U.S. patent application number 13/247421 was filed with the patent office on 2013-03-28 for electrical generator for a cementing manifold.
The applicant listed for this patent is Paul Green, Russell Lewis, Richard David Peer, Lap Tan Tran. Invention is credited to Paul Green, Russell Lewis, Richard David Peer, Lap Tan Tran.
Application Number | 20130075106 13/247421 |
Document ID | / |
Family ID | 47909977 |
Filed Date | 2013-03-28 |
United States Patent
Application |
20130075106 |
Kind Code |
A1 |
Tran; Lap Tan ; et
al. |
March 28, 2013 |
ELECTRICAL GENERATOR FOR A CEMENTING MANIFOLD
Abstract
Apparatuses and methods comprising a cementing head comprising a
stationary body comprising a toothed ring; a rotating body disposed
below the stationary body, the rotating body comprising an armature
disposed inside the toothed ring; a battery disposed on the
rotating body; and a wire connected to the armature and the
battery.
Inventors: |
Tran; Lap Tan; (Houston,
TX) ; Peer; Richard David; (Katy, TX) ; Lewis;
Russell; (Humble, TX) ; Green; Paul; (Spring,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Tran; Lap Tan
Peer; Richard David
Lewis; Russell
Green; Paul |
Houston
Katy
Humble
Spring |
TX
TX
TX
TX |
US
US
US
US |
|
|
Family ID: |
47909977 |
Appl. No.: |
13/247421 |
Filed: |
September 28, 2011 |
Current U.S.
Class: |
166/373 ;
166/66.4 |
Current CPC
Class: |
E21B 33/05 20130101;
E21B 41/0085 20130101 |
Class at
Publication: |
166/373 ;
166/66.4 |
International
Class: |
E21B 34/06 20060101
E21B034/06; E21B 43/10 20060101 E21B043/10 |
Claims
1. A cementing head comprising: a stationary body comprising a
toothed ring; a rotating body disposed below the stationary body,
the rotating body comprising an armature disposed inside the
toothed ring; a battery disposed on the rotating body; and a wire
connected to the armature and the battery.
2. The cementing head of claim 1, further comprising at least one
torque converter disposed on the rotating body.
3. The cementing head of claim 2, wherein the torque converter is
electrically connected to the battery.
4. The cementing head of claim 2, wherein the torque converter is
electrically connected to the armature.
5. The cementing head of claim 2, wherein the torque converter is
electrically connected to the battery and the armature.
6. The cementing head of claim 1, further comprising a swivel
disposed on the armature, wherein the wire is connected to the
swivel.
7. The cementing head of claim 1, further comprising a heat jacket
disposed over the battery.
8. The cementing head of claim 1, further comprising a radio
frequency receiver/transceiver disposed on the rotating body.
9. The cementing head of claim 1, wherein the toothed ring
comprises a plurality of magnets.
10. The cementing head of claim 6, wherein the armature comprises a
coil of wire.
11. A cementing head comprising: a stationary body comprising an
armature; a rotating body disposed at least partially inside the
armature; a battery disposed on the rotating body; and a wire
connected to the armature and the battery.
12. The cementing head of claim 11, further comprising at least one
torque converter disposed on the rotating body.
13. The cementing head of claim 12, wherein the torque converter is
electrically connected to the battery.
14. The cementing head of claim 12, wherein the torque converter is
electrically connected to the armature.
15. The cementing head of claim 12, wherein the torque converter is
electrically connected to the battery and the armature.
16. The cementing head of claim 11, further comprising a heat
jacket disposed over the battery.
17. The cementing head of claim 11, further comprising a radio
frequency receiver/transceiver disposed on the rotating body.
18. The cementing head of claim 11, wherein the rotating body
comprises a plurality of magnets.
19. A method of generating electrical power, the method comprising:
disposing a cementing head on a well head, the cementing head
comprising a rotating body, an armature, a stationary body, and a
battery; actuating the rotating body; generating an electrical
voltage in the armature; and transferring the electrical voltage
from the armature to the battery.
20. The method of claim 19, further comprising: transferring the
electrical voltage to a torque converter; and actuating a cementing
valve on the cementing head.
Description
BACKGROUND
[0001] 1. Field
[0002] Embodiments disclosed herein relate to a cementing head for
generating electrical power. More specifically, embodiments
disclosed herein relate to apparatuses and methods for generating
electrical power to actuate valves on cementing heads.
[0003] 2. Background ART
[0004] A well-known method of drilling hydrocarbon wells involves
disposing a drill bit at the end of a drill string and rotating the
drill string from the surface utilizing either a top drive unit or
a rotary table set in the drilling rig floor. As the well is
formed, it is desirable to line the well bore. Thus, as drilling
continues, progressively smaller diameter tubulars comprising
casing and/or liner strings may be installed end-to-end to line the
drilled borehole. As the well is drilled deeper, each string is run
through and secured to the lower end of the previous string to line
the borehole wall. The string is then cemented into place by
flowing cement down the flowbore of the string and up the annulus
formed by the string and the borehole wall.
[0005] To conduct the cementing operation, typically a cementing
manifold is disposed between the top drive unit or rotary table and
the drill string. Due to its position in the drilling assembly, the
cementing manifold must suspend the weight of the drill pipe,
contain pressure, transmit torque, and allow unimpeded rotation of
the drill string. When utilizing a top drive unit, a separate inlet
is typically provided to connect the cement lines to the cementing
manifold. This allows cement to be discharged through the cementing
manifold into the drill string without flowing through the top
drive unit.
[0006] In operation, the cementing manifold allows fluids, such as
drilling mud or cement, to flow there through while simultaneously
enclosing and protecting from that flow, a series of projectiles,
e.g., darts and spheres that are released on demand and in sequence
to perform various operations downhole. Thus, as fluid flows
through the cementing manifold, the darts and/or spheres are
isolated from the fluid flow until they are ready for release.
[0007] Conventional cementing manifolds are available in a variety
of configurations, with the most common configuration including a
single sphere/single dart manifold. Using such a device, the sphere
is dropped at a predetermined time during drilling to perform a
particular function. For example, a sphere may be dropped to form a
temporary seal or closure of the flowbore of the drill string or to
actuate a downhole tool, such as a liner hanger, in advance of the
cementing operation. Once the cement has been pumped downhole, the
dart is dropped to perform another operation, such as wiping cement
from the inner wall of a string of downhole tubular members.
[0008] Another common cementing manifold employs a single
sphere/double dart configuration. The sphere may be released to
actuate a downhole tool, for example, followed by the first dart
being launched immediately ahead of the cement, and the second dart
being launched immediately following the cement. Thus, the dual
darts cap the "ends" of the cement and prevent the cement from
mixing with drilling fluid as the cement is pumped downhole through
the drill string. Each dart typically also performs another
operation upon reaching the bottom of the drill string, such as
latching into a larger dart to wipe cement from the string of
downhole tubular members.
[0009] Whether the cementing manifold includes a single
sphere/single dart or single sphere/double dart configuration,
there are operational characteristics common to both. Loading and
certification of the cementing manifold is not performed at the
drill site. Instead, the sphere and dart(s) are typically loaded
into the cementing manifold, with the customer present to verify
the loading procedure, prior to transporting the cementing manifold
to the drill site. Also, the majority of cementing jobs require a
single sphere and at most two darts. Thus, a cementing manifold
with a single sphere/single dart or single sphere/double dart
configuration is sufficient for most cementing jobs.
[0010] Usually, two loaded cementing manifolds, including one for
backup purposes, are then transported to the drilling rig. Prior to
conducting a cementing job, rotation of the drill string is
interrupted so that a loaded cementing manifold may be installed
between the cementing swivel and drill string. In some
configurations, the cementing manifold weighs several thousand
pounds and may be 13 feet in length. Thus, given the weight and
size of the cementing manifold, lifting it into position, which may
be 20-30 feet above the rig floor, raises concerns for the safety
of rig personnel. Therefore, it is desirable to reduce the size and
weight of the cementing manifold so that installation of the
cementing manifold may be both safer and easier.
[0011] Once the cementing manifold is installed, rotation of the
drill string may resume, at least until the cementing operation
begins. As previously stated, a sphere and dart(s) are released to
perform various tasks at different stages of a cementing operation.
During most cementing operations, actuation of valves to release
the sphere and darts is performed manually by rig personnel.
Rotation of the drilling string is again interrupted to allow rig
personnel to traverse the thirty or so feet above the rig floor to
the cementing manifold and manually actuate valves on the cementing
manifold to release the sphere and darts, this too raises safety
concerns. For this reason, some cementing manifolds may now be
actuated to release the sphere and darts via remote control from
the rig floor. Remote control actuation also allows rotation of the
drill string to continue uninterrupted because rig personnel remain
on the rig floor, a safe distance from the rotating equipment.
[0012] Verification that the sphere or dart has been released from
the cementing manifold is performed by visual inspection. In the
case of manual actuation, as the sphere or dart exits the cementing
manifold, a flag on the cementing manifold is triggered. While this
flag is designed to be visible from the rig floor, resetting the
flag requires rig personnel to ascend the rig to manually reset the
flag, there again raising safety concerns. In the case of remote
control actuation, instead of a triggered flag, rig personnel view
an indicating device that changes orientation on the cementing
manifold when a sphere or dart has been released. However, the
indicator is often shrouded within a plate assembly, requiring the
rotating speed of the drill string be reduced so that rig personnel
can clearly see the indicator orientation from the rig floor.
[0013] Thus, at the minimum, releasing a sphere or dart and
verifying that release requires slowing the rotation of the drill
string. Further, such release and verification frequently requires
rig personnel to ascend the rig to the cementing manifold, raising
concerns for the safety of rig personnel. Therefore, it would be an
improvement to remotely actuate and remotely verify the release of
spheres and darts from the cementing manifold, including resetting
any involved devices prior to subsequent releases, without either
the need to reduce the rotation speed of the drill string or for
rig personnel to position themselves in proximity of the cementing
manifold.
[0014] During multiple phase cementing operations, a pressure
driven device is typically used to sequentially control the
cementing head. Each time a pressurized medium is applied to the
cementing head a cylinder turns a cam shaft to a predetermined
angle, which passes the pressurized medium to a selective actuator
and the actuator activates an associated valve on the cementing
head. This operation may be repeated until all of the valves are
activated and the shaft returns to its original position. In order
to pressure drive the valves, a pressure chamber is mounted on the
cementing head and is recharged with high pressure from one
cementing operation to the next. The pressure chamber is typically
large in size and requires assembly/disassembly between cementing
jobs.
[0015] Once the cementing operation is complete, the cementing
manifold may be empty. Typically, the cementing manifold is not
reloaded and recertified on the drilling rig. Rather the empty
manifold is removed from the drill string and stored on the
drilling rig until it can be transported back to the service base
for reloading and recertification.
[0016] Despite the valuable contributions in the art, it would be
desirable to have apparatuses and methods for remotely actuating
cementing manifolds.
SUMMARY
[0017] In one aspect, embodiments disclosed herein relate to a
cementing head comprising a stationary body comprising a toothed
ring; a rotating body disposed below the stationary body, the
rotating body comprising an armature disposed inside the toothed
ring; a battery disposed on the rotating body; and a wire connected
to the armature and the battery.
[0018] In a further aspect, embodiments aim at a cementing head
comprising a stationary body comprising an armature; a rotating
body disposed at least partially inside the armature; a battery
disposed on the rotating body; and a wire connected to the armature
and the battery.
[0019] In yet a further aspect, embodiments pertain to methods of
generating electrical power, the method comprising disposing a
cementing head on a well head, the cementing head comprising a
rotating body, an armature, a stationary body, and a battery;
actuating the rotating body; generating an electrical voltage in
the armature; and transferring the electrical voltage from the
armature to the battery.
[0020] Other aspects and advantages will be apparent from the
following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
[0021] FIG. 1 is a schematic of a cementing operation according to
embodiments of the present disclosure.
[0022] FIG. 2 is a side view of a cementing manifold according to
embodiments of the present disclosure.
[0023] FIG. 3 is a side view of a cementing head according to
embodiments of the present disclosure.
[0024] FIG. 4 is a side view of a cementing head according to
embodiments of the present disclosure.
DETAILED DESCRIPTION
[0025] Embodiments disclosed herein relate generally to a cementing
head for generating electrical power. More specifically,
embodiments disclosed herein relate to apparatuses and methods for
generating electrical power to actuate valves on cementing
heads.
[0026] Certain terms are used throughout the following description
and claims to refer to particular features or, components. As one
skilled in the art will appreciate, different persons may refer to
the same feature or component by different names. This document
does not intend to distinguish between components or features that
differ in name but not function. Further, the drawing figures are
not necessarily to scale. Certain features and components herein
may be shown exaggerated in scale or in somewhat schematic form,
and some details of conventional elements may not be shown in
interest of clarity and conciseness.
[0027] In the following discussion and in the claims, the terms
"including" and "comprising" are used in an open-ended fashion, and
thus should be interpreted to mean "including, but not limited to .
. . " Also, the term "couple" or "couples" is intended to mean
either an indirect or direct connection. Thus, if a first device
couples to a second device, that connection may be through a direct
connection, or through an indirect connection via other devices and
connections.
[0028] FIG. 1 schematically depicts an exemplary drilling system,
one of many in which cementing manifolds and methods disclosed
herein may be employed The drilling system 100 includes a derrick
102 with a rig floor 104 at its lower end having an opening 106
through which drill string 108 extends downwardly into a well bore
110. The drill string 108 is driven rotatably by a top drive
drilling unit 120 that is suspended from the derrick 102 by a
traveling block 122. The traveling block 122 is supported and
moveable upwardly and downwardly by a cabling 124 connected at its
upper end to a crown block 126 and actuated by conventional powered
draw works 128. Corrected below the top drive unit 120 is a kelly
valve 130, a pup joint 132, a cementing swivel 160, and a cementing
manifold, such as the canister fed cementing manifold 200,
described more fully below. A flag sub 150, which provides a visual
indication when a dart or sphere passes therethrough, is connected
below the cementing manifold 200 and above the drill string 108. A
drilling fluid line 134 routes drilling fluid to the top drive unit
120, and a cement line 136 routes cement through a valve 138 to the
swivel 160. Tie-off connections 162, 164 secure the cementing
swivel 160 to the derrick 102.
[0029] FIG. 1 depicts one example of a drilling environment in
which the cementing manifolds and methods disclosed herein may be
utilized. One of ordinary skill in the art will readily appreciate,
however, that the embodiments disclosed herein are not limited to
use with a particular type of drilling system. Rather, these
embodiments may be utilized in other drilling environments such as,
for example, to cement casing into an offshore well bore.
[0030] FIG. 2 schematically depicts a representative cementing
manifold connected above to a cementing swivel and below to a drill
string. As described in reference to and shown in FIG. 1, the
cementing swivel 160 and the cementing manifold 200 are coupled to
a drill string 108. Cement is provided to the cementing swivel 160
through cement line 136. The cement passes through the cementing
swivel 160 and into the cementing manifold 200 through a fluid
entry port 202. The cement continues through the cementing manifold
200 via a through-passage, such as a flowbore, and finally exits
the cementing manifold through a fluid exit port 204. As the cement
flows through the cementing manifold 200, projectiles, such as a
dart and/or a sphere, may be released into the cement flow at
desired times.
[0031] Referring to FIG. 3, a side perspective view of a cementing
manifold according to embodiments of the present disclosure is
shown. The cementing head 300 is illustrated having a lower tubular
body 301 (i.e., a rotating body) and an upper tubular body 302
(i.e., a stationary body). Lower tubular body 301 is configured to
rotate during a cementing operation, while upper tubular body 302
is configured to remain relatively stationary. Lower tubular body
301 is coupled to a rotor 303 at a first end 304 of lower tubular
body 301. The rotor 303 is coupled to lower tubular body 301 so
that as lower tubular body 301 rotates, rotor 303 also rotates.
Rotor 303 may be coupled to lower tubular body 301 using various
connection techniques, such as threadable connections, screws,
rivets, brazing, and the like.
[0032] Lower tubular body 301 also includes various electrical
components, such as a plurality of torque converters 305, one or
more batteries 306, and a plurality of valves (not independently
shown). Torque converters 305 are disposed on the outside of lower
tubular body 301 and are in electrical communication with the one
or more valves. The torque converters 305 are configured to convert
direct current ("DC") to alternating current ("AC"), such that when
a selected circuit is closed, the torque converter 305 drives an
associated valve, opening or closing the valve, and thereby
controlling the cementing operation.
[0033] The plurality of torque converters 305, in embodiments, may
be electrically connected to one or more batteries 306. The
batteries may be used to store energy produced by the generator,
which will be explained in detail below. Thus, in certain
embodiments, the stored energy may be transferred to one or more
torque converters 305 for use in actuating one or more valves. The
connections 307 between the one or more batteries 306 and the
torque convertors 305 may be through any type of conductive wire
known in the industry. In embodiments separate connections 307 may
be provided between individual torque converters 305 and the one or
batteries 306, while in other embodiments, a single connection 307
may be established between all of the one or more batteries 306 and
the torque converters 305.
[0034] The one or more batteries 306 may also be surrounded by a
heat jacket (not illustrated), such that if cold temperatures are
encountered, the one or more batteries 306 will continue to hold a
charge. Depending on the types of torque converters 305 used, a
heat jacket may surround one or more of the torque converters 305
as well. Other components may also be present with respect to lower
tubular body 301. For example, in certain embodiments, an outer
protective sleeve may surround all or part of lower tubular body
301, including the valves, torque converters 305 and/or battery
306.
[0035] As explained above, the lower tubular body 301 is coupled to
rotor 303. Rotor 303 is configured to rotate along with the
rotation of lower tubular body 301 during use of the cementing head
300. In this embodiment, rotor 303 includes a plurality of wires or
a coil and constitutes the voltage inducing component of the
generator. Rotor 303 is disposed partially inside an armature 308.
Armature 308 is stationary and includes a toothed ring or gear 309
configured to electrically interact with rotor 303. A plurality of
electromagnets or permanent magnets may be disposed in toothed ring
309 (for example through press-fitting) and thus, the toothed ring
309 constitutes the magnetic field component of the electrical
generator. As rotor 303 rotates during use of cementing head 300, a
change in magnetic flux density at the coils induces an electrical
voltage that may be transferred to armature 308. The mechanical
power of the rotating cement head 300 is thus converted to
electrical power, such that the armature 308 electromotive force
drives the armature 308 current, which may be transferred and
stored in the battery 306. Alternatively, the electrical power may
be transferred directly to the torque converters 306 for use in
actuating valves of the cement head 300.
[0036] The armature 308 is connected to the battery 306 and/or
torque converters 305 through connections 307. In certain aspects,
a swivel 310 may provide the connection between connections 307 and
armature 308, as lower tubular body 301 rotates while upper tubular
body 302, including the stationary armature 308, does not
rotate.
[0037] Referring to FIG. 4, a side perspective view of a cementing
manifold according to embodiments of the present disclosure is
shown. Many of the components are the same as those described with
respect to FIG. 3; however, the method by which energy is generated
differs. Accordingly, like number represent like components, even
though the way the components are used may differ.
[0038] The cementing head 300 is illustrated having a lower tubular
body 301 and an upper tubular body 302. Lower tubular body 301 is
configured to rotate during a cementing operation, while upper
tubular body 302 is configured to remain relatively stationary.
Lower tubular body 301 is coupled to a rotor 303 at a first end 304
of lower tubular body 301. The rotor 303 is coupled to lower
tubular body 301 so that as lower tubular body 301 rotates, rotor
303 also rotates.
[0039] Lower tubular body 301 also includes various electrical
components, such as a plurality of torque converters 305, one or
more batteries 306, and a plurality of valves (not independently
shown), as discussed above with respect to FIG. 3. Torque
converters 305 are disposed on the outside of lower tubular body
301 and are in electrical communication with the one or more
valves. The torque converters 305 are configured to convert DC to
AC such that when a selected circuit is closed, the torque
converter 305 drives an associated valve, opening or closing the
valve, and thereby controlling the cementing operation.
[0040] The plurality of torque converters 305, in embodiments, may
be electrically connected to one or more batteries 306. The
connections 307 between the one or more batteries 306 and the
torque convertors 305 may be through any type of conductive wire
known in the industry. In certain embodiments separate connections
307 may be provided between individual torque converters 305 and
the one or batteries 306, while in other embodiments, a single
connection 307 may be established between all of the one or more
batteries 306 and the torque converters 305. In embodiments, a
single connection 307 transfers generated energy to battery 306,
through a torque converter 305a, and then to other individual
torque converters 305b-305d.
[0041] In embodiments, lower tubular body 301 is coupled to rotor
303. Rotor 303 is configured to rotate along with the rotation of
lower tubular body 301 during use of the cementing head 300. Rotor
303 is coupled to an armature 308, which is wound by wire to
produce a coil. Thus, as rotor 303 rotates, armature 308 also
rotates. Armature 308 is disposed inside toothed ring or gear 309,
which may also include a plurality of electromagnets or permanent
magnets disposed therein. Toothed ring or gear 309 is stationary,
thus, as rotor 303 rotates armature 308 a change in magnetic flux
density induces an electrical voltage in the coil or wires in
armature 308. Thus, the mechanical power is converted to electrical
power so that the electrical power may be transferred to either
battery 306 or torque converters 305 for actuating one or more
valves.
[0042] In embodiments, the armature 308 is connected to the battery
306 and/or torque converters 305 through connections 307. As both
lower tubular body 301, including rotor 303 rotate with armature
308, the connections 307 may be directly between battery 305 and
armature 308. While a swivel (not shown) may be used, the swivel is
not necessary.
[0043] Those of ordinary skill in the art will appreciate that the
configuration of rotor 303, armature 308, and toothed ring 309 may
vary, and any of the rotor 303, armature 308 and toothed ring 309
may rotate or be stationary, regardless of the naming conventions
used herein. Those of ordinary skill in the art will appreciate
that the rotor 303, armature 308, and toothed ring 309 may be
either a magnetic field component or a power-producing component,
depending on design requirements of cementing head 300. For
example, in alternate embodiments, a toothed ring 309 having a
plurality of magnets may be coupled to rotor 303, thus, the
magnetic field generating component rotates with the lower tubular
body 301. In embodiments, the coil may be stationary and
communicate directly with armature 308, which may also be
stationary. In embodiments, the toothed ring 309 may be coupled to
the rotor 303 as well as the armature 309, and all three components
may be configured to rotate during operation of the cementing head
300. In such an embodiment, the coil would remain stationary, and
the electrical voltage induced by the coil would be transferred to
the armature, which is rotating, for transference to one or more of
the batteries 306 and/or torque converters 305.
[0044] In embodiments, cementing head 300 may also include a radio
frequency receiver/transceiver (not illustrated) connected to one
or more torque converters 305 and/or batteries 306. The radio
frequency receiver/transceiver may be used to wirelessly provide a
signal to actuate one or more of the valves, thereby allowing the
cementing operation to be controlled from a remote location. The
radio frequency signal may be generated by an operator working from
a computer, such as a laptop.
[0045] In embodiments, additional components may also be used to
further enhance the electrical power generation. For example, in
embodiments a commutator may be used to more efficiently remove
power from the generator. Additionally, speed of rotation of the
lower tubular body 301 may be modulated to adjust the voltage
applied to the battery 306.
[0046] During operation of embodiments of the above described
cementing head, and in the interests of generating electrical power
during the cementing operation, an operator may dispose a cementing
head on a well head. The cementing head may include a rotating
body, an armature, a stationary body, and a battery. The rotating
body may then be actuated as the cementing operation commences,
thereby resulting in an electrical voltage being generated in the
armature. The generated electrical voltage may subsequently be
transferred to the battery or directly to torque converters
allowing for the actuation of one or more cementing valves of the
cementing head. The cementing operation may thus be controlled by
sending signals, such as radio frequency signals, to the one or
more valves.
[0047] While the present disclosure has been described with respect
to a limited number of embodiments, those skilled in the art,
having benefit of this disclosure, will appreciate that other
embodiments may be devised which do not depart from the scope of
the disclosure as described herein. Accordingly, the scope of the
disclosure should be limited only by the attached claims.
* * * * *