Systems and methods for controlling flow from a wellbore annulus

Abstract

A rotating control device for sealing an annulus includes an outer housing, and a seal assembly disposed within the outer housing and configured to seal against a rotating tubular member extending axially through a throughbore of the outer housing, wherein the seal assembly includes an inner housing, a first proximity sensor disposed along an inner surface of the outer housing, and a first sensor element disposed along an outer surface of the inner housing, wherein the first proximity sensor is configured to measure the rotational speed of the seal assembly in response to rotation of the seal assembly in the outer housing.

What is claimed is: 
     
         1 . A rotating control device for sealing an annulus extending from a subterranean wellbore, the rotating control device comprising:
 an outer housing including a central axis, a first end, a second end opposite the first end, an outer surface extending axially from the first end to the second end, and an inner surface extending axially from the first end to the second end, wherein the inner surface defines a throughbore extending axially through the outer housing, and wherein the outer housing comprises a plurality of circumferentially-spaced bores extending radially from the outer surface to the throughbore;   a seal assembly disposed within the outer housing and configured to seal against a rotating tubular member extending axially through the throughbore of the outer housing, wherein the seal assembly comprises an outer surface including a receptacle; and   a plurality of actuatable locking pins, wherein each locking pin is moveably disposed in one of the bores of the outer housing and is configured to move radially relative to the outer housing between a locked position with a radially inner end the locking pin seated in the receptacle and an unlocked position with the radially inner end of the locking pin removed from the receptacle.   
     
     
         2 . The rotating control device of  claim 1 , wherein the inner surface of the outer housing comprises an annular shoulder configured to engage a mating annular shoulder on the outer surface of the seal assembly. 
     
     
         3 . The rotating control device of  claim 2 , wherein the annular shoulder of the outer housing comprises a frustoconical surface configured to slidingly engage a mating frustoconical surface of the annular shoulder of the seal assembly. 
     
     
         4 . The rotating control device of  claim 2 , wherein the radially inner end of each locking pin comprises a chamfered profile configured to engage a corresponding chamfered profile of the outer surface of the seal assembly and urge the annular shoulder of the seal assembly in engagement with the annular shoulder of the outer housing. 
     
     
         5 . The rotating control device of  claim 1 , wherein each locking pin comprises a fluid passage configured to be pressurized to transition the locking pin between the unlocked position and the locked position. 
     
     
         6 . The rotating control device of  claim 1 , further comprising a position sensor disposed in one of the locking pins, wherein the position sensor is configured to output a signal indicating the position of the locking pin in the locked position or the unlocked position. 
     
     
         7 . The rotating control device of  claim 6 , further comprising a stab plate coupled to the outer surface of the outer housing, wherein the stab plate comprises:
 a first fluid connector in fluid communication with a first fluid conduit;   a second fluid connector in fluid communication with a second fluid conduit; and   an electrical connector in signal communication with the position sensor;   wherein at least one of the locking pins is configured to transition from the unlocked position to the locked position in response to pressurization of the first fluid conduit;   wherein at least one of the locking pins is configured to transition from the locked position to the unlocked position in response to pressurization of the second fluid conduit.   
     
     
         8 . The rotating control device of  claim 2 , wherein the radially inner end of each locking pin comprises a shoulder extending orthogonal the central axis of the outer housing. 
     
     
         9 . The rotating control device of  claim 1 , wherein:
 the outer housing includes a first passage extending from the inner surface to the outer surface and a second passage extending from the inner surface to the outer surface;   the seal assembly comprises an inner housing including a first passage extending from an inner surface to an outer surface of the inner housing and a second passage extending from the inner surface to the outer surface of the inner housing;   the first passage of the outer housing is in fluid communication with the first passage of the inner housing, and wherein the first passage of the outer housing and the first passage of the inner housing are configured to supply a lubricating fluid to a bearing chamber of the inner housing; and   the second passage of the outer housing is in fluid communication with the second passage of the inner housing, and wherein the second passage of the outer housing and the second passage of the inner housing are configured to receive the lubricating fluid from the bearing chamber.   
     
     
         10 . The rotating control device of  claim 9 , wherein:
 the first and second passages of the outer housing each include a check valve; and   the first and second passages of the inner housing each include a check valve.   
     
     
         11 . The rotating control device of  claim 1 , further comprising:
 a first proximity sensor disposed along the inner surface of the outer housing; and   a first sensor element disposed along an outer surface of an inner housing of the seal assembly;   wherein the first proximity sensor is configured to measure the rotational speed of the seal assembly in response to rotation of the seal assembly in the outer housing.   
     
     
         12 . The rotating control device of  claim 11 , further comprising:
 a second proximity sensor disposed along the inner surface of the housing; and   a second sensor element disposed along the outer surface of the inner housing;   wherein the second sensor element is configured to detect a leak in a sealing element of the seal assembly in response to leakage across the sealing element.   
     
     
         13 . A rotating control device for sealing an annulus extending from a subterranean wellbore, the rotating control device comprising:
 an outer housing including a central axis, a first end, a second end opposite the first end, an outer surface extending axially from the first end to the second end, and an inner surface extending axially from the first end to the second end, wherein the inner surface defines a throughbore extending axially through the outer housing, and wherein the outer housing comprises a plurality of circumferentially-spaced bores extending radially from the outer surface to the throughbore;   a plurality of actuatable locking pins, wherein each locking pin is moveably disposed in one of the bores of the outer housing and is configured to move radially relative to the outer housing between a locked position with a radially inner end the locking pin seated in the receptacle and an unlocked position with the radially inner end of the locking pin removed from the receptacle.   
     
     
         14 . The rotating control device of  claim 13 , further comprising:
 a seal assembly configured to be removably disposed within the outer housing, wherein the seal assembly comprises an outer surface including a receptacle configured to receive a radially inner end of each locking pin of the outer housing.   
     
     
         15 . The rotating control device of  claim 14 , wherein the seal assembly has a first position seated within the throughbore of the outer housing and a second position removed from the throughbore of the outer housing. 
     
     
         16 . The rotating control device of  claim 15 , wherein the seal assembly is configured to be lowered into the throughbore of the outer housing at the first end of the outer housing. 
     
     
         17 . The rotating control device of  claim 14 , wherein the inner surface of the outer housing comprises an annular shoulder and the outer surface of the seal assembly comprises an annular shoulder configured to axially abut the annular shoulder of the outer housing in the first position. 
     
     
         18 . The rotating control device of  claim 14 , wherein each locking pin comprises a fluid passage configured to be pressurized to transition the locking pin between the unlocked position and the locked position. 
     
     
         19 . The rotating control device of  claim 18 , wherein each locking pin comprises a position sensor configured to indicate the position of the locking pin in the locked position or the unlocked position. 
     
     
         20 . A rotating control device for sealing an annulus extending from a subterranean wellbore, comprising:
 an outer housing including a central axis, a first end, a second end opposite the first end, an inner surface extending axially from the first end to the second end, and an outer surface extending between the first end and the second end, wherein the inner surface defines a throughbore extending axially through the outer housing, and wherein the outer housing includes a first passage extending from the inner surface to the outer surface and a second passage extending from the inner surface to the outer surface; and   a seal assembly disposed within the outer housing and configured to seal against a rotating tubular member extending axially through the throughbore of the outer housing, wherein the seal assembly comprises an inner housing including a first end, a second end opposite the first end, an inner surface extending axially from the first end to the second end of the inner housing, and an outer surface extending between the first end and the second end of the inner housing, wherein the inner housing includes a first passage extending from the inner surface to the outer surface of the inner housing and a second passage extending from the inner surface to the outer surface of the inner housing;   wherein the first passage of the outer housing is in fluid communication with the first passage of the inner housing, and wherein the first passage of the outer housing and the first passage of the inner housing are configured to supply a lubricating fluid to a bearing chamber of the inner housing;   wherein the second passage of the outer housing is in fluid communication with the second passage of the inner housing, and wherein the second passage of the outer housing and the second passage of the inner housing are configured to receive the lubricating fluid from the bearing chamber.   
     
     
         21 . The rotating control device of claim of  claim 20 , wherein:
 the first and second passages of the outer housing each include a check valve; and   the first and second passages of the inner housing each include a check valve.   
     
     
         22 . The rotating control device of  claim 20 , further comprising:
 a plurality of fluid conduits in fluid communication with the first and second passages of the outer housing; and   a sensor coupled to one of the fluid conduits, wherein the sensor is configured to measure at least one of pressure and temperature of fluid disposed in the fluid conduit.   
     
     
         23 . The rotating control device of  claim 22 , further comprising a stab plate coupled to the outer housing and including a fluid connector coupled to an end of one of the fluid conduits. 
     
     
         24 . The rotating control device of  claim 22 , further comprising a lubrication system coupled to the plurality of fluid conduits, wherein the lubrication system is configured to circulate lubricating fluid in a continuous circuit through the bearing chamber of the inner housing of the seal assembly. 
     
     
         25 . The rotating control device of  claim 20 , further comprising a sensor coupled to the outer housing and in fluid communication with the bore of the outer housing, wherein the sensor is configured to measure at least one of pressure and temperature of fluid disposed in the bore of the outer housing. 
     
     
         26 . A rotating control device for sealing an annulus extending from a subterranean wellbore, comprising:
 an outer housing including a central axis, a first end, a second end opposite the first end, an inner surface extending axially from the first end to the second end, and an outer surface extending from the first end to the second end, wherein the inner surface defines a throughbore extending axially through the outer housing;   a seal assembly disposed within the outer housing and configured to seal against a rotating tubular member extending axially through the throughbore of the outer housing, wherein the seal assembly comprises an inner housing including a first end, a second end opposite the first end of the inner housing, an inner surface extending axially from the first end of the inner housing to the second end of the inner housing, and an outer surface extending from the first end of the inner housing to the second end of the inner housing;   a first proximity sensor disposed along the inner surface of the outer housing; and   a first sensor element disposed along the outer surface of the inner housing;   wherein the first proximity sensor is configured to measure the rotational speed of the seal assembly in response to rotation of the seal assembly in the outer housing.   
     
     
         27 . The rotating control device of  claim 26 , wherein the first sensor element comprises a magnetic member. 
     
     
         28 . The rotating control device of  claim 26 , further comprising:
 a second proximity sensor disposed along the inner surface of the housing;   a second sensor element disposed along the outer surface of the inner housing;   wherein the second sensor element is configured to detect a leak in a sealing element of the seal assembly in response to leakage across the sealing element.   
     
     
         29 . The rotating control device of  claim 28 , wherein the second sensor element comprises a sensor element assembly comprising:
 a housing;   a piston slidably disposed in the housing;   a biasing member configured to bias the piston towards a radially inner position; and   a burst disc configured to rupture in response to leakage across the sealing element.   
     
     
         30 . The rotating control device of  claim 29 , wherein, in response to the rupture of the burst disc, the piston is configured to be actuated into a radially outer position. 
     
     
         31 . The rotating control device of  claim 30 , wherein, in response to the piston of the sensor element assembly being disposed in the radially outer position, the second proximity sensor is configured to output a signal. 
     
     
         32 . The rotating control device of  claim 30 , further comprising:
 a transducer disposed along the outer surface of a sleeve disposed in the inner housing of the seal assembly, wherein the transducer is configured to measure the pressure of fluid disposed in a bore of the sleeve; and   a transmitter disposed along the inner surface of the outer housing;   wherein the transducer is configured to wirelessly communicate signals indicative of the pressure of fluid disposed in the bore of the sleeve to the transmitter.   
     
     
         33 . A method for sealing an annulus of a marine riser with a rotating control device (RCD), the method comprising:
 (a) coupling an outer housing of the RCD to the marine riser;   (b) lowering a seal assembly into the outer housing of the RCD after (a), wherein the seal assembly is configured to seal against a drillstring extending through the outer housing and the marine riser; and   (c) extending a plurality of locking pins radially inward from the outer housing into a receptacle in an outer surface of the seal assembly after (b) to secure the seal assembly within the outer housing.   
     
     
         34 . The method of  claim 33 , further comprising (d) flowing a fluid from an annulus disposed between the seal assembly and the outer housing through a port extending through the outer housing. 
     
     
         35 . The method of  claim 33 , wherein (b) comprises landing an annular landing profile of the seal assembly against a corresponding landing profile of the outer housing. 
     
     
         36 . The method of  claim 33 , wherein (c) comprises engaging a chamfered profile of an inner end of each locking pin against a corresponding chamfered profile of the receptacle of the seal assembly. 
     
     
         37 . The method of  claim 33 , wherein (c) comprises pressurizing a fluid passage extending through each locking pin to displace each locking pin into the receptacle of the outer surface of the seal assembly.