Hydraulic connector system

A system including a mineral extraction system, including a tubular with a fluid passage, a hydraulic connector system configured to couple to the tubular, the hydraulic connector system, including a hydraulic block configured to couple to one or more fluid lines, and a sleeve coupled to the hydraulic block and configured to move axially with respect to the hydraulic block to couple and uncouple the hydraulic connector system with the tubular.

BACKGROUND

In order to extract hydrocarbons from the earth wells are drilled in surface and subsea locations. However, before production or extraction of hydrocarbons begins, exploratory wells are typically drilled to confirm the presence of hydrocarbons. In a subsea environment, an exploratory drill ship may be used to drill a well to check for hydrocarbons. If oil is discovered, the exploratory drill ship seals the casings in the well until production systems can be deployed to begin extraction. Once the production systems are in place, the productions systems couple to the casing in the well using a connector. The connector links the pipes in the well with a production string (e.g., pipes or casings coupled to a rig) that carries the hydrocarbons out of the well. In order to block hydrocarbons from escaping, the connector is secured and sealed between the casing in the well and the production string (e.g., pipes coupled to a rig).

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

The embodiments discussed below include a hydraulic connector system that enables resource extraction from sub-sea locations by providing a connection between a production string and a well. More specifically, the hydraulic connector system is capable of coupling and sealing with a casing (e.g., tubular) in a wellhead. As will be explained in detail below, the hydraulic connector system includes a hydraulic block, a sleeve, a lock system, and one or more seals. In operation, the hydraulic block couples to and receives fluid from one or more fluid lines. The hydraulic connectors system uses the fluid flowing through the one or more fluid lines to perform various operations including coupling, uncoupling, and sealing with a casing. For example, the hydraulic block directs fluid into a actuation chamber to drive a sleeve axially and energize a lock system. The hydraulic block may also use fluid from one or more fluid lines to actuate seals and test seal integrity in the hydraulic connector system.

FIG. 1is a block diagram that illustrates a mineral extraction system10(e.g., subsea hydrocarbon extraction system) that can extract various minerals and natural resources, including hydrocarbons (e.g., oil and/or natural gas) from a seabed. As explained above, during exploration a drillship may drill a well12enabling extraction of hydrocarbons from mineral deposit14. After drilling the well12, a production system (e.g., a rig) may be deployed to begin extraction of hydrocarbons (e.g., production). In order to couple the production system to the well12, a production string16(e.g., pipes, casings) with a hydraulic connector18is lowered in axial direction20until the hydraulic connector18couples to a casing22in a wellhead hub24. Once coupled, the hydraulic connector18forms a secure connection that enables extraction of hydrocarbons through the well-bore26, while blocking hydrocarbons from escaping into the subsea environment. In order to couple to and seal with the casing22, the hydraulic connector18includes a locking system28and seals30(e.g., annular seals). In operation, the hydraulic connector18uses hydraulic pressure in fluid lines32to control the locking system28, energize one or more seals30, and/or test seal integrity of one or more seals30.

FIG. 2is a perspective view of an embodiment of a hydraulic connector18. The hydraulic connector18includes a hydraulic block50(e.g., annular body) with a plurality of connectors52(e.g., hydraulic fluid ports). As will be explained in detail below, the connectors52receive fluid (e.g., hydraulic fluid), through the fluid lines32seen inFIG. 1(e.g., control lines), enabling the hydraulic connector18to couple to and seal with a well12. For example, surrounding the hydraulic block50is a sleeve54(e.g., annular sleeve). In operation, fluid enters between the hydraulic block50and the sleeve54, which drives the sleeve54in axial direction56and energizes the locking mechanism28. Moreover, in some embodiments, the hydraulic connector18includes a guide skirt58(e.g., annular skirt) that couples to the sleeve54. The guide skirt58includes a flared end60(e.g., diverging and/or conical inner surface) that facilitates alignment with the casing22(seen inFIG. 1) as the hydraulic connector18is lowered into position. Finally, in some embodiments, one or more eyebolts62(e.g., 1, 2, 3, 4, 5) may couple to the hydraulic block50enabling wires or cables to lower the hydraulic connector18into position.

FIG. 3is a cross-sectional view along line3-3ofFIG. 2of an embodiment of a hydraulic connector18in an unlocked position. As illustrated, the hydraulic block50is lowered in axial direction20until a ledge80(e.g., annular shoulder or axial abutment) of the hydraulic block50contacts a corresponding axial abutment81of the casing22. In this position, the hydraulic connector18is ready to lock (e.g., couple) and seal with the casing22using the respective locking system28and one or more seals30. The locking system28includes one or more lock segments82(e.g., 1, 2, 3, 4, 5, or more) that are spaced circumferentially about the casing22and an energizing ring84. In some embodiments, the lock system28may in include a c-ring instead of the lock segments82. The lock segments82couple to the energizing ring84with one or more shear pins86and connectors88(e.g., threaded fasteners, screws, bolts, pins, etc.). The energizing ring84in turn couples to the sleeve54with a connector90(e.g., threaded fasteners, screw, bolt, pins, etc.). As illustrated, the sleeve54circumferentially surrounds the hydraulic block50forming an actuation chamber92(e.g., annular chamber) that enables fluid (e.g., hydraulic fluid) to drive the sleeve54in axial direction56. Thus, the sleeve54may also be described as a piston, piston sleeve, or hydraulically activated sleeve54. As explained above, hydraulic fluid is pumped into the hydraulic block50through one or more fluid lines32(e.g., 1, 2, 3, 4, or more) and the respective connectors52. The hydraulic fluid is then guided through one or more passages94(e.g., axial and radial passages) in the hydraulic block50to the actuation chamber92. The actuation chamber92retains the hydraulic fluid using one or more seals96and98(e.g., circumferential or annular seals) between the hydraulic block50and the sleeve54. As fluid enters the actuation chamber92, the hydraulic pressure drives the sleeve54in axial direction56. As illustrated, the sleeve54couples to the hydraulic block with one or more connectors100(e.g., threaded fasteners, screws, bolts, pins, etc.) that pass through one or more apertures102in the outer sleeve54, before coupling to one or more axial slots104in the hydraulic block50. Accordingly, as hydraulic fluid enters and exits the actuation chamber92, the sleeve54is able to move axially in directions20and56, as the connectors100move within the axial slots104. Thus, the connectors100and axial slots104may represent an axial guide or anti-rotation guide. For example, each connector100may be a male anti-rotation feature or axial guide, while slot104may be a female anti-rotation feature or axial guide.

FIG. 4is a cross-sectional view along line3-3ofFIG. 2of an embodiment of a hydraulic connector18in a locked position. As explained above, when hydraulic fluid is pumped into the actuation chamber92, the pressure drives the sleeve54in axial direction54. The axial movement of the sleeve54then pulls the energizing ring84in axial direction56. As the energizing ring84moves in axial direction56, the energizing ring84shears through the shear pin86enabling the connector88to move within the slot120. As illustrated, the energizing ring84and lock segments82include respective angled surfaces122and124(e.g., acutely tapered or conical surfaces) that contact each other forming an angled interface126. The angled surfaces122and124and angled interface126are acutely angled relative to a central axis19(e.g., acute angle of 1 to 75, 2 to 60, 3 to 50, 4 to 40, or 5 to 30 degrees). In operation, the angled interface126enables the energizing ring84to drive the lock segments82radially inward in radial directions128and130, to couple the lock segments82to the casing22. In other words, the energizing ring84compresses the lock segments82against the casing22. In some embodiments, the lock segments82may include teeth or protrusions132that facilitate coupling between the lock segments82and the outer surface134of the casing22. Once coupled, the hydraulic connector18may remove the hydraulic pressure from the fluid in the actuation chamber92. In order to block the sleeve54from sliding again in axial direction20, after removing the hydraulic pressure, the hydraulic connector18includes a lock ring system136. As will be explained in detail below, the lock ring system136includes a lock ring138with protrusions140(e.g., teeth) that engage corresponding grooves142(e.g., annular grooves) on an interior surface144of the sleeve54. The lock ring system136uses the protrusions140to selectively engage and disengage the grooves142on the sleeve54. When the lock ring system136uses the protrusions140to engage the grooves142, the lock ring system136blocks movement of the sleeve54in axial direction20, which keeps the lock segments82coupled to the casing22. In order to uncouple the hydraulic connector18from the casing22, the lock ring system136may disengage the protrusions140from the grooves142enabling the sleeve54and energizing ring84to move in axial direction20. As the energizing ring84moves in axial direction20, the energizing ring84removes the radial force, in direction128and130, to compress the lock segments82against the casing22. Accordingly, the lock segments82may move in radial directions146and148enabling the hydraulic connector18to disconnect from the casing22.

FIG. 5is a top view of an embodiment of a hydraulic connector18. As illustrated, the sleeve54circumferentially surrounds the hydraulic block50. As will be explained in detail below, the hydraulic block50include multiple hydraulic passages (e.g., passage94) that enable fluid to actuate seals, test seals, drive the sleeve54in axial direction56, and actuate the lock ring system136(e.g., disengage the lock ring system136). These hydraulic passages in turn couple to a respective fluid or fluid line32via a connector52(seen inFIG. 1).

FIG. 6is a cross-sectional view along line6-6ofFIG. 2of an embodiment of a hydraulic connector18in a locked position. Once the hydraulic connector18couples to the casing22, the hydraulic connector18may test seals to detect whether the hydraulic connector18forms a proper seal with the casing22. For example, the hydraulic connector18may include two seals170and172(e.g., circumferential seals) that rest within respective grooves174and176(e.g., circumferential or annular grooves) in the hydraulic block50. The seals170and172are positioned at different axial positions within the hydraulic block50to sealingly engage the outer surface134of the casing22. In order to test the whether the seals170and172are sealingly engaged with the casing22, the hydraulic block50includes an axial fluid passage178that fluidly couples to a radial passage180. In operation, fluid flows through the axial passage178and into the radial passage180, which then directs the fluid toward a space182(e.g., annular space) between the seals170and172, testing whether the seals170and172have formed a proper seal with the casing22. For example, a seal test system may monitor whether the pressure of the fluid in the axial fluid passage178and radial passage180stays the same or changes over time (e.g., loses pressure) to determine whether the seals170and172have formed a proper seal. In some embodiments, the radial passage180may extend completely through the hydraulic block50. Accordingly, some embodiments may include a plug184that blocks fluid flow, through the axial passage178and the radial passage180, from entering the actuation chamber92.

FIG. 7is a cross-sectional view along line7-7ofFIG. 5of an embodiment of a hydraulic connector18in a locked position. In some embodiments, the hydraulic connector18may include seals200and202(e.g., annular seals) that rest within respective annular grooves204and206in the hydraulic block50. After lowering the hydraulic connector18, the seals200and202may be actuated to form a seal with the casing22. For example, once the hydraulic connector18couples to the casing22, the hydraulic connector18may actuate seal202using pressurized fluid that flows through an axial passage208that fluidly couples to a radial passage210. In operation, fluid flows through the axial passage208and into the radial passage210. The radial passage210then directs the fluid toward the seal202. As pressure builds in the axial and radial passages208,210, the fluid drives and actuates the seal202forming a seal with the casing22. In some embodiments, the radial passage210may extend completely through the hydraulic block50. Accordingly, some embodiments may include a plug208that blocks fluid flow from exiting through the radial passage210and contacting the sleeve54.

FIG. 8is a cross-sectional view along line8-8ofFIG. 5of an embodiment of a hydraulic connector18in a locked position. As explained above, the hydraulic connector18may include seals200and202that are actuated to form a seal with the casing22. For example, once the hydraulic connector18couples to the casing22, the hydraulic connector18may actuate the seal200using pressurized fluid that flows through an axial passage230that fluidly couples to a radial passage232. In operation, fluid flows through the axial passage230and into the radial passage232, which then directs the fluid toward the seal200. As pressure builds in the axial and radial passages230,232the fluid drives and actuates the seal200forming a seal with the casing22. In some embodiments, radial passage232may extend completely through the hydraulic block50. Accordingly, some embodiments may include a plug234that blocks fluid flow from exiting through the radial passage210and contacting the sleeve54.

FIG. 9is a cross-sectional view within line9-9ofFIG. 7of an embodiment of a lock ring system136in a locked position. In order to selectively enable and block the sleeve54from sliding in axial direction20, the hydraulic connector18includes the lock ring system136. As explained above, the lock ring system136includes a lock ring138(e.g., segmented ring or c-ring) with protrusions140(e.g., teeth) that engage corresponding grooves142(e.g., annular grooves) on an interior surface144of the sleeve54. In some embodiments, the lock ring system136may include a plurality of segments that engage sleeve54. In operation, the protrusions140and grooves142block axial movement of the sleeve54in axial direction20. In some embodiments, the protrusions140may be angled upward toward axial direction56and the grooves142may be angled downward toward axial direction20. In this configuration, the protrusions140and grooves142enable the sleeve54to move axially in direction56during actuation of the locking system28while still blocking axial movement of the sleeve54in axial direction20.

As illustrated, the lock ring138rests within a groove250(e.g., annular groove) and is biased with a spring252in radial direction148, so that the protrusions140engage the recesses142on the sleeve54. The spring252, in turn rests within a counter bore254of the lock ring138and surrounds a rod255of a piston256. The piston256(e.g., retraction piston) couples to the lock ring138with a connector258(e.g., threaded fastener, bolt, screw, latch, hook, weld, braze, etc.) enabling the piston256to retract the lock ring138in radial direction130. As illustrated, the spring252contacts an interior surface260of the groove250and biases the lock ring138in radial direction148enabling the lock ring138to couple to the sleeve54and block movement of the sleeve54in axial direction20. In order to retract the lock ring138, fluid is pumped through a fluid passage262in the hydraulic block50. The fluid travels through the passage262, where the fluid contacts a seal ring264(e.g., annular ring). The seal ring264couples to the hydraulic block50with one or more connectors266(e.g., threaded fastener, bolts, screws, latch, hook, weld, braze, etc.). The seal ring264redirects the fluid from the passage262into the fluid passage268. As the fluid flows through the fluid passage268, the fluid enters a piston chamber270driving the piston256in radial direction130. The movement of the piston256in radial direction130enables the piston256to retract the lock ring138by compressing the spring252(i.e., fluid pressure over comes spring force of the spring252). In order to maintain fluid pressure the lock ring system136may include multiple seals272. For example, the seal ring272and hydraulic block50may include a respective seal274and276(e.g., annular seals) that block fluid flowing through passage262from escaping between the seal ring272and the hydraulic block50. As illustrated, the seals274,276rest within respective grooves280and282(e.g., annular grooves) of the seal ring264and hydraulic block50. The piston256may also include one or more seals284and286that block fluid from escaping the piston chamber270, enabling pressure buildup within the chamber270for actuation of the piston256. Accordingly, the lock ring system82may move in radial directions146and148enabling the hydraulic connector18to connect and disconnect from the casing22.