Patent Application
20180283137
Various ground drilling operations are known, such as exploring and/or extracting oil and other natural resources from subterranean deposits. Typically, a drilling operation is conducted on a drill rig comprising a raised drilling platform or work floor located proximate the drilling location. A blowout preventer (BOP) system comprises large, specialized valves or similar mechanical devices, used to seal, control and monitor fluid and/or gas wells. A blowout preventer manages extreme erratic pressures and uncontrolled oil and/or gas flow emanating from a well reservoir during drilling, which can lead to an event known as a blowout or kick. A blowout preventer system can include an assembly of several stacked blowout preventers of varying type and function, as well as auxiliary components. A typical BOP system can include components such as electrical and hydraulic lines, control pods, hydraulic accumulators, test valves, kill and choke lines and valves, rams, valves, seals, riser joints, hydraulic connectors, and a support frame.
Features and advantages of the invention will be apparent from the detailed description which follows, taken in conjunction with the accompanying drawings, which together illustrate, by way of example, features of the invention; and, wherein:
Reference will now be made to the exemplary embodiments illustrated, and specific language will be used herein to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended.
As used herein, the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, an object that is “substantially” enclosed would mean that the object is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context. However, generally speaking the nearness of completion will be so as to have the same overall result as if absolute and total completion were obtained. The use of “substantially” is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result.
As used herein, “adjacent” refers to the proximity of two structures or elements. Particularly, elements that are identified as being “adjacent” may be either abutting or connected. Such elements may also be near or close to each other without necessarily contacting each other. The exact degree of proximity may in some cases depend on the specific context.
An initial overview of technology embodiments is provided below and then specific technology embodiments are described in further detail later. This initial summary is intended to aid readers in understanding the technology more quickly, but is not intended to identify key features or essential features of the technology, nor is it intended to limit the scope of the claimed subject matter.
The present technology is directed to a drilling system of a drilling rig for facilitating extraction of subterranean natural resources, the drilling system comprising a blow-out preventer arranged to close a borehole and divert a fluid (e.g., oil and/or gas); a first choke valve in selective fluid communication with the blow-out preventer; a first electric choke actuator communicatively coupled to a first variable control device, the first electric choke actuator being operable to regulate fluid flow diverted by the blow-out preventer through the first choke valve and to a surface fluid reservoir; a motor control center communicatively coupled to the first variable control device the first electric choke actuator operable to receive and transmit rig data, wherein the rig data includes position data associated with a position of the first electric choke actuator, and rig control data associated with at least one well-control parameter; and a user interface device communicatively coupled to the motor control center, and configured to display information pertaining to the rig data, wherein the user interface device is operable to transmit choke control commands to the motor control center for operational control of the first electric choke actuator.
The present technology if further directed to a drilling rig for extracting subterranean natural resources, comprising a drill rig control system for controlling operations of a drilling rig, the drill rig control system comprising a user interface device; and a choke system comprising: a choke valve associated with a blow-out preventer of the drilling rig system; an electric choke actuator that controls the choke valve; and a variable control device for actuating the electric choke actuator, the choke system being integrated with the drill rig control system to facilitate common control of the drill rig control system and the choke system from the user interface device.
The present technology is still further directed to a choke system, comprising a choke valve; an electric choke actuator for controlling the choke valve to regulate fluid flow of subterranean natural resources; and a variable control device in communication with the electric choke actuator and comprising: a motor control center interface operable to communicatively couple the variable control device to a motor control center of a drill rig control system for integrating the choke system with the drill rig control system, wherein the electric choke actuator is controllable via the motor control center and the variable control device.
The present technology is also directed to a method for controlling an electric choke system and a drilling rig control system of a drill rig, the method comprising generating rig data associated with a drilling rig; sending the rig data from a motor control center to a user interface device, wherein the rig data includes position data associated with a position of an electric choke actuator of a choke system, and rig control data associated with at least one well-control parameter of the drilling rig control system; displaying information on a user interface device pertaining to the rig data; and transmitting a choke control command from the user interface device to the motor control center that transmits the choke control command(s) to a variable control device for operational control of the electric choke actuator to regulate fluid flow through a choke valve.
The present technology is also directed to a method for facilitating control of an electric choke system on a drill rig, the method comprising identifying a choke system on a drill rig, the choke system comprising a first choke valve and a first electric choke actuator associated with the choke valve; connecting a variable control device to the first electric choke actuator; connecting, via a motor control center interface of the choke system, the variable control device to a motor control center of a drill rig control system of a drill rig for integrating the choke system with the drill rig control system, wherein the first electric choke actuator and the first choke valve are controllable via the motor control center and the drill rig control system through a user interface device; and facilitating transmission of a first choke control command from the user interface device to the motor control center that transmits the first choke control command to the variable control device to control the position of the first choke valve via the first electric choke actuator.
The present technology is also directed to a method for controlling an electric choke system on a drill rig via a drilling rig control system, the method comprising monitoring, via a user interface device, a first choke valve position of an electric choke system and at least one well-control parameter of a drilling rig control system of a drilling rig; closing a blow-out preventer of the drilling rig to close a borehole from atmosphere and to divert fluid to the first choke valve; and modifying the position of the first choke valve via the user interface device to regulate fluid flow through the first choke valve.
To further describe the present technology, examples are now provided with reference to the figures.
In one example of the present disclosure, fluid and/or gas can be diverted by the BOP 102 (when closed) to a choke manifold 107 in a typical manner. The choke manifold 107 is configured to divert fluid to a first choke valve 106a via a first choke line 108a, and to a second choke valve 106b via a second choke line 108b (one or more choke valves may be used). A first electric choke actuator 110a can be operably coupled to the first choke valve 106a to control the position of the first choke valve 106a to regulate fluid flow (diverted by the BOP 102) through the first choke valve 106a to a surface fluid reservoir 112. Likewise, a second electric choke actuator 110b can be operably coupled to the second choke valve 106b to control and actuate the second choke valve 106b to regulate fluid flow (diverted by the BOP 102) through the second choke valve 106b to the surface fluid reservoir 112. Each of these choke actuators 110a and 110b, and associated choke valves 106a and 106b, can be individually and selectively controlled and activated (e.g., one choke actuator and choke valve can be operated independent of and while the other choke actuator and choke valve are caused to be inactive). Although not described here in detail, those skilled in the art will recognize that a variety of pipes, valves, and other mechanisms may existed between the reservoir 112 and the choke valves 106a and 106b, such as in a typical choke/kill manifold arrangement. The first choke valve 106a and the electric choke actuator 110a are commonly (and collectively) referred to as a “choke”, which can comprise commercially available chokes, such as a “CAM30-DC multi-trim drilling choke” sold by Cameron corporation.
In one example, both first and second electric choke actuators 110a and 110b can be controlled from a drilling operator cabin 114 that structurally supports a variety of control components. For instance, first and second variable control devices 116a and 116b can be supported in the drilling operator cabin 114 and can each be communicatively coupled to respective first and second electric choke actuators 110a and 110b via wired or wireless connectivity (e.g., via Ethernet cables, wireless network components for signal transmission, etc.). The first and second variable control devices 116a and 116b can comprise variable frequency drives (VFDs) that are commercially available, such as any number of VFDs sold in the industry (e.g., ABB branded VFDs). Each variable control device 116a and 116b can be communicatively coupled to a motor control center 118 (MCC) supported in the drilling operator cabin 114, for example. The MCC 118 can comprise any suitable computing device, such as the computing device 202 as described in related U.S. patent application Ser. No. ______ filed ______ (Attorney Docket No. 3749-008), which is incorporated by reference herein in its entirety. Various MCCs are commercially available for use on drilling rigs, such as those sold by Solids Control System corporation, or Seimens corporation. Thus, the variable control devices 116a and 116b can be coupled to respective choke actuators 110a and 110b via typical power and signal wiring, as noted on
The MCC 118 can comprise a robust set of drives, networks, servers, breakers, switches, and other electrical and mechanical components that may be used for a variety of purposes as pertaining to a drilling rig, such as for controlling site well rig, chokes, motors, mud pumps, mud circulation areas, oil tank areas, boiler rooms, logging power, blowout preventer and hydraulic station, and well site lighting and living power. Such components, systems, etc. supported by an MCC are known in the industry and are not discussed in detail herein. The MCC 118 can comprise a central processing unit (CPU) 120 having a processor, memory, drilling rig information modules, remote choke control modules, choke position control modules, etc., such as described in the above-incorporated U.S. patent application Ser. No. ______.
The MCC 118 can be communicatively coupled (e.g., by Ethernet cables, or via wireless components for signal transmission) to first and second user interface devices 124a and 124b located in the drilling operator cabin 114, in one example. Each user interface device 124a and 124b can be configured to display rig data transmitted from the MCC 118 as gathered from various devices and mechanisms on the drilling rig. With the present technology, and as will be described in further detail below, the MCC 118 can receive, process, and transmit rig data that includes not only rig control data (as previously done), but now also choke position data. The choke position data can be associated with a position of the first and/or second electric choke actuators 110a and 110b. That is, the position of the electric choke actuators 110a and 110b corresponds to a position of the well choke valve. Thus, the position of the electric choke actuators 110a and 110b can be used to determine whether the well choke valve is closed or to what degree or percentage that the well choke valve is open. The rig data can be associated with at least one well-control parameter 128a-n. In some examples, the at least one well-control parameter 128a-n can comprise at least one of well pressure information, mud pump information, fluid flow rate information, mast information, casing information, return percentage information, and other drilling rig information gathered from the systems, components, mechanisms, etc. on the drilling rig. Thus, the at least one well-control parameter 128a-n can be associated with at least one well-control device 129a-n of the drilling rig, such as devices and mechanisms that assist with drilling operations, such as mud pumps, various sensors (e.g., for fluid pressure and flow, casing and motor positions, etc.), drilling motors, hydraulic pumps, drill bits, turntables, etc. The at least one well-control device 129a-n can be coupled to the MCC 118 via suitable power and signal lines.
Such rig data can be received by the MCC 118 via a plurality of sensors associated with the drilling rig (further discussed herein), and then the rig data can be sent by the MCC 118 to each of first and second user interface devices 124a and 124b (or to a single user interface device). Each user interface device 124a and 124b can be configured to display data or information pertaining to the rig data. For example, the user interface 124a can include a graphical user interface that includes a choke valve control 126a (i.e., associated with choke actuator position data) and at least one well-control parameter 128a-n (i.e., associated with rig control data).
As further shown on
Importantly, a drilling operator can monitor choke position and other drilling rig information from a common user interface device, and the operator can change the position of choke(s) from the user interface device while concurrently monitoring drilling rig information and/or controlling drilling rig functionality, systems, mechanisms, etc. Thus, the choke control system (e.g., 204 discussed below) can be fully integrated into the drilling rig control system (e.g., 202 discussed below) of the drilling rig for common control and monitoring of each respective system. Essentially, integration of the choke system with the drilling rig control system means that the choke system and well control chokes are tied into the same (industrial) data network as that used to control the various other functions, systems, etc. of the drilling rig, such as via the drilling rig control system. In contrast, as discussed above, existing systems do not have choke systems integrated with any such drilling rig systems and networks. Indeed, prior choke systems comprise entirely different, independent systems that require the operator to operate these systems and its associated equipment from an independent control system. The integrated aspect of a choke or choke control system with the drill rig control system as taught by the present disclosure can dramatically reduce the likelihood for human error because the choke system and drill rig control system are integrated and monitored/controlled from a single user interface from a drilling operator cabin, for example. Other advantages arising from such “integration” are further discussed herein.
In one example, the MCC 118 can comprise a computing system comprising at least one processor; a memory device including instructions that, when executed by the at least on processor, cause the computing system to provide position data for the first electric choke actuator (e.g., 110a) configured to control a first choke valve (e.g., 106a) in selective fluid communication with a blow-out preventer (e.g., 102) arranged to close a borehole and divert a fluid; receive a choke position command (e.g., from 126a) to move the first electric choke actuator (e.g., 110a) from a first position to a second position (as discussed above); send a control signal (e.g., via the MCC 118 and variable control device 116a) to the first electric choke actuator (e.g., 110a) that causes the electric choke actuator to move from the first position to the second position; and provide updated position data for the second position of the electric choke actuator (e.g., displayed on the user interface 124a). This is further described in above-incorporated U.S. patent application Ser. No. ______.
To integrate the choke system 204 with the drill rig control system 202, in one example, the variable control device 116a of the choke system 204 can comprise a motor control center (MCC) interface 206 that communicatively couples the variable control device 116a to the MCC 118 of the drill rig control system 202, thereby integrating the choke system 204 with the drill rig control system 202. The MCC interface 206 can comprise a cable or data port for attaching or connecting a data cable (e.g., Ethernet line) between the variable control device 116a and the MCC 118. The MCC 118 can comprise a VFD interface (not shown), such as a cable or data port for attaching the data cable that extends between the MCC 118 and the variable control device 116a. The variable control device 116a can also comprise an electric choke actuator interface 210 communicatively coupling the variable control device 116a to the electric choke actuator 110a via a data cable (e.g., Ethernet line). Thus, the MCC interface 206 communicatively couples the variable control device 116a to the user interface device 124a via the MCC 118. As a result, the user interface device 124a facilitates operator control of the variable control device 116a to actuate the electric choke actuator 110a to move the first choke valve 106a from a first position to a second position to regulate fluid flow, as further discussed above. In other words, the choke system 204, and particularly the electric choke actuator 110a and the choke valve 106a, can be controlled by the user through the same user interface device 124a that is used to control the other functions and systems of the drilling rig 202 (by way of the drill rig control system 202), the choke system 204 being controlled by the user via the MCC 118 and the variable control device 116a that is integrated into the MCC 118.
Thus, the choke system 204 is designed on an open/closed circuit concept for initiating and stopping movement of the electric chokes, where choke position is regulated by a 4-20 mA output that is calibrated and converted to a “percentage open” identifier on the user interface (124a, 124b), for instance. Specifically, each choke actuator 110a and 110b is assigned an individual IP address, which is how the MCC 118 (CPU) distinguishes between each choke actuator 110a and 110b. Control messages sent to the choke system 134 are routed to the choke system 134 using the IP addresses. The control messages instruct the choke system 134 to actuate the electric choke actuator 110a. Thus in receiving a control message at the choke system 134, a control signal is generated that results in actuating the electric choke actuator 110a (similarly with the electric choke actuator 110b). Therefore, the software and hardware of the system interact through a series of open/closed circuit signals such that movement and position of the choke valves 106a and 106b can be monitored,
In some examples, the variable control device 116a can further comprise a user interface 208 operable to facilitate control of the electric choke actuator 110a without reliance or dependency upon the drill rig control system 202. The user interface 208 can comprise independent controls/buttons for manually or otherwise controlling a position of the choke actuator 110a and choke valve 106a, and it can also display choke valve information, such as choke position. Therefore, the user interface 208 can act as a back-up or alternative or redundant user interface for the drilling operator if needed, or when desired.
In one example, the variable control device 116a can comprise a driller cabin mount 212 configured to facilitate mounting of the variable control device 116a to a structural element of a driller cabin (e.g., 114 of
Moreover, with existing systems, the operator may not be aware of the exact position of each choke valve, which can cause various undesirable fluid flow regulation issues. Unlike these prior systems, as described with the examples of the present technology disclosed herein, the drilling operator can monitor in real-time and can control the exact position of choke valves (e.g., 106a, 106b), and can simultaneously or with a simple screen or display toggle function depending upon the user interface setup, monitor and/or control at least one-well control parameter (e.g., 128a-n) all from a common user interface device (e.g., 124a, 124b, 300). As a further advantage, the drilling operator can control operation of the choke actuators (e.g., 110a, 110b) from the driller cabin and via the user interface device because the entire system is integrated (e.g., the choke system 204 integrated with the drilling control system 202 of
In one example, the MCC 118 can comprise at least one wireless transmitter/transceiver 214 for transmitting (and/or receiving) data to/from a remote computer system 216 and/or a remote well choke control 218 for controlling the choke system 204, namely the first electric choke actuator 110a (and any other choke actuator of the drilling rig). The wireless transmitter(s) 214 can be located outside of the housing of the MCC 118 yet communicatively coupled to the MCC 118 in a suitable matter. The wireless transmitter(s) 214 can be based upon and can utilize any known long-range and/or short-range wireless transmitting and/or receiving technology capable of transferring and/or receiving information using radio waves or other energy without wires, such as Bluetooth technology, RF technology, or satellite communication technology.
In one aspect, the remote well choke control 218 can comprise a wireless controller that the drilling operator can carry around a drill rig and that can be used to remotely control the choke system 204, and particularly the first electric choke actuator 110a (and any other choke actuators) via the transmitter 214 of the MCC 118. The wireless controller can comprise command buttons for changing a position of the electric choke actuators and choke valve(s), and graphical displays for showing the position of the choke actuators and/or the choke valve(s). Thus, control of the choke system 204 can be made to be interchangeable between the user interface device 124a and the remote well choke control 218. Interchangeability of the control of the choke system 204 can also be between the user interface device 124a and the user interface 208 on the variable control device 116a discussed above.
In one aspect, the remote computer system 216 can be located remotely (e.g., hundreds of miles from the actual location of the drilling rig), such as at a central command center that remotely monitors various aspects of the drilling rig or possibly multiple drilling rigs. In one example, communication between the remote computer system 216 and the transmitter 214 of the MCC 118 of the drilling rig 200 can be transmitted using satellite communication technology, Choke systems on existing or prior drilling rigs are only controllable locally from the driller rig by a driller operator, which can be a major safety issue if the operator is not available to control the choke system, is slow to control the choke system, etc., or if communication between drilling rig system operators and choke system operators breaks down or is interrupted, thereby leading to a possible catastrophic blow-out event. In the present disclosure, the remote computer system 216 can be configured to allow a remote user to remotely monitor and control the choke system 204 and its various choke actuators (e,g., 110a and 110b) from a remote location far from the drilling rig. Thus, control of the choke system 204 and the choke actuators 110a can be interchangeable between the user interface device 124a and the remote computer system 216 due to the communicatively seamless and systemic integration of the choke system 204 and the drill rig control system 202 of the drilling rig 200. In one aspect, the remote computer system 216 can override local control of the choke system 204 from the drilling rig 200, wherein the remote computer system 216 can be used to control the choke system 204 and the choke actuators 110a and 110b remotely via the MCC 118 and the variable control devices 116a and 116b via satellite communication, as discussed above.
Reference was made to the examples illustrated in the drawings and specific language was used herein to describe the same. It will nevertheless be understood that no limitation of the scope of the technology is thereby intended. Alterations and further modifications of the features illustrated herein and additional applications of the examples as illustrated herein are to be considered within the scope of the description.
Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more examples. In the preceding description, numerous specific details were provided, such as examples of various configurations to provide a thorough understanding of examples of the described technology. It will be recognized, however, that the technology may be practiced without one or more of the specific details, or with other methods, components, devices, etc. In other instances, well-known structures or operations are not shown or described in detail to avoid obscuring aspects of the technology.
Although the subject matter has been described in language specific to structural features and/or operations, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features and operations described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims. Numerous modifications and alternative arrangements may be devised without departing from the spirit and scope of the described technology.
