US20170260820A1

US20170260820A1 - Method and Apparatus for Suction Monitoring and Control in Rig Pumps

Info

Publication number: US20170260820A1
Application number: US15/066,094
Authority: US
Inventors: Ossama Sehsah
Original assignee: Saudi Arabian Oil Co
Current assignee: Saudi Arabian Oil Co
Priority date: 2016-03-10
Filing date: 2016-03-10
Publication date: 2017-09-14
Also published as: WO2017156353A1

Abstract

A pumping system includes a primary suction tank including a first pressure sensor operatively connected to a first portable suction control for measuring a first pressure of a fluid coming from the primary suction tank, and a first flow meter operatively connected to the first portable suction control for measuring a first flow rate of the fluid coming from the primary suction tank, wherein an output of the primary suction tank is controlled by a first valve, a secondary suction tank, a rig pump operatively connected to the primary suction tank, and the secondary suction tank, and a rig stand pipe connected to a drilling well, and a controller operatively connected to the first portable suction control, the first valve, and a second flow meter configured to measure a second flow rate of the fluid coming out of the rig pump.

Description

TECHNICAL FIELD

Example embodiments relate to methods and systems for suction monitoring and control in rig mud pumps for drilling wells.

BACKGROUND

In a drilling operation, whether offshore or on land, teeth of a drill bit grind the rock and break it into small pieces. These rock pieces must be continuously removed from the path of the drill bit for the operation to continue. To that end, a mud pump injects drilling fluid or mud fluid in the form of a jet to remove the cut rock pieces from the path of the drill bit so that the operation may continue. Thus, the mud pump plays the role of heart in keeping the mud fluid flowing to remove the broken rocks and facilitate movement of the drill bit. In modern drilling operations, without the operational mud pump(s), the drilling comes to a halt.
A mud pump is a large heavy-duty, high-pressure reciprocating pump. A typical pump is a single- or double acting, two or three-cylinder piston pump whose pistons travel in replaceable liners and are driven by a crankshaft actuated by an engine or a motor. The pump is typically positioned on or right next to the drilling platform or drilling well.
The lubricating fluid also called mud is continuously used for drilling operations. The mud is usually placed in steel tanks on a rig, where the mud is circulated through the wellbore during drilling and well workover operations. In addition to its function of bringing cuttings to the surface, drilling mud cools and lubricates the bit and drill stem, protects against blowouts by holding back subsurface pressures, and deposits a mud cake on the wall of the borehole to prevent loss of drilling fluids to the formation.
The pump forces the drilling mud through the drill pipe and drill collars and to the drill bit. The drilling mud jets out from the bit nozzles with great speed and moves the debris out of the path of the drill bit. The contaminated mud then moves back up to the surface for filtering and further processing for reuse. Since the pump interior parts come in contact with the mud including rock pieces of varying sizes, and experience harsh environment including an extensive vibratory environment, damage may occur to those parts. In general, the pump components, like liners, valves, seats, etc., degrade gradually and it is difficult to determine when the pump may be suffer functional failure.
These mud pumps are expensive pieces of machinery and are integral to a drilling operation. When the mud pump breaks, drilling operations must stop, and either the drilling contractor or operator has to bear the expenses for the associated downtime. Down times of a few days can be very expensive. Many groups have experimented with mud pump monitors, but have tried to solve the problem by mounting detection and monitoring sensors inside the pump itself. These attempts have failed for two main reasons. Firstly, the sensors are exposed to a hostile environment like high pressures up to 7500 psi, excessive heat, and corrosive fluids where the sensors are easily damaged and become useless. Secondly, machine tolerances are so small in high-pressure pumps, like mud pumps, that attaching an additional piece, in the form of a replaceable sensor, is not only impractical but also adversely affects pump performance.
In other instances, the rig mud pumps might stop or perform with lower efficiency due to suction problems, which could be a result of inadequate supply fluid rate or change in fluid properties and/or quality. This can also lead to a well control incident or affect the drilling process' performance and safety.

SUMMARY

Accordingly, example embodiments disclosed provide systems and methods for suction monitoring and control in rig mud pumps that are overcome the limitations and drawbacks of prior art systems.
One example embodiment is a pumping system for use in a drilling well. The pumping system includes a first suction tank including a first pressure sensor operatively connected to a first portable suction control for measuring a first pressure of a fluid coming from the first suction tank, and a first flow meter operatively connected to the first portable suction control for measuring a first flow rate of the fluid coming from the first suction tank, wherein an output of the first suction tank may be controlled by a first valve. The pumping system also includes a second suction tank including a second pressure sensor operatively connected to a second portable suction control for measuring a second pressure of the fluid coming from the second suction tank, and a second flow meter operatively connected to the second portable suction control for measuring a second flow rate of the fluid coming from the second suction tank, wherein an output of the second suction tank may be controlled by a second valve, a rig pump operatively connected to the first suction tank, and the second suction tank, and a rig stand pipe connected to the drilling well, and a controller operatively connected to the first portable suction control, the second portable suction control, the first valve, the second valve, and a third flow meter configured to measure a third flow rate of the fluid coming out of the rig pump. The controller may be configured to at least partially open the second valve to divert suction intake from the first suction tank to the second suction tank based on the first pressure, the first flow rate, or the third flow rate.
In some example embodiments, the controller may be further configured to at least partially close the first valve to divert suction intake from the first suction tank to the second suction tank. The controller may be also configured to at least partially open the first valve to divert suction intake from the second suction tank to the first suction tank based on the second pressure, the second flow rate, or third flow rate. The controller may be also configured to at least partially close the second valve to divert suction intake from the second suction tank to the first suction tank. The first suction tank further includes a first level meter for measuring a first level of the fluid in the first suction tank. In one example embodiment, the second suction tank further includes a second level meter for measuring a second level of the fluid in the second suction tank. The first valve may be disposed approximately at a distance of four feet or less from the first portable suction control. The second valve may be disposed approximately at a distance of four feet or less from the second portable suction control. The pumping system can also include a human machine interface operatively connected to the controller for displaying a message and receiving an instruction from an operator.
Another example embodiment is a method for monitoring and controlling suction in a drilling well. The method includes measuring, by a first pressure sensor, a first pressure of a fluid coming from a first suction tank, measuring, by a first flow sensor, a first flow rate of the fluid coming from the first suction tank, measuring, by a second flow sensor, a second flow rate of the fluid coming out of a rig pump operatively connected to the first suction tank, and actuating, by a controller, a first valve adapted to control suction from the first tank, to divert suction intake from the first suction tank to a second suction tank, wherein the actuating may be based on the first pressure, the first flow rate, or the second flow rate. The method may also include measuring, by a second pressure sensor, a second pressure of the fluid coming from the second suction tank, measuring, by a third flow meter, a third flow rate of the fluid coming from the second suction tank, and actuating, by the controller, a second valve adapted to control suction from the second tank, to divert suction intake from the second suction tank to the first suction tank, wherein the actuating may be based on the second pressure, the second flow rate, or the third flow rate.
Another example embodiment is an apparatus including a primary suction tank including a first pressure sensor operatively connected to a first portable suction control for measuring a first pressure of a fluid coming from the primary suction tank, and a first flow meter operatively connected to the first portable suction control for measuring a first flow rate of the fluid coming from the primary suction tank, wherein an output of the primary suction tank may be controlled by a first valve, a secondary suction tank, a rig pump operatively connected to the primary suction tank, and the secondary suction tank, and a rig stand pipe connected to a drilling well, and a controller operatively connected to the first portable suction control, the first valve, and a second flow meter configured to measure a second flow rate of the fluid coming out of the rig pump. The controller may be configured to at least partially open a second valve to divert suction intake from the primary suction tank to the secondary suction tank based on the first pressure, the first flow rate, or the second flow rate.
In some example embodiments, the secondary suction tank further includes a second pressure sensor operatively connected to a second portable suction control for measuring a second pressure of the fluid coming from the secondary suction tank, and a third flow meter operatively connected to the second portable suction control for measuring a third flow rate of the fluid coming from the secondary suction tank, wherein an output of the secondary suction tank may be controlled by a second valve. The controller may be further connected to the second portable suction control, and the second valve. The controller may be also configured to at least partially close the first valve to divert suction intake from the primary suction tank to the secondary suction tank. The controller may be also configured to at least partially open the first valve to divert suction intake from the secondary suction tank to the primary suction tank based on the second pressure, the second flow rate, or third flow rate. The controller may be may also be configured to at least partially close the second valve to divert suction intake from the secondary suction tank to the primary suction tank.
In some example embodiments, the primary suction tank further includes a first level meter for measuring a first level of the fluid in the primary suction tank, or the secondary suction tank further includes a second level meter for measuring a second level of the fluid in the secondary suction tank. The first valve may be disposed approximately at a distance of four feet or less from the first portable suction control, or the second valve may be disposed approximately at a distance of four feet or less from the second portable suction control. The apparatus may also include a human machine interface operatively connected to the controller for displaying a message and receiving an instruction from an operator.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the features, advantages and objects of the invention, as well as others which may become apparent, are attained and can be understood in more detail, more particular description of the invention briefly summarized above may be had by reference to the embodiment thereof which is illustrated in the appended drawings, which drawings form a part of this specification. It is to be noted, however, that the drawings illustrate only example embodiments of the invention and is therefore not to be considered limiting of its scope as the invention may admit to other equally effective embodiments.

FIG. 1 illustrates an example pumping system for monitoring and controlling suction in a rig mud pump for use in a drilling well, according to one or example embodiments of the disclosure.

FIG. 2 illustrates example operations in a method for monitoring and controlling suction in a rig mud pump for use in a drilling well, according to one or more example embodiments of the disclosure.

FIG. 3 illustrates an example operations in another method for monitoring and controlling suction in a rig mud pump for use in a drilling well, according to one or more example embodiments of the disclosure.

DETAILED DESCRIPTION

The methods and systems of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The methods and systems of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout.
Turning now to the figures, FIG. 1 illustrates an example pumping system 100 for pumping mud into drilling well 20 via rig stand pipe 18, according to one or more example embodiments. The system 100 includes a rig mud pump 1 which receives mud from and is operatively connected to a rig suction tank 22 via a suction pipe 24. Rig suction tank 22 includes one or more pressure sensors 5, 7 operatively connected to a portable suction control 8 for measuring a pressure of a fluid coming from the rig suction tank 22. Pressure sensors 5, 7 measure pressure of the fluid in the tank 22. Pressure sensors 5, 7 act as a transducer and generate a signal as a function of the pressure imposed. Pressure sensors 5, 7 can include any type of pressure sensor, including but not limited to, absolute pressure sensor, gauge pressure sensor, vacuum pressure sensor, differential pressure sensor, and a sealed pressure sensor. The transducer within the pressure sensor may include a piezoresistive strain gauge, capacitive sensor, electromagnetic sensor, optical sensor, potentiometric sensor, resonant sensor, thermal sensor, or an ionization sensor.
Rig suction tank 22 also includes one or more flow meters 4, 6 operatively connected to the portable suction control 8 for measuring a flow rate of the fluid coming from the rig suction tank 22. Flow meters 4, 6 measure flow of the fluid from rig suction tank 22, quantifying bulk fluid movement. Flow can be measured in a variety of ways. In some example embodiments, flow can be measured by measuring the velocity of fluid over a known area or by measuring volume of fluid flow per minute or per sec. Flow meters 4,6 can include any type of flow meters known in the art, including but not limited to, optical flow meters, mechanical flow meters including rotary piston meters, oval gear meters, gear meters, helical gear meters, nutating disk meters, turbine flow meters, Woltman meters, single jet meters, paddle wheel meters, multiple jet meters, Pelton wheel meters, current meters, pressure-based meters including venture meters, orifice plate meters, dall tube meters, pitot-static tube meters, multi-hole pressure probe meters, cone meters, linear resistance meters, as well as electromagnetic, ultrasonic and Coriolis flow meters.
Rig suction tank 22 further includes a level meter 3 for measuring a level of the fluid in the rig suction tank 22. An output of the rig suction tank 22 can be controlled by a valve 2, which can be disposed approximately at a distance of four feet or less from the portable suction control 8. The valve 2 may be able to control the volume of mud being outputted by rig suction tank 22, as well as the pressure and flow rate of the mud.
Pumping system 100 also includes a secondary suction tank 26 that is operatively connected to rig pump 1 via suction pipe 28. Similar to rig suction tank 22, secondary suction tank 26 includes one or more pressure sensors 11, 14 operatively connected to a portable suction control 15 for measuring a pressure of a fluid coming from the secondary suction tank 26. Pressure sensors 11, 14 measure pressure of the fluid in the tank 26. Pressure sensors 11, 14 act as a transducer and generate a signal as a function of the pressure imposed. Pressure sensors 11, 14 can include any type of pressure sensor, including but not limited to, absolute pressure sensor, gauge pressure sensor, vacuum pressure sensor, differential pressure sensor, and a sealed pressure sensor. The transducer within the pressure sensor may include a piezoresistive strain gauge, capacitive sensor, electromagnetic sensor, optical sensor, potentiometric sensor, resonant sensor, thermal sensor, or an ionization sensor.
Secondary suction tank 26 also includes one or more flow meters 12, 13 operatively connected to the portable suction control 15 for measuring a flow rate of the fluid coming from the secondary suction tank 26. Flow meters 12, 13 measure flow of the fluid from rig suction tank 26, quantifying bulk fluid movement. Flow can be measured in a variety of ways. In some example embodiments, flow can be measured by measuring the velocity of fluid over a known area or by measuring volume of fluid flow per minute or per sec. Flow meters 12, 13 can include any type of flow meters known in the art, including but not limited to, optical flow meters, mechanical flow meters including rotary piston meters, oval gear meters, gear meters, helical gear meters, nutating disk meters, turbine flow meters, Woltman meters, single jet meters, paddle wheel meters, multiple jet meters, Pelton wheel meters, current meters, pressure-based meters including venture meters, orifice plate meters, dall tube meters, pitot-static tube meters, multi-hole pressure probe meters, cone meters, linear resistance meters, as well as electromagnetic, ultrasonic and Coriolis flow meters.
Secondary suction tank 26 further includes a level meter 10 for measuring a level of the fluid in the secondary suction tank 26. An output of the secondary suction tank 26 can be controlled by a valve 16, which can be disposed approximately at a distance of four feet or less from the portable suction control 15. The valve 16 may be able to control the volume of mud being outputted by secondary suction tank 26, as well as the pressure and flow rate of the mud.
Pumping system 100 also includes a controller 9 that is operatively connected to portable suction control 8, portable suction control 15, valves 2, 16, and another flow meter 17 that is configured to measure a flow rate of the fluid coming out of the rig pump 1. Flow meter 17 can measure flow of the fluid coming from rig pump 1, quantifying bulk fluid movement. Flow can be measured in a variety of ways. In some example embodiments, flow can be measured by measuring the velocity of fluid over a known area or by measuring volume of fluid flow per minute or per sec. Flow meter 17 can include any type of flow meters known in the art, including but not limited to, optical flow meters, mechanical flow meters including rotary piston meters, oval gear meters, gear meters, helical gear meters, nutating disk meters, turbine flow meters, Woltman meters, single jet meters, paddle wheel meters, multiple jet meters, Pelton wheel meters, current meters, pressure-based meters including venture meters, orifice plate meters, dall tube meters, pitot-static tube meters, multi-hole pressure probe meters, cone meters, linear resistance meters, as well as electromagnetic, ultrasonic and Coriolis flow meters.
The controller 9 may be a programmable logic controller (PLC) or programmable controller 9 that may include a digital computer or one or more processors. Controller 9 may be designed for multiple arrangements of digital and analog inputs and outputs, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. According to one example embodiment, programs to control machine operation may be typically stored in a battery-backed-up or non-volatile memory. Controller 9 can be programmed in a variety of ways, from the relay-derived ladder logic to programming languages such as specially adapted dialects of BASIC and C. Another example method is state logic, a very high-level programming language designed to program PLCs based on state transition diagrams.
According to one example embodiment, controller 9 may be configured to at least partially open valve 16 and at least partially close valve 2 to divert suction intake from rig suction tank 22 to the secondary suction tank 26 based on the flow rate measured by flow meter 17 or the pressure measured by pressure sensors 5, 7, or the flow rate measured by flow meters 4, 6. In one example, the controller 9 may sense that the flow rate of the fluid, for example mud, being pumped out of the rig pump 1 is lower than a threshold value. When the flow rate of the mud being pumped falls below a predetermined threshold value, controller 9 may be configured to at least partially open valve 16 and at least partially close valve 2 to divert suction intake from rig suction tank 22 to the secondary suction tank 26. In another example, when the flow rate of the mud being pumped out of rig suction tank 22 falls below a predetermined threshold value, controller 9 may be configured to at least partially open valve 16 and at least partially close valve 2 to divert suction intake from rig suction tank 22 to the secondary suction tank 26. Similarly, a drop in pressure at rig suction tank 22 below a predetermined pressure may cause the controller 9 to at least partially open valve 16 and at least partially close valve 2 to divert suction intake from rig suction tank 22 to the secondary suction tank 26. After the flow rate at flow meter 17 reaches the threshold value, the controller 9 may keep valve 16 open to provide sufficient and continuous mud supply from secondary suction tank 26. In another instance, if the controller 9 senses that the suction from secondary suction tank 26 is lower than the predetermined threshold value, then the controller 9 may at least partially open the first valve 2 and at least partially close the second valve 16 to divert suction intake from the secondary suction tank 26 to the first suction tank 22 on the flow rate measured by flow meter 17 or the pressure measured by pressure sensors 11, 14, or the flow rate measured by flow meters 12, 13. In another example, when the flow rate of the mud being pumped out of rig suction tank 26 falls below a predetermined threshold value, controller 9 may be configured to at least partially open the first valve 2 and at least partially close valve 16 to divert suction intake from secondary suction tank 26 to the rig suction tank 22. Similarly, a drop in pressure at secondary suction tank 26 below a predetermined pressure may cause the controller 9 to at least partially open the first valve 2 and at least partially close valve 16 to divert suction intake from secondary suction tank 26 to the rig suction tank 22.
In one example embodiment, the pumping system 100 can also include a human machine interface that may be connected to the controller for displaying a message and receiving an instruction from an operator. The controller 9 may actuate valves 2, 16 based on an input received form the operator.
FIG. 2 illustrates an example method 200 for monitoring and controlling suction in a drilling well, according to one or more example embodiments. For purposes of simplicity of explanation, the example method disclosed herein is presented and described as a series of blocks (with each block representing an action or an operation in a method, for example). However, it is to be understood and appreciated that the disclosed method is not limited by the order of blocks and associated actions or operations, as some blocks may occur in different orders and/or concurrently with other blocks from those that are shown and described herein. For example, the various methods (or processes or techniques) in accordance with this disclosure can be alternatively represented as a series of interrelated states or events, such as in a state diagram. Furthermore, not all illustrated blocks, and associated action(s), may be required to implement a method in accordance with one or more aspects of the disclosure. Further yet, two or more of the disclosed methods or processes can be implemented in combination with each other, to accomplish one or more features or advantages described herein.
At step 202, the method includes measuring, by a first pressure sensor, a first pressure of a fluid coming from a first suction tank. At step 204, the method includes measuring, by a first flow sensor, a first flow rate of the fluid coming from the first suction tank. At step 206, the method includes measuring, by a second flow sensor, a second flow rate of the fluid coming out of a rig pump operatively connected to the first suction tank. At step 208, the method includes actuating, by a controller or by an apparatus including at least one memory device having programmed instructions and at least one processor functionally coupled to the at least one memory device and configured to execute the programmed instructions, a first valve adapted to control suction from the first tank, and to divert suction intake from the first suction tank to a second suction tank. The actuation of the valve may be based on the value of the first pressure, the first flow rate, or the second flow rate. According to another example embodiment, method 300 may also include measuring, by a second pressure sensor, a second pressure of the fluid coming from the second suction tank at step 302. At 304, the method 300 may include measuring, by a third flow meter, a third flow rate of the fluid coming from the second suction tank. At step 306, the method 300 may include actuating, by a controller or by an apparatus including at least one memory device having programmed instructions and at least one processor functionally coupled to the at least one memory device and configured to execute the programmed instructions, a second valve adapted to control suction from the second tank, and to divert suction intake from the second suction tank to the first suction tank. The step of actuating the second valve may be based on the value of the second pressure, the second flow rate, or the third flow rate, as described in one or more of the previous example embodiments. The term “actuating” as described herein may involve opening or closing a valve, either partially or fully, as suited for the purpose described above.
Accordingly, one example embodiment is an apparatus including a primary suction tank including a first pressure sensor operatively connected to a first portable suction control for measuring a first pressure of a fluid coming from the primary suction tank, and a first flow meter operatively connected to the first portable suction control for measuring a first flow rate of the fluid coming from the primary suction tank, wherein an output of the primary suction tank may be controlled by a first valve. The apparatus also includes a secondary suction tank, and a rig pump operatively connected to the primary suction tank, and the secondary suction tank, and a rig stand pipe connected to a drilling well. The apparatus also includes a controller operatively connected to the first portable suction control, the first valve, and a second flow meter configured to measure a second flow rate of the fluid coming out of the rig pump. The controller may be configured to at least partially open a second valve to divert suction intake from the primary suction tank to the secondary suction tank based on the first pressure, the first flow rate, or the second flow rate.
In some example embodiments, the secondary suction tank further includes a second pressure sensor operatively connected to a second portable suction control for measuring a second pressure of the fluid coming from the secondary suction tank, and a third flow meter operatively connected to the second portable suction control for measuring a third flow rate of the fluid coming from the secondary suction tank, wherein an output of the secondary suction tank may be controlled by a second valve. The controller may be further connected to the second portable suction control, and the second valve. The controller may be also configured to at least partially close the first valve to divert suction intake from the primary suction tank to the secondary suction tank. The controller may be also configured to at least partially open the first valve to divert suction intake from the secondary suction tank to the primary suction tank based on the second pressure, the second flow rate, or third flow rate. The controller may be may also be configured to at least partially close the second valve to divert suction intake from the secondary suction tank to the primary suction tank.
In some example embodiments, the primary suction tank further includes a first level meter for measuring a first level of the fluid in the primary suction tank, or the secondary suction tank further includes a second level meter for measuring a second level of the fluid in the secondary suction tank. The first valve may be disposed approximately at a distance of four feet or less from the first portable suction control, or the second valve may be disposed approximately at a distance of four feet or less from the second portable suction control. The apparatus, in one example embodiment, also includes a human machine interface operatively connected to the controller for displaying a message and receiving an instruction from an operator.
Accordingly, example embodiments disclosed provide systems and methods for suction monitoring and control in rig mud pumps that are overcome the limitations and drawbacks of prior art systems. One example embodiment relates to a pumping system including a flow meter with pressure sensor at the suction pipe with level control at a distance four feet or less from the suction pipe. Signals can be sent to a PLC with a monitor, such as a human machine interface (HMI) to analyze and alarm, and operate an actuated valve to switch or divert the suction intake to a backup suction until fixing the problem. Monitoring and controlling pressure, level, and flow in the suction pipe or flow out of the pump is one aspect of this process. Suction pressure versus level may indicate mud weight and rheology, while flow in the suction pipe versus flow out of the pump may indicate the pump performance. This addition to the rig mud pump system may be necessary for well control and drilling process performance and for safety, especially for drilling wells.
Example embodiments disclosed provide a suction monitor and control system for mud pumps in a drilling environment, where two sets of flow meters and pressure sensors are located at two different suction pipes with level control at a distance of about four feet or less from the suction pipe. Monitoring signals are sent from the flow meters and pressure sensors to a programmable logic controller (PLC) with a human-machine interface for further analysis and generating an alarm, if necessary. A valve may be actuated, in response to a control signal received from the PLC, to switch or divert the suction intake to a backup suction tank if a problem is detected.
The Specification, which includes the Summary, Brief Description of the Drawings and the Detailed Description, and the appended Claims refer to particular features (including process or method steps) of the disclosure. Those of skill in the art understand that the invention includes all possible combinations and uses of particular features described in the Specification. Those of skill in the art understand that the disclosure is not limited to or by the description of embodiments given in the Specification.
Those of skill in the art also understand that the terminology used for describing particular embodiments does not limit the scope or breadth of the disclosure. In interpreting the Specification and appended Claims, all terms should be interpreted in the broadest possible manner consistent with the context of each term. All technical and scientific terms used in the Specification and appended Claims have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs unless defined otherwise.
As used in the Specification and appended Claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly indicates otherwise. The verb “comprises” and its conjugated forms should be interpreted as referring to elements, components or steps in a non-exclusive manner. The referenced elements, components or steps may be present, utilized or combined with other elements, components or steps not expressly referenced. The verb “operatively connecting” and its conjugated forms means to complete any type of required junction, including electrical, mechanical or fluid, to form a connection between two or more previously non-joined objects. If a first component is operatively connected to a second component, the connection can occur either directly or through a common connector. “Optionally” and its various forms means that the subsequently described event or circumstance may or may not occur. The description includes instances where the event or circumstance occurs and instances where it does not occur.
Conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain implementations could include, while other implementations do not include, certain features, elements, and/or operations. Thus, such conditional language generally is not intended to imply that features, elements, and/or operations are in any way required for one or more implementations or that one or more implementations necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and/or operations are included or are to be performed in any particular implementation.
The systems and methods described herein, therefore, are well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While example embodiments of the system and method has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications may readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the system and method disclosed herein and the scope of the appended claims.

Claims

1. A pumping system for use in a drilling well, the pumping system comprising:

a first suction tank comprising a first pressure sensor operatively connected to a first portable suction control for measuring a first pressure of a fluid coming from the first suction tank, and a first flow meter operatively connected to the first portable suction control for measuring a first flow rate of the fluid coming from the first suction tank, wherein an output of the first suction tank is controlled by a first valve;

a second suction tank comprising a second pressure sensor operatively connected to a second portable suction control for measuring a second pressure of the fluid coming from the second suction tank, and a second flow meter operatively connected to the second portable suction control for measuring a second flow rate of the fluid coming from the second suction tank, wherein an output of the second suction tank is controlled by a second valve;

a rig pump operatively connected to the first suction tank, and the second suction tank, and a rig stand pipe connected to the drilling well; and

a controller operatively connected to the first portable suction control, the second portable suction control, the first valve, the second valve, and a third flow meter configured to measure a third flow rate of the fluid coming out of the rig pump,

wherein the controller is configured to:

at least partially open the second valve to divert suction intake from the first suction tank to the second suction tank based on the first pressure, the first flow rate, or the third flow rate.

2. The pumping system of claim 1, wherein the controller is further configured to at least partially close the first valve to divert suction intake from the first suction tank to the second suction tank.

3. The pumping system of claim 2, wherein the controller is further configured to at least partially open the first valve to divert suction intake from the second suction tank to the first suction tank based on the second pressure, the second flow rate, or third flow rate.

4. The pumping system of claim 3, wherein the controller is further configured to at least partially close the second valve to divert suction intake from the second suction tank to the first suction tank.

5. The pumping system of claim 1, wherein the first suction tank further comprises a first level meter for measuring a first level of the fluid in the first suction tank.

6. The pumping system of claim 1, wherein the second suction tank further comprises a second level meter for measuring a second level of the fluid in the second suction tank.

7. The pumping system of claim 1, wherein the first valve is disposed approximately at a distance of four feet or less from the first portable suction control or the rig pump.

8. The pumping system of claim 1, wherein the second valve is disposed approximately at a distance of four feet or less from the second portable suction control or the rig pump.

9. The pumping system of claim 1, further comprising: a human machine interface operatively connected to the controller for displaying a message and receiving an instruction from an operator.

10. A method for monitoring and controlling suction in a drilling well, the method comprising:

measuring, by a first pressure sensor, a first pressure of a fluid coming from a first suction tank;

measuring, by a first flow sensor, a first flow rate of the fluid coming from the first suction tank;

measuring, by a second flow sensor, a second flow rate of the fluid coming out of a rig pump operatively connected to the first suction tank; and

actuating, by a controller, a first valve adapted to control suction from the first tank, to divert suction intake from the first suction tank to a second suction tank, wherein the actuating is based on the first pressure, the first flow rate, or the second flow rate.

11. The method of claim 10, further comprising:

measuring, by a second pressure sensor, a second pressure of the fluid coming from the second suction tank;

measuring, by a third flow meter, a third flow rate of the fluid coming from the second suction tank; and

actuating, by the controller, a second valve adapted to control suction from the second tank, to divert suction intake from the second suction tank to the first suction tank, wherein the actuating is based on the second pressure, the second flow rate, or the third flow rate.

12. An apparatus comprising:

a primary suction tank comprising a first pressure sensor operatively connected to a first portable suction control for measuring a first pressure of a fluid coming from the primary suction tank, and a first flow meter operatively connected to the first portable suction control for measuring a first flow rate of the fluid coming from the primary suction tank, wherein an output of the primary suction tank is controlled by a first valve;

a secondary suction tank;

a rig pump operatively connected to the primary suction tank, and the secondary suction tank, and a rig stand pipe connected to a drilling well; and

a controller operatively connected to the first portable suction control, the first valve, and a second flow meter configured to measure a second flow rate of the fluid coming out of the rig pump,

wherein the controller is configured to:

at least partially open a second valve to divert suction intake from the primary suction tank to the secondary suction tank based on the first pressure, the first flow rate, or the second flow rate.

13. The apparatus of claim 12, wherein the secondary suction tank further comprises a second pressure sensor operatively connected to a second portable suction control for measuring a second pressure of the fluid coming from the secondary suction tank, and a third flow meter operatively connected to the second portable suction control for measuring a third flow rate of the fluid coming from the secondary suction tank, wherein an output of the secondary suction tank is controlled by the second valve.

14. The apparatus of claim 13, wherein the controller is further connected to the second portable suction control, and the second valve.

15. The apparatus of claim 14, wherein the controller is further configured to at least partially close the first valve to divert suction intake from the primary suction tank to the secondary suction tank.

16. The apparatus of claim 15, wherein the controller is further configured to at least partially open the first valve to divert suction intake from the secondary suction tank to the primary suction tank based on the second pressure, the second flow rate, or third flow rate.

17. The apparatus of claim 16, wherein the controller is further configured to at least partially close the second valve to divert suction intake from the secondary suction tank to the primary suction tank.

18. The apparatus of claim 12, wherein the primary suction tank further comprises a first level meter for measuring a first level of the fluid in the primary suction tank, or the secondary suction tank further comprises a second level meter for measuring a second level of the fluid in the secondary suction tank.

19. The apparatus of claim 13, wherein the first valve is disposed approximately at a distance of four feet or less from the first portable suction control or the rig pump, or the second valve is disposed approximately at a distance of four feet or less from the second portable suction control or the rig pump.

20. The apparatus of claim 12, further comprising: a human machine interface operatively connected to the controller for displaying a message and receiving an instruction from an operator.