We were honored to have Saravanan Sundaramoorthy from NOV Inc. present at the SIMULIA Americas Users Conference, May 1-2, 2024 in Novi, Michigan.

Slide 4 video:

Abstract

The Active Control Device (ACD) is a leading-edge technology in deep water non-rotating active sealing system used to seal and divert drilling fluid in the annulus to the topside MPD manifold during Managed Pressure Drilling (MPD) operations. This equipment is fully integrated into the drilling riser system and is located below the tension ring. In an applied surface back pressure (ASBP) MPD application, the ACD uses two independent spherical annular packers to activate and control two seal sleeve elements assembled in an 18¾ inch OD Seal Sleeve Assembly (SSA). The SSA is held in place within the annular packers by upper and lower locking dogs. When activated, the annular packers close on the seal sleeve element elastomers, causing the seal sleeves to deflect radially inward, to seal against rotating/axially moving drill string.

The Seal Sleeve Assembly (SSA) consists of a polymer honeycomb insert co-molded with elastomeric component. The nonrotating Polymer insert provides wear resistance for contacting the drill string and elastomeric buffer material holds the polymer insert in place with the Annular packer element during activation.

This paper details about the design and development of ACD Seal sleeves & Annular Packers using advanced hyperelastic simulation using Abaqus Implicit/Explicit solvers. Lab scale testing were used to define detailed material model inputs and material model characterization/validations were carried out using strain energy potential functions/ Abaqus user subroutines for Elastomeric and polymeric components to capture the nonlinear and nearly incompressible attributes of the elastomeric components in the simulation.

Correlation between the simulation and the prototype test results for various API 16RCD, API 16A and real-world operating conditions validates the standard design and analysis techniques/methods for further design improvements/variants. This has led to fast-track development of Active Control Device sealing element for different drill pipe sizes and reduces number of prototypes, tests needed during the qualification phase to validate the field scenarios.

Presenter Bio

Saravanan Sundaramoorthy works as a Lead Elastomer Product Development and Subject Matter Expert for Managed Pressure Drilling at NOV Inc. He has over 20 years of experience in design and development of NOV's patented Non-Rotating Active Control Devices (ACD) for deepwater drilling applications, Rotating Control Devices (RCD) for land/Jack-up applications, Annular Blowout Preventers (BOP), and Isolation Valves by utilizing his expertise in Implicit/Explicit Dynamic Simulations, Hyper elasticity, Visco-plasticity, Fatigue & Fracture calculations of metallic and non-metallic materials. Saravanan has extensive experience in Managed Pressure Drilling/Underbalanced drilling, Continuous Circulation Systems, Pressure control equipment, and well control methods for deepwater drilling operations. He is involved in various automation programs to control ACD for Deepwater drilling operations, Kick/Loss detections, and the development of real-time condition-based monitoring of ACD Seal sleeves using AI-ML. Saravanan Sundaramoorthy holds a master's degree in mechanical engineering, published over 15 research/conference papers and holds 5 patents.