Automated Well Control Method and Apparatus

• US 20120274475A1
• Filed: 12/16/2011
• Published: 11/01/2012
• Est. Priority Date: 04/26/2011
• Status: Active Grant

• Current Assignee: Hydril USA Distribution LLC (GE Aerospace)
• Original Assignee: Vetco Gray Incorporated (Baker Hughes Company)
• Inventors: Milne, Eric L., Ebenezer, Joseph P.
• Granted Patent: US 9,019,118 B2
• Time in Patent Office: Days
• US Class Current: 340/853.1
• CPC Class Codes: E21B 47/001 for underwater installation
• CPC Class Codes: E21B 47/10 Locating fluid leaks, intrusions or movements

Abstract

A drilling control system monitors and compares drilling and completion operation sensor values and autonomously acts in response to conditions such as a kick or surge. Sensors in various combinations may monitor return fluid flow rate, fluid inflow rate, wellhead bore pressure, temperature of returning fluid, torque, rate of penetration and string weight change. The control system has corresponding control logic to monitor, warn and act based on the sensor inputs. The actions may include the warning of support personnel, closing an annular blowout preventer, shearing drill pipe using a ram shear, pumping heavier fluid down choke and kill lines, disconnecting the riser or various other actions.

Claims

1. An apparatus providing for automatic detection and control of a kick during well drilling and completion operations, comprising:

a plurality of sensors adapted to be coupled to a wellhead assembly for producing current sensor values of a well undergoing operations;

a control system having a processor containing a database of known sensor values indicative of a kick event, the processor having means for receiving and the current sensor values from the sensors and comparing the current sensor values against the known sensor values; and

the control system having an automated warning component that alerts operations personnel if the comparison indicates a kick event.

2. The apparatus according to claim 1, wherein at least one of the sensors comprises:

a return flow rate sensor adapted to be coupled to a fluid return conduit of the drilling rig.

3. The apparatus according to claim 1, wherein at least one of the sensors comprises:

an upward flowing fluid temperature sensor adapted to be coupled to the wellhead assembly.

4. The apparatus according to claim 1, wherein at least one of the sensors comprises:

a wellhead bore pressure sensor adapted to be coupled to the wellhead assembly.

5. The apparatus according to claim 1, wherein at least one of the sensors comprises:

an inflow rate sensor adapted to be coupled to an input fluid conduit of the drilling rig.

6. The apparatus according to claim 1, wherein at least one of the sensors comprises:

a string weight sensor adapted to be coupled to a top drive of the drilling rig.

7. The apparatus according to claim 1, wherein at least one of the sensors comprises:

a rate of penetration sensor adapted to be coupled to a top drive of the drilling rig.

8. The apparatus according to claim 1, wherein at least one of the sensors comprises:

a torque sensor adapted to be coupled to the top drive of the drilling rig.

9. An apparatus providing for automatic detection and control of a kick during a subsea well drilling and completion operation with a rig connected to a subsea wellhead assembly via a riser and blowout preventer, the apparatus comprising:

a plurality of sensors, including a pressure sensor adapted to be coupled to the wellhead assembly and a return flow rate sensor adapted to be coupled to a fluid return conduit of the drilling rig;

a control system having a processor having a database with known ranges of wellhead pressure and return flow rates indicative of a kick event, the processor having means for receiving and comparing signal values from the pressure sensor and the return flow rate sensor against the known ranges; and

the control system is linked to the BOP to close the BOP autonomously in response to indications of a kick event.

10. The apparatus according to claim 9, wherein:

the BOP has a riser disconnect; and

the control system is linked to the riser disconnect to autonomously disconnect the riser from the BOP in response to indication of a kick.

11. The apparatus according to claim 9, wherein the sensors further comprise:

an upward flowing fluid temperature sensor adapted to be coupled to the wellhead assembly;

an inflow rate sensor adapted to be coupled to an input fluid conduit of the drilling rig; and

the control system receives a signal from the upward flowing fluid temperature sensor and the inflow rate sensor for processing.

12. The apparatus according to claim 9, wherein the sensors further comprise:

a string weight sensor adapted to be coupled to a top drive of the drilling rig;

a rate of penetration sensor adapted to be coupled to a top drive of the drilling rig;

a torque sensor adapted to be coupled to the top drive of the drilling rig; and

the control system receives a signal from the string weight sensor, the rate of penetration sensor, and the torque sensor for processing.

13. A method for providing automatic detection and control of a kick during subsea well drilling and completion operations with a rig connected to a subsea wellhead assembly via a riser and blowout preventer (BOP), comprising:

coupling sensors to the wellhead assembly and various components of the rig to indicate conditions within the well;

providing a control system with a database of known sensor values that may be indicative of a pressure kick, and linking the control system to the sensors;

with the control system, determining the existence of a kick event by comparing the known sensor values to current sensor values received from the sensors; and

automatically alerting operations personnel when a kick event is detected.

14. The method according to claim 13, further comprising:

autonomously closing the blowout preventer with the control system to control the kick.

15. The method according to claim 13, further comprising:

autonomously disconnecting the riser from the BOP with the control system.

16. The method according to claim 13, wherein:

coupling sensors to the wellhead assembly and various components of the rig comprises coupling a pressure sensor to the wellhead assembly.

17. The method according to claim 13, wherein:

coupling sensors to the wellhead assembly and various components of the drilling rig comprises coupling a return flow rate sensor to a fluid return conduit of the drilling rig.

18. The method according to claim 13, wherein:

coupling sensors to the wellhead assembly and various components of the drilling rig comprises coupling a return flow rate sensor to a fluid return conduit of the drilling rig and an inflow rate sensor to an input fluid conduit of the drilling rig.

19. The method according to claim 13, wherein:

coupling sensors to the wellhead assembly and various components of the drilling rig comprises coupling a string weight sensor, a rate of penetration sensor, and a torque sensor to a top drive of the drilling rig.

20. The method according to claim 13, wherein:

coupling sensors to the wellhead assembly and various components of the drilling rig comprises coupling a rise inclination sensor to the drilling rig.