System, program products, and methods for controlling drilling fluid parameters
First Claim
Patent Images
1. A system for controlling drilling fluid attributes and parameters, the system comprising:
- a drilling apparatus having at least one casing string cemented within a subterranean wellbore, a combination of the wellbore and the at least one casing string having a plurality of locations of interest located at separate locations;
a drilling string run within the at least one casing string;
an annulus formed between an external surface of the drilling string and inner surface of the innermost at least one casing string;
a drilling fluid inlet;
a drilling fluid outlet;
a drilling fluid circulating through the drilling fluid inlet, down through the drilling string, up through the annulus, and out the drilling fluid outlet;
at least one monitor positioned to monitor drilling fluid parameters of the drilling fluid entering the drilling string;
at least one monitor positioned to monitor drilling fluid parameters of the drilling fluid exiting the annulus;
an output port choke in communication with the annulus and the drilling fluid outlet;
a dynamic density control computer in communication with the choke and including a processor and memory associated with the processor to store operating instructions therein;
means for measuring expansion and compressibility of drilling fluid conducting drilling assembly components associated with drilling fluid circulation and compressibility of a surrounding earth formation to formulate a description of the physical behavior of the wellbore components;
means for performing a cased hole pressure test to determine a volume associated with expansion of pressurized drilling fluid carrying components of the drilling assembly during drilling operations;
means for performing an integrity and fracture pressure test to determine integrity of the cement sealing the at least one casing string to the wellbore and fracture pressure of an associated earth formation to thereby determine a dynamic maximum pressure that can exist at a lower end of the casing string without fracturing the associated earth formation or bonding of the cement; and
dynamic density control program product stored in the memory of the dynamic density control computer and including instructions that when executed by the processor of the dynamic density control computer, cause the computer to perform the operations of;
determining separately for each of the plurality of separated locations of interest at least one drilling fluid control variable system limitation of a drilling fluid control variable,measuring a value of an operationally induced drilling fluid parameter at each of a plurality of separate locations when drilling,predicting separately for each of the plurality of separated locations of interest a value of the drilling fluid control variable responsive to each measured drilling fluid parameter value, andcontrolling a drilling fluid parameter responsive to each predicted control variable value and each associated at least one drilling fluid control variable system limitation.
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Accused Products
Abstract
Embodiments of systems, program products, and methods for controlling drilling fluid parameters are provided. These embodiments, for example, provide dynamic density control with highly adaptive, real-time, process-control and are scalable to any rig, large or small, on land or water. Combined static and dynamic stresses and displacements can be determined continuously at strategic locations in and around the wellbore of a well so that insitu and operational induced pressure window limitations at specific weak-points or other locations of interest are controlled.
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Citations
35 Claims
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1. A system for controlling drilling fluid attributes and parameters, the system comprising:
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a drilling apparatus having at least one casing string cemented within a subterranean wellbore, a combination of the wellbore and the at least one casing string having a plurality of locations of interest located at separate locations; a drilling string run within the at least one casing string; an annulus formed between an external surface of the drilling string and inner surface of the innermost at least one casing string; a drilling fluid inlet; a drilling fluid outlet; a drilling fluid circulating through the drilling fluid inlet, down through the drilling string, up through the annulus, and out the drilling fluid outlet; at least one monitor positioned to monitor drilling fluid parameters of the drilling fluid entering the drilling string; at least one monitor positioned to monitor drilling fluid parameters of the drilling fluid exiting the annulus; an output port choke in communication with the annulus and the drilling fluid outlet; a dynamic density control computer in communication with the choke and including a processor and memory associated with the processor to store operating instructions therein; means for measuring expansion and compressibility of drilling fluid conducting drilling assembly components associated with drilling fluid circulation and compressibility of a surrounding earth formation to formulate a description of the physical behavior of the wellbore components; means for performing a cased hole pressure test to determine a volume associated with expansion of pressurized drilling fluid carrying components of the drilling assembly during drilling operations; means for performing an integrity and fracture pressure test to determine integrity of the cement sealing the at least one casing string to the wellbore and fracture pressure of an associated earth formation to thereby determine a dynamic maximum pressure that can exist at a lower end of the casing string without fracturing the associated earth formation or bonding of the cement; and dynamic density control program product stored in the memory of the dynamic density control computer and including instructions that when executed by the processor of the dynamic density control computer, cause the computer to perform the operations of; determining separately for each of the plurality of separated locations of interest at least one drilling fluid control variable system limitation of a drilling fluid control variable, measuring a value of an operationally induced drilling fluid parameter at each of a plurality of separate locations when drilling, predicting separately for each of the plurality of separated locations of interest a value of the drilling fluid control variable responsive to each measured drilling fluid parameter value, and controlling a drilling fluid parameter responsive to each predicted control variable value and each associated at least one drilling fluid control variable system limitation. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A system for controlling drilling fluid attributes and parameters, the system comprising:
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a drilling as apparatus having at least one casing string cemented within a subterranean wellbore, a combination of the wellbore and the at least one casing string having a plurality of locations of interest located at separate locations; a drilling string run within the at least one casing string; an annulus formed between an external surface of the drilling string and inner surface of the innermost at least one casing string; a drilling fluid inlet; a drilling fluid outlet; a drilling fluid circulating through the drilling fluid inlet, down through the drilling string, up through the annulus, and out the drilling fluid outlet; at least one monitor positioned to monitor drilling fluid parameters of the drilling fluid entering the drilling string; at least one monitor positioned to monitor drilling fluid parameters of the drilling fluid exiting the annulus; an output port choke in communication with the annulus and the drilling fluid outlet; a pressure gauge positioned adjacent the drilling string to measure drilling fluid pressure during each test; databases containing the following data in computer readable format accessible to the dynamic density control computer to formulate a description of the physical behavior of the wellbore components; data indicating parameters of each stratae of earth formation associated with the wellbore, data indicating pore fluid quantifications within each stratae of earth formation, data indicating parameters of each casing string, data indicating parameters of each layer of cement associated with the wellbore, and data indicating parameters of the drilling fluid within the drilling string and annulus; a dynamic density control computer in communication with the choke and including a processor and memory associated with the processor to store operating instructions therein; and dynamic density control program product stored in the memory of the dynamic density control computer and including instructions that when executed by the processor of the dynamic density control computer, cause the computer to perform the operations of; determining separately for each of the plurality of separated locations of interest at least one drilling fluid control variable system limitation of a drilling fluid control variable, measuring a value of an operationally induced drilling fluid parameter at each of a plurality of separate locations when drilling, predicting a value of the drilling fluid control variable separately for each of the plurality of separated locations of interest responsive to each measured drilling fluid parameter value, controlling a drilling fluid parameter responsive to each predicted control variable value and each associated at least one drilling fluid control variable system limitation, measuring over time an increase in fluid pressure and volume of fluid pumped into the drilling apparatus, and generating at least one of the following;
a pressure verses volume curve and a pressure verses volume versus time curve,determining a maximum dynamic bottom hole pressure at future depths to be drilled responsive to at least a portion of the data in the databases and at least one of a plurality of operational simulations to thereby enhance drilling requirements management, and determining an effect of mud channels in the casing string cement responsive to at least one of the simulations. - View Dependent Claims (10)
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11. A system for controlling drilling fluid attributes and parameters, the system comprising:
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a drilling apparatus having at least one casing string cemented within a subterranean wellbore, a combination of the wellbore and the at least one casing string having a plurality of locations of interest located at separate locations; a drilling string run within the at least one casing string; an annulus formed between an external surface of the drilling string and inner surface of the innermost at least one casing string; a drilling fluid inlet; a drilling fluid outlet; a drilling fluid circulating through the drilling fluid inlet, down through the drilling string, up through the annulus, and out the drilling fluid outlet; at least one monitor positioned to monitor drilling fluid parameters of the drilling fluid entering the drilling string; at least one monitor positioned to monitor drilling fluid parameters of the drilling fluid exiting the annulus; an output port choke in communication with the annulus and the drilling fluid outlet; a test pump fluid reservoir; a test pressure pump in fluid communication with an interior conduit of the drilling string and the test pump fluid reservoir to deliver test fluid under pressure to the drilling string to thereby simulate ballooning and breathing that occurs during drilling operations; a flowmeter positioned in fluid communication between the test pressure pump and the drilling string to monitor a volume of the test fluid delivered to the drilling string; a pressure gauge positioned in fluid communication with fluid output from the test pump to monitor a pressure of the test fluid delivered to the drilling string; the fluid reservoir positioned to receive test fluid not lost to encroachment into a rock formation adjacent the lower end of the at least one casing string or cement associated with the at least one casing string, the total test fluid delivered by the test pump equal to test fluid attributable to ballooning plus test fluid lost due to encroachment; a fluid reservoir level sensor positioned to sense an amount of the test fluid lost to encroachment indicated by a difference in a pre-test fluid level and a post-test fluid level; a dynamic density control computer in communication with the choke and including a processor and memory associated with the processor to store operating instructions therein; dynamic density control program product stored in the memory of the dynamic density control computer and including instructions that when executed by the processor of the dynamic density control computer, cause the computer to perform the operations of; determining the volume of test fluid attributable to ballooning of the drilling apparatus components during drilling operations, determining at least one drilling fluid control variable system limitation of a drilling fluid control variable separately for each of the plurality of separated locations of interest, measuring a value of an operationally induced drilling fluid parameter at each of a plurality of separate locations when drilling, predicting a value of the drilling fluid control variable responsive to each measured drilling fluid parameter value separately for each of the plurality of separated locations of interest, and controlling a drilling fluid parameter responsive to each predicted control variable value and each associated at least one drilling fluid control variable system limitation. - View Dependent Claims (12)
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13. A system for controlling drilling fluid attributes and parameters, the system comprising:
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a drilling apparatus having at least one casing string cemented within a subterranean wellbore, a combination of the wellbore and the at least one casing string having a plurality of locations of interest located at separate locations; a drilling string run within the at least one casing string; an annulus formed between an external surface of the drilling string and inner surface of the innermost at least one casing string; a drilling fluid inlet; a drilling fluid inlet sensor positioned adjacent the drilling fluid inlet; a drilling fluid bottom wellbore sensor positioned adjacent the bottom of the wellbore; a drilling fluid outlet; a drilling fluid outlet sensor positioned adjacent the drilling fluid outlet; a drilling fluid circulating through the drilling fluid inlet, down through the drilling string, up through the annulus, and out the drilling fluid outlet; at least one monitor positioned to monitor drilling fluid parameters of the drilling fluid entering the drilling string; at least one monitor positioned to monitor drilling fluid parameters of the drilling fluid exiting the annulus; an output port choke in communication with the annulus and the drilling fluid outlet; a dynamic density control computer in communication with the choke and including a processor and memory associated with the processor to store operating instructions therein; dynamic density control program product stored in the memory of the dynamic density control computer and including instructions that when executed by the processor of the dynamic density control computer, cause the computer to perform the operations of; determining at least one drilling fluid control variable system limitation of a drilling fluid control variable separately for each of the plurality of separated locations of interest, measuring a value of an operationally induced drilling fluid parameter at each of a plurality of separate locations when drilling, to include measuring a value of an operationally induced drilling fluid parameter by the inlet sensor at the inlet, by the outlet sensor at the outlet, and by the bottom wellbore sensor, predicting a value of the drilling fluid control variable responsive to each measured drilling fluid parameter value separately for each of the plurality of separated locations of interest, and controlling a drilling fluid parameter responsive to each predicted control variable value and each associated at least one drilling fluid control variable system limitation; and one or more of the following simulators accessible to the dynamic density control program product to formulate a description of the physical behavior of the wellbore components; a wellbore breathing, ballooning, and rebounding simulator positioned to account for expansion and contraction of the wellbore and surrounding volume under dynamic conditions, a hydraulics loop simulator positioned to determine frictional pressure drop for drilling fluid carrying components throughout the drilling assembly, a pressure control simulator positioned to provide data to control fluid kicks, a wellbore stability simulator positioned to determine fracture pressures and collapse pressures of adjacent earth formations, a hydraulics optimization simulator positioned to provide data to optimize hydraulic energy at a drill bit used to drill the wellbore, a drilling simulator positioned to determine rate of penetration parameters, a formation productivity simulator positioned to assess the production impairment due to drilling fluid invasion, and a geomechanics model positioned to provide data indicating how earth formations react with the drilling apparatus under varying conditions of pressure, temperature, density, and flow rate; the operation of predicting a value for each control variable separately for each of the plurality of separated locations of interest including the operation of receiving by at least one of the simulators each measured drilling fluid parameter value and returning at least one predicted value. - View Dependent Claims (14)
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15. A method of controlling drilling fluid parameters, the method comprising the steps of:
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determining at least one drilling fluid control variable system limitation of a drilling fluid control variable separately for each of a plurality of separated locations of interest in a drilling system having at least one casing string cemented in a wellbore and a drilling string positionable therethrough, the step of determining including at least one of the following; performing at least one cased hole pressure test prior to running the drilling string through the casing string to determine an amount of drilling fluid volume input into the drilling system attributable to ballooning during drilling operations, performing at least one cased hole pressure test after running the drilling string to determine an amount of drilling fluid volume input into the drilling system attributable to compression of the drilling string during drilling operations, each cased hole pressure test comprising the steps of; filling the cased wellbore with fluid, sealing each drilling system fluid supply inlet and outlet, applying pressure to the fluid by pumping additional fluid into the drilling system by a pressure pump to thereby compress the drilling fluid, radially expand the casing string and associated cement layer, and compress an earth formation surrounding the wellbore, measuring over time an increase in fluid pressure and volume of fluid pumped into the drilling system, generating at least one of the following;
a pressure verses volume curve and a pressure verses volume versus time curve,releasing the pressure to allow return of fluid, measuring an amount of fluid returning, and determining a difference between the amount of additional fluid pumped into the drilling system and the amount of fluid returned defining a balloon volume, the difference indicating at least one of the following;
an amount of potential expansion of components of the drilling system due to a high pressure condition, an amount of potential contraction corresponding with removal of the high-pressure condition, and an amount of compressibility of the drilling string due to a high-pressure condition, andperforming a drilling system integrity and fracture pressure test to determine integrity of cement sealing, the casing string to the wellbore to thereby determine a maximum pressure that can exist at the lower end of the casing string without fracturing and associated earth formation or bonding of the cement, to include; drilling the wellbore below a lower end of the casing string, circulating drilling fluid through the drilling system, determining a steady-state dynamic pressure adjacent the bottom hole, increasing pressure in the drilling system, detecting a loss in fluid volume greater than the ballooning volume, and determining fracture pressure responsive to the detecting a loss in fluid volume to thereby determine a maximum dynamic pressure for the respective location of interest; measuring a value of an operationally induced drilling fluid parameter at each of a plurality of separate locations when drilling; determining an effect of mud channels in the casing string cement responsive to results of the cased hole pressure test; predicting a value of the drilling fluid control variable separately for each of the plurality of separated locations of interest responsive to each measured drilling fluid parameter value; and controlling a drilling fluid parameter responsive to each predicted control variable value and each associated at least one drilling fluid control variable system limitation. - View Dependent Claims (16, 17, 18, 19, 20, 21)
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22. A method of controlling drilling fluid parameters, the method comprising the steps of:
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determining at least one drilling fluid control variable system limitation of a drilling fluid control variable separately for each of a plurality of separated locations of interest in a drilling system having at least one casing string cemented in a wellbore and a drilling string positionable therethrough, each location of interest including a separate wellbore component weak point, the step of determining including the step of establishing local wellhead baseline data separately for each of the plurality of separate wellbore component weak points, to include for each wellbore component weak point the steps of; running a drilling string through the wellbore to account for compressibility of the drilling string when subjected to interior and exterior fluid pressure, filling at least a portion of the drilling system including the at least one casing string with fluid, sealing each drilling system fluid supply inlet and outlet, applying pressure to the fluid by pumping additional fluid into the drilling system by a pressure pump to thereby compress the drilling fluid, radially expand wellbore components of the drilling system, and compress an earth formation surrounding the wellbore, measuring over time a volume of fluid pumped into the drilling system and a corresponding increase in fluid pressure, generating at least one of the following;
a pressure verses volume curve and a pressure verses volume versus time curve,releasing the pressure to allow return of fluid responsive to reaching a preselected pressure limitations, measuring an amount of fluid returning, and determining a difference between the amount of additional fluid pumped into the drilling system and the amount of fluid returned, the difference indicating at least one of the following;
an amount of potential expansion of components of the drilling system due to a high pressure condition, an amount of potential contraction corresponding with removal of the high-pressure condition, and an amount of compressibility of a drilling system component due to a high-pressure condition;measuring a value of an operationally induced drilling fluid parameter at each of a plurality of separate locations when drilling; predicting a value of the drilling fluid control variable separately for each of the plurality of separated locations of interest responsive to each measured drilling fluid parameter value;
the step of predicting including the steps of;establishing a desired bottom hole pressure responsive to a pressure level limitation for each of the plurality of weak points, monitoring a plurality of drilling fluid mass and energy parameters in real-time for drilling fluid entering and exiting the drilling system, and executing a plurality of simulations using a corresponding plurality of drilling system simulators responsive to the local well baseline data to determine for each of the plurality of separate wellbore component weak points at least one of the following;
a maximum pressure level and a minimum pressure level to support drilling operations;controlling a drilling fluid parameter responsive to each predicted control variable value and each associated at least one drilling fluid control variable system limitation, to include the step of modifying at least one drilling fluid parameter within at least one of the following;
a drilling string and an annulus of the drilling system, to control the bottom hole pressure within constraints of each pressure level limitation for the plurality of weak points; anddetermining a maximum dynamic bottom hole pressure at future depths to be drilled responsive to at least a portion of the local wellhead baseline data results to thereby enhance drilling requirements management. - View Dependent Claims (23)
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24. A tangible computer readable medium that is readable by a computer controlling drilling fluid parameters in a drilling system, the computer readable medium storing a set of instructions that, when executed by the computer, cause the computer to perform the following operations, comprising:
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determining at least one drilling fluid control variable system limitation of a drilling fluid control variable separately for each of a plurality of separated locations of interest in a drilling system having at least one casing string positioned in a wellbore and a drilling string positionable therethrough, the operation of determining including at least one of the following; performing at least one cased hole pressure test prior to running the drilling string through the casing string to determine an amount of drilling fluid volume input into the drilling system attributable to ballooning during drilling operations, performing at least one cased hole pressure test after running the drilling string to determine an amount of drilling, fluid volume input into the drilling system attributable to compression of the drilling string during drilling operations, the operation of performing a cased hole pressure test comprising; signaling a pump controller of a pressure pump to pump additional fluid into the drilling system to thereby compress the drilling fluid, radially expand the casing string and associated cement layer, and compress an earth formation surrounding the wellbore, measuring over time an increase in fluid pressure and volume of fluid pumped into the drilling system, generating at least one of the following;
a pressure verses volume curve and a pressure verses volume versus time curve,signaling a pump controller of the pressure pump to cease pumping to allow return of fluid, measuring an amount of fluid returning, and determining a difference between the amount of additional fluid pumped into the drilling system and the amount of fluid returned, the difference indicating at least one of the following;
an amount of potential expansion of components of the drilling system due to a high pressure condition, an amount of potential contraction corresponding with removal of the high-pressure condition, and an amount of compressibility of the drilling string due to a high-pressure condition, andperforming a drilling system integrity and fracture pressure test to determine integrity of cement sealing the casing string to the wellbore to thereby determine a maximum pressure that can exist at the lower end of the casing string without fracturing and associated earth formation or bonding of the cement; measuring a value of an operationally induced drilling fluid parameter at each of a plurality of separate locations when drilling; predicting separately for each of the plurality of separated locations of interest a value of the drilling fluid control variable responsive to each measured drilling fluid parameter value; and controlling a drilling fluid parameter responsive to each predicted control variable value and each associated at least one drilling fluid control variable system limitation. - View Dependent Claims (25, 26, 27, 28, 29, 30, 31, 32)
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33. A tangible computer readable medium that is readable by a computer controlling drilling fluid parameters in a drilling system, the computer readable medium storing a set of instructions that, when executed by the computer, cause the computer to perform the following operations, comprising:
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determining at least one drilling fluid control variable system limitation of a drilling fluid control variable separately for each of a plurality of separated locations of interest in a drilling system having at least one casing string positioned in a wellbore and a drilling string positionable therethrough, each location of interest including a separate wellbore component weak point, the operation of determining including the operation of establishing local wellhead baseline data separately for each of the plurality of separate wellbore component weak points, the operation of establishing local wellhead baseline data including for each wellbore component weak point; signaling a pump controller of a pressure pump to pump additional fluid into the drilling system to thereby compress the drilling fluid, radially expand the casing string and associated cement layer, and compress an earth formation surrounding the wellbore, measuring over time an increase in fluid pressure and volume of fluid pumped into the drilling system, generating at least one of the following;
a pressure verses volume curve and a pressure verses volume versus time curve,signaling a pump controller of the pressure pump to cease pumping to allow return of fluid, measuring an amount of fluid returning, determining a difference between the amount of additional fluid pumped into the drilling system and the amount of fluid returned, the difference indicating at least one of the following;
an amount of potential expansion of components of the drilling system due to a high pressure condition, an amount of potential contraction corresponding with removal of the high-pressure condition, and an amount of compressibility of the drilling string due to a high-pressure condition, anddetermining a volume of fluid associated with a volume reduction due to compressibility of the drilling string when positioned in the wellbore and when subjected to interior and exterior fluid pressure; measuring a value of an operationally induced drilling fluid parameter at each of a plurality of separate locations when drilling; predicting separately for each of the plurality of separated locations of interest a value of the drilling fluid control variable responsive to each measured drilling fluid parameter value; the operation of predicting including the operations of; establishing a desired bottom hole pressure responsive to a pressure level limitation for each of the plurality of weak points, monitoring a plurality of drilling fluid mass and energy parameters in real-time for drilling fluid entering and exiting the drilling system, and executing a plurality of simulations using a corresponding plurality of drilling system simulators responsive to the local well baseline data to determine for each of the plurality of separate wellbore component weak points at least one of the following;
a maximum pressure level and a minimum pressure level to support drilling operations; andcontrolling a drilling fluid parameter responsive to each predicted control variable value and each associated at least one drilling fluid control variable system limitation, to include the operation of modifying at least one drilling fluid parameter within at least one of the following;
a drilling string and an annulus of the drilling system, to control the bottom hole pressure within constraints of each pressure level limitation for the plurality of weak points. - View Dependent Claims (34, 35)
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Specification