SEAL ASSEMBLY FOR A ROTATING CONTROL DEVICE

Abstract

An insert assembly for a rotating control device (RCD) includes a seal element configured to form an annular seal about a tubular as the tubular rotates, moves axially, or both. The insert assembly also includes a support member positioned within the seal element, wherein the support member includes a shape memory alloy.

Description

This application claims priority to and the benefit of U.S. Patent Application Ser. No. 63/375,147, filed Sep. 9, 2022, which is incorporated by reference herein in its entirety.

BACKGROUND

This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

Natural resources have a profound effect on modern economies and societies. In order to meet the demand for such natural resources, numerous companies invest significant amounts of time and money in searching for, accessing, and extracting oil, natural gas, and other natural resources. Particularly, once a desired natural resource is discovered below the surface of the earth, drilling systems are often employed to access the desired natural resource. These drilling systems can be located onshore or offshore depending on the location of the desired natural resource. Such drilling systems may include a drilling fluid system configured to circulate drilling fluid into and out of a wellbore to facilitate drilling the wellbore.

BRIEF DESCRIPTION

A summary of certain embodiments disclosed herein is set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below.

In one embodiment, an insert assembly for a rotating control device (RCD) includes a seal element configured to form an annular seal about a tubular as the tubular rotates, moves axially, or both. The insert assembly also includes a support member positioned within the seal element, wherein the support member includes a shape memory alloy.

In one embodiment, a rotating control device (RCD) for a drilling system includes a housing that defines a center bore, an insert positioned in the housing, and a seal assembly supported by the insert and configured to form an annular seal about a tubular in the center bore. The seal assembly includes a seal element and a support member, and the support member includes a shape memory alloy.

In one embodiment, a drilling system includes a tubular configured to move axially and to rotate to drill a wellbore. The drilling system also includes a rotating control device (RCD) that includes a housing that defines a central bore, an insert positioned in the housing, and a seal element supported by the insert and configured to form an annular seal about the tubular to block a fluid flow from the wellbore to a platform. The RCD also includes a support member embedded in the seal element, wherein the support member includes a shape memory alloy.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying figures in which like characters represent like parts throughout the figures, wherein:

FIG. 1 is a schematic diagram of a drilling system, in accordance with an embodiment of the present disclosure;

FIG. 2 is a perspective view of a portion of a seal assembly for a rotating control device (RCD) that may be used in the drilling system of FIG. 1, in accordance with an embodiment of the present disclosure;

FIG. 3 is a schematic cross-sectional side view of a rotating control device (RCD) that may be used in the drilling system of FIG. 1, wherein a seal assembly of the RCD is in a first configuration, in accordance with an embodiment of the present disclosure;

FIG. 4 is a schematic cross-sectional side view of the RCD of FIG. 3, wherein the seal assembly of the RCD is in a second configuration, in accordance with an embodiment of the present disclosure;

FIG. 5 is a schematic cross-sectional side view of a rotating control device (RCD) that may be used in the drilling system of FIG. 1, wherein a fluid circuit is provided to drive the seal assembly relative to a housing of the RCD, in accordance with an embodiment of the present disclosure; and

FIG. 6 is a schematic cross-sectional side view of a rotating control device (RCD) that may be used in the drilling system of FIG. 1, wherein a seal assembly of the RCD is suspended from an insert of the RCD, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

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.

When introducing elements of various embodiments, the articles “a,” “an,” “the,” “said,” and the like, are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” “having,” and the like are intended to be inclusive and mean that there may be additional elements other than the listed elements. The use of “top,” “bottom,” “above,” “below,” and variations of these terms is made for convenience, but does not require any particular orientation of the components relative to some fixed reference, such as a direction of gravity.

A drilling system may include a drilling fluid system that is configured to circulate drilling fluid into and out of a wellbore to facilitate drilling the wellbore. For example, the drilling fluid system may provide a flow of the drilling fluid through a tubular (e.g., drill string) as the tubular rotates a drill bit that is positioned at a distal end portion of the tubular. The drilling fluid may exit through one or more openings at the distal end portion of the tubular and may return toward a platform of the drilling system via an annular space between the tubular and a casing that lines the wellbore.

In some cases, the drilling system may use managed pressure drilling (“MPD”). MPD regulates a pressure and a flow of the drilling fluid within the tubular so that the flow of the drilling fluid does not over pressurize a well (e.g., expand the well) and/or blocks the well from collapsing under its own weight. The ability to manage the pressure and the flow of the drilling fluid enables use of the drilling system to drill in various locations, such as locations with relatively softer sea beds.

Embodiments of the present disclosure relate generally to a rotating control device (RCD) with a seal assembly that is configured to seal against a tubular (e.g., drill string) that extends through the RCD. More particularly, the seal assembly may include a seal element (e.g., annular seal element) that is configured to contact the tubular to form an annular seal that extends circumferentially about the tubular. The seal assembly may also include a support structure (e.g., annular support structure) that is internal to the seal element (e.g., molded into the seal element). The seal element may be formed from an elastomer material, and the support structure may be formed from a shape memory alloy. For example, the shape memory alloy may include nickel and titanium (e.g., NiTi; nitinol). Further, the support structure may have any suitable shape or configuration, such as a mesh (e.g., woven or interlaced wires that form the mesh; wire mesh). The RCD may also include an insert (e.g., annular insert), which may be a rigid body that surrounds the seal assembly to provide support to the seal assembly.

In order to maintain the annular seal about the tubular as the tubular is tripped into a wellbore, the seal assembly may deform away from its original shape (e.g., increase its inner diameter) and relax toward its original shape (e.g., decrease its inner diameter), which induces stress in the elastomer material of the seal element. Advantageously, in the present embodiments, some of the stress is transferred to the support structure (e.g., the stress on the elastomer material of the seal element is reduced, as compared to other seal assemblies without the support structure). Further, the seal assembly may repeatedly deform and relax to varying degrees as different portions of the tubular (e.g., pipes with one diameter and radially expanded joints with another diameter, wherein the radially expanded joints form connections between adjacent pipes) move through the seal assembly. When the support structure is formed from the shape memory alloy, the support structure may fully deform and still be capable of fully relaxing to return to its original shape. Thus, when the support structure is formed from the shape memory alloy, the support structure may provide reliable, consistent, and long-lasting support to the elastomer material of the seal element. In this way, the seal assembly may have lower maintenance costs, longer life span, more reliable sealing, and so forth.

It should be appreciated that the annular seal formed between the seal assembly and the tubular extending through the RCD may block fluid flow through an annular space that surrounds the tubular. For example, the annular seal may block drilling fluid, cuttings, and/or natural resources (e.g., carbon dioxide, hydrogen sulfide) from passing across the RCD from the wellbore toward a platform. In some embodiments, the fluid flow may be diverted toward another suitable location (e.g., a collection tank) other than the platform. The RCD and its components (e.g., the seal assembly) may generally experience and be subjected to high pressure from the wellbore (e.g., below the RCD). In some environments and implementations (e.g., when located at or near a sea floor; at certain depths below a sea surface), the RCD and its components (e.g., the seal assembly) may also generally experience and be subjected to high pressure due to water depth (e.g., above the RCD). Accordingly, it is presently recognized that it may be desirable for the seal assembly to have certain geometric features (e.g., tapered surfaces; axially-facing surfaces; undulating surfaces) and/or other types of features, such as the support structure embedded within the seal element.

As noted herein, the seal assembly of the RCD may form the annular seal against the tubular as the tubular rotates and/or moves axially within the wellbore. In some embodiments, the RCD may include one or more bearings to facilitate rotation of the seal assembly of the RCD with the tubular as the tubular rotates and/or moves axially within the wellbore (e.g., the seal assembly of the RCD may be driven to rotate by the tubular). However, in some embodiments, the tubular may rotate or slip against the seal assembly as the tubular rotates and/or moves axially within the wellbore. Further, the RCD may be passive without external actuators and/or external forces that drive the seal assembly toward the tubular. However, the seal assembly may be active with external actuators and/or external forces that drive the seal assembly toward the tubular. Indeed, it should be appreciated that the seal assembly with the support structure embedded in the seal element may be used in combination with any of a variety of other features.

FIG. 1 is a schematic diagram that illustrates an embodiment of a drilling system 10 that is configured to carry out drilling operations. The drilling system 10 may be a subsea system, although the disclosed embodiments may be used in a land-based (e.g., surface) system. The drilling system 10 may use MPD techniques. As illustrated, the drilling system 10 includes a wellhead assembly 12 coupled to a mineral deposit 14 via a well 16 having a wellbore 18.

The wellhead assembly 12 may include or be coupled to multiple components that control and regulate activities and conditions associated with the well 16. For example, the wellhead assembly 12 generally includes or is coupled to pipes, bodies, valves, and seals that enable drilling of the well 16, route produced minerals from the mineral deposit 14, provide for regulating pressure in the well 16, and provide for the injection of drilling fluids into the wellbore 18. A conductor 22 may provide structure for the wellbore 18 and may block collapse of the sides of the well 16 into the wellbore 18. A casing 24 may be disposed within the conductor 22. The casing 24 may provide structure for the wellbore 18 and may facilitate control of fluid and pressure during drilling of the well 16. The wellhead assembly 12 may include a tubing spool, a casing spool, and a hanger (e.g., a tubing hanger or a casing hanger) to enable installation of the casing 24. As shown, the wellhead assembly 12 may include or be coupled to a blowout preventer (BOP) assembly 26, which may include one or more BOPs (e.g., one or more ram BOPs, one or more annular BOPs, or a combination thereof). For example, the BOP assembly 26 shown in FIG. 1 includes a ram BOP having moveable rams 28 configured to seal the wellbore 18.

A drilling riser 30 may extend between the BOP assembly 26 and a platform 32. The platform 32 may include various components that facilitate operation of the drilling system 10, such as pumps, tanks, and power equipment. The platform 32 may also include a derrick 34 that supports a tubular 36 (e.g., drill string), which may extend through the drilling riser 30. A drilling fluid system 38 may direct the drilling fluid into the tubular 36, and the drilling fluid may exit through one or more openings at a distal end portion 40 of the tubular 36 and may return (along with cuttings and/or other substances from the well 16) toward the platform 32 via an annular space (e.g., between the tubular 36 and the casing 24 that lines the wellbore 18; between the tubular 36 and the drilling riser 30). A drill bit 42 may be positioned at the distal end portion 40 of the tubular 36. The tubular 36 may rotate within the drilling riser 30 to rotate the drill bit 42, thereby enabling the drill bit 42 to drill and form the well 16.

As shown, the drilling system 10 may include a rotating control device (RCD) 44 that is configured to block fluid flow through the annular space that surrounds the tubular 36. For example, the RCD 44 may be configured to block the drilling fluid, cuttings, and/or other substances from passing across the RCD 44 from the well 16 toward the platform 32. The RCD 44 may be positioned at any suitable location within the drilling system 10, such as any suitable location between the wellbore 18 and the platform 32. For example, as shown, the RCD 44 may be positioned along the drilling riser 30 (e.g., in-line with the drilling riser 30) and between the BOP assembly 26 and the platform 32. In some embodiments, the RCD 44 may be positioned at or near a sea floor, such as closer to the sea floor than a sea surface, mounted or fastened to the BOP assembly 26 or other portion of the wellhead assembly 12, or other suitable location.

The RCD 44 and its components may be described with reference to the axial axis 2 (or axial direction), a radial axis 4 (or radial direction), and a circumferential axis 6 (or direction) to facilitate discussion. In operation, the tubular 36 may be rotated in the circumferential direction 6 and/or may be moved along the axial axis 2 to enable the drill bit 42 to drill the well 16. The RCD 44 and its components may provide the annular seal even as the tubular 36 is rotated in the circumferential direction 6 and/or moved along the axial axis 2.

FIG. 2 is a perspective view of an embodiment of a portion of a seal assembly 50 (e.g., annular seal assembly) that may be used in the RCD of FIG. 1. As shown, the seal assembly 50 includes a seal element 52 (e.g., annular seal element) and a support structure 54 (e.g., annular support structure). Further, an insert 56 (e.g., annular insert or rigid body) is positioned to circumferentially surround the seal assembly 50 to provide support to the seal assembly 50. Together, the seal assembly 50 and the insert 56 may form an insert assembly. As shown, the insert 56 includes tabs 60 (e.g., annular tabs) configured to engage corresponding tabs 62 (e.g., annular tabs) of the seal element 52. In this way, the tabs 60 and the corresponding tabs 62 form a key-slot interface. It should be appreciated that the tabs 60 and the corresponding tabs 62 may have any suitable configuration, cross-sectional shape, and/or other features that operate to effectively couple the seal element 52 to the insert 56. Further, any suitable fastener (e.g., adhesive; threaded fasteners, such as bolts) and/or techniques (e.g., interference fit, friction fit) may be utilized to effectively couple the seal element 52 to the insert 56.

The seal element 52 extends along the axial axis 2 from a first end 64 to a second end 66. Additionally, the seal element includes a radially outer surface 58 (e.g., annular surface) that is configured to face away from the tubular when the tubular extends through the RCD and a radially inner surface 68 (e.g., annular surface) that is configured to face toward the tubular when the tubular extends through the RCD. Further, at least portions of the radially inner surface 68 are configured to contact and seal against the tubular when the tubular extends through the RCD. The radially inner surface 68 may have a wavy or undulating cross-sectional shape (e.g., peaks and valleys) that creates varying inner diameters along a length of the seal element 52 (e.g., between the first end 64 and the second end 66) at least while the seal assembly 50 is in a first configuration (e.g., an original, initial, or relaxed state; when not sealed against the tubular).

As shown, the support structure 54 is embedded within the seal element 52 (e.g., positioned between the radially outer surface 58 and the radially inner surface 68 along the radial axis 4; covered by the seal element 52; molded into the seal element 52). The seal element 52 may be formed from an elastomer material, and the support structure 54 may be formed from a shape memory alloy. For example, the shape memory alloy may include nickel and titanium (e.g., NiTi; nitinol). As shown in FIG. 2, the support structure 54 is a mesh (e.g., woven or interlaced wires that form the mesh; wire mesh); however, the support structure 54 may have any suitable shape or configuration.

Further, as shown in FIG. 2, the support structure 54 extends along the axial axis 2 from a first end 70 to a second end 72. Additionally, the support structure 54 may be formed into a sheet (e.g., mesh sheet) with a wavy or undulating cross-sectional shape (e.g., peaks and valleys) that creates varying inner diameters along a length of the support structure 54 (e.g., between the first end 70 and the second end 72) at least while the seal assembly 50 is in the first configuration. Thus, as shown in FIG. 2, respective profiles or cross-sectional shapes of the radially inner surface 68 of the seal element 52 and the support structure 54 may correspond to one another (e.g., match) at least while the seal assembly 50 is in the first configuration. For example, a distance 74 (e.g., normal distance) between the radially inner surface 68 of the seal element 52 and the support structure 54 is generally constant along most or all of the respective lengths of the seal element 52 and the support structure 54, such as along at least 50, 70, 80, 90, or 95 percent of the respective lengths while the seal assembly 50 is in the first configuration. In some cases, the distance 74 is generally constant except proximate to the second end 66, where the distance 74 increases as the support structure 54 extends radially outwardly while the seal element 52 extends generally axially. It should be appreciated that numerous variations are envisioned. For example, the support structure 54 may include multiple sheets (e.g., mesh sheets) stacked along the radial axis 4, the distance 74 may vary along the respective lengths of the seal element 52 and the support structure 54, the respective profiles or cross-sectional shapes may include fewer or more peaks and valleys (e.g., 2, 3, 4, 5, 6, 7, or more), and so forth.

Certain features of the respective profiles or cross-sectional shapes shown in FIG. 2 may facilitate effective, reliable sealing between the seal assembly 50 and the tubular, as well as return of the seal assembly 50 to the first configuration (e.g., from a second configuration or a deformed state; when sealed against the tubular), particularly in certain environments with high pressure both below and above the seal assembly 50. For example, the radially inner surface 68 of the seal element 52 may include multiple surfaces (e.g., annular surfaces), such as an upper tapered surface 80 (e.g., extends radially inwardly from the first end 64 of the seal element 52), a first axially-extending surface 82, an intermediate tapered surface 84 (e.g., extends radially outwardly from the first axially-extending surface 82), a second axially-extending surface 86, a lower tapered surface 88 (e.g., extends radially inwardly from the second axially-extending surface 86), and/or a third axially-extending surface 90. In some embodiments, the seal element 52 includes the lower axially-facing surface 92 (e.g., annular surface). In some embodiments, the upper tapered surface 80 and the lower axially-facing surface 92 may be sized (e.g., surface area) to balance or otherwise provide desirable forces across the seal assembly 50 due to the high pressure both below and above the seal assembly 50. Further, the respective wavy or undulating cross-sectional shapes of the seal element 52 and the support structure 54 may facilitate return of the seal assembly 50 from the second configuration (e.g., the deformed state) to the first configuration (e.g., the original state). For example, in operation, the seal element 52 and the support structure 54 deform as the seal assembly 50 seals against the tubular. Then, the support structure 54 may return to its original state, as well as drive or assist the seal element 52 to return to or at least toward its original state, once the tubular is removed from the RCD (or once the seal assembly 50 otherwise disengages from the tubular).

FIG. 3 is a schematic cross-sectional side view of an embodiment of the RCD 44, wherein the seal assembly 50 of the RCD 44 is in the first configuration (e.g., the original state). FIG. 4 is a schematic cross-sectional side view of an embodiment of the RCD 44, wherein the seal assembly 50 of the RCD 44 is in the second configuration (e.g., the deformed state). For image clarity and to simplify discussion, FIGS. 3 and 4 are merely schematic so as to generally represent that at least some changes (e.g., deformation) occur between the first configuration (FIG. 3) and the second configuration (FIG. 4) of the seal assembly 50. Indeed, the seal element 52 and the support structure 54 may not deform to have a generally vertical or straight line in the cross-section as shown, but this is intended to generally represent that the support structure 54 will deform in some way. For example, in some embodiments, the profiles or the cross-sectional shapes of the seal element 52 and the support structure 54 may include more variation in the peaks and valleys (e.g., in the inner diameter) in the first configuration as compared to the second configuration. However, it should be appreciated the seal assembly 50 and its components may demonstrate any of a variety of profiles or cross-sectional shapes in the first configuration and the second configuration.

As shown, the RCD 44 includes a housing 100 (e.g., annular housing) that defines a center bore 102 and a cavity 104 (e.g., annular cavity). The seal assembly 50 and the insert 56 are positioned within the cavity 104 of the housing 100. As described herein, the seal assembly 50 may be an annular assembly that wraps circumferentially around the center bore 102. However, the seal assembly 50 or portions thereof (e.g., the seal element 52 and/or the support structure 54) may include multiple separate segments (e.g., that extend about a half, a quarter, or an eighth of a circumference of the center bore 102 at least while the seal assembly 50 is in the second configuration to form the annular seal against the tubular 36. Similarly, the insert 56 may be annular to wrap circumferentially around the seal assembly 50.

In operation, the tubular 36 may be inserted into the center bore 102. Because the seal assembly 50 protrudes into the center bore 102 and/or because the inner diameter of the seal assembly 50 is less than an outer diameter of the tubular 36, the seal assembly 50 contacts and engages with the tubular 36. Further, the contact between the seal assembly 50 and the tubular 36 may cause the seal assembly 50 to form the annular seal about the tubular 36 and may cause the seal assembly 50 to change from the first configuration to the second configuration.

During drilling operations, the tubular 36 may rotate in the circumferential direction 6 and/or move along the axial axis 2. In some embodiments, the seal assembly 50 is supported on bearing 110 (e.g., bearing ring; annular bearing; cylindrical bearing) to rotate with the tubular 36 (e.g., the rotation of the tubular 36 drives the rotation of the seal assembly 50). Thus, the rotation of the tubular 36 may drive the rotation of the seal assembly 50 and/or the insert 56 relative to the housing 100 (e.g., facilitated by the bearing 110). In this way, the tubular 36 may not slip or rotate relative to the seal element 52, which may reduce wear on the seal element 52. In FIGS. 3 and 4, the bearing 110 is positioned between the insert 56 and the housing 100 along the radial axis 4; however, the bearing 110 may be positioned at any suitable location to enable the rotation of the tubular 36 to drive the rotation of the seal assembly 50.

As noted herein, the seal assembly 50 with the support structure 54 embedded in the seal element 52 may be used in combination with any of a variety of other features. For example, the seal assembly 50 may be used in combination with other features that enable the tubular 36 to rotate or slip against the seal assembly 50 as the tubular 36 rotates and/or moves axially through the RCD 44. Further, in FIGS. 3 and 4, the RCD 44 and the annular seal formed by the seal assembly 50 may be passive without external actuators and/or external forces that drive the seal assembly 50 toward the tubular 36. However, the RCD 44 and the annular seal formed by the seal assembly 50 may be active with external actuators and/or external forces that drive the seal assembly 50 toward the tubular 36.

With the forgoing in mind, FIG. 5 is a schematic cross-sectional side view of an embodiment of the RCD 44, wherein a fluid circuit 120 is provided to drive the seal assembly 50 of the RCD 44 toward the tubular 36. To facilitate discussion, a first portion of FIG. 5 on a first side (e.g., right side) of an axis 122 is in the first configuration (e.g., original state) and a second portion of FIG. 5 on a second side (e.g., left side) of the axis 122 is in the second configuration (e.g., deformed state). For image clarity and to simplify discussion, FIG. 5 is merely schematic so as to generally represent that at least some changes (e.g., deformation) occur between the first configuration and the second configuration of the seal assembly 50. Indeed, the seal element 52 and the support structure 54 may not deform to a generally vertical or straight line in the cross-section as shown, but this is intended to generally represent that the support structure 54 will deform in some way. For example, the profiles or the cross-sectional shapes of the seal element 52 and the support structure 54 may deform to include more variation in the peaks and valleys (e.g., in the inner diameter) in the first configuration as compared to the second configuration. However, it should be appreciated the seal assembly 50 and its components may demonstrate any of a variety of profiles or cross-sectional shapes in the first configuration and the second configuration.

In some embodiments, the RCD 44 may include or be coupled to the fluid circuit 120 that enables circulation of a fluid through a chamber 130 (e.g., annular sealed chamber). The chamber 130 may be located between the seal assembly 50 and the housing 100. In FIG. 5, the chamber 130 is more particularly defined between the radially outer surface 58 of the seal assembly 50 and a surface(s) 128 of the insert 56. The fluid circuit 120 may include a fluid source 132 and a fluid drain 134. A controller 136 may control a first valve 138 to enable flow from the fluid source 132 to the chamber 130 and/or may control a second valve 140 to enable flow from the chamber 130 to the fluid drain 134. It should be appreciated that the fluid source 132 and the fluid drain 134 may be the same fluid tank and/or may be otherwise fluidly coupled to one another. The circulation of the fluid through the chamber 130 may adjust a position of the seal assembly 50 relative to the housing 100 (and the tubular 36, when the tubular 36 is within the housing 100). The valves 138, 140 may be controlled in a coordinated manner, such as to effectuate a change in a volume of the fluid within the chamber 130, to thereby change a volume of the chamber 130 to drive the seal assembly 50 radially relative to the housing 100 (and the tubular 36, when the tubular 36 is within the housing 100).

The controller 136 may control the delivery of the fluid from the fluid source 132 to the chamber 130 based on any of a variety of inputs, such as in response to an input received from a user interface device at the platform (e.g., from an operator) and/or in response to an input received from one or more sensors, such as one or more sensors that monitor one or more parameters indicative of the annular seal formed between the seal assembly 50 and the tubular 36, wellbore conditions, rotation of the tubular 36, or the like. For example, the controller 136 may receive an input that indicates an undesirable pressure below the RCD 44 (e.g., between the wellhead and the RCD 44) and/or above the RCD 44 (e.g., between the platform and the RCD 44) and may then adjust (e.g., increase) the fluid pressure in the chamber 130 to form and/or adjust (e.g., increase) the annular seal (e.g., sealing force; radial force) between the seal assembly 50 and the tubular 36. As another example, the controller 136 may receive an input that indicates that the tubular 36 will begin to move or is moving within the RCD 44 (e.g., rotating and/or moving in the axial direction 2), and the controller 136 may then adjust (e.g., increase or decrease) the fluid pressure in the chamber 130 to thereby form and/or adjust (e.g., increase or decrease) the annular seal between the seal assembly 50 and the tubular 36. In this way, the RCD 44 may provide an adjustable and dynamic seal about the tubular 36 (e.g., as the tubular 36 rotates and/or moves in the axial direction 2 through the RCD 44).

As shown in FIG. 5, the controller 136 includes a processor 142 and a memory device 144. It should be appreciated that the controller 136 may be a dedicated controller for the RCD 44 and/or the controller 136 may be part of or include a distributed controller with one or more electronic controllers in communication with one another to carry out the various techniques disclosed herein. The processor 142 may also include one or more processors configured to execute software, such as software for processing signals and/or controlling the components of the RCD 44. The memory device 144 disclosed herein may include one or more memory devices (e.g., a volatile memory, such as random access memory [RAM], and/or a nonvolatile memory, such as read-only memory [ROM]) that may store a variety of information and may be used for various purposes. For example, the memory device 144 may store processor-executable instructions (e.g., firmware or software) for the processor 142 to execute, such as instructions for processing signals and/or controlling the components of the RCD 44. It should be appreciated that the controller 136 may include various other components, such as a communication device that is capable of communicating data or other information (e.g., a current configuration of the RCD 44) to various other devices (e.g., a remote computing system or display system at the platform).

As noted herein, the seal assembly 50 with the support structure 54 embedded in the seal element 52 may have any of a variety of profiles or cross-sectional shapes. As one additional example to facilitate discussion, FIG. 6 is a schematic cross-sectional side view of an embodiment of the RCD 44, wherein a seal assembly 150 (e.g., annular seal assembly) of the RCD 44 is suspended from an insert 156 (e.g., annular insert) of the RCD 44. For image clarity and to simplify discussion, FIG. 6 is merely schematic so as to generally represent the seal assembly 150 in a second configuration (e.g., deformed state).

As shown, the seal assembly 150 includes a seal element 152 (e.g., annular seal element) and a support structure 154 (e.g., annular support structure). The seal assembly 150 may be suspended from the insert 156, such as via corresponding tabs (e.g., key-slot interface) or other suitable fastener (e.g., adhesive; threaded fastener(s), such as bolt(s)). The seal element 152 includes a radially inner surface 158 (e.g., annular surface) that is configured to contact and form an annular seal about the tubular 36 when the tubular 36 extends through the RCD 44. The radially inner surface 158 and/or other surfaces of the seal element 152 may have a wavy or undulating cross-sectional shape (e.g., peaks and valleys) that creates varying inner diameters at least while the seal assembly 150 is in a first configuration (e.g., original, initial, or relaxed state; when not sealed against the tubular 36).

As shown, the support structure 154 is embedded within the seal element 152 (e.g., covered by the seal element 152). The seal element 152 may be formed from an elastomer material, and the support structure 154 may be formed from a shape memory alloy. For example, the shape memory alloy may include nickel and titanium (e.g., NiTi; nitinol). The support structure 154 may be a mesh (e.g., woven or interlaced wires that form the mesh; wire mesh); however, the support structure 154 may have any suitable shape or configuration. The support structure 154 may be formed into a sheet (e.g., mesh sheet) with a wavy or undulating cross-sectional shape (e.g., peaks and valleys) that creates varying inner diameters at least while the seal assembly 150 is in the first configuration.

It should be appreciated that the various elements shown and described with reference to FIGS. 2-6 may be combined in any suitable manner. For example, the bearing 110 shown in FIGS. 3 and 4 may be used with the chamber 130 shown in FIG. 5. In such cases, the bearing 110 may be positioned radially between the insert 56 and the housing 100 (e.g., radially between a radially outer surface of the insert 56 and a radially inner surface of the housing 100) and/or a rotary union assembly may be provided to enable a flow of the fluid into the chamber 130 in conjunction with rotation of the seal assembly 50, the chamber 130, and the insert 56 relative to the housing 100.

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 intended to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the following appended claims.

Claims

1. An insert assembly for a rotating control device (RCD), the insert assembly comprising:

a seal element configured to form an annular seal about a tubular as the tubular rotates, moves axially, or both; and

a support member positioned within the seal element, wherein the support member comprises a shape memory alloy.

2. The insert assembly of claim 1, wherein the seal element comprises an elastomer.

3. The insert assembly of claim 2, wherein the support member is molded into the seal element.

4. The insert assembly of claim 1, wherein the support member comprises a wire mesh.

5. The insert assembly of claim 1, wherein the shape memory alloy comprises nitinol.

6. The insert assembly of claim 1, wherein the seal element and the support member are annular.

7. The insert assembly of claim 1, comprising a rigid insert that circumferentially surrounds the seal element.

8. The insert assembly of claim 1, wherein the seal element comprises a radially inner surface with a wavy cross-sectional profile.

9. The insert assembly of claim 1, wherein the support member comprises a wavy cross-sectional profile.

10. The insert assembly of claim 1, wherein a radially inner surface of the seal element comprises tapered portions that taper relative to an axial axis and axially extending portions that extend along the axial axis.

11. The insert assembly of claim 1, wherein an upper surface of the seal element tapers relative to an axial axis, and a lower surface of the seal element faces the axial axis.

12. The insert assembly of claim 1, comprising bearings configured to facilitate rotation of the insert assembly relative to a housing of the RCD.

13. A rotating control device (RCD) for a drilling system, the RCD comprising:

a housing that defines a center bore;

an insert positioned in the housing; and

a seal assembly supported by the insert and configured to form an annular seal about a tubular in the center bore, wherein the seal assembly comprises a seal element and a support member, and the support member comprises a shape memory alloy.

14. The RCD of claim 13, wherein the seal element comprises an elastomer.

15. The RCD of claim 13, wherein the support member comprises a wire mesh.

16. The RCD of claim 13, wherein the shape memory alloy comprises nitinol.

17. The RCD of claim 13, wherein the support member comprises a wavy cross-sectional profile.

18. The RCD of claim 13, comprising bearings configured to facilitate rotation of the insert and the seal assembly relative to the housing.

19. A drilling system, comprising:

a tubular configured to move axially and to rotate to drill a wellbore; and

a rotating control device (RCD), comprising: a housing that defines a central bore; an insert positioned in the housing; a seal element supported by the insert and configured to form an annular seal about the tubular to block a fluid flow from the wellbore to a platform; and a support member embedded in the seal element, wherein the support member comprises a shape memory alloy.

20. The drilling system of claim 19, wherein the support member comprises a wire mesh.