By way of example, the outer member 402 may have an interior with a circular transverse cross-section and an exterior with a polygonal transverse cross-section.

In particular, FIG. 4 shows the energy harvesting device 420 including at least two components. The first component is the rotor 422 located on the rotating component of the inner member 404, which is the mandrel 408 in FIG. 4. The rotor 422 may include one or more magnets fixed to the mandrel 408 (and/or fixed to the outer member 402). The second component is the stator 424. The stator 424 may remain rotationally fixed as the rotor 422 rotates, but may also move independently such that there is relative rotational motion of the rotor 422 and the stator 424. The stator 424 may include a plurality of electrical wires, for example in a set of coils. The movement of the magnets in the rotor 422 by the discrete coils in the stator 424 may induce alternating current in the wires and therefore form an alternator in the RCD 400. The energy harvesting device 420 may induce an alternating electric current in the stator 424, which may be conducted to the electrical energy storage system 418. The electrical energy storage system 418 may thereby receive a substantially continuous supply of electrical energy during operation of the drilling system while the mandrel 408 rotates.

In another embodiment, the energy harvesting device 420 may include a dynamo with the magnetic field being continuous relative to the armature moving through the magnetic field. The movement of the armature relative to the magnet field is a matter of the relative frame of reference. However, the armature may move through the magnetic field continuously, providing a direct electrical current. In an embodiment, the rotor 422 may be the armature that rotates relative to the magnetic field provided by a field of the stator 424. In another embodiment, the rotor 422 may be the source of the magnetic field and the stator 424 may be the armature around the circumference of the rotor 422. The energy harvesting device 420 may be thereby configured to produce direct electrical current by using the rotor 422 and stator 424 as a field and armature in a dynamo-style system.

The energy harvesting device 420 may be in electrical communication with the electrical energy storage system 418. The electrical communication may include conductive wiring 426. In an embodiment, the conductive wiring 426 may be electromagnetically shielded. The electromagnetic shielding of the conductive wiring 426 may allow the RDC 400 to be used in an environment with other electromagnetic signals or fields with less concern for interference between the electrical current flowing therethrough and/or interference in the conductive wiring 426 from surrounding electromagnetic signals or fields. The conductive wiring 426 may also provide electrical communication between the electrical energy storage system 418 and the actuators 416 that moves the locking member 412-1, 412-2.

The electrical energy storage system 418 may receive a substantially continuous supply of electrical energy from the energy harvesting device 420 whenever the mandrel 408 is rotating relative to the outer member 402. The substantially continuous supply of electrical energy from the energy harvesting device 420 may be greater than the self-discharge rate of the electrical energy storage system 418. The electrical energy storage system 418 may remain near or at a full charge of electrical energy during this time, such that the electrical energy storage system 418 may have a capacity and self-discharge rate sufficient to retain electrical energy to move the locking members 412 after idle periods.

The idle periods may be up to one month during some drilling operations. The energy harvesting device 420, however, may not be the only source of electrical energy for the electrical energy storage system 418. The electrical energy storage system 418 may also include a connection to allow electrical communication with an auxiliary electrical energy source (not shown in FIG. 4). A connection in the electrical energy storage system 418 to an auxiliary electrical energy source may allow the electrical energy storage system 418 to remain at or near a full charge of electrical energy during idle periods. Similarly, a connection in the electrical energy storage system 418 to an auxiliary electrical energy source may allow the electrical energy storage system 418 to increase the amount of charge in the electrical energy storage system 418 without the energy harvesting device 420 generating electrical energy. This may enable an RCD in accordance with the present disclosure to have an electrical energy storage system 418 at or near a full charge at the start of drilling operations by charging the electrical energy storage system 418 prior to the assembly of the drilling system. The auxiliary electrical energy source may additionally or alternatively be used in the case of a failure of the electrical energy source.

The RCD 400 depicted in FIG. 4 is also an example of a device utilizing a plurality of locking members. In the embodiment shown in FIG. 4, the upper and lower locking members 412-1, 412-2 may each engage respective upper and lower housing shoulders 414-1, 414-2. As shown in FIG. 4, an upper locking member 412-1 may limit longitudinal movement of the inner member 404 relative to the outer member 402 in the upward direction. A lower locking member 412-2 may limit longitudinal movement of the inner member 404 relative to the outer member 402 in the downward direction. The upper and lower housing shoulders 414-1, 414-2 are shown in FIG. 4 as being proximate the respective ends of the bearing assembly housing 406. In other embodiments, the shoulder may be a recession in a side of the bearing assembly housing 406. The recession-style shoulder may be located at any point along the side of the bearing assembly housing 406. In another example, a locking member (such as locking member 112 shown in FIG. 1) may simply apply sufficient pressure against the outer surface of the inner member 404 to limit longitudinal movement of the inner member 404.

As shown in FIG. 4, the RCD 400 may include a communication module 428. The communication module 428 may be in electrical communication with the electrical energy storage system 418 and/or receive electrical energy therefrom, similarly to the actuators 416. The communication module 428 may also be in data communication with the actuators 416 and/or a control device 442 remotely located to the RCD 400. The control device 442 may be a laptop computer, a desktop computer, a handheld computer (such as a personal digital assistant, smartphone, tablet, etc.), a simple electrical switch, other control devices, or combinations thereof. The control device 442 may receive data from the communication module 428 regarding the status and/or condition of the RCD 400. Additionally or in the alternative, the control device 442 may communicate data to the communication module 428 to control the RCD 400. For example, in an embodiment, the control device 442 may send a command to the communication module 428 to actuate the actuators 416. A signal may then be sent from the communication module 428 to the actuators 416 via conductive wiring 426. In an embodiment, the communication module 428 may be in data communication with the control device via a wired data connection, a wireless data connection, or both.

A wireless connection may be any suitable wireless communication known in the art, such as a radio signal, wireless local area network (or Wi-Fi) connection, a cellular connection, a Bluetooth connection, a personal area network, or similar. A wireless connection may reduce or eliminate wire routing challenges, such as when the communication module 428 is underwater. However, wireless communication signals may be restricted depending on the drilling location, and a wired data connection may be used, as well. A wired data connection may also be of any suitable type known in the art, such as an electrical cable (coaxial cable, multicore cable, ribbon cable, twinax cable, twin-lead cable) or an optical cable, with any appropriate connection type, such as a BNC connector or RJ-45 connector. In a particular embodiment, the wired connection may include a Category 5, Category 5e, or Category 6 cable.

Referring again to FIG. 4, the communication module 428 may also communicate or store data from a measurement module 430. The measurement module 430 may be located in or on the outer member 402 and in communication with the annular space through which the drilling fluid may flow. The measurement module 430 may collect measurements of the drilling fluid in the annular space such as pressure, temperature, or other values that are pertinent to the operation of the drilling system. In some embodiments, the measurement module 430 may measure a characteristic of the drill string, the wellbore, the formation surrounding the wellbore, other characteristics, or combinations thereof.

As shown in FIG. 5, the energy harvesting device 520 may be connected to the lower portion of the RCD and include a turbine 526 disposed in the annular space around the periphery of the outer member 502. The turbine 526 may rotate due to the flow of drilling fluid 542 through the annular space before the flow is diverted out the outlet 544 of the RCD. The turbine 526 may convert the linear flow of the drilling fluid 542 to rotational movement that is similar to the movement of the mandrel 508 during drilling operations. The rotation of the turbine 526 may then generate electrical energy using rotor 522 and a stator 524 in a similar fashion as described in relation to the rotation of the mandrel 408 and rotor 422 and stator 424 in FIG. 4.

FIG. 6 depicts another embodiment of an RCD 600 having an energy harvesting device 620 in accordance with the present disclosure. The energy harvesting device 620 of FIG. 6 includes a rotor 622 and stator 624 including one or more magnetic fields and armatures, respectively, similar to those described in relation to FIG. 4. In an embodiment, the rotor 622 and stator 624 may be disposed inside the bearing assembly housing 606. Contained within the bearing assembly housing 606 is a bearing assembly 632 containing bearings 634, similar to the bearing assembly 432 and bearings 434 as described in relation to FIG. 4. The bearings 634 may provide longitudinal and lateral support to the mandrel 608, allowing the mandrel 108 to rotate with less resistance. The bearing assembly 632 may also contain a lubricating fluid contained within the bearing assembly housing 606 to cool and lubricate the bearings 434.

FIG. 7 depicts an embodiment of an RCD 700 having more than one electrical energy harvesting component and more than one energy storing components. Additional components may be used to safeguard for a failure of one component and allow the device to continue operation without leading to non-productive time on the drilling system. In an embodiment, the RCD 700 may include a plurality of energy harvesting devices 720. The energy harvesting devices 720 may be each in communication with the electrical energy storage system 718 in electrical parallel with one another. If, for example, one of the energy harvesting devices 720 were to fail (e.g. an electrical connection were to disconnect), the remaining energy harvesting device or devices 720 may continue to provide electrical energy to the electrical energy storage system 718 during operation.

In another embodiment, different types of energy harvesting devices, such as those depicted in FIGS. 4 and 5, may be employed to allow energy harvesting from multiple sources. For example, an energy harvesting device 420 may convert rotation of the mandrel 408 to electrical energy while another energy harvesting device 520 converts flow of the drilling fluid 542 through the annular space to electrical energy, as well. Such an embodiment may provide electrical energy to the electrical energy storage system 418, 518 when either the mandrel 408 rotates or drilling fluid 542 is pumped through the wellbore 16.

Similarly, the RCD 700 may include a plurality of electrical energy storage systems 718. The electrical energy storage systems 718 may also be in electrical parallel with one another. With the electrical energy storage systems 718 in parallel, a failure of one may not render the RCD 700 powerless and unable to provide electrical energy to operate the actuators 716 or the communication module 728. Additionally, an RCD 700 having a plurality of electrical energy storage systems 718 may enable the communication module 728 to provide a notification to the control device regarding any failures detected in the plurality of electrical energy storage systems 718 or the plurality of energy harvesting devices 720.

While the embodiments of RCDs have been primarily described with reference to wellbore drilling operations, the RCDs may be used in applications other than the drilling of a well. In other embodiments, RCDs according to the present disclosure may be used outside a well or other downhole environment used for the production of natural resources. For instance, an RCD of the present disclosure may be used in a borehole used for placement of utility lines. Accordingly, the term “wellbore” should not be interpreted to limit tools, systems, assemblies, or methods of the present disclosure to any particular industry or field.

The terms “approximately,” “about,” and “substantially” as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of a stated amount. Further, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, any references to “up” and “down” or “above” or “below” are merely descriptive of the relative position or movement of the related elements. Additionally, the terms “rotor” and “stator” are intended to describe components which rotate or otherwise move relative to one another. From the perspective of an outside reference frame, the stator may be rotationally stationary while the rotor rotates, the stator may rotate while the rotor remains rotationally stationary, or both the rotor and stator may rotate.

The present disclosure may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the disclosure is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

1. An apparatus comprising:

an inner member, at least part of the inner member configured to rotate about a longitudinal axis;

a locking member configured to move toward the longitudinal axis of the inner member and engage a shoulder of the inner member and thereby inhibit longitudinal movement of the inner member; and

an actuator configured to move the locking member, the actuator being configured to be actuated by an electrical power source.

2. The apparatus of claim 1, further comprising a communication device operatively associated with the actuator.

3. The apparatus of claim 2, wherein the communication device is selected from the group consisting of a wireless communication device and a wired communication device.

4. The apparatus of claim 1, wherein the actuator is electromechanical.

5. The rotating control device of claim 1, further comprising a plurality of locking members, the first locking member configured to engage a first shoulder of the inner member and the second locking member configured to engage a second shoulder of the inner member.

6. The apparatus of claim 1, further comprising an electrical energy storage system in electrical communication with the actuator and configured to provide electrical energy to the actuator.

7. An apparatus comprising:

an outer member;

an inner member disposed concentrically within the outer member, at least part of the inner member configured to rotate relative to the outer member, the inner member having a longitudinal axis;

an energy harvesting device configured to convert the relative rotation of the inner member and outer member to electrical energy;

an electrical energy storage system configured to store electrical energy from the energy harvesting device, the electrical energy storage system in electrical communication with the energy harvesting device;

a locking member configured to move toward the longitudinal axis of the inner member and engage a shoulder of the inner member and thereby inhibit longitudinal movement of the inner member relative to the outer member; and

an electromechanical actuator in electrical communication with the electrical energy storage system and configured to move the locking member.

9. The apparatus of claim 7, wherein the energy harvesting device comprises an electromechanical generator.

10. The apparatus of claim 7, further comprising magnets disposed on the at least part of the inner member configured to rotate relative to the outer member.

11. The apparatus of claim 7, wherein the electrical energy storage system comprises an auxiliary connection to provide electrical communication with an auxiliary electrical energy source.

12. The apparatus of claim 7, wherein the electromechanical actuator comprises a linear actuator.

13. The apparatus of claim 7, wherein the electromechanical actuator comprises a rotary actuator.

14. The apparatus of claim 7, wherein the electrical energy storage system is configured to store electrical energy sufficient to actuate the electromagnetic actuator after one month with electrical energy provided to the electrical energy storage system.

15. An apparatus comprising:

a cylindrical outer member;

a cylindrical inner member disposed concentrically within the cylindrical outer member and configured to rotate relative to the outer member, the cylindrical inner member having a longitudinal axis;

an energy harvesting device configured to convert the relative rotation of the cylindrical inner member and the cylindrical outer member to electrical energy;

an electrical energy storage system in electrical communication with the energy harvesting device;

a first locking member configured to move radially relative to the cylindrical outer member toward the longitudinal axis of the inner member and engage a first shoulder of the cylindrical inner member and thereby prevent longitudinal movement of the cylindrical inner member relative to the cylindrical outer member in a first direction;

a second locking member configured to move axially relative to the cylindrical outer member and engage a second shoulder of the cylindrical inner member and thereby prevent longitudinal movement of the cylindrical inner member relative to the cylindrical outer member in a second direction, the second direction opposing the first direction; and

an electromechanical actuator in electrical communication with the electrical energy storage system and configured to move at least the first locking member.

16. The apparatus of claim 15, further comprising a second electrical energy storage system in parallel electrical communication with the electrical energy storage system.

17. The apparatus of claim 15, further comprising a second energy harvesting device in parallel electrical communication with the energy harvesting device.

18. The apparatus of claim 15, wherein the first locking member is movable independently of the second locking member.

19. The apparatus of claim 15, further comprising a communication device in electrical communication with the electrical energy storage system.

20. The apparatus of claim 19, further comprising a data collection module in electrical communication with the electrical energy storage system and informational communication with the communication device,

wherein the data collection module is configured to collect wellbore data and the communication device is configured to transmit the wellbore data to a remote receiver.