Patent Publication Number: US-9850745-B2

Title: Hydraulic connector system

Description:
BACKGROUND 
     This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present invention, 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 invention. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art. 
     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). 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Various features, aspects, and advantages of the present invention 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 block diagram of an embodiment of a mineral extraction system; 
         FIG. 2  is a perspective view of an embodiment of a hydraulic connector system; 
         FIG. 3  is a cross-sectional view along line  3 - 3  of  FIG. 2  of an embodiment of a hydraulic connector system in an unlocked position; 
         FIG. 4  is a cross-sectional view along line  3 - 3  of  FIG. 2  of an embodiment of a hydraulic connector system in a locked position; 
         FIG. 5  is a top view of an embodiment of a hydraulic connector system; 
         FIG. 6  is a cross-sectional view along line  6 - 6  of  FIG. 2  of an embodiment of a hydraulic connector system in a locked position; 
         FIG. 7  is a cross-sectional view along line  7 - 7  of  FIG. 5  of an embodiment of a hydraulic connector system in a locked position; 
         FIG. 8  is a cross-sectional view along line  8 - 8  of  FIG. 5  of an embodiment of a hydraulic connector system in a locked position; and 
         FIG. 9  is a cross-sectional view within line  9 - 9  of  FIG. 7  of an embodiment of a lock ring system in a locked position. 
     
    
    
     DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS 
     One or more specific embodiments of the present invention will be described below. These described embodiments are only exemplary of the present invention. 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&#39; 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. 
     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. 1  is a block diagram that illustrates a mineral extraction system  10  (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 well  12  enabling extraction of hydrocarbons from mineral deposit  14 . After drilling the well  12 , 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 well  12 , a production string  16  (e.g., pipes, casings) with a hydraulic connector  18  is lowered in axial direction  20  until the hydraulic connector  18  couples to a casing  22  in a wellhead hub  24 . Once coupled, the hydraulic connector  18  forms a secure connection that enables extraction of hydrocarbons through the well-bore  26 , while blocking hydrocarbons from escaping into the subsea environment. In order to couple to and seal with the casing  22 , the hydraulic connector  18  includes a locking system  28  and seals  30  (e.g., annular seals). In operation, the hydraulic connector  18  uses hydraulic pressure in fluid lines  32  to control the locking system  28 , energize one or more seals  30 , and/or test seal integrity of one or more seals  30 . 
       FIG. 2  is a perspective view of an embodiment of a hydraulic connector  18 . The hydraulic connector  18  includes a hydraulic block  50  (e.g., annular body) with a plurality of connectors  52  (e.g., hydraulic fluid ports). As will be explained in detail below, the connectors  52  receive fluid (e.g., hydraulic fluid), through the fluid lines  32  seen in  FIG. 1  (e.g., control lines), enabling the hydraulic connector  18  to couple to and seal with a well  12 . For example, surrounding the hydraulic block  50  is a sleeve  54  (e.g., annular sleeve). In operation, fluid enters between the hydraulic block  50  and the sleeve  54 , which drives the sleeve  54  in axial direction  56  and energizes the locking mechanism  28 . Moreover, in some embodiments, the hydraulic connector  18  includes a guide skirt  58  (e.g., annular skirt) that couples to the sleeve  54 . The guide skirt  58  includes a flared end  60  (e.g., diverging and/or conical inner surface) that facilitates alignment with the casing  22  (seen in  FIG. 1 ) as the hydraulic connector  18  is lowered into position. Finally, in some embodiments, one or more eyebolts  62  (e.g., 1, 2, 3, 4, 5) may couple to the hydraulic block  50  enabling wires or cables to lower the hydraulic connector  18  into position. 
       FIG. 3  is a cross-sectional view along line  3 - 3  of  FIG. 2  of an embodiment of a hydraulic connector  18  in an unlocked position. As illustrated, the hydraulic block  50  is lowered in axial direction  20  until a ledge  80  (e.g., annular shoulder or axial abutment) of the hydraulic block  50  contacts a corresponding axial abutment  81  of the casing  22 . In this position, the hydraulic connector  18  is ready to lock (e.g., couple) and seal with the casing  22  using the respective locking system  28  and one or more seals  30 . The locking system  28  includes one or more lock segments  82  (e.g., 1, 2, 3, 4, 5, or more) that are spaced circumferentially about the casing  22  and an energizing ring  84 . In some embodiments, the lock system  28  may in include a c-ring instead of the lock segments  82 . The lock segments  82  couple to the energizing ring  84  with one or more shear pins  86  and connectors  88  (e.g., threaded fasteners, screws, bolts, pins, etc.). The energizing ring  84  in turn couples to the sleeve  54  with a connector  90  (e.g., threaded fasteners, screw, bolt, pins, etc.). As illustrated, the sleeve  54  circumferentially surrounds the hydraulic block  50  forming an actuation chamber  92  (e.g., annular chamber) that enables fluid (e.g., hydraulic fluid) to drive the sleeve  54  in axial direction  56 . Thus, the sleeve  54  may also be described as a piston, piston sleeve, or hydraulically activated sleeve  54 . As explained above, hydraulic fluid is pumped into the hydraulic block  50  through one or more fluid lines  32  (e.g., 1, 2, 3, 4, or more) and the respective connectors  52 . The hydraulic fluid is then guided through one or more passages  94  (e.g., axial and radial passages) in the hydraulic block  50  to the actuation chamber  92 . The actuation chamber  92  retains the hydraulic fluid using one or more seals  96  and  98  (e.g., circumferential or annular seals) between the hydraulic block  50  and the sleeve  54 . As fluid enters the actuation chamber  92 , the hydraulic pressure drives the sleeve  54  in axial direction  56 . As illustrated, the sleeve  54  couples to the hydraulic block with one or more connectors  100  (e.g., threaded fasteners, screws, bolts, pins, etc.) that pass through one or more apertures  102  in the outer sleeve  54 , before coupling to one or more axial slots  104  in the hydraulic block  50 . Accordingly, as hydraulic fluid enters and exits the actuation chamber  92 , the sleeve  54  is able to move axially in directions  20  and  56 , as the connectors  100  move within the axial slots  104 . Thus, the connectors  100  and axial slots  104  may represent an axial guide or anti-rotation guide. For example, each connector  100  may be a male anti-rotation feature or axial guide, while slot  104  may be a female anti-rotation feature or axial guide. 
       FIG. 4  is a cross-sectional view along line  3 - 3  of  FIG. 2  of an embodiment of a hydraulic connector  18  in a locked position. As explained above, when hydraulic fluid is pumped into the actuation chamber  92 , the pressure drives the sleeve  54  in axial direction  54 . The axial movement of the sleeve  54  then pulls the energizing ring  84  in axial direction  56 . As the energizing ring  84  moves in axial direction  56 , the energizing ring  84  shears through the shear pin  86  enabling the connector  88  to move within the slot  120 . As illustrated, the energizing ring  84  and lock segments  82  include respective angled surfaces  122  and  124  (e.g., acutely tapered or conical surfaces) that contact each other forming an angled interface  126 . The angled surfaces  122  and  124  and angled interface  126  are acutely angled relative to a central axis  19  (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 interface  126  enables the energizing ring  84  to drive the lock segments  82  radially inward in radial directions  128  and  130 , to couple the lock segments  82  to the casing  22 . In other words, the energizing ring  84  compresses the lock segments  82  against the casing  22 . In some embodiments, the lock segments  82  may include teeth or protrusions  132  that facilitate coupling between the lock segments  82  and the outer surface  134  of the casing  22 . Once coupled, the hydraulic connector  18  may remove the hydraulic pressure from the fluid in the actuation chamber  92 . In order to block the sleeve  54  from sliding again in axial direction  20 , after removing the hydraulic pressure, the hydraulic connector  18  includes a lock ring system  136 . As will be explained in detail below, the lock ring system  136  includes a lock ring  138  with protrusions  140  (e.g., teeth) that engage corresponding grooves  142  (e.g., annular grooves) on an interior surface  144  of the sleeve  54 . The lock ring system  136  uses the protrusions  140  to selectively engage and disengage the grooves  142  on the sleeve  54 . When the lock ring system  136  uses the protrusions  140  to engage the grooves  142 , the lock ring system  136  blocks movement of the sleeve  54  in axial direction  20 , which keeps the lock segments  82  coupled to the casing  22 . In order to uncouple the hydraulic connector  18  from the casing  22 , the lock ring system  136  may disengage the protrusions  140  from the grooves  142  enabling the sleeve  54  and energizing ring  84  to move in axial direction  20 . As the energizing ring  84  moves in axial direction  20 , the energizing ring  84  removes the radial force, in direction  128  and  130 , to compress the lock segments  82  against the casing  22 . Accordingly, the lock segments  82  may move in radial directions  146  and  148  enabling the hydraulic connector  18  to disconnect from the casing  22 . 
       FIG. 5  is a top view of an embodiment of a hydraulic connector  18 . As illustrated, the sleeve  54  circumferentially surrounds the hydraulic block  50 . As will be explained in detail below, the hydraulic block  50  include multiple hydraulic passages (e.g., passage  94 ) that enable fluid to actuate seals, test seals, drive the sleeve  54  in axial direction  56 , and actuate the lock ring system  136  (e.g., disengage the lock ring system  136 ). These hydraulic passages in turn couple to a respective fluid or fluid line  32  via a connector  52  (seen in  FIG. 1 ). 
       FIG. 6  is a cross-sectional view along line  6 - 6  of  FIG. 2  of an embodiment of a hydraulic connector  18  in a locked position. Once the hydraulic connector  18  couples to the casing  22 , the hydraulic connector  18  may test seals to detect whether the hydraulic connector  18  forms a proper seal with the casing  22 . For example, the hydraulic connector  18  may include two seals  170  and  172  (e.g., circumferential seals) that rest within respective grooves  174  and  176  (e.g., circumferential or annular grooves) in the hydraulic block  50 . The seals  170  and  172  are positioned at different axial positions within the hydraulic block  50  to sealingly engage the outer surface  134  of the casing  22 . In order to test the whether the seals  170  and  172  are sealingly engaged with the casing  22 , the hydraulic block  50  includes an axial fluid passage  178  that fluidly couples to a radial passage  180 . In operation, fluid flows through the axial passage  178  and into the radial passage  180 , which then directs the fluid toward a space  182  (e.g., annular space) between the seals  170  and  172 , testing whether the seals  170  and  172  have formed a proper seal with the casing  22 . For example, a seal test system may monitor whether the pressure of the fluid in the axial fluid passage  178  and radial passage  180  stays the same or changes over time (e.g., loses pressure) to determine whether the seals  170  and  172  have formed a proper seal. In some embodiments, the radial passage  180  may extend completely through the hydraulic block  50 . Accordingly, some embodiments may include a plug  184  that blocks fluid flow, through the axial passage  178  and the radial passage  180 , from entering the actuation chamber  92 . 
       FIG. 7  is a cross-sectional view along line  7 - 7  of  FIG. 5  of an embodiment of a hydraulic connector  18  in a locked position. In some embodiments, the hydraulic connector  18  may include seals  200  and  202  (e.g., annular seals) that rest within respective annular grooves  204  and  206  in the hydraulic block  50 . After lowering the hydraulic connector  18 , the seals  200  and  202  may be actuated to form a seal with the casing  22 . For example, once the hydraulic connector  18  couples to the casing  22 , the hydraulic connector  18  may actuate seal  202  using pressurized fluid that flows through an axial passage  208  that fluidly couples to a radial passage  210 . In operation, fluid flows through the axial passage  208  and into the radial passage  210 . The radial passage  210  then directs the fluid toward the seal  202 . As pressure builds in the axial and radial passages  208 ,  210 , the fluid drives and actuates the seal  202  forming a seal with the casing  22 . In some embodiments, the radial passage  210  may extend completely through the hydraulic block  50 . Accordingly, some embodiments may include a plug  208  that blocks fluid flow from exiting through the radial passage  210  and contacting the sleeve  54 . 
       FIG. 8  is a cross-sectional view along line  8 - 8  of  FIG. 5  of an embodiment of a hydraulic connector  18  in a locked position. As explained above, the hydraulic connector  18  may include seals  200  and  202  that are actuated to form a seal with the casing  22 . For example, once the hydraulic connector  18  couples to the casing  22 , the hydraulic connector  18  may actuate the seal  200  using pressurized fluid that flows through an axial passage  230  that fluidly couples to a radial passage  232 . In operation, fluid flows through the axial passage  230  and into the radial passage  232 , which then directs the fluid toward the seal  200 . As pressure builds in the axial and radial passages  230 ,  232  the fluid drives and actuates the seal  200  forming a seal with the casing  22 . In some embodiments, radial passage  232  may extend completely through the hydraulic block  50 . Accordingly, some embodiments may include a plug  234  that blocks fluid flow from exiting through the radial passage  210  and contacting the sleeve  54 . 
       FIG. 9  is a cross-sectional view within line  9 - 9  of  FIG. 7  of an embodiment of a lock ring system  136  in a locked position. In order to selectively enable and block the sleeve  54  from sliding in axial direction  20 , the hydraulic connector  18  includes the lock ring system  136 . As explained above, the lock ring system  136  includes a lock ring  138  (e.g., segmented ring or c-ring) with protrusions  140  (e.g., teeth) that engage corresponding grooves  142  (e.g., annular grooves) on an interior surface  144  of the sleeve  54 . In some embodiments, the lock ring system  136  may include a plurality of segments that engage sleeve  54 . In operation, the protrusions  140  and grooves  142  block axial movement of the sleeve  54  in axial direction  20 . In some embodiments, the protrusions  140  may be angled upward toward axial direction  56  and the grooves  142  may be angled downward toward axial direction  20 . In this configuration, the protrusions  140  and grooves  142  enable the sleeve  54  to move axially in direction  56  during actuation of the locking system  28  while still blocking axial movement of the sleeve  54  in axial direction  20 . 
     As illustrated, the lock ring  138  rests within a groove  250  (e.g., annular groove) and is biased with a spring  252  in radial direction  148 , so that the protrusions  140  engage the recesses  142  on the sleeve  54 . The spring  252 , in turn rests within a counter bore  254  of the lock ring  138  and surrounds a rod  255  of a piston  256 . The piston  256  (e.g., retraction piston) couples to the lock ring  138  with a connector  258  (e.g., threaded fastener, bolt, screw, latch, hook, weld, braze, etc.) enabling the piston  256  to retract the lock ring  138  in radial direction  130 . As illustrated, the spring  252  contacts an interior surface  260  of the groove  250  and biases the lock ring  138  in radial direction  148  enabling the lock ring  138  to couple to the sleeve  54  and block movement of the sleeve  54  in axial direction  20 . In order to retract the lock ring  138 , fluid is pumped through a fluid passage  262  in the hydraulic block  50 . The fluid travels through the passage  262 , where the fluid contacts a seal ring  264  (e.g., annular ring). The seal ring  264  couples to the hydraulic block  50  with one or more connectors  266  (e.g., threaded fastener, bolts, screws, latch, hook, weld, braze, etc.). The seal ring  264  redirects the fluid from the passage  262  into the fluid passage  268 . As the fluid flows through the fluid passage  268 , the fluid enters a piston chamber  270  driving the piston  256  in radial direction  130 . The movement of the piston  256  in radial direction  130  enables the piston  256  to retract the lock ring  138  by compressing the spring  252  (i.e., fluid pressure over comes spring force of the spring  252 ). In order to maintain fluid pressure the lock ring system  136  may include multiple seals  272 . For example, the seal ring  272  and hydraulic block  50  may include a respective seal  274  and  276  (e.g., annular seals) that block fluid flowing through passage  262  from escaping between the seal ring  272  and the hydraulic block  50 . As illustrated, the seals  274 ,  276  rest within respective grooves  280  and  282  (e.g., annular grooves) of the seal ring  264  and hydraulic block  50 . The piston  256  may also include one or more seals  284  and  286  that block fluid from escaping the piston chamber  270 , enabling pressure buildup within the chamber  270  for actuation of the piston  256 . Accordingly, the lock ring system  82  may move in radial directions  146  and  148  enabling the hydraulic connector  18  to connect and disconnect from the casing  22 . 
     While the invention 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 invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the following appended claims.