Modular Wellbore Pressure Control for Narrow Drilling Windows
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Solution Overview
Problem
Conventional managed pressure drilling (MPD) systems are cumbersome and difficult to deploy in limited spaces, such as offshore and mountainous drilling sites, due to their complex structure and large size, which restricts their application in complex formations.
Innovation Solution
An active intelligent wellbore pressure control system comprising a ground multi-parameter online monitoring system, a rotary blowout preventer, a wellhead back pressure compensation manifold, an automatic plugging material filling device, an MPD intelligent control system, and a remote monitoring and control system, which simplifies the structure and allows for flexible installation, reducing the need for a skid-mounted device and enabling remote operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional MPD systems are used, then pressure control capability is achieved, but device complexity and occupied area increase
Solution Approach 1:
The system divides the MPD equipment into independent modular units: a drilling unit with drilling device, a well control unit with blowout preventer and throttle manifold, and a fluid processing unit with gas-liquid separator and vibrating screen. Each module can function independently and be deployed separately, reducing overall system complexity while maintaining pressure control capability.
Solution Approach 2:
The throttle manifold is designed with multi-functional capabilities, integrating back pressure compensation, flow control, and pressure regulation functions into a single device. This universal design eliminates the need for multiple separate equipment pieces, reducing device complexity while preserving comprehensive pressure control functionality.
2Reliability
If conventional MPD systems are used, then pressure control capability is achieved, but occupied area increases
Solution Approach 1:
By segmenting the system into compact modular units, each module occupies minimal space and can be positioned closely together. The independent modules include the drilling device, blowout preventer, throttle manifold, gas-liquid separator, and vibrating screen, arranged in a space-efficient configuration that significantly reduces the total occupied area compared to conventional integrated MPD systems.
Solution Approach 2:
The system employs nested arrangements where smaller components are integrated within larger equipment structures. For example, the throttle manifold is positioned within the well control unit, and the vibrating screen is integrated with the gas-liquid separator structure, creating a compact nested configuration that minimizes the equipment's footprint.
3Reliability
If conventional MPD systems are used, then pressure control function is provided, but ease of operation decreases
Solution Approach 1:
The segmented modular design allows each unit to be independently transported, installed, and operated. The drilling unit, well control unit, and fluid processing unit can be set up separately and connected through standardized interfaces, significantly improving installation flexibility and ease of operation while maintaining the complete pressure control function.
Solution Approach 2:
The system incorporates dynamically adjustable components including electrically controlled throttle valves that can be remotely adjusted during operation, and modular connections that can be easily reconfigured. This dynamic design enhances operational flexibility, allowing the system to adapt to different drilling conditions and site constraints without requiring complex reinstallation.
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 system enhances pressure control precision, broadens the 'drilling safety density window', reduces equipment costs, and expands the application range of MPD technology to challenging drilling environments by providing a more compact, efficient, and cost-effective solution for wellbore pressure management.
Implementation Method 1
a gas-liquid separator, wherein the one end of the wellhead back pressure compensation manifold extends to the upper side of the slurry pool; one end of the wellhead back pressure compensation manifold is connected to a gas-liquid separator through a pipeline
Implementation Method 2
the slurry tank is connected to a vibrating screen through a pipeline; a slurry pool is disposed below the vibrating screen
Data Source
AI summary
The present invention discloses an active intelligent wellbore pressure control system, which includes a ground multi-parameter online monitoring system (86), a rotary blowout preventer (1), a wellhead back pressure compensation manifold, an automatic plugging material filling device (62), a drilling device, an MPD intelligent control system (87), a remote monitoring and control system (88), and a high-precision hydraulic calculation system (105). The present invention provides a wellbore pressure control thought of “plugging and control integration”, improves the pressure resistance of a formation by circularly plugging while drilling, realizes active control of a wellbore pressure, effectively broadens a “drilling safety density window” of the formation, reduces the requirements on the pressure control precision of a wellbore pressure control device, solves the problem that a conventional MPD technology cannot deal with the situation that the “drilling safety density window” of the formation is extremely narrow or even zero, and expands the application range of the MPD technology.