Patent Publication Number: US-11396781-B2

Title: Diverter for drilling operation

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is a continuation of U.S. application Ser. No. 15/229,589, filed on Aug. 5, 2016, which claims priority to U.S. provisional patent application No. 62/201,362, filed on Aug. 5, 2015. The entire contents of each of the above documents is hereby incorporated herein by reference. 
    
    
     FIELD OF THE DISCLOSURE 
     The present disclosure relates to diverters for drilling operations. 
     BACKGROUND OF THE DISCLOSURE 
     While drilling a wellbore, a diverter may be positioned to divert any high pressure fluid resulting from, for example, a blowout, away from the drilling floor. A diverter may couple to an upper end of a casing or a riser and be positioned about the drill string as the wellbore is drilled. Traditionally, the diverter is positioned beneath the drill floor or rotary table and includes one or more outlets that may be coupled to exhaust conduits away from the drill floor. 
     SUMMARY 
     The present disclosure provides for a diverter assembly. A diverter assembly includes a diverter body assembly. The diverter body assembly includes a diverter body, the diverter body fluidly coupled to the annulus of a wellbore via a casing or riser, and the diverter body including one or more diverter outlet ports fluidly coupled to the annulus of the wellbore. The diverter body assembly also includes an upper packer assembly. The upper packer assembly includes a packer sleeve, the packer sleeve mechanically coupled to the diverter body. The packer sleeve includes one or more breach lock slots. The upper packer assembly also includes an upper packer body having one or more packer breach lock tabs engaged with the breach lock slots of the packer sleeve. The diverter assembly also includes a diverter support housing, the diverter support housing coupled to the diverter body assembly. 
     The present disclosure also provides for a method. The method includes providing a diverter body assembly including a diverter body, the diverter body fluidly coupled to the annulus of a wellbore via a casing or riser, and the diverter body including one or more diverter outlet ports fluidly coupled to the annulus of the wellbore. The method also includes coupling a packer sleeve to the diverter body, and inserting an upper packer body into the packer sleeve such that one or more packer breach lock tabs of the upper packer body engage one or more corresponding breach lock slots of the packer sleeve. The method additionally includes rotating the upper packer body to a closed position such that the breach lock slots retain the upper packer body to the packer sleeve and sealing, with the upper packer body, between the diverter body and a drill string passing therethrough. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present disclosure is best understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion. 
         FIG. 1  depicts a cross section view of a diverter assembly consistent with at least one embodiment of the present disclosure. 
         FIG. 2  depicts a perspective view of a diverter support housing consistent with at least one embodiment of the present disclosure. 
         FIG. 3  depicts a perspective view of the housing cylinder of the diverter support housing of  FIG. 2 . 
         FIG. 4  depicts a cross section view of the housing cylinder of  FIG. 3 . 
         FIG. 5  depicts a cross section view of a diverter body assembly consistent with at least one embodiment of the present disclosure. 
         FIG. 5A  depicts a cross section view of a diverter body assembly consistent with at least one embodiment of the present disclosure. 
         FIG. 5B  depicts a cross section view of a diverter body assembly consistent with at least one embodiment of the present disclosure. 
         FIG. 5C  depicts a cross section view of a diverter body assembly consistent with at least one embodiment of the present disclosure. 
         FIG. 6  depicts a cross section view of a diverter body of the diverter assembly of  FIG. 5 . 
         FIG. 7  depicts a perspective view of the diverter body of  FIG. 6 . 
         FIG. 8  depicts a diverter upper retainer of the diverter assembly of  FIG. 5 . 
         FIG. 9  depicts a cross section of a diverter lower assembly, spacer spool, overshot, and mandrel consistent with at least one embodiment of the present disclosure. 
         FIG. 10  depicts a lock ring consistent with at least one embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. 
       FIG. 1  depicts a cross section of diverter assembly  100  consistent with at least one embodiment of the present disclosure. In some embodiments, diverter assembly  100  may include diverter support housing  101 . Diverter support housing  101  may be mechanically coupled to a drill floor (not shown) or other component of a drilling rig by, for example and without limitation, one or more structural beams underneath and supporting the drill floor. Diverter support housing  101  may be mechanically coupled to diverter body assembly  121 . Diverter assembly  100  further includes diverter lower assembly  151 , spacer spool pipe  171  and overshot housing  181 . Diverter body assembly  121  may be mechanically coupled to diverter lower assembly  151 , which may be mechanically coupled to spacer spool pipe  171 . Spacer spool pipe  171  may be mechanically coupled to overshot housing  181 . Diverter body assembly  121 , diverter lower assembly  151 , spacer spool pipe  171 , and overshot housing  181  may each be generally tubular and may form diverter assembly bore  104  therethrough. In some embodiments a drill string (not shown) may extend through diverter assembly bore  104 . Overshot housing  181  may fit around a tubular such as a riser or a portion of casing such that diverter assembly bore  104  is coupled to the annulus of the wellbore via the riser or portion of casing. 
     In some embodiments, as depicted in  FIGS. 2-4 , diverter support housing  101  may include housing cylinder  102 . Housing cylinder  102  may be coupled to base plate  103  as shown in  FIG. 2 . Base plate  103  mechanically couples diverter support housing  101  to the drilling rig. In some embodiments, one or more outlet pipes may be fluidly connected to diverter assembly bore  104 . In some embodiments, outlet pipes  105  may be formed at least partially in diverter support housing  101 . During operation, one or more outlet pipes  105  may conduct fluid from diverter assembly bore  104 , which is fluidly connected to the interior of diverter assembly  100  as discussed herein below. In some embodiments, outlet pipes  105  may include couplers adapted to couple to exhaust conduits, allowing fluids to be routed to locations away from the drilling rig. For example and without limitation, the couplers may be flange couplings  107  as shown in  FIG. 2 , though one having ordinary skill in the art with the benefit of this disclosure will understand that any pipe coupling may be used without deviating from the scope of this disclosure. Outlet pipes  105  (shown removed in  FIGS. 3, 4 ) may couple to outlet ports  109  formed in housing cylinder  102 . In some embodiments, inlet ports  111  may be fluidly coupled to inlet pipes  113  to, for example, allow fluid to be introduced into housing cylinder  102 . 
     As shown in  FIGS. 3 and 4 , in some embodiments, housing cylinder  102  may include housing breach lock slots  115 . Housing breach lock slots  115  may, as understood in the art, allow one or more corresponding breach lock tabs  123  ( FIG. 5 ) from diverter body assembly  121  to axially enter thereinto and, upon rotation of diverter body assembly  121 , axially lock diverter body assembly  121  to diverter support housing  101 . In some embodiments, housing breach lock slots  115  may include rotation stop  117  to retard further rotation of diverter body assembly  121  when in a locked position. Likewise, rotation of diverter body assembly  121  in the opposite direction may move breach lock tabs  123  into an open position, to allow diverter body assembly  121  to be axially removed from diverter support housing  101 . Rotation stop  117  may in some embodiments retard rotation of diverter body assembly  121  in both rotational directions. 
     As depicted in  FIGS. 5 and 6 , in some embodiments, diverter body assembly  121  may include diverter body  125 . Diverter body  125  may include one or more diverter outlet ports  127 , corresponding with outlet ports  109  of diverter support housing  101  thereby fluidly coupling diverter outlet ports  127  to outlet pipes  105  and the annulus of a wellbore. In some embodiments, as depicted in  FIG. 5 , one or more seals  129  may be positioned between diverter body  125  and housing cylinder  102  to, for example and without limitation, provide a fluid seal between diverter outlet ports  127  and outlet ports  109 . In some embodiments, diverter body  125  may be fluidly coupled to the annulus of a wellbore via a casing or riser. 
     In some embodiments, diverter body assembly  121  may include upper packer assembly  131 . Upper packer assembly  131  may form a fluid seal between diverter body  125  and a drill string (not shown) passing therethrough. Upper packer assembly  131  may include packer sleeve  132 . Packer sleeve  132  may fit within packer recess  133  (shown in  FIG. 6 ) within diverter body  125 . Packer sleeve  132  may, in some embodiments, be coupled to diverter body  125  by, for example and without limitation, threaded fasteners such as bolts  137 . Upper packer assembly  131  may include upper packer body  136  adapted to fit within packer sleeve  132 . Upper packer body may be annular. In some embodiments, upper packer body  136  may be inserted into or removed from packer sleeve  132  in an axial direction. In some embodiments, upper packer body  136  may be coupled to packer sleeve  132  and thus to diverter body  125  by upper retainer  135 . In some embodiments, upper retainer  135  may include one or more breach lock slots  139  (shown in detail in  FIG. 8 ) corresponding to one or more corresponding breach lock tabs  140  positioned on an end of upper packer body  136  to allow upper packer body  136  to couple thereto as upper packer body  136  is rotated into a closed position from the open position used to insert upper packer body  136  into packer sleeve  132 . 
     In some embodiments, as depicted in  FIG. 5 , upper packer assembly  131  may include two outer seals  141  coupled to upper packer body  136 . Outer seals  141  may provide a fluid seal between upper packer assembly  131  and diverter body  125 . In some embodiments, upper packer assembly  131  may include two inner seals  143  coupled to upper packer body  136 . Inner seals  143  may provide a fluid seal between upper packer assembly  131  and a drill string (not shown) during a drilling operation. In some embodiments, outer seals  141  and inner seals  143  may be fluid actuated to extend and seal between the respective members. In some such embodiments, outer seals  141  and inner seals  143  may be, for example and without limitation, inflatable seals. In some embodiments, outer seals  141  and inner seals  143  may be inflated simultaneously or may be selectively inflated independently. In some embodiments, outer seals  141  and inner seals  143  may be inflated by one or more ports. In some embodiments, inner seals  143  may provide a fluid seal against multiple diameters or pipe sizes of a drill string. One having ordinary skill in the art with the benefit of this disclosure will understand that any number of outer seals  141  and inner seals  143  may be utilized without deviating from the scope of this disclosure. For example, in some embodiments, as depicted in  FIG. 5A , upper packer assembly  131 ′ may include three outer seals  141 ′ and three inner seals  143 ′. In some embodiments, outer seals  141 ′ may be positioned as part of upper packer assembly  131 ′. In some embodiments, as depicted in  FIG. 5B , outer seals  141 ″ may be positioned as part of packer sleeve  132 ′ positioned within diverter body  125  as previously discussed. In such an embodiment, outer seals  141 ″ may seal against upper packer assembly  131 ″. 
     Stresses on outer seals  141  and inner seals  143  may cause the seals to deteriorate. In order to service or replace seals  141 ,  143 , upper packer body  136  may be removed from the rest of diverter body assembly  121 . In some such embodiments, upper packer body  136  may be rotated such that breach lock tabs  140  are aligned with breach lock slots  139  in an unlocked position, allowing upper packer body  136  to be axially removed from diverter body assembly  121 . Replacement may similarly be accomplished by axially inserting upper packer body  136  into diverter body assembly  121  and rotating upper packer body  136  until breach lock tabs  140  are in a locked position within breach lock slots  139 . 
     In some embodiments, as shown in  FIG. 5 , diverter lower assembly  151  may couple to the lower end of diverter body  125 . In some embodiments, diverter lower assembly  151  may couple to diverter body  125  by a breach-lock assembly as described herein. In some embodiments, diverter lower assembly  151  may include mounting flange  153  to mechanically couple diverter lower assembly  151  to the lower end of diverter body  125  by, for example and without limitation, threaded fasteners such as bolts  155 . Diverter lower assembly  151  may be a tubular member. As depicted in  FIG. 9 , diverter lower assembly  151  may include a breach lock assembly including lock ring retainer  157 . Lock ring retainer  157  may be a generally annular protrusion from the exterior surface of diverter lower assembly  151 . Lock ring retainer  157  may, for example, retain lock ring  161  to diverter lower assembly  151 . As depicted in  FIG. 10 , lock ring  161  may include retaining flange  163  adapted to contact lock ring retainer  157  and prevent lock ring  161  from sliding off the end of diverter lower assembly  151 . Lock ring  161  may further include breach lock slots  165  to couple to spacer spool pipe  171  and between spacer spool pipe  171  and overshot housing  181  as discussed herein. 
     In some embodiments, diverter lower assembly  151  may couple to spacer spool pipe  171  as depicted in  FIG. 9 . In some embodiments, spacer spool pipe  171  may include upper coupler  173 . In some embodiments upper coupler  173  may include one or more breach lock tabs  175  adapted to engage with breach lock slots  165  of lock ring  161 . In such an embodiment, spacer spool pipe  171  may be coupled to diverter lower assembly  151  by axially engaging the two members and inserting breach lock tabs  175  into breach lock slots  165  of lock ring  161 . Lock ring  161  may then be rotated such that breach lock slots  165  engage breach lock tabs  175 , retaining diverter lower assembly  151  to spacer spool pipe  171 . 
     In some embodiments, spacer spool pipe  171  may include lock ring retainer  205 . Lock ring retainer  205  may be a generally annular protrusion from the exterior surface of spacer spool pipe  171 . Lock ring retainer  205  may, for example, retain lock ring  201  to spacer spool pipe  171  as discussed above with respect to diverter lower assembly. Lock ring  201  may include retaining flange  203  adapted to contact lock ring retainer  205  and prevent lock ring  201  from sliding off the end of spacer spool pipe  171 . 
     In some embodiments, spacer spool pipe  171  may couple to overshot housing  181 . In some embodiments, overshot housing  181  may include upper coupler  183 . In some embodiments upper coupler  183  may include one or more overshot breach lock tabs  185  adapted to engage with overshot breach lock slots  165  of overshot lock ring  161 . In such an embodiment, overshot housing  181  may be coupled to spacer spool pipe  171  by axially engaging the two members and inserting overshot breach lock tabs  185  into overshot breach lock slots  165  of overshot lock ring. Overshot lock ring  161  may then be rotated such that overshot breach lock slots  165  engage overshot breach lock tabs  185 , retaining spacer spool pipe  171  to overshot housing  181 . 
     In some embodiments, as shown in  FIG. 9 , overshot housing  181  may be adapted to slip over a casing portion or riser, depicted as mandrel  191 . Overshot housing  181  may be tubular and may include a plurality of seals  187  positioned within annular grooves  189  formed on the inner surface thereof. Seals  187  may serve to provide a fluid seal between mandrel  191  and diverter assembly bore  104 . In some embodiments, two or three seals  187  may be utilized. In some embodiments, mandrel  191  may include lower coupler  197 . Lower coupler  197  may allow mandrel  191  to couple to additional drilling components. In some embodiments, lower coupler  197  may include coupler flange  199 . 
     The foregoing outlines features of several embodiments so that a person of ordinary skill in the art may better understand the aspects of the present disclosure. Such features may be replaced by any one of numerous equivalent alternatives, only some of which are disclosed herein. One of ordinary skill in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. One of ordinary skill in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.