Modular MPD Choke Manifold for Cost-Effective Pressure Control
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Solution Overview
Problem
Existing managed pressure drilling (MPD) systems are costly and not economically viable for unconventional well drilling, where the safety benefits of surface back pressure are desirable but the full conventional MPD system is not economically feasible.
Innovation Solution
A modular MPD system that includes a single manifold that can be assembled into a full MPD skid with two chokes for redundancy and a full bore bypass line, allowing for customizable configurations based on drilling conditions and costs, with remote HMI control and programmable PRV.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a full conventional MPD system is deployed, then safety benefits of surface back pressure are achieved, but cost becomes prohibitively high for unconventional well drilling
Solution Approach 1:
The MPD system is divided into modular components (choke manifold, HMI control, PRV, bypass line) that can be independently selected and assembled. This allows customers to purchase only the specific modules needed for their safety requirements rather than acquiring a complete conventional MPD system, thereby reducing overall cost while maintaining essential safety functions.
Solution Approach 2:
The choke manifold is designed with multiple functional capabilities including set point control, bypass functionality, and integration with PRV. This multi-functionality allows a single modular unit to perform multiple safety-critical tasks that would traditionally require separate equipment, reducing the total system cost while maintaining comprehensive safety coverage.
2Adaptability or versatility
If a full conventional MPD system is deployed, then complete MPD functionality is achieved, but economic viability is compromised for unconventional wells
Solution Approach 1:
The system is segmented into discrete functional modules that can be configured in different combinations based on project requirements. Customers drilling unconventional wells can select a minimal viable configuration (e.g., choke manifold with basic HMI) to achieve economic viability, while still obtaining core MPD functionality.
Solution Approach 2:
The modular architecture enables partial implementation of full MPD functionality. Customers can deploy a subset of MPD features (such as surface back pressure control without all associated automation) that provides sufficient functionality for unconventional wells while reducing costs to economically viable levels.
3Adaptability or versatility
If the manifold is configured with multiple chokes and full bypass line, then equipment redundancy and versatility are improved, but system complexity and cost increase
Solution Approach 1:
Redundant components such as multiple chokes and bypass lines are provided as separate modular units that can be attached to the manifold only when needed. This allows the base system to remain simple for basic applications, while redundancy and versatility can be added on-demand for more complex drilling scenarios, managing system complexity while providing adaptability.
4Productivity
If the manifold can be assembled while connected to flowline, then operational flexibility and productivity are improved, but risk of contamination or damage increases
Solution Approach 1:
The manifold is pre-configured with standardized connection interfaces and quick-connect couplings that enable safe assembly and disconnection while connected to the flowline. These pre-engineered connection points include proper sealing mechanisms and alignment features that minimize the risk of contamination or damage during field assembly operations.
Data Source
AI summary
The modular managed pressured drilling system provides multiple skids with individual chokes and PRVs on the skids. These skids secure to one another to construct a modular MPD system that provides the proper equipment for the drilling operation. An inlet flow junction and an outlet flow junction are secured to each skid. The flow junctions provide multiple ports to provide different pathways for the drilling fluid through the flow junctions. The flow junctions may direct the fluid through a first choke, a second choke, a pressure relief valve, or a bypass.