Managed Pressure Drilling Flow Measurement with Dynamic Valve Control
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Solution Overview
Problem
The Coriolis mass flowmeter used in managed pressure drilling systems faces limitations due to lower pressure rating, accuracy issues at low flow rates, and increased measurement errors caused by gas breakout and flashing, which affect the precision of drilling fluid flow measurements.
Innovation Solution
A drilling system with multiple flowmeters in parallel communication, where upstream and downstream valves control pressure and flow distribution to minimize measurement errors, using Coriolis, curved tube, or V-cone flowmeters, and secondary chokes to maintain gas in solution and adjust pressure within flowmeters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a Coriolis mass flowmeter is used to measure drilling fluid flow, then measurement precision is improved, but the device can only be positioned downstream from chokes due to lower pressure rating
Solution Approach 1:
The system is divided into multiple segments: a first valve upstream of the flowmeter to control upstream pressure, and a second valve downstream of the flowmeter to control downstream pressure and maintain pressure within the flowmeter's rating. This segmentation allows the flowmeter to be positioned downstream from chokes while maintaining measurement precision through active pressure management.
2Productivity
If flow rate is increased to improve productivity, then drilling efficiency is improved, but measurement accuracy deteriorates at low flow rates with typical mass flowmeters
Solution Approach 1:
The system actively changes the pressure parameter within the flowmeter using the second downstream valve to optimize measurement accuracy across different flow rates. By maintaining appropriate pressure conditions, the flowmeter can accurately measure both low and high flow rates, enabling improved drilling efficiency without sacrificing measurement precision.
3Reliability
If pressure is increased to control wellbore influxes, then well control is improved, but gas breakout and flashing increase causing measurement errors
Solution Approach 1:
The system uses feedback from flow measurements and pressure monitoring to dynamically adjust valve positions. The control system receives data from the flowmeter and pressure sensors, then adjusts the first and second valves to maintain optimal pressure conditions that prevent gas breakout and flashing, ensuring both well control and measurement accuracy.
Solution Approach 2:
The system dynamically changes pressure parameters within the flowmeter using the second downstream valve to maintain conditions that prevent gas breakout and flashing. By actively managing pressure to stay within optimal ranges, the system achieves both effective well control and accurate flow measurements even during high-pressure operations.
4Device complexity
If a single flowmeter is used to simplify the system, then device complexity is reduced, but the system cannot maintain accurate measurements across wide flow rate ranges
Solution Approach 1:
The system uses dynamic valve control to adapt a single flowmeter to different flow rate conditions. The first upstream valve and second downstream valve are dynamically adjusted based on real-time flow and pressure conditions, enabling the single flowmeter to accurately measure across a wide range of flow rates that would otherwise require multiple specialized flowmeters.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances the accuracy of drilling fluid flow measurements across a wide range of flow rates, reduces measurement errors, and maintains gas in solution, improving the reliability of drilling operations by selectively distributing flow through the most suitable flowmeter based on real-time conditions.
Implementation Method 1
The Coriolis flowmeter is valued for its precision and ability to measure volumetric flow rate, mass flow rate, and fluid density simultaneously
Implementation Method 2
one or more valves or chokes to control pressure in drilling fluid flow
Implementation Method 3
A measurement of drilling fluid flow from the wellbore is obtained
Data Source
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AI summary
A drilling system for drilling a wellbore has one or more valves or chokes to control the upstream pressure of drilling fluid flow in a controlled pressure drilling operation. A measurement is obtained of the drilling fluid flow from the wellbore. Based on the obtained measurement, the drilling fluid flow is selectively distributed with a distributor through one or more of a plurality of flowmeters, such as Coriolis meters. A reading of the drilling fluid flow is obtained from the selected flowmeter (s). Upstream pressure in the drilling fluid flow is controlled with the one or more valve based at least in part on the reading from the one or more selected flowmeters. The reading can be a flow rate, a pressure, or the like compared to capacities of the flowmeters. Additional valves downstream of the flowmeters can be controlled based on cavitation that the valves are estimated to produce.