Compact MPD Manifold With Sensor Voting and Bypass Pressure Control
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Solution Overview
Problem
Conventional managed pressure drilling (MPD) systems are costly and not economically viable for unconventional wells, lacking efficient pressure control and safety benefits without significant rig modifications.
Innovation Solution
A compact MPD manifold system with a rotating control device (RCD) incorporating multiple pressure transducers for data validation and a fail-safe isolation valve, allowing for accurate pressure control and automated set point management without rig modifications, utilizing a Coriolis meter for flow measurement and remote monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a full conventional MPD system is installed, then accurate pressure control and safety benefits are achieved, but system cost and complexity increase significantly
Solution Approach 1:
The patent divides the MPD system into modular components: a rotating control device (RCD) with integrated pressure control, a separate choke manifold, and a bypass system. This segmentation allows the core pressure control functionality to be implemented without requiring a complete conventional MPD system, reducing overall complexity while maintaining reliability.
Solution Approach 2:
The patent combines the pressure control valve and pressure transducers directly into the rotating control device (RCD), merging multiple functions into a single integrated component. This integration eliminates the need for separate pressure control equipment, reducing system complexity while maintaining accurate pressure control capability.
2Reliability
If a full conventional MPD system is installed, then surface back pressure control is achieved, but system cost increases making it not economically viable
Solution Approach 1:
The patent extracts only the essential pressure control functionality from the conventional MPD system, implementing a simplified version that includes pressure transducers, a control valve, and a choke manifold. By taking out only the critical components needed for surface back pressure control rather than implementing the full conventional system, the patent achieves the required reliability at a lower cost.
Solution Approach 2:
The patent employs a simplified pressure control system that uses off-the-shelf components and a basic control algorithm rather than expensive proprietary MPD system equipment. This approach uses more economical, readily available components to achieve the necessary pressure control function without the high cost of conventional MPD systems.
3Reliability
If three pressure transducers are used for data validation, then measurement reliability is improved through 2 out of 3 voting, but device complexity and cost increase
Solution Approach 1:
The patent implements a redundant array of three pressure transducers with a 2-out-of-3 voting algorithm that detects and isolates faulty sensors before they can compromise pressure control. This beforehand cushioning approach uses simple redundancy and majority voting to ensure measurement reliability, avoiding the need for complex single-sensor diagnostic systems.
4Ease of manufacture
If the MPD choke system is integrated without rig modification, then installation ease and cost are improved, but adaptability to conventional operations is reduced
Solution Approach 1:
The patent implements a dynamically configurable system with an isolatable choke manifold and bypass line that can be activated or deactivated based on operational needs. The system includes valves and isolation points that allow the choke to be disconnected or bypassed, enabling the system to adapt between MPD operations and conventional drilling operations without requiring rig modification.
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
Provides accurate, low-cost, and safe pressure control for unconventional wells with reduced system weight and cost, enabling surface back pressure application without the need for full conventional MPD systems, ensuring precise pressure management and quick reaction times.
Implementation Method 1
The three transducers measure the upstream choke pressure
Implementation Method 2
The metering system includes a Coriolis meter or other flowmeter with remote transmitter
Implementation Method 3
A full bore fail last position actuated isolation valve is located downstream from the spool
Implementation Method 4
The validated pressure is used by a control system to accurately manipulate the choke/flow control device to accurately control the well bore (Annular) pressure
Data Source
AI summary
A managed pressure drilling manifold provides accurate back pressure control of a well head when drilling. The MPD system provides two paths for the drilling fluid to flow from the RCD to the flowline. The drilling fluid flows along an MPD path sending the drilling fluids through at least one sensor, preferably three sensors, a flow control device, and a flowmeter. The MPD system also provides a bypass path that isolates the flow control device and flowmeter while direct the drilling fluid from the RCD to the bypass to avoid the flow control device and flowmeter. The MPD system provides three valves that direct the drilling fluid in the bypass path or the MPD path.