Control of hydraulic power flowrate for managed pressure drilling

• US 10,107,052 B2
• Filed: 02/05/2016
• Issued: 10/23/2018
• Est. Priority Date: 02/05/2016
• Status: Active Grant

• Current Assignee: Weatherford Technology Holdings, LLC (Weatherford International PLC)
• Original Assignee: Weatherford Technology Holdings, LLC (Weatherford International PLC)
• Inventors: Northam, Paul R., Dillard, Walter S.
• Primary Examiner(s): Harcourt, Brad
• Application Number:
  US15/017,418
• Publication Number:
  US 20170226813A1
• Time in Patent Office: 991 Days
• CPC Class Codes: E21B 21/08 Controlling or monitoring pressure or flow of drilling fluid, e.g. automatic filling of boreholes, automatic control of bottom pressure valve arrangements therefor E21B21/10
• CPC Class Codes: E21B 21/106 Valve arrangements outside the borehole, e.g. kelly valves valves specifically for maintaining circulation of drilling fluid while connecting or disconnecting tubular joints E21B21/019
• CPC Class Codes: E21B 47/06 Measuring temperature or pressure

Abstract

An assembly uses a choke to control flow of wellbore fluid in a drilling system. A controller operatively coupled to the choke can control opening/closing of the choke with hydraulic power and an actuator. The control operates the opening/closing of the choke with a choke control value to control a parameter in the drilling system, such as pressure or flow. The control measure a time for the choke to at least reach a position toward a full open/closed position during a full opening/closing operation and calculates a current opening/closing speed of the choke. When this current speed is compared to a previously stored speed, the control adjusts the choke control value for the choke based on any difference.

Claims

1. A method of drilling a wellbore with a drilling system having at least one choke, the method comprising:

controlling a parameter in the drilling system using the at least one choke by operating the at least one choke with at least one choke control value;

storing an opening speed of the at least one choke; and

maintaining an opening response of the at least one choke consistent over time during operation by at least periodically performing the steps comprising;

measuring a first time for the at least one choke to at least reach a first position during an opening operation;

calculating a current opening speed of the at least one choke based on the measured first time to at least reach the first position; and

adjusting the at least one choke control value for the at least one choke based on the current opening speed differing from the stored opening speed.

2. The method of claim 1, wherein the method further comprises:

storing a closing speed of the at least one choke; and

maintaining a closing response of the at least one choke consistent over time operation by at least periodically performing the steps comprising;

measuring a second time for the at least one choke to at least reach a second position during a closing operation;

calculating a current closing speed of the at least one choke based on the measured second time to at least reach the second position; and

adjusting the at least one choke control value for the at least one choke based on the current closing speed differing from the stored closing speed.

4. The method of claim 1, further comprising updating the stored opening speed with the current opening speed.

5. The method of claim 1, wherein measuring the first time for the at least one choke to at least reach the first position during the opening operation comprises initiating the opening operation of the at least one choke toward a full open position.

6. The method of claim 5, wherein initiating the opening operation comprises receiving a manual or an automatic initiation of the opening operation toward the full open position.

7. The method of claim 5, wherein initiating the opening operation comprises holding a valve in a first state feeding hydraulic fluid to an actuator of the at least one choke.

8. The method of claim 1, wherein measuring the first time for the at least one choke to at least reach the first position comprises measuring the first time for the at least one choke to reach the first position of approximately 95 percent open.

9. The method of claim 1, wherein calculating the current opening speed of the at least one choke based on the measured first time to at least reach the first position comprises:

determining travel of the at least one choke from a current position to the first position; and

dividing the determined travel by the first time for the current opening speed.

10. The method of claim 1, wherein adjusting the at least one choke control value for the at least one choke based on the current opening speed differing from the stored opening speed comprises determining that the current opening speed differs from the stored opening speed at least by a threshold.

11. The method of claim 1, wherein adjusting the at least one choke control value for the at least one choke based on the current opening speed differing from the stored opening speed comprises adjusting the at least one choke control value of a proportional-integral-derivative control for the at least one choke.

12. The method of claim 1, wherein the at least one choke comprises first and second chokes operable in simultaneous operation to control the parameter in the drilling system;

and wherein operating the at least one choke with at least one choke control value comprises operating the first and second chokes with a same choke control or with separate choke controls.

13. The method of claim 1, wherein adjusting the at least one choke control value for the at least one choke based on the current opening speed differing from the stored opening speed comprises adjusting, for the at least one choke, at least one of a gain of a proportional-integral-derivative control, a set point, a pressure dead-band, a flow differential dead-band, and a time duration before reaction.

3. The method 1, wherein controlling the parameter in the drilling system using the at least one choke comprises at least one of:

controlling surface back pressure in the wellbore;

controlling flow rate of drilling fluid out of the wellbore;

controlling pressure during a drillpipe connection while drilling with the drilling system;

controlling pressure during a loss detected while drilling with the drilling system; and

controlling flow during a kick detected while drilling with the drilling system.

14. A method of drilling a wellbore with a drilling system having at least one choke, the method comprising:

controlling a parameter in the drilling system using the at least one choke by operating the at least one choke with at least one choke control value;

storing a closing speed of the at least one choke; and

maintaining a closing response of the at least one choke consistent over time during operation by at least periodically performing the steps comprising;

measuring a time for the at least one choke to at least reach a first position during a closing operation;

calculating a current closing speed of the at least one choke based on the measured time to at least reach the first position; and

adjusting the at least one choke control value for the at least one choke based on the current closing speed differing from the stored closing speed.

15. The method of claim 14, wherein measuring the time for the at least one choke to at least reach the first position during the closing operation comprises initiating the closing operation of the at least one choke toward a full closed position.

16. The method of claim 14, wherein measuring the time for the at least one choke to at least reach the first position comprises measuring the time for the at least one choke to reach the first position of approximately 95 percent open.

17. The method of claim 14, wherein calculating the current closing speed of the at least one choke based on the measured time to at least reach the first position comprises:

determining travel of the at least one choke from a current position to the first position; and

dividing the determined travel by the first time for the current closing speed.

18. The method of claim 14, wherein adjusting the at least one choke control value for the at least one choke based on the current closing speed differing from the stored closing speed comprises determining that the current closing speed differs from the stored closing speed at least by a threshold.

19. The method of claim 14, wherein adjusting the at least one choke control value for the at least one choke based on the current closing speed differing from the stored closing speed comprises adjusting the at least one choke control value of a proportional-integral-derivative control for the at least one choke.

20. An assembly used with a drilling system for drilling a wellbore, the assembly comprising:

at least one choke operable to control a parameter in the drilling system;

at least one actuator disposed with the at least one choke and actuating operation of the at least one choke in response to supplied power; and

a controller operatively coupled to the at least one actuator, the controller controlling the supplied power to the at least one actuator and controlling opening and/or closing of the at least one choke therewith, the controller configured to;

operate opening and/or closing of the at least one choke with at least one choke control value to control the parameter in the drilling system;

store an opening and/or closing speed of the at least one choke;

at least periodically perform a calibration to maintain an opening or closing response of the at least one choke consistent over time during operation, the controller in the calibration configured to;

measure a time for the at least one choke to at least reach a position during an opening and/or closing operation;

calculate a current opening/closing speed of the at least one choke based on the measured time to at least reach the position; and

adjust the at least one choke control value for the at least one choke based on the current opening and/or closing speed differing from the stored opening and/or closing speed.

21. A control of at least one choke used in a drilling system for drilling a wellbore, the control comprising:

storage storing an opening and/or closing speed of the at least one choke and storing at least one choke control value for operating the at least one choke; and

a programmable control device operatively coupled to the storage and to the at least one choke, the programmable control device being operable to;

operate opening and/or closing of the at least one choke with the at least one choke control value to control a parameter in the drilling system;

at least periodically perform a calibration to maintain an opening or closing response of the at least one choke consistent over time during operation, the programmable control device in the calibration configured to;

measure a time for the at least one choke to at least reach a position during an opening/closing operation;

calculate a current opening and/or closing speed of the at least one choke based on the measured time to at least reach the position; and

adjust the at least one choke control value for the at least one choke based on the current opening and/or closing speed differing from the stored opening and/or closing speed.