System for controlling the operating pressures within a subterranean borehole

• US 6,575,244 B2
• Filed: 07/31/2001
• Issued: 06/10/2003
• Est. Priority Date: 07/31/2001
• Status: Expired due to Term

• Current Assignee: M-I LLC (SLB), Voith Sulzer Papiermaschinen GmbH (Voith GmbH & Co. KGaA)
• Original Assignee: M-I LLC (SLB)
• Inventors: Chang, Lingo, Suter, Roger, Burkhard, Alan
• Primary Examiner(s): Bagnell, David
• Assistant Examiner(s): BOMAR, THOMAS S
• Application Number:
  US09/918,929
• Publication Number:
  US 20030024737A1
• Time in Patent Office: 679 Days
• Field of Search: 175/25, 175/48, 166/250.01, 166/250.07, 166/250.15, 166/370, 166/373, 166/374, 166/66, 731/525.1, 731/522.2, 731/524.6, 703/9, 703/10
• US Class Current: 166/250.15
• 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

Abstract

A borehole includes a tubular member, a sealing member for sealing an annulus between the tubular member and the borehole, a pump for pumping fluidic materials into the tubular member, and an automatic choke for controllably releasing pressurized fluidic materials out of the annulus. A system and method monitor the operating pressure within the tubular member and compare the actual operating pressure with a desired operating pressure. The difference between the actual and desired operating pressure is then processed to control the operation of the automatic choke to thereby controllably bleed pressurized fluidic materials out of the annulus thereby creating back pressure within the borehole.

Claims

1. A method of controlling one or more operating pressures within a subterranean borehole that includes a tubular member positioned within the borehole that defines an annulus between the tubular member and the borehole, a sealing member for sealing the annulus between the tubular member and the borehole, a pump for pumping fluidic materials into the tubular member, and an automatic choke for controllably releasing fluidic materials out of the annulus between the tubular member and the borehole, comprising:

sensing an operating pressure within the tubular member and generating an actual tubular member pressure signal representative of the actual operating pressure within the tubular member;

comparing the actual tubular member pressure signal with a target tubular member pressure signal representative of a target operating pressure within the tubular member and generating an error signal representative of the difference between the actual tubular member pressure signal and the target tubular member pressure signal; and

processing the error signal to generate a set point pressure signal for controlling the operation of the automatic choke, wherein processing the error signal comprises;

multiplying the error signal by a gain K_p;

integrating the error signal and multiplying the integral of the error signal by a gain K_i; and

differentiating the error signal and multiplying the differential of the error signal by a gain K_d.

2. A method of controlling one or more operating pressures within a subterranean borehole that includes a tubular member positioned within the borehole that defines an annulus between the tubular member and the borehole, a sealing member for sealing the annulus between the tubular member and the borehole, a pump for pumping fluidic materials into the tubular member, and an automatic choke for controllably releasing fluidic materials out of the annulus between the tubular member and the borehole, comprising:

sensing an operating pressure within the tubular member and generating an actual tubular member pressure signal representative of the actual operating pressure within the tubular member;

comparing the actual tubular member pressure signal with a target tubular member pressure signal representative of a target operating pressure within the tubular member and generating an error signal representative of the difference between the actual tubular member pressure signal and the target tubular member pressure signal; and

processing the error signal to generate a set point pressure signal for controlling the operation of the automatic choke, wherein the processing comprises compensating for a time lag.

3. The method of claim 2, wherein the time lag comprises:

a pressure transient time lag.

4. The method of claim 2, wherein the time lag comprises:

a time lag between a generation of the target tubular member pressure signal and a corresponding operation of the automatic choke.

5. A method of controlling one or more operating pressures within a subterranean borehole that includes a tubular member positioned within the borehole that defines an annulus between the tubular member and the borehole, a sealing member for sealing the annulus between the tubular member and the borehole, a pump for pumping fluidic materials into the tubular member, and an automatic choke for controllably releasing fluidic materials out of the annulus between the tubular member and the borehole, comprising:

sensing an operating pressure within the tubular member and generating an actual tubular member pressure signal representative of the actual operating pressure within the tubular member;

comparing the actual tubular member pressure signal with a target tubular member pressure signal representative of a target operating pressure within the tubular member and generating an error signal representative of the difference between the actual tubular member pressure signal and the target tubular member pressure signal; and

processing the error signal to generate a set point pressure signal for controlling the operation of the automatic choke, wherein the processing comprises anticipating changes in the target tubular member pressure signal.

6. A method of controlling one or more operating pressures within a subterranean borehole that includes a tubular member positioned within the borehole that defines an annulus between the tubular member and the borehole, a sealing member for sealing the annulus between the tubular member and the borehole, a pump for pumping fluidic materials into the tubular member, and an automatic choke for controllably releasing fluidic materials out of the annulus between the tubular member and the borehole, comprising:

sensing an operating pressure within the tubular member and generating an actual tubular member pressure signal representative of the actual operating pressure within the tubular member;

comparing the actual tubular member pressure signal with a target tubular member pressure signal representative of a target operating pressure within the tubular member and generating an error signal representative of the difference between the actual tubular member pressure signal and the target tubular member pressure signal; and

processing the error signal to generate a set point pressure signal for controlling the operation of the automatic choke, wherein the processing comprises anticipating perturbations in the borehole.

7. A method of controlling one or more operating pressures within a subterranean borehole that includes a tubular member positioned within the borehole that defines an annulus between the tubular member and the borehole, a sealing member for sealing the annulus between the tubular member and the borehole, a pump for pumping fluidic materials into the tubular member, and an automatic choke for controllably releasing fluidic materials out of the annulus between the tubular member and the borehole, comprising:

sensing an operating pressure within the tubular member and generating an actual tubular member pressure signal representative of the actual operating pressure within the tubular member;

comparing the actual tubular member pressure signal with a target tubular member pressure signal representative of a target operating pressure within the tubular member and generating an error signal representative of the difference between the actual tubular member pressure signal and the target tubular member pressure signal;

processing the error signal to generate a set point pressure signal for controlling the operation of the automatic choke;

determining a transient response of one or more operating parameters within the borehole;

modeling the transfer function of the borehole as a function of the determined transient response; and

modifying the processing of the error signal as a function of the modeled transfer function of the borehole.

8. The method of claim 7, wherein the operating parameters comprise:

the actual operating pressure within the tubular member.

9. The method of claim 7, wherein the operating parameters comprise:

an actual operating pressure within the annulus between the tubular member and the borehole.

10. The method of claim 7, wherein the operating parameters comprise:

a pressure transient time.

11. The method of claim 7, further comprising:

determining an actual operating pressure within the bottom of the borehole;

comparing the operating pressure within the bottom of the borehole with a theoretical value of the operating pressure within the borehole generated by the modeled transfer function of the borehole; and

modifying the processing of the error signal as a function of the comparison.

12. The method of claim 11, further comprising:

determining if the actual operating pressure within the bottom of the borehole and the theoretical operating pressure within the bottom of the borehole are converging; and

modifying the processing of the error signal as a function of the convergence.

13. The method of claim 11, further comprising:

determining if the actual operating pressure within the bottom of the borehole and the theoretical operating pressure within the bottom of the borehole are diverging; and

modifying the processing of the error signal as a function of the divergence.

14. The method of claim 11, further comprising:

determining if there is a steady state offset between the actual operating pressure within the bottom of the borehole and the theoretical operating pressure; and

modifying the processing of the error signal as a function of the steady state offset.

15. A system for controlling one or more operating pressures within a subterranean borehole that includes a tubular member positioned within the borehole that defines an annulus between the tubular member and the borehole, a sealing member for sealing the annulus between the tubular member and the borehole, a pump for pumping fluidic materials into the tubular member, and an automatic choke for controllably releasing fluidic materials out of the annulus between the tubular member and the borehole, comprising:

means for sensing an operating pressure within the tubular member and generating an actual tubular member pressure signal representative of the actual operating pressure within the tubular member;

means for comparing the actual tubular member pressure signal with a target tubular member pressure signal representative of a target operating pressure within the tubular member and generating an error signal representative of the difference between the actual tubular member pressure signal and the target tubular member pressure signal; and

means for processing the error signal to generate a set point pressure signal for controlling the operation of the automatic choke, wherein the means for processing the error signal comprises;

means for multiplying the error signal by a gain K_p;

means for integrating the error signal and multiplying the integral of the error signal by a gain K_i; and

means for differentiating the error signal and multiplying the differential of the error signal by a gain K_d.

16. A system for controlling one or more operating pressures within a subterranean borehole that includes a tubular member positioned within the borehole that defines an annulus between the tubular member and the borehole, a sealing member for sealing the annulus between the tubular member and the borehole, a pump for pumping fluidic materials into the tubular member, and an automatic choke for controllably releasing fluidic materials out of the annulus between the tubular member and the borehole, comprising:

means for sensing an operating pressure within the tubular member and generating an actual tubular member pressure signal representative of the actual operating pressure within the tubular member;

means for comparing the actual tubular member pressure signal with a target tubular member pressure signal representative of a target operating pressure within the tubular member and generating an error signal representative of the difference between the actual tubular member pressure signal and the target tubular member pressure signal; and

means for processing the error signal to generate a set point pressure signal for controlling the operation of the automatic choke, wherein the means for processing the error signal comprises means for compensating for a time lag.

17. The system of claim 16, wherein the time lag comprises:

a pressure transient time lag.

18. The system of claim 16, wherein the time lag comprises:

a time lag between a generation of the target tubular member pressure signal and a corresponding operation of the automatic choke.

19. A system for controlling one or more operating pressures within a subterranean borehole that includes a tubular member positioned within the borehole that defines an annulus between the tubular member and the borehole, a sealing member for sealing the annulus between the tubular member and the borehole, a pump for pumping fluidic materials into the tubular member, and an automatic choke for controllably releasing fluidic materials out of the annulus between the tubular member and the borehole, comprising:

means for sensing an operating pressure within the tubular member and generating an actual tubular member pressure signal representative of the actual operating pressure within the tubular member;

means for comparing the actual tubular member pressure signal with a target tubular member pressure signal representative of a target operating pressure within the tubular member and generating an error signal representative of the difference between the actual tubular member pressure signal and the target tubular member pressure signal; and

means for processing the error signal to generate a set point pressure signal for controlling the operation of the automatic choke, wherein the means for processing the error signal comprises means for anticipating changes in the target tubular member pressure signal.

20. A system for controlling one or more operating pressures within a subterranean borehole that includes a tubular member positioned within the borehole that defines an annulus between the tubular member and the borehole, a sealing member for sealing the annulus between the tubular member and the borehole, a pump for pumping fluidic materials into the tubular member, and an automatic choke for controllably releasing fluidic materials out of the annulus between the tubular member and the borehole, comprising:

means for sensing an operating pressure within the tubular member and generating an actual tubular member pressure signal representative of the actual operating pressure within the tubular member;

means for comparing the actual tubular member pressure signal with a target tubular member pressure signal representative of a target operating pressure within the tubular member and generating an error signal representative of the difference between the actual tubular member pressure signal and the target tubular member pressure signal; and

means for processing the error signal to generate a set point pressure signal for controlling the operation of the automatic choke, wherein the means for processing the error signal comprises means for anticipating perturbations in the borehole.

21. A system for controlling one or more operating pressures within a subterranean borehole that includes a tubular member positioned within the borehole that defines an annulus between the tubular member and the borehole, a sealing member for sealing the annulus between the tubular member and the borehole, a pump for pumping fluidic materials into the tubular member, and an automatic choke for controllably releasing fluidic materials out of the annulus between the tubular member and the borehole, comprising:

means for sensing an operating pressure within the tubular member and generating an actual tubular member pressure signal representative of the actual operating pressure within the tubular member;

means for comparing the actual tubular member pressure signal with a target tubular member pressure signal representative of a target operating pressure within the tubular member and generating an error signal representative of the difference between the actual tubular member pressure signal and the target tubular member pressure signal;

means for processing the error signal to generate a set point pressure signal for controlling the operation of the automatic choke;

means for determining a transient response of one or more operating parameters within the borehole;

means for modeling the transfer function of the borehole as a function of the determined transient response; and

means for modifying the processing of the error signal as a function of the modeled transfer function of the borehole.

22. The system of claim 21, wherein the operating parameters comprise:

the actual operating pressure within the tubular member.

23. The system of claim 21, wherein the operating parameters comprise:

an actual operating pressure within the annulus between the tubular member and the borehole.

25. The system of claim 21, further comprising:

means for determining an actual operating pressure within the bottom of the borehole;

means for comparing the operating pressure within the bottom of the borehole with a theoretical value of the operating pressure within the borehole generated by the modeled transfer function of the borehole; and

means for modifying the processing of the error signal as a function of the comparison.

26. The system of claim 25, further comprising:

means for determining if the actual operating pressure within the bottom of the borehole and the theoretical operating pressure within the bottom of the borehole are converging; and

means for modifying the processing of the error signal as a function of the convergence.

27. The system of claim 25, further comprising:

means for determining if the actual operating pressure within the bottom of the borehole and the theoretical operating pressure within the bottom of the borehole are diverging; and

means for modifying the processing of the error signal as a function of the divergence.

28. The system of claim 25, further comprising:

means for determining if there is a steady state offset between the actual operating pressure within the bottom of the borehole and the theoretical operating pressure; and

means for modifying the processing of the error signal as a function of the steady state offset.

24. The system 21, wherein the operating parameters comprise:

a pressure transient time.

29. A system for controlling one or more operating pressures within a subterranean borehole that includes a tubular member positioned within the borehole that defines an annulus between the tubular member and the borehole, a sealing member for sealing the annulus between the tubular member and the borehole, a pump for pumping fluidic materials into the tubular member, and an automatic choke for controllably releasing fluidic materials out of the annulus between the tubular member and the borehole, comprising:

a sensor for sensing an operating pressure within the tubular member and generating an actual tubular member pressure signal representative of the actual operating pressure within the tubular member;

a comparator for comparing the actual tubular member pressure signal with a target tubular member pressure signal representative of a target operating pressure within the tubular member and generating an error signal representative of the difference between the actual tubular member pressure signal and the target tubular member pressure signal; and

a processor for processing the error signal to generate a set point pressure signal for controlling the operation of the automatic choke, wherein the processor comprises;

a multiplier for multiplying the error signal by a gain K_p;

an integrator for integrating the error signal and multipliying the integral of the error signal by a gain K_i; and

a differentiator for differentiating the error signal and multiplying the differential of the error signal by a gain K_d.

30. A system for controlling one or more operating pressures within a subterranean borehole that includes a tubular member positioned within the borehole that defines an annulus between the tubular member and the borehole, a sealing member for sealing the annulus between the tubular member and the borehole, a pump for pumping fluidic materials into the tubular member, and an automatic choke for controllably releasing fluidic materials out of the annulus between the tubular member and the borehole, comprising:

a sensor br sensing an operating pressure within the tubular member and generating an actual tubular member pressure signal representative of the actual operating pressure within the tubular member;

a comparator for comparing the actual tubular member pressure signal with a target tubular member pressure signal representative of a target operating pressure within the tubular member and generating an error signal representative of the difference between the actual tubular member pressure signal and the target tubular member pressure signal; and

a processor for processing the error signal to generate a set point pressure signal for controlling the operation of the automatic choke, wherein the processor comprises a lag compensator for compensating for a time lag.

31. The system of claim 30, wherein the time lag comprises:

a pressure transient time lag.

32. The system of claim 30, wherein the time lag comprises:

a time lag between a generation of the target tubular member pressure signal and a corresponding operation of the automatic choke.

33. A system for controlling one or more operating pressures within a subterranean borehole that includes a tubular member positioned within the borehole that defines an annulus between the tubular member and the borehole, a sealing member for sealing the annulus between the tubular member and the borehole, a pump for pumping fluidic materials into the tubular member, and an automatic choke for controllably releasing fluidic materials out of the annulus between the tubular member and the borehole, comprising:

a sensor for sensing an operating pressure within the tubular member and generating an actual tubular member pressure signal representative of the actual operating pressure within the tubular member;

a comparator for comparing the actual tubular member pressure signal with a target tubular member pressure signal representative of a target operating pressure within the tubular member and generating an error signal representative of the difference between the actual tubular member pressure signal and the target tubular member pressure signal; and

a processor for processing the error signal to generate a set point pressure signal for controlling the operation of the automatic choke, wherein the processor comprises a feedforward control for anticipating changes in the target tubular member pressure signal.

34. A system for controlling one or more operating pressures within a subterranean borehole that includes a tubular member positioned within the borehole that defines an annulus between the tubular member and the borehole, a sealing member for sealing the annulus between the tubular member and the borehole, a pump for pumping fluidic materials into the tubular member, and an automatic choke for controllably releasing fluidic materials out of the annulus between the tubular member and the borehole, comprising:

a sensor for sensing an operating pressure within the tubular member and generating an actual tubular member pressure signal representative of the actual operating pressure within the tubular member;

a comparator for comparing the actual tubular member pressure signal with a target tubular member pressure signal representative of a target operating pressure within the tubular member and generating an error signal representative of the difference between the actual tubular member pressure signal and the target tubular member pressure signal; and

a processor for processing the error signal to generate a set point pressure signal for controlling the operation of the automatic choke, wherein processor comprises a feedforward control for anticipating perturbations in the borehole.

35. A system for controlling one or more operating pressures within a subterranean borehole that includes a tubular member positioned within the borehole that defines an annulus between the tubular member and the borehole, a sealing member for sealing the annulus between the tubular member and the borehole, a pump for pumping fluidic materials into the tubular member, and an automatic choke for controllably releasing fluidic materials out of the annulus between the tubular member and the borehole, comprising:

a sensor for sensing an operating pressure within the tubular member and generating an actual tubular member pressure signal representative of the actual operating pressure within the tubular member;

a comparator for comparing the actual tubular member pressure signal with a target tubular member pressure signal representative of a target operating pressure within the tubular member and generating an error signal representative of the difference between the actual tubular member pressure signal and the target tubular member pressure signal;

a processor for processing the error signal to generate a set point pressure signal for controlling the operation of the automatic choke;

a control element for determining a transient response of one or more operating parameters within the borehole;

a control element for modeling the transfer function of the borehole as a function of the determined transient response; and

a control element for modifying the processing of the error signal by the processor as a function of the modeled transfer function of the borehole.

36. The system of claim 35, wherein the operating parameters comprise:

the actual operating pressure within the tubular member.

37. The system of claim 35, wherein the operating parameters comprise:

an actual operating pressure within the annulus between the tubular member and the borehole.

38. The system of claim 35, wherein the operating parameters comprise:

a pressure transient time.

39. The system of claim 35, further comprising:

a sensor for determining an actual operating pressure within the bottom of the borehole;

a control element for comparing the operating pressure within the bottom of the borehole with a theoretical value of the operating pressure within the borehole generated by the modeled transfer function of the borehole; and

a control element for modifying the processing of the error signal by the processor as a function of the comparison.

40. The system of claim 39, further comprising:

a control element for determining if the actual operating pressure within the bottom of the borehole and the theoretical operating pressure within the bottom of the borehole are converging; and

a control element for modifying the processing of the error signal by the processor as a function of the convergence.

41. The system of claim 39, further comprising:

a control element for determining if the actual operating pressure within the bottom of the borehole and the theoretical operating pressure within the bottom of the borehole are diverging; and

a control element for modifying the processing of the error signal by the processor as a function of the divergence.

42. The system of claim 39, further comprising:

a control element for determining if there is a steady state offset between the actual operating pressure within the bottom of the borehole and the theoretical operating pressure; and

a control element for modifying the processing of the error signal by the processor as a function of the steady state offset.

43. A method of controlling one or more operating pressures within a subterranean borehole that includes a tubular member positioned within the borehole that defines an annulus between the tubular member and the borehole, a sealing member for sealing the annulus between the tubular member and the borehole, a pump for pumping fluidic materials into the tubular member, and an automatic choke for controllably releasing fluidic materials out of the annulus between the tubular member and the borehole, comprising:

sensing an operating pressure within the tubular member and generating an actual tubular member pressure signal representative of the actual operating pressure within the tubular member;

comparing the actual tubular member pressure signal with a target tubular member pressure signal representative of a target operating pressure within the tubular member and generating an error signal representative of the difference between the actual tubular member pressure signal and the target tubular member pressure signal; and

processing the error signal to generate a hydraulic set point pressure, the set point pressure being processed by the automatic choke to control the actual pressure in the annulus, and the actual pressure in the annulus being processed to adjust the actual tubular member pressure.