EP3242991B1 - Control of multiple hydraulic chokes in managed pressure drilling - Google Patents
Control of multiple hydraulic chokes in managed pressure drilling Download PDFInfo
- Publication number
- EP3242991B1 EP3242991B1 EP16701218.6A EP16701218A EP3242991B1 EP 3242991 B1 EP3242991 B1 EP 3242991B1 EP 16701218 A EP16701218 A EP 16701218A EP 3242991 B1 EP3242991 B1 EP 3242991B1
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- European Patent Office
- Prior art keywords
- choke
- hydraulic
- control valve
- unit
- return
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- 238000005553 drilling Methods 0.000 title claims description 41
- 239000012530 fluid Substances 0.000 claims description 38
- 230000004044 response Effects 0.000 claims description 22
- 238000000034 method Methods 0.000 claims description 16
- 238000004891 communication Methods 0.000 claims description 13
- 238000011144 upstream manufacturing Methods 0.000 claims description 8
- 238000005086 pumping Methods 0.000 claims description 2
- 230000015572 biosynthetic process Effects 0.000 description 8
- 230000004941 influx Effects 0.000 description 8
- 230000007423 decrease Effects 0.000 description 4
- 230000008901 benefit Effects 0.000 description 3
- 230000009977 dual effect Effects 0.000 description 3
- 230000000694 effects Effects 0.000 description 2
- 230000004043 responsiveness Effects 0.000 description 2
- 230000002411 adverse Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
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- 238000005520 cutting process Methods 0.000 description 1
- 230000001934 delay Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000002706 hydrostatic effect Effects 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
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- 238000012423 maintenance Methods 0.000 description 1
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- 238000004904 shortening Methods 0.000 description 1
Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B21/00—Methods or apparatus for flushing boreholes, e.g. by use of exhaust air from motor
- E21B21/08—Controlling or monitoring pressure or flow of drilling fluid, e.g. automatic filling of boreholes, automatic control of bottom pressure
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B21/00—Methods or apparatus for flushing boreholes, e.g. by use of exhaust air from motor
- E21B21/01—Arrangements for handling drilling fluids or cuttings outside the borehole, e.g. mud boxes
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B21/00—Methods or apparatus for flushing boreholes, e.g. by use of exhaust air from motor
- E21B21/08—Controlling or monitoring pressure or flow of drilling fluid, e.g. automatic filling of boreholes, automatic control of bottom pressure
- E21B21/085—Underbalanced techniques, i.e. where borehole fluid pressure is below formation pressure
Definitions
- the disclosure relates to a method and apparatus to control multiple hydraulic chokes in a managed pressure drilling system.
- controlled pressure drilling includes managed pressure drilling (MPD), underbalanced drilling (UBD), and air drilling (AD) operations.
- MPD managed pressure drilling
- UBD underbalanced drilling
- AD air drilling
- MPD Managed Pressure Drilling
- a MPD system uses a closed and pressurizable mud-return system, a rotating control device (RCD), and a choke manifold to control the wellbore pressure during drilling.
- RCD rotating control device
- the various MPD techniques used in the industry allow operators to drill successfully in conditions where conventional technology simply will not work by allowing operators to manage the pressure in a controlled fashion during drilling.
- the bit drills through a formation, and pores become exposed and opened.
- formation fluids i . e ., gas
- the drilling system pumps this gas, drilling mud, and the formation cuttings back to the surface.
- the pressure drops, meaning more gas from the formation may be able to enter the wellbore. If the hydrostatic pressure is less than the formation pressure, then even more gas can enter the wellbore.
- FIG. 1A schematically shows a controlled pressure drilling system 10 according to the prior art.
- this system 10 is a Managed Pressure Drilling (MPD) system having a rotating control device (RCD) 12 from which a drill string and drill bit (not shown) extend downhole in a wellbore through a formation.
- the rotating control device 12 can include any suitable pressure containment device that keeps the wellbore closed at all time while the wellbore is being drilled.
- the system 10 also includes mud pumps (not shown), a standpipe (not shown), a mud tank (not shown), a mud gas separator 18, and various flow lines (14, 16, etc.), as well as other conventional components.
- the MPD system 10 includes an automated choke manifold 20 that is incorporated into the other components of the system 10.
- a drilling system 10 with a choke manifold 20 is the Secure Drilling TM System available from Weatherford. Details related to such a system are disclosed in U.S. Pat. No. 7,044,237 .
- the automated choke manifold 20 manages pressure during drilling and is incorporated into the system 10 downstream from the rotating control device 12 and upstream from the gas separator 18.
- the manifold 20 has chokes 22A-B, choke actuators 24A-B, a mass flow meter 26, pressure sensors, a hydraulic power unit 50 to actuate the chokes 22A-B, and a controller 40 to control operation of the manifold 20.
- the system 10 uses the rotating control device 12 to keep the well closed to atmospheric conditions. Fluid leaving the well flows through the automated choke manifold 20, which measures return flow and density using the flow meter 26 installed in line with the chokes 22A-B. Software components of the manifold 20 then compare the flow rate in and out of the wellbore, the injection pressure (or standpipe pressure), the surface backpressure (measured upstream from the drilling chokes 22), the position of the chokes 22A-B, and the mud density. Comparing these variables, the system 10 identifies minute downhole influxes and losses on a real-time basis and to manage the annulus pressure during drilling. All of the monitored information can be displayed for the operator at the controller 40.
- the controller 40 monitors for any deviations in values and alerts the operators of any problems that might be caused by a fluid influx into the wellbore from the formation or a loss of drilling mud into the formation. In addition, the controller 40 can automatically detect, control, and circulate out such influxes by operating the chokes 22A-B on the choke manifold 20 with the power unit 50.
- a possible fluid influx can be noted when the "flow out” value (measured from flow meter 26) deviates from the “flow in” value (measured from the mud pumps).
- an alert notifies the operator to apply the brake until it is confirmed safe to drill. Meanwhile, no change in the mud pump rate is needed at this stage.
- the controller 40 automatically closes the choke 22A-B to a determined degree to increase surface backpressure in the wellbore annulus and stop the influx.
- the controller 40 circulates the influx out of the well by automatically adjusting the surface backpressure, thereby increasing the downhole circulating pressure and avoiding a secondary influx.
- a hydraulic power unit 50 includes a hydraulic reservoir 52, one or more hydraulic pumps 54, one or more accumulators 56, hydraulic choke control valves 58A-B, and necessary piping, fittings, and valves.
- Each choke 22A-B located in the choke unit 20 has its actuator 24A-B connected by flow paths 55A-B to one of the hydraulic choke control valves 58A-B located in hydraulic power unit 50.
- This type of arrangement is disclosed in US 2005/092523 , which shows chokes located with actuators and connected by flowpaths to a remote hydraulic power unit/control valve unit of a console.
- the flow-paths 55A-B for the hydraulic power used to control the chokes 22A-B may need to travel some distance (e.g ., 12 ft. or so). Additionally, the flow paths 55A-B can be coupled with various bends, not necessarily depicted in this schematic view. Further, wave pulses may tend to originate from the pump(s) 54 and travel along the flow paths 55A-B.
- any hydraulic hoses used for the flow-paths 55A-B can elastically expand ( i . e ., expand diametrically) as the hydraulic pressure increases.
- the hydraulic hoses used for the flow-paths 55A-B can elastically contract ( i . e ., contract diametrically) as the hydraulic pressure decreases.
- the hoses for the flow-paths 55A-B can effectively respond as an accumulator and can further exaggerate or reduce the responsiveness of the choke actuators.
- the distance, bends, wave pulses, and the like can create hydraulic frictional losses and delays that hinder the response of the chokes 22A-B during operations.
- the hydraulic losses in the flow-path 55A can be different from the hydraulic losses in flow-path 55B depending on construction of the materials or differences in geometries. This can lead to a different system response between the chokes 22A-B, which requires a more complex control algorithm for the controller 40. For example, one hydraulic choke 22A may tend to respond more slowly than the other choke 22B.
- electric actuation of the chokes 22A-B may have faster response times (i.e., closing and opening times for the chokes 22A-B) when compared to hydraulic actuation.
- electric actuation on the drilling rig may not be desirable or even possible for various reasons so that hydraulic actuation may be preferred.
- an assembly is used with remote hydraulic power to control flow of wellbore fluid in a drilling system, according to appended claim 1.
- a skid or a manifold can have the at least one choke, the at least one hydraulic actuator, and the at least one control valve disposed thereon.
- a housing can have the at least one control valve and can be connected to the hydraulic actuator.
- At least one accumulator can be disposed with the at least one choke and can be coupled to the supply upstream of the at least one control valve.
- the at least one control valve can couple to the hydraulic actuator with a pair of pilot-operated check valves disposed in fluid communication between the at least one control valve and the hydraulic actuator.
- a stage tank can be disposed with the at least one choke and can receive the return of the remote hydraulic power from the at least one control valve.
- a pump in fluid communication with the stage tank can be operable to pump the return from the stage tank.
- the at least one control valve can be electrically operable between a first state of no flow, a second state of parallel flow, and a third state of cross flow between the supply and the return with the at least one hydraulic actuator.
- a controller can control operation of at least the at least one control valve.
- the assembly can have at least one choke, at least one hydraulic actuator, and at least one control valve.
- the assembly can have at least two ( e . g ., two or more) chokes.
- At least two hydraulic actuators can be disposed respectively with the at least two chokes to actuate operation of the respective chokes in response to hydraulic power.
- At least two control valves can be disposed respectively with the at least two chokes. The at least two control valves can control supply of the remote hydraulic power respectively to the at least two hydraulic actuators and can control return of the remote hydraulic power respectively from the at least two hydraulic actuators.
- a first juncture disposed with the at least two chokes can split a common supply line of the supply to at least two supply legs connected respectively to the at least two control valves.
- a second juncture disposed with the at least two chokes can combine at least two return legs connected respectively from the at least two control valves to a common return line of the return.
- the assembly can further include a source of the remote hydraulic power having a supply line and a return line.
- the at least one choke, the at least one hydraulic actuator, and the at least one control valve can be disposed away from the source of the remote hydraulic power.
- a first skid can have the source, while a second skid can have the at least one choke, the at least one hydraulic actuator, and the at least one control valve disposed thereon.
- the source can include a reservoir and a pump.
- the reservoir is coupled to the return line
- the pump is coupled to the reservoir and the supply line and is operable to provide the hydraulic power via the supply line.
- the source can also have an accumulator accumulating the supply of the remote hydraulic power.
- a method is used with a remote source of hydraulic power to control flow of wellbore fluid in a drilling system, according to appended claim 14.
- Disposing the at least one hydraulic actuator and the at least one control valve with the at least one choke can involve disposing them together on a skid.
- the method can further include disposing at least one accumulator with the at least one choke, and accumulating the supply of the hydraulic power upstream of the at least one control valve.
- the method can further include disposing a pair of pilot-operated check valves in fluid communication between the at least one control valve and the hydraulic actuator, and controlling the supply and the return with the pair of pilot-operated check valves.
- the method can further include receiving the return of the hydraulic power from the at least one control valve at a stage tank disposed with the at least one choke, and pumping the return from the stage tank to the remote source with a pump disposed with the at least one choke.
- disposing the at least one hydraulic actuator and the at least one control valve with the at least one choke can involve housing the at least one control valve to the hydraulic actuator. Also, controlling with the at least one control valve can include electrically operating the at least one control valve between a first state of no flow, a second state of parallel flow, and a third state of cross flow between the supply and return with the at least one hydraulic actuator.
- Systems and methods disclosed herein can be used to control one or more hydraulic chokes in a managed pressure drilling system.
- teachings of the present disclosure can apply equally to other types of controlled pressure drilling systems, such as other MPD systems (Pressurized Mud-Cap Drilling, Returns-Flow-Control Drilling, Dual Gradient Drilling, etc.) as well as to Underbalanced Drilling (UBD) systems, as will be appreciated by one skilled in the art having the benefit of the present disclosure.
- MPD Pressure Mud-Cap Drilling, Returns-Flow-Control Drilling, Dual Gradient Drilling, etc.
- UBD Underbalanced Drilling
- a hydraulic power unit 120 includes a hydraulic reservoir 122, one or more hydraulic pumps 124, and necessary piping, fittings and valves. These components can be housed together on a skid or manifold.
- a supply line 125A from the pumps 124 communicates the hydraulic power to the choke unit 100 positioned some distance away from the power unit 120.
- a return line 125B from the control unit 100 returns the hydraulics to the reservoir 122.
- Each choke 110A-B is actuated by a hydraulic actuator 112A-B controlled by one of the hydraulic choke control valves 140A-B located with the choke 110A-B.
- the independent control valves 140A-B are used to mitigate differences in the chokes 110A-B and provide independent feedback control of the chokes 110A-B.
- Pilot-actuated check valves 142 can be disposed between the control valves 140A-B and the chokes' actuators 112A-B, as shown in Fig 6 .
- These components of the choke unit 100 can be housed together on a skid or manifold.
- the control valve 140A-B typically has three settings, such as a closed setting closing off both supply and return lines 125A-B, an open setting permitting parallel flow through the lines 125A-B, and a cross-setting that switches the flow direction between the lines 125A-B.
- the control valves 140A-B can be operated by solenoid valves or the like with control signals from control lines A and B of the controller 40, as noted herein.
- the hydraulic power directed by the control valve 140A-B operates the respective hydraulic actuators 112A-B for the chokes 11 0A-B.
- the supply line 125A communicates hydraulic power from the power unit 120 to a supply splitter 127A, which splits the communication to parallel supply legs 129A connected to the control valves 140A-B. Conversely, parallel return legs 129B connect from the control valves 140A-B to a return splitter 127B, which combines the communication to the return line 125B.
- any hydraulic hoses used for the flow-paths can elastically expand ( i . e ., expand diametrically) as the hydraulic pressure increases and can elastically contract ( i . e ., contract diametrically) as the hydraulic pressure decreases.
- measurable increases and decreases in hydraulic fluid volume can occur due to the pressure changes and can exaggerate or reduce the responsiveness of the choke actuators.
- each hydraulic choke control valve 140A-B can be arranged such that the lengths of hydraulic lines 129A-B after the splitters 127A-B to the control valves 140A-B can match and the number of fittings between the splitters 127A-B and each choke 110A-B can be the same.
- the hydraulic lines 125A-B from the power unit 120 to the splitters 127A-B do not necessarily need a matching length and the like, although they could.
- each choke actuator 112A-B having the control valves 140A-B located directly adjacent to each choke actuator 112A-B allows the one main supply line 125A and matching supply legs 129A after the supply splitter 127A to be used to operate both the chokes 110A-B.
- the single hydraulic supply line 125A splits off with the supply splitter or juncture 127A at or near the location of the chokes 140A-B to the matching supply legs 129A so that the hydraulic losses to each choke 110A-B can be relatively equal.
- This split arrangement of the return legs 129B, return splitter 127B, and the single return line 125B can also be used for the hydraulic returns of the chokes 110A-B to the power unit 120.
- the arrangement of lines 125A-B, splitters 127A-B, and split legs 129A-B in this manner can make any potential hydraulic losses between each choke 110A-B and the hydraulic power relatively the same.
- one or more accumulators 126 can be located with the chokes 110A-B instead of being located at the power unit 120. With the accumulators 126 located in this way, the hydraulic response time for the set of two or more chokes 110A-B can be reduced. Using the accumulator(s) 126 can also minimize the response time should the choke unit 100 use a single choke 110.
- any potential wave pules generated by the pumps 124 can be dampened, which can improve the choke response.
- a damper such as a biased piston, could be added downstream of the one or more pumps 124.
- the particular type of pump 124 used can further reduce any potential pulses.
- the common supply line 125A which can use larger or more rigid tubing, to deliver hydraulic fluid near the chokes 11 0A-B before splitting at the splitter 127 to supply the dual control valves 140A-B and choke actuators 112A-B can reduce effects of tubing oscillation in the hydraulic system.
- having shorter lines of communication after the accumulator 126 can reduce the total volume of hydraulic fluid between the accumulator 126 and chokes' actuators 112A-B, thus providing faster response.
- one accumulator 126 can couple to both the return and the supply. Connection of the accumulator 126 to the return may allow for bleed down of the accumulator 126 and may not be needed.
- the use of two accumulators 126, one for each of the split legs 129A-B may help improve the chokes' response times by shortening the distance between the stored energy and the hydraulic actuators 112A-B. Having two smaller accumulators 126 compared to a single larger one may also allow for different space requirements on the skid or manifold for the choke unit 100. If human intervention is required to bypass the chokes 110A-B, it may be facilitated by having the accumulator 126 close to the chokes 110A-B since the accumulator 126 needs to be isolated before the choke 110A-B is manually bypassed.
- lighter components can be used in the solenoid of the control valve 140 to improve its response.
- Quick disconnects can be used for the various couplings and fittings in the hydraulic system. If the quick disconnect affects the choke's response, this could be mitigated by moving the quick disconnect to just upstream of the actuators 112A-B.
- each actuator 112A-B and choke 110A-B can be integrated as a unit. This makes sense from an assembly standpoint since different choke-actuator combinations are not typically used.
- Figure 2A shows an arrangement where the hydraulic power unit 120 can be implemented as one skid or manifold that couples by the lines 125A-B to the choke unit 100 implemented as another skid or manifold having dual chokes 110A-B and the other components.
- the hydraulic power unit 120 can be implemented as one skid or manifold that couples by the lines 125A-B to the choke unit 100 implemented as another skid or manifold having dual chokes 110A-B and the other components.
- the hydraulic power unit 120 can be implemented as one skid or manifold that couples by the lines 125A-B to the choke unit 100 implemented as another skid or manifold having dual chokes 110A-B and the other components.
- the hydraulic power unit 120 can operate a single choke 110, which can be housed on another skid.
- the hydraulic power unit 120 includes the hydraulic reservoir 122, the one or more hydraulic pumps 124, the accumulator 126, and necessary piping, fittings, and valves. These components can be housed together on a skid or manifold.
- First supply and return lines 123A from the pumps 124 communicate the hydraulic power and returns between the power unit 120 and the choke unit 100 positioned some distance away from the power unit 120.
- second supply and return lines 123B communicate the hydraulic power and returns between the power unit 120 and the choke unit 100.
- Each choke 110A-B is actuated by its hydraulic actuator 112A-B controlled by one of the hydraulic choke control valves 140A-B located with the choke 110A-B.
- the localized control valves 140A-B are used to mitigate differences in the chokes 11 0A-B and provide independent feedback control of the chokes 11 0A-B.
- Pilot-actuated check valves 142 can be disposed between the control valves 140A-B and the chokes' actuators 112A-B.
- FIGs 3-5 schematically illustrate additional arrangements hydraulic power units 120 and choke units 100 according to the present disclosure.
- the hydraulic power unit 120 includes a tank or reservoir 122, a pump 124, and an accumulator 126. These components are implemented on a skid or manifold for the unit 120 and connect by supply and return lines 125A-B to the choke unit 100, which can be housed on a separate skid or manifold.
- the choke unit 100 includes a choke 110, a hydraulic actuator 112, and a control valve 140. Pilot-operated check valves 142 may be used between the control valve 140 and the choke's actuator 112. This arrangement places the hydraulic switching of hydraulic power from the power unit 120 at, near, or on the choke 110 of the choke unit 100, which can have a number of benefits as disclosed herein.
- Figure 4 shows a similar arrangement to Figure 3 except that the choke unit 100 includes the accumulator 126 on its skid near the choke 110.
- the accumulator 126 on the supply line 125A can have a number of benefits stemming from its close proximity to the choke 110.
- Backpressure in the hydraulic return line 125B downstream of the choke 110 can be another consideration in choke response.
- the return tank 122 can be moved closer to the choke 110 to reduce backpressure.
- a second tank can be added to the return to help deal with backpressure.
- Figure 5 shows an additional arrangement in which components ( e . g ., control valve 140, actuator 112, choke 110, accumulator 126, etc.) are disposed at the choke unit 100.
- the choke unit 100 further includes an auxiliary pump 150 and a stage tank 152 on the return from the control valve 140.
- Expended fluid in the collection tank 152 can then be pumped by the auxiliary pump 150 to the reservoir tank 122 on the hydraulic power unit 120 via the return line 125B.
- the stage tank 152 can include a level sensor 154.
- the auxiliary pump 150 can pump fluid back to the unit's main tank 122. Since the distance along the return line 125B can be quite long (e.g., 3.66 m (12 ft), or so), use of the auxiliary pump 150 and collection tank 152 can facilitate the travel of the expelled fluid back to the reservoir tank 122 by reducing the line friction and any potential backpressure that the expelled fluid might otherwise encounter.
- stage tank 152 as in Figure 5 immediately downstream of the choke 110 can improve sluggish choke response.
- the hydraulic fluid from the choke actuator 112 can empty directly at atmospheric pressure into the stage tank 152 to then be pumped back by the auxiliary pump 150. This can eliminate the extended and closed return line typically used to return expelled fluid to the hydraulic power unit 120.
- sluggish choke response can be caused by backpressure in both the supply and return of the hydraulic power.
- integrating hydraulic components closer to choke 110 and its actuator 112 can improve the sluggish choke response and improve operation. With that said, some of these hydraulic components can be affixed to, integrated into, or otherwise made part of the choke 110 and its actuator 112.
- Figure 6 shows an arrangement of a control valve 140, a hydraulic actuator 112, and a choke 110 for the choke unit 100.
- the supply line 125A and return line 125B couple by fittings 162 to an adapter or housing 160.
- the housing 160 can hold the control valve 140 and its related components, such as the pilot-actuated check valves 142 and solenoid (not shown).
- the supply line 125A can include an accumulator 126 that is mounted on the choke unit 100 near the choke 110.
- the return line 125B can couple to the collection tank 152 and auxiliary pump 150 as before to return expended hydraulics from the choke 110.
- the housing 160 can be affixed to or incorporated into the hydraulic actuator 112 for the choke 110.
- the housing 160 can be sealed in communication with hydraulic ports 114 of the hydraulic actuator 112 using gaskets, seals, etc.
- the housing 160 can be used to retrofit or integrate with an existing choke actuator and can be configured to do so in a number of ways.
- the hydraulic actuator 112 for the choke 110 can be a worm gear actuator.
- High-pressure fluid communicated from the control valve 140 to a first port 114A can rotate the worm gear to close the choke 110 while low-pressure fluid is expelled from a second port 114B.
- high-pressure fluid communicated from the control valve 140 to the second port 114B can rotate the worm gear to open the choke 110 while low-pressure fluid is expelled from the first port 114A.
- the control valve 140 directs the high-pressure fluid from the supply line 125A and returns the low-pressure fluid to the return line 125B.
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Description
- This is non-provisional of
U.S. Provisional Appl. 62/099,939, filed 05-JAN-2015 - The disclosure relates to a method and apparatus to control multiple hydraulic chokes in a managed pressure drilling system.
- Several controlled pressure drilling techniques are used to drill wellbores. In general, controlled pressure drilling includes managed pressure drilling (MPD), underbalanced drilling (UBD), and air drilling (AD) operations.
- In the Managed Pressure Drilling (MPD) technique, a MPD system uses a closed and pressurizable mud-return system, a rotating control device (RCD), and a choke manifold to control the wellbore pressure during drilling. The various MPD techniques used in the industry allow operators to drill successfully in conditions where conventional technology simply will not work by allowing operators to manage the pressure in a controlled fashion during drilling.
- During drilling, the bit drills through a formation, and pores become exposed and opened. As a result, formation fluids (i.e., gas) can mix with the drilling mud. The drilling system then pumps this gas, drilling mud, and the formation cuttings back to the surface. As the gas rises up the borehole, the pressure drops, meaning more gas from the formation may be able to enter the wellbore. If the hydrostatic pressure is less than the formation pressure, then even more gas can enter the wellbore.
-
Figure 1A schematically shows a controlledpressure drilling system 10 according to the prior art. As shown here, thissystem 10 is a Managed Pressure Drilling (MPD) system having a rotating control device (RCD) 12 from which a drill string and drill bit (not shown) extend downhole in a wellbore through a formation. The rotatingcontrol device 12 can include any suitable pressure containment device that keeps the wellbore closed at all time while the wellbore is being drilled. Thesystem 10 also includes mud pumps (not shown), a standpipe (not shown), a mud tank (not shown), amud gas separator 18, and various flow lines (14, 16, etc.), as well as other conventional components. In addition to these, theMPD system 10 includes anautomated choke manifold 20 that is incorporated into the other components of thesystem 10. - One suitable example of a
drilling system 10 with achoke manifold 20 is the Secure Drilling™ System available from Weatherford. Details related to such a system are disclosed inU.S. Pat. No. 7,044,237 . - The
automated choke manifold 20 manages pressure during drilling and is incorporated into thesystem 10 downstream from the rotatingcontrol device 12 and upstream from thegas separator 18. Themanifold 20 haschokes 22A-B,choke actuators 24A-B, amass flow meter 26, pressure sensors, ahydraulic power unit 50 to actuate thechokes 22A-B, and acontroller 40 to control operation of themanifold 20. - The
system 10 uses therotating control device 12 to keep the well closed to atmospheric conditions. Fluid leaving the well flows through theautomated choke manifold 20, which measures return flow and density using theflow meter 26 installed in line with thechokes 22A-B. Software components of themanifold 20 then compare the flow rate in and out of the wellbore, the injection pressure (or standpipe pressure), the surface backpressure (measured upstream from the drilling chokes 22), the position of thechokes 22A-B, and the mud density. Comparing these variables, thesystem 10 identifies minute downhole influxes and losses on a real-time basis and to manage the annulus pressure during drilling. All of the monitored information can be displayed for the operator at thecontroller 40. - During drilling operations, the
controller 40 monitors for any deviations in values and alerts the operators of any problems that might be caused by a fluid influx into the wellbore from the formation or a loss of drilling mud into the formation. In addition, thecontroller 40 can automatically detect, control, and circulate out such influxes by operating thechokes 22A-B on thechoke manifold 20 with thepower unit 50. - For example, a possible fluid influx can be noted when the "flow out" value (measured from flow meter 26) deviates from the "flow in" value (measured from the mud pumps). When an influx is detected, an alert notifies the operator to apply the brake until it is confirmed safe to drill. Meanwhile, no change in the mud pump rate is needed at this stage.
- In a form of auto kick control, however, the
controller 40 automatically closes thechoke 22A-B to a determined degree to increase surface backpressure in the wellbore annulus and stop the influx. Next, thecontroller 40 circulates the influx out of the well by automatically adjusting the surface backpressure, thereby increasing the downhole circulating pressure and avoiding a secondary influx. - On the other hand, a possible fluid loss can be noted when the "flow in" value (measured from the pumps) is greater than the "flow out" value (measured by the flow meter 26). Similar steps as those above but suited for fluid loss can then be implemented by the
controller 40 to manage the pressure during drilling in this situation. - When the managed
pressure drilling system 10 is deployed on a drilling rig floor, hydraulic power is typically supplied remotely to thechokes 22A-B of thesystem 10. As shown inFig. 1B , ahydraulic power unit 50 includes ahydraulic reservoir 52, one or more hydraulic pumps 54, one ormore accumulators 56, hydraulicchoke control valves 58A-B, and necessary piping, fittings, and valves. Eachchoke 22A-B located in thechoke unit 20 has itsactuator 24A-B connected byflow paths 55A-B to one of the hydraulicchoke control valves 58A-B located inhydraulic power unit 50. This type of arrangement is disclosed inUS 2005/092523 , which shows chokes located with actuators and connected by flowpaths to a remote hydraulic power unit/control valve unit of a console. - As will be appreciated, the flow-
paths 55A-B for the hydraulic power used to control thechokes 22A-B may need to travel some distance (e.g., 12 ft. or so). Additionally, theflow paths 55A-B can be coupled with various bends, not necessarily depicted in this schematic view. Further, wave pulses may tend to originate from the pump(s) 54 and travel along theflow paths 55A-B. - Moreover, any hydraulic hoses used for the flow-
paths 55A-B can elastically expand (i.e., expand diametrically) as the hydraulic pressure increases. Conversely, the hydraulic hoses used for the flow-paths 55A-B can elastically contract (i.e., contract diametrically) as the hydraulic pressure decreases. When the length of the hoses for the flow-paths 55A-B is long, a large volume of fluid can be contained in the hoses, thereby causing measurable increases and decreases in hydraulic fluid volume corresponding to these pressure changes. As a result, the hoses for the flow-paths 55A-B can effectively respond as an accumulator and can further exaggerate or reduce the responsiveness of the choke actuators. - Consequently, the distance, bends, wave pulses, and the like can create hydraulic frictional losses and delays that hinder the response of the
chokes 22A-B during operations. Moreover, when managed pressure drilling uses two ormore chokes 22A-B in simultaneous operation, the hydraulic losses in the flow-path 55A can be different from the hydraulic losses in flow-path 55B depending on construction of the materials or differences in geometries. This can lead to a different system response between thechokes 22A-B, which requires a more complex control algorithm for thecontroller 40. For example, onehydraulic choke 22A may tend to respond more slowly than the other choke 22B. - It is recognized that electric actuation of the
chokes 22A-B may have faster response times (i.e., closing and opening times for thechokes 22A-B) when compared to hydraulic actuation. However, electric actuation on the drilling rig may not be desirable or even possible for various reasons so that hydraulic actuation may be preferred. - What is needed is a way to mitigate any timing differences that may occur when multiple hydraulic chokes are operating simultaneously, as well as improve the response of individual chokes in a choke manifold for a drilling system. Therefore, the subject matter of the present disclosure is directed to overcoming, or at least reducing the effects of, one or more of the problems set forth above.
- According to the present disclosure, an assembly is used with remote hydraulic power to control flow of wellbore fluid in a drilling system, according to appended claim 1.
- A skid or a manifold can have the at least one choke, the at least one hydraulic actuator, and the at least one control valve disposed thereon. Also, a housing can have the at least one control valve and can be connected to the hydraulic actuator. At least one accumulator can be disposed with the at least one choke and can be coupled to the supply upstream of the at least one control valve.
- The at least one control valve can couple to the hydraulic actuator with a pair of pilot-operated check valves disposed in fluid communication between the at least one control valve and the hydraulic actuator. Additionally, a stage tank can be disposed with the at least one choke and can receive the return of the remote hydraulic power from the at least one control valve. In this case, a pump in fluid communication with the stage tank can be operable to pump the return from the stage tank.
- The at least one control valve can be electrically operable between a first state of no flow, a second state of parallel flow, and a third state of cross flow between the supply and the return with the at least one hydraulic actuator. Finally, a controller can control operation of at least the at least one control valve.
- As noted above, the assembly can have at least one choke, at least one hydraulic actuator, and at least one control valve. In various embodiment, the assembly can have at least two (e.g., two or more) chokes. At least two hydraulic actuators can be disposed respectively with the at least two chokes to actuate operation of the respective chokes in response to hydraulic power. At least two control valves can be disposed respectively with the at least two chokes. The at least two control valves can control supply of the remote hydraulic power respectively to the at least two hydraulic actuators and can control return of the remote hydraulic power respectively from the at least two hydraulic actuators.
- In this arrangement, a first juncture disposed with the at least two chokes can split a common supply line of the supply to at least two supply legs connected respectively to the at least two control valves. Also, a second juncture disposed with the at least two chokes can combine at least two return legs connected respectively from the at least two control valves to a common return line of the return.
- The assembly can further include a source of the remote hydraulic power having a supply line and a return line. The at least one choke, the at least one hydraulic actuator, and the at least one control valve can be disposed away from the source of the remote hydraulic power. For example, a first skid can have the source, while a second skid can have the at least one choke, the at least one hydraulic actuator, and the at least one control valve disposed thereon.
- The source can include a reservoir and a pump. The reservoir is coupled to the return line, and the pump is coupled to the reservoir and the supply line and is operable to provide the hydraulic power via the supply line. The source can also have an accumulator accumulating the supply of the remote hydraulic power.
- According to the present disclosure, a method is used with a remote source of hydraulic power to control flow of wellbore fluid in a drilling system, according to appended claim 14.
- Disposing the at least one hydraulic actuator and the at least one control valve with the at least one choke can involve disposing them together on a skid. The method can further include disposing at least one accumulator with the at least one choke, and accumulating the supply of the hydraulic power upstream of the at least one control valve.
- The method can further include disposing a pair of pilot-operated check valves in fluid communication between the at least one control valve and the hydraulic actuator, and controlling the supply and the return with the pair of pilot-operated check valves. The method can further include receiving the return of the hydraulic power from the at least one control valve at a stage tank disposed with the at least one choke, and pumping the return from the stage tank to the remote source with a pump disposed with the at least one choke.
- In the method, disposing the at least one hydraulic actuator and the at least one control valve with the at least one choke can involve housing the at least one control valve to the hydraulic actuator. Also, controlling with the at least one control valve can include electrically operating the at least one control valve between a first state of no flow, a second state of parallel flow, and a third state of cross flow between the supply and return with the at least one hydraulic actuator.
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Fig. 1A diagrammatically illustrates a managed pressure drilling system having a choke manifold according to the prior art. -
Fig. 1B schematically illustrates features of the prior art choke manifold. -
Fig. 2A schematically illustrates one arrangement of a hydraulic power unit and a choke manifold according to the present disclosure. -
Fig. 2B schematically illustrates another arrangement of a hydraulic power unit and a choke manifold according to the present disclosure. -
Figs. 3-5 schematically illustrate additional arrangements hydraulic power units and choke manifolds according to the present disclosure. -
Fig. 6 schematically illustrates a choke having an integrated arrangement of a control valve, pilot-operated check valves, and a hydraulic actuator. - Systems and methods disclosed herein can be used to control one or more hydraulic chokes in a managed pressure drilling system. Although discussed in this context, the teachings of the present disclosure can apply equally to other types of controlled pressure drilling systems, such as other MPD systems (Pressurized Mud-Cap Drilling, Returns-Flow-Control Drilling, Dual Gradient Drilling, etc.) as well as to Underbalanced Drilling (UBD) systems, as will be appreciated by one skilled in the art having the benefit of the present disclosure.
- As shown in one arrangement of
Figure 2A , ahydraulic power unit 120 includes ahydraulic reservoir 122, one or morehydraulic pumps 124, and necessary piping, fittings and valves. These components can be housed together on a skid or manifold. Asupply line 125A from thepumps 124 communicates the hydraulic power to thechoke unit 100 positioned some distance away from thepower unit 120. In a similar fashion, areturn line 125B from thecontrol unit 100 returns the hydraulics to thereservoir 122. Eachchoke 110A-B is actuated by ahydraulic actuator 112A-B controlled by one of the hydraulicchoke control valves 140A-B located with thechoke 110A-B. Theindependent control valves 140A-B are used to mitigate differences in thechokes 110A-B and provide independent feedback control of thechokes 110A-B. Pilot-actuatedcheck valves 142 can be disposed between thecontrol valves 140A-B and the chokes'actuators 112A-B, as shown inFig 6 . These components of thechoke unit 100 can be housed together on a skid or manifold. - The
control valve 140A-B typically has three settings, such as a closed setting closing off both supply andreturn lines 125A-B, an open setting permitting parallel flow through thelines 125A-B, and a cross-setting that switches the flow direction between thelines 125A-B. Thecontrol valves 140A-B can be operated by solenoid valves or the like with control signals from control lines A and B of thecontroller 40, as noted herein. In turn, the hydraulic power directed by thecontrol valve 140A-B operates the respectivehydraulic actuators 112A-B for the chokes 11 0A-B. - The
supply line 125A communicates hydraulic power from thepower unit 120 to asupply splitter 127A, which splits the communication to parallelsupply legs 129A connected to thecontrol valves 140A-B. Conversely,parallel return legs 129B connect from thecontrol valves 140A-B to areturn splitter 127B, which combines the communication to thereturn line 125B. - With the disclosed configuration, the lengths of the hydraulic communication between the
choke actuators 112A-B and the corresponding hydraulicchoke control valve 140A-B are significantly reduced or eliminated. As noted above, any hydraulic hoses used for the flow-paths can elastically expand (i.e., expand diametrically) as the hydraulic pressure increases and can elastically contract (i.e., contract diametrically) as the hydraulic pressure decreases. As a result, measurable increases and decreases in hydraulic fluid volume can occur due to the pressure changes and can exaggerate or reduce the responsiveness of the choke actuators. Here, however, thechoke control valves 140A-B are located in proximity to theactuators 112A-B so that long hydraulic hoses and large volumes of hydraulic fluid are no longer used between thecontrol valves 140A-B and thechoke actuators 112A-B. Overall, this configuration ofFigure 2A can improve the choke response. - Additionally, the mounting of each hydraulic
choke control valve 140A-B can be arranged such that the lengths ofhydraulic lines 129A-B after thesplitters 127A-B to thecontrol valves 140A-B can match and the number of fittings between thesplitters 127A-B and eachchoke 110A-B can be the same. (In general, thehydraulic lines 125A-B from thepower unit 120 to thesplitters 127A-B do not necessarily need a matching length and the like, although they could.) - In particular, having the
control valves 140A-B located directly adjacent to each choke actuator 112A-B allows the onemain supply line 125A and matchingsupply legs 129A after thesupply splitter 127A to be used to operate both thechokes 110A-B. The singlehydraulic supply line 125A splits off with the supply splitter orjuncture 127A at or near the location of thechokes 140A-B to the matchingsupply legs 129A so that the hydraulic losses to eachchoke 110A-B can be relatively equal. This split arrangement of thereturn legs 129B, returnsplitter 127B, and thesingle return line 125B can also be used for the hydraulic returns of thechokes 110A-B to thepower unit 120. The arrangement oflines 125A-B,splitters 127A-B, and splitlegs 129A-B in this manner can make any potential hydraulic losses between eachchoke 110A-B and the hydraulic power relatively the same. - Because the
choke unit 100 can use one commonhydraulic line 125A from thepower unit 120, one ormore accumulators 126 can be located with thechokes 110A-B instead of being located at thepower unit 120. With theaccumulators 126 located in this way, the hydraulic response time for the set of two ormore chokes 110A-B can be reduced. Using the accumulator(s) 126 can also minimize the response time should thechoke unit 100 use asingle choke 110. - As noted above, wave pulses originating from a pump can adversely affect choke performance. In the present arrangement with the
control valves 140A-B (and optionally the accumulator(s) 126) positioned away from the one ormore pumps 124, any potential wave pules generated by thepumps 124 can be dampened, which can improve the choke response. In fact, a damper (not shown), such as a biased piston, could be added downstream of the one or more pumps 124. Additionally, the particular type ofpump 124 used can further reduce any potential pulses. - Moreover, the
common supply line 125A, which can use larger or more rigid tubing, to deliver hydraulic fluid near the chokes 11 0A-B before splitting at the splitter 127 to supply thedual control valves 140A-B and chokeactuators 112A-B can reduce effects of tubing oscillation in the hydraulic system. Likewise, having shorter lines of communication after theaccumulator 126 can reduce the total volume of hydraulic fluid between theaccumulator 126 and chokes'actuators 112A-B, thus providing faster response. - As shown in
Figure 2A , oneaccumulator 126 can couple to both the return and the supply. Connection of theaccumulator 126 to the return may allow for bleed down of theaccumulator 126 and may not be needed. Alternatively, the use of twoaccumulators 126, one for each of thesplit legs 129A-B may help improve the chokes' response times by shortening the distance between the stored energy and thehydraulic actuators 112A-B. Having twosmaller accumulators 126 compared to a single larger one may also allow for different space requirements on the skid or manifold for thechoke unit 100. If human intervention is required to bypass thechokes 110A-B, it may be facilitated by having theaccumulator 126 close to thechokes 110A-B since theaccumulator 126 needs to be isolated before thechoke 110A-B is manually bypassed. - In some additional features, lighter components can be used in the solenoid of the
control valve 140 to improve its response. Quick disconnects can be used for the various couplings and fittings in the hydraulic system. If the quick disconnect affects the choke's response, this could be mitigated by moving the quick disconnect to just upstream of theactuators 112A-B. For repair or maintenance, each actuator 112A-B and choke 110A-B can be integrated as a unit. This makes sense from an assembly standpoint since different choke-actuator combinations are not typically used. - As noted above,
Figure 2A shows an arrangement where thehydraulic power unit 120 can be implemented as one skid or manifold that couples by thelines 125A-B to thechoke unit 100 implemented as another skid or manifold havingdual chokes 110A-B and the other components. Other arrangements are possible. For example, one skid having ahydraulic power unit 120 can operate asingle choke 110, which can be housed on another skid. - As shown in another arrangement of
Figure 2B , thehydraulic power unit 120 includes thehydraulic reservoir 122, the one or morehydraulic pumps 124, theaccumulator 126, and necessary piping, fittings, and valves. These components can be housed together on a skid or manifold. First supply andreturn lines 123A from thepumps 124 communicate the hydraulic power and returns between thepower unit 120 and thechoke unit 100 positioned some distance away from thepower unit 120. In a similar fashion, second supply and returnlines 123B communicate the hydraulic power and returns between thepower unit 120 and thechoke unit 100. - Each
choke 110A-B is actuated by itshydraulic actuator 112A-B controlled by one of the hydraulicchoke control valves 140A-B located with thechoke 110A-B. As noted previously, thelocalized control valves 140A-B are used to mitigate differences in the chokes 11 0A-B and provide independent feedback control of the chokes 11 0A-B. Pilot-actuatedcheck valves 142 can be disposed between thecontrol valves 140A-B and the chokes'actuators 112A-B. These components of thechoke unit 100 can be housed together on a skid or manifold. -
Figures 3-5 schematically illustrate additional arrangementshydraulic power units 120 and chokeunits 100 according to the present disclosure. InFigure 3 , thehydraulic power unit 120 includes a tank orreservoir 122, apump 124, and anaccumulator 126. These components are implemented on a skid or manifold for theunit 120 and connect by supply andreturn lines 125A-B to thechoke unit 100, which can be housed on a separate skid or manifold. - As shown here, the
choke unit 100 includes achoke 110, ahydraulic actuator 112, and acontrol valve 140. Pilot-operatedcheck valves 142 may be used between thecontrol valve 140 and the choke'sactuator 112. This arrangement places the hydraulic switching of hydraulic power from thepower unit 120 at, near, or on thechoke 110 of thechoke unit 100, which can have a number of benefits as disclosed herein. -
Figure 4 shows a similar arrangement toFigure 3 except that thechoke unit 100 includes theaccumulator 126 on its skid near thechoke 110. As noted herein, theaccumulator 126 on thesupply line 125A can have a number of benefits stemming from its close proximity to thechoke 110. - Backpressure in the
hydraulic return line 125B downstream of thechoke 110 can be another consideration in choke response. Thereturn tank 122 can be moved closer to thechoke 110 to reduce backpressure. Alternatively, a second tank can be added to the return to help deal with backpressure. For example,Figure 5 shows an additional arrangement in which components (e.g.,control valve 140,actuator 112, choke 110,accumulator 126, etc.) are disposed at thechoke unit 100. Here, thechoke unit 100 further includes anauxiliary pump 150 and astage tank 152 on the return from thecontrol valve 140. As high pressure hydraulics are communicated to thechoke 110 via the high-pressure supply line 125A to actuate thechoke 110 with theactuator 112, expended hydraulics from thecontrol valve 140 travel along the low-pressure return to thestage tank 152, which can be exposed to atmospheric pressure. This produces an advantageous pressure differential close to thecontrol valve 140 so that its operation can be faster and so the choke response can be improved. - Expended fluid in the
collection tank 152 can then be pumped by theauxiliary pump 150 to thereservoir tank 122 on thehydraulic power unit 120 via thereturn line 125B. As shown inFigure 5 , thestage tank 152 can include alevel sensor 154. When the fluid reaches a certain level in thestage tank 152, theauxiliary pump 150 can pump fluid back to the unit'smain tank 122. Since the distance along thereturn line 125B can be quite long (e.g., 3.66 m (12 ft), or so), use of theauxiliary pump 150 andcollection tank 152 can facilitate the travel of the expelled fluid back to thereservoir tank 122 by reducing the line friction and any potential backpressure that the expelled fluid might otherwise encounter. - As can be seen, the addition of the
stage tank 152 as inFigure 5 immediately downstream of thechoke 110 can improve sluggish choke response. The hydraulic fluid from thechoke actuator 112 can empty directly at atmospheric pressure into thestage tank 152 to then be pumped back by theauxiliary pump 150. This can eliminate the extended and closed return line typically used to return expelled fluid to thehydraulic power unit 120. - As detailed above, sluggish choke response can be caused by backpressure in both the supply and return of the hydraulic power. As in the various arrangements disclosed above, integrating hydraulic components closer to choke 110 and its
actuator 112 can improve the sluggish choke response and improve operation. With that said, some of these hydraulic components can be affixed to, integrated into, or otherwise made part of thechoke 110 and itsactuator 112. - For example,
Figure 6 shows an arrangement of acontrol valve 140, ahydraulic actuator 112, and achoke 110 for thechoke unit 100. Thesupply line 125A and returnline 125B couple byfittings 162 to an adapter orhousing 160. As shown, thehousing 160 can hold thecontrol valve 140 and its related components, such as the pilot-actuatedcheck valves 142 and solenoid (not shown). As before, thesupply line 125A can include anaccumulator 126 that is mounted on thechoke unit 100 near thechoke 110. Thereturn line 125B can couple to thecollection tank 152 andauxiliary pump 150 as before to return expended hydraulics from thechoke 110. - In general, the
housing 160 can be affixed to or incorporated into thehydraulic actuator 112 for thechoke 110. For example, thehousing 160 can be sealed in communication with hydraulic ports 114 of thehydraulic actuator 112 using gaskets, seals, etc. In this way, thehousing 160 can be used to retrofit or integrate with an existing choke actuator and can be configured to do so in a number of ways. - In some arrangements, for example, the
hydraulic actuator 112 for thechoke 110 can be a worm gear actuator. High-pressure fluid communicated from thecontrol valve 140 to afirst port 114A can rotate the worm gear to close thechoke 110 while low-pressure fluid is expelled from asecond port 114B. In the reverse, high-pressure fluid communicated from thecontrol valve 140 to thesecond port 114B can rotate the worm gear to open thechoke 110 while low-pressure fluid is expelled from thefirst port 114A. Meanwhile, thecontrol valve 140 directs the high-pressure fluid from thesupply line 125A and returns the low-pressure fluid to thereturn line 125B.
Claims (18)
- An assembly used with remote hydraulic power communicated between a power unit (120) and a choke unit (100) via a supply line (125A) and a return line (125B) to control flow of wellbore fluid in a drilling system, the power unit (120) positioned some distance away from the choke unit (100), the assembly comprising:at least one choke (110) disposed at the choke unit (100) and being operable to control the flow of the wellbore fluid to other portions of the drilling system (10);at least one hydraulic actuator (112) disposed with the at least one choke (110) at the choke unit (100) and actuating operation of the at least one choke (110) in response to the remote hydraulic power; andat least one control valve (140) disposed with the at least one choke (110) at the choke unit (100), the at least one control valve (140) controlling supply of the remote hydraulic power from the power unit (120) to the at least one hydraulic actuator (112) via the supply line (125A) and controlling return of the remote hydraulic power from the at least one hydraulic actuator (112) to the power unit (120) via the return line (125B).
- The assembly of claim 1, further comprising one of:
a skid housing the choke unit (100) having at least one choke (110), the at least one hydraulic actuator (112), and the at least one control valve (140) disposed thereon;at least one accumulator (126) located with the at least one choke (110) at the choke unit and coupled to the supply upstream of the at least one control valve (140);a housing having the at least one control valve (140) and being connected to the at least one hydraulic actuator (120); and,a controller (40) controlling operation of at least the at least one control valve (40). - The assembly of claim 1, wherein the at least one control valve (140) couples to the at least one hydraulic actuator (112) with a pair of pilot-operated check valves (142) disposed in fluid communication between the at least one control valve (140) and the at least one hydraulic actuator (112).
- The assembly of claim 1, further comprising:a stage tank (152) located with the at least one choke (110) at the choke unit (100) and receiving the return of the remote hydraulic power from the at least one control valve (140); anda stage pump (150) in fluid communication with the stage tank (152) and being operable to pump the return from the stage tank (152).
- The assembly of any one of claims 1 to 4, wherein the at least one control valve (140) is electrically operable between a first state of no flow, a second state of parallel flow, and a third state of cross flow between the supply and the return with the at least one hydraulic actuator (112).
- The assembly of claim 5, wherein:the at least one hydraulic actuator (112) comprises a worm gear actuator, comprising first and second hydraulic ports (114A-B) configured to actuate operation of the at least one choke (110) in response to the remote hydraulic power communicated with the first and second hydraulic ports (114A-B);the at least one control valve (140) in the first state closing off both the supply (125A) an return lines (125B);the at least one control valve (140) in the second and third states connects the supply (125A) of the supply line and the return (125B) of the return line (125B) of the remote hydraulic power to the first and second hydraulic ports (114A-B);the at least one control valve (140) in the second state of parallel flow to close the at least one choke (110) is configured to control the supply of the remote hydraulic power from the supply line (125A) to the first hydraulic port (114A) of the at least one hydraulic actuator (112) and is configured to control the return of the remote hydraulic power from the second hydraulic port (114B) of the at least one hydraulic actuator (112) to the return line (125B) to the second remote location; andthe at least one control valve (140) in the third state of cross flow to open the at least one choke (110) is configured to cross the supply of the supply line (125A) and the return of the return line (125B) relative to the first and second hydraulic ports (114A-B).
- The assembly of claim 1, wherein the at least one choke (110) comprises two or more chokes (110) operable to control the flow of the wellbore fluid to the other portions of the drilling system (10);
wherein the at least hydraulic actuator (112) comprises two or more hydraulic actuators (112) disposed at the choke unit (100) respectively with the two or more chokes (110) and actuating operation of the respective chokes (110) in response to the remote hydraulic power; and wherein the at least control valve (112) comprises two or more control valves (112) disposed at the choke unit (100) respectively with the two or more chokes (110), the two or more control valves (112) controlling the supply of the remote hydraulic power respectively to the two or more hydraulic actuators (112) and controlling the return of the remote hydraulic power respectively from the two or more hydraulic actuators (112). - The assembly of claim 7, comprising:a first juncture located with the two or more chokes (110) at the choke unit (100) and splitting the supply line (125A) of the supply to two or more supply legs (129A) connected respectively to the two or more control valves (110); and,a second juncture (127B) located with the two or more chokes (110) and combining two or more return legs (129B) connected respectively from the two or more control valves (110) to the return line (125B) of the return.
- The assembly of claim 7, further comprising at least one accumulator located with the two or more chokes (110) at the choke unit (100) and coupled to the supply upstream of the two or more control valves (100),
wherein the two or more control valves (110) each couples to the respective hydraulic actuator (112) with a pair of pilot-operated check valves (142) disposed in fluid communication between the each control valve (11) and the respective hydraulic actuator (112). - The assembly of claim 1, further comprising a source (120) of the remote hydraulic power disposed on the remote hydraulic power unit (120) and having a return line (125B), wherein the at least one choke (110), the at least one hydraulic actuator (112), and the at least one control valve (140) are disposed at the choke unit (100) away from the source (120) of the remote hydraulic power, wherein the source comprises:a reservoir (122) coupled to the return line (125B); anda source pump (124) coupled to the reservoir (122) and the supply line (125A), the source pump (124) operable to provide the hydraulic power via the supply line (125A).
- The assembly of claim 10, further comprising:a stage tank (152) located with the at least one choke (110) at the choke unit and receiving the return of the remote hydraulic power from the at least one control valve (140); and,a stage pump (150) in fluid communication with the stage tank (152) and being operable to pump the return from the stage tank (152) to the source (120).
- The assembly of claim 10, wherein the source comprises an accumulator (126) accumulating the supply of the remote hydraulic power.
- The assembly of claim 10, comprising a first skid housing the power unit (120) having the source (120); and a second skid housing the choke unit (100) having the at least one choke (110), the at least one choke (110), the at least one hydraulic actuator (112), and the at least one control valve (140) disposed thereon.
- A method used with a remote source of hydraulic power communicated between a power unit (120) and a choke unit (100) via a supply line (125A) to control flow of wellbore fluid in a drilling system (10), the power unit positioned some distance away from the choke unit (100), the method comprising:disposing at least one hydraulic actuator (112) and at least one control valve (140) on the choke unit (100) with at least one choke (110);controlling the flow of the wellbore fluid to other portions of the drilling system (10) by operating the at least one choke (110) with the at least one hydraulic actuator (112); andoperating the hydraulic actuator with the hydraulic power communicated between the hydraulic power unit (120) and the choke unit (100) by -controlling, with the at least one control valve (140), disposed on the choke unit (100), supply of the hydraulic power from the remote source on the choke unit (100) to the at least one hydraulic actuator disposed on the choke unit (100), andcontrolling, with the at least one control valve (140) disposed on the choke unit (100), return of the hydraulic power to the remote source disposed on the hydraulic power unit (120) from the at least one hydraulic actuator (112) disposed on the choke unit (100).
- The method of claim 14, wherein disposing the at least one hydraulic actuator (112) and the at least one control valve (140) with the at least one choke (110) comprises disposing them together on a skid for the choke unit (100); or,
Wherein disposing the at least one hydraulic actuator (112) and the at least one control valve (140) with the at least one choke (110) on the choke unit (100) comprises housing the at least one control valve (140) on the hydraulic actuator (112). - The method of claim 14, further comprising one of:disposing at least one accumulator (126) at the choke unit (100) with the at least one choke (11) and accumulating the supply of hydraulic power upstream of the at least one control valve (140);disposing a pair of pilot-operated check valves (142) in fluid communication between the at least one control valve (140) and the at least one hydraulic actuator (112) and controlling the supply and the return with the pair of pilot-operated check valves; and,receiving the return of the hydraulic power from the at least one control valve (140) at a stage tank (152) disposed at the choke unit (100) with the at least one choke (110), andpumping the return from the stage tank (152) to the remote source with a pump disposed at the choke unit (100) with the at least one choke (110).
- The method of any one of claims 14 to 16, wherein controlling with the at least one control valve (140) comprises electrically operating the at least one control valve (140) between a first state of no flow, a second state of parallel flow, and a third state of cross flow between the supply and return with the at least one hydraulic actuator.
- The method of claim 17,wherein the at least one hydraulic actuator (112) comprises a worm gear actuator, comprising first and second hydraulic ports (114A-B) configured to actuate operation of the at least one choke (110) in response to the remote hydraulic power communicated with the first and second hydraulic ports (114A-B);wherein controlling comprises:controlling, with the at least one control valve (140) disposed on the choke unit (100) in the second state of parallel flow to close the at least one choke (110), the supply of the hydraulic power via the supply line (125A) from the remote source to the first hydraulic port (114A) of the at least one hydraulic actuator (112), and controlling the return of the hydraulic power via the return line (125B) to the remote source from the at least one hydraulic actuator (112); andcontrolling, with the at least one control valve in the third state of cross flow to open the at least one choke (110), the supply of the hydraulic power via the supply line (125A) from the remote source to the second hydraulic port (114B) of the at least one hydraulic actuator (112), and controlling the return of the hydraulic power to the remote source via the return line (125B) from the at least one hydraulic actuator (140).
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US201562099936P | 2015-01-05 | 2015-01-05 | |
PCT/US2016/012134 WO2016111979A1 (en) | 2015-01-05 | 2016-01-05 | Control of multiple hydraulic chokes in managed pressure drilling |
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EP3242991A1 EP3242991A1 (en) | 2017-11-15 |
EP3242991B1 true EP3242991B1 (en) | 2024-04-10 |
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EP16701218.6A Active EP3242991B1 (en) | 2015-01-05 | 2016-01-05 | Control of multiple hydraulic chokes in managed pressure drilling |
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EP (1) | EP3242991B1 (en) |
BR (1) | BR112017014564B1 (en) |
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BR112017014564B1 (en) | 2022-08-09 |
BR112017014564A2 (en) | 2018-04-10 |
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