Control panel, and digital display units and sensors therefor

According to one aspect, a digital display unit includes a microcontroller to process digital information received from one or more sensors, a display, and a switch in electrical communication with the microcontroller so that the microcontroller displays an output on the display that is specific to a type of sensor. The type of sensor may be selected from a position sensor, a pressure sensor, and a stroke counter. The digital display unit may be part of a choke control panel. The microcontroller and the display may be disposed in an enclosure, and an electrical power source may be disposed in the enclosure to supply electrical power to the microcontroller and the one or more sensors. A digital hydraulic choke position sensor assembly and a digital pressure sensor assembly are also described, one or both of which may be used in a system for drilling an oil or gas well.

TECHNICAL FIELD

This disclosure relates in general to control panels and, in particular, a choke control panel for a choke system used in, for example, a system for drilling an oil or gas well.

BACKGROUND OF THE DISCLOSURE

During the drilling of an oil or gas well, backpressure control devices or “chokes” are used to impose backpressure on drilling fluid. Choke control panels may be used to monitor and/or control the imposition of backpressure by chokes. In some cases, choke control panels employ particularized and expensive gauges, which are not easily interchangeable. Additionally, some choke control panels or sensors and gauges thereof are dependent upon an external power source, such as a power source on a drilling rig. Still other choke control panels or gauges thereof do not provide sufficient incremental resolution of the values of different operation parameters, and/or are not operationally compatible with different types of chokes, such as both hydraulic and electric chokes. Therefore, what is needed is an apparatus, system or method that addresses one or more of the foregoing issues, among others.

SUMMARY

In a first aspect, there is provided a system that includes a frame; a first digital display unit connected to the frame and capable of receiving digital information from each of a plurality of sensors, the first digital display unit including a first microcontroller to process digital information received from one or more sensors in the plurality of sensors; a first display in electrical communication with the first microcontroller; and a first switch in electrical communication with the first microcontroller so that, when the first microcontroller receives digital information from the one or more sensors in the plurality of sensors, the first microcontroller recognizes a first type of sensor from which the first microcontroller either is, or at least should be, receiving the digital information and displays a first output on the first display that is specific to the recognized first type of sensor; and a second digital display unit connected to the frame and capable of receiving digital information from each of the plurality of sensors, the second digital display unit including a second microcontroller to process digital information received from one or more other sensors in the plurality of sensors; a second display in electrical communication with the second microcontroller; and a second switch in electrical communication with the second microcontroller so that, when the second microcontroller receives the digital information from the one or more other sensors in the plurality of sensors, the second microcontroller recognizes a second type of sensor from which the second microcontroller either is, or at least should be, receiving the digital information; wherein the second type of sensor is different from the first type of sensor, the second switch is different from the first switch, and the second microcontroller displays a second output on the second display that is specific to the recognized second type of sensor and thus different from the first output.

In an exemplary embodiment, each of the first and second types of sensors is selected from the group consisting of a position sensor, a pressure sensor, and a stroke counter.

In another exemplary embodiment, the first type of sensor is a digital hydraulic choke position sensor, the second type of sensor is one of a digital pressure sensor and a digital stroke counter, and the frame and the first and second digital display units are part of a choke control panel.

In certain exemplary embodiments, the first output includes a value corresponding to the degree to which a hydraulic choke is open or closed; and wherein the second output includes one of a pressure value and a stroke rate.

In an exemplary embodiment, the system includes a digital hydraulic choke position sensor assembly adapted to determine the choke position of the hydraulic choke, the hydraulic choke including a rod, the digital hydraulic choke position sensor assembly being of the first type of sensor and including a housing adapted to be connected to the hydraulic choke, the housing defining a longitudinally-extending passage; and a digital position sensor disposed in the longitudinally-extending passage to sense movement of the rod and output digital information corresponding to the sensed movement; wherein the digital position sensor is adapted to be in electrical communication with the first microcontroller.

In another exemplary embodiment, the second type of sensor is the digital pressure sensor; and wherein the system further includes a digital pressure sensor assembly being of the second type of sensor, the digital pressure sensor assembly including a cover including first and second opposing end portions; a longitudinally-extending passage formed in the first end portion; a connector located at the second end portion and in electrical communication with the second microcontroller; and a pressure transducer adapted to be in electrical communication with the connector; and a plurality of components via which the pressure transducer is in electrical communication with the connector, wherein the components extend within the longitudinally-extending passage.

In certain exemplary embodiments, the first digital display unit includes a first enclosure and a first lid assembly connected thereto, the first lid assembly including the first microcontroller, the first display, and the first switch; and wherein the second digital display unit includes a second enclosure and a second lid assembly connected thereto, the second lid assembly including the second microcontroller, the second display, and the second switch.

In an exemplary embodiment, the second microcontroller is identical to the first microcontroller; wherein the second enclosure is identical to the first enclosure; wherein the second display is identical to the first display; and wherein the second switch is different from the first switch.

In another exemplary embodiment, the first and second lid assemblies are interchangeable between the first and second enclosures so that, when the first and second lid assemblies are interchanged: the first digital display unit includes the first enclosure and the second lid assembly connected thereto, and the second digital display unit includes the second enclosure and the first lid assembly connected thereto.

In certain exemplary embodiments, the first digital display unit includes a first electrical power source in electrical communication with the first microcontroller to supply electrical power thereto; wherein the second digital display unit includes a second electrical power source in electrical communication with the second microcontroller to supply electrical power thereto; and wherein the second electrical power source is independent of the first electrical power source.

In an exemplary embodiment, the system includes the plurality of sensors; wherein first electrical power source is in electrical communication with the one or more sensors to supply electric power thereto; and wherein the second electrical power source is in electrical communication with the one or more other sensors to supply electrical power thereto.

In a second aspect, there is provided an apparatus capable of receiving digital information from each of a plurality of sensors, the apparatus including a first microcontroller to process digital information received from one or more sensors in the plurality of sensors; a first display in electrical communication with the first microcontroller; and a first switch in electrical communication with the first microcontroller so that, when the first microcontroller receives the digital information from the one or more sensors in the plurality of sensors, the first microcontroller recognizes a first type of sensor from which the first microcontroller either is, or at least should be, receiving the digital information and displays a first output on the first display that is specific to the recognized first type of sensor.

In an exemplary embodiment, the apparatus includes a first enclosure in which each of the first microcontroller and the first display are disposed; and a first electrical power source disposed in the first enclosure to supply electrical power to the first microcontroller and each of the one or more sensors.

In another exemplary embodiment, the first type of sensor is selected from the group consisting of a position sensor, a pressure sensor, and a stroke counter.

In certain exemplary embodiments, the first type of sensor is a digital hydraulic choke position sensor; and wherein the first output includes a value corresponding to the degree to which a hydraulic choke is open or closed.

In an exemplary embodiment, the first type of sensor is one of a pressure sensor and a stroke counter; and wherein the first output includes one of a pressure value and a stroke rate.

In another exemplary embodiment, the apparatus includes a first enclosure and a first lid assembly connected thereto, the first lid assembly including the first microcontroller, the first display, and the first switch.

In certain exemplary embodiments, the apparatus includes a second lid assembly that is interchangeable with the first lid assembly so that, when the second lid assembly is interchanged with the first lid assembly, the second lid assembly is connected to the first enclosure instead of the first lid assembly being connected to the first enclosure; wherein the second lid assembly includes a second microcontroller to process digital information received from one or more other sensors in the plurality of sensors; a second display in electrical communication with the second microcontroller; and a second switch in electrical communication with the second microcontroller so that, when the second microcontroller receives the digital information from the one or more other sensors in the plurality of sensors, the second microcontroller recognizes a second type of sensor from which the second microcontroller either is, or at least should be, receiving the digital information and displays a second output on the second display that is specific to the recognized second type of sensor.

In a third aspect, there is provided an apparatus capable of receiving digital information from each of a plurality of sensors, the apparatus including a first enclosure; a first microcontroller disposed in the enclosure to process digital information received from one or more sensors in the plurality of sensors; a first display disposed in the enclosure and in electrical communication with the first microcontroller; and a first electrical power source disposed in the enclosure to supply electrical power to the first microcontroller and each of the one or more sensors.

In an exemplary embodiment, the apparatus includes a first switch in electrical communication with the first microcontroller so that, when the first microcontroller receives the digital information from the one or more sensors in the plurality of sensors, the first microcontroller recognizes a first type of sensor from which the first microcontroller either is, or at least should be, receiving the digital information and displays a first output on the first display that is specific to the recognized first type of sensor.

In another exemplary embodiment, the first type of sensor is selected from the group consisting of a position sensor, a pressure sensor, and a stroke counter.

In certain exemplary embodiments, the first type of sensor is a digital hydraulic choke position sensor; and wherein the first output includes a value corresponding to the degree to which a hydraulic choke is open or closed.

In an exemplary embodiment, the first type of sensor is one of a pressure sensor and a stroke counter; and wherein the first output includes one of a pressure value and a stroke rate.

In another exemplary embodiment, the apparatus includes a first lid assembly connected to the first enclosure, the first lid assembly including the first microcontroller, the first display, and the first switch.

In certain exemplary embodiments, the apparatus includes a second lid assembly that is interchangeable with the first lid assembly so that, when the second lid assembly is interchanged with the first lid assembly, the second lid assembly is connected to the first enclosure instead of the first lid assembly being connected to the first enclosure; wherein the second lid assembly includes a second microcontroller to process digital information received from one or more other sensors in the plurality of sensors; a second display in electrical communication with the second microcontroller; and a second switch in electrical communication with the second microcontroller so that, when the second microcontroller receives the digital information from the one or more other sensors in the plurality of sensors, the second microcontroller recognizes a second type of sensor from which the second microcontroller either is, or at least should be, receiving the digital information and displays a second output on the second display that is specific to the recognized second type of sensor.

In a fourth aspect, there is provided a kit including a plurality of enclosures; and a plurality of lid assemblies, each lid assembly in the plurality of lid assemblies being connectable to each enclosure in the plurality of enclosures; wherein each lid assembly includes a microcontroller capable of receiving and processing digital information from each sensor in a plurality of sensors; and a display in electrical communication with the microcontroller; wherein the respective microcontrollers of the lid assemblies are identical to one another; wherein each lid assembly includes a switch in electrical communication with the corresponding microcontroller of the lid assembly; and wherein each one of the switches is different from the other switches so that, when the lid assemblies are connected to the enclosures, respectively, and each of the microcontrollers receives digital information from one or more sensors in the plurality of sensors: at least one of the switches causes the corresponding microcontroller to recognize a first type of sensor from which the microcontroller either is, or at least should be, receiving the digital information and displays a first output on the corresponding display that is specific to the recognized first type of sensor; and at least one other of the switches causes the corresponding microcontroller to recognize a second type of sensor from which the microcontroller either is, or at least should be, receiving the digital information and displays a second output on the corresponding display that is specific to the recognized second type of sensor.

In an exemplary embodiment, the second type of sensor is different from the first type of sensor, the second switch is different from the first switch, and the second output is different from the first output.

In another exemplary embodiment, each of the first and second types of sensors is selected from the group consisting of a position sensor, a pressure sensor, and a stroke counter.

In certain exemplary embodiments, the first type of sensor is a digital hydraulic choke position sensor, the second type of sensor is one of a digital pressure sensor and a digital stroke counter, and the frame and the first and second digital display units are part of a choke control panel.

In an exemplary embodiment, the first output includes a value corresponding to the degree to which a hydraulic choke is open or closed; and wherein the second output includes one of a pressure value and a stroke rate.

In another exemplary embodiment, the kit includes a digital hydraulic choke position sensor assembly adapted to determine the choke position of the hydraulic choke, the hydraulic choke including a rod, the digital hydraulic choke position sensor assembly being of the first type of sensor and including: a housing adapted to be connected to the hydraulic choke, the housing defining a longitudinally-extending passage; and a digital position sensor disposed in the longitudinally-extending passage to sense movement of the rod and output digital information corresponding to the sensed movement; wherein the digital position sensor is adapted to be in electrical communication with one of the microcontrollers.

In certain exemplary embodiments, the second type of sensor is the digital pressure sensor; and wherein the kit further includes a digital pressure sensor assembly being of the second type of sensor, the digital pressure sensor assembly including a cover including first and second opposing end portions; a longitudinally-extending passage formed in the first end portion; a connector located at the second end portion and adapted to be in electrical communication with one of the microcontrollers; a pressure transducer in electrical communication with the connector; and a plurality of components via which the pressure transducer is in electrical communication with the connector, wherein the components extend within the longitudinally-extending passage.

In a fifth aspect, there is provided a digital hydraulic choke position sensor assembly adapted to determine the choke position of a hydraulic choke, the hydraulic choke including a first rod, the digital hydraulic choke position sensor assembly including a housing adapted to be connected to the hydraulic choke, the housing defining a longitudinally-extending passage; and a digital position sensor disposed in the longitudinally-extending passage to sense movement of the first rod and output digital information corresponding to the sensed movement.

In an exemplary embodiment, the digital hydraulic choke position sensor assembly includes an actuator button connected to the digital position sensor and adapted to engage the first rod of the hydraulic choke; and a connector assembly in electrical communication with the digital position sensor.

In another exemplary embodiment, the housing includes first and second opposing end portions; wherein the first end portion is adapted to be connected to the hydraulic choke; wherein the actuator button is located at the first end portion; and wherein the connector assembly is located at the second end portion.

In certain exemplary embodiments, the digital position sensor includes a tubular enclosure, a second rod extending in, and movable relative to, the tubular enclosure, and a cable assembly extending between the tubular enclosure and the connector assembly; and wherein the actuator button is connected to the distal end of the second rod.

In an exemplary embodiment, the longitudinally-extending passage includes a reduced-diameter portion in which the tubular enclosure and the cable assembly are disposed; and an enlarged-diameter portion in which at least a portion of the second rod is disposed.

In another exemplary embodiment, the actuator button includes an external shoulder; wherein the longitudinally-extending passage defines an internal surface of the housing; wherein the digital hydraulic choke position sensor assembly further includes a compression spring through which at least the second rod extends; and wherein the compression spring extends between the external shoulder of the actuator button and the internal surface of the housing so that the compression spring is compressed when the actuator button moves towards the internal surface.

In certain exemplary embodiments, the digital hydraulic choke position sensor assembly includes a plurality of fasteners to hold the digital position sensor in place within the longitudinally-extending passage.

In an exemplary embodiment, a region is formed in the second end portion and defines an axially-facing surface of the housing; wherein the reduced-diameter portion of the longitudinally-extending passage is adjacent the region; and wherein the connector assembly is connected to the axially-facing surface of the housing.

In a sixth aspect, there is provided a digital pressure sensor assembly that includes a cover including first and second opposing end portions; a longitudinally-extending passage formed in the first end portion; a connector located at the second end portion; a pressure transducer in electrical communication with the connector; and a plurality of components via which the pressure transducer is in electrical communication with the connector, wherein the components extend within the longitudinally-extending passage.

In an exemplary embodiment, the plurality of components includes a printed circuit board; a first cable assembly extending between the pressure transducer and the printed circuit board; and a second cable assembly extending between the printed circuit board and the connector.

In another exemplary embodiment, the digital pressure sensor assembly includes a base connected to the cover at the first end portion thereof; and a first bore formed through the base and in which the pressure transducer is disposed.

In certain exemplary embodiments, the digital pressure sensor assembly includes a region formed in the second end portion of the cover and defining an axially-facing surface of the cover; and a second bore formed through the axially-facing surface of the cover so that the region is in fluid communication with the longitudinally-extending passage; wherein the connector is connected to the axially-facing surface and at least a portion of the connector is disposed in the second bore.

In an exemplary embodiment, a first end portion of the base, which opposes the cover, is shaped in the form of a male hammer union nose; and wherein a nozzle is defined by the first bore at the first end portion.

In another exemplary embodiment, the digital pressure sensor assembly includes a nut connected to the base; wherein the first bore defines an internal shoulder; and wherein the pressure transducer is captured between the nut and the internal shoulder.

In certain exemplary embodiments, the plurality of components includes a printed circuit board disposed in the longitudinally-extending passage; a first cable assembly extending between the pressure transducer and the printed circuit board, wherein the first cable assembly extends through the nut and within the longitudinally-extending passage; and a second cable assembly extending between the printed circuit board and the connector and within the longitudinally-extending passage.

In a seventh aspect, there is provided a method including at least one step according to one or more aspects of the present disclosure.

Other aspects, features, and advantages will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, which are a part of this disclosure and which illustrate, by way of example, principles of the inventions disclosed.

DETAILED DESCRIPTION

In an exemplary embodiment, as illustrated inFIG. 1, a control panel, or a choke control panel, for a hydraulic choke system is generally referred to by the reference numeral10and includes a frame12to which digital display units14,16,18and20, and hydraulic control equipment22, are connected. The frame12includes a pivotally-mounted cover12a, which pivots between an open position (shown inFIG. 1) and a closed position in which the digital display units14,16,18and20are covered (not shown). The hydraulic control equipment22includes at least one control lever, such as a joystick22a. In several exemplary embodiments, the hydraulic control equipment22includes one or more hydraulic pumps, one or more air-operated hydraulic pumps, one or more manually-operated hydraulic pumps, one or more hydraulic reservoir assemblies, one or more hydraulic hoses, and tubing. In several exemplary embodiments, the hydraulic control equipment22includes conventional hydraulic control equipment used to control one or more hydraulic chokes, which may be part of a system for drilling an oil or gas well. In several exemplary embodiments, the choke control panel10may be characterized as either a remote operating console or a choke control console.

Referring toFIG. 2with continuing reference toFIG. 1, illustrated is a diagrammatic view of a portion of a system24for drilling an oil or gas well. The system24includes the choke control panel10. Hydraulic chokes26and28are operably coupled to the hydraulic control equipment22. In several exemplary embodiments, each of the hydraulic chokes26and28is in fluid communication with one or more components of the hydraulic control equipment22. Digital hydraulic choke position sensors30and32are operably coupled to the hydraulic chokes26and28, respectively. Under conditions to be described below, the digital hydraulic choke positions sensors30and32are adapted to measure the degree to which the hydraulic chokes26and28are open or closed, respectively. In an exemplary embodiment, the digital hydraulic choke position sensor30is in electrical communication with the digital display unit14via cable assemblies34and36, and the digital hydraulic choke position sensor32is in electrical communication with the digital display unit14via a cable assembly38and the cable assembly36. In an exemplary embodiment, the cable assemblies34and38connect to the cable assembly36via a two-to-one connector or a Y connector, which connector may be mounted within, or outside of, the frame12.

Digital stroke sensors or counters40and42are in electrical communication with the digital display unit20. In an exemplary embodiment, the digital stroke counter40is in electrical communication with the digital display unit20unit via cable assemblies44and46, and the digital stroke counter42is in electrical communication with the digital display unit20via a cable assembly48and the cable assembly46. In an exemplary embodiment, the cable assemblies44and48connect to the cable assembly46via a two-to-one connector or a Y connector, which connector may be mounted outside of, or within, the frame12. The digital stroke counters40and42are operably coupled to pumps50and52, respectively. In an exemplary embodiment, each of the pumps50and52is a positive displacement drilling fluid (or mud) pump, which facilitates the circulation of drilling fluid or mud down through a drilling or casing string that extends within a wellbore, and up through an annular region defined between the wellbore and the drilling or casing string. Under conditions to be described below, the digital stroke counters40and42are adapted to provide an indication of fluid flow rate out of the pumps50and52, respectively.

Digital pressure sensors54and56are in electrical communication with the digital display units16and18, respectively. In an exemplary embodiment, the digital pressure sensors54and56are in electrical communication with the digital display units16and18, respectively, via cable assemblies58and60, respectively. The digital pressure sensor54is operably coupled to a standpipe62, and the digital pressure sensor56is operably coupled to casing64. Under conditions to be described below, the digital pressure sensors54and56are adapted to measure respective pressures at the standpipe62and the casing64.

Each of the cable assemblies34,36,38,44,46,48,58and60may include one or more cable assemblies, one or more additional connectors, one or more connector mounting plates, or any combination thereof. One or more of the cable assemblies34,36,38,44,46,48,58and60may be combined in whole or in part with one or more of the other cable assemblies34,36,38,44,46,48,58and60.

In several exemplary embodiments, although not shown inFIG. 2, the system24includes additional components or systems such as, for example, any type of drilling rig including, but not limited to, a land-based drilling rig, a jack-up rig, a semi-submersible rig, a drill ship, a coil tubing rig, a platform rig, a slant rig, or a casing drilling rig, among others.

In an exemplary embodiment, as illustrated inFIG. 3with continuing reference toFIGS. 1 and 2, the digital display unit14includes a lid assembly66, a lid gasket68, battery holders70aand70b, a battery holder gasket72, a five-sided enclosure74, batteries76aand76b, a connector assembly78, battery lids80aand80b, and a cap assembly82. When the digital display unit14is assembled, the lid assembly66is connected to a lip74aof the enclosure74via pluralities of fasteners84aand84b. The lid gasket68is sandwiched between the lid assembly66and the lip74a. The battery holders70aand70bare disposed within the enclosure74and connected to a bottom side74athereof via a plurality of fasteners86. The battery holder gasket72is sandwiched between the bottom side74aand the battery holders70aand70b. The batteries76aand76bare disposed within the battery holders70aand70b, respectively. The battery lids80aand80bare connected to the respective bottom portions of the battery holders70aand70b, respectively, thereby capturing the batteries76aand76bwithin the battery holders70aand70b, respectively. In an exemplary embodiment, the batteries76aand76bare disposed in the battery holders70aand70b, respectively, via respective cut-outs (not shown) formed through the bottom side74a, and the battery lids80aand80bare connected to the battery holders70aand70b, respectively, via the respective cut-outs. The connector assembly78is connected to the bottom side74avia a plurality of fasteners88. The cap assembly82is connected to the connector78, and may cover the bottom end of the connector assembly78when the connector assembly78is not connected to a cable assembly.

In an exemplary embodiment, each of the batteries76aand76bprovides fast voltage recovery after long-term storage and/or usage, and high energy density. In an exemplary embodiment, each of the batteries76aand76bis a lithium battery. In an exemplary embodiment, each of the batteries76aand76bis a 3.6 V primary lithium-thionyl chloride (Li—SOCl2) battery. In an exemplary embodiment, each of the batteries76aand76bis, includes, or is part of, a Tadiran® TL-5930 lithium battery.

In an exemplary embodiment, as illustrated inFIGS. 4 and 5with continuing reference toFIGS. 1-3, the lid assembly66includes a printed circuit board90, with which microcontroller94, digital displays96a,96b,96cand96d, and connectors98,100and102, are in electrical communication. The foregoing components may be in electrical communication with the microcontroller94via surface mount technology, through-hole technology, one or more additional cable assemblies, one or more additional connectors, one or more additional printed circuit boards, other components or systems, and/or any combination thereof. Via the printed circuit board90, the microcontroller94is in electrical communication with each of the displays96a,96b,96cand96d, and the connectors100and102. In an exemplary embodiment, the microcontroller94includes an MSP430™ microcontroller, which is available from Texas Instruments. In an exemplary embodiment, each of the displays96a,96b,96cand96dis a liquid crystal display. In an exemplary embodiment, each of the displays96a,96b,96cand96dis a seven-segment extended temperature range liquid crystal display. In an exemplary embodiment, each of the displays96a,96b,96cand96dis a seven-segment 0.7-inch extended temperature range liquid crystal display.

As shown inFIGS. 4 and 5, the connector assembly78is in electrical communication with the connector100via a cable assembly104and a connector105. In an exemplary embodiment, the connector assembly78and the connector105may be characterized as part of the cable assembly104. Although not shown inFIG. 3, the cable assembly104and the connector105are disposed within the enclosure74, extending from the connector assembly78to the connector100on the printed circuit board90. A connector106is connected to, and in electrical communication with, the connector assembly78. In an exemplary embodiment, the connector106is coupled to a cable mounting plate (not shown), which is connected to the frame12. In an exemplary embodiment, the connector106, the connector assembly78, and the cable assembly104are part of the cable assembly36, which is shown inFIG. 2. Therefore, each of the digital hydraulic choke position sensors30and32is in electrical communication with the microcontroller94via the connector106, the connector assembly78, the cable assembly104, the connector100, and the printed circuit board90.

As shown inFIG. 4, a connector108is connected to, and in electrical communication with, the connector102. In an exemplary embodiment, the connector102is a flexible printed circuit (FPC) connector. In an exemplary embodiment, the connector102is a flexible printed circuit (FPC) surface mount technology (SMT) connector. A switch110is in electrical communication with the connector108. The switch110is part of the lid assembly66and will be described in further detail below.

As shown inFIGS. 4 and 6, the batteries76aand76bare in electrical communication with a connector112via the respective battery holders70aand70band a cable assembly114. The connector112and the cable assembly114are disposed within the enclosure74. In an exemplary embodiment, the connector112may be characterized as part of the cable assembly114. As shown inFIG. 4, the connector112is connected to, and in electrical communication with, the connector98. Under conditions to be described below, the batteries76aand76bare adapted to supply electrical power to the electrical components on the printed circuit board90, including the microcontroller94. The batteries76aand76bsupply electrical power to such components via the respective holders70aand70b, the cable assembly114, the connector112, the connector98, and the printed circuit board90. Additionally, the batteries76aand76bare adapted to supply electrical power to the digital hydraulic choke position sensors30and32. The batteries76aand76bsupply electrical power to the digital hydraulic choke position sensors30and32via the respective holders70aand70b, the cable assembly114, the connector112, the connector98, the printed circuit board90, the connector100, the cable assembly104, the connector78, the connector106, the cable assembly36, and the respective cable assemblies34and38.

In several exemplary embodiments, any of the connectors and connector assemblies described herein that are connected to cable assemblies may be characterized as part of those cable assemblies. In several exemplary embodiments, any of the connectors described herein may be characterized as connector assemblies and vice versa. In several exemplary embodiments, any of the connectors, connector assemblies and cable assemblies described herein may be combined in whole or in part to form one or more cable assemblies, or may be characterized as one or more cable assemblies.

In an exemplary embodiment, as illustrated inFIG. 7with continuing reference toFIGS. 1-6, the lid assembly66further includes transparent back plate116, transparent inserts118aand118b, a lid120, and an overlay assembly122. When the lid assembly66is assembled, the printed circuit board90, the back plate116, the inserts118aand118b, and the lid120are connected together via a plurality of fasteners124. The overlay assembly122is connected to the lid120via a mounting adhesive124(shown inFIG. 8). The back plate116is sandwiched between the printed circuit board90and the lid120, and the inserts118aand118bare sandwiched between the back plate116and the lid120. The insert118ais aligned with the displays96aand96b, and the insert118ais aligned with the displays96cand96d(the displays96band96dare not shown inFIG. 7).

In an exemplary embodiment, as illustrated inFIG. 8with continuing reference toFIGS. 1-7, the overlay assembly122includes a graphic overlay126, a dome spacer panel128, a dome retainer panel130, buttons or domes132a,132b,132cand132d, a panel134to which the switch110is connected, the connector108, a connector stiffener136, a connector filler138, and the mounting adhesive124. The dome spacer panel128is laminated with adhesive on both sides, and is sandwiched between the graphic overlay126and the dome retainer panel130, thereby connecting the graphic overlay126to the dome retainer panel130. The dome retainer panel130is backed with an adhesive, which connects the dome retainer panel130to the panel134. The domes132a,132b,132cand132dare captured between the dome retainer panel130and the panel134. The switch110is a circuit, and one or more of the domes132a,132b,132cand132dmay form part of the circuit. The mounting adhesive124connects the overlay assembly122to the lid120. A slot124ais formed through the mounting adhesive124.

In an exemplary embodiment, as illustrated inFIGS. 9A and 9Bwith continuing reference toFIGS. 1-8, the graphic overlay126indicates choke position of two chokes. The connector108is a tail connector having a pin #1. The connector108extends generally horizontally through the slot124a. Referring toFIG. 10, illustrated is a diagrammatic view of a switch schematic140of the switch110. As noted above, in an exemplary embodiment, the connector102is a flexible printed circuit (FPC) connector, with which the connector108is in electrical communication when the overlay assembly122is connected to the lid120. Under conditions to be described below, the switch110electrically communicates with the microcontroller94, via the connector108, the connector102and the printed circuit board90, so that the microcontroller94recognizes the type of sensor from which it is (or at least should be) receiving digital information (i.e., a position sensor such as the digital hydraulic choke position sensors30and32) and, based on that sensor type, accordingly processes the digital information and displays relevant output specific to that sensor type on one or more of the displays96a,96b,96cand96d.

In view of the foregoing, in an exemplary embodiment, the digital display unit14can be used to monitor either hydraulic chokes or electric chokes.

In an exemplary embodiment, the digital display unit16includes components that are identical to corresponding components of the digital display unit14described above. These identical components will be referred to by the same reference numerals, followed by the phrase “of the digital display unit16”. The digital display unit16differs from the digital display unit14in two respects. First, instead of being in electrical communication with the digital hydraulic choke position sensors30and32, the connector78of the digital display unit16is in electrical communication with the digital pressure sensor54, as shown inFIG. 2. The second difference is that the digital display unit16does not include an overlay assembly that is identical to the overlay assembly122of the digital display unit14. Instead, the digital display unit16includes an overlay assembly142, an exemplary embodiment of which is illustrated inFIG. 11and described in further detail below.

Referring toFIG. 11with continuing reference toFIGS. 1-10, the overlay assembly142of the digital display unit16includes a graphic overlay144, a dome spacer panel146, a dome retainer panel148, buttons or domes150a,150b,150cand150d, a panel152to which a switch154is connected, a connector156, a connector stiffener158, a connector filler160, and a mounting adhesive162. The dome spacer panel146is laminated with adhesive on both sides, and is sandwiched between the graphic overlay144and the dome retainer panel148, thereby connecting the graphic overlay144to the dome retainer panel148. The dome retainer panel148is backed with an adhesive, which connects the dome retainer panel148to the panel152. The domes150a,150b,150cand150dare captured between the dome retainer panel148and the panel152. The switch154is a circuit, and one or more of the domes150a,150b,150cand150dmay form part of the circuit. The mounting adhesive162connects the overlay assembly142to the lid120of the digital display unit16. A slot162ais formed through the mounting adhesive162.

In an exemplary embodiment, as illustrated inFIGS. 12A and 12Bwith continuing reference toFIGS. 1-11, the graphic overlay144of the digital display unit16indicates a pressure measurement and thus is different from the graphic overlay of the digital unit display14, which indicates choke position. The connector156is a tail connector having a pin #1. The connector156extends generally horizontally through the slot162a. Referring toFIG. 13, illustrated is a diagrammatic view of a switch schematic164of the switch154. The switch154is different from the switch110, as indicated by a comparison between the switch schematic140shown inFIG. 10and the switch schematic164shown inFIG. 13. In an exemplary embodiment, the connector102of the digital display unit16is a flexible printed circuit (FPC) connector, with which the connector156is in electrical communication when the overlay assembly142is connected to the lid120of the digital display unit16. Under conditions to be described below, the switch154electrically communicates with the microcontroller94of the digital display unit16, via the connector156, the connector102of the digital display unit16, and the printed circuit board90of the digital display unit16, so that the microcontroller94of the digital display unit16recognizes the type of sensor from which it is (or at least should be) receiving digital information (i.e., a pressure sensor such as the digital pressure sensor54) and, based on that sensor type, accordingly processes the digital information and displays relevant output specific to that sensor type on one or more of the displays96a,96b,96cand96dof the digital display unit16.

The remainder of the digital display unit16is identical to the digital display unit14and therefore the remainder of the digital display unit16will not be described in detail. In an exemplary embodiment, instead of the connector assembly78of the digital display unit16being in electrical communication with the connector106, the connector assembly78of the digital display unit16is in electrical communication with another connector (not shown) that is equivalent to the connector106(shown inFIG. 4), which other connector may be coupled to a cable mounting plate (not shown) that is connected to the frame12.

In an exemplary embodiment, the digital display unit18is identical to the digital display unit16and therefore will not be described in detail. Instead of being in electrical communication with the digital pressure sensor54, the connector78of the digital display unit18is in electrical communication with the digital pressure sensor56, as shown inFIG. 2. In an exemplary embodiment, the connector assembly78of the digital display unit18is in electrical communication with yet another connector (not shown) that is equivalent to the connector106(shown inFIG. 4), which other connector may be coupled to a cable mounting plate (not shown) that is connected to the frame12.

In an exemplary embodiment, the digital display unit20includes components that are identical to corresponding components of the digital display unit14described above. These identical components will be referred to by the same reference numerals, followed by the phrase “of the digital display unit20”. The digital display unit20differs from the digital display unit14in two respects. First, instead of being in electrical communication with the digital hydraulic choke position sensors30and32, the connector78of the digital display unit20is in electrical communication with each of the digital stroke counters40and42, as shown inFIG. 2. The second difference is that the digital display unit20does not include an overlay assembly that is identical to the overlay assembly122of the digital display unit14. Instead, the digital display unit16includes an overlay assembly166, an exemplary embodiment of which is illustrated inFIG. 14and described in further detail below.

Referring toFIG. 14with continuing reference toFIGS. 1-13, the overlay assembly166of the digital display unit20includes a graphic overlay168, a dome spacer panel170, a dome retainer panel172, buttons or domes174a,174b,174cand174d, a panel176to which a switch178is connected, a connector180, a connector stiffener182, a connector filler184, and a mounting adhesive186. The dome spacer panel170is laminated with adhesive on both sides, and is sandwiched between the graphic overlay168and the dome retainer panel172, thereby connecting the graphic overlay168to the dome retainer panel172. The dome retainer panel172is backed with an adhesive, which connects the dome retainer panel172to the panel176. The domes174a,174b,174cand174dare captured between the dome retainer panel172and the panel176. The switch178is a circuit, and one or more of the domes174a,174b,174cand174dmay form part of the circuit. The mounting adhesive186connects the overlay assembly166to the lid120of the digital display unit20. A slot186ais formed through the mounting adhesive186.

In an exemplary embodiment, as illustrated inFIGS. 15A and 15Bwith continuing reference toFIGS. 1-14, the graphic overlay168of the digital display unit20indicates stroke count and total strokes, and thus is different from the graphic overlay of the digital unit display14, which indicates choke position. The connector180is a tail connector having a pin #1. The connector180extends generally horizontally through the slot162a. Referring toFIG. 16, illustrated is a diagrammatic view of a switch schematic188of the switch178. The switch178is different from each of the switches110and154, as indicated by a comparison between the switch schematic140shown inFIG. 10, the switch schematic164shown inFIG. 13, and the switch schematic188shown inFIG. 16. In an exemplary embodiment, the connector102of the digital display unit20is a flexible printed circuit (FPC) connector, with which the connector180is in electrical communication when the overlay assembly166is connected to the lid120of the digital display unit20. Under conditions to be described below, the switch178electrically communicates with the microcontroller94of the digital display unit20, via the connector180, the connector102of the digital display unit20, and the printed circuit board90of the digital display unit20, so that the microcontroller94of the digital display unit20recognizes the type of sensor from which it is (or at least should be) receiving digital information (i.e., a stroke counter such as the digital stroke counters40and42) and, based on that sensor type, accordingly processes the digital information and displays relevant output specific to that sensor type on one or more of the displays96a,96b,96cand96dof the digital display unit20.

The remainder of the digital display unit20is identical to the digital display unit14and therefore the remainder of the digital display unit20will not be described in detail. In an exemplary embodiment, the connector assembly78of the digital display unit20is in electrical communication with still yet another connector (not shown) that is equivalent to the connector106(shown inFIG. 4), which other connector may be coupled to a cable mounting plate (not shown) that is connected to the frame12.

As indicated above, each of the digital display units14,16,18and20includes a respective combination of the connector assembly78, the cable assembly104, and the connector105; thus, any one of the respective combinations can receive (and transmit) digital information to the corresponding printed circuit board90from (or to) any of the sensors, namely the digital hydraulic choke position sensors30and32, the digital stroke counters40and42, the digital pressure sensor54, or the digital pressure sensor56. However, the manner in which the corresponding microcontroller94processes the received digital information and displays relevant output depends upon which of the switches110,154and178is in electrical communication with the microcontroller94. Additionally, any one combination of the connector assembly78, the cable assembly104, and the connector105can be used to supply electrical power from the corresponding batteries76aand76bto the digital hydraulic choke position sensors30and32, the digital stroke counters40and42, the digital pressure sensor54, or the digital pressure sensor56. In an exemplary embodiment, each of the connector assembly78and the connector105may have fourteen pins, two of which are associated with the digital hydraulic choke position sensor30, two of which are associated with the digital hydraulic choke position sensor32, three of which are associated with the digital stroke counter40, three of which are associated with the digital stroke counter42, and four of which are associated with the digital pressure sensors54and56.

In operation, in an exemplary embodiment, with continuing reference toFIGS. 1-16, the choke control panel10is used to monitor one or more operation parameters during the operation of at least the portion illustrated inFIG. 2of the system24for drilling an oil or gas well, and also to control the hydraulic chokes26and28from the location of the choke control panel10.

In an exemplary embodiment, during the operation of the system24, one or both of the pumps50and52facilitate the circulation of drilling fluid or mud down through a drilling or casing string that extends within a wellbore, and up through an annular region defined between the wellbore and the drilling or casing string. One or both of the hydraulic chokes26and28may be opened and/or closed to control the imposition of backpressure on the drilling fluid. In several exemplary embodiments, one or both of the hydraulic chokes26and28may be controlled by opening and/or closing the hydraulic chokes26and28using the hydraulic control equipment22of the choke control panel10, including the joystick22a. This control of the hydraulic chokes26and28may be informed by monitoring, using the choke control panel10, one or more operation parameters including, but not limited to, the respective stroke counts (and thus flow rate indications) of the pumps50and52, the pressure at the standpipe62, the pressure at the casing64, and the respective choke positions of the hydraulic chokes26and28.

In an exemplary embodiment, to monitor the respective choke positions of the hydraulic chokes26and28, the digital hydraulic choke position sensors30and32sense the degree to which the hydraulic chokes26and28are open or closed, and then transmit digital readings or information corresponding to the sensed open/closed degrees to the digital display unit14. The digital hydraulic choke position sensor30transmits the digital information to the digital display unit14via the cable assemblies34and36. The digital hydraulic choke position sensor32transmits the digital information to the digital display unit14via the cable assemblies38and36. At the digital display unit14, the digital information from the digital hydraulic choke position sensors30and32is transmitted to the microcontroller94of the digital display unit14via the connector106, and the connector assembly78, the cable assembly104, the connector105, the connector100, and the printed circuit board90of the digital display unit14. The switch110electrically communicates with the microcontroller94of the digital display unit14, via the connector108, the connector102and the printed circuit board90of the digital display unit14, so that the microcontroller94of the digital display unit14recognizes the type of sensor from which it is (or at least should be) receiving digital information, namely a position sensor, such as the digital hydraulic choke position sensors30and32. Based on this recognition, the microcontroller94accordingly processes the digital information and outputs relevant digital output specific to that sensor type on one or more of the displays96a,96b,96cand96dof the digital display unit14. In an exemplary embodiment, the microcontroller94of the digital display unit14may output one or more values corresponding to the degree to which the hydraulic chokes26and28are open or closed; such values include, for example, the percentage that the hydraulic choke26is open on the display96aof the digital display unit14, a number indicating the degree to which the hydraulic choke26is open on the display96cof the digital display unit14, the percentage that the hydraulic choke28is open on the display96bof the digital display unit14, and a number indicating the degree to which the hydraulic choke26is open on the display96dof the digital display unit14.

Before, during and/or after the transmission of digital information to the digital display unit14, the batteries76aand76bof the digital display unit14supply electrical power to the electrical components on the printed circuit board90of the digital display unit14, including the microcontroller94. The batteries76aand76bof the digital display unit14supply electrical power to such components via the respective holders70aand70b, the cable assembly114, the connector112, the connector98, and the printed circuit board90of the digital display unit14. Additionally, before, during and/or after the transmission of digital information to the digital display unit14, the batteries76aand76bof the digital display unit14supply electrical power to the digital hydraulic choke position sensors30and32via the respective holders70aand70b, the cable assembly114, the connector112, the connector98, the printed circuit board90, the connector100, the cable assembly104, and the connector78of the digital display unit14, as well as the connector106, the cable assembly36, and the respective cable assemblies34and38.

In an exemplary embodiment, to monitor the pressure at the standpipe62, the digital pressure sensor54senses the pressure at the standpipe62, and then transmits digital readings or information corresponding to the sensed pressure to the digital display unit16. The digital pressure sensor54transmits the digital information to the digital display unit16via the cable assembly58. At the digital display unit16, the digital information from the digital pressure sensor54is transmitted to the microcontroller94of the digital display unit16via a connector that is equivalent to the connector106, and also via the connector assembly78, the cable assembly104, the connector105, the connector100, and the printed circuit board90of the digital display unit16. The switch154electrically communicates with the microcontroller94of the digital display unit16, via the connector108, the connector102and the printed circuit board90of the digital display unit16, so that the microcontroller94of the digital display unit16recognizes the type of sensor from which it is (or at least should be) receiving digital information, namely a pressure sensor, such as the digital pressure sensor54. Based on this recognition, the microcontroller94accordingly processes the digital information and outputs relevant digital output specific to that sensor type on one or more of the displays96a,96b,96cand96dof the digital display unit16. In an exemplary embodiment, the microcontroller94of the digital display unit16may output, for example, the pressure value at the standpipe62on one or both of the displays96aand96bof the digital display unit16.

Before, during and/or after the transmission of digital information to the digital display unit16, the batteries76aand76bof the digital display unit16supply electrical power to the electrical components on the printed circuit board90of the digital display unit16, including the microcontroller94. The batteries76aand76bof the digital display unit16supply electrical power to such components via the respective holders70aand70b, the cable assembly114, the connector112, the connector98, and the printed circuit board90of the digital display unit16. Additionally, before, during and/or after the transmission of digital information to the digital display unit16, the batteries76aand76bof the digital display unit16supply electrical power to the digital pressure sensor54via the respective holders70aand70b, the cable assembly114, the connector112, the connector98, the printed circuit board90, the connector100, the cable assembly104, and the connector78of the digital display unit16, as well as a connector that is equivalent to the connector106, and the cable assembly58.

In an exemplary embodiment, to monitor the pressure at the casing64, the digital pressure sensor56senses the pressure at the casing64, and then transmits digital readings or information corresponding to the sensed pressure to the digital display unit18. The digital pressure sensor56transmits the digital information to the digital display unit18via the cable assembly60. At the digital display unit18, the digital information from the digital pressure sensor56is transmitted to the microcontroller94of the digital display unit18via a connector that is equivalent to the connector106, and also via the connector assembly78, the cable assembly104, the connector105, the connector100, and the printed circuit board90of the digital display unit18. The switch178electrically communicates with the microcontroller94of the digital display unit18, via the connector108, the connector102and the printed circuit board90of the digital display unit18, so that the microcontroller94of the digital display unit16recognizes the type of sensor from which it is (or at least should be) receiving digital information, namely a pressure sensor, such as the digital pressure sensor56. Based on this recognition, the microcontroller94accordingly processes the digital information and outputs relevant digital output specific to that sensor type on one or more of the displays96a,96b,96cand96dof the digital display unit18. In an exemplary embodiment, the microcontroller94of the digital display unit18may output, for example, a pressure value at the casing64on one or both of the displays96aand96bof the digital display unit18.

Before, during and/or after the transmission of digital information to the digital display unit18, the batteries76aand76bof the digital display unit18supply electrical power to the electrical components on the printed circuit board90of the digital display unit18, including the microcontroller94. The batteries76aand76bof the digital display unit18supply electrical power to such components via the respective holders70aand70b, the cable assembly114, the connector112, the connector98, and the printed circuit board90of the digital display unit18. Additionally, before, during and/or after the transmission of digital information to the digital display unit18, the batteries76aand76bof the digital display unit18supply electrical power to the digital pressure sensor56via the respective holders70aand70b, the cable assembly114, the connector112, the connector98, the printed circuit board90, the connector100, the cable assembly104, and the connector78of the digital display unit18, as well as a connector that is equivalent to the connector106, and the cable assembly60.

In an exemplary embodiment, to monitor the respective stroke counts (and thus flow rate indications) of the pumps50and52, the digital stroke counters40and42sense the respective strokes of the pumps50and52, and then transmit digital readings or information corresponding to the sensed strokes to the digital display unit20. The digital stroke counter40transmits the digital information to the digital display unit20via the cable assemblies44and46. The digital stroke counter42transmits the digital information to the digital display unit20via the cable assemblies48and46. At the digital display unit20, the digital information from the digital stroke counters40and42is transmitted to the microcontroller94of the digital display unit20via a connector that is equivalent to the connector106, and the connector assembly78, the cable assembly104, the connector105, the connector100, and the printed circuit board90of the digital display unit20. The switch178electrically communicates with the microcontroller94of the digital display unit20, via the connector108, the connector102and the printed circuit board90of the digital display unit20, so that the microcontroller94of the digital display unit20recognizes the type of sensor from which it is (or at least should be) receiving digital information, namely a stroke counter, such as the digital stroke counters40and42. Based on this recognition, the microcontroller94accordingly processes the digital information and outputs relevant digital output specific to that sensor type on one or more of the displays96a,96b,96cand96dof the digital display unit20. In an exemplary embodiment, the microcontroller94of the digital display unit20may output, for example, a stroke rate such as the strokes per minute of the pump50on the display96aof the digital display unit20, the total strokes of the pump50on the display96cof the digital display unit20, a stroke rate such as the strokes per minute of the pump52on the display96bof the digital display unit20, and the total strokes of the pump52on the display96dof the digital display unit20.

Before, during and/or after the transmission of digital information to the digital display unit20, the batteries76aand76bof the digital display unit20supply electrical power to the electrical components on the printed circuit board90of the digital display unit20, including the microcontroller94. The batteries76aand76bof the digital display unit20supply electrical power to such components via the respective holders70aand70b, the cable assembly114, the connector112, the connector98, and the printed circuit board90of the digital display unit20. Additionally, before, during and/or after the transmission of digital information to the digital display unit20, the batteries76aand76bof the digital display unit20supply electrical power to the digital stroke counters40and42via the respective holders70aand70b, the cable assembly114, the connector112, the connector98, the printed circuit board90, the connector100, the cable assembly104, and the connector78of the digital display unit20, as well as a connector that is equivalent to the connector106, the cable assembly46, and the respective cable assemblies44and48.

As indicated above, each of the digital display units14,16,18and20includes a respective combination of the connector assembly78, the cable assembly104, and the connector105; thus, any one of the respective combinations can receive and transmit digital information to the corresponding printed circuit board90from the digital hydraulic choke position sensors30and32, the digital stroke counters40and42, the digital pressure sensor54, or the digital pressure sensor56. However, the manner in which the corresponding microcontroller94processes the received digital information and displays relevant output depends upon which of the switches110,154and178is in electrical communication with the microcontroller94. Additionally, any one combination of the connector assembly78, the cable assembly104, and the connector105can be used to supply electrical power from the corresponding batteries76aand76bto the digital hydraulic choke position sensors30and32, the digital stroke counters40and42, the digital pressure sensor54, or the digital pressure sensor56.

In view of the foregoing, in an exemplary embodiment, the use of the digital display units14,16,18and20provides better monitoring accuracy and acuity, and higher incremental resolution of the values of different operation parameters, when compared to the use of analog gauges for the same operation parameters.

In view of the foregoing, in an exemplary embodiment, the commonality in components between the digital display units14,16,18and20facilitates the maintenance of the digital display units, reduces manufacturing and maintenance costs, and increases the usefulness of spare parts because the spare parts can be used on different ones of the digital display units14,16,18and20. In several exemplary embodiments, all of the above-described components in each of the digital display units14,16,18and20may be common, or identical, with the exception of some of the parts in the overlay assemblies122,142and166; such uncommon or different parts may include the switches110,154and178, and the graphic overlays126,144and128. The uniformity of the digital display units14,16,18and20reduces costs because parts can be purchased in large quantities, and reduces the number of components a service call technician needs to have available when making remote service calls.

In view of the foregoing, in an exemplary embodiment, any one of the digital display units14,16,18and20may be easily interchanged with any other of the digital display units14,16,18and20by just interchanging the respective overlay assemblies66.

In view of the foregoing, in an exemplary embodiment, as noted above, the digital display unit14is operable with either hydraulic chokes or electric chokes.

In view of the foregoing, in an exemplary embodiment, the ability of each of the digital display units14,16,18or20to supply electrical power to the sensor(s) with which it is in electrical communication (the sensors30and32, the sensor54, the sensor56, or the sensors or counters40and42) eliminates the susceptibility of the choke control panel10to power losses from another source, such as a drilling rig that is part of the system24. In other words, the choke control panel10may be operated without being dependent upon the supply of electrical power from the drilling rig. The choke control panel10operates independently of other electrical power sources. Additionally, the sensors30and32, the sensor54, the sensor56, and the counters40and42operate with their own respective electrical power sources (i.e., the batteries76aand76bof the corresponding digital display unit14,16,18and20), independently of the other electrical powers sources in the choke control panel10.

In an exemplary embodiment, as illustrated inFIGS. 17, 18 and 19with continuing reference toFIGS. 1-16, the digital hydraulic choke position sensor30is an assembly that includes a housing194and a sleeve196connected thereto. An end portion194aof the housing194extends within the sleeve196, and an opposing end portion194bincludes a flange194c. A region200is formed in the end portion194a, defining an axially-facing surface194dof the housing194. Radially-extending bores202aand202bare formed through the housing194adjacent the region200. A longitudinally-extending passage204is defined by the housing194. The passage204includes a reduced-diameter portion204aadjacent the region200, and an enlarged-diameter portion204bthat extends from the reduced-diameter portion204ato the end portion194b. Radially-extending bores206aand206bare formed through the housing194adjacent the reduced-diameter portion204a.

A digital position sensor208extends within the longitudinally-extending passage204defined by the housing194. In an exemplary embodiment, the digital position sensor208is, includes, or is part of, a linear potentiometer. In an exemplary embodiment, the digital position sensor208is, includes, or is part of, an Omega® LP803-02 linear potentiometer. In an exemplary embodiment, the digital position sensor208includes a tubular enclosure208aand a rod208bextending therein. The rod208bis movable relative to the tubular enclosure208a. Respective portions of the tubular enclosure208aand the rod208bextend through a compression spring210.

An actuator button212is connected to the distal end of the rod208band includes an external shoulder212a. In an exemplary embodiment, the actuator button212is connected to the distal end portion of the rod208bvia a threaded engagement with an external threaded connection208cat the distal end portion of the rod208b. The compression spring210extends between the external shoulder212aand a frusto-conical transition internal surface194eof the housing194, which internal surface extends between the portions204aand204bof the passage204. As shown inFIG. 19, a connector assembly214is in electrical communication with the digital position sensor208via a cable assembly216(the cable assembly16is not shown inFIG. 18). In an exemplary embodiment, the connector assembly214may be characterized as part of the cable assembly216, and/or the connector assembly214and the cable assembly216may be characterized as part of the digital position sensor208. As shown inFIG. 18, the connector assembly214is connected to the axially-facing surface194d. Although not shown inFIG. 18, the cable assembly216is disposed in the reduced-diameter portion204aof the passage204. The connector assembly214is connected to, and in electrical communication with, the cable assembly34, as indicated inFIG. 2.

As shown inFIG. 18, the sleeve196includes radially-extending bores196aand196b, which are concentric with the radially-extending bores206aand206b, respectively. Set screws218aand218bare positioned in the radially-extending bores206aand206b, respectively, and engage the tubular enclosure208a, holding the digital position sensor208in place within the longitudinally-extending passage204. Fasteners, such as cap screws220aand220b, extend through the bores196aand196b, respectively, and into the bores206aand206b, respectively. The cap screws220aand220bconnect the sleeve196to the housing194and hold in place the set screws218aand218b, respectively, thereby ensuring that the digital position sensor208is held in place by the set screws218aand218b.

The flange194cof the housing194is connected to a corresponding flange (not shown) of the hydraulic choke26. An end of an actuator rod26aof the hydraulic choke26engages the end face of the actuator button212opposing the external shoulder212a.

In operation, in an exemplary embodiment, as the hydraulic choke26is opened using the hydraulic control equipment22, the actuator rod26amoves to the right, as viewed inFIG. 18, causing the actuator button212to also move to the right, as viewed inFIG. 18. As a result, the spring210is compressed, the rod208bmoves relative to the tubular enclosure208a, and the movement of the rod208bis sensed by the digital position sensor208. In response, the digital position sensor208transmits or outputs digital information corresponding to the sensed movement to the digital display unit14via the cable assembly216, the connector assembly214, and the cable assemblies34and36, in accordance with the foregoing. As the hydraulic choke26is closed using the hydraulic control equipment22, the actuator rod26amoves to the left, as viewed inFIG. 18. As a result, the spring210decompresses, pushing the actuator button212and thus the rod208b, relative to the tubular enclosure208aand to the left, as viewed inFIG. 18, and maintaining the engagement between the actuator button212and the actuator rod26a. In response, the digital position sensor208transmits or outputs digital information corresponding to the sensed movement of the rod208brelative to the tubular enclosure208a. This digital information is transmitted to the digital display unit14via the cable assembly216, the connector assembly214, and the cable assemblies34and36, in accordance with the foregoing. Before, during and/or after this transmission of digital information, the digital position sensor208of the digital hydraulic choke position sensor30is electrically powered by the batteries76aand76bof the digital display unit14via the cable assemblies34and36, the connector assembly214, and the cable assembly216, in accordance with the foregoing.

In view of the foregoing, in several exemplary embodiments, it is clear that the digital hydraulic choke position sensor30ofFIGS. 17-19permits digital sensing or measurement of the degree to which the hydraulic choke26is opened or closed, without requiring any modifications to the hydraulic choke26to accommodate the digital sensing or measurement. In several exemplary embodiments, the digital hydraulic choke position sensor30ofFIGS. 17-19enables the use of a digital gauge output, on the displays96a,96b,96cand96dof the digital display unit14, to monitor the choke position of a hydraulic choke, namely the hydraulic choke26. In several exemplary embodiments, the digital position sensor208is protected from the environment by the housing194. In several exemplary embodiments, the connection between the connector assembly214and the cable assembly34is protected by the sleeve196. In an exemplary embodiment, the sleeve196may be disconnected from the housing194, and a bar (not shown) may inserted through the bores202aand202band used as a handle to carry the housing194as necessary.

In an exemplary embodiment, the digital hydraulic choke position sensor32is identical to the exemplary embodiment of the digital hydraulic choke position sensor30illustrated inFIGS. 17-19, and therefore neither the digital hydraulic choke position sensor32nor the operation thereof will be described in detail. Instead of being connected to the hydraulic choke26, the digital hydraulic choke position sensor32is connected to the hydraulic choke28, as indicated inFIG. 2. Instead of being connected to, and in electrical communication with, the cable assembly34, the connector assembly214of the digital hydraulic choke position sensor32is connected to, and in electrical communication with, the cable assembly38, as indicated inFIG. 2.

In an exemplary embodiment, as illustrated inFIGS. 20, 21, 22 and 23with continuing reference toFIGS. 1-19, the digital pressure sensor54is an assembly that includes a handle assembly224, a connector226, a cover228, a plurality of fasteners230, a sensor assembly232(FIGS. 21-23), an annular sealing element such as an O-ring234(FIGS. 21 and 23), and a base236.

As shown inFIG. 22, the sensor assembly232includes a pressure transducer238, a plurality of solder sleeves240, a nut242, a cable assembly244, a printed circuit board246, and a cable assembly248, which is connected to, and in electrical communication with, the connector226. In an exemplary embodiment, the connector226may be characterized as part of the sensor assembly232. In an exemplary embodiment, the pressure transducer238is a Keller Series 8 Pressure Transducer. The printed circuit board246is in electrical communication with the pressure transducer238via the cable assembly244and the solder sleeves240. The connector226is in electrical communication with the printed circuit board246via the cable assembly248. The connector226is also in electrical communication with the cable assembly58, as indicated inFIG. 2. Under conditions to be described below, the pressure transducer238senses fluid pressure, and one or more components of the printed circuit board246output digital information corresponding to the sensed fluid pressure.

As shown inFIGS. 20 and 23, a region228ais formed in an end portion228bof the cover228. The region228adefines an axially-facing surface228cof the cover228. Radially-extending bores228dand228eare formed through the cover228adjacent the region228a. The handle assembly224is connected to the cover228using the bores228dand228e, as indicated inFIG. 20. A longitudinally-extending passage228fis formed in the end portion228gthat opposes the end portion228b. A bore228his formed through the surface228cso that the region228ais in fluid communication with the passage228fvia the bore228h. The end portion228gincludes a flange228i, through which the fasteners230extend to connect the cover228to the base236.

The base236includes an axial end surface236a, in which an annular groove236bis formed. The O-ring234is disposed in the annular groove236band sealingly engages the flange228i, thereby sealing the connection between the cover228and the base236. A bore236cis formed in the axial end surface236aand through the base236. An end portion236d, which opposes the axial end surface236a, is shaped in the form of a male hammer union nose. Thus, the end portion236dpermits the digital pressure sensor54to be operably coupled to the standpipe62via a hammer union, which employs the end portion236d. In several exemplary embodiments, instead of a male hammer union nose, the end portion236dmay have other shapes, features, elements, etc. to connect the digital pressure sensor54to another component so that the digital pressure sensor54is operably coupled to the standpipe62; such other shapes, features, elements, etc. include, but are not limited to, an external threaded connection, an internal threaded connection, or any combination thereof.

As shown or indicated inFIGS. 20, 21, 22 and 23, the connector226is connected to the surface228cof the cover228and extends within the bore228h. The printed circuit board246is disposed in the passage228f. Although not shown inFIG. 23, the cable assembly248is disposed in the passage228f. The pressure transducer238is disposed in the bore236c. In an exemplary embodiment, the pressure transducer238includes one or more O-rings extending thereabout, which sealingly engage inside surfaces of the base236. The nut242is engaged with the axial end surface236a, and threadably engages an internal threaded connection236eformed in the bore236, thereby engaging the upper portion (as viewed inFIG. 23) of the pressure transducer238. As a result, the pressure transducer238is captured between the nut242and an internal shoulder236fdefined by the bore236c. The cable assembly244extends through the nut242. A nozzle236gis defined by the bore236at the end portion236d.

In operation, in an exemplary embodiment, the pressure transducer238measures or senses the pressure at the standpipe62, and transmits signal(s) corresponding to the sensed pressure to the printed circuit board246via the cable assembly244. Component(s) of the printed circuit board246process the received signals and output or transmit digital information corresponding to the sensed pressure to the digital display unit16via the cable assembly248, the connector assembly226, and the cable assembly58, in accordance with the foregoing. Before, during and/or after this transmission of digital information, the sensor assembly232is electrically powered by the batteries76aand76bof the digital display unit16via the cable assembly58and the connector assembly226, in accordance with the foregoing.

In view of the foregoing, in several exemplary embodiments, it is clear that the digital pressure sensor54ofFIGS. 20-23permits digital sensing or measurement of the pressure at the standpipe62, without requiring any, or at least significant, modifications to the fluid flow system of which the standpipe62is a part. Indeed, as noted above, the digital pressure sensor54may be connected using a conventional union arrangement, such as hammer union, so that the digital pressure sensor54is operably coupled to the standpipe62. In several exemplary embodiments, the digital pressure sensor54ofFIGS. 20-23enables the use of a digital gauge output, on one or more of the displays96a,96b,96cand96dof the digital display unit16, to monitor pressure at the standpipe62. In several exemplary embodiments, the sensor assembly232(including the printed circuit board246and the pressure transducer238) is protected from the environment by the cover228and the base236. In several exemplary embodiments, the connection between the connector assembly226and the cable assembly58is protected, at least in part, by the portion of the cover228surrounding the region228a; in an exemplary embodiment, a sleeve may be connected to the cover228to further protect this connection.

In an exemplary embodiment, the digital pressure sensor56is identical to the exemplary embodiment of the digital pressure sensor54illustrated inFIGS. 20-23, and therefore neither the digital pressure sensor56nor the operation thereof will be described in detail. Instead of being operably coupled to the standpipe62, the digital pressure sensor56is operably coupled to the casing64, as indicated inFIG. 2. Instead of being connected to, and in electrical communication with, the cable assembly58, the connector226of the digital pressure sensor56is connected to, and in electrical communication with, the cable assembly60, as indicated inFIG. 2.

In several exemplary embodiments, to count the strokes of the pump50, the digital stroke counter40senses the rotation frequency of a magnet rotating on a pump shaft of the pump50. Likewise, in several exemplary embodiments, to count the strokes of the pump52, the digital stroke counter42senses the rotation frequency of a magnet rotating on a pump shaft of the pump52. In several exemplary embodiments, each of the digital stroke counters40and42is, includes, or is part of, a Sensor Solutions® S63B-EHSB-3OCM2 Hall or Magneto Resistive Switch Sensor.

In several exemplary embodiments, each of the digital stroke counters40and42is a conventional digital stroke counter for a positive displacement drilling fluid (or mud) pump.

In an exemplary embodiment, different components of the choke control panel10, as well as the system24, may be color coded to assist in the above-described connections between components. For example, in one exemplary embodiment, the lid120of the overlay assembly66of the digital display unit14may be red in color, the portion of the frame12adjacent to where the digital display unit14is connected to the frame12may be red in color, the connector106and/or a connector mounting plate portion to which the cable assembly36connects may be red in color, and the cable assembly36may be red in color. The lid120of the overlay assembly66of the digital display unit16may be blue in color, the portion of the frame12adjacent to where the digital display unit16is connected to the frame12may be blue in color, a connector equivalent to the connector106and/or a connector mounting plate portion to which the cable assembly58connects may be blue in color, and the cable assembly58may be blue in color. The lid120of the overlay assembly66of the digital display unit18may be green in color, the portion of the frame12adjacent to where the digital display unit18is connected to the frame12may be green in color, a connector equivalent to the connector106and/or a connector mounting plate portion to which the cable assembly60connects may be green in color, and the cable assembly60may be green in color. The lid120of the overlay assembly66of the digital display unit20may be yellow in color, the portion of the frame12adjacent to where the digital display unit20is connected to the frame12may be yellow in color, a connector equivalent to the connector106and/or a connector mounting plate portion to which the cable assembly46connects may be yellow in color, and the cable assembly46may be yellow in color.

In several exemplary embodiments, one or more of the digital display units14,16,18and20may be operably coupled to the hydraulic control equipment22so that the hydraulic control equipment22automatically controls the hydraulic choke26and/or28based on the digital information received and processed by the one or more digital display units14,16,18and20. In an exemplary embodiment, the hydraulic chokes26and28are so controlled using one or more programmable logic controllers (PLCs).

In several exemplary embodiments, one of the hydraulic chokes26and28may be omitted; in several exemplary embodiments, the digital display unit14may be modified to display operation parameter(s) for a single hydraulic choke. In several exemplary embodiments, one of the pumps50and52may be omitted; in several exemplary embodiments, the digital display unit20may be modified to display operation parameter(s) for a single pump.

In several exemplary embodiments, one or more of the digital display units14,16,18and20may be omitted from the choke control panel10. In several exemplary embodiments, one or more additional digital display units that are either identical to one or more of the digital display units14,16,18and20, or identical except for one or more different switches and/or graphic overlays, may be added to the choke control panel10.

In several exemplary embodiments, instead of, or in addition to being used to monitor and/or control (automatically or otherwise) systems or components in the system24for drilling an oil or gas well, the choke control panel10, one or more components of the choke control panel10, including one or more of the digital display units14,16,18and20, or one or more features thereof, may be used to monitor and/or control (automatically or otherwise) systems or components in other systems such as, for example, mud-gas separator systems.

In several exemplary embodiments, all electrical communication, digital information transmission, electrical power transmission, etc. described herein via specified components (such as specific connectors and specific cable assemblies) are not limited to those specified components, and any such communication and transmission may occur via other components in addition to, or instead of, those specified components, and/or via a subset of one or more of those specified components.

In an exemplary embodiment, as illustrated inFIG. 24with continuing reference toFIGS. 1-23, an illustrative node250for implementing one or more of the above-described exemplary embodiments is depicted. The node250includes a microprocessor250a, an input device250b, a storage device250c, a video controller250d, a system memory250e, a display250f, and a communication device250gall interconnected by one or more buses250h. In several exemplary embodiments, the storage device250cmay include a floppy drive, hard drive, CD-ROM, optical drive, any other form of storage device and/or any combination thereof. In several exemplary embodiments, the storage device250cmay include, and/or be capable of receiving, a floppy disk, CD-ROM, DVD-ROM, or any other form of computer-readable medium that may contain executable instructions. In several exemplary embodiments, the communication device250gmay include a modem, network card, or any other device to enable the node to communicate with other nodes. In several exemplary embodiments, any node represents a plurality of interconnected (whether by intranet or Internet) computer systems, including without limitation, personal computers, mainframes, PDAs, smartphones and cell phones.

In several exemplary embodiments, one or more of the components of the choke control panel10or the system24include at least the node250and/or components thereof, and/or one or more nodes that are substantially similar to the node250and/or components thereof. In several exemplary embodiments, one or more of the above-described components of the node250and/or the system10include respective pluralities of same components.

In several exemplary embodiments, a computer system typically includes at least hardware capable of executing machine readable instructions, as well as the software for executing acts (typically machine-readable instructions) that produce a desired result. In several exemplary embodiments, a computer system may include hybrids of hardware and software, as well as computer sub-systems. In an exemplary embodiment, a computer system may include a programmable logic controller (PLC).

In several exemplary embodiments, hardware generally includes at least processor-capable platforms, such as client-machines (also known as personal computers or servers), and hand-held processing devices (such as smart phones, tablet computers, personal digital assistants (PDAs), or personal computing devices (PCDs), for example). In several exemplary embodiments, hardware may include any physical device that is capable of storing machine-readable instructions, such as memory or other data storage devices. In several exemplary embodiments, other forms of hardware include hardware sub-systems, including transfer devices such as modems, modem cards, ports, and port cards, for example. In an exemplary embodiment, hardware may include a programmable logic controller (PLC).

In several exemplary embodiments, software includes any machine code stored in any memory medium, such as RAM or ROM, and machine code stored on other devices (such as floppy disks, flash memory, or a CD ROM, for example). In several exemplary embodiments, software may include source or object code. In several exemplary embodiments, software encompasses any set of instructions capable of being executed on a node such as, for example, on a client machine, server, or programmable logic controller (PLC).

In several exemplary embodiments, combinations of software and hardware could also be used for providing enhanced functionality and performance for certain embodiments of the present disclosure. In an exemplary embodiment, software functions may be directly manufactured into a silicon chip. Accordingly, it should be understood that combinations of hardware and software are also included within the definition of a computer system and are thus envisioned by the present disclosure as possible equivalent structures and equivalent methods.

In several exemplary embodiments, computer readable mediums include, for example, passive data storage, such as a random access memory (RAM) as well as semi-permanent data storage such as a compact disk read only memory (CD-ROM). One or more exemplary embodiments of the present disclosure may be embodied in the RAM of a computer to transform a standard computer into a new specific computing machine. In several exemplary embodiments, data structures are defined organizations of data that may enable an embodiment of the present disclosure. In an exemplary embodiment, a data structure may provide an organization of data, or an organization of executable code.

In several exemplary embodiments, any networks and/or one or more portions thereof, may be designed to work on any specific architecture. In an exemplary embodiment, one or more portions of any networks may be executed on a single computer, local area networks, client-server networks, wide area networks, internets, hand-held and other portable and wireless devices and networks.

In several exemplary embodiments, a database may be any standard or proprietary database software, such as Oracle, Microsoft Access, SyBase, or DBase II, for example. In several exemplary embodiments, the database may have fields, records, data, and other database elements that may be associated through database specific software. In several exemplary embodiments, data may be mapped. In several exemplary embodiments, mapping is the process of associating one data entry with another data entry. In an exemplary embodiment, the data contained in the location of a character file can be mapped to a field in a second table. In several exemplary embodiments, the physical location of the database is not limiting, and the database may be distributed. In an exemplary embodiment, the database may exist remotely from the server, and run on a separate platform. In an exemplary embodiment, the database may be accessible across the Internet. In several exemplary embodiments, more than one database may be implemented.

In several exemplary embodiments, a plurality of instructions stored on a computer readable medium may be executed by one or more processors to cause the one or more processors to carry out or implement in whole or in part the above-described operation of each of the above-described exemplary embodiments of the choke control panel10or components thereof, the system24or components thereof, and/or any combination thereof. In several exemplary embodiments, such a processor may include any of the microcontrollers94, any processor(s) that are part of the components of the choke control panel10or the system24, and/or any combination thereof, and such a computer readable medium may be distributed among one or more components of the choke control panel10or the system24. In several exemplary embodiments, such a processor may execute the plurality of instructions in connection with a virtual computer system. In several exemplary embodiments, such a plurality of instructions may communicate directly with the one or more processors, and/or may interact with one or more operating systems, middleware, firmware, other applications, and/or any combination thereof, to cause the one or more processors to execute the instructions.

In the foregoing description of certain embodiments, specific terminology has been resorted to for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes other technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as “left” and right”, “front” and “rear”, “above” and “below” and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

In addition, the foregoing describes only some embodiments of the invention(s), and alterations, modifications, additions and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive.