Note: Descriptions are shown in the official language in which they were submitted.
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MANAGED PRESSURE DRILLING MANIFOLD, MODULES, AND METHODS
Cross-Reference to Related Applications
This application claims the benefit of the filing date of, and priority to,
U.S. Patent
Application No. 62/480,158, filed March 31, 2017, the entire disclosure of
which is hereby
incorporated herein by reference.
This application also claims the benefit of the filing date of, and priority
to, U.S. Patent
Application No. 15/704,747, filed September 14, 2017, the entire disclosure of
which is hereby
incorporated herein by reference.
This application also claims the benefit of the filing date of, and priority
to, U.S. Patent
Application No. 62/576,395, filed October 24, 2017, the entire disclosure of
which is hereby
incorporated herein by reference.
Technical Field
The present disclosure relates generally to oil and gas exploration and
production operations
and, more particularly, to a managed pressure drilling ("MPD") manifold used
during oil and gas
drilling operations.
Background
An MPD system may include drilling choke(s) and a flow meter, with the
drilling choke(s)
and the flow meter being separate and distinct from one another. The drilling
choke(s) are in fluid
communication with a wellbore that traverses a subterranean formation. As a
result, the drilling
system may be used to control backpressure in the wellbore as part of an
adaptive drilling process
that allows greater control of the annular pressure profile throughout the
wellbore. During such a
process, the flow meter measures the flow rate of drilling mud received from
the wellbore. In some
cases, the configuration of the drilling choke(s) and/or the flow meter may
decrease the efficiency of
drilling operations, thereby presenting a problem for operators dealing with
challenges such as, for
example, continuous duty operations, harsh downhole environments, and multiple
extended-reach
lateral wells, among others. Further, the configuration of the drilling
choke(s) and/or the flow meter
may adversely affect the transportability and overall footprint of the
drilling choke(s) and/or the
flow meter at the wellsite. Finally, the separate and distinct nature of the
drilling choke(s) and the
flow meter can make it difficult to inspect, service, or repair the drilling
choke(s) and/or the flow
meter, and/or to coordinate the inspection, service, repair, or replacement of
the drilling choke(s)
and/or the flow meter. Therefore, what is needed is a method, apparatus, or
system that addresses
one or more of the foregoing issues, and/or one or more other issues.
Brief Description of the Drawings
Figure 1 is a diagrammatic view of a drilling system including, among other
components, an
MPD manifold, according to one or more embodiments of the present disclosure.
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Figure 2 is a diagrammatic view of the MPD manifold of Figure 1 in a first
configuration,
the MPD manifold including a choke module, a flow meter module, and a valve
module, according
to one or more embodiments of the present disclosure.
Figure 3 is a diagrammatic view of another embodiment of the MPD manifold of
Figure 1 in
a second configuration, the MPD manifold including a choke module, a flow
meter module, and a
valve module, according to one or more embodiments of the present disclosure.
Figure 4(a) is a perspective view of a first embodiment of the MPD manifold of
any one of
Figures 1-3 with the flow meter module extending in a generally horizontal
orientation, the choke
module of the MPD manifold including a first pair of flow blocks, and the
valve module of the MPD
manifold including a second pair of flow blocks, according to one or more
embodiments of the
present disclosure.
Figure 4(b) is a left side elevational view of the MPD manifold of Figure
4(a), according to
one or more embodiments of the present disclosure.
Figure 4(c) is a rear elevational view of the MPD manifold of Figure 4(a),
according to one
or more embodiments of the present disclosure.
Figure 4(d) is a right side elevational view of the MPD manifold of Figure
4(a), according to
one or more embodiments of the present disclosure.
Figure 4(e) is a front elevational view of the MPD manifold of Figure 4(a),
according to one
or more embodiments of the present disclosure.
Figure 4(f) is a top plan view of the MPD manifold of Figure 4(a), according
to one or more
embodiments of the present disclosure.
Figure 5(a) is a perspective view of one of the flow blocks from the first
pair of Figures 4(a)-
(f), according to one or more embodiments of the present disclosure.
Figure 5(b) is a cross-sectional view of the flow block of Figure 5(a), taken
along the line
5(b)-5(b) of Figure 5(a), according to one or more embodiments of the present
disclosure.
Figure 6(a) is a perspective view of one of the flow blocks from the second
pair of Figures
4(a)-(f), according to one or more embodiments of the present disclosure.
Figure 6(b) is a cross-sectional view of the flow block of Figure 6(a), taken
along the line
6(b)-6(b) of Figure 6(a), according to one or more embodiments of the present
disclosure.
Figure 7(a) is a perspective view of a second embodiment of the MPD manifold
of any one
of Figures 1-3 with the flow meter module extending in a generally vertical
orientation, the choke
module of the MPD manifold including the first pair of flow blocks, and the
valve module of the
MPD manifold including the second pair of flow blocks, according to one or
more embodiments of
the present disclosure.
Figure 7(b) is a left side elevational view of the MPD manifold of Figure
7(a), according to
one or more embodiments of the present disclosure.
Figure 7(c) is a right side elevational view of the MPD manifold of Figure
7(a), according to
one or more embodiments of the present disclosure.
Figure 7(d) is a top plan view of the MPD manifold of Figure 7(a), according
to one or more
embodiments of the present disclosure.
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Figure 8 is a flow chart illustration of a method for controlling the
backpressure of a drilling
mud within a wellbore, according to one or more embodiments of the present
disclosure.
Figure 9 is a flow chart illustration of another method for controlling the
backpressure of a
drilling mud within a wellbore, according to one or more embodiments of the
present disclosure.
Figure 10(a) is a perspective view of a third embodiment of the MPD manifold
of any one of
Figures 1-3 with the flow meter module extending in a generally horizontal
orientation, the choke
module of the MPD manifold including a first pair of flow blocks, and the
valve module of the MPD
manifold including the second pair of flow blocks, according to one or more
embodiments of the
present disclosure.
Figure 10(b) is a left side elevational view of the MPD manifold of Figure
10(a), according
to one or more embodiments of the present disclosure.
Figure 10(c) is a rear elevational view of the MPD manifold of Figure 10(a),
according to
one or more embodiments of the present disclosure.
Figure 10(d) is a right side elevational view of the MPD manifold of Figure
10(a), according
to one or more embodiments of the present disclosure.
Figure 10(e) is a front elevational view of the MPD manifold of Figure 10(a),
according to
one or more embodiments of the present disclosure.
Figure 10(f) is a top plan view of the MPD manifold of Figure 10(a), according
to one or
more embodiments of the present disclosure.
Figure 11(a) is a perspective view of one of the flow blocks from the first
pair of Figures
10(a)-(f), according to one or more embodiments of the present disclosure.
Figure 11(b) is a cross-sectional view of the flow block of Figure 11(a),
taken along the line
11(b)-11(b) of Figure 11(a), according to one or more embodiments of the
present disclosure.
Figure 12(a) is a perspective view of a fourth embodiment of the MPD manifold
of any one
of Figures 1-3 with the flow meter module extending in a generally vertical
orientation, the choke
module of the MPD manifold including the first pair of flow blocks, and the
valve module of the
MPD manifold including the second pair of flow blocks, according to one or
more embodiments of
the present disclosure.
Figure 12(b) is a left side elevational view of the MPD manifold of Figure
12(a), according
to one or more embodiments of the present disclosure.
Figure 12(c) is a right side elevational view of the MPD manifold of Figure
12(a), according
to one or more embodiments of the present disclosure.
Figure 12(d) is a top plan view of the MPD manifold of Figure 12(a), according
to one or
more embodiments of the present disclosure.
Figure 13 is a flow chart illustration of a method for controlling the
backpressure of a
drilling mud within a wellbore, according to one or more embodiments of the
present disclosure.
Figure 14 is a flow chart illustration of another method for controlling the
backpressure of a
drilling mud within a wellbore, according to one or more embodiments of the
present disclosure.
Figure 15 is a diagrammatic illustration of a control unit adapted to be
connected to one or
more components (or sub-components) of the drilling system of Figure 1,
according to one or more
embodiments of the present disclosure.
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Figure 16 is a diagrammatic illustration of a computing device for
implementing one or more
embodiments of the present disclosure.
Detailed Description
In an embodiment, as illustrated in Figure 1, a drilling system is generally
referred to by the
.. reference numeral 10 and includes a wellhead 12, a blowout preventer
("BOP") 14, a rotating
control device ("RCD") 16, a drilling tool 18, an MPD manifold 20, a mud gas
separator ("MGS")
22, a vent or flare 24, a shaker 26, and a mud pump 28. The wellhead 12 is
located at the top or
head of an oil and gas wellbore 29 that penetrates one or more subterranean
formations, and is used
in oil and gas exploration and production operations such as, for example,
drilling operations. The
BOP 14 is operably coupled to the wellhead 12 to prevent blowout, i.e., the
uncontrolled release of
crude oil and/or natural gas from the wellbore 29 during drilling operations.
The drilling tool 18 is
operably coupled to a drill string (not shown), and extends within the
wellbore 29. The drill string
extends into the wellbore 29 through the BOP 14 and the wellhead 12. Moreover,
the RCD 16 is
operably coupled to the BOP 14, opposite the wellhead 12, and forms a friction
seal around the drill
string. The MPD manifold 20 is operably coupled to, and in fluid communication
with, the RCD 16.
The MGS 22 is operably coupled to, and in fluid communication with, the MPD
manifold 20. The
flare 24 and the shaker 26 are both operably coupled to, and in fluid
communication with, the MGS
22. The mud pump 28 is operably coupled between, and in fluid communication
with, the shaker 26
and the drill string.
In operation, the drilling system 10 is used to extend the reach or
penetration of the wellbore
29 into the one or more subterranean formations. To this end, the drill string
is rotated and weight-
on-bit is applied to the drilling tool 18, thereby causing the drilling tool
18 to rotate against the
bottom of the wellbore 29. At the same time, the mud pump 28 circulates
drilling fluid to the
drilling tool 18, via the drill string, as indicated by the arrows 30 and 32.
The drilling fluid is
discharged from the drilling tool 18 into the wellbore 29 to clear away drill
cuttings from the drilling
tool 18. The drill cuttings are carried back to the surface by the drilling
fluid via an annulus of the
wellbore 29 surrounding the drill string, as indicated by the arrow 34. The
drilling fluid and the drill
cuttings, in combination, are also referred to herein as "drilling mud."
As indicated by the arrow 34 in Figure 1, the drilling mud flows into the RCD
16 through the
wellhead 12 and the BOP 14. The RCD 16 diverts the flow of the drilling mud to
the MPD
manifold 20 while preventing, or at least reducing, communication between the
annulus of the
wellbore 29 and atmosphere. In this manner, the RCD 16 enables the drilling
system 10 to operate
as a closed-loop system. The MPD manifold 20 receives the drilling mud from
the RCD 16, and is
adjusted to maintain the desired backpressure within the wellbore 29, as will
be discussed in further
detail below. The MGS 22 receives the drilling mud from the MPD manifold 20,
and captures and
separates gas from the drilling mud. The captured and separated gas is sent to
the flare 24 to be
burnt off Alternatively, the flare 24 is omitted and the captured and
separated gas is reinjected into
the one or more subterranean formations. The shaker 26 receives the drilling
mud from the MGS
22, and removes the drill cuttings therefrom. The mud pump 28 then
recirculates the drilling fluid to
the drilling tool 18, via the drill string.
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In an embodiment, as illustrated in Figure 2 with continuing reference to
Figures 1, the MPD
manifold 20 includes a choke module 36, a flow meter module 38, and a valve
module 40. The
choke module 36 is operably coupled to, and adapted to be in fluid
communication with, the flow
meter module 38 via the valve module 40. The choke module 36, the flow meter
module 38, and the
valve module 40 are together mounted to a skid 42. In some embodiments, one or
more instruments
such as, for example, a temperature sensor 44, a densometer 46, and one or
more pressure sensors,
are operably coupled to the choke module 36. Additionally, one or more
instruments such as, for
example, a temperature sensor 48, a densometer 50, and one or more other
pressure sensors, are
operably coupled to the valve module 40. In some embodiments, one or more of
the temperature
.. sensors 44 and 48, one or more of the densometers 46 and 50, and pressure
sensor(s) are also
mounted to the skid 42. In some embodiments, one or more of the temperature
sensors 44 and 48,
one or more of the densometers 46 and 50, and pressure sensor(s) are part of
the MPD manifold 20.
In addition to, or instead of, being mounted to the skid 42, the choke module
36, the flow meter
module 38, and the valve module 40 may be freestanding on the ground or
mounted to a trailer (not
shown) that can be towed between operational sites.
During the operation of the drilling system 10, the valve module 40 receives
the drilling mud
from the RCD 16, as indicated by arrows 52 and 54. The temperature sensor 48
measures the
temperature of the drilling mud immediately before the drilling mud is
received by the valve module
40. In addition, the densometer 50 measures the density of the drilling mud
immediately before the
drilling mud is received by the valve module 40. In some embodiments, one or
more pressure
sensors (not shown in Figure 2) measure the pressure of the drilling mud
immediately before the
drilling mud is received by the valve module 40; in some embodiments, the
temperature sensor 48
and/or the densometer 50 includes the one or more pressure sensors. The valve
module 40 routes
the drilling mud to the flow meter module 38, as indicated by arrow 56. The
flow meter module 38
measures the flow rate of the drilling mud before communicating the drilling
mud back to the valve
module 40, as indicated by arrow 57. The valve module 40 then routes the
drilling mud to the choke
module 36, as indicated by arrow 58. The choke module 36 is adjusted to
maintain the desired
backpressure of the drilling mud within the wellbore 29. The MGS 22 receives
the drilling mud
from the choke module 36, as indicated by arrows 60 and 62. The temperature
sensor 44 measures
the temperature of the drilling mud immediately after the drilling mud is
discharged from the choke
module 36. In addition, the densometer 46 measures the density of the drilling
mud immediately
after the drilling mud is discharged from the choke module 36. In some
embodiments, one or more
other pressure sensors (not shown in Figure 2) measure the pressure of the
drilling mud immediately
after the drilling mud is discharged from the choke module 36; in some
embodiments, the
.. temperature sensor 44 and/or the densometer 46 includes the one or more
other pressure sensors.
In some embodiments, one of which is described in further detail below with
reference to
Figure 3, the temperature sensor 44 and the densometer 46 are operably coupled
to the valve module
rather than being operably coupled to the choke module 36. Additionally, the
temperature sensor
48 and the densometer 50 are operably coupled to the choke module 36 rather
than being operably
40 coupled to the valve module 40. As a result, the choke module 36
receives the drilling mud from the
RCD 16 and the MGS 22 receives the drilling mud from the valve module 40, as
will be described
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in further detail below with reference to Figure 3. In some embodiments,
pressure sensor(s) are also
operably coupled to the valve module 40. In some embodiments, pressure
sensor(s) are also
operably coupled to the choke module 36.
In an embodiment of the choke module 36, as illustrated in Figures 4(a)-(f)
with continuing
reference to Figures 2 and 3, the choke module 36 includes flow blocks 64a-b,
block valves 66a-e,
flow blocks 68a-b, and drilling chokes 70a-b. The block valves 66a-e are each
actuable between an
open configuration in which fluid flow is permitted therethrough, and a closed
configuration in
which fluid flow therethrough is prevented, or at least reduced. In some
embodiments, the block
valves 66a-e are gate valves. Alternatively, one or more of the block valves
66a-e may be another
type of valve such as, for example, a plug valve.
The block valve 66a is operably coupled to the flow block 64a. The flow block
68a is
operably coupled to the block valve 66a via, for example, a spool 72a. The
block valve 66a may
provide isolation of the flow block 68a from the flow block 64a. The block
valve 66b is operably
coupled to the flow block 64b. The drilling choke 70a is operably coupled to
the block valve 66b,
via, for example, a spool 74a. The block valve 66b may provide isolation of
the drilling choke 70a
from the flow block 64b. The drilling choke 70a is operably coupled to the
flow block 68a via, for
example, a spool 76a. The block valve 66c is operably coupled to the flow
block 64a adjacent the
block valve 66a. The flow block 68b is operably coupled to the block valve 66c
via, for example, a
spool 72b. The block valve 66c may provide isolation of the flow block 68b
from the flow block
64a. The block valve 66d is operably coupled to the flow block 64b adjacent
the block valve 66b.
The drilling choke 70b is operably coupled to the block valve 66d via, for
example, a spool 74b.
The block valve 66d may provide isolation of the drilling choke 70b from the
flow block 64b. The
drilling choke 70b is operably coupled to the flow block 68b via, for example,
a spool 76b. The
block valve 66e is operably coupled between the flow blocks 64a and 64b.
In some embodiments, each of the drilling chokes 70a and 70b is a 4-inch inner
diameter
(ID) choke. In some embodiments, each of the drilling chokes 70a and 70b
defines an inner
diameter of about 4 inches.
The choke module 36 is actuable between a backpressure control configuration
and a choke
bypass configuration. In the backpressure control configuration, the flow
block 64b is in fluid
communication with the flow block 64a via one or more of the drilling chokes
70a and/or 70b. In
some embodiments, when the choke module 36 is in the backpressure control
configuration, the
flow block 64b is not in fluid communication with the flow block 64a via the
block valve 66e (i.e.,
the block valve 66e is closed). During the operation of the drilling system
10, when the choke
module 36 is in the backpressure control configuration, one or more of the
drilling chokes 70a
and/or 70b are adjusted to account for changes in the flow rate of the
drilling mud so that the desired
backpressure within the wellbore 29 is maintained. In the choke bypass
configuration, the flow
block 64b is in fluid communication with the flow block 64a via the block
valve 66e. In some
embodiments, when the choke module 36 is in the choke bypass configuration,
the flow block 64b is
not in fluid communication with the flow block 64a via the drilling chokes 70a
or 70b. In some
embodiments, to enable such fluid communication between the flow blocks 64a
and 64b via the
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block valve 66e, the block valves 66a-d are actuated to the closed
configuration and the block valve
66e is actuated to the open configuration.
In some embodiments, one or more of the drilling chokes 70a and/or 70b are
manual chokes,
thus enabling rig personnel to manually control backpressure within the
drilling system 10 when the
choke module 36 is in the backpressure control configuration. In some
embodiments, one or more
of the drilling chokes 70a and/or 70b are automatic chokes controlled
automatically by electronic
pressure monitoring equipment when the choke module 36 is in the backpressure
control
configuration. In some embodiments, one or more of the drilling chokes 70a
and/or 70b are
combination manual/automatic chokes.
In some embodiments, when the choke module 36 is in the backpressure control
configuration, the flow block 64b is in fluid communication with the flow
block 64a via at least the
drilling choke 70a. To enable such fluid communication between the flow blocks
64a and 64b via
the drilling choke 70a, the block valves 66a and 66b are actuated to the open
configuration, and the
block valve 66e is actuated to the closed configuration. As a result, the flow
block 64b is in fluid
communication with the flow block 64a via at least the block valve 66b, the
spool 74a, the drilling
choke 70a, the spool 76a, the flow block 68a, the spool 72a, and the block
valve 66a, respectively.
In some embodiments, when the choke module 36 is in the backpressure control
configuration, the flow block 64b is in fluid communication with the flow
block 64a via at least the
drilling choke 70b. To enable such fluid communication between the flow blocks
64a and 64b via
the drilling choke 70b, the block valves 66c and 66d are actuated to the open
configuration, and the
block valve 66e is actuated to the closed configuration. As a result, the flow
block 64b is in fluid
communication with the flow block 64a via at least the block valve 66d, the
spool 74b, the drilling
choke 70b, the spool 76b, the flow block 68b, the spool 72b, and the block
valve 66c, respectively.
In some embodiments, the flow blocks 64a and 64b are substantially identical
to one another
and, therefore, in connection with Figures 5(a)-(b), only the flow block 64a
will be described in
detail below; however, the description below applies to both of the flow
blocks 64a and 64b. In an
embodiment, as illustrated in Figures 5(a)-(b) with continuing reference to
Figures 4(a)-(f), the flow
block 64a includes ends 78a-b and sides 80a-d. In some embodiments, the ends
78a and 78b are
spaced in a substantially parallel relation. In some embodiments, the sides
80a and 80b are spaced
in a substantially parallel relation, each extending from the end 78a to the
end 78b. In some
embodiments, the sides 80c and 80d are spaced in a substantially parallel
relation, each extending
from the end 78a to the end 78b. In some embodiments, one of which is shown in
Figures 5(a)-(b),
the sides 80a and 80b are spaced in a substantially parallel relation, and the
sides 80c and 80d are
spaced in a substantially parallel relation. In some embodiments, the sides
80a and 80b are spaced
in a substantially perpendicular relation with the sides 80c and 80d. In some
embodiments, the ends
78a and 78b are spaced in a substantially perpendicular relation with the
sides 80a and 80b. In some
embodiments, the ends 78a and 78b are spaced in a substantially perpendicular
relation with the
sides 80c and 80d. In some embodiments, one of which is shown in Figures 5(a)-
(b), the ends 78a
and 78b are spaced in a substantially perpendicular relation with the sides
80a, 80b, 80c, and 80d.
In addition, the flow block 64a defines an internal region 82 and fluid
passageways 84a-f. In
some embodiments, the fluid passageway 84a extends through the end 78a of the
flow block 64a
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into the internal region 82. In some embodiments, the fluid passageway 84b
extends through the
end 78b of the flow block 64a into the internal region 82. In some
embodiments, one of which
shown in Figures 5(a)-(b), the fluid passageway 84a extends through the end
78a of the flow block
64a into the internal region 82, and the fluid passageway 84b extends through
the end 78b of the
flow block 64a into the internal region 82. In some embodiments, the fluid
passageways 84a and
84b form a continuous fluid passageway together with the internal region 82.
In some
embodiments, the fluid passageway 84c extends through the side 80a of the flow
block 64a into the
internal region 82. In some embodiments, the fluid passageway 84d extends
through the side 80b of
the flow block 64a into the internal region 82. In some embodiments, one of
which is shown in
Figures 5(a)-(b), the fluid passageway 84c extends through the side 80a of the
flow block 64a into
the internal region 82, and the fluid passageway 84d extends through the side
80b of the flow block
64a into the internal region 82. In some embodiments, the fluid passageways
84c and 84d form a
continuous fluid passageway together with the internal region 82. In some
embodiments, one of
which is shown in Figures 5(a)-(b), the fluid passageways 84e and 84f each
extend through the side
80c of the flow block 64a into the internal region 82. In some embodiments,
one or more of the
fluid passageways 84a, 84c, or 84d are omitted from the flow block 64a, and/or
one or more fluid
passageways analogous to the fluid passageways 84a, 84c, or 84d of the flow
block 64a are omitted
from the flow block 64b.
In an embodiment of the choke module 36, as illustrated in Figures 4(a)-(f)
with continuing
reference to Figures 5(a)-(b), the block valve 66a is operably coupled to the
side 80c of the flow
block 64a and in fluid communication with the internal region 82 thereof via
the fluid passageway
84e, and the block valve 66c is operably coupled to the side 80c of the flow
block 64a (adjacent the
block valve 66a) and in fluid communication with the internal region 82
thereof via the fluid
passageway 84f The block valves 66b and 66d are operably coupled to the flow
block 64b in
substantially the same manner as the manner in which the block valves 66a and
66c are operably
coupled to the flow block 64a. The block valve 66e is operably coupled to the
side 80b of the flow
block 64a and in fluid communication with the internal region 82 thereof via
the fluid passageway
84d. Moreover, the block valve 66e is operably coupled to the flow block 64b
in substantially the
same manner as the manner in which the block valve 66e is operably coupled to
the flow block 64a,
except that the block valve 66e is operably coupled to a side of the flow
block 64b analogous to the
side 80a of the flow block 64a¨as a result, the block valve 66e is in fluid
communication with an
internal region of the flow block 64b via a fluid passageway analogous to the
fluid passageway 84c
of the flow block 64a.
In some embodiments, the operable coupling of the block valves 66a and 66c to
the flow
block 64a and the operable coupling of the block valves 66b and 66d to the
flow block 64b reduce
the number of fluid couplings, and thus potential leak paths, required to make
up the choke module
36. In some embodiments, the manner in which the block valves 66a and 66c are
operably coupled
to the flow block 64a and the manner in which the block valves 66b and 66d are
operably coupled to
the flow block 64b permit the drilling chokes 70a and 70b to be operably
coupled in parallel
between the flow blocks 64a and 64b. In some embodiments, the spacing between
the block valves
66a and 66c operably coupled to the flow block 64a and the spacing between the
block valves 66b
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and 66d operably coupled to the flow block 64b permit the drilling chokes 70a
and 70b to be
operably coupled in parallel between the flow blocks 64a and 64b.
In an embodiment, as illustrated in Figures 4(a)-(f) with continuing reference
to Figures 2
and 3, an embodiment of the valve module 40 is shown in which the valve module
40 includes flow
blocks 86a-b and valves 88a-e. The valves 88a-e are each actuable between an
open configuration
in which fluid flow is permitted therethrough, and a closed configuration in
which fluid flow
therethrough is prevented, or at least reduced. In some embodiments, the
valves 88a-e are gate
valves. Alternatively, one or more of the valves 88a-e may be another type of
valve such as, for
example, a plug valve. The valve 88e is operably coupled between the flow
blocks 86a and 86b.
The valve 88a is operably coupled to the flow block 86a. The valve 88b is
operably coupled to the
flow block 86a, opposite the valve 88a. The valve 88c is operably coupled to
the flow block 86b.
The valve 88d is operably coupled to the flow block 86b, opposite the valve
88c.
The valve module 40 is actuable between a flow metering configuration and a
meter bypass
configuration. In the flow metering configuration, the flow blocks 86a and 86b
are in fluid
communication via at least the valves 88b and 88d (e.g., the valves 88b and
88d are open) and the
flow meter module 38, and are not in fluid communication via the valve 88e
(i.e., the valve 88e is
closed). In some embodiments, when the valve module 40 is in the flow metering
configuration, the
valves 88a and 88e are closed and the valves 88b-d are open. Alternatively, in
some embodiments,
when the valve module is in the flow metering configuration, the valves 88c
and 88e are closed and
the valves 88a, 88b, and 88d are open. In the meter bypass configuration, the
flow blocks 86a and
86b are in fluid communication via the valve 88e (i.e., the valve 88e is
open), and are not in fluid
communication via the valves 88b and 88d (e.g., the valves 88b and 88d are
closed) and the flow
meter module 38. In some embodiments, when the valve module 40 is in the meter
bypass
configuration, the valves 88a, 88b, and 88d are closed and the valves 88c and
88e are open.
Alternatively, in some embodiments, when the valve module 40 is in the meter
bypass
configuration, the valves 88b-d are closed and the valves 88a and 88e are
open.
In some embodiments, the flow blocks 86a and 86b are substantially identical
to one another
and, therefore, in connection with Figures 6(a)-(b), only the flow block 86a
will be described in
detail below; however, the description below applies to both of the flow
blocks 86a and 86b. In an
embodiment, as illustrated in Figures 6(a)-(b) with continuing reference to
Figures 4(a)-(f), the flow
block 86a includes sides 90a-f. In some embodiments, the sides 90a and 90b are
spaced in a
substantially parallel relation. In some embodiments, the sides 90c and 90d
are spaced in a
substantially parallel relation, each extending from the side 90a to the side
90b. In some
embodiments, the sides 90e and 90f are spaced in a substantially parallel
relation, each extending
from the side 90a to the side 90b. In some embodiments, one of which is shown
in Figures 6(a)-(b),
the sides 90c and 90d are spaced in a substantially parallel relation, and the
sides 90e and 90f are
spaced in a substantially parallel relation. In some embodiments, the sides
90c and 90d are spaced
in a substantially perpendicular relation with the sides 90e and 90f. In some
embodiments, the sides
90a and 90b are spaced in a substantially perpendicular relation with the
sides 90c and 90d. In some
embodiments, the sides 90a and 90b are spaced in a substantially perpendicular
relation with the
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sides 90e and 90f. In some embodiments, one of which is shown in Figures 6(a)-
(b), the sides 90a
and 90b are spaced in a substantially perpendicular relation with the sides
90c, 90d, 90e, and 90f.
In addition, the flow block 86a defines an internal region 92 and fluid
passageways 94a-e. In
some embodiments, the fluid passageway 94a extends through the side 90a of the
flow block 86a
into the internal region 92. In some embodiments, the fluid passageway 94b
extends through the
side 90b of the flow block 86a into the internal region 92. In some
embodiments, one of which
shown in Figures 6(a)-(b), the fluid passageway 94a extends through the side
90a of the flow block
86a into the internal region 92, and the fluid passageway 94b extends through
the side 90b of the
flow block 86a into the internal region 92. In some embodiments, the fluid
passageways 94a and
94b form a continuous fluid passageway together with the internal region 92.
In some
embodiments, the fluid passageway 94c extends through the side 90c of the flow
block 86a into the
internal region 92. In some embodiments, the fluid passageway 94d extends
through the side 90d of
the flow block 86a into the internal region 92. In some embodiments, one of
which is shown in
Figures 6(a)-(b), the fluid passageway 94c extends through the side 90c of the
flow block 86a into
the internal region 92, and the fluid passageway 94d extends through the side
90d of the flow block
86a into the internal region 92. In some embodiments, the fluid passageways
94c and 94d form a
continuous fluid passageway together with the internal region 92. In some
embodiments, one of
which is shown in Figures 6(a)-(b), the fluid passageway 94e extends through
the side 90e of the
flow block 86a into the internal region 92.
In an embodiment of the valve module 40, as illustrated in Figures 4(a)-(f)
with continuing
reference to Figures 6(a)-(b), the valve 88a is operably coupled to the side
90a of the flow block 86a
and in fluid communication with the internal region 92 thereof via the fluid
passageway 94a, and the
valve 88b is operably coupled to the side 90b of the flow block 86a and in
fluid communication with
the internal region 92 thereof via the fluid passageway 94b. In some
embodiments, a blind flange
95a is operably coupled to the side 90e of the flow block 86a to prevent
communication between the
internal region 92 and atmosphere via the fluid passageway 94e. The valves 88c
and 88d are
operably coupled to the flow block 86b in substantially the same manner as the
manner in which the
valves 88a and 88b are operably coupled to the flow block 86a. In some
embodiments, a blind
flange 95b is operably coupled to the flow block 86b in substantially the same
manner as the manner
in which the blind flange 95a is operably coupled to the flow block 86a. The
valve 88e is operably
coupled to the side 90d of the flow block 86a and in fluid communication with
the internal region 92
thereof via the fluid passageway 94d. Moreover, the valve 88e is operably
coupled to the flow block
86b in substantially the same manner as the manner in which the valve 88e is
operably coupled to
the flow block 86a, except that the valve 88e is operably coupled to a side of
the flow block 86b
analogous to the side 90c of the flow block 86a¨as a result, the valve 88e is
in fluid communication
with an internal region of the flow block 86b via a fluid passageway analogous
to the fluid
passageway 94c of the flow block 86a.
In an embodiment of the flow meter 38, as illustrated in Figures 4(a)-(f) with
continuing
reference to Figures 2 and 3, an embodiment of the flow meter module 38 is
illustrated in which the
flow meter module 38 includes a flow meter 96, flow blocks 98a-b, and spools
100a-b. In some
embodiments, the flow meter 96 is a Coriolis flow meter. The spool 100a is
operably coupled to,
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and in fluid communication with, the flow block 98a, and the flow meter 96 is
operably coupled to,
and in fluid communication with, the flow block 98b. Alternatively, the spool
100a may be
operably coupled to, and in fluid communication with, the flow block 98b, and
the flow meter 96
may be operably coupled to, and in fluid communication with, the flow block
98a. The spool 100b
is operably coupled between, and in fluid communication with, the flow blocks
98a and 98b. In
some embodiments, a measurement fitting 102a is operably coupled to the flow
block 98a, opposite
the spool 100a. In addition to, or instead of, the measurement fitting 102a, a
measurement fitting
102b may be operably coupled to the flow block 98b, opposite the flow meter
96. In some
embodiments, pressure monitoring equipment 103 (shown in Figure 4(f)) such as,
for example,
electronic pressure monitoring equipment (including one or more pressure
sensors) for automatically
controlling one or more of the drilling chokes 70a and/or 70b, is operably
coupled to one or both of
the measurement fittings 102a and 102b. Instead of, or in addition to, the
electronic pressure
monitoring equipment, the pressure monitoring equipment 103 may include analog
pressure
monitoring equipment (including one or more pressure sensors), which may be
operably coupled to
one or both of the measurement fittings 102a and 102b.
When the MPD manifold 20 is assembled, the valve module 40 is operably coupled
between
the choke module 36 and the flow meter module 38. More particularly, the valve
88a is operably
coupled to the end 78b of the flow block 64a and in fluid communication with
the internal region 82
thereof via the fluid passageway 84b, and the valve 88c is operably coupled to
the flow block 64b in
substantially the same manner as the manner in which the valve 88a is operably
coupled to the flow
block 64a. In addition, the valve 88b is operably coupled to the spool 100a,
opposite the flow block
98a, and the valve 88d is operably coupled to the flow meter 96, opposite the
flow block 98b. As a
result, when the valve module 40 is operably coupled between the choke module
36 and the flow
meter module 38, as shown in Figures 4(a)-(f), the flow meter module 38
extends in a generally
horizontal orientation. In those embodiments in which the flow meter module 38
extends in the
generally horizontal orientation, the MPD manifold 20 is especially well
suited for use in onshore
drilling operations. In some embodiments, rather than the valve 88b being
operably coupled to the
spool 100a and the valve 88d being operably coupled to the flow meter 96, the
valve 88b is operably
coupled to the flow meter 96 and the valve 88d is operably coupled to the
spool 100a.
In an embodiment, as illustrated in Figures 4(a)-(f), the MPD manifold 20
further includes a
flow fitting 104a operably coupled to the side 90c of the flow block 86a and
in fluid communication
with the internal region 92 thereof via the fluid passageway 94c, and a flow
fitting 104b operably
coupled to the side 80a of the flow block 64a and in fluid communication with
the internal region 82
thereof via the fluid passageway 84c. In addition to, or instead of, the flow
fitting 104b, the MPD
manifold 20 may include a flow fitting 106a operably coupled to the flow block
64b in substantially
the same manner as the manner in which the flow fitting 104b is operably
coupled to the flow block
64a, except that the flow fitting 106a is operably coupled to a side of the
flow block 64b analogous
to the side 80b of the flow block 64a. Moreover, in addition to, or instead
of, the flow fitting 104a,
the MPD manifold 20 may include a flow fitting 106b operably coupled to the
flow block 86b in
substantially the same manner as the manner in which the flow fitting 104a is
operably coupled to
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the flow block 86a, except that the flow fitting 106b is operably coupled to a
side of the flow block
86b analogous to the side 90d of the flow block 86a.
In those embodiments in which the MPD manifold 20 includes the flow fittings
104a and
104b, the temperature sensor 48 and the densometer 50 may be operably coupled
to the valve
module 40 (as shown in Figure 2) via the flow fitting 104a, and the
temperature sensor 44 and the
densometer 46 may be operably coupled to the choke module 36 (as shown in
Figure 2) via the flow
fitting 104b. In such embodiments, the flow fitting 104a is adapted to receive
the drilling mud from
the RCD 16 and the MGS 22 is adapted to receive the drilling mud from the flow
fitting 104b. As a
result, the drilling mud may be permitted to flow through the flow meter 96
before flowing through
the drilling chokes 70a and/or 70b. Additionally, in those embodiments in
which the MPD manifold
includes the flow fittings 106a and 106b, the temperature sensor 48 and the
densometer 50 may
be operably coupled to the choke module 36 (as shown in Figure 3) via the flow
fitting 106a, and the
temperature sensor 44 and the densometer 46 may be operably coupled to the
valve module 40 (as
shown in Figure 3) via the flow fitting 106b. In such embodiments, the flow
fitting 106a is adapted
15 to receive the drilling mud from the RCD 16 and the MGS 22 is adapted to
receive the drilling mud
from the flow fitting 106b, as described in further detail below with
reference to Figure 3. As a
result, the drilling mud may be permitted to flow through the drilling chokes
70a and/or 70b before
flowing through the flow meter 96.
In some embodiments, a measurement fitting 108 is operably coupled to the flow
block 64b
20 and in fluid communication with an internal region thereof via a fluid
passageway analogous to the
fluid passageway 84a of the flow block 64a. In addition to, or instead of, the
measurement fitting
108, another measurement fitting (not shown) may be operably coupled to the
end 78a of the flow
block 64a and in fluid communication with the internal region 82 thereof via
the fluid passageway
84a. In some embodiments, pressure monitoring equipment 107 (shown in Figure
4(a)) such as, for
example, electronic pressure monitoring equipment (including one or more
pressure sensors) for
automatically controlling one or more of the drilling chokes 70a and/or 70b,
is operably coupled to
the measurement fitting 108 and/or the measurement fitting that is operably
coupled to the flow
block 64a. In addition to, or instead of, the electronic pressure monitoring
equipment, the pressure
monitoring equipment 107 may include analog pressure monitoring equipment
(including one or
more pressure sensors), which may be operably coupled to the measurement
fitting 108 and/or the
measurement fitting that is operably coupled to the flow block 64a.
In an embodiment, as illustrated in Figures 7(a)-(d) with continuing reference
to Figures
4(a)-(f), the valve module 40 is configurable so that, rather than the valve
88b being operably
coupled to the side 90b of the flow block 86a and in fluid communication with
the internal region 92
thereof via the fluid passageway 94b, the valve 88b is operably coupled to the
side 90e of the flow
block 86a and in fluid communication with the internal region 92 thereof via
the fluid passageway
94e. In addition, the valve 88d is operably coupled to the flow block 86b in
substantially the same
manner as the manner in which the valve 88b is operably coupled to the flow
block 86a. As a result,
when the valve module 40 is operably coupled between the choke module 36 and
the flow meter
module 38, as shown in Figures 7(a)-(d), the flow meter module 38 extends in a
generally vertical
orientation, thus significantly decreasing the overall footprint of the MPD
manifold 20. In those
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embodiments in which the flow meter module 38 extends in the generally
vertical orientation, the
MPD manifold 20 is especially well suited for use in offshore drilling
operations. In some
embodiments, the blind flange 95a is operably coupled to the side 90b of the
flow block 86a to
prevent communication between the internal region 92 and atmosphere via the
fluid passageway
94b. In some embodiments, the blind flange 95b is operably coupled to the flow
block 86b in
substantially the same manner as the manner in which the blind flange 95a is
operably coupled to
the flow block 86a.
In an embodiment, as illustrated in Figure 3 with continuing reference to
Figure 1, the MPD
manifold 20 is configurable so that, rather than being operably coupled to the
choke module 36, the
temperature sensor 44 and the densometer 46 are operably coupled to the valve
module 40.
Additionally, the MPD manifold 20 is configurable so that, rather than being
operably coupled to the
valve module 40, the temperature sensor 48 and the densometer 50 are operably
coupled to the
choke module 36. In some embodiments, in addition to the choke module 36, the
flow meter
module 38, and the valve module 40 being together mounted to the skid 42, one
or more of the
temperature sensors 44 and 48, and the densometers 46 and 50 are also mounted
to the skid 42.
During the operation of the drilling system 10, the choke module 36 receives
drilling mud from the
RCD 16, as indicated by arrows 110 and 112. The temperature sensor 48 measures
the temperature
of the drilling mud immediately before the drilling mud is received by the
choke module 36. In
addition, the densometer 50 measures the density of the drilling mud
immediately before the drilling
mud is received by the choke module 36. The choke module 36 is adjusted to
maintain the desired
backpressure of the drilling mud within the wellbore 29. The choke module 36
communicates the
drilling mud to the valve module 40, as indicated by arrow 114. The valve
module 40 routes the
drilling mud from the choke module 36 to the flow meter module 38, as
indicated by arrow 116.
The flow meter module 38 measures the flow rate of the drilling mud before
communicating the
drilling mud back to the valve module 40, as indicated by arrow 118. The MGS
22 receives the
drilling mud from the valve module 40, as indicated by arrows 120 and 122. The
temperature sensor
44 measures the temperature of the drilling mud immediately after the drilling
mud is discharged
from the valve module 40. In addition, the densometer 46 measures the density
of the drilling mud
immediately after the drilling mud is discharged from the valve module 40.
In some embodiments, to determine the weight of the drilling mud: the
temperature of the
drilling mud measured by the temperature sensor 44 is compared with the
temperature of the drilling
mud measured by the temperature sensor 48; the density of the drilling mud
measured by the
densometer 46 is compared with the density of the drilling mud measured by the
densometer 50;
and/or the respective pressure(s) of the drilling mud measured by the pressure
monitoring equipment
103 (shown in Figure 4(f)) operably coupled to the measurement fittings 102a
and 102b, the
pressure monitoring equipment 107 (shown in Figure 4(a)) operably coupled to
the measurement
fitting 108, pressure monitoring equipment operably coupled to another
measurement fitting of the
MPD manifold 20, or any combination thereof, are compared. Thus, the
temperature sensors 44 and
48, the densometers 46 and 50, and/or the pressure monitoring equipment 103
and/or 107 are
operable to determine whether the weight of the drilling mud is below a
critical threshold. In some
embodiments, in response to a determination that the weight of the drilling
mud is below the critical
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threshold: the weight of the drilling fluid circulated to the drilling tool
(as indicated by the arrows 30
and 32 in Figure 1) is increased, and/or the drilling chokes 70a and/or 70b
are adjusted to increase
the backpressure of the drilling mud within the wellbore 29. In this manner,
the temperature sensors
44 and 48, the densometers 46 and 50, and/or the pressure monitoring equipment
103 and/or 107
may be used to predict and prevent well kicks during drilling operations.
In some embodiments, to determine the amount of gas entrained in the drilling
mud: the
temperature of the drilling mud measured by the temperature sensor 44 is
compared with the
temperature of the drilling mud measured by the temperature sensor 48; the
density of the drilling
mud measured by the densometer 46 is compared with the density of the drilling
mud measured by
the densometer 50; and/or the respective pressure(s) of the drilling mud
measured by the pressure
monitoring equipment 103, the pressure monitoring equipment 107, pressure
monitoring equipment
operably coupled to another measurement fitting of the MPD manifold 20, or any
combination
thereof, are compared. Thus, the temperature sensors 44 and 48, the
densometers 46 and 50, and/or
the pressure monitoring equipment 103 and/or 107 are operable to determine
whether the amount of
gas entrained in the drilling mud is above a critical threshold. In some
embodiments, in response to
a determination that the amount of gas entrained in the drilling mud is above
the critical threshold:
the weight of the drilling fluid circulated to the drilling tool (as indicated
by the arrows 30 and 32 in
Figure 1) is increased, and/or the drilling chokes 70a and/or 70b are adjusted
to increase the
backpressure of the drilling mud within the wellbore 29. In this manner, the
temperature sensors 44
and 48, the densometers 46 and 50, and/or the pressure monitoring equipment
103 and/or 107 may
be used to predict and prevent well kicks during drilling operations.
In some embodiments, the temperature and density of the drilling mud measured
before the
drilling mud passes through the drilling chokes 70a and/or 70b are compared
with the temperature
and density of the drilling mud after the drilling mud passes through the
drilling chokes 70a and/or
70b. Further, in some embodiments, the temperature and pressure of the
drilling mud measured
before the drilling mud passes through the drilling chokes 70a and/or 70b are
compared with the
temperature and pressure of the drilling mud measured after the drilling mud
passes through the
drilling chokes 70a and/or 70b. Further still, in some embodiments, the
density and pressure of the
drilling mud measured before the drilling mud passes through the drilling
chokes 70a and/or 70b are
.. compared with the density and pressure of the drilling mud measured after
the drilling mud passes
through the drilling chokes 70a and/or 70b. Finally, in some embodiments, the
temperature, density,
and pressure of the drilling mud measured before the drilling mud passes
through the drilling chokes
70a and/or 70b are compared with the temperature, density, and pressure of the
drilling mud
measured after the drilling mud passes through the drilling chokes 70a and/or
70b.
In some embodiments, during the operation of the MPD manifold 20, the
execution of the
method 124, the execution of the method 142, or any combination thereof,
drilling mud is permitted
to flow through one of the drilling chokes 70a-b, and the one of the drilling
chokes 70a-b is
controlled in accordance with the foregoing; in some embodiments, the
remaining one of the drilling
chokes 70a-b is closed but is nevertheless provided for redundancy purposes
such as, for example, in
the event of operational problems with one or both of the one of the drilling
chokes 70a-b. In some
embodiments, during the operation of the MPD manifold 20, the execution of the
method 124, the
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execution of the method 142, or any combination thereof, drilling mud is
permitted to flow through
both of the drilling chokes 70a-b, and both of the drilling chokes 70a-b are
controlled in accordance
with the foregoing.
In an embodiment, as illustrated in Figure 8, a method of controlling
backpressure of a
drilling mud within a wellbore 29 is diagrammatically illustrated and
generally referred to by the
reference numeral 124. The method 124 includes receiving the drilling mud from
the wellbore 29 at
a step 126; either: controlling, using one or more of the drilling chokes 70a
and 70b, the
backpressure of the drilling mud within the wellbore 29 at a step 128, the
drilling chokes 70a and
70b being part of the choke module 36, or bypassing the drilling chokes 70a
and 70b of the choke
module 36 at a step 131; either: measuring, using the flow meter 96, a flow
rate of the drilling mud
received from the wellbore 29 at a step 134, the flow meter 96 being part of
the flow meter module
38, or bypassing the flow meter 96 of the flow meter module 38 at a step 136;
and discharging the
drilling mud at a step 138.
The drilling mud is received from the wellbore 29 at the step 126. In an
embodiment of the
step 126, the drilling mud is received from the wellbore 29 via the flow
fitting 104a operably
coupled to, and in fluid communication with, the internal region 92 of the
flow block 86a via the
fluid passageway 94c thereof. In another embodiment of the step 126, the
drilling mud is received
from the wellbore 29 via the flow fitting 106a operably coupled to the flow
block 64b in
substantially the same manner as the manner in which the flow fitting 104b is
operably coupled to
the flow block 64a, except that the flow fitting 106a is operably coupled to a
side of the flow block
64b analogous to the side 80b of the flow block 64a.
In some embodiments, one or more of the drilling chokes 70a and 70b control
the
backpressure of the drilling mud within the wellbore 29 at the step 128. In an
embodiment of the
step 128, one or more of the drilling chokes 70a and 70b are used to control
the backpressure of the
drilling mud within the wellbore 29 by: permitting fluid flow from the flow
block 64b to the flow
block 64a via one or both of the following element combinations: the block
valve 66b, the drilling
choke 70a, and the block valve 66a; the block valve 66d, the drilling choke
70b, and the block valve
66c; and preventing, or at least reducing, fluid flow from the flow block 64b
to the flow block 64a
via the block valve 66e. More particularly, one or more of the drilling chokes
70a and 70b may be
used to control the backpressure of the drilling mud within the wellbore 29 by
actuating the block
valves 66a-e so that: the block valves 66a-b are open and the block valves 66c-
e are closed; the
block valves 66c-d are open and the block valves 66a-b and 66e are closed; or
the block valves 66a-
d are open and the block valve 66e is closed.
In some embodiments, the drilling chokes 70a and 70b are bypassed at the step
131. In an
embodiment of the step 131, the drilling chokes 70a and 70b of the choke
module 36 are bypassed
by: permitting fluid flow from the flow block 64b to the flow block 64a via
the block valve 66e; and
preventing, or at least reducing, fluid flow from the flow block 64b to the
flow block 64a via each of
the following element combinations: the block valve 66b, the drilling choke
70a, and the block valve
66a; and the block valve 66d, the drilling choke 70b, and the block valve 66c.
More particularly, the
drilling chokes 70a and 70b of the choke module 36 are bypassed by actuating
the block valves 66a-
e so that: the block valves 66a-d are closed and the block valve 66e is open.
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In some embodiments, the flow meter 96 measures the flow rate of the drilling
mud received
form the wellbore 29 at the step 134. In some embodiments, to measure the flow
rate of the drilling
fluid at the step 134, the valve module 40 is used to communicate the drilling
mud to the flow meter
module 38. In an embodiment, the valve module 40 is used to communicate the
drilling mud to the
.. flow meter module 38 by: permitting fluid flow from the flow block 86a to
the flow block 86b via
the valve 88b, the flow meter 96, and the valve 88d; and preventing, or at
least reducing, fluid flow
from the flow block 86a to the flow block 86b via the valve 88e. More
particularly, the valve
module 40 may be used to communicate the drilling mud to the flow meter module
38 by actuating
the valves 88a-e so that either: the valves 88b-d are open and the valves 88a
and 88e are closed; or
the valves 88a, 88b, and 88d are open and the valves 88c and 88e are closed.
In an embodiment of the step 134, the drilling mud flows from the valve 88b,
through the
spool 100a, the flow block 98a, the spool 100b, the flow block 98b, and the
flow meter 96, and into
the valve 88d. During the flow of the drilling mud through the flow meter 96,
the flow meter 96
measures the flow rate of the drilling mud. In some embodiments, the flow
meter 96 is a Coriolis
flow meter.
In some embodiments, the flow meter 96 of the flow meter module 38 is bypassed
at the step
136. In an embodiment of the step 136, the flow meter 96 of the flow meter
module 38 is bypassed
by preventing, or at least reducing, fluid flow from the flow block 86a to the
flow block 86b via the
valve 88b, the flow meter 96, and the valve 88d; and permitting fluid flow
from the flow block 86a
.. to the flow block 86b via the valve 88e. More particularly, the flow meter
96 of the flow meter
module 38 may be bypassed by actuating the block valves 88a-e so that either:
the valves 88c and
88e are open and the valves 88a, 88b, and 88d are closed; or the valves 88a
and 88e are open and the
valves 88b-d are closed.
The method 124 includes discharging the drilling mud at the step 138. In an
embodiment of
the step 138, the drilling mud is discharged via either: the flow fitting 104b
operably coupled to, and
in fluid communication with, the internal region 82 of the flow block 64a via
the fluid passageway
84c thereof; or the flow fitting 106b operably coupled to the flow block 86b
in substantially the
same manner as the manner in which the flow fitting 104a is operably coupled
to the flow block 86a,
except that the flow fitting 106b is operably coupled to a side of the flow
block 86b analogous to the
side 90d of the flow block 86a.
In an embodiment of the steps 126 and 138, at the step 126 the drilling mud is
received from
the wellbore 29 via the flow fitting 104a operably coupled to, and in fluid
communication with, the
internal region 92 of the flow block 86a via the fluid passageway 94c thereof,
and at the step 138 the
drilling mud is discharged via the flow fitting 104b operably coupled to, and
in fluid communication
with, the internal region 82 of the flow block 64a via the fluid passageway
84c thereof. In another
embodiment of the steps 126 and 138, at the step 126 the drilling mud is
received from the wellbore
29 via the flow fitting 106a operably coupled to the flow block 64b in
substantially the same manner
as the manner in which the flow fitting 104b is operably coupled to the flow
block 64a, and at the
step 138 the drilling mud is discharged via the flow fitting 106b operably
coupled to the flow block
86b in substantially the same manner as the manner in which the flow fitting
104a is operably
coupled to the flow block 86a.
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In various embodiments, the steps of the method 124 may be executed with
different
combinations of steps in different orders and/or ways. For example, an
embodiment of the method
124 includes: the step 126 at which drilling mud is received from the wellbore
29 via the flow fitting
104a operably coupled to, and in fluid communication with, the internal region
92 of the flow block
86a via the fluid passageway 94c thereof during and/or after the step 126, the
step 134 at which the
drilling mud flows from the flow block 86a to the flow block 86b via the valve
88b, the spool 100a,
the flow block 98a, the spool 100b, the flow block 98b, the flow meter 96, and
the valve 88d (the
valves 88a and 88e are closed); during and/or after the step 134, the step 128
at which the drilling
mud flows from the flow block 86b to the flow block 64b via the valve 88c, and
from the flow block
64b to the flow block 64a via one or more of the following element
combinations: the block valve
66b, the drilling choke 70a, and the block valve 66a; and the block valve 66d,
the drilling choke
70b, and the block valve 66c (the block valve 66e is closed); and during
and/or after the step 128,
the step 138 at which the drilling mud is discharged via the flow fitting 104b
operably coupled to,
and in fluid communication with, the internal region 82 of the flow block 64a
via the fluid
passageway 84c thereof.
For another example, an embodiment of the method 124 includes: the step 126 at
which
drilling mud is received from the wellbore 29 via the flow fitting 104a
operably coupled to, and in
fluid communication with, the internal region 92 of the flow block 86a via the
fluid passageway 94c
thereof; during and/or after the step 126, the step 136 at which the drilling
mud flows from the flow
block 86a to the flow block 86b via the valve 88e (the valves 88a-d are
closed); during and/or after
the step 136, the step 128 at which the drilling mud flows from the flow block
86b to the flow block
64b via the valve 88c, and from the flow block 64b to the flow block 64a via
one or more of the
following element combinations: the block valve 66b, the drilling choke 70a,
and the block valve
66a; and the block valve 66d, the drilling choke 70b, and the block valve 66c
(the block valve 66e is
closed); and during and/or after the step 128, the step 138 at which the
drilling mud is discharged via
the flow fitting 104b operably coupled to, and in fluid communication with,
the internal region 82 of
the flow block 64a via the fluid passageway 84c thereof.
For yet another example, an embodiment of the method 124 includes: the step
126 at which
drilling mud is received from the wellbore 29 via the flow fitting 104a
operably coupled to, and in
fluid communication with, the internal region 92 of the flow block 86a via the
fluid passageway 94c
thereof; during and/or after the step 126, the step 134 at which the drilling
mud flows from the flow
block 86a to the flow block 86b via the valve 88b, the spool 100a, the flow
block 98a, the spool
100b, the flow block 98b, the flow meter 96, and the valve 88d (the valves 88a
and 88e are closed);
during and/or after the step 134, the step 131 at which the drilling mud flows
from the flow block
86b to the flow block 64b via the valve 88c, and from the flow block 64b to
the flow block 64a via
the block valve 66e (the block valves 66a-d are closed); and during and/or
after the step 131, the
step 138 at which the drilling mud is discharged via the flow fitting 104b
operably coupled to, and in
fluid communication with, the internal region 82 of the flow block 64a via the
fluid passageway 84c
thereof
For yet another example, an embodiment of the method 124 includes: the step
126 at which
drilling mud is received from the wellbore 29 via the flow fitting 104a
operably coupled to, and in
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fluid communication with, the internal region 92 of the flow block 86a via the
fluid passageway 94c
thereof; during and/or after the step 126, the step 136 at which the drilling
mud flows from the flow
block 86a to the flow block 86b via the valve 88e (the valves 88a-d are
closed); during and/or after
the step 136, the step 131 at which the drilling mud flows from the flow block
86b to the flow block
64b via the valve 88c, and from the flow block 64b to the flow block 64a via
the block valve 66e
(the block valves 66a-d are closed); and during and/or after the step 131, the
step 138 at which the
drilling mud is discharged via the flow fitting 104b operably coupled to, and
in fluid communication
with, the internal region 82 of the flow block 64a via the fluid passageway
84c thereof.
For yet another example, an embodiment of the method 124 includes: the step
126 at which
.. the drilling mud is received from the wellbore 29 via the flow fitting 106a
operably coupled to the
flow block 64b in substantially the same manner as the manner in which the
flow fitting 104b is
operably coupled to the flow block 64a; during and/or after the step 126, the
step 128 at which the
drilling mud flows from the flow block 64b to the flow block 64a via one or
more of the following
element combinations: the block valve 66b, the drilling choke 70a, and the
block valve 66a; and the
.. block valve 66d, the drilling choke 70b, and the block valve 66c (the block
valve 66e is closed);
during and/or after the step 128, the step 134 at which the drilling mud flows
from the flow block
64a to the flow block 86a via the valve 88a, and from the flow block 86a to
the flow block 86b via
the valve 88b, the spool 100a, the flow block 98a, the spool 100b, the flow
block 98b, the flow
meter 96, and the valve 88d (the valves 88c and 88e are closed); and during
and/or after the step
134, the step 138 at which the drilling mud is discharged via the flow fitting
106b operably coupled
to the flow block 86b in substantially the same manner as the manner in which
the flow fitting 104a
is operably coupled to the flow block 86a.
For yet another example, an embodiment of the method 124 includes: the step
126 at which
the drilling mud is received from the wellbore 29 via the flow fitting 106a
operably coupled to the
.. flow block 64b in substantially the same manner as the manner in which the
flow fitting 104b is
operably coupled to the flow block 64a; during and/or after the step 126, the
step 128 at which the
drilling mud flows from the flow block 64b to the flow block 64a via one or
more of the following
element combinations: the block valve 66b, the drilling choke 70a, and the
block valve 66a; and the
block valve 66d, the drilling choke 70b, and the block valve 66c (the block
valve 66e is closed);
.. during and/or after the step 128, the step 136 at which the drilling mud
flows from the flow block
64a to the flow block 86a via the valve 88a, and from the flow block 86a to
the flow block 86b via
the valve 88e (the valves 88b-d are closed); and during and/or after the step
136, the step 138 at
which the drilling mud is discharged via the flow fitting 106b operably
coupled to the flow block
86b in substantially the same manner as the manner in which the flow fitting
104a is operably
coupled to the flow block 86a.
For yet another example, an embodiment of the method 124 includes: the step
126 at which
the drilling mud is received from the wellbore 29 via the flow fitting 106a
operably coupled to the
flow block 64b in substantially the same manner as the manner in which the
flow fitting 104b is
operably coupled to the flow block 64a; during and/or after the step 126, the
step 131 at which the
drilling mud flows from the flow block 64b to the flow block 64a via the block
valve 66e (the block
valves 66a-d are closed); during and/or after the step 131, the step 134 at
which the drilling mud
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flows from the flow block 64a to the flow block 86a via the valve 88a, and
from the flow block 86a
to the flow block 86b via the valve 88b, the spool 100a, the flow block 98a,
the spool 100b, the flow
block 98b, the flow meter 96, and the valve 88d (the valves 88c and 88e are
closed); and during
and/or after the step 134, the step 138 at which the drilling mud is
discharged via the flow fitting
106b operably coupled to the flow block 86b in substantially the same manner
as the manner in
which the flow fitting 104a is operably coupled to the flow block 86a.
Finally, for yet another example, an embodiment of the method 124 includes:
the step 126 at
which the drilling mud is received from the wellbore 29 via the flow fitting
106a operably coupled
to the flow block 64b in substantially the same manner as the manner in which
the flow fitting 104b
is operably coupled to the flow block 64a; during and/or after the step 126,
the step 131 at which the
drilling mud flows from the flow block 64b to the flow block 64a via the block
valve 66e (the block
valves 66a-d are closed); during and/or after the step 131, the step 136 at
which the drilling mud
flows from the flow block 64a to the flow block 86a via the valve 88a, and
from the flow block 86a
to the flow block 86b via the valve 88e (the valves 88b-d are closed); and
during and/or after the
step 136, the step 138 at which the drilling mud is discharged via the flow
fitting 106b operably
coupled to the flow block 86b in substantially the same manner as the manner
in which the flow
fitting 104a is operably coupled to the flow block 86a.
In some embodiments, the configuration of the MPD manifold 20, including the
drilling
chokes 70a and 70b and the flow meter 96 used to carry out the method 124,
optimizes the
efficiency of the drilling system 10, thereby improving the cost and
effectiveness of drilling
operations. Such improved efficiency benefits operators dealing with
challenges such as, for
example, continuous duty operations, harsh downhole environments, and multiple
extended-reach
lateral wells, among others. In some embodiments, the configuration of the MPD
manifold 20,
including the drilling chokes 70a and 70b and the flow meter 96 used to carry
out the method 124,
favorably affects the size and/or weight of the MPD manifold 20, and thus the
transportability and
overall footprint of the MPD manifold 20 at the wellsite.
In some embodiments, the integrated nature of the drilling chokes 70a and 70b
and the flow
meter 96 on the MPD manifold 20 used to carry out the method 124 makes it
easier to inspect,
service, or repair the MPD manifold 20, thereby decreasing downtime during
drilling operations. In
some embodiments, the integrated nature of the drilling chokes 70a and 70b and
the flow meter 96
on the MPD manifold 20 used to carry out the method 124 makes it easier to
coordinate the
inspection, service, repair, or replacement of components of the MPD manifold
20 such as, for
example, the drilling chokes 70a and 70b and/or the flow meter 96, among other
components.
In this regard, an arrow 140 in Figures 4(b), 4(d), 7(b), and 7(c) indicates
the direction in
which the drilling choke 70a is readily removable from the choke module 36
upon decoupling of the
spools 72a and 74a from the block valves 66a and 66b, respectively, or
decoupling of the flow block
68a and the drilling choke 70a from the spools 72a and 74a, respectively.
Further, the arrow 140
indicates the direction in which the drilling choke 70b is readily removable
from the choke module
36 upon decoupling of the spools 72b and 74b from the block valves 66c and
66d, respectively, or
decoupling of the flow block 68b and the drilling choke 70b from the spools
72b and 74b,
respectively. Thus, either one of the drilling chokes 70a and 70b may be
readily inspected, serviced,
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repaired, or replaced during drilling operations while the other of the
drilling chokes 70a and 70b
remains in service.
In an embodiment, as illustrated in Figure 9, a method of controlling
backpressure of a
drilling mud within a wellbore 29 is diagrammatically illustrated and
generally referred to by the
reference numeral 142. The method 142 includes receiving the drilling mud from
the wellbore 29 at
a step 144; measuring, using a first sensor, a first physical property of the
drilling mud before the
drilling mud flows through the drilling chokes 70a and/or 70b at a step 146;
flowing the drilling mud
through the drilling chokes 70a and/or 70b at a step 148; measuring, using a
second sensor, the first
physical property of the drilling mud after the drilling mud flows through the
drilling chokes 70a
.. and/or 70b at a step 150; comparing the respective measurements of the
first physical property taken
by the first and second sensors at a step 152; determining, based on at least
the comparison of the
respective measurements of the first physical property taken by the first and
second sensors, an
amount of gas entrained in the drilling mud at a step 154; and adjusting the
drilling chokes 70a
and/or 70b, based on the determination of the amount of gas entrained in the
drilling mud, to control
the backpressure of the drilling mud within the wellbore 29 at a step 156. In
some embodiments,
when the amount of gas entrained in the drilling mud is above a critical
threshold, the drilling
chokes 70a and/or 70b are adjusted to increase the backpressure of the
drilling mud within the
wellbore 29. In some embodiments, in addition to, or instead of, determining
the amount of gas
entrained in the drilling mud, the step 154 includes determining, based on at
least the comparison of
.. the respective measurements of the first physical property taken by the
first and second sensors, the
weight of the drilling mud. As a result, the step 156 includes adjusting the
drilling chokes 70a
and/or 70b, based on the determination of the weight of the drilling mud, to
control the backpressure
of the drilling mud within the wellbore 29.
In an embodiment of the steps 146, 148, and 150, the first physical property
is density and
the first and second sensors are the densometers 46 and 50. In another
embodiment of the steps 146,
148, and 150, the first physical property is temperature and the first and
second sensors are the
temperature sensors 44 and 48. In yet another embodiment of the steps 146,
148, and 150, the first
physical property is pressure and the first and second sensors are pressure
sensors operably coupled
to the measurement fittings 102a, 102b, 108, and/or another measurement
fitting; in some
embodiments, these pressure sensors may be, may include, or may be a part of,
the pressure
monitoring equipment 103 and/or 107.
In some embodiments of the method 142, the steps 146, 148, and 150 further
include
measuring, using a third sensor, a second physical property of the drilling
mud before the drilling
mud flows through the drilling chokes 70a and/or 70b, measuring, using a
fourth sensor, the second
physical property of the drilling mud after the drilling mud flows through the
drilling chokes 70a
and/or 70b, and comparing the respective measurements of the second physical
property taken by
the third and fourth sensors. In some embodiments, determining the amount of
gas entrained in the
drilling mud is further based on the comparison of the respective measurements
of the second
physical property taken by the third and fourth sensors. In an embodiment, the
first physical
property is density and the first and second sensors are the densometers 46
and 50, and the second
physical property is temperature and the third and fourth sensors are the
temperature sensors 44 and
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48. In another embodiment, the first physical property is density and the
first and second sensors are
the densometers 46 and 50, and the second physical property is pressure and
the third and fourth
sensors are pressure sensors operably coupled to the measurement fittings
102a, 102b, 108, and/or
another measurement fitting; in some embodiments, these pressure sensors may
be, may include, or
may be a part of, the pressure monitoring equipment 103 and/or 107. In yet
another embodiment,
the first physical property is temperature and the first and second sensors
are the temperature sensors
44 and 48, and the second physical property is pressure and the third and
fourth sensors are pressure
sensors operably coupled to the measurement fittings 102a, 102b, 108, and/or
another measurement
fitting; in some embodiments, these pressure sensors may be, may include, or
may be a part of, the
.. pressure monitoring equipment 103 and/or 107.
In some embodiments of the method 142, the steps 146, 148, and 150 further
include
measuring, using a fifth sensor, a third physical property of the drilling mud
before the drilling mud
flows through the drilling chokes 70a and/or 70b, measuring, using a sixth
sensor, the third physical
property of the drilling mud after the drilling mud flows through the drilling
chokes 70a and/or 70b,
and comparing the respective measurements of the third physical property taken
by the fifth and
sixth sensors. In some embodiments, determining the amount of gas entrained in
the drilling mud is
further based on the comparison of the respective measurements of the third
physical property taken
by the fifth and sixth sensors. In an embodiment, the first physical property
is density and the first
and second sensors are densometers 46 and 50, the second physical property is
temperature and the
third and fourth sensors are the temperature sensors 44 and 48, and the third
physical property is
pressure and the fifth and sixth sensors are pressure sensors operably coupled
to the measurement
fittings 102a, 102b, 108, and/or another measurement fitting; in some
embodiments, these pressure
sensors may be, may include, or may be a part of, the pressure monitoring
equipment 103 and/or
107.
In an embodiment, as illustrated in Figures 10(a)-(f), the choke module 36 is
omitted from
IVIPD manifold 20 and replaced with a choke module 158¨the ability of the
choke module 36 to be
easily replaced by, or substituted with, the choke module 158 (or vice versa)
is denoted in Figures 2
and 3. The choke module 158 includes flow blocks 160a-b, block valves 162a-m,
bleed valves
163a-f, flow blocks 164a-c, and drilling chokes 166a-c. The block valves 162a-
m are each actuable
between an open configuration in which fluid flow is permitted therethrough,
and a closed
configuration in which fluid flow therethrough is prevented, or at least
reduced. In some
embodiments, the block valves 162a-m are gate valves. Alternatively, one or
more of the block
valves 162a-m may be another type of valve such as, for example, a plug valve.
The block valve
162m is operably coupled between the flow blocks 160a and 160b.
The block valve 162a is operably coupled to the flow block 160a. The bleed
valve 163a is
operably coupled to the block valve 162a, opposite the flow block 160a. The
block valve 162b is
operably coupled to the bleed valve 163a, opposite the block valve 162a. The
flow block 164a is
operably coupled to the block valve 162b, opposite the bleed valve 163a, via,
for example, a spool
168a. In combination, the bleed valve 163a and the block valves 162a and 162b
may provide a type
of "double block-and-bleed" isolation of the flow block 164a from the flow
block 160a. For
example, in some embodiments, to provide a type of "double block-and-bleed"
isolation of the flow
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block 164a from the flow block 160a, both of the block valves 162a and 162b
are closed, and the
bleed valve 163a is opened to permit any necessary bleeding or
depressurization of the fluid flow
path between the block valves 162a and 162b, ensuring that the flow block 164a
has been fluidically
isolated from the flow block 160a. In some embodiments, in combination, the
bleed valve 163a and
the block valves 162a and 162b provide a type of "double block-and-bleed"
isolation of the flow
block 164a from the flow block 160a and therefore, in some embodiments, this
combination is
especially suitable for offshore applications. The block valve 162c is
operably coupled to the flow
block 160b. The bleed valve 163b is operably coupled to the block valve 162c,
opposite the flow
block 160b. The block valve 162d is operably coupled to the bleed valve 163b,
opposite the block
valve 162c. The drilling choke 166a is operably coupled to the block valve
162d, opposite the bleed
valve 163b, via, for example, a spool 170a. In combination, the bleed valve
163b and the block
valves 162c and 162d may provide a type of "double block-and-bleed" isolation
of the drilling
choke 166a from the flow block 160b. For example, in some embodiments, to
provide a type of
"double block-and-bleed" isolation of the drilling choke 166a from the flow
block 160b, both of the
block valves 162c and 162d are closed, and the bleed valve 163b is opened to
permit any necessary
bleeding or depressurization of the fluid flow path between the block valves
162c and 162d,
ensuring that the drilling choke 166a has been fluidically isolated from the
flow block 160b. In
some embodiments, in combination, the bleed valve 163b and the block valves
162c and 162d
provide a type of "double block-and-bleed" isolation of the drilling choke
166a from the flow block
160b and therefore, in some embodiments, this combination is especially
suitable for offshore
applications. The drilling choke 166a is operably coupled to the flow block
164a via, for example, a
spool 172a.
The block valve 162e is operably coupled to the flow block 160a adjacent the
block valve
162a. The bleed valve 163c is operably coupled to the block valve 162e,
opposite the flow block
160a. The block valve 162f is operably coupled to the bleed valve 163c,
opposite the block valve
162e. The flow block 164b is operably coupled to the block valve 162f,
opposite the bleed valve
163c, via, for example, a spool 168b. In combination, the bleed valve 163c and
the block valves
162e and 162f may provide a type of "double block-and-bleed" isolation of the
flow block 164b
from the flow block 160a. For example, in some embodiments, to provide a type
of "double block-
and-bleed" isolation of the flow block 164b from the flow block 160a, both of
the block valves 162e
and 162f are closed, and the bleed valve 163c is opened to permit any
necessary bleeding or
depressurization of the fluid flow path between the block valves 162e and
162f, ensuring that the
flow block 164b has been fluidically isolated from the flow block 160a. In
some embodiments, in
combination, the bleed valve 163c and the block valves 162e and 162f provide a
type of "double
block-and-bleed" isolation of the flow block 164b from the flow block 160a and
therefore, in some
embodiments, this combination is especially suitable for offshore
applications. The block valve
162g is operably coupled to the flow block 160b adjacent the block valve 162c.
The bleed valve
163d is operably coupled to the block valve 162g, opposite the flow block
160b. The block valve
162h is operably coupled to the bleed valve 163d, opposite the block valve
162g. The drilling choke
166b is operably coupled to the block valve 162h, opposite the bleed valve
163d, via, for example, a
spool 170b. In combination, the bleed valve 163d and the block valves 162g and
162h may provide
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a type of "double block-and-bleed" isolation of the drilling choke 166b from
the flow block 160b.
For example, in some embodiments, to provide a type of "double block-and-
bleed" isolation of the
drilling choke 166b from the flow block 160b, both of the block valves 162g
and 162h are closed,
and the bleed valve 163d is opened to permit any necessary bleeding or
depressurization of the fluid
flow path between the block valves 162g and 162h, ensuring that the drilling
choke 166b has been
fluidically isolated from the flow block 160b. In some embodiments, in
combination, the bleed
valve 163d and the block valves 162g and 162h provide a type of "double block-
and-bleed"
isolation of the drilling choke 166b from the flow block 160b and therefore,
in some embodiments,
this combination is especially suitable for offshore applications. The
drilling choke 166b is operably
coupled to the flow block 164b via, for example, a spool 172b.
The block valve 162i is operably coupled to the flow block 160a adjacent the
block valve
162e. The bleed valve 163e is operably coupled to the block valve 162i,
opposite the flow block
160a. The block valve 162j is operably coupled to the bleed valve 163e,
opposite the block valve
162i. The flow block 164c is operably coupled to the block valve 162j,
opposite the bleed valve
163e, via, for example, a spool 168c. In combination, the bleed valve 163e and
the block valves
162i and 162j may provide a type of "double block-and-bleed" isolation of the
flow block 164c from
the flow block 160a. For example, in some embodiments, to provide a type of
"double block-and-
bleed" isolation of the flow block 164c from the flow block 160a, both of the
block valves 162i and
162j are closed, and the bleed valve 163e is opened to permit any necessary
bleeding or
depressurization of the fluid flow path between the block valves 162i and
162j, ensuring that the
flow block 164c has been fluidically isolated from the flow block 160a. In
some embodiments, in
combination, the bleed valve 163e and the block valves 162i and 162j provide a
type of "double
block-and-bleed" isolation of the flow block 164c from the flow block 160a and
therefore, in some
embodiments, this combination is especially suitable for offshore
applications. The block valve
162k is operably coupled to the flow block 160b adjacent the block valve 162g.
The bleed valve
163f is operably coupled to the block valve 162k, opposite the flow block
160b. The block valve
1621 is operably coupled to the bleed valve 163f, opposite the block valve
162k. The drilling choke
166c is operably coupled to the block valve 1621, opposite the bleed valve
163f, via, for example, a
spool 170c. In combination, the bleed valve 163f and the block valves 162k and
1621 may provide a
type of "double block-and-bleed" isolation of the drilling choke 166c from the
flow block 160b. For
example, in some embodiments, to provide a type of "double block-and-bleed"
isolation of the
drilling choke 166c from the flow block 160b, both of the block valves 162k
and 1621 are closed,
and the bleed valve 163f is opened to permit any necessary bleeding or
depressurization of the fluid
flow path between the block valves 162k and 1621, ensuring that the drilling
choke 166c has been
fluidically isolated from the flow block 160b. In some embodiments, in
combination, the bleed
valve 163f and the block valves 162k and 1621 provide a type of "double block-
and-bleed" isolation
of the drilling choke 166c from the flow block 160b and therefore, in some
embodiments, this
combination is especially suitable for offshore applications. The drilling
choke 166c is operably
coupled to the flow block 164c via, for example, a spool 172c.
In some embodiments, each of the bleed valves 163a-f is, includes, or is part
of, a needle
valve. In some embodiments, at least one of the bleed valves 163a-f is,
includes, or is part of, a
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needle valve. In some embodiments, one or more of the bleed valves 163a-f is,
includes, or is part
of, a needle valve. In some embodiments, each of the drilling chokes 166a-c is
a 4-inch inner
diameter (ID) choke. In some embodiments, each of the drilling chokes 166a-c
defines an inner
diameter of about 4 inches.
The choke module 158 is actuable between a backpressure control configuration
and a choke
bypass configuration. In the backpressure control configuration, the flow
block 160b is in fluid
communication with the flow block 160a via one or more of the drilling chokes
166a, 166b, and/or
166c. In some embodiments, when the choke module 158 is in the backpressure
control
configuration, the flow block 160b is not in fluid communication with the flow
block 160a via the
block valve 162m (i.e., the block valve 162m is closed). During the operation
of the drilling system
10, when the choke module 158 is in the backpressure control configuration,
one or more of the
drilling chokes 166a, 166b, and/or 166c are adjusted to account for changes in
the flow rate of the
drilling mud so that the desired backpressure within the wellbore 29 is
maintained. In the choke
bypass configuration, the flow block 160b is in fluid communication with the
flow block 160a via
the block valve 162m. In some embodiments, when the choke module 158 is in the
choke bypass
configuration, the flow block 160b is not in fluid communication with the flow
block 160a via the
drilling chokes 166a, 166b, or 166c. In some embodiments, to enable such fluid
communication
between the flow blocks 160a and 160b via the block valve 162m, the block
valves 162a-1 are
actuated to the closed configuration and the block valve 162m is actuated to
the open configuration.
In some embodiments, one or more of the drilling chokes 166a, 166b, and/or
166c are
manual chokes, thus enabling rig personnel to manually control backpressure
within the drilling
system 10 when the choke module 158 is in the backpressure control
configuration. In some
embodiments, one or more of the drilling chokes 166a, 166b, and/or 166c are
automatic chokes
controlled automatically by electronic pressure monitoring equipment when the
choke module 158
is in the backpressure control configuration. In some embodiments, one or more
of the drilling
chokes 166a, 166b, and/or 166c are combination manual/automatic chokes.
In some embodiments, when the choke module 158 is in the backpressure control
configuration, the flow block 160b is in fluid communication with the flow
block 160a via at least
the drilling choke 166a. To enable such fluid communication between the flow
blocks 160a and
160b via the drilling choke 166a, the block valves 162a, 162b, 162c, and 162d
are actuated to the
open configuration, and the block valve 162m is actuated to the closed
configuration. As a result,
the flow block 160b is in fluid communication with the flow block 160a via at
least the block valve
162c, the bleed valve 163a, the block valve 162d, the spool 170a, the drilling
choke 166a, the spool
172a, the flow block 164a, the spool 168a, the block valve 162b, the bleed
valve 163a, and the block
valve 162a, respectively.
In some embodiments, when the choke module 158 is in the backpressure control
configuration, the flow block 160b is in fluid communication with the flow
block 160a via at least
the drilling choke 166b. To enable such fluid communication between the flow
blocks 160a and
160b via the drilling choke 166b, the block valves 162e, 162f, 162g, and 162h
are actuated to the
open configuration, and the block valve 162m is actuated to the closed
configuration. As a result,
the flow block 160b is in fluid communication with the flow block 160a via at
least the block valve
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162g, the bleed valve 163d, the block valve 162h, the spool 170b, the drilling
choke 166b, the spool
172b, the flow block 164b, the spool 168b, the block valve 162f, the bleed
valve 163c, and the block
valve 162e, respectively.
In some embodiments, when the choke module 158 is in the backpressure control
configuration, the flow block 160b is in fluid communication with the flow
block 160a via at least
the drilling choke 166c. To enable such fluid communication between the flow
blocks 160a and
160b via the drilling choke 166c, the block valves 162i, 162j, 162k, and 1621
are actuated to the
open configuration, and the block valve 162m is actuated to the closed
configuration. As a result,
the flow block 160b is in fluid communication with the flow block 160a via at
least the block valve
1621, the bleed valve 163f, the block valve 1621, the spool 170c, the drilling
choke 166c, the spool
172c, the flow block 164c, the spool 168c, the block valve 162j, the bleed
valve 163e, and the block
valve 162i, respectively.
In some embodiments, the flow blocks 160a and 160b are substantially identical
to one
another and, therefore, in connection with Figures 11(a)-(b), only the flow
block 160a will be
described in detail below; however, the description below applies to both of
the flow blocks 160a
and 160b. In an embodiment, as illustrated in Figures 11(a)-(b) with
continuing reference to Figures
10(a)-(f), the flow block 160a includes ends 174a-b and sides 176a-d. In some
embodiments, the
ends 174a and 174b are spaced in a substantially parallel relation. In some
embodiments, the sides
176a and 176b are spaced in a substantially parallel relation, each extending
from the end 174a to
the end 174b. In some embodiments, the sides 176c and 176d are spaced in a
substantially parallel
relation, each extending from the end 174a to the end 174b. In some
embodiments, one of which is
shown in Figures 11(a)-(b), the sides 176a and 176b are spaced in a
substantially parallel relation,
and the sides 176c and 176d are spaced in a substantially parallel relation.
In some embodiments,
the sides 176a and 176b are spaced in a substantially perpendicular relation
with the sides 176c and
176d. In some embodiments, the ends 174a and 174b are spaced in a
substantially perpendicular
relation with the sides 176a and 176b. In some embodiments, the ends 174a and
174b are spaced in
a substantially perpendicular relation with the sides 176c and 176d. In some
embodiments, one of
which is shown in Figures 11(a)-(b), the ends 174a and 174b are spaced in a
substantially
perpendicular relation with the sides 176a, 176b, 176c, and 176d.
In addition, the flow block 160a defines an internal region 178 and fluid
passageways 180a-
g. In some embodiments, the fluid passageway 180a extends through the end 174a
of the flow block
160a into the internal region 178. In some embodiments, the fluid passageway
180b extends
through the end 174b of the flow block 160a into the internal region 178. In
some embodiments,
one of which shown in Figures 11(a)-(b), the fluid passageway 180a extends
through the end 174a
of the flow block 160a into the internal region 178, and the fluid passageway
180b extends through
the end 174b of the flow block 160a into the internal region 178. In some
embodiments, the fluid
passageways 180a and 180b form a continuous fluid passageway together with the
internal region
178. In some embodiments, the fluid passageway 180c extends through the side
176a of the flow
block 160a into the internal region 178. In some embodiments, the fluid
passageway 180d extends
through the side 176b of the flow block 160a into the internal region 178. In
some embodiments,
one of which is shown in Figures 11(a)-(b), the fluid passageway 180c extends
through the side
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176a of the flow block 160a into the internal region 178, and the fluid
passageway 180d extends
through the side 176b of the flow block 160a into the internal region 178. In
some embodiments,
the fluid passageways 180c and 180d form a continuous fluid passageway
together with the internal
region 178. In some embodiments, one of which is shown in Figures 11(a)-(b),
the fluid
passageways 180e, 180f, and 180g each extend through the side 176c of the flow
block 160a into the
internal region 178. In some embodiments, one or more of the fluid passageways
180a, 180c, or
180d are omitted from the flow block 160a, and/or one or more fluid
passageways analogous to the
fluid passageways 180a, 180c, or 180d of the flow block 160a are omitted from
the flow block 160b.
In an embodiment of the choke module 158, as illustrated in Figures 10(a)-(f)
with
continuing reference to Figures 11(a)-(b), it can be seen that the block valve
162a is operably
coupled to the side 176c of the flow block 160a and in fluid communication
with the internal region
178 thereof via the fluid passageway 180e, the block valve 162e is operably
coupled to the side 176c
of the flow block 160a (adjacent the block valve 162a) and in fluid
communication with the internal
region 178 thereof via the fluid passageway 180f, and the block valve 162i is
operably coupled to
the side 176c of the flow block 160a (adjacent the block valve 162e) and in
fluid communication
with the internal region 178 thereof via the fluid passageway 180g. The block
valves 162c, 162g,
and 162k are operably coupled to the flow block 160b in substantially the same
manner as the
manner in which the block valves 162a, 162e, and 162i are operably coupled to
the flow block 160a.
The block valve 162m is operably coupled to the side 176b of the flow block
160a and in fluid
communication with the internal region 178 thereof via the fluid passageway
180d. Moreover, the
block valve 162m is operably coupled to the flow block 160b in substantially
the same manner as
the manner in which the block valve 162m is operably coupled to the flow block
160a, except that
the block valve 162m is operably coupled to a side of the flow block 160b
analogous to the side
176a of the flow block 160a¨as a result, the block valve 162m is in fluid
communication with an
internal region of the flow block 160b via a fluid passageway analogous to the
fluid passageway
180c of the flow block 160a.
In some embodiments, the operable coupling of the block valves 162a, 162e, and
162i to the
flow block 160a and the operable coupling of the block valves 162c, 162g, and
162k to the flow
block 160b reduces the number of fluid couplings, and thus potential leak
paths, required to make up
the choke module 158. In some embodiments, the manner in which the block
valves 162a, 162e,
and 162i are operably coupled to the flow block 160a and the manner in which
the block valves
162c, 162g, and 162k are operably coupled to the flow block 160b permit the
drilling chokes 166a-c
to be operably coupled in parallel between the flow blocks 160a and 160b. In
some embodiments,
the spacing between the block valves 162a, 162e, and 162i operably coupled to
the flow block 160a
and the spacing between the block valves 162c, 162g, and 162k operably coupled
to the flow block
160b permit the drilling chokes 166a-c to be operably coupled in parallel
between the flow blocks
160a and 160b.
When the MPD manifold 20 is assembled with the choke module 158, rather than
the choke
module 36, the valve module 40 is operably coupled between the choke module
158 and the flow
meter module 38. More particularly, the valve 88a is operably coupled to the
end 174b of the flow
block 160a and in fluid communication with the internal region 178 thereof via
the fluid passageway
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180b, and the valve 88c is operably coupled to the flow block 160b in
substantially the same manner
as the manner in which the valve 88a is operably coupled to the flow block
160a. In addition, the
valve 88b is operably coupled to the spool 100a, opposite the flow block 98a,
and the valve 88d is
operably coupled to the flow meter 96, opposite the flow block 98b. As a
result, when the valve
module 40 is operably coupled between the choke module 158 and the flow meter
module 38, as
shown in Figures 10(a)-(f), the flow meter module 38 extends in a generally
horizontal orientation.
In those embodiments in which the flow meter module 38 extends in the
generally horizontal
orientation, the MPD manifold 20 is especially well suited for use in onshore
drilling operations. In
some embodiments, rather than the valve 88b being operably coupled to the
spool 100a and the
valve 88d being operably coupled to the flow meter 96, the valve 88b is
operably coupled to the
flow meter 96 and the valve 88d is operably coupled to the spool 100a.
In an embodiment, as illustrated in Figures 10(a)-(f), the MPD manifold 20
further includes a
flow fitting 182a operably coupled to the side 90c of the flow block 86a and
in fluid communication
with the internal region 92 thereof via the fluid passageway 94c, and a flow
fitting 182b operably
coupled to the side 176a of the flow block 160a and in fluid communication
with the internal region
178 thereof via the fluid passageway 180c. Further, in addition to, or instead
of, the flow fitting
182b, the MPD manifold 20 may include a flow fitting 184a operably coupled to
the flow block
160b in substantially the same manner as the manner in which the flow fitting
182b is operably
coupled to the flow block 160a, except that the flow fitting 184a is operably
coupled to a side of the
flow block 160b analogous to the side 176b of the flow block 160a. Finally, in
addition to, or
instead of, the flow fitting 182a, the MPD manifold 20 may include a flow
fitting 184b operably
coupled to the flow block 86b in substantially the same manner as the manner
in which the flow
fitting 182a is operably coupled to the flow block 86a, except that the flow
fitting 184b is operably
coupled to a side of the flow block 86b analogous to the side 90d of the flow
block 86a.
In those embodiments in which the MPD manifold 20 includes the flow fittings
182a and
182b, the temperature sensor 48 and the densometer 50 may be operably coupled
to the valve
module 40 (as shown in Figure 2) via the flow fitting 182a, and the
temperature sensor 44 and the
densometer 46 may be operably coupled to the choke module 158 (as shown in
Figure 2) via the
flow fitting 182b. In such embodiments, the flow fitting 182a is adapted to
receive the drilling mud
.. from the RCD 16 and the MGS 22 is adapted to receive the drilling mud from
the flow fitting 182b.
As a result, the drilling mud may be permitted to flow through the flow meter
96 before flowing
through the drilling chokes 166a, 166b, and/or 166c. Additionally, in those
embodiments in which
the MPD manifold 20 includes the flow fittings 184a and 184b, the temperature
sensor 48 and the
densometer 50 may be operably coupled to the choke module 158 (as shown in
Figure 3) via the
flow fitting 184a, and the temperature sensor 44 and the densometer 46 may be
operably coupled to
the valve module 40 (as shown in Figure 3) via the flow fitting 184b. In such
embodiments, the
flow fitting 184a is adapted to receive the drilling mud from the RCD 16 and
the MGS 22 is adapted
to receive the drilling mud from the flow fitting 184b, as described in
further detail below with
reference to Figure 3. As a result, the drilling mud may be permitted to flow
through the drilling
chokes 166a, 166b, and/or 166c before flowing through the flow meter 96.
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In some embodiments, a measurement fitting 186 is operably coupled to the flow
block 160b
and in fluid communication with an internal region thereof via a fluid
passageway analogous to the
fluid passageway 180a of the flow block 160a. In addition to, or instead of,
the measurement fitting
186, another measurement fitting (not shown) may be operably coupled to the
end 174a of the flow
block 160a and in fluid communication with the internal region 178 thereof via
the fluid passageway
180a. In some embodiments, pressure monitoring equipment 185 (shown in Figure
10(a)) such as,
for example, electronic pressure monitoring equipment (including one or more
pressure sensors) for
automatically controlling one or more of the drilling chokes 166a, 166b,
and/or 166c, is operably
coupled to the measurement fitting 186 and/or the measurement fitting that is
operably coupled to
the flow block 160a. In addition to, or instead of, the electronic pressure
monitoring equipment, the
pressure monitoring equipment 185 may include analog pressure monitoring
equipment (including
one or more pressure sensors), which may be operably coupled to the
measurement fitting 186
and/or the measurement fitting that is operably coupled to the flow block
160a.
In an embodiment, as illustrated in Figures 12(a)-(d) with continuing
reference to Figures
10(a)-(f), the valve module 40 is configurable so that, rather than the valve
88b being operably
coupled to the side 90b of the flow block 86a and in fluid communication with
the internal region 92
thereof via the fluid passageway 94b, the valve 88b is operably coupled to the
side 90e of the flow
block 86a and in fluid communication with the internal region 92 thereof via
the fluid passageway
94e. In addition, the valve 88d is operably coupled to the flow block 86b in
substantially the same
manner as the manner in which the valve 88b is operably coupled to the flow
block 86a. As a result,
when the valve module 40 is operably coupled between the choke module 158 and
the flow meter
module 38, as shown in Figures 12(a)-(d), the flow meter module 38 extends in
a generally vertical
orientation, thus significantly decreasing the overall footprint of the MPD
manifold 20. In those
embodiments in which the flow meter module 38 extends in the generally
vertical orientation, the
MPD manifold 20 is especially well suited for use in offshore drilling
operations. In some
embodiments, the blind flange 95a is operably coupled to the side 90b of the
flow block 86a to
prevent communication between the internal region 92 and atmosphere. In some
embodiments, the
blind flange 95b is operably coupled to the flow block 86b in substantially
the same manner as the
manner in which the blind flange 95a is operably coupled to the flow block
86a.
In some embodiments, to determine the weight of the drilling mud: the
temperature of the
drilling mud measured by the temperature sensor 44 is compared with the
temperature of the drilling
mud measured by the temperature sensor 48; the density of the drilling mud
measured by the
densometer 46 is compared with the density of the drilling mud measured by the
densometer 50;
and/or the respective pressure(s) of the drilling mud measured by the pressure
monitoring equipment
103 (shown in Figure 10(f)) operably coupled to the measurement fittings 102a
and 102b, the
pressure monitoring equipment 185 (shown in Figure 10(a)) operably coupled to
the measurement
fitting 186, pressure monitoring equipment operably coupled to another
measurement fitting of the
MPD manifold 20, or any combination thereof, are compared. Thus, the
temperature sensors 44 and
48, the densometers 46 and 50, and/or the pressure monitoring equipment 103
and/or 185 are
operable to determine whether the weight of the drilling mud is below a
critical threshold. In some
embodiments, in response to a determination that the weight of the drilling
mud is below the critical
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threshold: the weight of the drilling fluid circulated to the drilling tool
(as indicated by the arrows 30
and 32 in Figure 1) is increased, and/or the drilling chokes 166a, 166b,
and/or 166c are adjusted to
increase the backpressure of the drilling mud within the wellbore 29. In this
manner, the
temperature sensors 44 and 48, the densometers 46 and 50, and/or the pressure
monitoring
equipment 103 and/or 185 may be used to predict and prevent well kicks during
drilling operations.
In some embodiments, to determine the amount of gas entrained in the drilling
mud: the
temperature of the drilling mud measured by the temperature sensor 44 is
compared with the
temperature of the drilling mud measured by the temperature sensor 48; the
density of the drilling
mud measured by the densometer 46 is compared with the density of the drilling
mud measured by
the densometer 50; and/or the respective pressure(s) of the drilling mud
measured by the pressure
monitoring equipment 103, the pressure monitoring equipment 185, pressure
monitoring equipment
operably coupled to another measurement fitting of the MPD manifold 20, or any
combination
thereof, are compared. Thus, the temperature sensors 44 and 48, the
densometers 46 and 50, and/or
the pressure monitoring equipment 103 and/or 185 are operable to determine
whether the amount of
gas entrained in the drilling mud is above a critical threshold. In some
embodiments, in response to
a determination that the amount of gas entrained in the drilling mud is above
the critical threshold:
the weight of the drilling fluid circulated to the drilling tool (as indicated
by the arrows 30 and 32 in
Figure 1) is increased, and/or the drilling chokes 166a, 166b, and/or 166c are
adjusted to increase
the backpressure of the drilling mud within the wellbore 29. In this manner,
the temperature sensors
44 and 48, the densometers 46 and 50, and/or the pressure monitoring equipment
103 and/or 185
may be used to predict and prevent well kicks during drilling operations.
In some embodiments, the temperature and density of the drilling mud measured
before the
drilling mud passes through the drilling chokes 166a, 166b, and/or 166c are
compared with the
temperature and density of the drilling mud after the drilling mud passes
through the drilling chokes
166a, 166b, and/or 166c. Further, in some embodiments, the temperature and
pressure of the
drilling mud measured before the drilling mud passes through the drilling
chokes 166a, 166b, and/or
166c are compared with the temperature and pressure of the drilling mud
measured after the drilling
mud passes through the drilling chokes 166a, 166b, and/or 166c. Further still,
in some
embodiments, the density and pressure of the drilling mud measured before the
drilling mud passes
through the drilling chokes 166a, 166b, and/or 166c are compared with the
density and pressure of
the drilling mud measured after the drilling mud passes through the drilling
chokes 166a, 166b,
and/or 166c. Finally, in some embodiments, the temperature, density, and
pressure of the drilling
mud measured before the drilling mud passes through the drilling chokes 166a,
166b, and/or 166c
are compared with the temperature, density, and pressure of the drilling mud
measured after the
drilling mud passes through the drilling chokes 166a, 166b, and/or 166c.
In an embodiment, as illustrated in Figure 13, a method of controlling
backpressure of a
drilling mud within a wellbore 29 is diagrammatically illustrated and
generally referred to by the
reference numeral 188. The method 188 includes receiving the drilling mud from
the wellbore 29 at
a step 190; either: controlling, using one or more of the drilling chokes 166a-
c, the backpressure of
the drilling mud within the wellbore 29 at a step 192, the drilling chokes
166a-c being part of the
choke module 158, or bypassing the drilling chokes 166a-c of the choke module
158 at a step 194;
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either: measuring, using the flow meter 96, a flow rate of the drilling mud
received from the
wellbore 29 at a step 196, the flow meter 96 being part of the flow meter
module 38, or bypassing
the flow meter 96 of the flow meter module 38 at a step 198; and discharging
the drilling mud at a
step 200. In some embodiments, the steps 196 and 198 of the method 188 are
substantially identical
to the steps 134 and 136 of the method 124; therefore, the steps 196 and 198
will not be discussed in
further detail.
The drilling mud is received from the wellbore 29 at the step 190. In an
embodiment of the
step 190, the drilling mud is received from the wellbore 29 via the flow
fitting 182a operably
coupled to, and in fluid communication with, the internal region 92 of the
flow block 86a via the
fluid passageway 94c thereof. In another embodiment of the step 190, the
drilling mud is received
from the wellbore 29 via the flow fitting 184a operably coupled to the flow
block 160b in
substantially the same manner as the manner in which the flow fitting 182b is
operably coupled to
the flow block 160a, except that the flow fitting 184a is operably coupled to
a side of the flow block
160b analogous to the side 176b of the flow block 160a.
In some embodiments, one or more of the drilling chokes 166a-c control the
backpressure of
the drilling mud within the wellbore 29 at the step 192. In an embodiment of
the step 192, one or
more of the drilling chokes 166a-c are used to control the backpressure of the
drilling mud within
the wellbore 29 by: permitting fluid flow from the flow block 160b to the flow
block 160a via one or
both of the following element combinations: the block valve 162c, the bleed
valve 163b, the block
valve 162d, the drilling choke 166a, the block valve 162b, the bleed valve
163a, and the block valve
162a; the block valve 162g, the bleed valve 163d, the block valve 162h, the
drilling choke 166b, the
block valve 162f, the bleed valve 163c, and the block valve 162e; and the
block valve 162k, the
bleed valve 163f, the block valve 1621, the drilling choke 166c, the block
valve 162j, the bleed valve
163e, and the block valve 162i; and preventing, or at least reducing, fluid
flow from the flow block
160b to the flow block 160a via the block valve 162e. More particularly, one
or more of the drilling
chokes 166a-c may be used to control the backpressure of the drilling mud
within the wellbore 29 by
actuating the block valves 162a-m so that: the block valves 162a-d are
actuated to the open
configuration and the block valves 162e-m are actuated to the closed
configuration; the block valves
162e-h are actuated to the open configuration and the block valves 162a-d and
162i-m are actuated
to the closed configuration; the block valves 162i-1 are actuated to the open
configuration and the
block valves 162a-h and 162m are actuated to the closed configuration; the
block valves 162a-h are
actuated to the open configuration and the block valves 162i-m are actuated to
the closed
configuration; the block valves 162a-d and 162i-1 are actuated to the open
configuration and the
block valves 162e-h and 162m are actuated to the closed configuration; the
block valves 162e-1 are
actuated to the open configuration and the block valves 162a-d and 162m are
actuated to the closed
configuration; or the block valves 162a-1 are actuated to the open
configuration and the block valve
162m is actuated to the closed configuration.
In some embodiments, the drilling chokes 166a-c are bypassed at the step 194.
In an
embodiment of the step 194, the drilling chokes 166a-c of the choke module 158
are bypassed by:
permitting fluid flow from the flow block 160b to the flow block 160a via the
block valve 162m;
and preventing, or at least reducing, fluid flow from the flow block 160b to
the flow block 160a via
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each of the following element combinations: the block valve 162c, the bleed
valve 163b, the block
valve 162d, the drilling choke 166a, the block valve 162b, the bleed valve
163a, and the block valve
162a; the block valve 162g, the bleed valve 163d, the block valve 162h, the
drilling choke 166b, the
block valve 162f, the bleed valve 163c, and the block valve 162e; and the
block valve 162k, the
bleed valve 163f, the block valve 1621, the drilling choke 166c, the block
valve 162j, the bleed valve
163e, and the block valve 162i. More particularly, the drilling chokes 166a-c
of the choke module
158 are bypassed by actuating the block valves 162a-m so that: the block
valves 162a-1 are closed
and the block valve 162m is open.
The method 188 includes discharging the drilling mud at the step 200. In an
embodiment of
the step 200, the drilling mud is discharged via either: the flow fitting 182b
operably coupled to, and
in fluid communication with, the internal region 178 of the flow block 160a
via the fluid
passageway 180c thereof; or the flow fitting 184b operably coupled to the flow
block 86b in
substantially the same manner as the manner in which the flow fitting 182a is
operably coupled to
the flow block 86a, except that the flow fitting 184b is operably coupled to a
side of the flow block
86b analogous to the side 90d of the flow block 86a.
In an embodiment of the steps 190 and 200, at the step 190 the drilling mud is
received from
the wellbore 29 via the flow fitting 182a operably coupled to, and in fluid
communication with, the
internal region 92 of the flow block 86a via the fluid passageway 94c thereof,
and at the step 200 the
drilling mud is discharged via the flow fitting 182b operably coupled to, and
in fluid communication
with, the internal region 178 of the flow block 160a via the fluid passageway
180c thereof. In
another embodiment of the steps 190 and 200, at the step 190 the drilling mud
is received from the
wellbore 29 via the flow fitting 184a operably coupled to the flow block 160b
in substantially the
same manner as the manner in which the flow fitting 182b is operably coupled
to the flow block
160a, and at the step 200 the drilling mud is discharged via the flow fitting
184b operably coupled to
the flow block 86b in substantially the same manner as the manner in which the
flow fitting 182a is
operably coupled to the flow block 86a.
In various embodiments, the steps of the method 188 may be executed with
different
combinations of steps in different orders and/or ways. For example, an
embodiment of the method
188 includes: the step 190 at which drilling mud is received from the wellbore
29 via the flow fitting
182a operably coupled to, and in fluid communication with, the internal region
92 of the flow block
86a via the fluid passageway 94c thereof; during and/or after the step 190,
the step 196 at which the
drilling mud flows from the flow block 86a to the flow block 86b via the valve
88b, the spool 100a,
the flow block 98a, the spool 100b, the flow block 98b, the flow meter 96, and
the valve 88d (the
valves 88a and 88e are closed); during and/or after the step 196, the step 192
at which the drilling
mud flows from the flow block 86b to the flow block 160b via the valve 88c,
and from the flow
block 160b to the flow block 160a via one or more of the following element
combinations: the block
valve 162c, the bleed valve 163b, the block valve 162d, the drilling choke
166a, the block valve
162b, the bleed valve 163a, and the block valve 162a; the block valve 162g,
the bleed valve 163d,
the block valve 162h, the drilling choke 166b, the block valve 162f, the bleed
valve 163c, and the
block valve 162e; and the block valve 162k, the bleed valve 163f, the block
valve 1621, the drilling
choke 166c, the block valve 162j, the bleed valve 163e, and the block valve
162i (the block valve
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162m is closed); and during and/or after the step 192, the step 200 at which
the drilling mud is
discharged via the flow fitting 182b operably coupled to, and in fluid
communication with, the
internal region 178 of the flow block 160a via the fluid passageway 180c
thereof
For another example, an embodiment of the method 188 includes: the step 190 at
which
drilling mud is received from the wellbore 29 via the flow fitting 182a
operably coupled to, and in
fluid communication with, the internal region 92 of the flow block 86a via the
fluid passageway 94c
thereof; during and/or after the step 190, the step 198 at which the drilling
mud flows from the flow
block 86a to the flow block 86b via the valve 88e (the valves 88a, 88b, and
88d are closed); during
and/or after the step 198, the step 192 at which the drilling mud flows from
the flow block 86b to the
flow block 160b via the valve 88c, and from the flow block 160b to the flow
block 160a via one or
more of the following element combinations: the block valve 162c, the bleed
valve 163b, the block
valve 162d, the drilling choke 166a, the block valve 162b, the bleed valve
163a, and the block valve
162a; the block valve 162g, the bleed valve 163d, the block valve 162h, the
drilling choke 166b, the
block valve 162f, the bleed valve 163c, and the block valve 162e; and the
block valve 162k, the
bleed valve 163f, the block valve 1621, the drilling choke 166c, the block
valve 162j, the bleed valve
163e, and the block valve 162i (the block valve 162m is closed); and during
and/or after the step
192, the step 200 at which the drilling mud is discharged via the flow fitting
182b operably coupled
to, and in fluid communication with, the internal region 178 of the flow block
160a via the fluid
passageway 180c thereof.
For yet another example, an embodiment of the method 188 includes: the step
190 at which
drilling mud is received from the wellbore 29 via the flow fitting 182a
operably coupled to, and in
fluid communication with, the internal region 92 of the flow block 86a via the
fluid passageway 94c
thereof; during and/or after the step 190, the step 196 at which the drilling
mud flows from the flow
block 86a to the flow block 86b via the valve 88b, the spool 100a, the flow
block 98a, the spool
100b, the flow block 98b, the flow meter 96, and the valve 88d (the valves 88a
and 88e are closed);
during and/or after the step 196, the step 194 at which the drilling mud flows
from the flow block
86b to the flow block 160b via the valve 88c, and from the flow block 160b to
the flow block 160a
via the block valve 162m (the block valves 162a-1 are closed); and during
and/or after the step 194,
the step 200 at which the drilling mud is discharged via the flow fitting 182b
operably coupled to,
and in fluid communication with, the internal region 178 of the flow block
160a via the fluid
passageway 180c thereof.
For yet another example, an embodiment of the method 188 includes: the step
190 at which
drilling mud is received from the wellbore 29 via the flow fitting 182a
operably coupled to, and in
fluid communication with, the internal region 92 of the flow block 86a via the
fluid passageway 94c
thereof; during and/or after the step 190, the step 198 at which the drilling
mud flows from the flow
block 86a to the flow block 86b via the valve 88e (the valves 88a, 88b, and
88d are closed); during
and/or after the step 198, the step 194 at which the drilling mud flows from
the flow block 86b to the
flow block 160b via the valve 88c, and from the flow block 160b to the flow
block 160a via the
block valve 162m (the block valves 162a-1 are closed); and during and/or after
the step 194, the step
200 at which the drilling mud is discharged via the flow fitting 182b operably
coupled to, and in
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fluid communication with, the internal region 178 of the flow block 160a via
the fluid passageway
180c thereof.
For yet another example, an embodiment of the method 188 includes: the step
190 at which
the drilling mud is received from the wellbore 29 via the flow fitting 184a
operably coupled to the
flow block 160b in substantially the same manner as the manner in which the
flow fitting 182b is
operably coupled to the flow block 160a; during and/or after the step 190, the
step 192 at which the
drilling mud flows from the flow block 160b to the flow block 160a via one or
more of the
following element combinations: the block valve 162c, the bleed valve 163b,
the block valve 162d,
the drilling choke 166a, the block valve 162b, the bleed valve 163a, and the
block valve 162a; the
block valve 162g, the bleed valve 163d, the block valve 162h, the drilling
choke 166b, the block
valve 162f, the bleed valve 163c, and the block valve 162e; and the block
valve 162k, the bleed
valve 163f, the block valve 1621, the drilling choke 166c, the block valve
162j, the bleed valve 163e,
and the block valve 162i (the block valve 162m is closed); during and/or after
the step 192, the step
196 at which the drilling mud flows from the flow block 160a to the flow block
86a via the valve
88a, and from the flow block 86a to the flow block 86b via the valve 88b, the
spool 100a, the flow
block 98a, the spool 100b, the flow block 98b, the flow meter 96, and the
valve 88d (the valves 88c
and 88e are closed); and during and/or after the step 196, the step 200 at
which the drilling mud is
discharged via the flow fitting 184b operably coupled to the flow block 86b in
substantially the
same manner as the manner in which the flow fitting 182a is operably coupled
to the flow block 86a.
For yet another example, an embodiment of the method 188 includes: the step
190 at which
the drilling mud is received from the wellbore 29 via the flow fitting 184a
operably coupled to the
flow block 160b in substantially the same manner as the manner in which the
flow fitting 182b is
operably coupled to the flow block 160a; during and/or after the step 190, the
step 192 at which the
drilling mud flows from the flow block 160b to the flow block 160a via one or
more of the
following element combinations: the block valve 162c, the bleed valve 163b,
the block valve 162d,
the drilling choke 166a, the block valve 162b, the bleed valve 163a, and the
block valve 162a; the
block valve 162g, the bleed valve 163d, the block valve 162h, the drilling
choke 166b, the block
valve 162f, the bleed valve 163c, and the block valve 162e; and the block
valve 162k, the bleed
valve 163f, the block valve 1621, the drilling choke 166c, the block valve
162j, the bleed valve 163e,
and the block valve 162i (the block valve 162m is closed); during and/or after
the step 192, the step
198 at which the drilling mud flows from the flow block 160a to the flow block
86a via the valve
88a, and from the flow block 86a to the flow block 86b via the valve 88e (the
valves 88b, 88c and
88d are closed); and during and/or after the step 198, the step 200 at which
the drilling mud is
discharged via the flow fitting 184b operably coupled to the flow block 86b in
substantially the
same manner as the manner in which the flow fitting 182a is operably coupled
to the flow block 86a.
For yet another example, an embodiment of the method 188 includes: the step
190 at which
the drilling mud is received from the wellbore 29 via the flow fitting 184a
operably coupled to the
flow block 160b in substantially the same manner as the manner in which the
flow fitting 182b is
operably coupled to the flow block 160a; during and/or after the step 190, the
step 194 at which the
drilling mud flows from the flow block 160b to the flow block 160a via the
block valve 162m (the
block valves 162a-1 are closed); during and/or after the step 194, the step
196 at which the drilling
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mud flows from the flow block 160a to the flow block 86a via the valve 88a,
and from the flow
block 86a to the flow block 86b via the valve 88b, the spool 100a, the flow
block 98a, the spool
100b, the flow block 98b, the flow meter 96, and the valve 88d (the valves 88c
and 88e are closed);
and during and/or after the step 196, the step 200 at which the drilling mud
is discharged via the
flow fitting 184b operably coupled to the flow block 86b in substantially the
same manner as the
manner in which the flow fitting 182a is operably coupled to the flow block
86a.
Finally, for yet another example, an embodiment of the method 188 includes:
the step 190 at
which the drilling mud is received from the wellbore 29 via the flow fitting
184a operably coupled
to the flow block 160b in substantially the same manner as the manner in which
the flow fitting
182b is operably coupled to the flow block 160a; during and/or after the step
190, the step 194 at
which the drilling mud flows from the flow block 160b to the flow block 160a
via the block valve
162m (the block valves 162a-1 are closed); during and/or after the step 194,
the step 198 at which the
drilling mud flows from the flow block 160a to the flow block 86a via the
valve 88a, and from the
flow block 86a to the flow block 86b via the valve 88e (the valves 88b-d are
closed); and during
and/or after the step 198, the step 200 at which the drilling mud is
discharged via the flow fitting
184b operably coupled to the flow block 86b in substantially the same manner
as the manner in
which the flow fitting 182a is operably coupled to the flow block 86a.
In some embodiments, the configuration of the MPD manifold 20, including the
drilling
chokes 166a-c and the flow meter 96 used to carry out the method 188,
optimizes the efficiency of
the drilling system 10, thereby improving the cost and effectiveness of
drilling operations. Such
improved efficiency benefits operators dealing with challenges such as, for
example, continuous
duty operations, harsh downhole environments, and multiple extended-reach
lateral wells, among
others. In some embodiments, the configuration of the MPD manifold 20,
including the drilling
chokes 166a-c and the flow meter 96 used to carry out the method 188,
favorably affects the size
and/or weight of the MPD manifold 20, and thus the transportability and
overall footprint of the
MPD manifold 20 at the wellsite.
In some embodiments, the integrated nature of the drilling chokes 166a-c and
the flow meter
96 on the MPD manifold 20 used to carry out the method 188 makes it easier to
inspect, service, or
repair the MPD manifold 20, thereby decreasing downtime during drilling
operations. In some
embodiments, the integrated nature of the drilling chokes 166a-c and the flow
meter 96 on the MPD
manifold 20 used to carry out the method 188 makes it easier to coordinate the
inspection, service,
repair, or replacement of components of the MPD manifold 20 such as, for
example, the drilling
chokes 166a-c and/or the flow meter 96, among other components. In this
regard, an arrow 202 in
Figures 10(b), 10(d), 12(b), and 12(c) indicates the direction in which the
drilling choke 166a is
readily removable from the choke module 158 upon decoupling of the spools 168a
and 170a from
the block valves 162b and 162d, respectively, or decoupling of the flow block
164a and the drilling
choke 166a from the respective spools 168a and 170a.
Further, the arrow 202 indicates the direction in which the drilling choke
166b is readily
removable from the choke module 158 upon decoupling of the spools 168b and
170b from the block
valves 162f and 162h, respectively, or decoupling of the flow block 164b and
the drilling choke
166b from the respective spools 168b and 170b. Further still, the arrow 202
indicates the direction
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in which the drilling choke 166c is readily removable from the choke module
158 upon decoupling
of the spools 168c and 170c from the block valves 162j and 1621, respectively,
or decoupling of the
flow block 164c and the drilling choke 166c from the respective spools 168c
and 170c.
Accordingly, one of the drilling chokes 166a-c may be readily inspected,
serviced, repaired, or
replaced during drilling operations while the other of the drilling chokes
166a-c remains in service.
In an embodiment, as illustrated in Figure 14, a method of controlling
backpressure of a
drilling mud within a wellbore 29 is diagrammatically illustrated and
generally referred to by the
reference numeral 204. The method 204 includes receiving the drilling mud from
the wellbore 29 at
a step 206; measuring, using a first sensor, a first physical property of the
drilling mud before the
drilling mud flows through the drilling chokes 166a, 166b, and/or 166c at a
step 208; flowing the
drilling mud through the drilling chokes 166a, 166b, and/or 166c at a step
210; measuring, using a
second sensor, the first physical property of the drilling mud after the
drilling mud flows through the
drilling chokes 166a, 166b, and/or 166c at a step 212; comparing the
respective measurements of the
first physical property taken by the first and second sensors at a step 214;
determining, based on at
least the comparison of the respective measurements of the first physical
property taken by the first
and second sensors, an amount of gas entrained in the drilling mud at a step
216; and adjusting the
drilling chokes 166a, 166b, and/or 166c, based on the determination of the
amount of gas entrained
in the drilling mud, to control the backpressure of the drilling mud within
the wellbore 29 at a step
218. In some embodiments, when the amount of gas entrained in the drilling mud
is above a critical
threshold, the drilling chokes 166a, 166b, and/or 166c are adjusted to
increase the backpressure of
the drilling mud within the wellbore 29. In some embodiments, in addition to,
or instead of,
determining the amount of gas entrained in the drilling mud, the step 216
includes determining,
based on at least the comparison of the respective measurements of the first
physical property taken
by the first and second sensors, the weight of the drilling mud. As a result,
the step 218 includes
adjusting the drilling chokes 166a, 166b, and/or 166c, based on the
determination of the weight of
the drilling mud, to control the backpressure of the drilling mud within the
wellbore 29.
In an embodiment of the steps 208, 210, and 212, the first physical property
is density and
the first and second sensors are the densometers 46 and 50. In another
embodiment of the steps 208,
210, and 212, the first physical property is temperature and the first and
second sensors are
temperature sensors 44 and 48. In yet another embodiment of the steps 208,
210, and 212, the first
physical property is pressure and the first and second sensors are pressure
sensors operably coupled
to the measurement fittings 102a, 102b, 186, and/or another measurement
fitting; in some
embodiments, these pressure sensors may be, may include, or may be a part of,
the pressure
monitoring equipment 103 and/or 185.
In some embodiments of the method 204, the steps 208, 210, and 212 further
include
measuring, using a third sensor, a second physical property of the drilling
mud before the drilling
mud flows through the drilling chokes 166a, 166b, and/or 166c, measuring,
using a fourth sensor,
the second physical property of the drilling mud after the drilling mud flows
through the drilling
chokes 166a, 166b, and/or 166c, and comparing the respective measurements of
the second physical
property taken by the third and fourth sensors. In some embodiments,
determining the amount of
gas entrained in the drilling mud is further based on the comparison of the
respective measurements
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of the second physical property taken by the third and fourth sensors. In an
embodiment, the first
physical property is density and the first and second sensors are the
densometers 46 and 50, and the
second physical property is temperature and the third and fourth sensors are
the temperature sensors
44 and 48. In another embodiment, the first physical property is density and
the first and second
sensors are the densometers 46 and 50, and the second physical property is
pressure and the third
and fourth sensors are pressure sensors operably coupled to the measurement
fittings 102a, 102b,
186, and/or another measurement fitting; in some embodiments, these pressure
sensors may be, may
include, or may be a part of, the pressure monitoring equipment 103 and/or
185. In yet another
embodiment, the first physical property is temperature and the first and
second sensors are the
temperature sensors 44 and 48, and the second physical property is pressure
and the third and fourth
sensors are pressure sensors operably coupled to the measurement fittings
102a, 102b, 186, and/or
another measurement fitting.
In some embodiments of the method 204, the steps 208, 210, and 212 further
include
measuring, using a fifth sensor, a third physical property of the drilling mud
before the drilling mud
flows through the drilling chokes 166a, 166b, and/or 166c, measuring, using a
sixth sensor, the third
physical property of the drilling mud after the drilling mud flows through the
drilling chokes 166a,
166b, and/or 166c, and comparing the respective measurements of the third
physical property taken
by the fifth and sixth sensors. In some embodiments, determining the amount of
gas entrained in the
drilling mud is further based on the comparison of the respective measurements
of the third physical
property taken by the fifth and sixth sensors. In an embodiment, the first
physical property is
density and the first and second sensors are densometers 46 and 50, the second
physical property is
temperature and the third and fourth sensors are the temperature sensors 44
and 48, and the third
physical property is pressure and the fifth and sixth sensors are pressure
sensors operably coupled to
the measurement fittings 102a, 102b, 186, and/or another measurement fitting;
in some
embodiments, these pressure sensors may be, may include, or may be a part of,
the pressure
monitoring equipment 103 and/or 185.
In some embodiments, during the operation of the MPD manifold 20, the
execution of the
method 188, the execution of the method 204, or any combination thereof,
drilling mud is permitted
to flow through two of the drilling chokes 166a-c, and the two of the drilling
chokes 166a-c are
controlled in accordance with the foregoing; in some embodiments, the
remaining one of the drilling
chokes 166a-c is closed but is nevertheless provided for redundancy purposes
such as, for example,
in the event of operational problems with one or both of the two of the
drilling chokes 166a-c. In
some embodiments, during the operation of the MPD manifold 20, the execution
of the method 188,
the execution of the method 204, or any combination thereof, drilling mud is
permitted to flow
through all three of the drilling chokes 166a-c, and all three of the drilling
chokes 166a-c are
controlled in accordance with the foregoing. In some embodiments, the above-
described "double
block-and-bleed" functionality provided, in part, by the bleed valves 163a-f,
as well as the flow
capacity provided by the use of at least two of the drilling chokes 166a-c,
make the choke module
158 especially suitable for offshore applications. In some embodiments, the
above-described
"double block-and-bleed" functionality provided, in part, by the bleed valves
163a-f, as well as the
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flow capacity provided by the use of all of three of the drilling chokes 166a-
c, make the choke
module 158 especially suitable for offshore applications.
In an embodiment, as illustrated in Figure 15, a control unit is
diagrammatically illustrated
and generally referred to by the reference numeral 220-the control unit 220
includes a processor
222 and a non-transitory computer readable medium 224 operably coupled
thereto, a plurality of
instructions being stored on the non-transitory computer readable medium 224,
the instructions
being accessible to, and executable by, the processor 222. In some
embodiments, as illustrated in
Figures 4(a)-(c), (e), and (f), the control unit 220 is in communication with
the drilling chokes 70a
and/or 70b. In those embodiments in which the choke module 36 is omitted and
replaced with the
choke module 158, instead of being in communication with the drilling chokes
70a and/or 70b, the
control unit 220 may be in communication with the drilling chokes 166a, 166b,
and/or 166c, as
illustrated in Figures 10(a)-(c), (e), and (f).
In some embodiments, as illustrated in Figures 2 and 3, the control unit 220
is also in
communication with the flow meter module 38 and, therefore, the control unit
220 may
communicate control signals to the drilling chokes 70a and/or 70b (or the
drilling chokes 166a,
166b, and/or 166c) based on measurement data received from the flow meter
module 38. In some
embodiments, as illustrated in Figures 2 and 3, the control unit 220 is also
in communication with
the temperature sensors 44 and 48 and, therefore, the control unit 220 may
communicate control
signals to the drilling chokes 70a and/or 70b (or the drilling chokes 166a,
166b, and/or 166c) based
on measurement data received from the temperature sensors 44 and 48. In some
embodiments, as
illustrated in Figures 2 and 3, the control unit 220 is also in communication
with the densometers 46
and 50 and, therefore, the control unit 220 may communicate control signals to
the drilling chokes
70a and/or 70b (or the drilling chokes 166a, 166b, and/or 166c) based on
measurement data received
from the densometers 46 and 50. In some embodiments, the control unit 220 is
also in
communication with pressure sensors operably coupled to the measurement
fittings 102a, 102b, 108,
186 and/or another measurement fitting, and, therefore, the control unit 220
may communicate
control signals to the drilling chokes 70a and/or 70b (or the drilling chokes
166a, 166b, and/or 166c)
based on measurement data received from the pressure sensors; in some
embodiments, these
pressure sensors may be, may include, or may be part of, the pressure
monitoring equipment 103,
107, and/or 185. Finally, in some embodiments, the control unit 220 is also in
communication with
one or more other sensors associated with the drilling system 10 such as, for
example, one or more
sensors associated with the drilling tool 18, the wellhead 12, the BOP 14, the
RCD 16, the MGS 22,
the flare 24, the shaker 26, and/or the mud pump 28; therefore, the control
unit 220 may
communicate control signals to the drilling chokes 70a and/or 70b (or the
drilling chokes 166a,
166b, and/or 166c) based on measurement data received from the one or more
sensors.
In some embodiments, a plurality of instructions, or computer program(s), are
stored on a
non-transitory computer readable medium, the instructions or computer
program(s) being accessible
to, and executable by, one or more processors. In some embodiments, the one or
more processors
execute the plurality of instructions (or computer program(s)) to operate in
whole or in part the
above-described embodiments. In some embodiments, the one or more processors
are part of the
control unit 220, one or more other computing devices, or any combination
thereof. In some
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embodiments, the non-transitory computer readable medium is part of the
control unit 220, one or
more other computing devices, or any combination thereof.
In an embodiment, as illustrated in Figure 16, a computing device 1000 for
implementing
one or more embodiments of one or more of the above-described networks,
elements, methods
and/or steps, and/or any combination thereof, is depicted. The computing
device 1000 includes a
microprocessor 1000a, an input device 1000b, a storage device 1000c, a video
controller 1000d, a
system memory 1000e, a display 1000f, and a communication device 1000g all
interconnected by
one or more buses 1000h. In some embodiments, the storage device 1000c may
include a floppy
drive, hard drive, CD-ROM, optical drive, any other form of storage device
and/or any combination
thereof. In some embodiments, the storage device 1000c may include, and/or be
capable of
receiving, a floppy disk, CD-ROM, DVD-ROM, or any other form of computer-
readable medium
that may contain executable instructions. In some embodiments, the
communication device 1000g
may include a modem, network card, or any other device to enable the computing
device to
communicate with other computing devices. In some embodiments, any computing
device
represents a plurality of interconnected (whether by intranet or Internet)
computer systems,
including without limitation, personal computers, mainframes, PDAs,
smartphones and cell phones.
In some embodiments, one or more of the components of the above-described
embodiments
include at least the computing device 1000 and/or components thereof, and/or
one or more
computing devices that are substantially similar to the computing device 1000
and/or components
thereof In some embodiments, one or more of the above-described components of
the computing
device 1000 include respective pluralities of same components.
In some embodiments, a computer system typically includes at least hardware
capable of
executing machine readable instructions, as well as the software for executing
acts (typically
machine-readable instructions) that produce a desired result. In some
embodiments, a computer
system may include hybrids of hardware and software, as well as computer sub-
systems.
In some embodiments, hardware generally includes at least processor-capable
platforms,
such as client-machines (also known as personal computers or servers), and
hand-held processing
devices (such as smart phones, tablet computers, personal digital assistants
(PDAs), or personal
computing devices (PCDs), for example). In some embodiments, hardware may
include any
physical device that is capable of storing machine-readable instructions, such
as memory or other
data storage devices. In some embodiments, other forms of hardware include
hardware sub-
systems, including transfer devices such as modems, modem cards, ports, and
port cards, for
example.
In some embodiments, software includes any machine code stored in any memory
medium,
such as RAM or ROM, and machine code stored on other devices (such as floppy
disks, flash
memory, or a CD ROM, for example). In some embodiments, software may include
source or
object code. In some embodiments, software encompasses any set of instructions
capable of being
executed on a computing device such as, for example, on a client machine or
server.
In some embodiments, combinations of software and hardware could also be used
for
providing enhanced functionality and performance for certain embodiments of
the present
disclosure. In an embodiment, software functions may be directly manufactured
into a silicon chip.
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Accordingly, it should be understood that combinations of hardware and
software are also included
within the definition of a computer system and are thus envisioned by the
present disclosure as
possible equivalent structures and equivalent methods.
In some embodiments, computer readable mediums include, for example, passive
data
storage, such as a random access memory (RAM) as well as semi-permanent data
storage such as a
compact disk read only memory (CD-ROM). One or more embodiments of the present
disclosure
may be embodied in the RAM of a computer to transform a standard computer into
a new specific
computing machine. In some embodiments, data structures are defined
organizations of data that
may enable an embodiment of the present disclosure. In an embodiment, a data
structure may
provide an organization of data, or an organization of executable code.
In some embodiments, any networks and/or one or more portions thereof, may be
designed
to work on any specific architecture. In an embodiment, one or more portions
of any networks may
be executed on a single computer, local area networks, client-server networks,
wide area networks,
internets, hand-held and other portable and wireless devices and networks.
In some embodiments, a database may be any standard or proprietary database
software. In
some embodiments, the database may have fields, records, data, and other
database elements that
may be associated through database specific software. In some embodiments,
data may be mapped.
In some embodiments, mapping is the process of associating one data entry with
another data entry.
In an embodiment, the data contained in the location of a character file can
be mapped to a field in a
second table. In some embodiments, the physical location of the database is
not limiting, and the
database may be distributed. In an embodiment, the database may exist remotely
from the server,
and run on a separate platform. In an embodiment, the database may be
accessible across the
Internet. In some embodiments, more than one database may be implemented.
In some embodiments, a plurality of instructions stored on a non-transitory
computer
readable medium may be executed by one or more processors to cause the one or
more processors to
carry out or implement in whole or in part the above-described operation of
each of the above-
described embodiments of the drilling system 10, the MPD manifold 20, the
method 124, the
method 142, the method 188, the method 204, and/or any combination thereof. In
some
embodiments, such a processor may include one or more of the microprocessor
1000a, the processor
222, and/or any combination thereof, and such a non-transitory computer
readable medium may
include the computer readable medium 224 and/or may be distributed among one
or more
components of the drilling system 10 and/or the MPD manifold 20. In some
embodiments, such a
processor may execute the plurality of instructions in connection with a
virtual computer system. In
some embodiments, such a plurality of instructions may communicate directly
with the one or more
processors, and/or may interact with one or more operating systems,
middleware, firmware, other
applications, and/or any combination thereof, to cause the one or more
processors to execute the
instructions.
In a first aspect, the present disclosure introduces a managed pressure
drilling ("MPD")
manifold adapted to receive drilling mud from a wellbore, the MPD manifold
including: a first
module including one or more drilling chokes; a second module including a flow
meter; and a third
module including first and second flow blocks operably coupled in parallel
between the first and
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second modules; wherein the one or more drilling chokes are adapted to control
backpressure of the
drilling mud within the wellbore; and wherein the flow meter is adapted to
measure a flow rate of
the drilling mud received from the wellbore. In an embodiment, the third
module further includes: a
first valve operably coupled between, and in fluid communication with, the
first flow block and the
first module; a second valve operably coupled between, and in fluid
communication with, the first
flow block and the second module; a third valve operably coupled between, and
in fluid
communication with, the second flow block and the first module; and a fourth
valve operably
coupled between, and in fluid communication with, the second flow block and
the second module.
In an embodiment, the third module further includes a fifth valve operably
coupled between, and in
fluid communication with, the first and second flow blocks. In an embodiment,
the third module is
actuable between: a first configuration in which fluid flow is permitted from
the first flow block to
the second flow block via the second valve, the flow meter, and the fourth
valve, and fluid flow is
prevented, or at least reduced, from the first flow block to the second flow
block via the fifth valve;
and a second configuration in which fluid flow is prevented, or at least
reduced, from the first flow
block to the second flow block via the second valve, the flow meter, and the
fourth valve, and fluid
flow is permitted from the first flow block to the second flow block via the
fifth valve. In an
embodiment, in the first configuration, the first, second, third, fourth, and
fifth valves are actuated so
that either: the second, third, and fourth valves are open and the first and
fifth valves are closed, or
the first, second, and fourth valves are open and the third and fifth valves
are closed; and wherein, in
the second configuration, the first, second, third, fourth, and fifth valves
are actuated so that either:
the third and fifth valves are open and the first, second, and fourth valves
are closed, or the first and
fifth valves are open and the second, third, and fourth valves are closed. In
an embodiment, the first
and second fluid passageways of the first flow block are generally coaxial,
and the first and second
fluid passageways of the second flow block are generally coaxial, so that the
second module,
including the flow meter, extends in a generally horizontal orientation. In an
embodiment, the first
and second fluid passageways of the first flow block define generally
perpendicular axes, and the
first and second fluid passageways of the second flow block define generally
perpendicular axes, so
that the second module, including the flow meter, extends in a generally
vertical orientation. In an
embodiment, the first and second flow blocks each include first, second,
third, fourth, fifth, and sixth
sides, the third, fourth, fifth, and sixth sides extending between the first
and second sides, the first,
third, and fourth fluid passageways extending through the first, third, and
fourth sides, respectively,
and the second fluid passageway extending through either the second side or
the fifth side. In an
embodiment, the second module further includes third and fourth flow blocks,
and first and second
spools, the first spool being operably coupled to, and in fluid communication
with, the third flow
block, the second spool being operably coupled between, and in fluid
communication with, the third
and fourth flow blocks, and the flow meter being operably coupled to, and in
fluid communication
with, the fourth flow block.
In a second aspect, the present disclosure also introduces a managed pressure
drilling
("MPD") manifold adapted to receive drilling mud from a wellbore, the MPD
manifold including: a
first module including one or more drilling chokes; a second module including
a flow meter; and a
third module operably coupled between, and in fluid communication with, the
first and second
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modules, the third module being configured to support the second module in
either: a generally
horizontal orientation; or a generally vertical orientation; wherein the one
or more drilling chokes
are adapted to control backpressure of the drilling mud within the wellbore;
and wherein the flow
meter is adapted to measure a flow rate of the drilling mud received from the
wellbore. In an
embodiment, the first and second modules are together mounted to either a skid
or a trailer so that,
when so mounted, the first and second modules are together towable between
operational sites. In
an embodiment, the third module includes first and second flow blocks operably
coupled in parallel
between the first and second modules, the first and second flow blocks each
defining an internal
region and first, second, third, fourth, and fifth fluid passageways extending
into the internal region.
In an embodiment, when the third module supports the second module in the
generally horizontal
orientation: the first module is operably coupled to, and in fluid
communication with, the internal
region of the first flow block via the first fluid passageway thereof, and the
second module is
operably coupled to, and in fluid communication with, the internal region of
the first flow block via
the second fluid passageway thereof; and the first module is operably coupled
to, and in fluid
communication with, the internal region of the second flow block via the first
fluid passageway
thereof, and the second module is operably coupled to, and in fluid
communication with, the internal
region of the second flow block via the second fluid passageway thereof In an
embodiment, when
the third module supports the second module in the generally vertical
orientation: the first module is
operably coupled to, and in fluid communication with, the internal region of
the first flow block via
the first fluid passageway thereof, and the second module is operably coupled
to, and in fluid
communication with, the internal region of the first flow block via the fifth
fluid passageway
thereof; and the first module is operably coupled to, and in fluid
communication with, the internal
region of the second flow block via the first fluid passageway thereof, and
the second module is
operably coupled to, and in fluid communication with, the internal region of
the second flow block
via the fifth fluid passageway thereof. In an embodiment, the first and second
flow blocks each
include first, second, third, fourth, fifth, and sixth sides, the third,
fourth, fifth, and sixth sides
extending between the first and second sides, and the first, second, third,
fourth, and fifth fluid
passageways extending through the first, second, third, fourth, and fifth
sides. In an embodiment,
the third module further includes first, second, third, fourth, and fifth
valves, the first and second
valves being operably coupled to, and in fluid communication with, the first
flow block and the
respective first and second modules, the third and fourth valves being
operably coupled to, and in
fluid communication with, the second flow block and the respective first and
second modules, and
the fifth valve being operably coupled between, and in fluid communication
with, the first and
second flow blocks. In an embodiment, the second module further includes first
and second flow
blocks, and first and second spools, the first spool being operably coupled
to, and in fluid
communication with, the first flow block, the second spool being operably
coupled between, and in
fluid communication with, the first and second flow blocks, and the flow meter
being operably
coupled to, and in fluid communication with, the second flow block.
In a third aspect, the present disclosure also introduces a managed pressure
drilling ("MPD")
manifold adapted to receive drilling mud from a wellbore, the MPD manifold
including: a first flow
block into which the drilling mud is adapted to flow from the wellbore; a
second flow block into
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which the drilling mud is adapted to flow from the first flow block; a first
valve operably coupled to
the first and second flow blocks; and a choke module including a first
drilling choke, the choke
module being actuable between: a backpressure control configuration in which:
the first drilling
choke is in fluid communication with the first flow block to control
backpressure of the drilling mud
within the wellbore; the second flow block is in fluid communication with the
first flow block via
the first drilling choke; and the second flow block is not in fluid
communication with the first flow
block via the first valve; and a choke bypass configuration in which: the
first drilling choke is not in
fluid communication with the first flow block; the second flow block is not in
fluid communication
with the first flow block via the first drilling choke; and the second flow
block is in fluid
communication with the first flow block via the first valve. In an embodiment,
the MPD manifold
further includes a valve module operably coupled to the choke module, the
valve module including a
second valve; and a flow meter module operably coupled to the valve module,
the flow meter
module including a flow meter; wherein the valve module is actuable between: a
flow metering
configuration in which: the second flow block is in fluid communication with
the first flow block
via the flow meter; and the second flow block is not in fluid communication
with the first flow block
via the second valve; and a meter bypass configuration in which: the second
flow block is not in
fluid communication with the first flow block via the flow meter; and the
second flow block is in
fluid communication with the first flow block via the second valve. In an
embodiment, the choke
module further includes a second drilling choke; and wherein the second flow
block is adapted to be
in fluid communication with the first flow block via one or both of the first
drilling choke and the
second drilling choke. In an embodiment, the valve module includes either the
first flow block or
the second flow block. In an embodiment, the choke module includes the first
flow block and the
valve module includes the second flow block. In an embodiment, the choke
module includes the
second flow block and the valve module includes the first flow block. In an
embodiment, the flow
meter is a Coriolis flow meter. In an embodiment, the choke module includes
the first valve. In an
embodiment, the choke module includes either the first flow block or the
second flow block. In an
embodiment, the choke module includes the first valve, the first flow block,
and the second flow
block.
In a fourth aspect, the present disclosure introduces a choke module adapted
to receive
drilling mud from a wellbore, the choke module including first and second
fluid blocks; and first and
second drilling chokes operably coupled in parallel between the first and
second fluid blocks;
wherein each of the first and second drilling chokes is adapted to control a
backpressure of the
drilling mud within the wellbore. In an embodiment, the choke module further
includes first,
second, third, and fourth valves, the first and second valves being operably
coupled to, and in fluid
communication with, the first fluid block, the third and fourth valves being
operably coupled to, and
in fluid communication with, the second fluid block, the first drilling choke
being operably coupled
between, and in fluid communication with, the first and third valves, and the
second drilling choke
being operably coupled between, and in fluid communication with, the second
and fourth valves. In
an embodiment, the choke module further includes a fifth valve operably
coupled between, and in
fluid communication with, the first and second fluid blocks. In an embodiment,
the choke module is
actuable between a first configuration in which fluid flow is permitted from
the first fluid block to
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the second fluid block via one or both of the following element combinations:
the first valve, the
first drilling choke, and the third valve, and the second valve, the second
drilling choke, and the
fourth valve; and fluid flow is prevented, or at least reduced, from the first
fluid block to the second
fluid block via the fifth valve; and a second configuration in which fluid
flow is permitted from the
first fluid block to the second fluid block via the fifth valve; and fluid
flow is prevented, or at least
reduced, from the first fluid block to the second fluid block via each of the
following element
combinations: the first valve, the first drilling choke, and the third valve,
and the second valve, the
second drilling choke, and the fourth valve. In an embodiment, when the choke
module is in the
first configuration, the first, second, third, fourth, and fifth valves are
actuated so that either: the first
and third valves are open and the second, fourth, and fifth valves are closed,
the second and fourth
valves are open and the first, third, and fifth valves are closed, or the
first, second, third, and fourth
valves are open and the fifth valve is closed; and, when the choke module is
in the second
configuration, the first, second, third, fourth, and fifth valves are actuated
so that the first, second,
third, and fourth valves are closed and the fifth valve is open. In an
embodiment, the first and
second fluid blocks each define an internal region and first, second, third,
and fourth fluid
passageways extending into the internal region. In an embodiment, the first,
second, and fifth valves
are in fluid communication with the internal region of the first fluid block
via the respective first,
second, and third fluid passageways thereof; and the third, fourth, and fifth
valves are in fluid
communication with the internal region of the second fluid block via the
respective first, second, and
fourth fluid passageways thereof In an embodiment, the first and second fluid
blocks each include
first and second ends, and first, second, third, and fourth sides extending
between the first and
second ends, the first and second fluid passageways extending through the
first side, and the third
and fourth fluid passageways extending through the second and third sides,
respectively.
In a fifth aspect, the present disclosure introduces a method of controlling
backpressure of a
drilling mud within a wellbore, the method including receiving the drilling
mud from the wellbore;
either: controlling, using first and/or second drilling chokes, the
backpressure of the drilling mud
within the wellbore, the first and second drilling chokes being part of a
first module, the first module
further including first and second fluid blocks between which the first and
second drilling chokes are
operably coupled in parallel, or bypassing the first and second drilling
chokes of the first module;
and discharging the drilling mud. In an embodiment, the first module further
includes first, second,
third, and fourth valves, the first and second valves being operably coupled
to, and in fluid
communication with, the first fluid block, the third and fourth valves being
operably coupled to, and
in fluid communication with, the second fluid block, the first drilling choke
being operably coupled
between, and in fluid communication with, the first and third valves, and the
second drilling choke
being operably coupled between, and in fluid communication with, the second
and fourth valves. In
an embodiment, the first module further includes a fifth valve operably
coupled between, and in
fluid communication with, the first and second fluid blocks. In an embodiment,
controlling, using
the first and/or second drilling chokes, the backpressure of the drilling mud
within the wellbore
includes permitting fluid flow from the first fluid block to the second fluid
block via one or both of
the following element combinations: the first valve, the first drilling choke,
and the third valve, and
the second valve, the second drilling choke, and the fourth valve; and
preventing, or at least
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reducing, fluid flow from the first fluid block to the second fluid block via
the fifth valve; and
bypassing the first and second drilling chokes of the first module includes
permitting fluid flow from
the first fluid block to the second fluid block via the fifth valve; and
preventing, or at least reducing,
fluid flow from the first fluid block to the second fluid block via each of
the following element
.. combinations: the first valve, the first drilling choke, and the third
valve, and the second valve, the
second drilling choke, and the fourth valve. In an embodiment, controlling,
using the first and/or
second drilling chokes, the backpressure of the drilling mud within the
wellbore includes actuating
the first, second, third, fourth, and fifth valves so that: the first and
third valves are open and the
second, fourth, and fifth valves are closed, the second and fourth valves are
open and the first, third,
.. and fifth valves are closed, or the first, second, third, and fourth valves
are open and the fifth valve
is closed; and bypassing the first and second drilling chokes of the first
module includes actuating
the first, second, third, fourth, and fifth valves so that the first, second,
third, and fourth valves are
closed and the fifth valve is open. In an embodiment, the first and second
fluid blocks each define
an internal region and first, second, third, and fourth fluid passageways
extending into the internal
-- region. In an embodiment, the first, second, and fifth valves are in fluid
communication with the
internal region of the first fluid block via the respective first, second, and
third fluid passageways
thereof; and the third, fourth, and fifth valves are in fluid communication
with the internal region of
the second fluid block via the respective first, second, and fourth fluid
passageways thereof. In an
embodiment, the first and second fluid blocks each include first and second
ends, and first, second,
-- third, and fourth sides extending between the first and second ends, the
first and second fluid
passageways extending through the first side, and the third and fourth fluid
passageways extending
through the second and third sides, respectively.
In a sixth aspect, the present disclosure introduces a managed pressure
drilling ("MPD")
manifold adapted to receive drilling mud from a wellbore, the MPD manifold
including a first
.. module including one or more drilling chokes; a second module including a
flow meter; and a third
module operably coupled between, and in fluid communication with, the first
and second modules,
the third module being configured to support the second module in either: a
generally horizontal
orientation, or a generally vertical orientation; wherein, when the MPD
manifold receives the
drilling mud from the wellbore: the one or more drilling chokes are adapted to
control backpressure
-- of the drilling mud within the wellbore, and the flow meter is adapted to
measure a flow rate of the
drilling mud received from the wellbore. In an embodiment, the first and
second modules are
together mounted to either a skid or a trailer so that, when so mounted, the
first and second modules
are together towable between operational sites. In an embodiment, the third
module includes first
and second flow blocks operably coupled in parallel between the first and
second modules, the first
-- and second flow blocks each defining an internal region and first, second,
third, fourth, and fifth
fluid passageways extending into the internal region. In an embodiment, when
the third module
supports the second module in the generally horizontal orientation: the first
module is operably
coupled to, and in fluid communication with, the internal region of the first
flow block via the first
fluid passageway thereof, and the second module is operably coupled to, and in
fluid
-- communication with, the internal region of the first flow block via the
second fluid passageway
thereof; and the first module is operably coupled to, and in fluid
communication with, the internal
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region of the second flow block via the first fluid passageway thereof, and
the second module is
operably coupled to, and in fluid communication with, the internal region of
the second flow block
via the second fluid passageway thereof. In an embodiment, when the third
module supports the
second module in the generally vertical orientation: the first module is
operably coupled to, and in
fluid communication with, the internal region of the first flow block via the
first fluid passageway
thereof, and the second module is operably coupled to, and in fluid
communication with, the internal
region of the first flow block via the fifth fluid passageway thereof; and the
first module is operably
coupled to, and in fluid communication with, the internal region of the second
flow block via the
first fluid passageway thereof, and the second module is operably coupled to,
and in fluid
communication with, the internal region of the second flow block via the fifth
fluid passageway
thereof In an embodiment, the first and second flow blocks each include first,
second, third, fourth,
fifth, and sixth sides, the third, fourth, fifth, and sixth sides extending
between the first and second
sides, and the first, second, third, fourth, and fifth fluid passageways
extending through the first,
second, third, fourth, and fifth sides. In an embodiment, the third module
further includes first,
second, third, fourth, and fifth valves, the first and second valves being
operably coupled to, and in
fluid communication with, the first flow block and the respective first and
second modules, the third
and fourth valves being operably coupled to, and in fluid communication with,
the second flow
block and the respective first and second modules, and the fifth valve being
operably coupled
between, and in fluid communication with, the first and second flow blocks. In
an embodiment, the
third module is actuable between: a first configuration in which fluid flow is
permitted from the first
flow block to the second flow block via the second valve, the flow meter, and
the fourth valve, and
fluid flow is prevented, or at least reduced, from the first flow block to the
second flow block via the
fifth valve; and a second configuration in which fluid flow is prevented, or
at least reduced, from the
first flow block to the second flow block via the second valve, the flow
meter, and the fourth valve,
and fluid flow is permitted from the first flow block to the second flow block
via the fifth valve. In
an embodiment, in the first configuration, the first, second, third, fourth,
and fifth valves are
actuated so that either: the second, third, and fourth valves are open and the
first and fifth valves are
closed, or the first, second, and fourth valves are open and the third and
fifth valves are closed; and,
in the second configuration, the first, second, third, fourth, and fifth
valves are actuated so that
either: the third and fifth valves are open and the first, second, and fourth
valves are closed, or the
first and fifth valves are open and the second, third, and fourth valves are
closed. In an embodiment,
the second module further includes first and second flow blocks, and first and
second spools, the
first spool being operably coupled to, and in fluid communication with, the
first flow block, the
second spool being operably coupled between, and in fluid communication with,
the first and second
flow blocks, and the flow meter being operably coupled to, and in fluid
communication with, the
fourth flow block. In an embodiment, the flow meter is a coriolis flow meter.
In a seventh aspect, the present disclosure introduces a method of controlling
backpressure
of a drilling mud within a wellbore, the method including receiving the
drilling mud from the
wellbore; either: controlling, using one or more drilling chokes, the
backpressure of the drilling mud
within the wellbore, the one or more drilling chokes being part of a first
module, or bypassing the
one or more drilling chokes of the first module; either: measuring, using a
flow meter, a flow rate of
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the drilling mud received from the wellbore, the flow meter being part of a
second module, or
bypassing the flow meter of the second module; communicating the drilling mud
between the first
and second modules using a third module, the third module being configured to
support the second
module in either: a generally horizontal orientation, or a generally vertical
orientation; and
discharging the drilling mud. In an embodiment, the first and second modules
are together mounted
to either a skid or a trailer so that, when so mounted, the first and second
modules are together
towable between operational sites. In an embodiment, the third module includes
first and second
flow blocks operably coupled in parallel between the first and second modules,
the first and second
flow blocks each defining an internal region and first, second, third, fourth,
and fifth fluid
.. passageways extending into the internal region. In an embodiment, when the
third module supports
the second module in the generally horizontal orientation: the first module is
operably coupled to,
and in fluid communication with, the internal region of the first flow block
via the first fluid
passageway thereof, and the second module is operably coupled to, and in fluid
communication
with, the internal region of the first flow block via the second fluid
passageway thereof; and the first
module is operably coupled to, and in fluid communication with, the internal
region of the second
flow block via the first fluid passageway thereof, and the second module is
operably coupled to, and
in fluid communication with, the internal region of the second flow block via
the second fluid
passageway thereof In an embodiment, when the third module supports the second
module in the
generally vertical orientation: the first module is operably coupled to, and
in fluid communication
with, the internal region of the first flow block via the first fluid
passageway thereof, and the second
module is operably coupled to, and in fluid communication with, the internal
region of the first flow
block via the fifth fluid passageway thereof; and the first module is operably
coupled to, and in fluid
communication with, the internal region of the second flow block via the first
fluid passageway
thereof, and the second module is operably coupled to, and in fluid
communication with, the internal
region of the second flow block via the fifth fluid passageway thereof. In an
embodiment, the first
and second flow blocks each include first, second, third, fourth, fifth, and
sixth sides, the third,
fourth, fifth, and sixth sides extending between the first and second sides,
and the first, second, third,
fourth, and fifth fluid passageways extending through the first, second,
third, fourth, and fifth sides.
In an embodiment, the third module further includes first, second, third,
fourth, and fifth valves, the
first and second valves being operably coupled to, and in fluid communication
with, the first flow
block and the respective first and second modules, the third and fourth valves
being operably
coupled to, and in fluid communication with, the second flow block and the
respective first and
second modules, and the fifth valve being operably coupled between, and in
fluid communication
with, the first and second flow blocks. In an embodiment, communicating the
drilling mud between
the first and second modules using the third module includes: permitting fluid
flow from the first
flow block to the second flow block via the second valve, the flow meter, and
the fourth valve; and
preventing, or at least reducing, fluid flow from the first flow block to the
second flow block via the
fifth valve; and bypassing the flow meter of the second module includes:
preventing, or at least
reducing, fluid flow from the first flow block to the second flow block via
the second valve, the flow
meter, and the fourth valve; and permitting fluid flow from the first flow
block to the second flow
block via the fifth valve. In an embodiment, communicating the drilling mud
between the first and
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second modules using the third module includes actuating the first, second,
third, fourth, and fifth
valves so that either: the second, third, and fourth valves are open and the
first and fifth valves are
closed; or the first, second, and fourth valves are open and the third and
fifth valves are closed; and
bypassing the flow meter of the second module includes actuating the first,
second, third, fourth, and
fifth valves so that either: the third and fifth valves are open and the
first, second, and fourth valves
are closed; or the first and fifth valves are open and the second, third, and
fourth valves are closed.
In an embodiment, the second module further includes first and second flow
blocks, and first and
second spools, the first spool being operably coupled to, and in fluid
communication with, the first
flow block, the second spool being operably coupled between, and in fluid
communication with, the
first and second flow blocks, and the flow meter being operably coupled to,
and in fluid
communication with, the fourth flow block. In an embodiment, the flow meter is
a coriolis flow
meter.
In an eighth aspect, the present disclosure introduces a choke module adapted
to receive
drilling mud from a wellbore, the choke module including a first fluid block
defining an internal
region and first and second fluid passageways extending into the internal
region, the first fluid block
including first and second ends, and first, second, third, and fourth sides
extending between the first
and second ends, the first and second fluid passageways extending through the
first side. In an
embodiment, the choke module further includes first and second drilling chokes
operably coupled
to, and in fluid communication with, the internal region of the first fluid
block via the respective first
and second fluid passageways thereof; wherein each of the first and second
drilling chokes is
adapted to control a backpressure of the drilling mud within the wellbore. In
an embodiment, the
choke module further includes a first valve operably coupled between, and in
fluid communication
with, the first fluid block and the first drilling choke; and a second valve
operably coupled between,
and in fluid communication with, the first fluid block and the second drilling
choke. In an
embodiment, the choke module further includes a second fluid block defining an
internal region and
first and second fluid passageways extending into the internal region, the
second fluid block
including first and second ends, and first, second, third, and fourth sides
extending between the first
and second ends, the first and second fluid passageways extending through the
first side; wherein
the first and second drilling chokes are operably coupled to, and in fluid
communication with, the
internal region of the second fluid block via the respective first and second
fluid passageways
thereof In an embodiment, the choke module further includes a valve operably
coupled between,
and in fluid communication with, the respective internal regions of the first
and second fluid blocks.
In an embodiment, the choke module further includes a first valve operably
coupled between, and in
fluid communication with, the second fluid block and the first drilling choke;
and a second valve
operably coupled between, and in fluid communication with, the second fluid
block and the second
drilling choke. In an embodiment, the first fluid block further defines a
third fluid passageway
extending through the second side thereof and adapted to receive the drilling
mud from the wellb ore.
In an embodiment, the first fluid block further defines a fourth fluid
passageway extending through
the first end thereof and adapted to communicate the drilling mud via a
measurement fitting
connected to the first end.
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In a ninth aspect, the present disclosure introduces a method of controlling
backpressure of a
drilling mud within a wellbore, the method including receiving the drilling
mud from the wellbore;
measuring, using a first sensor, a first physical property of the drilling mud
before the drilling mud
flows through one or more drilling chokes; flowing the drilling mud through
the one or more drilling
chokes; measuring, using a second sensor, the first physical property of the
drilling mud after the
drilling mud flows through the one or more drilling chokes; comparing the
respective measurements
of the first physical property taken by the first and second sensors;
determining, based on at least the
comparison of the respective measurements of the first physical property taken
by the first and
second sensors, an amount of gas entrained in the drilling mud; and adjusting
the one or more
drilling chokes, based on at least the determination of the amount of gas
entrained in the drilling
mud, to control the backpressure of the drilling mud within the wellbore;
wherein, when the amount
of gas entrained in the drilling mud is above a critical threshold, the one or
more drilling chokes are
adjusted to increase the backpressure of the drilling mud within the wellbore.
In an embodiment,
the first physical property is density and the first and second sensors are
densometers. In an
embodiment, the first physical property is temperature and the first and
second sensors are
temperature sensors. In an embodiment, the first physical property is pressure
and the first and
second sensors are pressure sensors. In an embodiment, the method further
includes measuring,
using a third sensor, a second physical property of the drilling mud before
the drilling mud flows
through the one or more drilling chokes; measuring, using a fourth sensor, the
second physical
property of the drilling mud after the drilling mud flows through the one or
more drilling chokes;
and comparing the respective measurements of the second physical property
taken by the third and
fourth sensors; wherein determining the amount of gas entrained in the
drilling mud is further based
on the comparison of the respective measurements of the second physical
property taken by the third
and fourth sensors. In an embodiment, the first physical property is density
and the first and second
sensors are densometers; and the second physical property is temperature and
the third and fourth
sensors are temperature sensors. In an embodiment, the first physical property
is density and the
first and second sensors are densometers; and the second physical property is
pressure and the third
and fourth sensors are pressure sensors. In an embodiment, the first physical
property is temperature
and the first and second sensors are temperature sensors; and the second
physical property is
.. pressure and the third and fourth sensors are pressure sensors. In an
embodiment, the method
further includes: measuring, using a fifth sensor, a third physical property
of the drilling mud before
the drilling mud flows through the one or more drilling chokes; measuring,
using a sixth sensor, the
third physical property of the drilling mud after the drilling mud flows
through the one or more
drilling chokes; and comparing the respective measurements of the third
physical property taken by
the fifth and sixth sensors; wherein determining the amount of gas entrained
in the drilling mud is
further based on the comparison of the respective measurements of the third
physical property taken
by the fifth and sixth sensors. In an embodiment, the first physical property
is density and the first
and second sensors are densometers; the second physical property is
temperature and the third and
fourth sensors are temperature sensors; and the third physical property is
pressure and the fifth and
sixth sensors are pressure sensors.
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In a tenth aspect, the present disclosure introduces a managed pressure
drilling ("MPD")
manifold adapted to receive drilling mud from a wellbore, the MPD manifold
including a first
module including one or more drilling chokes; and a second module including a
flow meter, the
second module being operably coupleable to the first module in either: a
generally horizontal
orientation, or a generally vertical orientation; wherein the first and second
modules are together
mounted to either a skid or a trailer so that, when so mounted, the first and
second modules are
together towable between operational sites; and wherein, when the MPD manifold
receives the
drilling mud from the wellbore: the one or more drilling chokes are adapted to
control backpressure
of the drilling mud within the wellbore; and the flow meter is adapted to
measure a flow rate of the
drilling mud received from the wellbore. In an embodiment, the first module
further includes first
and second fluid blocks, the one or more drilling chokes of the first module
including first and
second drilling chokes operably coupled in parallel between the first and
second fluid blocks. In an
embodiment, the first module further includes first, second, third, and fourth
valves, the first and
second valves being operably coupled to, and in fluid communication with, the
first fluid block, the
third and fourth valves being operably coupled to, and in fluid communication
with, the second fluid
block, the first drilling choke being operably coupled between, and in fluid
communication with, the
first and third valves, and the second drilling choke being operably coupled
between, and in fluid
communication with, the second and fourth valves. In an embodiment, the first
module further
includes a fifth valve operably coupled between, and in fluid communication
with, the first and
second fluid blocks. In an embodiment, the first module is actuable between: a
first configuration in
which: fluid flow is permitted from the second fluid block to the first fluid
block via one or both of
the following element combinations: the first valve, the first drilling choke,
and the third valve; and
the second valve, the second drilling choke, and the fourth valve; and fluid
flow is prevented, or at
least reduced, from the second fluid block to the first fluid block via the
fifth valve; and a second
configuration in which: fluid flow is permitted from the second fluid block to
the first fluid block via
the fifth valve; and fluid flow is prevented, or at least reduced, from the
second fluid block to the
first fluid block via each of the following element combinations: the first
valve, the first drilling
choke, and the third valve; and the second valve, the second drilling choke,
and the fourth valve. In
an embodiment, in the first configuration, the first, second, third, fourth,
and fifth valves are
actuated so that either: the first and third valves are open and the second,
fourth, and fifth valves are
closed, the second and fourth valves are open and the first, third, and fifth
valves are closed, or the
first, second, third, and fourth valves are open and the fifth valve is
closed; and, in the second
configuration, the first, second, third, fourth, and fifth valves are actuated
so that: the first, second,
third, and fourth valves are closed and the fifth valve is open. In an
embodiment, the first and
second fluid blocks each define an internal region and first, second, third,
fourth, fifth, and sixth
fluid passageways extending into the internal region. In an embodiment, the
first, second, and fifth
valves are in fluid communication with the internal region of the first fluid
block via the respective
fifth, sixth, and fourth fluid passageways thereof; and the third, fourth, and
fifth valves are in fluid
communication with the internal region of the second fluid block via the
respective fifth, sixth, and
third fluid passageways thereof. In an embodiment, the MPD manifold further
includes a third
module operably coupled to, and in fluid communication with: the internal
region of the first fluid
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block via the second fluid passageway thereof; the internal region of the
second fluid block via the
second fluid passageway thereof; and the flow meter of the second module. In
an embodiment, the
first module further includes one or both of: a first flow fitting operably
coupled to, and in fluid
communication with, the internal region of the second fluid block via the
fourth fluid passageway
thereof, the first flow fitting being adapted to receive the drilling mud from
the wellbore; and a
second flow fitting operably coupled to, and in fluid communication with, the
internal region of the
first fluid block via the third fluid passageway thereof, the second flow
fitting being adapted to
discharge the drilling mud from the first module. In an embodiment, the first
module further
includes one or both of: a first measurement fitting operably coupled to, and
in fluid communication
with, the internal region of the first fluid block via the first fluid
passageway thereof; and a second
measurement fitting operably coupled to, and in fluid communication with, the
internal region of the
second fluid block via the first fluid passageway thereof. In an embodiment,
the first and second
fluid blocks each include first and second ends, and first, second, third, and
fourth sides extending
between the first and second ends, the first and second fluid passageways
extending through the first
and second ends, respectively, the third and fourth fluid passageways
extending through the first and
second sides, respectively, and the fifth and sixth fluid passageways each
extending through the
third side. In an embodiment, the second module further includes first and
second flow blocks, and
first and second spools, the first spool being operably coupled to, and in
fluid communication with,
the first flow block, the second spool being operably coupled between, and in
fluid communication
with, the first and second flow blocks, and the flow meter being operably
coupled to, and in fluid
communication with, the second flow block. In an embodiment, the second module
further includes
one or both of: a first measurement fitting operably coupled to, and in fluid
communication with, the
first flow block; and a second measurement fitting operably coupled to, and in
fluid communication
with, the second flow block. In an embodiment, the flow meter is a coriolis
flow meter. In an
embodiment, the MPD manifold further includes a third module, the third module
including first and
second flow blocks and first, second, third, and fourth valves, the first
valve being operably coupled
to, and in fluid communication with, the first flow block and the first
module, the second valve
being operably coupled to, and in fluid communication with, the first flow
block and the second
module, the third valve being operably coupled to, and in fluid communication
with, the second
flow block and the first module, and the fourth valve being operably coupled
to, and in fluid
communication with, the second flow block and the second module. In an
embodiment, the third
module further includes a fifth valve operably coupled between, and in fluid
communication with,
the first and second flow blocks; and wherein the third module is actuable
between: a first
configuration in which fluid flow is permitted from the first flow block to
the second flow block via
the second valve, the flow meter, and the fourth valve, and fluid flow is
prevented, or at least
reduced, from the first flow block to the second flow block via the fifth
valve; and a second
configuration in which fluid flow is prevented, or at least reduced, from the
first flow block to the
second flow block via the second valve, the flow meter, and the fourth valve,
and fluid flow is
permitted from the first flow block to the second flow block via the fifth
valve. In an embodiment,
in the first configuration, the first, second, third, fourth, and fifth valves
are actuated so that either:
the second, third, and fourth valves are open and the first and fifth valves
are closed, or the first,
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second, and fourth valves are open and the third and fifth valves are closed;
and, in the second
configuration, the first, second, third, fourth, and fifth valves are actuated
so that either: the third and
fifth valves are open and the first, second, and fourth valves are closed, or
the first and fifth valves
are open and the second, third, and fourth valves are closed. In an
embodiment, the first and second
flow blocks each define an internal region, and first, second, third, and
fourth fluid passageways,
each extending into the internal region. In an embodiment, the first, second,
and fifth valves are in
fluid communication with the internal region of the first flow block via the
respective first, second,
and fourth fluid passageways thereof; and the third, fourth, and fifth valves
are in fluid
communication with the internal region of the second flow block via the
respective first, second, and
third fluid passageways thereof. In an embodiment, the first and second fluid
passageways of the
first flow block are generally coaxial and the first and second fluid
passageways of the second flow
block are generally coaxial so that the second module, including the flow
meter, extends in the
generally horizontal orientation. In an embodiment, the first and second fluid
passageways of the
first flow block define generally perpendicular axes and the first and second
fluid passageways of
the second flow block define generally perpendicular axes so that the second
module, including the
flow meter, extends in the generally vertical orientation. In an embodiment,
the first and second
flow blocks each include first, second, third, fourth, fifth, and sixth sides,
the third, fourth, fifth, and
sixth sides extending between the first and second sides, the first, third,
and fourth fluid
passageways extending through the respective first, third, and fourth sides,
and the second fluid
passageway extending through either the second side or the fifth side. In an
embodiment, the third
module further includes one or both of: a first flow fitting operably coupled
to, and in fluid
communication with, the internal region of the first flow block via the third
fluid passageway
thereof, the first flow fitting being adapted to receive the drilling mud from
the wellbore; or a
second flow fitting operably coupled to, and in fluid communication with, the
internal region of the
second flow block via the fourth fluid passageway thereof, the second flow
fitting being adapted to
discharge the drilling mud from the third module.
In an eleventh aspect, the present disclosure introduces a managed pressure
drilling ("MPD")
manifold adapted to receive drilling mud from a wellbore, the MPD manifold
including a first
module including: first and second fluid blocks, and first and second drilling
chokes operably
coupled in parallel between the first and second fluid blocks; and a second
module including a flow
meter; wherein, when the MPD manifold receives the drilling mud from the
wellbore: the one or
more drilling chokes are adapted to control backpressure of the drilling mud
within the wellbore;
and the flow meter is adapted to measure a flow rate of the drilling mud
received from the wellbore.
In an embodiment, the first module further includes first, second, third, and
fourth valves, the first
and second valves being operably coupled to, and in fluid communication with,
the first fluid block,
the third and fourth valves being operably coupled to, and in fluid
communication with, the second
fluid block, the first drilling choke being operably coupled between, and in
fluid communication
with, the first and third valves, and the second drilling choke being operably
coupled between, and
in fluid communication with, the second and fourth valves. In an embodiment,
the first module
further includes a fifth valve operably coupled between, and in fluid
communication with, the first
and second fluid blocks. In an embodiment, the first module is actuable
between: a first
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configuration in which: fluid flow is permitted from the second fluid block to
the first fluid block via
one or both of the following element combinations: the first valve, the first
drilling choke, and the
third valve; and the second valve, the second drilling choke, and the fourth
valve; and fluid flow is
prevented, or at least reduced, from the second fluid block to the first fluid
block via the fifth valve;
and a second configuration in which: fluid flow is permitted from the second
fluid block to the first
fluid block via the fifth valve; and fluid flow is prevented, or at least
reduced, from the second fluid
block to the first fluid block via each of the following element combinations:
the first valve, the first
drilling choke, and the third valve; and the second valve, the second drilling
choke, and the fourth
valve. In an embodiment, in the first configuration, the first, second, third,
fourth, and fifth valves
are actuated so that either: the first and third valves are open and the
second, fourth, and fifth valves
are closed, the second and fourth valves are open and the first, third, and
fifth valves are closed, or
the first, second, third, and fourth valves are open and the fifth valve is
closed; and, in the second
configuration, the first, second, third, fourth, and fifth valves are actuated
so that: the first, second,
third, and fourth valves are closed and the fifth valve is open. In an
embodiment, the first and
second fluid blocks each define an internal region and first, second, third,
fourth, fifth, and sixth
fluid passageways extending into the internal region. In an embodiment, the
first, second, and fifth
valves are in fluid communication with the internal region of the first fluid
block via the respective
fifth, sixth, and fourth fluid passageways thereof; and the third, fourth, and
fifth valves are in fluid
communication with the internal region of the second fluid block via the
respective fifth, sixth, and
third fluid passageways thereof. In an embodiment, the IVIPD manifold further
includes a third
module operably coupled to, and in fluid communication with: the internal
region of the first fluid
block via the second fluid passageway thereof; the internal region of the
second fluid block via the
second fluid passageway thereof; and the flow meter of the second module. In
an embodiment, the
first module further includes one or both of: a first flow fitting operably
coupled to, and in fluid
communication with, the internal region of the second fluid block via the
fourth fluid passageway
thereof, the first flow fitting being adapted to receive the drilling mud from
the wellbore; and a
second flow fitting operably coupled to, and in fluid communication with, the
internal region of the
first fluid block via the third fluid passageway thereof, the second flow
fitting being adapted to
discharge the drilling mud from the first module. In an embodiment, the first
module further
includes one or both of: a first measurement fitting operably coupled to, and
in fluid communication
with, the internal region of the first fluid block via the first fluid
passageway thereof; and a second
measurement fitting operably coupled to, and in fluid communication with, the
internal region of the
second fluid block via the first fluid passageway thereof. In an embodiment,
the first and second
fluid blocks each include first and second ends, and first, second, third, and
fourth sides extending
between the first and second ends, the first and second fluid passageways
extending through the first
and second ends, respectively, the third and fourth fluid passageways
extending through the first and
second sides, respectively, and the fifth and sixth fluid passageways each
extending through the
third side. In an embodiment, the second module further includes first and
second flow blocks, and
first and second spools, the first spool being operably coupled to, and in
fluid communication with,
the first flow block, the second spool being operably coupled between, and in
fluid communication
with, the first and second flow blocks, and the flow meter being operably
coupled to, and in fluid
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communication with, the second flow block. In an embodiment, the second module
further includes
one or both of: a first measurement fitting operably coupled to, and in fluid
communication with, the
first flow block; and a second measurement fitting operably coupled to, and in
fluid communication
with, the second flow block. In an embodiment, the flow meter is a coriolis
flow meter.
In a twelfth aspect, the present disclosure introduces a managed pressure
drilling ("MPD")
manifold adapted to receive drilling mud from a wellbore, the MPD manifold
including a first
module including one or more drilling chokes; a second module including a flow
meter; and a third
module including first and second flow blocks operably coupled in parallel
between the first and
second modules; wherein, when the MPD manifold receives the drilling mud from
the wellbore: the
one or more drilling chokes are adapted to control backpressure of the
drilling mud within the
wellbore; and the flow meter is adapted to measure a flow rate of the drilling
mud received from the
wellbore. In an embodiment, the third module further includes first, second,
third, and fourth
valves, the first and second valves being operably coupled to, and in fluid
communication with, the
first flow block and the respective first and second modules, and the third
and fourth valves being
operably coupled to, and in fluid communication with, the second flow block
and the respective first
and second modules. In an embodiment, the third module further includes a
fifth valve operably
coupled between, and in fluid communication with, the first and second flow
blocks; and wherein
the third module is actuable between: a first configuration in which fluid
flow is permitted from the
first flow block to the second flow block via the second valve, the flow
meter, and the fourth valve,
and fluid flow is prevented, or at least reduced, from the first flow block to
the second flow block
via the fifth valve; and a second configuration in which fluid flow is
prevented, or at least reduced,
from the first flow block to the second flow block via the second valve, the
flow meter, and the
fourth valve, and fluid flow is permitted from the first flow block to the
second flow block via the
fifth valve. In an embodiment, in the first configuration, the first, second,
third, fourth, and fifth
valves are actuated so that either: the second, third, and fourth valves are
open and the first and fifth
valves are closed, or the first, second, and fourth valves are open and the
third and fifth valves are
closed; and wherein, in the second configuration, the first, second, third,
fourth, and fifth valves are
actuated so that either: the third and fifth valves are open and the first,
second, and fourth valves are
closed, or the first and fifth valves are open and the second, third, and
fourth valves are closed. In
an embodiment, the first and second flow blocks each define an internal
region, and first, second,
third, and fourth fluid passageways, each extending into the internal region.
In an embodiment, the
first, second, and fifth valves are in fluid communication with the internal
region of the first flow
block via the respective first, second, and fourth fluid passageways thereof;
and the third, fourth, and
fifth valves are in fluid communication with the internal region of the second
flow block via the
respective first, second, and third fluid passageways thereof In an
embodiment, the first and second
fluid passageways of the first flow block are generally coaxial and the first
and second fluid
passageways of the second flow block are generally coaxial so that the second
module, including the
flow meter, extends in a generally horizontal orientation. In an embodiment,
the first and second
fluid passageways of the first flow block define generally perpendicular axes
and the first and
second fluid passageways of the second flow block define generally
perpendicular axes so that the
second module, including the flow meter, extends in a generally vertical
orientation. In an
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embodiment, the first and second flow blocks each include first, second,
third, fourth, fifth, and
sixth sides, the third, fourth, fifth, and sixth sides extending between the
first and second sides, the
first, third, and fourth fluid passageways extending through the first, third,
and fourth sides,
respectively, and the second fluid passageway extending through either the
second side or the fifth
side. In an embodiment, the third module further includes one or both of: a
first flow fitting
operably coupled to, and in fluid communication with, the internal region of
the first flow block via
the third fluid passageway thereof, the first flow fitting being adapted to
receive the drilling mud
from the wellbore; and a second flow fitting operably coupled to, and in fluid
communication with,
the internal region of the second flow block via the fourth fluid passageway
thereof, the second flow
fitting being adapted to discharge the drilling mud from the third module. In
an embodiment, the
second module further includes third and fourth flow blocks, and first and
second spools, the first
spool being operably coupled to, and in fluid communication with, the third
flow block, the second
spool being operably coupled between, and in fluid communication with, the
third and fourth flow
blocks, and the flow meter being operably coupled to, and in fluid
communication with, the fourth
flow block. In an embodiment, the second module further includes one or both
of: a first
measurement fitting operably coupled to, and in fluid communication with, the
third flow block; and
a second measurement fitting operably coupled to, and in fluid communication
with, the fourth flow
block. In an embodiment, the flow meter is a coriolis flow meter.
In a thirteenth aspect, the present disclosure introduces a method of
controlling backpressure
of a drilling mud within a wellbore, the method including receiving the
drilling mud from the
wellbore; either: controlling, using one or more drilling chokes, the
backpressure of the drilling mud
within the wellbore, the one or more drilling chokes being part of a first
module, or bypassing the
one or more drilling chokes of the first module; either: measuring, using a
flow meter, a flow rate of
the drilling mud received from the wellbore, the flow meter being part of a
second module, or
bypassing the flow meter of the second module; and discharging the drilling
mud; wherein the
second module is operably coupleable to the first module in either: a
generally horizontal
orientation, or a generally vertical orientation; and wherein the first and
second modules are together
mounted to either a skid or a trailer so that, when so mounted, the first and
second modules are
together towable between operational sites. In an embodiment, the first module
further includes first
and second fluid blocks, the one or more drilling chokes of the first module
including first and
second drilling chokes operably coupled in parallel between the first and
second fluid blocks. In an
embodiment, the first module further includes first, second, third, and fourth
valves, the first and
second valves being operably coupled to, and in fluid communication with, the
first fluid block, the
third and fourth valves being operably coupled to, and in fluid communication
with, the second fluid
block, the first drilling choke being operably coupled between, and in fluid
communication with, the
first and third valves, and the second drilling choke being operably coupled
between, and in fluid
communication with, the second and fourth valves. In an embodiment, the first
module further
includes a fifth valve operably coupled between, and in fluid communication
with, the first and
second fluid blocks. In an embodiment, controlling, using the one or more
drilling chokes, the
backpressure of the drilling mud within the wellbore includes: permitting
fluid flow from the second
fluid block to the first fluid block via one or both of the following element
combinations: the first
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valve, the first drilling choke, and the third valve; and the second valve,
the second drilling choke,
and the fourth valve; and preventing, or at least reducing, fluid flow from
the second fluid block to
the first fluid block via the fifth valve; and bypassing the one or more
drilling chokes of the first
module includes: permitting fluid flow from the second fluid block to the
first fluid block via the
fifth valve; and preventing, or at least reducing, fluid flow from the second
fluid block to the first
fluid block via each of the following element combinations: the first valve,
the first drilling choke,
and the third valve; and the second valve, the second drilling choke, and the
fourth valve. In an
embodiment, controlling, using the one or more drilling chokes, the
backpressure of the drilling mud
within the wellbore includes actuating the first, second, third, fourth, and
fifth valves so that either:
.. the first and third valves are open and the second, fourth, and fifth
valves are closed, the second and
fourth valves are open and the first, third, and fifth valves are closed, or
the first, second, third, and
fourth valves are open and the fifth valve is closed; and bypassing the one or
more drilling chokes of
the first module includes actuating the first, second, third, fourth, and
fifth valves so that: the first,
second, third, and fourth valves are closed and the fifth valve is open. In an
embodiment, the first
and second fluid blocks each define an internal region and first, second,
third, fourth, fifth, and sixth
fluid passageways extending into the internal region. In an embodiment, the
first, second, and fifth
valves are in fluid communication with the internal region of the first fluid
block via the respective
fifth, sixth, and fourth fluid passageways thereof; and the third, fourth, and
fifth valves are in fluid
communication with the internal region of the second fluid block via the
respective fifth, sixth, and
third fluid passageways thereof. In an embodiment, the method further includes
communicating,
using a third module, the drilling mud to the second module, the third module
being operably
coupled to, and in fluid communication with: the internal region of the first
fluid block via the
second fluid passageway thereof; the internal region of the second fluid block
via the second fluid
passageway thereof; and the flow meter of the second module. In an embodiment,
receiving the
drilling mud from the wellbore includes receiving, via a first flow fitting,
the drilling mud from the
wellbore, the first flow fitting being operably coupled to, and in fluid
communication with either:
the internal region of the second fluid block via the fourth fluid passageway
thereof, or the third
module; and discharging the drilling mud includes discharging, via a second
flow fitting, the drilling
mud, the second flow fitting being operably coupled to, and in fluid
communication with, either: the
third module, or the internal region of the first fluid block via the third
fluid passageway thereof. In
an embodiment, the first module further includes one or both of: a first
measurement fitting operably
coupled to, and in fluid communication with, the internal region of the first
fluid block via the first
fluid passageway thereof; and a second measurement fitting operably coupled
to, and in fluid
communication with, the internal region of the second fluid block via the
first fluid passageway
thereof In an embodiment, the first and second fluid blocks each include first
and second ends, and
first, second, third, and fourth sides extending between the first and second
ends, the first and
second fluid passageways extending through the first and second ends,
respectively, the third and
fourth fluid passageways extending through the first and second sides,
respectively, and the fifth and
sixth fluid passageways each extending through the third side. In an
embodiment, the second
module further includes first and second flow blocks, and first and second
spools, the first spool
being operably coupled to, and in fluid communication with, the first flow
block, the second spool
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being operably coupled between, and in fluid communication with, the first and
second flow blocks,
and the flow meter being operably coupled to, and in fluid communication with,
the second flow
block. In an embodiment, the second module further includes one or both of: a
first measurement
fitting operably coupled to, and in fluid communication with, the first flow
block; and a second
measurement fitting operably coupled to, and in fluid communication with, the
second flow block.
In an embodiment, the flow meter is a coriolis flow meter. In an embodiment,
the method further
includes communicating, using a third module, the drilling fluid to the second
module, the third
module including first and second flow blocks and first, second, third, and
fourth valves, the first
valve being operably coupled to, and in fluid communication with, the first
flow block and the first
module, the second valve being operably coupled to, and in fluid communication
with, the first flow
block and the second module, the third valve being operably coupled to, and in
fluid communication
with, the second flow block and the first module, and the fourth valve being
operably coupled to,
and in fluid communication with, the second flow block and the second module.
In an embodiment,
the third module further includes a fifth valve operably coupled between, and
in fluid
communication with, the first and second flow blocks. In an embodiment,
communicating, using
the third module, the drilling fluid to the second module includes: permitting
fluid flow from the
first flow block to the second flow block via the second valve, the flow
meter, and the fourth valve;
and preventing, or at least reducing, fluid flow from the first flow block to
the second flow block via
the fifth valve; and wherein bypassing the flow meter of the second module
includes: preventing, or
at least reducing, fluid flow from the first flow block to the second flow
block via the second valve,
the flow meter, and the fourth valve; and permitting fluid flow from the first
flow block to the
second flow block via the fifth valve. In an embodiment, communicating, using
the third module,
the drilling fluid to the second module includes actuating the first, second,
third, fourth, and fifth
valves so that either: the second, third, and fourth valves are open and the
first and fifth valves are
closed, or the first, second, and fourth valves are open and the third and
fifth valves are closed; and
bypassing the flow meter of the second module includes actuating the first,
second, third, fourth, and
fifth valves so that either: the third and fifth valves are open and the
first, second, and fourth valves
are closed, or the first and fifth valves are open and the second, third, and
fourth valves are closed.
In an embodiment, the first and second flow blocks each define an internal
region, and first, second,
third, and fourth fluid passageways, each extending into the internal region.
In an embodiment, the
first, second, and fifth valves are in fluid communication with the internal
region of the first flow
block via the respective first, second, and fourth fluid passageways thereof;
and the third, fourth, and
fifth valves are in fluid communication with the internal region of the second
flow block via the
respective first, second, and third fluid passageways thereof In an
embodiment, the first and second
fluid passageways of the first flow block are generally coaxial and the first
and second fluid
passageways of the second flow block are generally coaxial so that the second
module, including the
flow meter, extends in the generally horizontal orientation. In an embodiment,
the first and second
fluid passageways of the first flow block define generally perpendicular axes
and the first and
second fluid passageways of the second flow block define generally
perpendicular axes so that the
.. second module, including the flow meter, extends in the generally vertical
orientation. In an
embodiment, the first and second flow blocks each include first, second,
third, fourth, fifth, and
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sixth sides, the third, fourth, fifth, and sixth sides extending between the
first and second sides, the
first, third, and fourth fluid passageways extending through the respective
first, third, and fourth
sides, and the second fluid passageway extending through either the second
side or the fifth side. In
an embodiment, receiving the drilling mud from the wellbore includes
receiving, via a first flow
fitting, the drilling mud from the wellbore, the first flow fitting being
operably coupled to, and in
fluid communication with either: the first module, or the internal region of
the first flow block via
the third fluid passageway thereof; and discharging the drilling mud includes
discharging, via a
second flow fitting, the drilling mud, the second flow fitting being operably
coupled to, and in fluid
communication with, either: the internal region of the second flow block via
the fourth fluid
passageway thereof, or the first module.
In a fourteenth aspect, the present disclosure introduces a method of
controlling backpressure
of a drilling mud within a wellbore, the method including receiving the
drilling mud from the
wellbore; either: controlling, using one or more drilling chokes, the
backpressure of the drilling mud
within the wellbore, the one or more drilling chokes being part of a first
module, or bypassing the
one or more drilling chokes of the first module; either: measuring, using a
flow meter, a flow rate of
the drilling mud received from the wellbore, the flow meter being part of a
second module, or
bypassing the flow meter of the second module; and discharging the drilling
mud; wherein the first
module further includes first and second fluid blocks, the one or more
drilling chokes of the first
module including first and second drilling chokes operably coupled in parallel
between the first and
second fluid blocks. In an embodiment, the first module further includes
first, second, third, and
fourth valves, the first and second valves being operably coupled to, and in
fluid communication
with, the first fluid block, the third and fourth valves being operably
coupled to, and in fluid
communication with, the second fluid block, the first drilling choke being
operably coupled
between, and in fluid communication with, the first and third valves, and the
second drilling choke
being operably coupled between, and in fluid communication with, the second
and fourth valves. In
an embodiment, the first module further includes a fifth valve operably
coupled between, and in
fluid communication with, the first and second fluid blocks. In an embodiment,
controlling, using
the one or more drilling chokes, the backpressure of the drilling mud within
the wellbore includes
permitting fluid flow from the second fluid block to the first fluid block via
one or both of the
following element combinations: the first valve, the first drilling choke, and
the third valve; and the
second valve, the second drilling choke, and the fourth valve; and preventing,
or at least reducing,
fluid flow from the second fluid block to the first fluid block via the fifth
valve; and bypassing the
one or more drilling chokes of the first module includes permitting fluid flow
from the second fluid
block to the first fluid block via the fifth valve; and preventing, or at
least reducing, fluid flow from
the second fluid block to the first fluid block via each of the following
element combinations: the
first valve, the first drilling choke, and the third valve; and the second
valve, the second drilling
choke, and the fourth valve. In an embodiment, controlling, using the one or
more drilling chokes,
the backpressure of the drilling mud within the wellbore includes actuating
the first, second, third,
fourth, and fifth valves so that either: the first and third valves are open
and the second, fourth, and
fifth valves are closed, the second and fourth valves are open and the first,
third, and fifth valves are
closed, or the first, second, third, and fourth valves are open and the fifth
valve is closed; and
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bypassing the one or more drilling chokes of the first module includes
actuating the first, second,
third, fourth, and fifth valves so that: the first, second, third, and fourth
valves are closed and the
fifth valve is open. In an embodiment, the first and second fluid blocks each
define an internal
region and first, second, third, fourth, fifth, and sixth fluid passageways
extending into the internal
.. region. In an embodiment, the first, second, and fifth valves are in fluid
communication with the
internal region of the first fluid block via the respective fifth, sixth, and
fourth fluid passageways
thereof; and the third, fourth, and fifth valves are in fluid communication
with the internal region of
the second fluid block via the respective fifth, sixth, and third fluid
passageways thereof. In an
embodiment, the method further includes communicating, using a third module,
the drilling mud to
the second module, the third module being operably coupled to, and in fluid
communication with:
the internal region of the first fluid block via the second fluid passageway
thereof; the internal
region of the second fluid block via the second fluid passageway thereof; and
the flow meter of the
second module. In an embodiment, receiving the drilling mud from the wellbore
includes receiving,
via a first flow fitting, the drilling mud from the wellbore, the first flow
fitting being operably
.. coupled to, and in fluid communication with either: the internal region of
the second fluid block via
the fourth fluid passageway thereof, or the third module; and discharging the
drilling mud includes
discharging, via a second flow fitting, the drilling mud, the second flow
fitting being operably
coupled to, and in fluid communication with, either: the third module, or the
internal region of the
first fluid block via the third fluid passageway thereof. In an embodiment,
the first module further
includes one or both of: a first measurement fitting operably coupled to, and
in fluid communication
with, the internal region of the first fluid block via the first fluid
passageway thereof; and a second
measurement fitting operably coupled to, and in fluid communication with, the
internal region of the
second fluid block via the first fluid passageway thereof. In an embodiment,
the first and second
fluid blocks each include first and second ends, and first, second, third, and
fourth sides extending
between the first and second ends, the first and second fluid passageways
extending through the first
and second ends, respectively, the third and fourth fluid passageways
extending through the first and
second sides, respectively, and the fifth and sixth fluid passageways each
extending through the
third side. In an embodiment, the second module further includes first and
second flow blocks, and
first and second spools, the first spool being operably coupled to, and in
fluid communication with,
the first flow block, the second spool being operably coupled between, and in
fluid communication
with, the first and second flow blocks, and the flow meter being operably
coupled to, and in fluid
communication with, the second flow block. In an embodiment, the second module
further includes
one or both of: a first measurement fitting operably coupled to, and in fluid
communication with, the
first flow block; and a second measurement fitting operably coupled to, and in
fluid communication
with, the second flow block. In an embodiment, the flow meter is a coriolis
flow meter.
In a fifteenth aspect, the present disclosure introduces a method of
controlling backpressure
of a drilling mud within a wellbore, the method including receiving the
drilling mud from the
wellbore; either: controlling, using one or more drilling chokes, the
backpressure of the drilling mud
within the wellbore, the one or more drilling chokes being part of a first
module, or bypassing the
one or more drilling chokes of the first module; either: measuring, using a
flow meter, a flow rate of
the drilling mud received from the wellbore, the flow meter being part of a
second module, or
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bypassing the flow meter of the second module; communicating, using a third
module, the drilling
fluid to the second module, the third module including first and second flow
blocks operably
coupled in parallel between the first and second modules; and discharging the
drilling mud. In an
embodiment, the third module further includes first, second, third, and fourth
valves, the first valve
being operably coupled to, and in fluid communication with, the first flow
block and the first
module, the second valve being operably coupled to, and in fluid communication
with, the first flow
block and the second module, the third valve being operably coupled to, and in
fluid communication
with, the second flow block and the first module, and the fourth valve being
operably coupled to,
and in fluid communication with, the second flow block and the second module.
In an embodiment,
the third module further includes a fifth valve operably coupled between, and
in fluid
communication with, the first and second flow blocks. In an embodiment,
communicating, using
the third module, the drilling fluid to the second module includes: permitting
fluid flow from the
first flow block to the second flow block via the second valve, the flow
meter, and the fourth valve;
and preventing, or at least reducing, fluid flow from the first flow block to
the second flow block via
the fifth valve; and bypassing the flow meter of the second module includes:
preventing, or at least
reducing, fluid flow from the first flow block to the second flow block via
the second valve, the flow
meter, and the fourth valve; and permitting fluid flow from the first flow
block to the second flow
block via the fifth valve. In an embodiment, communicating, using the third
module, the drilling
fluid to the second module includes actuating the first, second, third,
fourth, and fifth valves so that
either: the second, third, and fourth valves are open and the first and fifth
valves are closed, or the
first, second, and fourth valves are open and the third and fifth valves are
closed; and bypassing the
flow meter of the second module includes actuating the first, second, third,
fourth, and fifth valves
so that either: the third and fifth valves are open and the first, second, and
fourth valves are closed,
or the first and fifth valves are open and the second, third, and fourth
valves are closed. In an
embodiment, the first and second flow blocks each define an internal region,
and first, second, third,
and fourth fluid passageways, each extending into the internal region. In an
embodiment, the first,
second, and fifth valves are in fluid communication with the internal region
of the first flow block
via the respective first, second, and fourth fluid passageways thereof and the
third, fourth, and fifth
valves are in fluid communication with the internal region of the second flow
block via the
.. respective first, second, and third fluid passageways thereof In an
embodiment, the first and second
fluid passageways of the first flow block are generally coaxial and the first
and second fluid
passageways of the second flow block are generally coaxial so that the second
module, including the
flow meter, extends in a generally horizontal orientation. In an embodiment,
the first and second
fluid passageways of the first flow block define generally perpendicular axes
and the first and
second fluid passageways of the second flow block define generally
perpendicular axes so that the
second module, including the flow meter, extends in a generally vertical
orientation. In an
embodiment, the first and second flow blocks each include first, second,
third, fourth, fifth, and
sixth sides, the third, fourth, fifth, and sixth sides extending between the
first and second sides, the
first, third, and fourth fluid passageways extending through the respective
first, third, and fourth
sides, and the second fluid passageway extending through either the second
side or the fifth side. In
an embodiment, receiving the drilling mud from the wellbore includes
receiving, via a first flow
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fitting, the drilling mud from the wellbore, the first flow fitting being
operably coupled to, and in
fluid communication with either: the first module, or the internal region of
the first flow block via
the third fluid passageway thereof; and discharging the drilling mud includes
discharging, via a
second flow fitting, the drilling mud, the second flow fitting being operably
coupled to, and in fluid
communication with, either: the internal region of the second flow block via
the fourth fluid
passageway thereof, or the first module. In an embodiment, the second module
further includes first
and second flow blocks, and first and second spools, the first spool being
operably coupled to, and
in fluid communication with, the first flow block, the second spool being
operably coupled between,
and in fluid communication with, the first and second flow blocks, and the
flow meter being
operably coupled to, and in fluid communication with, the second flow block.
In an embodiment,
the second module further includes one or both of: a first measurement fitting
operably coupled to,
and in fluid communication with, the first flow block; and a second
measurement fitting operably
coupled to, and in fluid communication with, the second flow block. In an
embodiment, the flow
meter is a coriolis flow meter.
It is understood that variations may be made in the foregoing without
departing from the
scope of the present disclosure.
In some embodiments, the elements and teachings of the various embodiments may
be
combined in whole or in part in some or all of the embodiments. In addition,
one or more of the
elements and teachings of the various embodiments may be omitted, at least in
part, and/or
combined, at least in part, with one or more of the other elements and
teachings of the various
embodiments.
In some embodiments, while different steps, processes, and procedures are
described as
appearing as distinct acts, one or more of the steps, one or more of the
processes, and/or one or more
of the procedures may also be performed in different orders, simultaneously
and/or sequentially. In
some embodiments, the steps, processes and/or procedures may be merged into
one or more steps,
processes and/or procedures.
In some embodiments, one or more of the operational steps in each embodiment
may be
omitted. Moreover, in some instances, some features of the present disclosure
may be employed
without a corresponding use of the other features. Moreover, one or more of
the above-described
embodiments and/or variations may be combined in whole or in part with any one
or more of the
other above-described embodiments and/or variations.
In the foregoing description of certain embodiments, specific terminology has
been resorted
to for the sake of clarity. However, the disclosure is not intended to be
limited to the specific terms
so selected, and it is to be understood that each specific term includes other
technical equivalents
which operate in a similar manner to accomplish a similar technical purpose.
Terms such as "left"
and right", "front" and "rear", "above" and "below" and the like are used as
words of convenience to
provide reference points and are not to be construed as limiting terms.
In this specification, the word "comprising" is to be understood in its "open"
sense, that is, in
the sense of "including", and thus not limited to its "closed" sense, that is
the sense of "consisting
only of'. A corresponding meaning is to be attributed to the corresponding
words "comprise",
"comprised" and "comprises" where they appear.
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Although some embodiments have been described in detail above, the embodiments
described are illustrative only and are not limiting, and those skilled in the
art will readily appreciate
that many other modifications, changes and/or substitutions are possible in
the embodiments without
materially departing from the novel teachings and advantages of the present
disclosure. Accordingly, all such modifications, changes, and/or substitutions
are intended to be
included within the scope of this disclosure as defined in the following
claims. In the claims, any
means-plus-function clauses are intended to cover the structures described
herein as performing the
recited function and not only structural equivalents, but also equivalent
structures. Moreover, it is
the express intention of the applicant not to invoke 35 U.S.C. 112,
paragraph 6 for any limitations
of any of the claims herein, except for those in which the claim expressly
uses the word "means"
together with an associated function.
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