Back Pressure Valve Manifold for MPD Gas Breakout Control
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Solution Overview
Problem
Managed Pressure Drilling (MPD) systems face issues with gas breakout from drilling mud due to pressure fluctuations, affecting Coriolis meter accuracy and risking overpressure events, especially with manually operated globe valves, which are prone to plugging and pressure imbalances.
Innovation Solution
A back pressure valve manifold system with automated flow control devices is installed downstream of the Coriolis meter, maintaining downstream pressure at 50% of surface back pressure, adjusting automatically to minimize gas breakout and ensure accurate flow rate measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a manually operated globe valve is installed downstream of the Coriolis meter to reduce gas breakout, then gas breakout is reduced, but the system becomes prone to plugging and pressure imbalances
Solution Approach 1:
The patent replaces the manually operated mechanical globe valve with an automated back pressure control system that uses electronic sensors and actuators to maintain downstream pressure. This substitution eliminates the plugging issues inherent in manual mechanical valves while providing more reliable and consistent pressure control downstream of the Coriolis meter.
Solution Approach 2:
The back pressure control system is designed to automatically maintain downstream pressure without manual intervention. The system self-regulates by using pressure sensors to detect downstream conditions and automatically adjusting the back pressure valve position, eliminating the need for manual operation and reducing the risk of human error or neglect.
2Productivity
If flow rate is increased through the manually adjusted fixed orifice, then productivity increases, but pressure upstream increases and Coriolis meter accuracy is affected
Solution Approach 1:
The patent transitions from a static fixed orifice to a dynamic back pressure control system that continuously adjusts the downstream pressure based on real-time flow conditions. This dynamic control maintains a relatively constant pressure differential across the Coriolis meter even as flow rate changes, thereby preserving measurement accuracy across a range of productivity levels.
Solution Approach 2:
The system incorporates pressure sensors that continuously monitor downstream pressure and provide feedback to the back pressure control mechanism. This feedback loop allows the system to automatically adjust the valve position to maintain optimal pressure conditions for Coriolis meter operation, ensuring accurate measurements regardless of flow rate variations.
3Stress or pressure
If flow rate is reduced through the manually adjusted fixed orifice, then pressure drops, but Coriolis meter accuracy becomes affected
Solution Approach 1:
The back pressure control system uses pressure sensors to continuously monitor downstream pressure and automatically adjusts the back pressure valve to maintain pressure within the optimal range for Coriolis meter operation. This feedback mechanism prevents pressure drops that would otherwise occur with reduced flow rates through a fixed orifice, thereby maintaining measurement accuracy.
Solution Approach 2:
The system proactively maintains downstream pressure before pressure drops can occur. By continuously monitoring pressure conditions and making preliminary adjustments to the back pressure valve, the system prevents pressure from falling below the threshold needed for accurate Coriolis meter operation, rather than reacting after accuracy is compromised.
4Device complexity
If a fixed orifice globe valve is used, then device complexity is reduced, but the system lacks adaptability to changing flow conditions
Solution Approach 1:
The back pressure control system serves multiple functions: it maintains downstream pressure for Coriolis meter accuracy, prevents gas breakout, protects downstream equipment from overpressure, and adapts to varying flow conditions. This multi-functionality compensates for the increased device complexity by providing comprehensive system protection and optimization through a single integrated control mechanism.
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
The system enhances measurement accuracy, reduces the risk of overpressure events, and protects downstream equipment by maintaining stable pressure, thereby improving safety and reducing erosion.
Implementation Method 1
gas breaks out of solution after the MPD drilling flow control device, generally, a drilling choke
Implementation Method 2
the Coriolis meter can measure volume flow rates and density of the drilling fluid
Data Source
AI summary
A system and method of maintaining back pressure located downstream of the flow meter maintains the pressure downstream of the flow meter in relation to the surface back pressure (SBP). At least one flow control device is located downstream of the flow meter. The flow control device (the BPV) automatically maintains the downstream pressure to less than or equal to fifty percent (50%) of the surface back pressure. A pressure regulator sets the back pressure to allow for a standalone device. Additional valves allow adjustment of the back pressure and allow for pressure relief and full flow bypass.