U.S. patent application number 17/500988 was filed with the patent office on 2022-03-03 for manifold implemented in multi-channel system for controlling flow of fluids in oil well.
The applicant listed for this patent is Controlled Fluids, Inc.. Invention is credited to Justin Jackson.
Application Number | 20220065072 17/500988 |
Document ID | / |
Family ID | |
Filed Date | 2022-03-03 |
United States Patent
Application |
20220065072 |
Kind Code |
A1 |
Jackson; Justin |
March 3, 2022 |
MANIFOLD IMPLEMENTED IN MULTI-CHANNEL SYSTEM FOR CONTROLLING FLOW
OF FLUIDS IN OIL WELL
Abstract
Manifold for controlling flow of fluids in multi-channel system
deployed in oil well including an orifice formed between inlet
ports and outlet ports. The orifice receives fluid through inlet
ports and is in fluid communication with a pressure system and
tank. The manifold includes a check valve connecting the orifice
and receiving/controlling flow of fluid. The manifold includes a
gas charged accumulator adapted to store hydraulic energy generated
at an inlet of the gas charged accumulator when pressure of the
fluid becomes greater than a precharge pressure. The manifold
includes a flow control valve connecting the check valve and gas
charged accumulator. The flow control valve and gas charged
accumulator control the opening of the check valve and prevent
improper operation of the manifold. The gas charged accumulator
dumps fluid into the tank quickly when the flow control valve moves
out of its intended position during a failure of drilling
operation.
Inventors: |
Jackson; Justin; (Beaumont,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Controlled Fluids, Inc. |
Beaumont |
TX |
US |
|
|
Appl. No.: |
17/500988 |
Filed: |
October 14, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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17324549 |
May 19, 2021 |
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17500988 |
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16909974 |
Jun 23, 2020 |
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17324549 |
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International
Class: |
E21B 34/08 20060101
E21B034/08; E21B 43/08 20060101 E21B043/08; E21B 43/14 20060101
E21B043/14 |
Claims
1. A manifold, comprising: an orifice formed between inlet ports
and outlet ports, wherein said orifice receives fluid through inlet
ports, and wherein said orifice is in a fluid communication with a
pressure system and a tank; a check valve connecting said orifice,
wherein said check valve receives and controls the flow the fluid;
a gas charged accumulator adapted to store hydraulic energy
generated at an inlet of said gas charged accumulator when pressure
of the fluid becomes greater than a precharge pressure; and a flow
control valve connecting said check valve and said gas charged
accumulator, wherein said flow control valve and said gas charged
accumulator control the opening of said check valve and prevent
improper operation of said manifold, and wherein said gas charged
accumulator dumps the fluid into said tank quickly when said flow
control valve moves out of its intended position during a failure
of drilling operation.
2. The manifold of claim 1, wherein said gas charged accumulator
dumps the fluid into said tank quickly via a solenoid valve.
3. The manifold of claim 1, wherein said gas charged accumulator
bleeds down the fluid on a time delay and prevents said check valve
from opening too soon.
4. The manifold of claim 1, wherein said flow control valve is a
check-resistor valve.
5. The manifold of claim 1, wherein said flow control valve further
comprises a check valve and an orifice with a screen.
6. The manifold of claim 1, wherein said manifold is made of steel
or steel alloy.
7. The manifold of claim 1, wherein said manifold is fabricated by
machining of a single block of steel or steel alloy.
8. The manifold of claim 1, wherein said manifold comprises a
coating from a group consisting of a zinc-nickel plated ductile
iron, a ceramic coating, a passivation layer or a corrosion
prevention layer.
9. A method of providing a manifold, said method comprising steps
of: providing an orifice formed between inlet ports and outlet
ports, said orifice receiving fluid through inlet ports, said
orifice in a fluid communication with a pressure system and a tank;
providing a check valve connecting said orifice, said check valve
receiving the fluid; providing a gas charged accumulator adapted to
store energy; providing a flow control valve connecting said check
valve and said gas charged accumulator; controlling the opening of
said check valve and preventing improper operation of said manifold
using said flow control valve and said gas charged accumulator
control; and operating said gas charged accumulator for dumping the
fluid into said tank quickly when said flow control valve moves out
of its intended position during a failure of drilling
operation.
10. The method of claim 9, further comprising dumping the fluid
into said tank quickly via a solenoid valve.
11. The method of claim 9, further comprising bleeding down the
fluid from said gas charged accumulator on a time delay for
preventing said check valve from opening too soon.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application further claims the benefit of the following
non-provisional applications, all of which are here expressly
incorporated by reference:
[0002] Ser. No. 16/909,974 titled "MANIFOLD IMPLEMENTED IN
MULTI-CHANNEL SYSTEM FOR CONTROLLING FLOW OF FLUIDS IN OIL WELL,"
filed on Jun. 23, 2020 with Attorney Docket No. CFIN002US0TR;
and
[0003] Ser. No. 17/324,549, titled "MANIFOLD IMPLEMENTED IN
MULTI-CHANNEL SYSTEM FOR CONTROLLING FLOW OF FLUIDS IN OIL WELL,"
filed on May 19, 2021 with Attorney Docket No. CFIN002US2.
FIELD OF THE DISCLOSURE
[0004] The present disclosure relates generally to multi-channel
systems implemented in oil wells; and more specifically to a
manifold, as a part of a top drive system, for controlling the flow
of fluids therein.
BACKGROUND OF THE DISCLOSURE
[0005] A wide variety of drilling rigs and methods are known for
drilling oil, gas, and water wellbores in subsurface formations. In
many known systems and methods, a single wellbore is drilled with a
drilling rig and then, to drill another wellbore, the drilling rig
is moved to a new location, often near the drilled wellbore. Such
rigs, which implement a top drive system, employ a manifold that
controls the flow of fluids from oil wells and directs it through
various outlets for disposal, measurements or storage, or to a
production line. Usually, manifolds include fluid inlets, control
valves, flow meters, and fluid outlets.
[0006] Typically, manifolds are used to promote the flow of fluid
from the oil or gas wells in compliance with the fluid flow
requirements of the project, through a feasible arrangement of
various flow paths. In order to control the flow of fluid through
them, valves are positioned within the pipe flow paths. These
valves can be opened or closed at various times based on
requirements.
[0007] Conventionally, manifolds are made of aluminum as it is
easier to machine due to its high malleability, lower material
cost, and lower matching and production costs. However, aluminum
manifolds face a common issue of washouts that arises from exposure
to constant high flow applications, particularly through small flow
paths, drilling paths, and orifices, as fluids erode the soft
internals of the manifold block. Furthermore, impacts and
vibrations from top drive operations can result in stress fractures
or wear along the corners or areas where wall thicknesses can be
marginal in an aluminum manifold, thereby further reducing the
manifold's longevity and functionality. Finally, aluminum has
maximum system working pressure limitations due to the metal's
inherent low tensile strength.
[0008] One example is disclosed in a U.S. Pat. No. 10,156,095
entitled "Top drive and power swivel with high pressure seals and
automatic refilling lubrication reservoir" (the "'095 Patent"). The
'095 Patent discloses a top drive or a power swivel with a high
pressure wash pipe and seal assembly which receives high pressure
drilling fluid from a mud pump and provides high pressure drilling
fluid to the drilling fluid side of a dual fluid reservoir. A
separating piston in the dual fluid reservoir moves toward the oil
side as hydraulic oil is used for lubrication. This dual fluid
reservoir with separating piston provides hydraulic oil at drilling
mud pressure as required by the set of unique high pressure seals
which are continuously lubricated and which generate minimal
heat.
[0009] Another example is disclosed in a U.S. Pat. No. 6,328,070
entitled "Valve arrangement for controlling hydraulic fluid flow to
a subsea system" (the "'070 Patent"). The '070 Patent discloses a
valve arrangement for controlling hydraulic fluid flow to a subsea
system which includes a plurality of docking modules each having a
valve element for controlling the flow of a fluid and a docking
module port for fluid flow between the valve element. The valve
arrangement additionally includes a manifold having manifold ports
of uniform cross-section. The docking modules can be
interchangeably mounted to the manifold ports as desired to tailor
the valve arrangement for any selected valve operation. The valve
arrangement also includes an adapter for alternately sealingly
interconnecting a first docking module port which is different in
shape or area than the cross section of the uniform size manifold
port to any selected manifold port so as to permit sealed fluid
flow between the first docking module port and the manifold port in
one configuration of the valve arrangement and sealingly
interconnecting a second docking module port of a different
cross-sectional shape or area than the first docking module port to
the same selected manifold port so as to permit sealed fluid flow
between a second valve element and the first manifold port in
another configuration of the valve arrangement.
[0010] Another example is disclosed in a US Patent Application No.
2016/0265288 entitled "Devices and methods for controlling a
multi-channel system in a petroleum well" (the "'288 Publication").
The '288 Publication discloses devices and methods for controlling
flow through a multi-channel system deployed in a petroleum well.
The devices of the invention feature a manifold with a plurality of
inlets operably connected to the passageways of the multi-channel
system. Individual flows of the multi-phase petroleum fluid from
the parallel passageways of the multi-channel system towards the
inlets of the manifold are controlled by opening or closing of
corresponding stopping valves installed on each inlet or group of
inlets. After exiting the inlets through the stopping valves, the
flows of the multi-phase fluid are consolidated and directed
towards single or multiple outlets of the manifold and ultimately
towards the outlet of the petroleum well. Individual opening or
closing of the stopping valves has the effect of increasing or
decreasing the total cross-sectional area available for producing
fluid flow through the well.
[0011] Another example is disclosed in a U.S. Pat. No. 10,048,673
entitled "High pressure blowout preventer system" (the "673
Patent"). The '673 Patent discloses a BOP system for use in a high
pressure subsea environment, including a BOP stack including a
lower marine riser package and a lower stack portion, the lower
stack portion having a plurality of BOP rams attached to a subsea
wellhead. The system also includes a riser subsystem extending from
a drilling vessel to the BOP stack and providing fluid
communication therebetween, a ship board subsystem electronically,
mechanically, and hydraulically connected to the BOP stack and the
riser subsystem to control the functions of the BOP stack and the
riser subsystem, and a safety instrumented system having a surface
logic solver and at least one subsea logic solver, the safety
instrumented system in communication with at least a portion of the
BOP rams to act as a redundant control system in case of failure of
the ship board subsystem.
[0012] The system, devices and methods of the cited documents
suffer from one or more limitations of the top drive system as
discussed above. Therefore, in light of the foregoing discussion,
there exists a need to overcome aforementioned limitations
associated with conventional aluminum manifolds for controlling
flow of fluids.
BRIEF SUMMARY OF THE DISCLOSURE
[0013] In the view of the above problems, the present disclosure
provides numerous innovations, improvements, and inventions
relating to the development of efficient and long-lasting manifolds
for top drive systems.
[0014] In one aspect, a manifold implemented in a multi-channel
system deployed in an oil or gas well for controlling flow of
fluids is provided. The multi-channel system includes a plurality
of passageways to convey one or more fluids from the oil well. The
manifold includes a body having a plurality of inlet ports and a
plurality of outlet ports, and a flow control arrangement provided
in the body. The plurality of inlet ports is in fluid communication
with the plurality of passageways. The flow control arrangement
further includes a channel formed between each one of the inlet
ports and one of the outlet ports, and a check valve arranged in
the channel at each one of the inlet ports of the body. The channel
is adapted to receive fluids through the inlet port of the body
creating a differential pressure between the inlet ports and the
outlet ports. The check valve is configured to regulate or direct
flow of fluids into the channel based on the created differential
pressure.
[0015] In one or more embodiments, the flow control arrangement of
the manifold further includes a filter screen arranged at each one
of the inlet ports to restrict impurities from entering the
channel.
[0016] In one or more embodiments, the check valve within the
manifold includes threads formed therein to be engaged with threads
formed in the channel proximal to the inlet port therein.
[0017] In one or more embodiments, the body of the manifold is made
of steel or steel alloy. In particular, the present subject matter
provides a manifold block that is first machined, and then plated
or coated. The potential coating materials may include zinc-nickel,
ceramic, a passivation coating, or any variety of plating processes
and approaches for preventing corrosion.
[0018] In one or more embodiments, the body of the manifold is
fabricated by machining of a single block of steel or steel
alloy.
[0019] In one or more embodiments, the body of the manifold is made
of zinc-nickel plated ductile iron.
[0020] In another aspect, a system for controlling the flow of
fluids is provided. The system includes a plurality of passageways
to transport one or more fluids from the oil well. The system
further includes a manifold in fluid communication with the
plurality of passageways. The manifold includes a body having a
plurality of inlet ports and a plurality of outlet ports, the
plurality of inlet ports being in fluid communication with the
plurality of passageways, and a flow control arrangement provided
in the body. The flow control arrangement includes a channel formed
between each one of the inlet ports and one of the outlet ports,
and a check valve arranged in the channel at each one of the inlet
ports of the body. The channel is adapted to receive fluids through
the inlet port of the body creating a differential pressure between
the inlet ports and the outlet ports. The check valve is configured
to regulate flow of fluids into the channel based on the created
differential pressure.
[0021] In one or more embodiments, the flow control arrangement
further includes a filter screen arranged at each one of the inlet
ports to restrict impurities from entering the channel.
[0022] In one or more embodiments, the check valve includes threads
formed therein to be engaged with threads formed in the channel
proximal to the inlet port therein.
[0023] In one or more embodiments, the body of the manifold is made
of steel or steel alloy.
[0024] In one or more embodiments, the body of the manifold is
fabricated by machining of a single block of steel or steel alloy.
By first machining the single block and then plating or coating the
block a superior construction results. Coatings may be applied
using zing-nickel, ceramic coating material, a passivation layer,
or any number of plating processes that provide corrosion
prevention.
[0025] In one or more embodiments, the body of the manifold is made
of zinc-nickel plated ductile iron.
[0026] In essence, therefore, the embodiments of the present
disclosure substantially eliminate or at least partially address
the aforementioned problems in the prior art by providing a novel
design that can be used for the development of durable and
efficient manifolds.
[0027] The foregoing summary is illustrative only and is not
intended to be in any way limiting. In addition to the illustrative
aspects, embodiments, and features described above, further
aspects, embodiments, and features will become apparent by
reference to the drawings and the following detailed
description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The present subject matter will now be described in detail
with reference to the drawings, which are provided as illustrative
examples of the subject matter so as to enable those skilled in the
art to practice the subject matter. It will be noted that
throughout the appended drawings, like features are identified by
like reference numerals. Notably, the FIGUREs and examples are not
meant to limit the scope of the present subject matter to a single
embodiment, but other embodiments are possible by way of
interchange of some or all of the described or illustrated elements
and, further, wherein:
[0029] FIG. 1 is a schematic illustration of components of a
drilling system having a manifold therein, in accordance with an
embodiment of the present disclosure;
[0030] FIG. 2A is a diagrammatic perspective view of a manifold
(such as, the manifold of FIG. 1) employed in the drilling system
of FIG. 1, in accordance with an embodiment of the present
disclosure;
[0031] FIG. 2B is a diagrammatic front view of the manifold of FIG.
2A, in accordance with an embodiment of the present disclosure;
[0032] FIG. 2C is a diagrammatic rear view of the manifold of FIG.
2A, in accordance with an embodiment of the present disclosure;
[0033] FIG. 2D is a diagrammatic top view of the manifold of FIG.
2A, in accordance with an embodiment of the present disclosure;
[0034] FIG. 2E is a diagrammatic bottom view of the manifold of
FIG. 2A, in accordance with an embodiment of the present
disclosure;
[0035] FIG. 2F is a diagrammatic left-side view of the manifold of
FIG. 2A, in accordance with an embodiment of the present
disclosure;
[0036] FIG. 2G is a diagrammatic right-side view of the manifold of
FIG. 2A, in accordance with an embodiment of the present
disclosure;
[0037] FIG. 3A is a schematic illustration of a hydraulic circuit
for the manifold of FIGS. 2A-2G as implemented in the drilling
system of FIG. 1, in accordance with an embodiment of the present
disclosure;
[0038] FIG. 3B is a schematic illustration of a section
representing a flow control arrangement in the hydraulic circuit of
FIG. 3A, in accordance with an embodiment of the present
disclosure;
[0039] FIG. 4A is a diagrammatic illustration of a check valve
implemented in the flow control arrangement of FIG. 3B, in
accordance with an embodiment of the present disclosure;
[0040] FIG. 4B is a diagrammatic illustration of a channel with the
check valve of FIG. 4A arranged therein, as implemented in the flow
control arrangement of FIG. 3B, in accordance with an embodiment of
the present disclosure;
[0041] FIG. 5 is a schematic illustration of a section of the
manifold of FIGS. 2A-2G depicting a section of the flow control
arrangement therein, in accordance with an embodiment of the
present disclosure; and
[0042] FIG. 6 is a schematic diagram of an Internal Blowout
Preventer (IBOP) circuit, in accordance with an embodiment of the
present disclosure.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0043] In the following description, for purposes of explanation,
numerous specific details are set forth in order to provide a
thorough understanding of the present disclosure. It will be
apparent, however, to one skilled in the art that the present
disclosure is not limited to these specific details.
[0044] Reference in this specification to "one embodiment" or "an
embodiment" means that a particular feature, structure, or
characteristic described in connection with the embodiment is
included in at least one embodiment of the present disclosure. The
appearance of the phrase "in one embodiment" in various places in
the specification are not necessarily all referring to the same
embodiment, nor are separate or alternative embodiments mutually
exclusive of other embodiments. Further, the terms "a" and "an"
herein do not denote a limitation of quantity, but rather denote
the presence of at least one of the referenced items. Moreover,
various features are described which may be exhibited by some
embodiments and not by others. Similarly, various requirements are
described which may be requirements for some embodiments but not
for other embodiments.
[0045] Certain terminology is used in the following description for
convenience only and is not limiting. The words "right," "left,"
"lower," and "upper" designate directions in the drawings to which
reference is made. The words "inwardly" and "outwardly" refer to
directions toward and away from, respectively, the geometric center
of the personalized air conditioning system and designated parts
thereof. The words "first", and "second", are only used to
represent a particular entity, and are not used to depict any
specific order. The terminology includes the words above
specifically mentioned, derivatives thereof and words of similar
import.
[0046] The present invention provides a system for controlling flow
of fluids from an oil or gas well. The present disclosure utilizes
an improved manifold and a methodology that can be employed during,
for example, well cleanup and flow periods or during other well
related procedures. The manifold is both adjustable and calibrated
to regulate the flow of well related fluids, such as multiphase
production fluids. Additionally, the manifold may be integrated
with other components at a surface location in an efficient
arrangement that facilitates regulation of fluid flow rates. In one
application, the combination of components of the manifold is used
to regulate the flow rate of a multiphase fluid before that
multiphase fluid enters a separator. Beneficially, in the present
disclosure, the manifold is fabricated from a much rigid metallic
alloy such as steel, instead of aluminum as in conventional
manifold systems. Steel grants the manifolds an enhanced resistance
to the washouts, fatigue or stress fractures, stress cracks, and
chipping associated with aluminum manifolds. In addition, using a
steel-based manifold greatly reduces the risk of accidentally
stripping a port and ruining the manifold.
[0047] In addition to use in an oil and/or gas field for promoting
the flow of fluid from the oil or gas wells in compliance with the
fluid flow requirements, the method and system of the present
disclosure may be used for other applications. Such other
applications may include, for example, heavy construction machines,
off-highway equipment etc.
[0048] Referring to FIG. 1, illustrated is a schematic illustration
of an implementation of a drilling system and a system for
controlling flow of fluids employed therein, in accordance with an
embodiment of the present disclosure. As shown, drilling system 100
includes tubular drill string 102 suspended from drilling rig 104.
Drill string 102 has a lower end which extends downwardly through
blowout preventer (BOP) stack 106 and into borehole 108. Drill bit
110 is attached to the lower end of drill string 102. Top drive
system 112 is operatively coupled to an upper end of drill string
102 for turning or rotating drill string 102 along with drill bit
110 in borehole 108. BOP stack 106 is coupled to well casing 112
via wellhead connecter 114.
[0049] When drilling is stopped (i.e., top drive system 112 is no
longer turning drill string 102 and drill bit 110), one or more
conventional annular BOPs 113 can be closed to effectively close
well bore from the atmosphere. Kill line "A," couples between fluid
injection line "B" via standpipe manifold 116 and conventional BOP
stack 106 via kill line valve 118. Kill line "A," permits fluid
communication between conventional surface fluid/mud pump 120 and
well bore when kill line valve 122 and valving in standpipe
manifold 116 are opened. Thus, while BOP 113 is closed,
conventional surface fluid/mud pump 120 may be used to pump fluid
from reservoir 122 into borehole 108 via fluid injection line B,
standpipe manifold 116, kill line "B", kill line valve 122, and BOP
stack 106. Alternatively, while BOP 113 is closed, conventional
surface fluid/mud pump 120 may be used to pump fluid from reservoir
122 into borehole 108 via fluid injection line "B", standpipe
manifold 116, drill string 102 and drill bit 110.
[0050] Surface fluid pump 120 pumps fluid from surface fluid
reservoir 122 through fluid injection line "B", through the upper
end of drill string 102, down the interior of drill string 102,
through drill bit 110 and into a borehole annulus. Choke line "C"
couples between conventional BOP stack 106 via choke line valve 124
and surface fluid reservoir 122 via manifold 126. Manifold 126
includes flow control arrangement 128. Flow control arrangement 128
controls flow rate through choke line "C" thereby controlling
pressure upstream of flow control arrangement 128.
[0051] Referring to FIGS. 2A-2G, illustrated are different views of
manifold 200 (such as, manifold 126 of FIG. 1) employed in system
100 of FIG. 1, in accordance with an embodiment of the present
disclosure. Throughout the present disclosure, the term "manifold"
as used herein refers to a flow-routing hardware with plurality of
inlet ports and plurality of outlet ports, which is used to
transport fluids and control fluid flow. The different types of
manifolds include, but are not limited to production (oil, gas, or
condensate), lift, water injection, and mixed (production and water
injection). Typically, manifolds are equipment which connect two or
more valves of a hydraulic system. A variety of block/isolate
valves can be combined in a single body configuration. Each of
these valves has a separate opening below in order to connect a
pipe. The main body or valve chamber is common to all. Such
manifolds commonly include ball, bleed, needle, and vent valves.
The use of such manifolds in savings in terms of space and
installation costs.
[0052] As shown in FIGS. 2A-2G, manifold 200 includes a body 202.
According to embodiments of the present disclosure, body 202 of
manifold 200 is made of steel or steel alloy. In the present
embodiments, body 202 of manifold 200 is fabricated by machining of
a single block of steel or steel alloy. Optionally, body 202 of
manifold 200 is made of zinc-nickel plated ductile iron. With the
present subject matter, manifold 200 may be first machined and then
plated or coated. Plating or coatings may be in the form of
zinc-nickel, ceramic coating material, a passivation layer, or any
number of plating processes capable of preventing corrosion of the
manifold steel.
[0053] As aforementioned, manifold 200 is implemented in a
multi-channel system, such as drilling system 100 of FIG. 1, as
deployed in an oil well, for controlling flow of fluids. Herein,
the multi-channel system includes a plurality of passageways (not
shown) to transport one or more fluids from the oil well.
[0054] Referring again to FIGS. 2A-2G, as shown, body 202, of
manifold 200, has a plurality of inlet ports 204 and a plurality of
outlet ports 206. Herein, the plurality of inlet ports 204 are in
fluid communication with the plurality of passageways of the
multi-channel system, as discussed in the preceding paragraph.
Manifold 200 further includes flow control arrangement (such as,
flow control arrangement 300B of FIG. 3B, as discussed later in the
description) provided in body 202. Such a flow control arrangement
is explained in detail with reference to FIGS. 3A and 3B. Further,
as shown, manifold 200 includes a set of multiple valves such as
valves 208 and 210. The various components in manifold 200 are
arranged as per the design requirement of manifold 200 and space
constraints in the drilling system (such as, system 100 of FIG. 1)
in which manifold 200 is implemented.
[0055] Referring to FIG. 3A, illustrated is hydraulic circuit
diagram 300A of manifold 200 of FIG. 2 as implemented in drilling
system 100 of FIG. 1, in accordance with an embodiment of the
present disclosure. Hydraulic circuit diagram 300A includes one or
more power sources, one or more valves, one or more controllers for
controlling an operation of the valves, one or more filters, one or
more orifices and channels, one or more inlets, one or more outlets
and so forth. Referring to FIG. 3B, illustrated is a section
representing flow control arrangement 300B in hydraulic circuit
diagram 300A of FIG. 3A, in accordance with an embodiment of the
present disclosure. Herein, flow control arrangement 300B includes
power source 302, check valve 304, channel 306 and filter screen
308.
[0056] In one aspect of the present disclosure, a single pressed-in
embodiment may include a check valve, orifice, and a filter screen.
Other embodiments may further provide two separate components, one
may be a thread-in check valve, another may be a one-thread-in
filter screen, and a machined orifice for matching performance
specifications according to a single-component design. Herein,
filter screen 308 is arranged at each one of the inlet ports (such
as, inlet ports 204) to restrict impurities from entering channel
306. Throughout the present disclosure, the term "filter screen" as
used herein refers to a device that may generally be in the form of
a mesh and is used to prevent impurities from reaching the outlet
ports thereby ensuring high cleanliness level of the fluid.
Moreover, it also ensures reliable operations of subsequent
apparatuses used in the system. These screens can be made up of
metal, alloys etc.
[0057] It may be understood that a valve when employed in a
steel-based manifold (such as, manifold 200 of the present
disclosure) may not seat properly due to the hard nature of the
steel. Such a valve may come unseated and thus may affect the
proper functioning of the manifold. This may not be a problem with
aluminum-based manifolds as known in the art because, with such
manifolds, the valve may be installed by pressing it into the
manifold, as the aluminum was malleable enough to conform to the
shape of the pressed valve. Some of the existing manifolds employ a
particular directional flow valve by Lee.RTM. company which has
integrated functionalities of a check valve, an orifice drilling,
and a last-chance filter screen.
[0058] Manifold 200 of the present disclosure reshape one or more
ports therein (as discussed in more detail with reference to FIG.
5, later in the description) to enable installation of a fixed
orifice (in the form of channel 306), a screen (such as, filter
screen 308), and thread-in check valve 304 with suitable
operational specifications. Such a distributed arrangement of flow
control arrangement 300B, replacing a single press-in seated check
valve as in the conventional manifolds, improves the reliability of
flow control arrangement 300B.
[0059] Referring to FIGS. 4A and 4B, illustrated are schematic
representations of components of the flow control arrangement of
FIG. 3B, in accordance with an embodiment of the present
disclosure. FIG. 4A represents check valve 400A to be implemented
in manifold 200 of the present disclosure. Throughout the present
disclosure, thread-in check valve 400A as used herein refers to
devices whose functions include, but not limited to, allowing free
flow in one direction while preventing flow in the reverse
direction, and regulating the pressure there through. Check valve
400A may be used to isolate portions of a hydraulic circuit or to
provide a free flow path around a restrictive valve. Optionally,
check valve 400A may be either manual or hydraulically actuated.
Check valve 400A is configured to regulate the flow of fluids into
channel 400A based on the created differential pressure. FIG. 4B
represents channel 400B into which check valve 400A is fitted in an
embodiment. Herein, channel 400B is formed between each one of the
inlet ports and one of the outlet ports of the manifold, as
discussed. Channel 400B is adapted to receive fluids through the
inlet port of the body creating a differential pressure between the
inlet ports and the outlet ports. Optionally, channel 400B may be a
fixed orifice or a variable orifice.
[0060] As may be contemplated from FIGS. 4A and 4B, check valve
400A is arranged in channel 400B at each one of the inlet ports
(such as inlet ports 204) of manifold 200. Herein, as may be seen
from FIGS. 4A and 4B, check valve 400A is a threaded valve that
ensures that check valve 400A is properly fixed into the channel
(i.e., channel 306) and eliminates any risk of disengagement of
check valve 400A from channel 306 in manifold 200, due to any
vibrations, forces or torques induced in flow control arrangement
300B. In the present embodiments, check valve 400A includes threads
formed therein to be engaged with corresponding threads formed in
channel 400B proximal to the inlet port therein. Such an
arrangement ensures that check valve 400A is properly seated in
body 202 of manifold 200 and does not get dislocated from its
original position due to pressure and constant vibrations in the
drilling system (such as, system 100 of FIG. 1).
[0061] Referring to FIG. 5, illustrated is a section of manifold
(such as, manifold 200) depicting the flow control arrangement
implemented therein, in accordance with an embodiment of the
present disclosure. As shown, check valve 400A of FIG. 4B is
arranged in port 502 of manifold 200; and channel 400B of FIG. 4B
forms part of port 504. As shown, there is a cross-drilling
connection 506 between port 502 and port 504, and thereby check
valve 400A is able to control an inflow of fluids, such as oil,
through port 502. As discussed, channel 400B may be a fixed orifice
including a filter screen (not shown) arranged at one end, within
port 504.
[0062] Manifold 200, when implemented in a fluid control and/or
regulation system such as drilling system 100 of FIG. 1, improves
the efficiency as well as reduces energy costs. Beneficially,
manifold 200 introduces shorter path flows which reduce pressure
drop and heat fluctuations, improving the overall energy efficiency
of system 100 of FIG. 1. Beneficially, manifold 200 also reduces
installation costs as well as fluid connections because of a
simpler, more compact design. Furthermore, manifold 200 mitigates
chances of oil leak due to a lesser number of connections, further
reducing the need for upkeep against fatigue, wear and loose
joints. Furthermore, manifold 200 being of a small and compact size
enables installation thereof in confined spaces of the drilling
systems, such as system 100 of FIG. 1 without requiring any
significant change in design of system 100.
[0063] FIG. 6 shows a schematic diagram of Internal Blowout
Preventer (IBOP) circuit 600, in accordance with one embodiment of
the present disclosure. IBOP circuit 600 includes hydraulic
cylinder 602. Hydraulic cylinder 602 opens or closes the top drive,
while the top drive rotates. Hydraulic cylinder 602 connects to
rotating link adapter 604. Rotating link adapter 604 connects to
rotating head 606 in a closed position. IBOP circuit 600 includes
double solenoid valve 608 that connects to solenoid valve 610
(referred as C04). In accordance with the present embodiment,
liquid/fluid flows in the direction 612 into IBOP circuit 600.
Fluid flows through orifice 614, which is in fluid communication
with pressure system 616 and tank 618. The fluid flows through
check valve CV4 (such as check valve 400A) in manifold assembly
620. In one example, check valve CV4 and orifice 614 are threaded
into position and secured with thread locker such as a Loctite, for
example. Further, IBOP circuit 600 includes gas charged accumulator
622 that compresses the gas and stores the energy. A person skilled
in the art understands that gas charged accumulator 622 stores
hydraulic energy generated at an inlet (not shown) of gas charged
accumulator 622 when pressure of the fluid becomes greater than a
precharge pressure. IBOP circuit 600 presents flow control valve
624. In one exemplary embodiment, flow control valve 624 includes a
check-resistor valve such as FCFA Lee.TM. check-resistor valve
(FCFA). Here, flow control valve 624 includes a check valve and an
orifice with a screen. An exemplary construction of flow control
valve 624 including check valve 304, channel/orifice 306 and filter
screen 308 is shown in FIG. 3A. This is in comparison with known
art in which a flow control valve includes check valve, orifice and
screen all in one.
[0064] In the present disclosure, flow control valve 624 is a part
of a timing circuit for the systems of IBOP circuit 600. Flow
control valve 624 works in conjunction with gas charged accumulator
622 to control the opening of check valve CV4. Flow control valve
624 and gas charged accumulator 622 control the opening of check
valve CV4 and prevent improper operation of IBOP circuit 600
thereby ensuring safe drilling operation.
[0065] In case of a failure during the drilling operation, flow
control valve 624 moves out of its intended position. Generally,
the movement flow control valve 624 is sporadic and is caused due
to the tight machine tolerances that are not easy to achieve.
Typically, a spacer is used to positively hold it in place, but
this is an added cost and can be forgotten/neglected during repair.
During failures, flow control valve 624 moving out of position
prevents the IBOP from building pressure on the "CLOSE" side,
preventing safe drilling operation.
[0066] In accordance with the present disclosure, when flow control
valve 624 falls out of place, then it allows gas charged
accumulator 622 to dump the liquid to tank 618 too quickly via
solenoid valve C04. Here, gas charged accumulator 622 bleeds down
on a time delay and prevents the pilot-to-close check valve CV4
from opening too soon. This provides more robust installation. In
one advantageous feature of the present disclosure, the flow
control valve 624 i.e., FCFA relies on special installation tooling
and close tolerances to positively stay in position. The
installation prevents flow control valve 624 from coming loose in
manifold assembly 620. As such, the presently disclosed IBOP
circuit 600 offers a hardware solution replacing existing circuit
at a much lower cost.
[0067] The presently disclosed manifold is made of steel instead of
aluminium. As such, the manifold provides strong and dependable
control solution that drilling demands. The multi-channel system is
machined out of zinc-nickel ductile iron block, which is more
durable than the standard aluminium. The manifold made of steel
provides the multi-channel system enhanced resistance to the
washouts associated with aluminium manifolds. In addition, using a
steel based block greatly reduces the risk of accidentally
stripping a port and ruining the manifold. The above factors
combine to provide a durable and long lasting top drive manifold
solution allows to perform drilling operations without worrying
about manifold failing.
[0068] The foregoing descriptions of specific embodiments of the
present disclosure have been presented for purposes of illustration
and description. They are not intended to be exhaustive or to limit
the present disclosure to the precise forms disclosed, and
obviously many modifications and variations are possible in light
of the above teaching. The exemplary embodiment was chosen and
described in order to best explain the principles of the present
disclosure and its practical application, to thereby enable others
skilled in the art to best utilize the present disclosure and
various embodiments with various modifications as are suited to the
particular use contemplated.
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