Managed pressure drilling manifold, modules, and methods

Abstract

A managed pressure drilling (“MPD”) manifold is adapted to receive drilling mud from a wellbore during oil and gas drilling operations. The MPD manifold includes one or more drilling chokes.

What is claimed is: 
     
         1 . A method of controlling backpressure of a drilling mud within a wellbore, the method comprising:
 receiving the drilling mud from the wellbore;   either:
 controlling, using one or more drilling chokes, the backpressure of the drilling mud within the wellbore, the one or more drilling chokes being part of a first module; or 
 bypassing the one or more drilling chokes of the first module; either: 
 measuring, using a flow meter, a flow rate of the drilling mud received from the wellbore, the flow meter being part of a second module; or 
 bypassing the flow meter of the second module; 
   communicating the drilling mud between the first and second modules using a third module, the third module being configured to support the second module in either:
 a generally horizontal orientation; or 
 a generally vertical orientation; 
   and   discharging the drilling mud.   
     
     
         2 . The method of  claim 1 , wherein the first and second modules are together mounted to either a skid or a trailer so that, when so mounted, the first and second modules are together towable between operational sites. 
     
     
         3 . The method of  claim 1 , wherein the third module comprises first and second flow blocks operably coupled in parallel between the first and second modules, the first and second flow blocks each defining an internal region and first, second, third, fourth, and fifth fluid passageways extending into the internal region. 
     
     
         4 . The method of  claim 3 , wherein, when the third module supports the second module in the generally horizontal orientation:
 the first module is operably coupled to, and in fluid communication with, the internal region of the first flow block via the first fluid passageway thereof, and the second module is operably coupled to, and in fluid communication with, the internal region of the first flow block via the second fluid passageway thereof; and   the first module is operably coupled to, and in fluid communication with, the internal region of the second flow block via the first fluid passageway thereof, and the second module is operably coupled to, and in fluid communication with, the internal region of the second flow block via the second fluid passageway thereof   
     
     
         5 . The method of  claim 4 , wherein, when the third module supports the second module in the generally vertical orientation:
 the first module is operably coupled to, and in fluid communication with, the internal region of the first flow block via the first fluid passageway thereof, and the second module is operably coupled to, and in fluid communication with, the internal region of the first flow block via the fifth fluid passageway thereof; and   the first module is operably coupled to, and in fluid communication with, the internal region of the second flow block via the first fluid passageway thereof, and the second module is operably coupled to, and in fluid communication with, the internal region of the second flow block via the fifth fluid passageway thereof.   
     
     
         6 . The method of  claim 3 , wherein the first and second flow blocks each comprise first, second, third, fourth, fifth, and sixth sides, the third, fourth, fifth, and sixth sides extending between the first and second sides, and the first, second, third, fourth, and fifth fluid passageways extending through the first, second, third, fourth, and fifth sides. 
     
     
         7 . The method of  claim 3 , wherein the third module further comprises first, second, third, fourth, and fifth valves, the first and second valves being operably coupled to, and in fluid communication with, the first flow block and the respective first and second modules, the third and fourth valves being operably coupled to, and in fluid communication with, the second flow block and the respective first and second modules, and the fifth valve being operably coupled between, and in fluid communication with, the first and second flow blocks. 
     
     
         8 . The method of  claim 7 ,
 wherein communicating the drilling mud between the first and second modules using the third module comprises:
 permitting fluid flow from the first flow block to the second flow block via the second valve, the flow meter, and the fourth valve; and 
 preventing, or at least reducing, fluid flow from the first flow block to the second flow block via the fifth valve; 
   and   wherein bypassing the flow meter of the second module comprises:
 preventing, or at least reducing, fluid flow from the first flow block to the second flow block via the second valve, the flow meter, and the fourth valve; and 
 permitting fluid flow from the first flow block to the second flow block via the fifth valve. 
   
     
     
         9 . The method of  claim 7 ,
 wherein communicating the drilling mud between the first and second modules using the third module comprises actuating the first, second, third, fourth, and fifth valves so that either:
 the second, third, and fourth valves are open and the first and fifth valves are closed; or 
 the first, second, and fourth valves are open and the third and fifth valves are closed; 
   and   wherein bypassing the flow meter of the second module comprises actuating the first, second, third, fourth, and fifth valves so that either:
 the third and fifth valves are open and the first, second, and fourth valves are closed; or 
 the first and fifth valves are open and the second, third, and fourth valves are closed. 
   
     
     
         10 . The method of  claim 1 , wherein the second module further comprises first and second flow blocks, and first and second spools, the first spool being operably coupled to, and in fluid communication with, the first flow block, the second spool being operably coupled between, and in fluid communication with, the first and second flow blocks, and the flow meter being operably coupled to, and in fluid communication with, the fourth flow block. 
     
     
         11 . The method of  claim 1 , wherein the flow meter is a coriolis flow meter. 
     
     
         12 . A method of controlling backpressure of a drilling mud within a wellbore, the method comprising:
 receiving the drilling mud from the wellbore;   either:
 controlling, using first and/or second drilling chokes, the backpressure of the drilling mud within the wellbore, the first and second drilling chokes being part of a first module, the first module further comprising first and second fluid blocks between which the first and second drilling chokes are operably coupled in parallel; or 
 bypassing the first and second drilling chokes of the first module; 
   and   discharging the drilling mud.   
     
     
         13 . The method of  claim 12 , wherein the first module further comprises first, second, third, and fourth valves, the first and second valves being operably coupled to, and in fluid communication with, the first fluid block, the third and fourth valves being operably coupled to, and in fluid communication with, the second fluid block, the first drilling choke being operably coupled between, and in fluid communication with, the first and third valves, and the second drilling choke being operably coupled between, and in fluid communication with, the second and fourth valves. 
     
     
         14 . The method of  claim 13 , wherein the first module further comprises a fifth valve operably coupled between, and in fluid communication with, the first and second fluid blocks. 
     
     
         15 . The method of  claim 14 ,
 wherein controlling, using the first and/or second drilling chokes, the backpressure of the drilling mud within the wellbore comprises:
 permitting fluid flow from the first fluid block to the second fluid block via one or both of the following element combinations:
 the first valve, the first drilling choke, and the third valve; and 
 the second valve, the second drilling choke, and the fourth valve; 
 
 and 
 preventing, or at least reducing, fluid flow from the first fluid block to the second fluid block via the fifth valve; 
   and   wherein bypassing the first and second drilling chokes of the first module comprises:
 permitting fluid flow from the first fluid block to the second fluid block via the fifth valve; and 
 preventing, or at least reducing, fluid flow from the first fluid block to the second fluid block via each of the following element combinations:
 the first valve, the first drilling choke, and the third valve; and 
 the second valve, the second drilling choke, and the fourth valve. 
 
   
     
     
         16 . The method of  claim 14 ,
 wherein controlling, using the first and/or second drilling chokes, the backpressure of the drilling mud within the wellbore comprises actuating the first, second, third, fourth, and fifth valves so that:
 the first and third valves are open and the second, fourth, and fifth valves are closed; 
 the second and fourth valves are open and the first, third, and fifth valves are closed; or 
 the first, second, third, and fourth valves are open and the fifth valve is closed; 
   and   wherein bypassing the first and second drilling chokes of the first module comprises actuating the first, second, third, fourth, and fifth valves so that the first, second, third, and fourth valves are closed and the fifth valve is open.   
     
     
         17 . The method of  claim 14 , wherein the first and second fluid blocks each define an internal region and first, second, third, and fourth fluid passageways extending into the internal region. 
     
     
         18 . The method of  claim 17 ,
 wherein the first, second, and fifth valves are in fluid communication with the internal region of the first fluid block via the respective first, second, and third fluid passageways thereof; and   wherein the third, fourth, and fifth valves are in fluid communication with the internal region of the second fluid block via the respective first, second, and fourth fluid passageways thereof.   
     
     
         19 . The method of  claim 18 , wherein the first and second fluid blocks each comprise first and second ends, and first, second, third, and fourth sides extending between the first and second ends, the first and second fluid passageways extending through the first side, and the third and fourth fluid passageways extending through the second and third sides, respectively. 
     
     
         20 . A choke module adapted to receive drilling mud from a wellbore, the choke module comprising:
 first and second fluid blocks; and   first and second drilling chokes operably coupled in parallel between the first and second fluid blocks;   wherein each of the first and second drilling chokes is adapted to control a backpressure of the drilling mud within the wellbore.   
     
     
         21 . The choke module of  claim 20 , further comprising first, second, third, and fourth valves, the first and second valves being operably coupled to, and in fluid communication with, the first fluid block, the third and fourth valves being operably coupled to, and in fluid communication with, the second fluid block, the first drilling choke being operably coupled between, and in fluid communication with, the first and third valves, and the second drilling choke being operably coupled between, and in fluid communication with, the second and fourth valves. 
     
     
         22 . The choke module of  claim 21 , further comprising a fifth valve operably coupled between, and in fluid communication with, the first and second fluid blocks. 
     
     
         23 . The choke module of  claim 22 , wherein the choke module is actuable between:
 a first configuration in which:
 fluid flow is permitted from the first fluid block to the second fluid block via one or both of the following element combinations:
 the first valve, the first drilling choke, and the third valve; and 
 the second valve, the second drilling choke, and the fourth valve; 
 
 and 
 fluid flow is prevented, or at least reduced, from the first fluid block to the second fluid block via the fifth valve; 
   and   a second configuration in which:
 fluid flow is permitted from the first fluid block to the second fluid block via the fifth valve; and 
 fluid flow is prevented, or at least reduced, from the first fluid block to the second fluid block via each of the following element combinations:
 the first valve, the first drilling choke, and the third valve; and 
 the second valve, the second drilling choke, and the fourth valve. 
 
   
     
     
         24 . The choke module of  claim 23 ,
 wherein, when the choke module is in the first configuration, the first, second, third, fourth, and fifth valves are actuated so that either:
 the first and third valves are open and the second, fourth, and fifth valves are closed; 
 the second and fourth valves are open and the first, third, and fifth valves are closed; or 
 the first, second, third, and fourth valves are open and the fifth valve is closed; 
   and   wherein, when the choke module is in the second configuration, the first, second, third, fourth, and fifth valves are actuated so that the first, second, third, and fourth valves are closed and the fifth valve is open.   
     
     
         25 . The choke module of  claim 22 , wherein the first and second fluid blocks each define an internal region and first, second, third, and fourth fluid passageways extending into the internal region. 
     
     
         26 . The choke module of  claim 25 ,
 wherein the first, second, and fifth valves are in fluid communication with the internal region of the first fluid block via the respective first, second, and third fluid passageways thereof; and   wherein the third, fourth, and fifth valves are in fluid communication with the internal region of the second fluid block via the respective first, second, and fourth fluid passageways thereof.   
     
     
         27 . The choke module of  claim 26 , wherein the first and second fluid blocks each comprise first and second ends, and first, second, third, and fourth sides extending between the first and second ends, the first and second fluid passageways extending through the first side, and the third and fourth fluid passageways extending through the second and third sides, respectively.