IP Library › Granted Patent US 10,655,410
Granted Patent B2
US 10,655,410 · App. 16/249,089 · Granted May 19, 2020

Dual gradient drilling system and method

Inventors: Austin Johnson (Houston, TX); Brian Piccolo (Houston, TX); Justin Fraczek (Houston, TX); Waybourn Anderson (Houston, TX); Christian Leuchtenberg (Singapore, SG)
Assignee: AMERIFORCE GROUP INC.
E21B21/08E21B17/01E21B21/001E21B21/067E21B21/106E21B33/06E21B33/064E21B43/129
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Quick Facts
Patent No.
US 10,655,410
App. No.
16/249,089
Granted
May 19, 2020
Kind
B2
Abstract

A dual gradient drilling system includes a subsea blowout preventer disposed above a wellhead, the subsea blowout preventer having a central lumen configured to provide access to a wellbore, a lower section of a marine riser fluidly connected to the subsea blowout preventer, a closed-hydraulic positive displacement subsea pump system fluidly connected to the lower section of the marine riser and disposed at a predetermined depth, an annular sealing system disposed above the closed-hydraulic positive displacement subsea pump system, and an independent mud return line fluidly connecting one or more pump heads of the closed-hydraulic positive displacement subsea pump system to a choke manifold disposed on a floating platform of a rig.

Claims (34)

1. A dual gradient drilling system comprising:

a subsea blowout preventer disposed above a wellhead, the subsea blowout preventer comprising a central lumen configured to provide access to a wellbore;

a lower section of a marine riser fluidly connected to the subsea blowout preventer;

a closed-hydraulic positive displacement subsea pump system fluidly connected to the lower section of the marine riser and disposed at a subsea depth from shallow to mid-riser depth or equivalent;

an independent mud return line fluidly connecting one or more pump heads of the closed-hydraulic positive displacement subsea pump system to a floating platform of a rig without use of an additional pump system; and

an annular sealing system disposed above the closed-hydraulic positive displacement subsea pump system,

wherein a pump speed of the closed-hydraulic positive displacement subsea pump system is adjusted to achieve a target amount of fluid mass in a fluidly connected system upstream of the closed-hydraulic positive displacement subsea pump to achieve a target inlet pressure of the closed-hydraulic positive displacement subsea pump.

2. The dual gradient drilling system of claim 1 , further comprising:

a bypass riser injection system configured to bypass the closed-hydraulic positive displacement subsea pump system for injection of fluids into the lower section of the marine riser disposed below the closed-hydraulic positive displacement subsea pump system in total loss drilling conditions.

3. The dual gradient drilling system of claim 1 , further comprising:

a pressure relief valve that fluidly connects the lower section of the marine riser disposed below the closed-hydraulic positive displacement subsea pump system to an upper section of the marine riser disposed above the annular sealing system.

4. The dual gradient drilling system of claim 1 , further comprising:

a pressure relief valve that fluidly connects the independent mud return line to a top section of the marine riser disposed above the annular sealing system.

5. The dual gradient drilling system of claim 1 , further comprising:

an anti-u-tubing flow stop valve disposed on a booster line.

6. The dual gradient drilling system of claim 1 , further comprising:

an anti-u-tubing flow stop valve disposed on the drill string downhole.

7. The dual gradient drilling system of claim 1 , further comprising:

an annular packer or sealing device disposed below the closed-hydraulic positive displacement subsea pump system.

8. The dual gradient drilling system of claim 1 , wherein the independent mud return line is configured to divert returning fluids from the lower section of the marine riser disposed below the closed-hydraulic positive displacement subsea pump system to a choke manifold disposed on the floating platform of the rig.

9. The dual gradient drilling system of claim 1 , wherein the closed-hydraulic positive displacement subsea pump system comprises a first pump head, an independent linear drive motor, and a second pump head.

10. The dual gradient drilling system of claim 9 , wherein each of the first pump head and the second pump head comprise an inlet port, a bottom check valve assembly, a fluid cavity disposed between pressure balanced liners, a top check valve assembly, and an outlet port.

11. The dual gradient drilling system of claim 9 , wherein the independent linear drive motor comprises a reciprocating piston having a first piston face and a second piston face that is electronically actuated to compress or uncompress a hydraulic drive fluid in a closed-hydraulic system.

12. The dual gradient drilling system of claim 10 , wherein the pressure balanced liners isolate drilling fluids from hydraulic drive fluid.

13. The dual gradient drilling system of claim 1 , wherein the closed-hydraulic positive displacement subsea pump system comprises a hydraulic drive fluid that is wholly contained by the pump system and is not vented into a sea.

14. The dual gradient drilling system of claim 1 , wherein the closed-hydraulic positive displacement subsea pump system does not include dynamic seals exposed to drilling fluids.

15. The dual gradient drilling system of claim 1 , wherein a second linear drive motor is used to drive a third pump head and a fourth pump head, wherein the third pump head and fourth pump head are synchronized with the first pump head and the second pump head to provide a smooth flow rate.

16. The dual gradient drilling system of claim 1 , wherein the annular sealing system comprises an active control device, a rotating control device, or an annular seal configured to seal an annulus surrounding a drill string disposed therethrough.

17. The dual gradient drilling system of claim 1 , wherein the annular sealing system comprises one or more sealing elements.

18. The dual gradient drilling system of claim 1 , wherein dual gradient drilling operations are conducted with continuous circulation.

19. The dual gradient drilling system of claim 1 , wherein gas in the marine riser is controlled by the annular sealing system and diversion of riser fluids through the independent mud return line to a choke manifold and a mud-gas-separator disposed on the floating platform of the rig.

20. The dual gradient drilling system of claim 1 , wherein an upper section of the marine riser disposed above the annular sealing system is voided during dual gradient drilling operations.

21. The dual gradient drilling system of claim 1 , wherein an upper section of the marine riser disposed above the annular sealing system is filled with fluids sufficient to reduce or eliminate a pressure differential across the annular sealing device.

22. The dual gradient drilling system of claim 1 , wherein the predetermined depth is a subsea depth in a range between 3500 feet and 5500 feet.

Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 2, 2019
From: JOHNSON, AUSTIN; PICCOLO, BRIAN; FRACZEK, JUSTIN; ANDERSON, WAYBOURN; LEUCHTENBERG, CHRISTIAN
To: AMERIFORGE GROUP INC.
Reel/Frame 049060/0900 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Feb 7, 2019
From: JOHNSON, AUSTIN; PICCOLO, BRIAN; FRACZEK, JUSTIN; ANDERSON, WAYBOURN; LEUCHTENBERG, CHRISTIAN
To: AMERIFORGE GROUP INC.
Reel/Frame 048264/0124 →
Continuity (4)
Continuation PCTUS2018036968 · Jun 11, 2018
Provisional Application 62517992 · Jun 12, 2017
Provisional Application 62560153 · Sep 18, 2017
Related Publication 20190145203A1 · May 16, 2019
Cited By (1)
US 12,560,047