SYSTEMS AND METHODS FOR CONTROLLING PARAMETERS OF DRILLING FLUID

Abstract

Provided are methods, apparatus, and computer-readable media for controlling parameters of drilling fluid. In an example, provided is a method including (i) receiving, by a drilling fluid flow controller, information indicating a measured inflow rate of drilling fluid flowing into a wellbore; (ii) receiving, by the drilling fluid flow controller, information indicating a measured outflow rate of the drilling fluid flowing out of the wellbore; (iii) calculating a differential flowrate between the measured inflow rate and the measured outflow rate; (iv) calculating a proportional gain from the differential flowrate and a setpoint; (v) calculating an integral gain from the differential flowrate and the setpoint; (vi) calculating, by the drilling fluid flow controller, a choke control output by summing the proportional gain with the integral gain; and (vii) moving, responsive to the choke control output, a position of the choke valve. Other methods, systems, and computer-readable media are also disclosed.

Description

CROSS REFERENCE TO RELATED APPLICATION

This Non-Provisional Patent Application claims the benefit of U.S. Provisional Patent Application No. 63/405,201, titled “SYSTEMS AND METHODS FOR CONTROLLING PARAMETERS OF DRILLING FLUID,” filed Sep. 9, 2022, the disclosure of which is incorporated herein, in its entirety, by reference.

FIELD OF DISCLOSURE

This disclosure relates generally to the technical field of well drilling, and more specifically, but not exclusively, to methods, apparatus, and computer program products relating to controlling parameters of drilling fluid.

BACKGROUND

Processes for drilling oil and natural gas wellbores generate great heat at drill bits, generate drill cuttings that must be removed from wellbores, and disturb formation fluids and gasses. To address these issues, drilling fluid, also known as drilling mud, is used to cool the drill bits, to remove the drill cuttings from the wellbores, and to provide hydrostatic pressure to control entrance of the formation fluids and gasses into the wellbores. Due to variability of conditions of the aforementioned issues, there is a need to control parameters of the drilling fluid.

Further, some drill operators perform underbalanced drilling, which is a well drilling process in which pressures of the drilling fluid in the wellbores are lower than pore pressures of the formations being drilled. During underbalanced drilling, formation fluids having pore pressures greater than the adjacent drilling fluid can enter the wellbores and travel up the wellbores to the surface of the earth. This condition is known as a kick. In some conditions, kicks can lead to blowouts causing equipment damage and injury to personnel. Thus, there are needs to identify occurrences of kicks and to control the kicks.

Accordingly, there are previously unaddressed and long-felt industry needs for methods and apparatus which improve upon conventional methods and apparatus.

SUMMARY

In some embodiments, provided is an apparatus for automatically controlling parameters of drilling fluid. In some examples, the apparatus can include (i) a choke valve having a choke valve position; (ii) an inflow flowmeter configured to generate information indicating a measured inflow rate of the drilling fluid flowing into a wellbore; (iii) an outflow flowmeter configured to generate information indicating a measured outflow rate of the drilling fluid flowing out of the wellbore, where the outflow flowmeter is located downstream from the choke valve; and (iv) a drilling fluid flow controller having a memory device storing instructions configured to cause the drilling fluid flow controller to automatically (A) receive the information indicating the measured inflow rate; (B) receive the information indicating the measured outflow rate; (C) calculate a differential flowrate between the measured inflow rate and the measured outflow rate; (D) calculate a proportional gain from the differential flowrate and a first setpoint; (E) calculate an integral gain from the differential flowrate and the first setpoint; and (F) calculate a choke control output by summing the proportional gain with the integral gain. The choke valve can be configured to adjust, responsive to the choke control output, the choke valve position to control the measured outflow rate of the drilling fluid.

In some examples, the outflow flowmeter can include a V-shaped flowmeter orifice.

In some examples, the memory can further store instructions configured to cause the drilling fluid flow controller to receive, from a user interface device, information describing the first setpoint.

In some embodiments, the apparatus can further include (i) a hydraulic actuator configured to adjust the choke valve position of the choke valve; (ii) a hydraulic accumulator storing pressurized hydraulic fluid; and (iii) an electrically operated valve configured to: (A) receive the choke control output from the drilling fluid flow controller and (B) control, responsive to the received choke control output, a flowrate of the hydraulic fluid from the hydraulic accumulator to the hydraulic actuator.

In some examples, the memory can further store instructions configured to cause the drilling fluid flow controller to automatically (i) compare the differential flowrate to a second setpoint, where the second setpoint describes a maximum allowed differential flowrate and (ii) modify, when the differential flowrate is equal to or greater than the second setpoint, the choke control output to adjust the choke valve position to reduce the differential flowrate. In some embodiments, the memory can further store instructions configured to cause the drilling fluid flow controller to receive, from a user interface device, information describing the second setpoint.

In some embodiments, the drilling fluid flow controller can include at least one of a field programmable gate array, a programmable logic device, an application-specific integrated circuit, a non-generic special-purpose processor, a gated logic device, or a dedicated hardware finite state machine.

In some examples, the memory can further store instructions configured to cause the drilling fluid flow controller to automatically (i) convert the information indicating the measured outflow rate of the drilling fluid flowing out of the wellbore to a human-readable form and (ii) display the human-readable form of the information indicating the measured outflow rate of the drilling fluid flowing out of the wellbore on a user interface device.

In some embodiments, provided is a method for automatically controlling parameters of drilling fluid. The method can include (i) receiving, by a drilling fluid flow controller, information indicating a measured inflow rate of the drilling fluid flowing into a wellbore; (ii) receiving, by the drilling fluid flow controller, information indicating a measured outflow rate of the drilling fluid flowing out of the wellbore and through an outflow flowmeter located downstream from a choke valve; (iii) automatically calculating, by the drilling fluid flow controller, a differential flowrate between the measured inflow rate and the measured outflow rate; (iv) automatically calculating, by the drilling fluid flow controller, a proportional gain from the differential flowrate and a first setpoint; (v) automatically calculating, by the drilling fluid flow controller, an integral gain from the differential flowrate and the first setpoint; (vi) automatically calculating, by the drilling fluid flow controller, a choke control output by summing the proportional gain with the integral gain; and (vii) automatically moving, responsive to the choke control output, a position of the choke valve.

In some examples, the outflow flowmeter can include a V-shaped flowmeter orifice.

In some examples, a method can further include receiving, by the drilling fluid flow controller and from a user interface device, information describing the first setpoint.

In some examples, the method can further include (i) automatically comparing, by the drilling fluid flow controller, the differential flowrate to a second setpoint, where the second setpoint describes a maximum allowed differential flowrate and (ii) automatically modifying, by the drilling fluid flow controller and when the differential flowrate is equal to or greater than the second setpoint, the choke control output to adjust the choke valve position to reduce the differential flowrate.

In some embodiments, the method can further include receiving, by the drilling fluid flow controller and from a user interface device, information describing the second setpoint.

In some examples, the method can further include (i) converting the information indicating the measured outflow rate of the drilling fluid flowing out of the wellbore to a human-readable form and (ii) displaying the human-readable form of the information indicating the measured outflow rate of the drilling fluid flowing out of the wellbore on a user interface device.

In some embodiments, provided is a non-transitory computer-readable medium, including processor-executable instructions stored thereon configured to cause a processor to (i) initiate receiving information indicating a measured inflow rate of drilling fluid flowing into a wellbore; (ii) initiate receiving information indicating a measured outflow rate of the drilling fluid flowing out of the wellbore and through an outflow flowmeter located downstream from a choke valve; (iii) initiate calculating a differential flowrate between the measured inflow rate and the measured outflow rate; (iv) initiate calculating a proportional gain from the differential flowrate and a first setpoint; (v) initiate calculating an integral gain from the differential flowrate and the first setpoint; and (vi) initiate calculating a choke control output by summing the proportional gain with the integral gain.

In some examples, the non-transitory computer-readable medium can further store instructions configured to cause the processor to initiate receiving, by the processor and from a user interface device, information describing the first setpoint.

In some examples, the non-transitory computer-readable medium can further store instructions configured to cause the processor to (i) initiate automatically comparing, by the processor, the differential flowrate to a second setpoint, where the second setpoint describes a maximum allowed differential flowrate and (ii) initiate automatically modifying, by the processor and when the differential flowrate is equal to or greater than the second setpoint, the choke control output to adjust the choke valve position to reduce the differential flowrate.

In some examples, the non-transitory computer-readable medium can further store instructions configured to cause the processor to initiate receiving, by the processor and from a user interface device, information describing the second setpoint.

In some embodiments, the processor can be a drilling fluid flow controller.

In some examples, the non-transitory computer-readable medium can further store instructions configured to cause the processor to initiate (i) converting the information indicating the measured outflow rate of the drilling fluid flowing out of the wellbore to a human-readable form and (ii) displaying the human-readable form of the information indicating the measured outflow rate of the drilling fluid flowing out of the wellbore on a user interface device.

In some embodiments, provided is an apparatus for automatically controlling parameters of drilling fluid. The apparatus can include (i) a choke valve having a choke valve position; (ii) an outflow flowmeter configured to generate information indicating a measured flowrate of the drilling fluid flowing out of a wellbore, where the outflow flowmeter is located downstream from the choke valve; and (iii) a drilling fluid flow controller having a memory device storing instructions configured to cause the drilling fluid flow controller to automatically: (A) receive the information indicating the measured flowrate; (B) calculate a proportional gain from the measured flowrate and a first setpoint; (C) calculate an integral gain from the measured flowrate and the first setpoint; and (D) calculate a choke control output by summing the proportional gain with the integral gain. The choke valve can be configured to adjust, responsive to the choke control output, the choke valve position to control the desired pressure or flow of the drilling fluid.

In some embodiments, the information indicating the measured flowrate or plastic viscosity (PV) can be received from a V-shaped flowmeter orifice.

In some embodiments, the measured flowrate or PV can be received from a digital transducer measuring actual pressure in front of the choke. In some examples, the memory can further store instructions configured to cause the controller to adjust the choke accordingly to the desired pressure setpoint, which is input from a user interface device. In an example, the memory further stores instructions configured to cause the drilling fluid flow controller to receive, from a user interface device, information describing the first setpoint.

The apparatus can include: (i) a hydraulic actuator configured to adjust a position of the choke valve; (ii) a hydraulic accumulator storing pressurized hydraulic fluid; and (iii) an electrically operated valve configured to: (A) receive the choke control output from the controller; and (B) control, responsive to the received choke control output, a flowrate of the hydraulic fluid from the hydraulic accumulator to the hydraulic actuator.

In some embodiments, the memory can further store instructions configured to cause the drilling fluid flow controller to automatically: (i) compare the information indicating the measured flowrate to a second setpoint, where the second setpoint describes a maximum allowed flowrate; and (ii) modify, when the measured flowrate is equal to or greater than the second setpoint, the choke control output to adjust the choke valve position to reduce the measured flowrate, an actual pressure, or both. In some embodiments, the memory can further store instructions configured to cause the drilling fluid flow controller to receive, from a user interface device, information describing the second setpoint.

In some embodiments, the drilling fluid flow controller can include at least one of a proportional integral derivative (PID) controller, a proportional integral (PI) controller, a field programmable gate array, a programmable logic device, an application-specific integrated circuit, a non-generic special-purpose processor, a gated logic device, a dedicated hardware finite state machine, or a combination thereof.

In some embodiments, provided is a method for automatically controlling parameters of drilling fluid. The method can include: (i) receiving, by a controller, information indicating a measured flowrate of the drilling fluid flowing out of a wellbore and through an outflow flowmeter located downstream from a choke valve; (ii) automatically calculating, by the drilling fluid flow controller, a proportional gain from the measured flowrate and a first setpoint; (iii) automatically calculating, by the drilling fluid flow controller, an integral gain from the measured flowrate and the first setpoint; (iv) automatically calculating, by the drilling fluid flow controller, a choke control output by summing the proportional gain with the integral gain; and (v) automatically moving, responsive to the choke control output, a position of the choke valve.

In some examples, the outflow flowmeter can include a V-shaped flowmeter orifice.

In some embodiments, the method can further include receiving, by the controller and from a user interface device, information describing the first setpoint.

In some examples, the method can further include: (i) automatically comparing, by the drilling fluid flow controller, the information indicating the measured flowrate to a second setpoint, where the second setpoint describes a maximum allowed flowrate; and (ii) automatically modifying, by the drilling fluid flow controller and when the measured flowrate is equal to or greater than the second setpoint, the choke control output to adjust the choke valve position to reduce the measured flowrate.

In some examples, the method can further include receiving, by the controller and from a user interface device, information describing the second setpoint.

In some embodiments, the above-described method can be encoded as computer-readable instructions on a non-transitory computer-readable medium. For example, a computer-readable medium may store processor-executable instructions configured to cause a processor to: (i) initiate receiving information indicating a measured flowrate of the drilling fluid flowing out of a wellbore and through an outflow flowmeter located downstream from a choke valve; (ii) initiate calculating a proportional gain from the measured flowrate and a first setpoint; (iii) initiate calculating an integral gain from the measured flowrate and the first setpoint; and (iv) initiate calculating a choke control output by summing the proportional gain with the integral gain.

In some embodiments, the processor can be a drilling fluid flow controller.

In some embodiments, the processor-executable instructions can further store computer-readable instructions configured to cause a processor to receive, by the processor and from a user interface device, information describing the first setpoint and the second setpoint.

In some examples, the processor-executable instructions can further store computer-readable instructions configured to cause the processor to: (i) initiate automatically comparing, by the processor, the information indicating the measured flowrate to a second setpoint, where the second setpoint describes a maximum allowed a measured flowrate; and (ii) initiate automatically modifying, by the processor and when the measured flowrate is equal to or greater than the second setpoint, the choke control output to adjust the choke valve position to reduce an actual pressure, the measured flowrate, or both.

In some embodiments, the processor-executable instructions can further store computer-readable instructions configured to cause the processor to initiate receiving, by the processor and from a user interface device, information describing the second setpoint.

In some examples, the processor, controller, or both can be a drilling fluid flow controller, a proportional integral derivative (PID) controller, a proportional integral (PI) controller, a field programmable gate array, a programmable logic device, an application-specific integrated circuit, a non-generic special-purpose processor, a gated logic device, a dedicated hardware finite state machine, or a combination thereof.

Features from any of the embodiments described herein may be used in combination with another embodiment in accordance with the general principles described herein. These and other embodiments, features, and advantages will be more fully understood upon reading this detailed description in conjunction with the accompanying drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are presented to describe examples of the present teachings and are not limiting. Together with this following description, the drawings demonstrate and explain various principles of the present disclosure.

FIG. 1 depicts an example system configured to control parameters of drilling fluid.

FIG. 2 depicts a block diagram of an example computing device suitable for use as a device configured to control a flow rate of drilling fluid.

FIG. 3 depicts a block diagram of an example method for controlling parameters of drilling fluid.

FIG. 4 depicts a block diagram of an example method for controlling parameters of drilling fluid.

FIG. 5 depicts a block diagram of an example method for controlling parameters of drilling fluid.

Each of the drawings is provided for illustration and description only and does not limit the present disclosure. In accordance with common practice, the features depicted by the drawings may not be drawn to scale. Accordingly, the dimensions of the depicted features may be arbitrarily expanded or reduced for clarity. In accordance with common practice, some of the drawings are simplified for clarity. Thus, the drawings may not depict all components of a particular apparatus or method. Further, like reference numerals denote like features throughout the specification and figures.

DETAILED DESCRIPTION

To address the previously unaddressed and long-felt industry needs for methods and apparatus which improve upon conventional methods and apparatus, provided are non-limiting example methods and apparatuses configured to automatically detect parameters of drilling fluid and to control the parameters of the drilling fluid.

Example parameters of the drilling fluid that can be detected, controlled, or both include drilling fluid pressures, drilling fluid flowrates, and combinations thereof. Examples of parameters of the drilling fluid that the provided methods and apparatuses can detect include, not are not limited to, a mass flow rate of drilling fluid flowing into a drill string, a mass flow rate of drilling fluid flowing out of a blowout preventer, a mass flow rate of drilling fluid flowing into a choke valve (i.e., a choke, a drilling choke), a mass flow rate of drilling fluid flowing out of a choke valve, a pressure (e.g., a measured pressure) indicating a mass flow rate of drilling fluid flowing into a drill string, a pressure (e.g., a measured pressure) indicating a mass flow rate of drilling fluid flowing out of a blowout preventer, a pressure (e.g., a measured pressure) indicating a mass flow rate of drilling fluid flowing into a choke valve, a pressure (e.g., a measured pressure) indicating a mass flow rate of drilling fluid flowing out of a choke valve, a drilling fluid pump output pressure, a casing pressure, an absolute pressure, a flow rate, or a combination thereof.

The provided devices can receive information describing the detected parameter(s) and process the information describing the detected parameter(s) (e.g., using at least one algorithm) to create at least one control output. In examples, the control output can be applied to an actuator configured to operate a valve, such as a choke valve, to control a flowrate of the drilling fluid, a pressure of the drilling fluid, or combination thereof. The control output can control electrical energy applied to an electric solenoid-actuated valve configured to control fluid flow from a hydraulic accumulator, which in turn can control a flowrate of the drilling fluid, a pressure of the drilling fluid, or combination thereof. The provided devices can also receive feedback information from valve position indicators, electric motors, the like, or combinations thereof and process the feedback information (e.g., using the algorithm) to further adjust the control output.

The examples disclosed hereby advantageously address the long-felt industry needs, as well as other previously unidentified needs, and mitigate shortcomings of conventional techniques. In some examples, systems and methods described herein can advantageously improve on conventional techniques. In some embodiments, methods and apparatuses described herein can advantageously automatically regulate pressure of drilling fluid, flowrate of drilling fluid, or both.

In some examples, methods and apparatuses described herein can advantageously automatically identify, indicate, respond, or a combination thereof to an increase in gas flow, fluid flow, or a combination thereof out of a formation into a wellbore. In a non-limiting example, the methods and apparatuses described herein can automatically adjust a position of a choke valve to respond to the increase in gas flow out of the formation and into the wellbore, fluid flow out of the formation and into the wellbore, or both (e.g., to control changes in drilling fluid flowrate, pressure due to a kick, or both). In some examples, methods and apparatuses described herein can advantageously adjust a position of a choke valve dependent upon measured pressure, measured flow rates of drilling fluid, or a combination thereof. Other advantages of the provided examples include ease-of-use, a small footprint, unmanned operation, flexible configurations, and combinations thereof.

Numerous examples are disclosed in this application's text and drawings. Alternate examples can be devised without departing from the scope of this disclosure. Additionally, conventional elements of the current teachings may not be described in detail, or may be omitted, to avoid obscuring aspects of the current teachings.

This description provides, with reference to FIGS. 1-2, detailed descriptions of example apparatus for controlling parameters of drilling fluid. Detailed descriptions of non-limiting aspects of example methods for controlling parameters of drilling fluid are provided in connection with FIGS. 3-5.

FIG. 1 depicts an example system 100 configured to control parameters of drilling fluid.

Processes for drilling oil and natural gas wellbores generate great heat at drill bits, generate drill cuttings that must be removed from wellbores, and disturb formation fluids and gasses. To address these issues, drilling fluid, also known as drilling mud, is used to cool the drill bits, to remove the drill cuttings from the wellbores, and to provide hydrostatic pressure to control entrance of the formation fluids and gasses into the wellbores.

In the example system 100, drilling fluid is pumped from an above-ground reservoir by a drilling fluid pump, through an orbit valve 105 and a blowout preventer 110 (BOP) configured for circulating operations, down through a drill string 115, to a drill bit, where the drilling fluid cools the drill bit. The drilling fluid exits the drill bit and then enters an annular space within the wellbore, where the drilling fluid flushes the drill cuttings from the vicinities of the drill bit into the annular space. The drilling fluid travels up the wellbore within the annular space toward the surface of the earth. Within the annular space, the drilling fluid also provides hydrostatic pressure to control entrance of the formation fluids and gasses into the wellbore. The drilling fluid then exits the annular space through the blowout preventer 110. In some examples, a choke valve can be located such that the drilling fluid flows through the choke valve. In some embodiments, the choke valve can be fastened to the blowout preventer 110. In some examples, the choke valve can be located in the flow path of the drilling fluid prior to the orbit valve 105.

The drilling fluid is then conveyed by a pipe to a manifold 120. The manifold 120 can include valves configured to permit flow of the drilling fluid, restrict the flow of the drilling fluid, completely prevent the flow of the drilling fluid, or combinations thereof. In examples, the manifold 120 can include at least one choke valve. The choke valve(s) can be hydraulically actuated, can have variable position(s) (i.e., can be used to throttle flow of the drilling fluid), or a combination thereof. In examples, the drilling fluid exiting the manifold 120 can be desanded, desilted, degassed (e.g., by gas buster 125 and flare stack 130), or combination thereof and then returned to the above-ground reservoir for circulation back down the drill string 115.

Gas busters and uses thereof are disclosed in U.S. Pat. No. 10,898,831, entitled “SEPARATING DRILLING CUTTINGS AND GAS USING A LIQUID SEAL,” issued Jan. 26, 2021, as well as in U.S. Pat. No. 11,077,390, entitled “SEPARATING DRILLING CUTTINGS AND GAS USING A LIQUID SEAL,” issued Aug. 3, 2021. These patents are incorporated herein by reference in their entireties.

FIG. 2 illustrates an example computing device 200 suitable for implementing examples of the disclosed subject matter. For example, the computing device 200 can be suitable for use to control at least one parameter of the drilling fluid in at least a portion of the example system 100. In examples, aspects of the computing device 200 can be implemented at least in part in a drilling fluid flow controller, a proportional integral derivative (PID) controller, a programmable logic controller (PLC), a desktop computer, a laptop computer, a server, a mobile device, a special-purpose computer, a non-generic computer, an electronic device described hereby (as is practicable), the like, or a combination thereof. In some examples, the disclosed subject matter can be implemented in, and used with, hardware devices, computer network devices, the like, or a combination thereof. The configuration depicted in FIG. 2 is an illustrative example and is not limiting.

In some examples, the computing device 200 can include a processor 205, a data bus 210, a memory 215, a display 220, a user interface 225, a fixed storage device 230, a removable storage device 235, a network interface 240, a sensor interface 245, a sensor 250, a network device 255, the like, or a combination thereof. These elements are described in further detail herein.

The processor 205 can be a hardware-implemented processing unit configured to control at least a portion of operation of the computing device 200. The processor 205 can perform logical and arithmetic operations based on processor-executable instructions stored within the memory 215. The processor 205 can be configured to execute instructions which cause the processor 205 to initiate at least a part of a method described hereby. In an example, the processor 205 can interpret instructions stored in the memory 215 to initiate at least a part of a method described hereby. In an example, the processor 205 can execute instructions stored in the memory 215 to initiate at least a part of a method described hereby. The instructions, when executed by the processor 205, can transform the processor 205 into a special-purpose processor that causes the processor to perform at least a part of a function described hereby. The processor 205 may also be referred to as a central processing unit (CPU), a special-purpose processor (e.g., a non-generic processor), or both.

The processor 205 can comprise or be a component of a physical processing system implemented with one or more processors. In some examples, the processor 205 can be implemented with at least a portion of: a microprocessor, a microcontroller, a digital signal processor (DSP) integrated circuit, a field programmable gate array (FPGA), a programmable logic device (PLD), an application-specific integrated circuit (ASIC), a controller, a state machine, a gated logic circuit, a discrete hardware component, a dedicated hardware finite state machine, a suitable physical device configured to manipulate information (e.g., calculating, logical operations, the like, or a combination thereof), the like, or a combination thereof.

The data bus 210 can couple components of the computing device 200. The data bus 210 can enable information communication between the processor 205 and one or more components coupled to the processor 205. In some examples, the data bus 210 can include a data bus, a power bus, a control signal bus, a status signal bus, the like, or a combination thereof. In an example, the components of the computing device 200 can be coupled together to communicate with each other using a different suitable mechanism.

The memory 215 generally represents any type or form of volatile storage device, non-volatile storage device, medium, the like, or a combination thereof. The memory 215 can store data, processor-readable instructions, the like, or a combination thereof. In an example, the memory 215 can store data, load data, maintain data, or a combination thereof. In an example, the memory 215 can store processor-readable instructions, load processor-readable instructions, maintain processor-readable instructions, or a combination thereof. In some embodiments, the memory 215 can store computer-readable instructions configured to cause a processor (e.g., the processor 205) to initiate performing at least a portion of a method described hereby. The memory 215 can be a main memory configured to store an operating system, an application program, the like, or a combination thereof. The memory 215 can store a basic input-output system (BIOS) which can control basic hardware operation such as interaction of the processor 205 with peripheral components. The memory 215 can also include a non-transitory machine-readable medium configured to store software. Software can mean any type of instructions, whether referred to as at least one of software, firmware, middleware, microcode, hardware description language, the like, or a combination thereof. Processor-readable instructions can include code (e.g., in source code format, in binary code format, executable code format, or in any other suitable code format).

The memory 215 can include at least one of read-only memory (ROM), random access memory (RAM), a flash memory, a cache memory, an erasable programmable read-only memory (EPROM), an electrically erasable programmable read-only memory (EEPROM), a register, a hard disk drive (HDD), a solid-state drive (SSD), an optical disk drive, other memory, the like, or a combination thereof which is configured to store information (e.g., data, processor-readable instructions, software, the like, or a combination thereof) and is configured to provide the information to the processor 205.

The display 220 can include a component configured to visually convey information to a user of the computing device 200. In examples, the display 220 can be a video display screen, such as a light-emitting diode (LED) screen, a touch screen, or both.

The user interface 225 can include user devices such as a switch, a keypad, a keyboard, a touch screen, a microphone, a speaker, an audio production device, a jack for coupling the computing device to an audio production device, the like, or a combination thereof. The user interface 225 can optionally include a user interface controller. The user interface 225 can include a component configured to convey information to a user of the computing device 200, a component configured to receive information from the user of the computing device 200, or both.

The fixed storage device 230 can include one or more hard drive, flash storage device, the like, or a combination thereof. The fixed storage device 230 can be an information storage device that is not configured to be removed during use. The fixed storage device 230 can optionally include a fixed storage device controller. The fixed storage device 230 can be integral with the computing device 200 or can be separate and accessed through an interface.

The removable storage device 235 can be integral with the computing device 200 or can be separate and accessed through other interfaces. The removable storage device 235 can be an information storage device which is configured to be removed during use, such as a memory card, a jump drive, a flash storage device, an optical disk, the like, or a combination thereof. The removable storage device 235 can optionally include a removable storage device controller. The removable storage device 235 can be integral with the computing device 200 or can be separate and accessed through an interface.

In examples, a computer-readable storage medium such as one or more of the memory 215, the fixed storage device 230, the removable storage device 235, a remote storage location, the like, or a combination thereof can store non-transitory computer-executable instructions configured to cause a processor (e.g., the processor 205) to implement, initiate, perform, or a combination thereof at least an aspect of the present disclosure. In some examples, the non-transitory computer-executable instructions can be configured to automatically cause the processor (e.g., the processor 205) to implement, initiate, perform, or a combination thereof at least an aspect of the present disclosure.

The network interface 240 can couple the processor 205 (e.g., via the data bus 210) to a network and enable exchanging information between the processor 205 and the network. In some examples, the network interface 240 can couple the processor 205 (e.g., via the data bus 210) to the network and enable exchanging information between the processor 205 and the sensor 250. For example, the network interface 240 can enable the processor 205 to communicate with one or more other network devices. In some nonlimiting examples, the network can couple the processor 205 to the network device 255 in a manner such that the processor 205 can control the network device 255.

The network interface 240 can couple to the network using any suitable technique and any suitable protocol. In some examples, the network interface 240 can include a data bus, a power bus, a control signal bus, a status signal bus, the like, or a combination thereof. Example techniques and protocols the network interface 240 can be configured to implement include digital cellular telephone, WiFi™, Bluetooth®, near-field communications (NFC), the like, or a combination thereof.

In some examples, the network interface 240 can be a programmable logic controller, a digital to analog converter, a servo controller, an input interface, an output interface (e.g. configured to output a choke control output), or a combination thereof. In some examples, a network can include an arrangement of at least one output interface and at least one network device (e.g. the network device 255). In some examples, the network can be an industrial network, a process automation network, or a combination thereof.

In some examples, the network interface 240 can couple the processor 205 to the network device 255. In some examples, the network can enable exchange of information between the processor 205 and the network device 255. In some examples, the network can enable exchange of information between the processor 205 and the sensor 250. The network can include one or more private networks, local networks, wide-area networks, the Internet, other communication networks, the like, or a combination thereof. In some examples, the network can be a wired network, a wireless network, an optical network, the like, or a combination thereof.

Some examples, the sensor interface 245 can couple the processor 205 (e.g., via the data bus 210) to the sensor 250. In some examples, the sensor interface 245 can couple the processor 205 (e.g., via the data bus 210) to the sensor 250 and enable exchanging information between the processor 205 and the sensor 250. For example, the sensor interface 245 can enable the processor 205 to receive, from the sensor 250, analog information, digital information, or both describing at least one characteristic of drilling fluid, such as a mass flow rate of drilling fluid flowing into a drill string, a mass flow rate of drilling fluid flowing out of a blowout preventer, a mass flow rate of drilling fluid flowing into a choke valve, a mass flow rate of drilling fluid flowing out of a choke valve, a pressure (e.g., a measured pressure) indicating a mass flow rate of drilling fluid flowing into a drill string, a pressure (e.g., a measured pressure) indicating a mass flow rate of drilling fluid flowing out of a blowout preventer, a pressure (e.g., a measured pressure a flow rate) indicating a mass flow rate of drilling fluid flowing into a choke valve, a pressure (e.g., a measured pressure) indicating a mass flow rate of drilling fluid flowing out of a choke valve, a drilling fluid pump output pressure, a casing pressure, an absolute pressure, a flow rate, a pressure of drilling fluid at a point in the drilling fluid flow path, or a combination thereof.

In examples, the sensor interface 245 can couple to the sensor 250 using any suitable technique and any suitable protocol. In some examples, the sensor interface 245 can perform analog-to-digital conversion, digital-to-analog conversion, or a combination thereof. In some examples, the sensor interface 245 can include a data bus, a power bus, a control signal bus, a status signal bus, the like, or a combination thereof. Example techniques and protocols the sensor interface 245 can be configured to implement to communicate information include Ethernet, digital cellular telephone, WiFi™, Bluetooth®, near-field communications (NFC), the like, or a combination thereof.

In an embodiment, the sensor 250 can sense a characteristic of the drilling fluid. In examples, the sensor 250 can produce an analog output indicating the at least one state, a digital output indicating the at least one state, or both. The sensor 250 can produce an output of the at least one state using any suitable technique, any suitable protocol, or both. In some examples, the sensor 250 can perform analog-to-digital conversion, digital-to-analog conversion, or a combination thereof. In some examples, the sensor 250 can include a data bus, a power bus, a control signal bus, a status signal bus, the like, or a combination thereof. Example techniques and protocols the sensor 250 can be configured to implement include ethernet, digital cellular telephone, WiFi™, Bluetooth®, near-field communications (NFC), the like, or a combination thereof.

In examples, the sensor 250 can include a pressure sensor, a differential pressure sensor/flow meter, a sensor described herein, a sensor configured to produce computer-processable data described herein, or combination thereof. In examples, the sensor 250 can be configured to sense at least one characteristic of drilling fluid, such as a mass flow rate of drilling fluid flowing into a drill string, a mass flow rate of drilling fluid flowing out of a blowout preventer, a mass flow rate of drilling fluid flowing into a choke valve, a mass flow rate of drilling fluid flowing out of a choke valve, a pressure (e.g., a measured pressure) indicating a mass flow rate of drilling fluid flowing into a drill string, a pressure (e.g., a measured pressure) indicating a mass flow rate of drilling fluid flowing out of a blowout preventer, a pressure (e.g., a measured pressure) indicating a mass flow rate of drilling fluid flowing into a choke valve, a pressure (e.g., a measured pressure) indicating a mass flow rate of drilling fluid flowing out of a choke valve, a drilling fluid pump output pressure, a casing pressure, an absolute pressure, a flow rate, a pressure of drilling fluid at a point in the drilling fluid flow path, or a combination thereof.

In some embodiments, the network device 255 can store computer-readable instructions configured to cause a processor (e.g., the processor 205) to initiate performing at least a portion of a method described hereby. In an example, the network device 255 can store non-transitory computer-executable instructions configured to cause a processor (e.g., the processor 205) to implement at least an aspect of the present disclosure. The non-transitory computer-executable instructions can be received by the processor 205 and implemented using at least a portion of techniques described hereby. In another example, information described hereby can be stored in the fixed storage device 230, the removable storage device 235, the network device 255, the like, or a combination thereof.

The network device 255 can include the sensor 250, a hardware device configured to couple the network to the sensor 250, a server, a digital information storage device, the like, or a combination thereof.

In some examples, the network device 255 can include user interface devices such as a switch, a keypad, a touch screen, a microphone, a speaker, an audio reproduction device, a jack for coupling the computing device to an audio reproduction device, the like, or a combination thereof. The network device 255 can optionally include a user interface controller. The network device 255 can include a component configured to convey information to a user of the computing device 200, a component configured to receive information from the user of the computing device 200, or both.

In some embodiments, the network device 255 can be an actuator figured to control at least one parameter of drilling fluid, a motor controller, a solenoid controller, a solenoid valve, a relay, an electromechanical actuator, a pump controller, a valve position controller, or combination thereof.

In some examples, the network device 255 can be coupled directly to the data bus 210. In some examples, the network device 255 can be coupled to the data bus 210 via a programmable logic controller, a digital to analog converter, a servo controller, an input interface, an output interface (e.g. configured to output a choke control output), or a combination thereof.

In some examples, all the components illustrated in FIG. 2 need not be present to practice the present disclosure. Further, the components can be coupled in different ways from those illustrated.

OVERVIEW OF EXAMPLE METHODS

FIG. 3 depicts a block diagram of an example method 300 for controlling parameters of drilling fluid. The method 300 can be performed at least in part by the apparatus described hereby, such as the computing device 200 in FIG. 2, other devices described herein, or a practicable combination thereof.

As illustrated in FIG. 3, at block 305, one or more of the devices described herein can receive information indicating a measured inflow rate of the drilling fluid flowing into a wellbore.

As illustrated in FIG. 3, at block 310, one or more of the devices described herein can receive information indicating a measured outflow rate of the drilling fluid flowing out of the wellbore and through an outflow flowmeter located downstream from a choke valve.

In an example, the outflow flowmeter includes a V-shaped flowmeter orifice.

As illustrated in FIG. 3, at block 315, one or more of the devices described herein can automatically calculate a differential flowrate between the measured inflow rate and the measured outflow rate.

As illustrated in FIG. 3, at block 320, one or more of the devices described herein can automatically calculate a proportional gain from the differential flowrate and a first setpoint. The first setpoint can indicate a target differential flowrate to maintain. In examples, an error value can be calculated as the difference between the differential flowrate and the first setpoint. The proportional gain can equal the error value multiplied by a proportional constant.

In an example, the method 300 can include receiving, from a user interface device, information describing the first setpoint.

In some embodiments, the information describing the first setpoint can be converted to a human-readable form that can be displayed on the user interface device.

As illustrated in FIG. 3, at block 325, one or more of the devices described herein can automatically calculate an integral gain from the differential flowrate and the first setpoint. The integral gain can equal an integral constant multiplied by an integral of the error value over a time period with respect to the respective value of time for a specific error value occurring during the time period.

As illustrated in FIG. 3, at block 330, one or more of the devices described herein can automatically calculate a choke control output by summing the proportional gain with the integral gain.

As illustrated in FIG. 3, at block 335, one or more of the devices described herein can automatically move, responsive to the choke control output, a position of the choke valve.

In some examples, the method 300 can further include (i) automatically comparing the information indicating the differential flowrate to a second setpoint, where the second setpoint describes a maximum allowed differential flowrate and (ii) automatically modifying, when the differential flowrate is equal to or greater than the second setpoint, the choke control output to adjust the choke valve position to reduce the differential flowrate. The method 300 can further include receiving, from a user interface device, information describing the second setpoint.

FIG. 4 depicts a block diagram of an example method 400 for controlling parameters of drilling fluid. The method 400 can be performed at least in part by the apparatus described hereby, such as the computing device 200 in FIG. 2, other devices described herein, or a practicable combination thereof.

As illustrated in FIG. 4, at block 405, one or more of the devices described herein can receive information indicating a measured flowrate of the drilling fluid flowing out of a wellbore and through an outflow flowmeter located downstream from a choke valve. In an example, the flowmeter can include a V-shaped flowmeter orifice. In examples, the outflow flowmeter can be downstream from the choke valve. In some examples, the outflow flowmeter can be fastened to the choke valve. In embodiments, a differential pressure measurement cell sensing a differential pressure of drilling fluid flowing through an orifice can provide drilling fluid flow measurements. In examples, a differential pressure measurement cell configured to sense differential pressure across an orifice can form a flowmeter.

In some embodiments, the information indicating the measured flowrate of the drilling fluid flowing out of the wellbore can be converted to a human-readable form than in turn can be displayed on a user interface device, such as a human-machine interface (HMI).

As illustrated in FIG. 4, at block 410, one or more of the devices described herein can automatically calculate a proportional gain from the measured flowrate and a first setpoint. In examples, an error value can be calculated as the difference between the measured flowrate and the first setpoint. The proportional gain can equal the error value multiplied by a proportional constant. The first setpoint can indicate a target flowrate to maintain. In some examples one or more of the devices described herein can receive a target mass flowrate and convert the target mass flowrate to the target flowrate. In some examples, the proportional gain may indicate a loss.

In some embodiments, the method 400 can further include receiving, from a user interface device, information describing the first setpoint.

In some embodiments, the information describing the first setpoint can be converted to a human-readable form than in turn can be displayed on the user interface device.

As illustrated in FIG. 4, at block 415, one or more of the devices described herein can automatically calculate an integral gain from the measured flowrate and the first setpoint. The integral gain can equal an integral constant multiplied by an integral of the error value over a time period with respect to the respective value of time for a specific error value occurring during the time period. In some examples, the integral gain may indicate a loss.

As illustrated in FIG. 4, at block 420, one or more of the devices described herein can automatically calculate a choke control output by summing (e.g., adding) the proportional gain with the integral gain. In some nonlimiting examples, the choke control output can be a binary signal in which a value of “1” causes the choke valve to open and a value of “0” causes the choke valve to close. In some nonlimiting examples, the choke control output can be a binary signal in which a value of “0” causes the choke valve to open and a value of “1” causes the choke valve to close. In some nonlimiting examples, the choke control output can be an analog signal configured to cause the choke valve to become more open. In some nonlimiting examples, the choke control output can be an analog signal configured to cause the choke valve to become less open.

In some examples, one or more of the devices described herein can automatically calculate an intermediate choke control value by summing the proportional gain with the integral gain.

As illustrated in FIG. 4, at block 425, one or more of the devices described herein can automatically move, responsive to the choke control output, a position of the choke valve to maintain the target flowrate of the drilling fluid. In some circumstances, the choke control output may indicate that no movement of the position of the choke valve is necessary, thus the choke valve need not be moved.

In examples, one or more of the devices described herein can receive choke valve position information from a sensor fastened to the choke valve and configured to transmit the choke valve position information indicating the position of the choke valve. In some embodiments, the choke valve position information can be converted to a human-readable form that in turn can be displayed on the user interface device.

One or more of the devices described herein can determine an error signal by comparing the intermediate choke control value to the received choke valve position information indicating the current position of the choke valve. The error signal can be compared to an array of fixed values, where each fixed value has a respective choke control output, to identify a respective value of the choke control output to adjust the position of the choke valve.

In some embodiments, the choke control output can be applied to a solenoid of a solenoid-actuated valve configured to control a flow of hydraulic fluid configured to actuate the choke valve. Closing the choke valve at least to some extent, if not completely, can increase drilling fluid pressure in the wellbore to suppress a kick. Opening the choke valve can relieve pressure in the wellbore. Varying the position of the choke valve can regulate pressure of drilling fluid in the wellbore to maintain an underbalanced condition, a balanced condition, or an overbalanced condition.

In some examples, the method 400 can further include: (i) automatically comparing the information indicating the measured flowrate to a second setpoint, where the second setpoint describes a maximum allowed flowrate and (ii) automatically modifying; when the measured flowrate is equal to the second setpoint, greater than the second setpoint, or both; the choke control output to adjust the choke valve position to reduce the measured flowrate by closing the choke valve. Closing the choke valve at least to some extent, if not completely, can increase drilling fluid pressure in the wellbore to suppress a kick.

In some examples, the method 400 can further include receiving, from the user interface device, information describing the second setpoint.

In some examples, the method 400 can further include receiving information describing a measured flowrate of drilling fluid in a portion of the drilling fluid system. The received information describing the measured flowrate can be compared to the information describing the second setpoint and when the measured flowrate equals the second setpoint (e.g., indicating a high drilling fluid outflow condition in the drilling fluid system), exceeds the second setpoint, or both, the method 400 automatically adjusts the choke control output to open the choke valve. In examples, under these circumstances, the choke control output can open the choke valve to a maximum open position. In examples, under these circumstances, the choke control output can open the choke valve to a maximum open position in a manner faster than adjustments made during typical operations. In some examples, when such an overpressure condition exists, the corresponding generated choke control output can have a high priority that supersedes other efforts (e.g. by the method 400) to generate a choke control output.

In some examples, the method 400 can further include receiving information describing a failure of a pressure sensor configured to measure pressure of drilling fluid in a portion of the drilling fluid system. In response to receiving the information describing the failure, the method 400 can automatically adjust the choke control output to open the choke valve. In examples, when failure of a pressure sensor is detected, the method 400 can generate a choke control output that opens the choke valve to a maximum open position.

In examples, under these circumstances the choke control output can open the choke valve to a maximum open position in a manner faster than adjustments made during typical operations. In some examples, when such a pressure sensor failure condition exists, the corresponding generated choke control output can have a high priority that supersedes other efforts (e.g. by the method 400) to generate a choke control output. In some examples, the pressure sensor can be configured to indicate a maximum pressure within the portion of the drilling fluid system.

In some examples, the method 400 can further include receiving information indicating the pressure sensor is connected to the device executing the method 400, but the pressure sensor is malfunctioning. In response to receiving the information indicating the pressure sensor is connected but malfunctioning, the method 400 can change a setpoint used to generate the choke control output, such as the first setpoint. For example, the method 400 can change the first setpoint to a failsafe value.

In some examples, the method 400 can further include receiving information describing a casing pressure sensor is not connected to a device executing the method 400. In response to receiving the information describing the lack of connection of the casing pressure sensor, the method 400 can automatically adjust the choke control output to open the choke valve. In examples, when the lack of connection of the casing pressure sensor is detected, the method 400 can generate a choke control output that opens the choke valve to a maximum open position. In examples, under these circumstances the choke control output can open the choke valve to a maximum open position in a manner faster than adjustments made during typical operations. In some examples, when such a lack of connection condition exists, the corresponding generated choke control output can have a high priority that supersedes other efforts (e.g. by the method 400) to generate a choke control output.

In some examples, the method 400 can further include receiving information indicating the casing pressure sensor is connected to the device executing the method 400, but the casing pressure sensor is malfunctioning. In response to receiving the information indicating the casing pressure sensor is connected but malfunctioning, the method 400 can change a setpoint used to generate the choke control output, such as the first setpoint. For example, the method 400 can change the first setpoint to a failsafe value.

In some examples, the method 400 can further include receiving information describing a manifold pressure sensor is not connected to a device executing the method 400. In response to receiving the information describing the lack of connection of the manifold pressure sensor, the method 400 can automatically adjust the choke control output to open the choke valve. In examples, when the lack of connection of the manifold pressure sensor is detected, the method 400 can generate a choke control output that opens the choke valve to a maximum open position. In examples, under these circumstances the choke control output can open the choke valve to a maximum open position in a manner faster than adjustments made during typical operations. In some examples, when such a lack of connection condition exists, the corresponding generated choke control output can have a high priority that supersedes other efforts (e.g. by the method 400) to generate a choke control output.

In some examples, the method 400 can further include receiving information indicating the manifold pressure sensor is connected to the device executing the method 400, but the manifold pressure sensor is malfunctioning. In response to receiving the information indicating the manifold pressure sensor is connected but malfunctioning, the method 400 can change a setpoint used to generate the choke control output, such as the first setpoint. For example, the method 400 can change the first setpoint to a failsafe value.

In some embodiments, method 400 can further include receiving information indicating resolution of the pressure sensor failure, the pressure sensor lack of connection, the pressure sensor malfunction, or combination thereof. In response to receiving the information, the method 400 can cease generating the choke control output superseding other efforts (e.g. by the method 400) to generate a choke control output. In some examples, the method 400 can return to automatically generating the choke control output based upon other efforts (e.g. by the method 400) that were previously superseded.

In examples, the method 400 can also include receiving information indicating a drilling fluid pump is to be started or stopped. Upon receipt of this information, the method 400 can initiate a timer. When the drilling fluid pump is stopped, the method 400 can rapidly close the choke valve when a monitored drilling fluid pressure drops below a minimum pressure setpoint. When the drilling fluid pump is started, the method 400 can open the choke valve to adjust for a surge of the drilling fluid when the pump is turned on.

In examples, the method 400 can include receiving a selection information indicating a selection of manual operation or automatic operation. The information can be received from a selector switch.

When the selection information indicates a selection of automatic operation, the method 400 can continuously cycle through steps 405 to 425. When the selection information indicates a selection of manual operation, the method 400 can cease automatic operation. When the selection information indicates a selection of manual operation, the method 400 can receive manual control input indicating a choke valve is to be moved in the open position or moved in the closed position. The method 400 in turn can generate the choke control output based upon the manual control input.

In further examples, a Gas Buster level sensor can use a radar sensor mounted to a top of an external tube installed on a side of the Gas Buster. A Gas Buster can be a separator device configured to remove gas from fluids (such as drilling fluid) circulated via a wellbore. The radar sensor can send a level output to a level sensor remote junction box which powers the radar sensor. This level output can then be sent to a device configured to control a choke valve and can be monitored on a user display device. An alarm can be issued when the level of the Gas Buster exceeds a level which has been input by a user. The system can also send Gas Buster level information through a Wellsite Information Transfer Specification (WITS) system to a rig data system, so the Gas Buster level information can be recorded.

A liquid can alarm can monitor a liquid can level sensor and when activated can send a liquid can level sensor output (e.g. via a level sensor remote junction box) to the device configured to control a choke valve and thus a high liquid can alarm indication, liquid can level sensor information, or both can be displayed on a user display device. The system can also send liquid can level sensor information through WITS to a rig data system, so the liquid can level sensor information can be recorded.

In some examples, a hydraulic system configured to actuate the choke valve can be configured to actuate three choke valves (e.g., instead of fewer choke valves). In this arrangement, all choke valves can be configured to be actuated individually or in unison. In some examples, a hydraulic system user display, a control device (e.g., an electric hydraulic accumulator panel), or both can be configured to indicate positions of more than two choke valves, operate more than two choke valves, or both. In some examples, the hydraulic system user display, control device, or both can be configured to be powered by either 220 volt electricity and can be configured to control, at the same time, at least two electric motors coupled to hydraulic system pumps to increase hydraulic flow in the system.

In some embodiments, a hydraulic system user display, a control device, or both can be configured to send information indicating a hydraulic system failure to the device configured to control the choke valve.

In some nonlimiting examples, a drilling fluid flow measurement device can implement an ABB FPD470P wedge flowmeter to monitor drilling fluid flow (in a non-limiting example, directly downstream of a choke valve). Drilling fluid flow information from the wedge flowmeter can be sent to the device configured to control the choke valve. The drilling fluid flow information can be compared with a flow rate of drilling fluid entering the drill string which can be recorded via WITS to create information indicating a difference in the flow rates of drilling fluid entering the wellbore and exiting the wellbore. In examples, this differential flow rate information can be input to the method 400.

In some examples, the drilling fluid flow information from the wedge flowmeter can be displayed on a user display device, thus showing flow rate of the drilling fluid at the location of the wedge flowmeter. Further, information from pressure sensors, flow rate sensors, or combinations thereof indicating flow rates of drilling fluid entering the wellbore and exiting the wellbore can be displayed on the user display device. This information can provide an operator with indications of conditions within the wellbore, such as the occurrence of a kick or loss of drilling fluid to a void in the formation. In some examples, a device provided herein can compare this flowrate information with a high-flow alarm setpoint, a low-flow alarm setpoint, or both to trigger respective alarms, indications on user display device (e.g., a display screen), or both. In some examples, the device provided herein can receive information indicating a high flow alarm setpoint, low-flow alarm setpoint, or both.

In some embodiments, the choke control output can be used to control a flow of hydraulic fluid to a hydraulically-actuated directional control valve that controls the direction of hydraulic fluid flow to an actuator configured to change a position of the choke valve. The hydraulic fluid can be supplied by a reservoir to at least one electric-powered hydraulic pump that provides pressurized hydraulic fluid to a hydraulic fluid supply line. At least one hydraulic accumulator can be connected to the hydraulic fluid supply line to store hydraulic fluid under pressure. The hydraulic fluid supply line can be connected to the solenoid actuated valve receiving the choke control output. The solenoid actuated valve can control flow of hydraulic fluid, based upon the choke control output, to the hydraulically actuated directional control valve. Hydraulic fluid returning from the hydraulically actuated directional control valve, from the actuator configured to change the position of the choke valve, or both can be returned to the reservoir for reuse.

FIG. 5 depicts a block diagram of an example method 500 for controlling parameters of drilling fluid. The method 400 can be performed at least in part by the apparatus described hereby, such as the computing device 200 in FIG. 2, other devices described herein, or a practicable combination thereof.

As illustrated in FIG. 5, at block 505, one or more of the devices described herein can receive information indicating a measured (i.e. actual) pressure of drilling fluid (e.g. flowing out of a wellbore) at a location upstream of a choke valve in the flow path of the drilling fluid.

In some embodiments, the information indicating the measured pressure of the drilling fluid can be converted to a human-readable form than in turn can be displayed on a user interface device, such as a human-machine interface (HMI).

As illustrated in FIG. 5, at block 510, one or more of the devices described herein can automatically calculate information indicating a differential pressure between the measured pressure of the drilling fluid and a desired pressure of the drilling fluid by comparing the information indicating the measured pressure of the drilling fluid to information indicating the desired pressure of the drilling fluid. The information indicating the desired pressure of the drilling fluid can indicate a target pressure of the drilling fluid to maintain.

In some embodiments, the method 500 can further include receiving, from a user interface device, information describing the desired pressure of the drilling fluid.

In some embodiments, the information indicating the differential pressure can be converted to a human-readable form than in turn can be displayed on a user interface device, such as a human-machine interface (HMI).

As illustrated in FIG. 5, at block 515, one or more of the devices described herein can automatically calculate a proportional gain from the information indicating the measured pressure of the drilling fluid and the desired pressure of the drilling fluid. In examples, an error value can be calculated as the difference between the measured pressure of the drilling fluid and the desired pressure of the drilling fluid. The proportional gain can equal the error value multiplied by a proportional constant. The desired pressure of the drilling fluid can indicate a target pressure to maintain. In some examples, the proportional gain may indicate a loss.

In some embodiments, the method 500 can further include receiving, from a user interface device, the information describing the desired pressure of the drilling fluid.

In some embodiments, the information describing the desired pressure of the drilling fluid can be converted to a human-readable form than in turn can be displayed on the user interface device.

As illustrated in FIG. 5, at block 520, one or more of the devices described herein can automatically calculate an integral gain from the information indicating the measured pressure of the drilling fluid and the desired pressure of the drilling fluid. The integral gain can equal an integral constant multiplied by an integral of the error value over a time period with respect to the respective value of time for a specific error value occurring during the time period. In some examples, the integral gain may indicate a loss.

As illustrated in FIG. 5, at block 525, one or more of the devices described herein can automatically calculate a choke control output by summing (e.g., adding) the proportional gain with the integral gain. In some examples, the choke control output can be a binary signal in which a value of “1” causes the choke valve to open and a value of “0” causes the choke valve to close. In some examples, the choke control output can be a binary signal in which a value of “0” causes the choke valve to open and a value of “1” causes the choke valve to close. In some nonlimiting examples, the choke control output can be an analog signal configured to cause the choke valve to become more open. In some nonlimiting examples, the choke control output can be an analog signal configured to cause the choke valve to become less open.

In some examples, one or more of the devices described herein can automatically calculate an intermediate choke control output value by summing the proportional gain with the integral gain.

As illustrated in FIG. 5, at block 530, one or more of the devices described herein can automatically move, responsive to the choke control output, a position of the choke valve to maintain the desired pressure of the drilling fluid. In some circumstances, the choke control output may indicate that no movement of the position of the choke valve is necessary, thus the choke valve need not be moved.

In examples, the method 500 can include receiving a selection information indicating a selection of manual operation or automatic operation. The information can be received from a selector switch.

When the selection information indicates a selection of automatic operation, the method 500 can continuously cycle through steps 505 to 530. When the selection information indicates a selection of manual operation, the method 500 can cease automatic operation. When the selection information indicates a selection of manual operation, the method 500 can receive manual control input indicating choke valve is to be moved in the open position or moved in the closed position. The method 500 in turn can generate the choke control output based upon the manual control input.

As used hereby, the term “example” means “serving as an example, instance, or illustration”. Any example described as an “example” is not necessarily to be construed as preferred or advantageous over other examples. Likewise, the term “examples” does not require all examples include the discussed feature, advantage, or mode of operation. Use of the terms “in one example,” “an example,” “in one feature,” and/or “a feature” in this specification does not necessarily refer to the same feature and/or example. Furthermore, a particular feature and/or structure can be combined with one or more other features and/or structures. Moreover, at least a portion of the apparatus described hereby can be configured to perform at least a portion of a method described hereby.

It should be noted the terms “connected,” “coupled,” and any variant thereof, mean any connection or coupling between elements, either direct or indirect, and can encompass a presence of an intermediate element between two elements which are “connected” or “coupled” together via the intermediate element. Coupling and connection between the elements can be physical, logical, or a combination thereof. Elements can be “connected” or “coupled” together, for example, by using one or more wires, cables, printed electrical connections, electromagnetic energy, and the like. The electromagnetic energy can have a wavelength at a radio frequency, a microwave frequency, a visible optical frequency, an invisible optical frequency, and the like, as practicable. These are several non-limiting and non-exhaustive examples.

The term “signal” can include any signal such as a data signal, an audio signal, a video signal, a multimedia signal, an analog signal, a digital signal, and the like. Information and signals described hereby can be represented using any of a variety of different technologies and techniques. For example, data, an instruction, a process step, a process block, a command, information, a signal, a bit, a symbol, and the like which are referred to hereby can be represented by a voltage, a current, an electromagnetic wave, a magnetic field, a magnetic particle, an optical field, an optical particle, and/or any practical combination thereof, depending at least in part on the particular application, at least in part on the desired design, at least in part on the corresponding technology, and/or at least in part on like factors.

A reference using a designation such as “first,” “second,” and so forth does not limit either the quantity or the order of those elements. Rather, these designations are used as a convenient method of distinguishing between two or more elements or instances of an element. Thus, a reference to first and second elements does not mean only two elements can be employed, or the first element must necessarily precede the second element. Also, unless stated otherwise, a set of elements can comprise one or more elements. In addition, terminology of the form “at least one of: A, B, or C” or “one or more of A, B, or C” or “at least one of the group consisting of A, B, and C” used in the description or the claims can be interpreted as “A or B or C or any combination of these elements”. For example, this terminology can include A, or B, or C, or A and B, or A and C, or A and B and C, or 2A, or 2B, or 2C, and so on.

The terminology used hereby is for the purpose of describing particular examples only and is not intended to be limiting. As used hereby, the singular forms “a,” “an,” and “the” include the plural forms as well, unless the context clearly indicates otherwise. In other words, the singular can portend the plural, where practicable. Further, the terms “comprises,” “comprising,” “includes,” and “including,” specify a presence of a feature, an integer, a step, a block, an operation, an element, a component, and the like, but do not necessarily preclude a presence or an addition of another feature, integer, step, block, operation, element, component, and the like.

Those of skill in the art will appreciate the example logical blocks, elements, modules, circuits, and steps described in the examples disclosed hereby can be implemented individually and/or collectively, as electronic hardware, computer software, or combinations of both, as practicable. To clearly illustrate this interchangeability of hardware and software, example components, blocks, elements, modules, circuits, and steps have been described hereby generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on an overall system. Skilled artisans can implement the described functionality in different ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present disclosure. In addition, any disclosure of components contained within other components should be considered example in nature since many other architectures can be implemented to achieve the same functionality.

At least a portion of the methods, sequences, algorithms or a combination thereof which are described in connection with the examples disclosed hereby can be embodied directly in hardware, in instructions executed by a processor (e.g., a processor described hereby), or in a combination thereof. In an example, a processor includes multiple discrete hardware components. Instructions can reside in a non-transient storage medium (e.g., a memory device), such as a random-access memory (RAM), a flash memory, a read-only memory (ROM), an erasable programmable read-only memory (EPROM), an electrically erasable programmable read-only memory (EEPROM), a register, a hard disk, a removable disk, a compact disc read-only memory (CD-ROM), any other form of storage medium, the like, or a combination thereof. An example storage medium (e.g., a memory device) can be coupled to the processor so the processor can read information from the storage medium, write information to the storage medium, or both. In an example, the storage medium can be integral with the processor.

Further, examples provided hereby are described in terms of sequences of actions to be performed by, for example, one or more elements of a computing device. The actions described hereby can be performed by a specific circuit (e.g., an application specific integrated circuit (ASIC)), by instructions being executed by one or more processors, or by a combination of both. Additionally, a sequence of actions described hereby can be entirely within any form of non-transitory computer-readable storage medium having stored thereby a corresponding set of computer instructions which, upon execution, cause an associated processor (such as a special-purpose processor) to perform at least a portion of a function described hereby. Additionally, a sequence of actions described hereby can be entirely within any form of non-transitory computer-readable storage medium having stored thereby a corresponding set of instructions which, upon execution, configure the processor to create specific logic circuits. Thus, examples may be in a number of different forms, all of which have been contemplated to be within the scope of the disclosure. In addition, for each of the examples described hereby, a corresponding electrical circuit of any such examples may be described hereby as, for example, “a logic circuit configured to” perform a described action.

In an example, when a general-purpose computer (e.g., a processor) is configured to perform at least a portion of a method described hereby, then the general-purpose computer becomes a special-purpose computer which is not generic and is not a general-purpose computer. In an example, loading a general-purpose computer with special programming can cause the general-purpose computer to be configured to perform at least a portion of a method described hereby. In an example, a combination of two or more related method steps disclosed hereby forms a sufficient algorithm. In an example, a sufficient algorithm constitutes special programming. In an example, special programming constitutes any software which can cause a computer (e.g., a general-purpose computer, a special-purpose computer, etc.) to be configured to perform one or more functions, features, steps algorithms, blocks, or a combination thereof, as disclosed hereby.

At least one example provided hereby can include a non-transitory (i.e., a non-transient) machine-readable medium and/or a non-transitory (i.e., a non-transient) computer-readable medium storing processor-executable instructions configured to cause a processor (e.g., a special-purpose processor) to transform the processor and any other cooperating devices into a machine (e.g., a special-purpose processor) configured to perform at least a part of a function described hereby, at least a part of a method described hereby, the like, or a combination thereof. Performing at least a part of a function described hereby can include initiating at least a part of a function described hereby, at least a part of a method described hereby, the like, or a combination thereof. In an example, execution of the stored instructions can transform a processor and any other cooperating devices into at least a part of an apparatus described hereby. A non-transitory (i.e., a non-transient) machine-readable medium specifically excludes a transitory propagating signal. Further, one or more examples can include a computer-readable medium embodying at least a part of a function described hereby, at least a part of a method described hereby, the like, or a combination thereof.

Nothing stated or depicted in this application is intended to dedicate any component, step, block, element, feature, object, benefit, advantage, or equivalent to the public, regardless of whether the component, step, block, element, feature, object, benefit, advantage, or the equivalent is recited in the claims. While this disclosure describes examples, changes and modifications can be made to the examples disclosed hereby without departing from the scope defined by the appended claims. A feature from any of the provided examples can be used in combination with one another feature from any of the provided examples in accordance with the general principles described hereby. The present disclosure is not intended to be limited to the specifically disclosed examples alone.

Claims

1. An apparatus for automatically controlling parameters of drilling fluid, comprising;

a choke valve having a choke valve position;

an inflow flowmeter configured to generate information indicating a measured inflow rate of the drilling fluid flowing into a wellbore;

an outflow flowmeter configured to generate information indicating a measured outflow rate of the drilling fluid flowing out of the wellbore, wherein the outflow flowmeter is located downstream from the choke valve; and

a drilling fluid flow controller having a memory device storing instructions configured to cause the drilling fluid flow controller to automatically: receive the information indicating the measured inflow rate; receive the information indicating the measured outflow rate; calculate a differential flowrate between the measured inflow rate and the measured outflow rate; calculate a proportional gain from the differential flowrate and a first setpoint; calculate an integral gain from the differential flowrate and the first setpoint; and calculate a choke control output by summing the proportional gain with the integral gain,

wherein the choke valve is configured to adjust, responsive to the choke control output, the choke valve position to control the measured outflow rate of the drilling fluid.

2. The apparatus of claim 1, wherein the outflow flowmeter comprises a V-shaped flowmeter orifice.

3. The apparatus of claim 1, wherein the memory further stores instructions configured to cause the drilling fluid flow controller to receive, from a user interface device, information describing the first setpoint.

4. The apparatus of claim 1, further comprising:

a hydraulic actuator configured to adjust the choke valve position of the choke valve;

a hydraulic accumulator storing pressurized hydraulic fluid; and

an electrically operated valve configured to: receive the choke control output from the drilling fluid flow controller; and control, responsive to the received choke control output, a flowrate of the hydraulic fluid from the hydraulic accumulator to the hydraulic actuator.

5. The apparatus of claim 1, wherein the memory further stores instructions configured to cause the drilling fluid flow controller to automatically:

compare the differential flowrate to a second setpoint, wherein the second setpoint describes a maximum allowed differential flowrate; and

modify, when the differential flowrate is equal to or greater than the second setpoint, the choke control output to adjust the choke valve position to reduce the differential flowrate.

6. The apparatus of claim 5, wherein the memory further stores instructions configured to cause the drilling fluid flow controller to receive, from a user interface device, information describing the second setpoint.

7. The apparatus of claim 1, wherein the drilling fluid flow controller comprises at least one of a field programmable gate array, a programmable logic device, an application-specific integrated circuit, a non-generic special-purpose processor, a gated logic device, or a dedicated hardware finite state machine.

8. The apparatus of claim 1, wherein the memory further stores instructions configured to cause the drilling fluid flow controller to automatically:

convert the information indicating the measured outflow rate of the drilling fluid flowing out of the wellbore to a human-readable form; and

display the human-readable form of the information indicating the measured outflow rate of the drilling fluid flowing out of the wellbore on a user interface device.

9. A method for automatically controlling parameters of drilling fluid, comprising;

receiving, by a drilling fluid flow controller, information indicating a measured inflow rate of the drilling fluid flowing into a wellbore;

receiving, by the drilling fluid flow controller, information indicating a measured outflow rate of the drilling fluid flowing out of the wellbore and through an outflow flowmeter located downstream from a choke valve;

automatically calculating, by the drilling fluid flow controller, a differential flowrate between the measured inflow rate and the measured outflow rate;

automatically calculating, by the drilling fluid flow controller, a proportional gain from the differential flowrate and a first setpoint;

automatically calculating, by the drilling fluid flow controller, an integral gain from the differential flowrate and the first setpoint;

automatically calculating, by the drilling fluid flow controller, a choke control output by summing the proportional gain with the integral gain; and

automatically moving, responsive to the choke control output, a position of the choke valve.

10. The method of claim 9, wherein the outflow flowmeter comprises a V-shaped flowmeter orifice.

11. The method of claim 9, further comprising receiving, by the drilling fluid flow controller and from a user interface device, information describing the first setpoint.

12. The method of claim 9, further comprising:

automatically comparing, by the drilling fluid flow controller, the differential flowrate to a second setpoint, wherein the second setpoint describes a maximum allowed differential flowrate; and

automatically modifying, by the drilling fluid flow controller and when the differential flowrate is equal to or greater than the second setpoint, the choke control output to adjust the choke valve position to reduce the differential flowrate.

13. The method of claim 12, further comprising receiving, by the drilling fluid flow controller and from a user interface device, information describing the second setpoint.

14. The method of claim 9, further comprising:

automatically converting the information indicating the measured outflow rate of the drilling fluid flowing out of the wellbore to a human-readable form; and

automatically displaying the human-readable form of the information indicating the measured outflow rate of the drilling fluid flowing out of the wellbore on a user interface device.

15. A non-transitory computer-readable medium, comprising processor-executable instructions stored thereon configured to cause a processor to:

initiate receiving information indicating a measured inflow rate of drilling fluid flowing into a wellbore;

initiate receiving information indicating a measured outflow rate of the drilling fluid flowing out of the wellbore and through an outflow flowmeter located downstream from a choke valve;

initiate calculating a differential flowrate between the measured inflow rate and the measured outflow rate;

initiate calculating a proportional gain from the differential flowrate and a first setpoint;

initiate calculating an integral gain from the differential flowrate and the first setpoint; and

initiate calculating a choke control output by summing the proportional gain with the integral gain.

16. The non-transitory computer-readable medium of claim 15, further storing instructions configured to cause the processor to initiate receiving, by the processor and from a user interface device, information describing the first setpoint.

17. The non-transitory computer-readable medium of claim 15, further storing instructions configured to cause the processor to:

initiate automatically comparing, by the processor, the differential flowrate to a second setpoint, wherein the second setpoint describes a maximum allowed differential flowrate; and

initiate automatically modifying, by the processor and when the differential flowrate is equal to or greater than the second setpoint, the choke control output to adjust the choke valve position to reduce the differential flowrate.

18. The non-transitory computer-readable medium of claim 17, further storing instructions configured to cause the processor to initiate receiving, by the processor and from a user interface device, information describing the second setpoint.

19. The non-transitory computer-readable medium of claim 15, wherein the processor is a drilling fluid flow controller.

20. The non-transitory computer-readable medium of claim 15, further storing instructions configured to cause the processor to:

initiate automatically converting the information indicating the measured outflow rate of the drilling fluid flowing out of the wellbore to a human-readable form; and

initiate automatically displaying the human-readable form of the information indicating the measured outflow rate of the drilling fluid flowing out of the wellbore on a user interface device.